Behncke WTI 100 Series User manual

Operating Instructions
Water/water heat exchanger
•Heating/swimming pool water (QWT, WTI)
•Solar system/swimming pool water (SWT, SWT-T)
Read the operating instructions before commencing any work!
Doc ID: 07/2015

Water/water heat exchanger – QWT, WTI, SWT, SWT-T
01.07.2015 2
BEHNCKE GmbH
Bavaria:
Michael-Haslbeck Strasse 13
85640 Putzbrunn, Germany
Telephone: [phone]
Fax: [phone]
Saxony-Anhalt:
Stoetterlinger Strasse 36 a
38835 Bühne, Germany
Telephone: [phone] - 796-0
Fax: [phone] / 796-30
Email:[email protected]om
Website: www.behncke.com

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Contents
General............................................................................................................... 4
1Safety........................................................................................................... 5
1.1 Dangers in working with this heat exchanger........................................................ 5
1.2 Safety instructions and tips ................................................................................ 6
1.3 Proper use........................................................................................................ 7
1.4 Sources of danger ............................................................................................. 8
1.5 Safety precautions at the installation site............................................................. 9
2Technical specifications.............................................................................. 10
2.1 QWT 100*...................................................................................................... 10
2.2 SWT 100* ...................................................................................................... 10
2.3 SWT 100 Titanium*......................................................................................... 11
2.4 WTI 100*....................................................................................................... 11
3 Setup/installation ...................................................................................... 12
3.1 Transport/storage ........................................................................................... 12
3.2 Setup and connection dimensions...................................................................... 12
3.3 Setup ............................................................................................................ 14
3.4 Installation..................................................................................................... 15
3.4.1 Installation layout above the water level ...................................................... 15
3.4.2 Installation layout below the water level ...................................................... 16
3.4.3 Connecting the heat exchanger................................................................... 16
4Function ..................................................................................................... 18
5Commissioning........................................................................................... 19
6Maintenance/repair.................................................................................... 20
6.1 Winter storage of the WHE in frost-free areas..................................................... 20
6.2 Winter storage of the WHE in areas exposed to freezing....................................... 20
6.2.1 Heat exchanger in vertical layout ................................................................ 20
6.2.2 Heat exchanger in horizontal layout............................................................. 20
7Maintenance of the stainless steel.............................................................. 21
8Faults and remedies ................................................................................... 22
9EC Declaration of Conformity in the context of the EC Directives ............... 23

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General
General
Dear customer
We congratulate you on your purchase of your new, high quality water heat exchanger "Made
in Germany".
Your specialist dealer will be pleased to provide any assistance you require.
Please read the installation instructions carefully.
Keep the installation instructions on hand for future reference.

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Safety
1 Safety
1.1 Dangers in working with this heat exchanger
The heat exchanger is manufactured in accordance with the latest technological advances and
recognised safety regulations. However, it may be dangerous when in use, as follows
•injury to the operator or
•third parties, or
•faults on the heat exchanger or
•damage to other objects.
All persons involved with installation, commissioning, operation, maintenance and repair of the
heat exchanger must meet the following requirements
•mentally and physically qualified.
•appropriately qualified.
•carefully observe the installation instructions.
The heat exchanger must used under the following conditions only
•for the intended use.
•in perfect technically safe condition.
Faults that could affect safety must be repaired by a qualified plumber.
Your safety is at stake.

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Safety
1.2 Safety instructions and tips
The following icons are used in the operating instructions:
DANGER!
This icon indicates an immediate danger to the health of persons.
WARNING!
This icon indicates a potential danger to the health of persons.
If it is not observed, serious injury may result.
CAUTION!
This icon indicates a potentially dangerous situation for the health of
persons.
If it is not observed, injury or property damage may result.
IMPORTANT!
This icon indicates important instructions for correct working with the system.
If the instructions are not observed, faults in the system or the surroundings
may result.

