Baelz Automatic BA 111 User manual

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BA_111_00_DEF_MJ_0419
Operating Instructions BA 111 / 112
Straight-Tube Heat Exchanger baelz 111 / baelz 112
Technical specications subject to change without notice Copyright according to ISO 16016

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
Table of Contents
1. SAFETY 4
1.1 Intended use 4
1.2 Instructions for the operator 4
1.3 Personnel 5
1.4 Before starting work 5
1.5 During operation 5
1.5.1 Transport, installation and assembly 5
1.5.2 Maintenance and repair 5
1.5.3 Hazard prevention 5
1.6 Working environment 5
2. PRODUCT DESCRIPTION 6
2.1 Identication 6
2.2 Straight-tube heat exchanger 6
2.3 Technical data 7
2.4 Pressure equipment directive 7
2.5 Water quality 7
3. TRANSPORT AND STORAGE 8
4. ASSEMBLY 9
4.1 Assembly instructions 9
4.2 Measuring equipment 9
4.3 Arrangement of the control system 10
4.4 Electricalwiringofthemeasuringandcontroldevicesaswellastheautomaticttings 10
4.5 Filling of the system 10
5. COMMISSIONING 11
5.1 Operating conditions 11
5.2 During commissioning: 11
5.3 During operation 13
6. MAINTENANCE AND CLEANING 14
6.1 Regular inspections and maintenance of the heat exchanger 14
6.2 Switching off the system 14
6.3 Cleaning the heat exchanger 14
6.4 Repair work on the heat exchanger 14
7. DECOMMISSIONING AND DISPOSAL 15
7.1 Decommissioning 15
7.2 Disposal 15

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
8. TROUBLESHOOTING 16
9. DIMENSIONAL DRAWING, ASSEMBLY PLAN, SYSTEM DIAGRAMS (EXAMPLES) 18
9.1 Tables baelz 111 /112 with tube length 1500 mm 19
9.2 baelz 111 /112 with tube lengths 1000 mm and 2000 mm 19
9.3 Example assembly plan with baelz 111 - Legend 21
9.4 Examples of system diagrams 22

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
1. SAFETY
Read these operating instructions, in particular the following safety instructions, carefully before installation and
operation.
Beware
Potentially hazardous situation that could result in minor injury.
Also indicates a hazard that may result in property damage.
Beware
Caution
Potentially harmful situation in which the product or an object in its
vicinity may be damaged.
Caution
Danger
Imminent danger of death or serious injury.
Danger
Warning
Potentially hazardous situation that may result in death or serious injury.
Warning
Application instructions and other useful information.
Informative explanations.
1.1 Intended use
The straight tube heat exchanger baelz 111 / baelz 112 is used in warm water heating systems.
To ensure proper use, make sure that the above type designation corresponds to the name plate on the heat
exchanger before starting any measures. The technical data of the heat exchanger and the permissible values for
operatingpressureandoperatingtemperatureapplyasspeciedonthenameplate.
Any use for tasks deviating from the above-mentioned intended use as well as operation under other than
the permissible pressure or temperature conditions is deemed to be improper use. The operator then bears
responsibility for risk to personnel and equipment as well as to other material assets in case of improper use!
Intended use also includes compliance with accident prevention and DIN VDE regulations as well as safe working
practices for all measures described in these operating instructions, taking into account the usual technical
regulations.
1.2 Instructions for the operator
Always keep the operating instructions available at the place where the heat exchanger is used!
During installation, operation and maintenance, observe the applicable occupational safety, accident prevention
and DIN VDE regulations. If necessary, observe additional regional, local or internal safety regulations.
Make sure that every person entrusted with one of the measures described in these operating instructions has
read and understood these instructions.
Info:
Tip:

