Behncke EWT 80-40 User manual

Dok-ID:04/2021
Installation Instruction
Your BEHNCKE -Specialist Dealer:
Electric Heat Exchanger
EWT-80-40/-41
EWT-80-70/-71

BEHNCKE GmbH
Bayern:
Michael-Haslbeck Straße 13
D-85640 Putzbrunn
Fon: +49 (0)89 / 45 69 17-0
Fax: +49 (0)89 / 45 69 17-61
Sachsen-Anhalt:
Stötterlinger Straße 36 a
D-38835 Bühne
Fon: [phone] / 796-0
Fax: [phone] / 796-30
E-Mail: [email protected]
Internet: www.behncke.com
English

Inhaltsverzeichnis
1 Safety 1
1.1 Risks When Handling Electric Heat Exchanger 1
1.2 Safety Instructions and Information 1
1.3 Intended Use 2
1.4 Sources of Danger 3
1.5 Safety Measures on the Installation Site 3
1.6 Safety Equipment 4
2 Technical Data 5
2.1 EWT 80-40 – Sleeve for Tube and Thread 1 1/2” 5
2.2 EWT 80-41 – Sleeve for Tube and Thread 11/2”with flow switch 5
2.3 EWT 80-70 – PVC Glued/Screwed Connection 5
2.4 EWT 80-71 – PVC Glued/Screwed Connection with flow switch 6
3 Set-up/Installation 6
3.1 Transportation/Storage 6
3.2 Set-up and Installation Dimensions 7
3.3 Set-up 11
3.4 Installation 11
3.5 Water Connection 12
3.5.1 Installation Layout above the Water Level 12
3.5.2 Installation Layout under the Water Level 13
3.5.3 Connecting the Electric Heat Exchanger to the Water Cycle of a Filter System 14
3.5.4 General Installation Instructions for Flow switch 14
3.7 Electrical Connections 15
3.6 Flow switch 15
4 Functional Course 16
5 Initial Operation 16
6 Maintenance/Repair 16
6.1 Hibernation of the EWT in Frost-proof Rooms 17
6.2 Hibernation of the EWT in Non Frost-proof Rooms 17
6.2.1 Electric Heat Exchanger with Vertical Layout 17
7.2.1 Electric Heat Exchanger with Horizontal Layout 17
7 Troubleshooting 17
8 Circuit Diagram 18
8.1 Switchbox for EWT 80-41/-71 19
9 Explosion Drawings and Piece Lists 20
9.1 EWT 80-40 20
9.2 EWT 80-41 21
9.3 EWT 80-70 22
9.4 EWT 80-71 23
9.5 Piece List 24
10 EG-Declaration of Conformity 25
11 Notes 26
Electric Heat Exchanger / Table of contents
English

1
Electric Heat Exchanger / Safety
English
The electric heat exchanger has been built on the basis of state-of-the-art technology and the approved
safety-technical guidelines. Nevertheless, risks might occur during use such as
– violation of operator or
– third parties
– impairments in electric heat exchanger or
– damage to other material values.
All persons, who are engaged in installation, initial operation, operation, maintenance and repair of the
electric heat exchanger, have to:
– be qualied accordingly.
– strictly observe these installation instructions.
„This appliance ist not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge, unless they have been given supervision or inst-
ruction concerning use of the appliance by a person responsible for their safety. Children should be super-
vised to ensure that they do not play with the appliance.“
The electric heat exchanger may only be used
– for the intended purpose.
– in a perfect safety-technical state.
In the case of disorders, which might impair safety, a sanitary expert is to be consulted.
In rooms where electrical appliances are in function should be a smoke detector installed.
It‘s all about your safety.
1 Safety
Symbol Signal word / Meaning
DANGER FROM ELECTRICITY
This symbol means warning of dangerous electric high power to the health of
persons.
Non-observance of this information might lead to severe injury.
DANGER
This symbol means possible danger to the health of persons.
Non-observance of this information might lead to severe injury.
TAKE CARE
This symbol means a possible hazard for the health of persons.
Non-observance of this information might lead to injury to persons. or damage to things.
IMPORTANT
This symbol gives important information for correct handling of the system.
Non-observance of this information might lead to disorders in the system or the
environment.
1.1 Risks When Handling Electric Heat Exchanger
1.2 Safety Instructions and Information
Non-observance of this information might lead to injury to persons or damage to things.

