Bühler technologies BWT Series Bedienungsanleitung

Fluidcontrol

Installation and Operation Instructions

Original instructions

Heat exchangers

BWT

BE340001

08/2019

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20

E-Mail: [email protected]

Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen

Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20

Internet: www.buehler-technologies.com

E-Mail: [email protected]

Read this instruction carefully prior to installation and/or use. Pay at-

tention particularly to all advises and safety instructions to prevent in-

juries. Bühler Technologies can not be held responsible for misusing

the product or unreliable function due to unauthorised modifications.

Document information

Document No..........................................................BE340001

Version.........................................................................08/2019

BWT

Contents

1 Introduction..................................................................................................................................................................................................................... 2

1.1 Intended use .........................................................................................................................................................................................................2

1.2 Scope of delivery..................................................................................................................................................................................................2

2 Safety instructions......................................................................................................................................................................................................... 3

2.1 Important advice................................................................................................................................................................................................. 3

2.2 General hazard warnings .................................................................................................................................................................................4

3 Transport and storage .................................................................................................................................................................................................. 5

4 Installation and connection........................................................................................................................................................................................6

4.1 Installation site requirements.........................................................................................................................................................................6

4.2 Installing the heat exchanger..........................................................................................................................................................................6

5 Operation and control .................................................................................................................................................................................................. 7

5.1 During starting .................................................................................................................................................................................................... 7

5.2 Start-up the heat exchanger............................................................................................................................................................................ 7

5.3 Venting / Ventilation of the heat exchanger.............................................................................................................................................. 7

5.4 Shut-down the heat exchanger ...................................................................................................................................................................... 7

5.5 Impact of Water Quality on Corrosion Resistance ....................................................................................................................................8

6 Maintenance.................................................................................................................................................................................................................. 10

7 Service and repair.......................................................................................................................................................................................................... 11

7.1 Troubleshooting .................................................................................................................................................................................................11

8 Disposal............................................................................................................................................................................................................................12

9 Appendices......................................................................................................................................................................................................................13

9.1 Technical data BWT ...........................................................................................................................................................................................13

9.1.1 B05 / B08 / B15..................................................................................................................................................................................... 13

9.1.2 B10 / B12 / B25 ......................................................................................................................................................................................14

9.1.3 B35 / B120 .............................................................................................................................................................................................. 15

9.1.4 B60..........................................................................................................................................................................................................16

9.1.5 Mounting brackets............................................................................................................................................................................. 17

9.2 Technical data BWT-N...................................................................................................................................................................................... 18

9.2.1 B05 / B08 / B15 .....................................................................................................................................................................................18

9.2.2 B10 / B28................................................................................................................................................................................................19

9.2.3 Mounting brackets............................................................................................................................................................................ 20

9.3 Technical Data BWT-DW ................................................................................................................................................................................. 21

9.3.1 B16........................................................................................................................................................................................................... 21

9.3.2 Mounting bracket............................................................................................................................................................................... 21

9.4 Approvals.............................................................................................................................................................................................................22

9.5 Calculations ........................................................................................................................................................................................................22

9.5.1 Calculating viscosity ......................................................................................................................................................................... 22

9.5.2 Table of operational viscosity for VG oil ..................................................................................................................................... 22

9.5.3 Calculating the pressure loss..........................................................................................................................................................23

9.6 Pressure loss in straight pipes.......................................................................................................................................................................23

10 Attached documents................................................................................................................................................................................................... 25

iBühler Technologies GmbHBE340001 ◦ 08/2019

BWT

1 Introduction

1.1 Intended use

BWT heat exchangers are suited for the cooling of oils in hydraulic and lubrication systems with water. Their scope is given by

their specifications. The use in other applications is not permitted without confirmation by Bühler Technologies GmbH.

1.2 Scope of delivery

– 1 x Heat exchanger

– Product documentation

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2 Safety instructions

2.1 Important advice

Operation of the device is only valid if:

– the product is used under the conditions described in the installation- and operation instruction, the intended application

according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-

gies GmbH can not be held responsible for any damage,

– when complying with the specifications and markings on the nameplates.

– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,

– monitoring devices and safety devices are installed properly,

– service and repair is carried out by Bühler Technologies GmbH,

– only original spare parts are used.

This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep

this manual for later use.

Signal words for warnings

DANGER

Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.

WARNING

Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not

avoided.

CAUTION

Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or

minor or medium injuries if not avoided.

NOTICE

Signal word for important information to the product.

Warning signs

In this manual, the following warning signs are used:

Warning against hazardous situations Warning against electrical voltage

Warning against acid and corrosive substances Warning against environmental hazard

Warning against high pressure General notice

Warning against hot surface Wear eye/face protection

Warning against potentially explosive atmo-

spheres

Wear protection gloves

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2.2 General hazard warnings

The equipment must be installed by a professional familiar with the safety requirements and risks.

Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent

malfunctions and avoid personal injuries and property damage.

The operator of the system must ensure:

– Safety notices and operating instructions are available and observed,

– The respective national accident prevention regulations are observed,

– The permissible data and operational conditions are maintained,

– Safety guards are used and mandatory maintenance is performed,

– Legal regulations are observed during disposal,

– compliance with national installation regulations.

Maintenance, Repair

Please note during maintenance and repairs:

– Repairs to the unit must be performed by Bühler authorised personnel.

– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.

– Always use genuine spare parts.

Always observe the applicable safety and operating regulations in the respective country of use when performing any type of

maintenance.

CAUTION Hot surface

Burning hazard

Let the device cool down before maintaining.

CAUTION High pressure

Hazard of injury due to flung off parts or oil, environmental hazard due to oil.

a) Before starting any maintenance or repair to the oil circuit, make sure that the device

is depressurized. This applies to the locking screws as well.

b) Avoid environmental pollution (oil spills) during cleaning or maintenance of the oil

circuit.

c) Use drip pans.