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
1.3 Personnel
Onlyqualiedpersonnelmayworkonthisheatexchangerorinitsvicinity.Qualiedpersonsaredeemedtobe
persons who are familiar with the installation, assembly, commissioning and operation or maintenance of the heat
exchangersandhavetheappropriatequalicationsfortheirjob.Necessaryorprescribedqualicationsinclude,
but are not limited to:
● Safety-relevantinstructionortraininginthiseldandobligationtocomplywithregionalandinternal
safety technology standards.
●Training or instruction in the care and use of appropriate safety and work protection equipment
in accordance with safety technology standards.
●First aid training.
Work in a safe manner and avoid any operation that would endanger the safety of persons or damage the heat
transfer station or other property in any way.
1.4 Before starting work
Beforecarryingoutanywork,checkwhetherthetypesspeciedherecorrespondtotheinformationonthename
plate of the heat exchanger: baelz 111 / baelz 112
1.5 During operation
Safe operation is only possible if transport, storage, assembly, operation and maintenance is carried out in a safe,
proper and professional manner.
1.5.1 Transport, installation and assembly
Observe the general installation and safety regulations for heating, ventilation, air conditioning and piping
systems. Use tools only for their intended purpose. Wear the required personal and other protective equipment.
1.5.2 Maintenance and repair
Ensurethatqualiedpersonneltaketheheatexchangeroutofoperationbeforecarryingoutmaintenanceor
repair work. As a rule, work must only be carried out on heat exchangers when they are not under pressure.
For maintenance and cleaning procedures, see chapter 6.
Immediatelyaftercompletionofmaintenancework,allsafetyandprotectivedevicesmustberettedorputinto
operation.
For the recommissioning procedure, see chapter 5.
1.5.3 Hazard prevention
Components of the heat exchanger which may become hot or cold must be protected against contact. Use
warning signs to indicate possible dangers, e.g. caused by hot or cold surfaces or operating errors.
1.6 Working environment
Notethespecicationsfortheworkingenvironmentinthetechnicaldata.

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01
03
02
04
05/03
010
Straight-Tube Heat Exchanger baelz 111 / baelz 112
2. PRODUCT DESCRIPTION
2.1 Identication
baelz 111 / 112:
01 = heating medium inlet
02 = condensate outlet
03 = secondary inlet (return)
04 = secondary outlet (feed)
05/03 = secondary discharge (G ½“)
010 = vent (G ½“)
2.2 Straight-tube heat exchanger
The baelz 111 / baelz 112 is a steam-heated straight-tube heat exchanger in vertical design, suitable for output
reglationusingcondensatebackup.Thewatertobeheatedowsthroughthetubes,whilesteamisfedthrough
the housing.
Thetubebundleisrmlyweldedin.Removableheadcoversallowtheinspectionandpossiblerepairofthetube
plates and tube expanded positions.
baelz 111 vertical straight-tube heat exchanger available in various sizes
baelz 112 as baelz 111, but suitable for drinking water
Every baelz 111 / baelz 112 heat exchanger is equipped with a name
plate. It contains information on the operating conditions of the device as
well as the device and serial number of the manufacturer.
Fig. 1: Example of a Baelz name plate for a heat exchanger
Fig. 2: Connections of
baelz 111 / baelz 112

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
Tabelle 1. baelz 111 / baelz 112 Manufacturing and testing according to PED 2014/68/EU
Baelz type tested according to Execution
baelz 111 PED 2014/68/EU,
Category / Module: I/A, II/A2,
III/G or IV/G or Art. 4(3) and AD
2000 regulation
standard
baelz 112 Suitable for drinking water, otherwise identical
to baelz 111
2.3 Technical data
Tabelle 2. Technical data, baelz 111 / 112
baelz 111 baelz 112
Tubes Steel / Copper / Stainless steel 1.4571
Tube plate Steel / Stainless steel Steel (Cu / VA plated) or stainless steel
Head Steel Steel stove enamelled / Stainless steel
Shell Steel Partsincontactwiththeuid1.4571
Insulation Mineral wool with galvanized sheet metal jacket 50 / 80 mm
Housing height min. 1000, max. 8000 mm
Diameter Ø 114 mm - Ø 1200 mm
Fluids on tube side Heatingwater,glycol,hotoil,neutralliquids.Otheruids
on inquiry Drinking water
Fluids on shell side Steam and condensate Steam and condensate
2.4 Pressure equipment directive
2.5 Water quality
To prevent corrosion in heat exchangers, water qualities must be checked and recorded at regular intervals.
Requirements for water quality can be found in our corrosion brochure, which we will be pleased to send you.
Hotwateruid:RequiredwaterqualityaccordingtoVDI2035-Preventionofdamageinhotwaterheating
systems according to DIN EN 12828

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
3. TRANSPORT AND STORAGE
Risk of injury due to non-compliance with safety regulations!
Beware
●Wear the required personal and other protective equipment.
●Avoid shocks, blows, vibrations and the like on the heat exchanger.
●Store the heat exchanger (and if necessary the complete station) in a dry place.
●Store the heat exchanger emptied and dried.
●For storage, provide unconnected heat exchangers with blind plugs.
●Any protective caps and blind plugs on the device openings must not be removed until the device is
mounted.