2
Electric Heat Exchanger / Safety
English
1.3 Intended Use
The electric heat exchanger is exclusively designed for heating bathwater with activated recirculating or
lter pump.
Any other mode of application is not regarded as intended use. The manufacturer Behncke ® GmbH is not liable
for any resulting damage. Other uses are only possible upon agreement with and approval by the manufacturer.
Water with the following values may only be used:
EWT 80-40/-41/-70/-71
Chloride content max. 500 mg/I
Free chlorine max. 1 ,3 mg/I
pH 6,8 - 8,2
Langelier index -0,3 – +0,3
The specic water resistance must not be less than ≤ 1100 Ω cm at 15°C.
Retrots and changes in the heat exchanger are prohibited for safety reasons.
For safety reasons, maintenance and repair work on the piping and electrical installation must only be
carried out by qualied personnel.
IMPORTANT
The intended use also includes
– observance of all pieces of information in the installation instructions and
– execution of inspection and maintenance activities.
Maximum permissible operational overpressure of 300 kPa (3 bar) must not be
exceeded.
Minimum permissible operational overpressure of 10 kPa (0.1 bar) must be
achieved.
The minimum throughput is 1000l/h.

3
Electric Heat Exchanger / Safety
English
1.4 Sources of Danger
TAKE CARE
The electric heat exchanger can be damaged.
If the maximum operational pressure of 300 kPa (3.0 bar) is exceeded,
the electric heat exchanger might develop leaks.
TAKE CARE
There is a risk of burns.
The connections and the electric heat exchanger might reach temperatures of
up to 100° C.
In the case of a failure of the safety devices (safety pressure limiter and/or
safety temperature limiter and/or ow control) strong overheating of the
electric heat exchanger is possible.
The installation of a ow control as an additional safety device is recommended.
(see EWT 80-41/-71)
It prevents the heating resistor from burning out during water standstill.
If the electric heat exchanger is installed more than 0.5 m below the surface of
the bathwater, the safety pressure limiter becomes ineffective.
The installation of a ow control is prescribed in this case as an additional
safety device.
TAKE CARE
The electric heat exchanger might be damaged.
If dripping water falls onto the outer skin or if metal particles enter the electric
heat exchanger, the risk of contact corrosion exists.
1.5 Safety Measures on the Installation Site
TAKE CARE
The electric heat exchanger or the environment can be damaged.
Please check the electric heat exchanger and its connections for tightness and
visible damage once a week during operation.
TAKE CARE
The danger of combustion exists.
In the case of a failure of the safety pressure limiter and the safety temperature
limiter, strong overheating of the electric heat exchanger is possible.
Do not store any combustible materials in the environment.
The installation of a ow control as an additional safety device is recommended.
(see EWT 80-41/-71) It prevents the heating resistor from burning through
during a water standstill.
The electric heat exchanger is to be installed in a frost-proof room with a mounting device made of plastic
or stainless steel.
Please ensure that the maximum operational overpressure of 300 kPa (3.0 bar) is not exceeded.

4
Electric Heat Exchanger / Safety
English
The warning sign on the electric heat exchanger refers to the dangers due to electric current.
The electric heat exchanger is equipped with a safety pressure limiter. The safety pressure limiter serves
as a low-water safeguarding device (see EWT 80-40 and -70).
1.6 Safety Equipment
TAKE CARE
The electric heat exchanger must be protected by at least two
safety circuit breakers.
The following combinations are offered by the factory
– with a control thermostat.
– with a control thermostat and a safety temperature limiter (STB).
– with a control thermostat, a STB and a Flow switch.
– with a contactor of up to 12 kW.
TAKE CARE
The electric heat exchanger can be damaged.
The electric heat exchanger may only be put into operation if it has been
ensured that the electric heat exchanger is continuously supplied with water during
operation. The water throughput must be at least 1000l/hour.
If no contactor has been installed by the factory, an external protection for switching the heating element
is necessary (e. g. Behncke control for EWT 80-xx).
Switchbox with contactor: 3–12 kW Article No. 304 006 12
15–18 kW Article No. 304 006 18
Controller including second contactor to facilitate emergency off including Indicator light (highly
recommended) for EWT 80-41/-71 with a control thermostat and STB:
3–12 kW Article No. 304 007 12
15–18 kW Article No. 304 007 18
– The switchbox is not included in the shipment – (and should be ordered separately).
The safety devices switch off the electric heat exchanger if impermissible values are reached.

