Bühler technologies BWT Series User manual

Fluidcontrol
Installation and Operation Instructions
Original instructions
Heat exchangers
BWT
BE340001
08/2019
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 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.
All rights reserved. Bühler Technologies GmbH 2019
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

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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!
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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.
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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: +
0
-
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
+
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 +
+
+
+
+
+
+
+
+
0
+
0
+
+
+
pH [2] < 6.0
6.0-7.5
7.5-9.0
> 9.0
Within 24 h 0
+
+
+
0
+
+
+
0
+
+
+
0
0
+
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
-
-
+
+
+
-
+
+
+
+
+
+
+
0/+
+
+
+
+
Chlorine gas (CI2) < 1
1-5
> 5
Within 5 h +
-
-
+
-
-
+
0
-
+
0
0/-
+
+
+
Hydrogen sulphide (H2S) < 0.05
> 0.05
No limit +
+
+
+
+
0/-
+
+
Free (aggressive)
carbon dioxide (CO2)
< 5
5-20
> 20
No limit +
+
+
+
+
+
+
+
+
+
0
-
+
+
+
Total hardness (°dH) 4.0-8.5 No limit + + + + +
Nitrate[1] (NO3
-) < 100
> 100
No limit +
+
+
+
+
+
+
0
+
+
Iron[3] (Fe) < 0.2
> 0.2
No limit +
+
+
+
+
+
+
0
+
+
Aluminium (Al) < 0.2
> 0.2
No limit +
+
+
+
+
+
+
0
+
+
Manganese[3] (Mn) < 0.1
> 0.1
No limit +
+
+
+
+
+
+
0
+
+
[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.
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CHLORIDE
CONTENT
MAXIMUM TEMPERATURE
60 °C 80 °C 80 °C 80 °C
= 10 ppm
= 25 ppm
= 50 ppm
= 80 ppm
= 150 ppm
= 300 ppm
> 300 ppm
SS 304
SS 304
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
SS 304
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
SS 304
SS 316
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
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6 Maintenance
During maintenance, remember:
– The equipment must be maintained by a professional familiar with the safety requirements and risks.
– Only perform maintenance work described in these operating and installation instructions.
– When performing maintenance of any type, observe the respective safety and operation regulations.
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.
If cooling media are used which are possibly contaminated, such as surface water, cooling circuit water (open circuit), heating
installation water (specially in the case of old installations) etc., filter having a mesh width of max. 0.6 mm should be provided
in the feed line. Furthermore, if such media are used, the unit should be operated with the largest possible mass flow. If the
mass flow is too small (partial load) the turbulence in plate heat exchanger may decrease and susceptibility of fouling may in-
crease.
If formation of deposits due to the water quality (e.g. high degrees of hardness or heavy contamination) is expected, the unit
should be cleaned at regular intervals. It is possible to clean the unit by rinsing. A weak acid, e.g. 5% phosphoric acid, or the
cleaning agents offered by relevant suppliers to clean copper and stainless steel should be used to rinse the unit.
CAUTION Acid and corrosive substances
Phosphoric acid can harm skin and eyes.
Wear protection gloves and face protection.
If possible, the rinsing process should be carried out in the opposite direction to that of the operating flow and, where necessary,
back rinsing connection should be provided in the piping. The unit must then be sufficiently rinsed using clear water to remove
all residues of cleaning liquid before the system is put into operating again.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
7.1 Troubleshooting
Problem / Failure Possible cause Solution
Cooling capacity not sufficient – Ambient air temperature is higher than
specified
– Select larger model
– Water flow too low – Raise water flow
– Cooling channels clogged – Cleaning, see chapter Maintenance
– Oil flow too low – Increase oil flow
– Oil channel clogged – Cleaning, see chapter Maintenance
– Oil circuit blocked – Open valves and cocks
Tab.1: Troubleshooting
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8 Disposal
Dispose of the parts in such a way that does not present a danger to other people’s heath or to the environment. Observe the
legal requirements in the country of use for the disposal of electrical components and oils and coolants.
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9 Appendices
9.1 Technical data BWT
Technical Data
Material Stainless steel 1.4401, Cu 99.9% and Cu-free soldering material.
Also Cu-free soldering materials as special versions BWT-N B5-B28, see data sheet 340005.
Flange B60 and up, in Swedish standard SS 2172, DIN 17175.