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
4. ASSEMBLY
See also: "Application Notes for Baelz Heat Exchanger Systems"
for important and useful information on assembly and operation.
4.1 Assembly instructions
●Make sure that the data on the name plate matches that on the order documents!
●Observe the specied maximum values for pressure and temperature!
●The baelz 111 / baelz 112 is a vertical heat exchanger. The static calculation of the area on which it
standsmustbebasedonthemaximumoperatingweight(=ownweight+waterweight).Theoormust
belevel.Fixingtotheooristobecarriedoutwithsufcientlydimensionedstonebolts.
●The feet of the heat exchanger are dimensioned for the maximum operating weight. Additional loads are
not permitted.
●For transport reasons, control valves are often installed "upside-down", i.e. with the actuator below the
valve. Please install them upright or horizontally, if the local conditions permit.
●Ensure that pipelines are connected free of tension.
●All connecting pieces and sockets must be connected free of load in accordance with AD 2000.
To protect the heat transfer surfaces from deposits, Baelz recommends installing
a baelz 70200 strainer on the inlet side of the heating medium and, if necessary, on the inlet side
  oftheuidtobeheated.
●When installing the heat exchanger, bear in mind that later removal may be necessary, e.g. for
maintenance.Providesufcientspaceforthisandinstallappropriateconnectionsandisolatingvalves.
●To ensure that the heat exchanger can be chemically cleaned without having to dismantle it, Baelz
recommends that additional connections be made to the heat exchanger, i.e. to all inlet and outlet pipes.
In addition, isolating valves are to be provided on these pipes.
●Welding work on the heat exchanger is only possible after consultation with the manufacturer.
4.2 Measuring equipment
●For Baelz heat exchangers 111 / 112, provide sockets in the pipes for pressure and / or temperature
measurement. The temperature measuring points in the vicinity of the heating surface have the
advantagethatevenwithstronglyreducedwaterow,temperaturemeasurementisstillpossible.So
close to the heating surface, however, a stable mean temperature cannot yet be reached. This affects
control accuracy and can lead to the safety temperature limiter responding prematurely. It is therefore
advisable to provide measuring points in the next pipe elbow so that the temperature measuring points
can be easily changed when commissioning the heat exchanger.
● Whenselectingthemeasuringpoints,makesurethatthefullactivesensorlengthisushedbythewater
ow.Thispreventsincorrectmeasurements.
●Immersion wells increase the dead time. Should these nevertheless be indispensable, they must be
arranged vertically or diagonally upwards so that the air gap between the sensor shaft and the well can
belledwithacontactliquid.
Info:
Caution
Caution
Tip:

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
● Foranaccuratemeasurementofstaticpressure,selectalocationwithsteadyow.Forthebest
measurement conditions, arrange deburred holes of 3 to 5 mm diameter in straight pipelines and
perpendiculartothedirectionofow.Thedistancetottingsordeectionsshouldbeatleast10to20
times the pipeline diameter.
The performance and correct functioning of a heat exchanger system must be monitored by measuring pressure,
temperatureandowratewithsufcientlyaccuratemeasuringequipment.Thedatacollectedinthiswayis
indispensable for possible service cases. Baelz therefore recommends installing the following measuring
equipment in addition to the supply sensors and limit thermostats:
1. 1 thermometer each for steam inlet and condensate outlet.
2. 1 thermometer each for secondary inlet and secondary outlet.
3. 1 manometer each for steam inlet and condensate outlet.
4. 1 manometer each for secondary inlet and secondary outlet, or at least suitable measuring connection
piece for the later connection of a manometer.
5. 1condensatemeter,oratleastonettingpieceforacondensatemeter,sothatatemporarymeterfor
maximum quantity setting can be installed during initial commissioning.
6. 1warmorhotwatermeteroronemeasuringoriceforthesecondarycircuit.
The necessary calming section must be available for all quantity measuring devices.
4.3 Arrangement of the control system
● Theassemblyplanspeciesthearrangementandfunctioningofthecontrolsystem.Asampleassembly
plan can be found in Fig. 5, page 20.
●Proper drainage of the steam inlet pipe is particularly important for steam heat transfer stations. This is
theonlywaytopreventwaterhammer,whichshortenstheservicelifeofthesystem.Theminimumow
rate on the secondary side in low load operation must also be guaranteed.
●Do not switch off circulating pumps until the condensate valve is closed and the condensate backup has
completely covered the heating surface.
●Night setbacks may not all take effect simultaneously when several circuits are present. The heat
exchanger can also be controlled according to the coldest circuit depending on the weather. This ensures
aminimumwaterowrate.
●See the operating instructions for each device to learn more about its control function.
4.4 Electrical wiring of the measuring and control devices as well as the automatic t-
tings
●An operating manual is enclosed with each individual device. If this individual device requires electrical
auxiliarypower,youwillndtheelectricalcircuitdiagramintheoperatinginstructions.
●If you have ordered a Baelz switchboard or a Baelz switch cabinet, the circuit diagram tailored to your
individual control circuit will also be supplied. Examples of typical system diagrams can be found on
pages 22 and 23.
●However, if you would like to receive an introduction to the system components supplied by us, please
contact Baelz customer service.
4.5 Filling of the system
● Thequalityrequirementsforthellingwaterdependonthetemperatureandheatingsurfaceload.
●For information on the required water quality, please see Chapter 2.5
Info:

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
Make sure that the system is lled with the intended uids and deaerated. Check the
system for leaks.
Check electrical components and control for operability.
Caution
5. COMMISSIONING
See also: "Application instructions for Baelz heat exchanger stations"
for important and useful information on assembly and operation.
5.1 Operating conditions
Observe the limiting values stated on the name plate for the operation of the baelz 111 / baelz 112.
Risk of personal injury or material damage if the values on the name plate are disregarded!
Pressure vessel with two pressure chambers!
Danger
Info:
5.2 During commissioning:
Start up the heat exchanger or the station as evenly as possible.
Avoid pressure peaks and thermal shocks!
Caution
Ensure that the secondary pump is connected in the correct direction of rotation and in
operation when the heating medium is owing. After-running of this pump is important!
Caution
1. Observetheoperatinginstructionsofthettingsattachedtotheheatexchangerandothercomponents
of the system.
2. Checkthattheconnectionsoftheheatexchangercorrespondtotheorderconrmation.Seealsochapter
2.1 of these operating instructions.
3. Setting the temperature sensor on the secondary outlet thermostat and the overtemperature thermostat:
●If a resistance thermometer is used as a temperature sensor at the secondary outlet (04), the setpoint is
adjusted at the controller with Baelz control.
●Use a special key to set the safety temperature limiter in the supply pipe to a temperature of approx.
10°Cabovethetemperatureatthesecondaryoutlet,unlessthexedvaluehasalreadybeensetinthe
factory.
●To limit the temperature of the condensate, set the thermostat to a temperature approx. 15 °C above the
desired temperature.
4. Make sure that the system is not under pressure. Deaerate the heat exchanger. If water escapes, screw
the plug back in. A vent valve is suitable here for the purpose of deaerating.
5. Pressure monitoring:
Typicallyasettingrangeof0.5-6barissufcientforheatingsystems.
●Max. pressure limiter: The pressure limiter must be set so that it responds upstream of the security valve.
●Min. pressure limiter: If the pressure drops below the set limiting value, the heat supply system is
switched off.