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Safety
1.3 Proper use
The QWT series heat exchanger is designed exclusively for heating pool water via hot water
heating.
The SWT series heat exchanger is designed exclusively for heating pool water via heat pump,
solar system or a low temperature heating system.
The WTI series heat exchanger is designed exclusively for heating pool water via hot water
heating; suitable for water with a raised chloride content (e.g. brine pools, therapy pools,
seawater pools).
The SWT-T series heat exchanger is designed exclusively for heating pool water via heat
pump, solar system or a low temperature heating system; suitable for water with a raised
chloride content (e.g. brine pools, therapy pools, seawater pools).
Any other use or use beyond this is not considered proper use. The manufacturer, BEHNCKE
® GmbH, will not be liable for any damage resulting from improper use.
Any other use requires consultation with and approval by the manufacturer.
IMPORTANT!
Proper use also includes
•following all directions in the installation instructions and
•compliance with inspection and maintenance schedules.
The maximum approved operating pressure must not be exceeded.
Heating coil (primary side) max. 1000 kPa (10 bar)
Pool water (secondary side) max. 300 kPa (3 bar)
Only water with the following values may be used:
QWT, SWT WTI, SWT-T
Chloride content max. 500 mg/ l max. 3000 mg/l
Free chlorine max. 1.3 mg/l unlimited
pH 6.5 - 8.2 6.5 - 8.2
Salt content – max. 3.5%
Conversions and modifications of the heat exchanger are prohibited for safety
reasons.

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Safety
1.4 Sources of danger
CAUTION!
The heat exchanger may be damaged.
If the max. operating pressure of 300 kPa (3 bar) is exceeded on the pool water
side or 1000 kPa (10 bar) on the heating water side, the heat exchanger may
sustain leaks.
WARNING!
There is a risk of combustion.
The connections on the heating water side of the heat exchanger can attain
temperatures up to 100 °C.
CAUTION!
The heat exchanger can heat up to the feed temperature of the heating water if
the pool water does not flow through it.
Connected plastic pipes may be thermally loaded to a non-permitted level and
thus become damaged.
CAUTION!
If the heating circuit is not locked with the circulating/filter pump, the heat
exchanger may heat up to the feed temperature of the heating water.
The heat exchanger may be damaged.
Due to water drips onto the exterior skin or metal parts being swept into the
heat exchanger may be subject to contact corrosion due to immersion in water.
CAUTION!
Pool water can become contaminated.
Metal parts being swept away into the heating coil of the heat exchanger can
cause leaks in the coil due to contact corrosion. Heating water can enter into
the pool water.

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Safety
1.5 Safety precautions at the installation site
The heat exchanger must be fitted in a frost-free area using the bracket supplied.
Make sure that the maximum positive operating pressure of 300 kPa (3 bar) on the secondary
side and 1000 kPa (10 bar) on the primary side is not exceeded.
CAUTION!
The heat exchanger or surroundings may be damaged.
Inspect the heat exchanger and its connections for leakage and external
damage at least once a week during pool operation.

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Technical specifications
2 Technical specifications
2.1 QWT 100*
Minimum pumping output
Output:
kW for
Heating
Pool water
Connection
Article
70 °C
m³/h
kPa
m³/h
kPa
Inches
Article no.
QWT 100-20
16
2
4.3
10
4.3
1 ½ ¾
305.018.00
QWT 100-30
20
2
6.4
10
4.9
1 ½ ¾
305.026.00
QWT 100-40
30
2
9.7
10
5.3
1 ½ ¾
305.033.00
QWT 100-70
50
3
3.5
12
6.6
1 ½ 1
305.017.00
QWT 100-104
90
5
14
15
11.25
2 1
305.027.00
QWT 100-140
115
2 x 3
2 x 3.5
20
12.9
2 1
305.037.00
QWT 100-209
200
2 x 5
2 x 14
25
25.3
2 1
305.047.00
2.2 SWT 100*
Minimum pumping output
Output:
kW for
Heating
Pool water
Connection
Item
70°C 50°C
m³/h
kPa
m³/h
kPa
Inches
Article no.
SWT 100-20
40 / 24
1.2
8
10
6
1 ½ ¾
330.004.00
SWT 100-25
65 / 35
1.8
27
10
7
1 ½ ¾
330.006.00
SWT 100-40
68 / 40
2.2
4
10
6
1 ½ 1
330.008.00
SWT 100-52
112 / 65
3.5
15
12
7
1 ½ 1
330.010.00