WARNING Voltage flashovers

Electrocution hazard

Do not earth the heat exchanger when carrying out welding work!

4 Bühler Technologies GmbH BE340001 ◦ 08/2019

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3 Transport and storage

The products should be transported only in its original packaging or a suitable replacement. Secure device for transportation.

When not in use, protect the equipment against moisture and heat. Keep it in a covered, dry and dust-free room at ambient

temperature.

5Bühler Technologies GmbHBE340001 ◦ 08/2019

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4 Installation and connection

4.1 Installation site requirements

Plate heat exchangers should be mounted leaving adequate clearance around each equipment for performing service work, etc.

Install in any position. Only when used as an evaporator or capacitor require it to be installed vertically, any other installation

position could result in decreased output.

4.2 Installing the heat exchanger

NOTICE

Piping must always be installed in such a way that no movement in the piping and no

unadmissible forces are transferred to the plate heat exchanger!

CAUTION Damages at the connection

Ensure no vibration is generated in the lines to prevent the plate heat exchanger connec-

tions from being damaged.

Incorrect installation or operation could result in a defect of the welded joint at the con-

nection, hence media mixing.

WARNING Voltage flashovers

Electrocution hazard

Do not earth the heat exchanger when carrying out welding work!

The designation of the connections on the plate heat exchanger is indicated in the nameplate. Please refer to the decal for the

connection position.

Soldered compact heat exchangers are connected parallel with counter flow. The circuits to be connected must be flushed prior

to making the connection.

The piping to and from the plate heat exchanger must have shut-off valves. In addition, venting must be provided at the highest

position in the upper connections, and drains in the lower connections.

When connection the plate heat exchanger, be sure the seals in the screw connections are clean.

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5 Operation and control

NOTICE

The device must not be operated beyond its specifications.

CAUTION Damages at the connection

Ensure no vibration is generated in the lines to prevent the plate heat exchanger connec-

tions from being damaged.

Incorrect installation or operation could result in a defect of the welded joint at the con-

nection, hence media mixing.

5.1 During starting

Before operation it must be checked that the operating data does not exceed the data indicated on the marker's nameplate. Fur-

thermore all bolted connections must be checked for tightness.

CAUTION Hazard due to high pressure of the pump

Do not exceed the nominal pressure.

Install safety valves (pressure relief valves) to pumps that generate higher pressures.

The pumps feeding the plate heat exchanger must be equipped with control valves. Pumps which generate pressures higher

than those specified for the unit must be equipped with safety valves. The water pump must not suction air to preclude operat-

ing faults through water hammers.

5.2 Start-up the heat exchanger

NOTICE

Pressure surges should be avoided!

To avoid hydraulic shocks the pumps should be started up against minimal opened valves. The valves in the supply and the re-

turn lines should be opened slowly, if possible simultaneously.

5.3 Venting / Ventilation of the heat exchanger

During the filling process the unit must be vented through the vent valves installed in the piping. Plate heat exchangers which

are not vented to a sufficient degree do not achieve full performance because the heating surface is covered by air. Furthermore

the corrosion risk increases when air remains in the unit.

5.4 Shut-down the heat exchanger

The two sides should be shut-down simultaneously and slowly. If this not possible the hot side should be shut down first.

If the cooler is shut down for a long time it should be drained completely and cleaned. The should be specially when there is a

danger of frost and when aggressive media are involved.

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5.5 Impact of Water Quality on Corrosion Resistance

The durability chart shown provides a greatly simplified overview of the corrosion resistance of stainless steels and soldering

materials in tap water at room temperature.

Explanations: +

Good resistance under normal conditions

Corrosion may occur specifically if other factors are rated 0

Not recommended

WATER CONTENT CONCENTRATION

(mg/L or ppm)

TIME LIMIT

Analyse before

AISI 304 AISI 316 254 SMO COPPER NICKEL

Board material Soldering material

Alkalinity (HCO3

-) < 70

70-300

> 300

Within 24 h +

0/+

Sulphate[1] (SO4

2-) < 70

70-300

> 300

No limit +

0/-

HCO3- / SO4

2- > 1.0

< 1.0

No limit +

0/-

Electric conductivity < 10 µS/cm

10-500 µS/cm

> 500 µS/cm

No limit +

pH [2] < 6.0

6.0-7.5

7.5-9.0

> 9.0

Within 24 h 0

Ammonium (NH4

+) < 2

2-20

> 20

Within 24 h +

0/-

Chlorides (CI-)

also see table below

< 100

100-200

200-300

> 300

No limit +

0/+

Chlorine gas (CI2) < 1

1-5

> 5

Within 5 h +

0/-

Hydrogen sulphide (H2S) < 0.05

> 0.05

No limit +

0/-

Free (aggressive)

carbon dioxide (CO2)

< 5

5-20

> 20

No limit +

Total hardness (°dH) 4.0-8.5 No limit + + + + +

Nitrate[1] (NO3

-) < 100

> 100

No limit +

Iron[3] (Fe) < 0.2

> 0.2

No limit +

Aluminium (Al) < 0.2

> 0.2

No limit +

Manganese[3] (Mn) < 0.1

> 0.1

No limit +

[1] Sulphates and nitrates act as inhibitors for pitting corrosion caused by chloride in pH-neutral environments.

[2] A low pH value (below 6) generally increases the corrosion risk and a high pH value (over 7.5) reduces the corrosion risk.

[3] Fe3+ and Mn4+ are strong oxidisers and can increase the risk of local corrosion in stainless steels.

SiO2 over 150 ppm increase the calcification risk.

8 Bühler Technologies GmbH BE340001 ◦ 08/2019

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