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
v
t = 90°C
0.5
0.5
4
0.7 1.41.0
0.7
1
1.4
2
3
5
10
7
02
01 03
p
14
20
max.
DPI
p
04 min.
WPI
3.02.0 5.0 107.0
20
40
50
30
10
t = 150°C
t = 110°C
v
t = 100°C
v
v
t = 130°C
v
Fig. 3: Pressure / temperature diagram for steam-heated heat exchangers
Heating steam pressure PDmax. (bar)
Water pressure PWmin. (bar)
Supply temperature
Water-side
temperature spread
∆tsecondary(°C)
6. Open all valves in the secondary circuit, including those at the consumers.
7. Switch on the circulation pump of the secondary circuit and throttle it to the required quantity. If the
consumers are not yet ready for operation, another way of reducing capacity should be provided so that
the safety devices are not triggered unintentionally.
8. Slowlyopenthettingsonthesteaminletside(01).Theprimarysideofthedeviceisnowunderthe
full pressure of the heating medium as the condensate control valve is still closed. You can now check
whether all connections are tight.
9. If a pressure limitation valve is used on site on the steam inlet side, adjust the operating pressure to suit
the operating conditions.
10. For all water heaters, make sure that at the given max. steam temperature the existing min. water
pressureonthesecondarysideissufcienttopreventtheformationofsteam.SeeFig.3(below).
11. Check the desired setpoint adjustment on the controller. Leave the manual control and isolating valve in
the condensate pipe closed. Press the "On" key on the controller. If the wiring is correct, the condensate
motor valve opens.

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
5.3 During operation
If vibration, noise, reduced power or other disturbances occur during operation, please refer to the
Troubleshooting table on page 16 and contact Baelz customer service if necessary.
Observe the following instructions for safe commissioning!
Beware
12. Open the condensate manual control and isolating valve very slowly to put the steam heat transfer
station into operation: First open the manual control valve by only one turn. After 15 minutes, check
the resulting temperature rise. If the maximum supply temperature (secondary output, 04) is already
exceeded, the condensate control valve is too large. Turn the manual control valve back accordingly. If
the supply temperature is not reached, open the manual control valve by one more turn. Wait another
15 minutes and repeat the temperature check and, if necessary, correct the hand wheel position. Now
secure the manual control valve so that it cannot be unintentionally misadjusted.
13. Since the temperature provides only limited information about the heat output, the correct condensate
discharge rate must in certain cases be set on the manual control valve using a condensate meter. The
approx.condensatedischargecapacityinl/min,whichmustowatnominalcapacity,isobtainedby
dividing the heat output in kcal/h by the numerical value 33000. If the capacity is given in kW, it must be
divided by the numerical value 38 in order to obtain the approx. condensate quantity in l/min. Particularly
advantageousiswhenthecondensatecontrolvalvecontainsabuilt-inowlimiter.Itcanbeeasily
adjustedtothemaximumowrate.
14. Now you can switch on the automatic operation. The automatic condensate control valve is controlled by
the controller by means of Open and Close pulses depending on the power consumption. Observe the
system for a few more hours and note the pressure and temperature values. Check the safety devices
for correct function by simulating controls as they may occur during operation.
After 1-2 hours of operation, tighten the screws of the seals!
Caution
15. It is imperative to tighten the screw connections of all seals gradually and evenly after 1-2 hours of operation.
Seealsochapter6.4.Thismeasureisnecessarybecausesealschangeundertheinuenceofheat.If
the retightening is not carried out in time, the seals may be damaged and the device may leak. This can
result in seals having to be replaced and, under certain circumstances, sealing surfaces having to be
reworked.
In new systems, strainers must be cleaned after the rst few days.
Caution
16. Cleanthestrainerstoremovedebristhatmayhavebeenushedfromthesystem'srecentlyputinto
servicepipesandttings.
17. Security valves are usually set for the pressure value ordered. Corrections must be made at the
manufacturer'sfactory.Installationssubjecttoinspectionmustbeinspectedaftercompletionbythebody
designatedinaccordancewiththePED.Thecerticateofafactoryconstructionandwaterpressuretest
must be submitted.