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Technical specifications
2.3 SWT 100 Titanium*
Minimum pumping output
Output:
kW for
Heating
Pool water
Connection
Item
70°C 50°C
m³/h
kPa
m³/h
kPa
Inches
Article no.
SWT 100-20
40 / 24
1.2
8
10
6
1 ½ ¾
331.004.00
SWT 100-40
68 / 40
2.2
4
10
6
1 ½ ¾
331.008.00
2.4 WTI 100*
Minimum pumping output
Output:
kW for
Heating
Pool water
Connection
Item
70 °C
m3/h
kPa
m3/h
kPa
Inches
Article no.
WTI 100-20
16
2
4.3
10
4.3
PVC 40 ¾
305.080.55
WTI 100-30
20
2
6.4
10
4.9
PVC 40 ¾
305.081.55
WTI 100-40
30
2
9.7
10
5.3
PVC 40 ¾
305.082.55
WTI 100-70
50
3
3.5
6.6
6.6
PVC 40 1
305.083.55
WTI 100-104
90
5
14
11.25
11.25
PVC 50 1
305.084.55
WTI 100-140
115
2 x 3
2 x 3.5
12.9
12.9
PVC 50 1
305.085.55
WTI 100-209
200
2 x 5
2 x 14
25.3
25.3
PVC 50 1
305.086.55
* Subject to modifications or custom versions.

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Setup/installation
3 Setup/installation
3.1 Transport/storage
Transport the water heat exchanger only when empty.
Always store the washed and drained water heat exchanger indoors in a non-aggressive
atmosphere.
3.2 Setup and connection dimensions
Item
A
mm
B
mm ø
C
mm
D
DN
E
Inches
F
Inches
QWT 100-20
275
125
90
50
1 1/2
3/4
QWT 100-30
315
125
135
50
1 1/2
3/4
QWT 100-40
385
125
205
50
1 1/2
3/4
QWT 100-70
520
190
290
50
1 1/2
1
QWT 100-104
660
190
430
60
2
1
SWT 100-20
530
153
335
50
1 1/2
3/4
SWT 100-25
710
153
520
50
1 1/2
3/4
SWT 100-40
800
190
570
50
1 1/2
1
SWT 100-52
1090
190
870
50
1 1/2
1

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Setup/installation
Item
A
mm
B
mm ø
C
mm
G
mm
D
DN
E
Inches
F
Inches
QWT 100-140
920
190
295
100
60
2
1
QWT 100-209
1190
190
430
100
60
2
1
Item
A
mm
B
mm ø
C
mm
D
DN
F
Inches
WTI 100-20
395
125
90
PVC DN40
3/4
WTI 100-30
440
125
135
PVC DN40
3/4
WTI 100-40
505
125
205
PVC DN40
3/4
WTI 100-70
640
190
290
PVC DN40
1"
WTI 100-104
820
190
425
PVC DN40
1"
SWT-T 100-20
545
153
335
PVC DN40
3/4
SWT-T 100-40
815
130
570
PVC DN40
1"

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Setup/installation
Item
A
mm
B
mm ø
C
mm
G
mm
D
DN
F
Inches
QWT 100-140
1080
190
295
100
PVC DN50
1
QWT 100-209
1350
190
430
100
PVC DN50
1
3.3 Setup
Set up the heat exchanger indoors in frost-proof, dry rooms with a non-aggressive atmosphere
only. Dripping water may damage the heat exchanger.
Make sure access for assembly and disassembly is guaranteed.
The heat exchanger can be installed above or below the water level.
CAUTION!
The following water values must be observed for the heat exchanger.
QWT, SWT WTI. SWT-T
Chloride content max. 500 mg/l max. 3000 mg/l
Free chlorine max. 1.3 mg/l unlimited
pH value 6.5 to 8.2 6.5 to 8.2
Salt content - max. 3.5 %
Max. water pressure, primary 1000 kPa (10 bar)
Max. water pressure, secondary 300 kPa (3 bar)
IMPORTANT!
When operating the heating circuit, the running empty of the heat exchanger on
the pool water side must be prevented.