5
Electric Heat Exchanger / Technical Data
English
Article Power
[kw]
Supply Voltage
[Volt]
Temperature
Selection
[C°]
Article No.
EWT 80-40 1,5 230 0 - 40 304 501 50
EWT 80-40 3 400 0 - 40 304 503 00
EWT 80-40 6 400 0 - 40 304 506 00
EWT 80-40 9 400 0 - 40 304 509 00
EWT 80-40 12 400 0 - 40 304 512 00
EWT 80-40 15 400 0 - 40 304 515 00
EWT 80-40 18 400 0 - 40 304 518 00
2.1 EWT 80-40 – Sleeve for Tube and Thread 1 1/2”
2 Technical Data
We reserve the right to make changes or special designs.
Article Power
[kw]
Supply Voltage
[Volt]
Temperature
Selection
[C°]
Article No.
EWT 80-41 1,5 230 0 - 40 304 401 50
EWT 80-41 3 400 0 - 40 304 403 00
EWT 80-41 6 400 0 - 40 304 406 00
EWT 80-41 9 400 0 - 40 304 409 00
EWT 80-41 12 400 0 - 40 304 412 00
EWT 80-41 15 400 0 - 40 304 415 00
EWT 80-41 18 400 0 - 40 304 418 00
2.2 EWT 80-41 – Sleeve for Tube and Thread 11/2”with flow switch
Article Power
[kw]
Supply Voltage
[Volt]
Temperature
Selection
[C°]
Article No.
EWT 80-70 1,5 230 0 - 40 304 501 57
EWT 80-70 3 400 0 - 40 304 503 07
EWT 80-70 6 400 0 - 40 304 506 07
EWT 80-70 9 400 0 - 40 304 509 07
EWT 80-70 12 400 0 - 40 304 512 07
EWT 80-70 15 400 0 - 40 304 515 07
EWT 80-70 18 400 0 - 40 304 518 07
2.3 EWT 80-70 – PVC Glued/Screwed Connection

6
Electric Heat Exchanger / Set-up/Installation
English
Article Power
[kw]
Supply Voltage
[Volt]
Temperature
Selection
[C°]
Article No.
EWT 80-71 1,5 230 0 - 40 304 401 57
EWT 80-71 3 400 0 - 40 304 403 07
EWT 80-71 6 400 0 - 40 304 406 07
EWT 80-71 9 400 0 - 40 304 409 07
EWT 80-71 12 400 0 - 40 304 412 07
EWT 80-71 15 400 0 - 40 304 415 07
EWT 80-71 18 400 0 - 40 304 418 07
2.4 EWT 80-71 – PVC Glued/Screwed Connection with flow switch
Transport the electric heat exchanger only after it has been drained.
Store the ushed and drained electric heat exchanger in interior rooms with nonaggressive atmosphere only.
3 Set-up/Installation
3.1 Transportation/Storage

7
Electric Heat Exchanger / Set-up/Installation
English
EWT 80-40
3.2 Set-up and Installation Dimensions
Article Power
[kw]
A
[mm]
B
[mm] C*
[Ø Zoll]
EWT 80-40 1,5 330 130 1 1/2
EWT 80-40 3 440 240 1 1/2
EWT 80-40 6 510 310 1 1/2
EWT 80-40 9 510 310 1 1/2
EWT 80-40 12 600 400 1 1/2
EWT 80-40 15 800 600 1 1/2
EWT 80-40 18 800 600 1 1/2
*Sleeve for turbe and thread

8
Electric Heat Exchanger / Set-up/Installation
English
EWT 80-41
Article Power
[kw]
A
[mm]
B
[mm] C*
[Ø Zoll]
EWT 80-41 1,5 400 200 1 1/2
EWT 80-41 3 510 310 1 1/2
EWT 80-41 6 580 380 1 1/2
EWT 80-41 9 580 380 1 1/2
EWT 80-41 12 670 470 1 1/2
EWT 80-41 15 870 670 1 1/2
EWT 80-41 18 870 670 1 1/2
*Sleeve for turbe and thread

9
Electric Heat Exchanger / Set-up/Installation
English
EWT 80-70
Article Power
[kw]
A
[mm]
B
[mm]
EWT 80-70 1,5 380 180
EWT 80-70 3 490 290
EWT 80-70 6 560 360
EWT 80-70 9 560 360
EWT 80-70 12 650 450
EWT 80-70 15 850 650
EWT 80-70 18 850 650
*Sleeve for turbe and thread