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
Procure replacement seals before starting repair work. Refer to the construction drawing or
order directly from Baelz stating the order and / or device number.
Baelz recommends concluding a maintenance contract with our technical customer service.
This ensures regular maintenance of your heat transfer system, extends its service life and
ensures reliable and safe operation.
6. MAINTENANCE AND CLEANING
Risk of scalding! Before cleaning and maintenance work, check whether the
device is depressurized and whether the uid temperatures have dropped so
low that scalding is ruled out.
●Only use Baelz original spare parts!
6.1 Regular inspections and maintenance of the heat exchanger
If you have not signed a maintenance contract with Baelz technical service, you must otherwise ensure that
regular inspections and maintenance are carried out in accordance with the relevant national regulations.
6.2 Switching off the system
If the system is switched off, only the condensate control valve receives a Close impulse and remains closed.
Thesecondarypumpcontinuestorunbrieytoreduceorpreventheataccumulationintheheatexchanger.
However, the steam valve remains open and thus the steam pressure is on the heat exchanger as well as on
the condensate rail. This prevents oxygen from entering the heat exchanger/condensate rail when the system is
switched off (risk of corrosion). The system self-checks with the condensate level probe at the steam inlet (01).
6.3 Cleaning the heat exchanger
●See chapter 2.5 for water quality requirements. If the water quality requirements are not met, it may
be necessary to clean the heat exchanger. Contamination restricts the performance of the system and
endangers the material. Hard incrustations in particular hinder the expansion of the heating system and
can thus cause material damage.
● Havedirtremovedatanearlystagebyaqualiedspecialistcompany.Limescalecanberemovedwith
acid. Do not use cleaning agents that attack the material. Make sure that no residues of the cleaning
agent remain in the heat exchanger.
●Only easily soluble hardeners (e.g. carbonate hardness) can be removed with acid mixtures. Poorly
soluble hardeners (e.g. gypsum) require a correspondingly greater effort. Only a chemical examination
of the contamination by a specialist company provides information about the potential success of a
cleaning.
●If sludge deposits are present in addition to limescale, the solvents must be mixed with special additives.
Normal acid mixtures are generally not suitable for the removal of sludge deposits. In this case, consult a
specialist company.
6.4 Repair work on the heat exchanger
Danger
Tip:
Tip:

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
●Removable head covers enable both ends of each tube to be inspected and repaired. In the case of
leakingtubeconnections,itmaysufcetoreworkthetubesheetconnectionwithaspecialmandrel.
However, it is more practical to drive in a guide bushing or a plug.
●Pipe openings can be sealed by shutting down the affected heating pipe using blind plugs.
Take care when tightening the ange couplings! Observe the following remarks.
Beware
● Tightentheangescrewscrosswiseandparticularlyevenly.Tooforcefulandunevenretighteningdistorts
theangesandleadstopermanentleakage.Tighteningtootightlycanalsocausethesealstoow.
Always observe the permissible surface pressure of the seals. Use a torque wrench and ensure that the
thread runs smoothly by applying heat-resistant lubricant on clean screws. Please refer to the Baelz data
sheet DS 80900...81100 for tightening torques depending on screw size and material.
7. DECOMMISSIONING AND DISPOSAL
Hot surfaces when insulation is removed! Risk of burns if touched!
Danger
7.1 Decommissioning
● Whendecommissioning,rstshutofftheheatingmedium.
●Shut down the ancillary equipment according to the relevant documentation.
●Empty the heat exchanger completely.
●Let the heat exchanger dry out as completely as possible to avoid standing liquids.
7.2 Disposal
●Dispose of or recycle the heat exchanger in accordance with national regulations.
●Do not dispose of lubricants and hazardous substances in household waste.

16 | 23W. Baelz & Sohn GmbH & Co. · Koepffstrasse 5 · 74076 Heilbronn · Germany · www.baelz.de Seite | Page
Straight-Tube Heat Exchanger baelz 111 / baelz 112
8. TROUBLESHOOTING
Problem Possible cause Solution
temperature / pressure too
high
heating capacity too high check control system and correct if
necessary
leaking control valve check valves and repair or replace if
necessary
greatly reduced power requirement or
manual control valve designed too large
throttle by means of manual control
valve
or replace manual control valve
(see also chapter 5.2: During
commissioning)
reduced heat exchanger
performance
intendedoperatingconditionsnotfullled check temperature, pressure and
owofheatingmedium
toolittleheatingmediumowsthrough
heat exchanger
●check strainer and clean if
necessary
●check opening of the isolating
valves and correct if necessary.
●check pipeline resistance
differential pressure too low /
controlvalveandassociatedttings
designed too small
re-designallttingsaccordingto
existing differential pressure
increasedowrateonthesecondaryside
(lower temperature difference is not due to
reduced heat exchanger performance)
reduceowrateonthesecondary
side
heat transfer surface dirty clean heat exchanger (see chapter
6.3: Cleaning the heat exchanger)
control valve remains in
OPEN position only very
briey
condensate limiting thermostat set too low
or defective
check the setting or function and
correct it
cooling of the heating medium too low Check whether the secondary
return temperature corresponds
to the design temperature, if so,
contamination of the heat transfer
surface is probable (see chapter
6.3: Cleaning the heat exchanger)