Operating pressure
static:
dynamic:
max. 30 bar
20 bar at 5M load cycle, 3Hz
Operating oil temperature max. +185 °C
9.1.1 B05 / B08 / B15
Type Item no. F
(mm)
Cooling capacity
(kW)
Oil connection
F3, F1
Water connection
F2, F4
Weight
(kg – net)
Volume
(Litre)
BWT B05x010 3405010 30 1.5 - 5.0 G ¾ 36 mm G ½ 27 mm 1.0 0.1
BWT B05x020 3405020 53 1.5 - 11 G ¾ 36 mm G ½ 27 mm 1.5 0.2
BWT B08x010 3408010 30 2.5 - 6.0 G ¾ 36 mm G ½ 27 mm 1.6 0.5
BWT B08x020 34080200 53 5.0 - 16 G ¾ 36 mm G ½ 27 mm 2.0 1.0
BWT B08x030 34080300 76 10 - 25 G ¾ 36 mm G ½ 27 mm 3.0 1.5
BWT B15x030 3415030 76 6.0 - 30 G ¾ 36 mm G ½ 27 mm 4.0 2.0
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9.1.2 B10 / B12 / B25
Type Item no. F
(mm)
Cooling capacity
(kW)
Oil connection
F3, F1
Water connection
F2, F4
Weight
(kg – net)
Volume
(Litre)
BWT B10x020 3410020 49 5 – 25 G 1 41 mm G ¾ 36 mm 4.0 1.0
BWT B10x030 3410030 72 10 - 40 G 1 41 mm G ¾ 36 mm 5.0 1.5
BWT B10x040 3410040 94 10 - 50 G 1 41 mm G ¾ 36 mm 7.0 2.0
BWT B10x050 3410050 116 15 - 60 G 1 ¼ 50 mm G 1 41 mm 8.0 3.0
BWT B10x070 3410070 161 20 - 65 G 1 ¼ 50 mm G 1 41 mm 10.0 3.5
BWT B10x090 3410090 206 20 - 80 G 1 ¼ 50 mm G 1 41 mm 13.0 4.0
BWT B12Hx060 3412060 145 35 - 85 G 1 ¼ 50 mm G 1 41 mm 13.5 4.3
BWT B25x030 3425030 72 13 - 45 G 1 ¼ 50 mm G 1 41 mm 10.0 2.0
BWT B25x040 3425040 94 13 - 65 G 1 ¼ 50 mm G 1 41 mm 12.0 3.0
BWT B25x060 3425060 139 20 - 90 G 1 ¼ 50 mm G 1 41 mm 17.0 5.0
BWT B25x080 3425080 184 25 - 105 G 1 ¼ 50 mm G 1 41 mm 21.0 7.0
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9.1.3 B35 / B120
Type Item no. F
(mm)
Cooling capacity
(kW)
Oil connection
F3, F1
Water connection
F2, F4
Weight
(kg – net)
Volume
(Litre)
BWT B35x040 3435040 103 30-105 G 1 ½ 60 mm G 1 ¼ 50 mm 18.0 5.0
BWT B35x050 3435050 127 55-145 G 1 ½ 60 mm G 1 ¼ 50 mm 21.0 7.0
BWT B35x060 3435060 151 55-155 G 1 ½ 60 mm G 1 ¼ 50 mm 24.0 8.0
BWT B35x090 3435090 223 55-175 G 1 ½ 60 mm G 1 ¼ 50 mm 34.0 12.0
BWT B120x040 3445040 103 40-125 G 1 ½ 60 mm G 1 ¼ 50 mm 23.0 6.0
BWT B120x060 3445060 151 55-190 G 1 ½ 60 mm G 1 ¼ 50 mm 31.0 10.0
BWT B120x080 3445080 199 65-245 G 1 ½ 60 mm G 1 ¼ 50 mm 40.0 14.0
BWT B120x120 3445120 295 135-280 G 1 ½ 60 mm G 1 ¼ 50 mm 57.0 21.0
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9.1.4 B60
Type Item no. F
(mm)
Cooling capacity
(kW)
Oil connection
F3, F1
Water connection
F2, F4
Weight
(kg – net)
Volume
(Litre)
BWT B60x040 3460040 104 30 - 113 SAE 2 ½ * SAE 2 33 9
BWT B60x060 3460060 147 35 - 165 SAE 2 ½ * SAE 2 42 13
BWT B60x080 3460080 190 40 - 216 SAE 2 ½ * SAE 2 52 17
BWT B60x100 3460100 232 43 - 267 SAE 2 ½ * SAE 2 61 22
BWT B60x120 3460120 275 56 - 301 SAE 2 ½ * SAE 2 70 26
BWT B60x140 3460140 318 76 - 316 SAE 2 ½ * SAE 2 80 31
* SAE connections at pressure range 3000 PSI
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9.1.5 Mounting brackets
Type Part no. A B for BWT type
BB05 34BB05 104 223
BB08 34BB08 104 347 B08 x 010
BB080 34BB080 108 355 B08 x 020 x 030
BB15 34BB15 104 501
BB10 34BB10 151 323
BB25 34BB25 151 561
BB35 34BB35 273 426
BB 45 34BB45 273 558
NOTICE!We recommend using two brackets for the types B35-090 and B120-060 up to B120-120.
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9.2 Technical data BWT-N
Technical Data
Material Stainless steel 1.4401, Cu-free soldering material (nickel-based solder)
Operating pressure
static: max. 10 bar
Operating oil temperature +350 °C
9.2.1 B05 / B08 / B15
Type Item no. F
(mm)
Cooling capacity
(kW)
Oil connection
F3, F1
Water connection
F2, F4
Weight
(kg – net)
Volume
(Litre)
BWT B05x010N 3405010N 30 1.5 - 5.0 G ¾ 36 mm G ½ 27 mm 1.0 0.1
BWT B05x020N 3405020N 53 1.5 - 11 G ¾ 36 mm G ½ 27 mm 1.5 0.2
BWT B08x010N 34080100N 30 2.5 - 6.0 G ¾ 36 mm G ½ 27 mm 1.6 0.5
BWT B08x020N 34080200N 53 5.0 - 16 G ¾ 36 mm G ½ 27 mm 2.0 1.0
BWT B08x030N 34080300N 76 10 - 25 G ¾ 36 mm G ½ 27 mm 3.0 1.5
BWT B15x030N 3415030N 76 6.0 - 30 G ¾ 36 mm G ½ 27 mm 4.0 2.0
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