10
Electric Heat Exchanger / Set-up/Installation
English
EWT 80-71
Article Power
[kw]
A
[mm]
B
[mm]
EWT 80-71 1,5 450 250
EWT 80-71 3 560 360
EWT 80-71 6 630 430
EWT 80-71 9 630 430
EWT 80-71 12 720 520
EWT 80-71 15 920 720
EWT 80-71 18 920 720
*Sleeve for turbe and thread

11
Electric Heat Exchanger / Set-up/Installation
English
3.3 Set-up
Set up the electric heat exchanger in frost-proof and dry rooms with non-aggressive atmophere only. Drip-
ping water might damage the electric heat exchanger.
Ensure easy access for installation and removal purposes.
The following water values are always to be observed for the electric heat exchanger.
TAKE CARE
The risk of combustion exists in the case of a failure of the safety devices.
Overheating of the electric heat exchanger might cause a re.
Draining of the electric heat exchanger during operation must be prevented. Do
not store any combustible material in the environment.
TAKE CARE
The following water values are always to be observed for the electric heat exchanger.
EWT 80-40/-41/-70/-71
Chloride contents max. 500 mg/I
Free chlorine max. 1 ,3 mg/I
pH 6,8 - 8,2
Langelier index -0.3 - +0.3
Water throughput min. 1000 I/h
Minimum operational overpressure 10 kPa (0,1 bar)
Maximum operational overpressure 300 kPa (3,0 bar)
3.4 Installation
Check the electric heat exchanger before installation for visible damage.
The electric heat exchanger can be installed horizontally or vertically above or below water level.
When installed either 0,5 m above or below the water-level the manometric safety switch (low-water safety
device) loses its effectiveness. In this event, instead of a manometric switch, it is absolutely necessary to t a
Behncke ® ow switch (see EWT 80-41/-71).

12
Electric Heat Exchanger / Set-up/Installation
English
3.5 Water Connection
3.5.1 Installation Layout above the Water Level
Figure: horizontal installation (EWT 80-40/-70)
Figure: horizontal installation (EWT 80-41/-71)
Figure: vertical installation (EWT 80-40/-70)

13
Electric Heat Exchanger / Set-up/Installation
English
3.5.2 Installation Layout under the Water Level
Figure: horizontal installation EWT 80-40/-70
Figure: horizontal installation EWT 80-41/-71
Figure: vertical installation EWT 80-40/-70

14
Electric Heat Exchanger / Set-up/Installation
English
3.5.3 Connecting the Electric Heat Exchanger to the Water Cycle of a Filter System
Install the electric heat exchanger in the pressure line (to the basin) after pump and lter.
The EWT 80-40/-41 is integrated into the water cycle via interior threads or tube connections with tube clips.
The EWT 80-70/-71 is integrated into the water cycle with PVC glued/screwed connections.
TAKE CARE
The electric heat exchanger can be damaged.
When the heat exchanger is connected to the water cycle, please take care that
metal particles do not enter the electric heat exchanger.
TAKE CARE
The electric heat exchanger might be damaged by chemicals.
Disinfecting devices are always to be installed in the ow direction after the
electric heat exchanger. The minimum distance must be 1 m and the order:
rst water hardness control, than chlorine vaccination is to be observed. If
chemicals (e. g. chlorine gas) are used, gases must not enter the electric heat
exchanger during lterstandstill times.
3.5.4 General Installation Instructions for Flow switch
At rst clean the piping system where the ow switch should be installed and remove any magnetic particles
such as weld spatters.
Straight pipe upstream and downstream of the ow switch must be at least 5 x pipe diameter.
The ow switch must only be installed in a horizontal pipe.
Contact the manufacturer for deviating positions.
Install the switch only vertically, max. deviation is 45° (g. 1).
Make sure that there are no magnetic elds close to the ow switch. Such elds can affect the proper
function of the instrument (g. 2).
There is an arrow on the ow switch. Make absolutely sure that this arrow is parallel with the pipe axis and
points into ow direction (g. 3).
Screw on the union nut 3/4“ made of plastic with a maximum torque of 8 Nm.
g. 1 g. 2g. 3