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
Problem Possible cause Solution
heat exchanger not running
smoothly
air in the system provide ventilation
steam formation on the secondary side check steam pressure limitation
heat transfer surface dirty clean heat exchanger (see chapter
6.3: Cleaning the heat exchanger)
leakage inside the heat exchanger see chapter 6.4 of these operating
instructions
defective valves or pumps Locate and repair or replace
device. If necessary, contact Baelz
customer service
leakage leakage to the outside Remove insulation, locate
leakage. If necessary, contact
Baelz customer service
leakage inside the heat exchanger see chapter 6.4 of these operating
instructions

18 | 23W. Baelz & Sohn GmbH & Co. · Koepffstrasse 5 · 74076 Heilbronn · Germany · www.baelz.de Seite | Page
Typenschild
(G½")
(G½")
Straight-Tube Heat Exchanger baelz 111 / baelz 112
Name plate
9. DIMENSIONAL DRAWING, ASSEMBLY PLAN, SYSTEM DIAGRAMS (EXAMPLES)
For dimensions and connection pieces of all standard types, see page 19
Fig. 4: Dimensional drawing baelz 111 / 112 - here type 111-219-195-15
Dimensions are approximate and may vary according to individual technical requirements!

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Straight-Tube Heat Exchanger baelz 111 / baelz 112
9.1 Tables baelz 111 /112 with tube length 1500 mm
9.2 baelz 111 /112 with tube lengths 1000 mm and 2000 mm
●The types in the tables (above) end with "15", e.g. 111-114-40-15 and have a tube length of 1500 mm.
●Types ending in "10" have a pipe length of 1000 mm. The total height H1 and the height dimensions H2
and H3 are approx. 500 mm less than for the corresponding type with a tube length of 1500 mm. For
example:
for 111-114-40-15: total height H1 = 1976 mm;
for 111-114-40-10: total height H1 = approx. 1476 mm (= 1976-500)
●Types ending in "20" have a pipe length of 2000 mm. The total height H1 and the height dimensions H2
and H3 are approx. 500 mm more than for the corresponding type with a tube length of 1500 mm. For
example:
for 111-114-40-15: total height H1 = 1976 mm;
for 111-114-40-20: total height H1 = approx. 2476 mm (= 1976+500)
* Connecting pieces 03 and 04 (DN 65, PN 16) in 4-hole execution
Tabelle 3. Connecting piece table baelz 111 /112 standard versions
Heating medium inlet Condensate outlet Secondary inlet Secondary outlet
Baelz type DN 01 PN 01 DN 02 PN 02 DN 03 PN 03 DN 04 PN 04
111-114-40-15 65 40 15 40 50 16 50 16
111-139-60-15 80 40 15 40 65* 16 65* 16
111-168-105-15 100 40 20 40 65* 16 65* 16
111-219-195-15 125 40 20 40 80 16 80 16
111-273-312-15 125 40 25 40 100 16 100 16
111-324-448-15 150 40 40 40 125 16 125 16
All connecting pieces acc. to EN 1092-1 type 11, sealing surface form B1
Tabelle 4. Dimension table baelz 111 /112 standard versions (dimensions in mm)
Baelz type D1 D2 D3 H1 H2 H3 H5 H6 L1 L2 L3 L4
111-114-40-15 114.3 275 410 1976 1864 1866 290 375 230 190 190 185
111-139-60-15 139.7 300 435 2006 1872 1891 295 390 240 215 215 198
111-168-105-15 168.3 330 480 2006 1872 1891 295 395 280 233 233 220
111-219-195-15 219.1 380 530 2036 1882 1911 305 410 315 265 265 245
111-273-312-15 273.0 435 585 2106 1917 1961 325 447 340 295 295 270
111-324-448-15 323.9 485 655 2150 1929 1991 335 480 380 325 325 300
Dimensions are approximate and may vary according to individual technical requirements!

20 | 23W. Baelz & Sohn GmbH & Co. · Koepffstrasse 5 · 74076 Heilbronn · Germany · www.baelz.de Seite | Page
Straight-Tube Heat Exchanger baelz 111 / baelz 112
Fig. 5: Example assembly plan Steam Terminal "Luxese Instant Heat" with baelz 111