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Setup/installation
3.4 Installation
Before installation, check that the heat exchanger has no visible damage.
The heat exchanger can be installed horizontally or vertically above or below the water level.
3.4.1 Installation layout above the water level

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Setup/installation
3.4.2 Installation layout below the water level
3.4.3 Connecting the heat exchanger
CAUTION!
Install the stop and drainage valves in the feed and return lines of the heating
circuit inside the frost-proof area of the building.
The heat exchanger may be damaged.
Ensure that the water quality and maximum pressure levels are observed.
CAUTION!
The heat exchanger may be damaged.
When installing a third-party circuit, make sure that metal parts cannot enter
the heat exchanger.
The heat exchanger and steel pipes are electrically isolated by brass
connections.
The heat exchanger can be damaged by chemicals.

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Setup/installation
CAUTION!
Purification equipment should always be installed after the heat exchanger.
When using chemicals (e.g. chlorine gas), it is not permitted for any gases to
penetrate the heat exchanger during filter standstill times.
3.4.3.1 QWT/SWT/WTI/SWT-T connection to a circulating pump/filter system
•Connect the hot water circuit to the primary side of the heat exchanger.
•Connect the secondary side of the heat exchanger to the pool water pipe via pipe
connections using pipe clips or via the internal thread with plastic/brass screw
connectors.
•Connect the WTI and SWT-T on the secondary side to the pool water pipework using
PVC adhesive pipe bonds.
3.4.3.2 QWT 100-140/100-209 and WTI 100-140/100-209 connection to a filter
system
•Connect both heating coils of the heat exchanger to the heating water circuit.
•Connect the secondary side of the heat exchanger to the pool water pipe via pipe
connections using pipe clips or via the internal thread with plastic/brass screw
connectors.
•Connect the WTI on the secondary side to the pool water pipework using PVC adhesive
pipe bonds.

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Function
4 Function
In the QWT counterflow heat exchanger, the heat from the heating water circuit is transferred
to the pool water circuit.
In the WTI counterflow heat exchanger, the heat from the heating water circuit is transferred
to the pool water circuit. The WTI is manufactured from titanium and is suitable for use with
water with raised free chlorine values (e.g. brine pools, therapy pools, seawater pools).
In the SWT counterflow heat exchanger, the heat from the low temperature heating water
circuit or the solar system is transferred to the pool water circuit. The SWT-T is manufactured
from titanium and is suitable for use with water with raised free chlorine values (e.g. brine
pools, therapy pools, seawater pools).
A temperature sensor can be inserted into the integrated clamp in the immersion sleeve. In
combination with a control, the temperature of the pool water can be controlled via the
temperature controller.

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Commissioning
5 Commissioning
WARNING!
Have you read and understood these operating instructions – particularly
chapter 1 Safety? Do not operate the heat exchanger if you have not read and
understood the instructions!
The heat exchanger may be damaged.
Do not climb on the heat exchanger.
Always close all stop valves in both water circuits before performing any
maintenance and cleaning work.
•Drain both water circuits.

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Maintenance/repair
6 Maintenance/repair
Inspect the heat exchanger and connections for leaks once a week.
6.1 Winter storage of the WHE in frost-free areas
CAUTION!
Changes to technical systems by unqualified persons may result in injuries and
property damage.
If decommissioned in frost-free areas, the heat exchanger must be completely
filled with water.
6.2 Winter storage of the WHE in areas exposed to freezing
The heat exchanger can be stored under freezing conditions after the following preparations.
•Close stop valves in both water circuits.
•Drain the heat exchanger and connecting pipes to the stop valves.
6.2.1 Heat exchanger in vertical layout
•Completely drain the heat exchanger via the drain fittings.
6.2.2 Heat exchanger in horizontal layout
•Remove the heat exchanger in horizontal layout.
•Rinse the heat exchanger to remove contamination, and store dry.