15
Electric Heat Exchanger / Set-up/Installation
English
DANGER FROM ELECTRICITY
The connection can only be made by professionals. The rules according to
VDE 0100 must be respected. The rules of the local EVU/RU must be respected.
Outside of Germany are the countries own regulations.
The heat exchanger must be permanently connected to xed pipework which is
tted with a protective earth conduktor.
TAKE CARE
The electric heat exchanger must be protected by at least two safety
circuit breakers.
The following combinations are offered by the factory
– with a control thermostat.
– with a control thermostat and a safety temperature limiter (STB).
– with a control thermostat, a STB and a Flow switch.
– with a contactor up to 12 kW.
If no contactor has been installed by the factory, an external protection for
switching the heating element is necessary (e. g. Behncke control for EWT 80-xx).
IMPORTANT
It should be ensured that the electric heat exchanger can only be switched on if the
water throughput is ensured.
The electrical connections are to be effected in accordance with the switch dia-
gram. For safety reasons, an FI safety switch is to be integrated into the voltage
supply (30 mA). All metal parts are to be integrated into equipotential bonding.
3.6 Flow switch
3.7 Electrical Connections
DANGER FROM ELECTRICITY
Risk to life through electrical voltage!
Switch off the electrical system before you connect leads of the supply cable.
brown/black = connections for Reed contact
The reed contact is electrically insulated (protection class II) and integrated into a
plastic sleeve.
TAKE CARE
Lebensgefahr durch elektrische Spannung!
The maximum electrical contact capacity indicated onto the type shield must
not be exceeded, otherwise the reed contact, which is integrated in the switching
unit, will be damaged. The switching capacity is reduced with inductive loads.
Information about the protective system can be ordered at the manufacturer.

16
Electric Heat Exchanger / Functional Course
English
4 Functional Course
In the electric heat exchanger, heat is transferred to the bathwater through the heatingelement.
The thermostat regulates the water temperature in accordance with the adjusted value, range from 0 to 40°C.
EWT 80-40/-70: If the required operating overpressure falls to below 6 kPa (0.06 bar) due to insufcient water
throughput, the safety pressure limiter switches off the electric heat exchanger.
EWT 80-41/-71: If the required overpressure falls to below 36 l/min. due to insufcient water throughput, the
Flow switch switches off the electric heat exchanger.
Special made with safety temperature limites: The safety temperature limiter protects from overheating. It
switches the electric heat exchanger off at a temperature of 44°C.
By pressing the disorder button, the electric heat exchanger can be put into normal operation again after
removal of the disorder.
5 Initial Operation
Have you read and understood these operating instructions - in particular Chapter 1, Safety? Only then are
you allowed to start the electric heat exchanger.
• Adjust the desired bathwater temperature in the thermostat.
The electric heat exchanger heats the bathwater as long as the adjusted temperature has not been reached.
TAKE CARE
The electric heat exchanger can be damaged.
Work in piping and electrical installation are only to be effected by specialist
personnel for safety reasons.
Do not step on the heat exchanger.
Only carry out maintenance and repair work with closed blocking and control
units in the water cycle.
Ventilate the entire water cycle, otherwise can the heating element harm to
take.
6 Maintenance/Repair
Check the heat exchanger and its connections for their tightness once a week and ventilate the entire water cycle.
TAKE CARE
The electric heat exchanger can be damaged.
Work in the electrical heat exchanger are only to be effected by specialist per-
sonnel for safety reasons.
Do not step on the electric heat exchanger.
Only carry out work in the piping connections with closed blocking and control
units in the water cycle!

17
Electric Heat Exchanger / Troubleshooting
English
6.1 Hibernation of the EWT in Frost-proof Rooms
TAKE CARE
Intervention in technical systems by unqualied persons might lead to injury or
damage.
For hibernation in frost-proof rooms, the electric heat exchanger must be
completely lled with water or be completely drained.
6.2 Hibernation of the EWT in Non Frost-proof Rooms
TAKE CARE
Expert hibernation without frost damage is possible if the following steps are
observed:
• Close blocking units in the water cycle (the blocking units must be installed in
frost-free rooms).
• Flush and drain electric heat exchanger and adjoining pipes until blocking units.
6.2.1 Electric Heat Exchanger with Vertical Layout
Drain electric heat exchanger completely via drain ttings.
7 Troubleshooting
Effects Checking the possible cause
No performance is the electric heat exchanger connected to the
electrical supply?
have the blocking units been opened?
is the electric heat exchanger completely lled with
water?
has the electric heat exchanger been ventilated?
is there sufcient ow (see Technical Data) in the
electric heat exchanger?
Electric heat exchanger further heated up, despite
deactivated bathwater recirculating pump
has the lock between bathwater pump and electric
heat is exchanger been activated?
7.2.1 Electric Heat Exchanger with Horizontal Layout
Remove heat exchanger with horizontal layout.
Flush heat exchanger in order to remove contamination and store in a dry place.