Danfoss S19 Guide

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User Guide
Plate Type Heat Exchangers, Single plate & Semi-welded
Installation, Commissioning and Maintenance

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
2 | BC172686461130en-000201 © Danfoss | DCS (ms) | 2019.07
Introduction.............................................................................................................................................................................................................. 3
Safety alert notices ............................................................................................................................................................................................. 3
General .......................................................................................................................................................................................................................... 4
Design: Single plate and Semi-welded.............................................................................................................................................. 6
Frame ................................................................................................................................................................................................................... 6
Single Plates.................................................................................................................................................................................................... 6
Semi-welded plates (plate cassettes)............................................................................................................................................ 6
Gaskets................................................................................................................................................................................................................ 6
Description................................................................................................................................................................................................................. 7
Right (R)/ Left (L) plates........................................................................................................................................................................... 7
Right and left plates, Single plates.................................................................................................................................................. 7
Storage........................................................................................................................................................................................................................... 8
Installation ................................................................................................................................................................................................................. 8
Transport and lifting.................................................................................................................................................................................. 9
Piping system.........................................................................................................................................................................................................10
Filtration .................................................................................................................................................................................................. 10
Installing the pipe connections.......................................................................................................................................................10
Commissioning.....................................................................................................................................................................................................11
Start-up process .........................................................................................................................................................................................11
Shut-down ................................................................................................................................................................................................................12
Shut-down for a short period...........................................................................................................................................................12
Shut-down for a long period.............................................................................................................................................................12
Maintenance ...........................................................................................................................................................................................................12
CIP cleaning...................................................................................................................................................................................................12
Cleaning agents guidance..................................................................................................................................................................12
Opening the plate heat exchanger ..............................................................................................................................................13
Mechanical/Manual Cleaning...........................................................................................................................................................14
Plate/Cassette replacement...............................................................................................................................................................15
Gasket replacement.................................................................................................................................................................................15
Closing the plate heat exchanger..................................................................................................................................................16
Regular Service of the plate heat exchanger.........................................................................................................................17
Additional service for semi-welded heat exchanger .......................................................................................................17
Troubleshooting..................................................................................................................................................................................................18
After sales service ...................................................................................................................................................................................... 19
Ordering parts .............................................................................................................................................................................................19
Modications to the heat exchanger..........................................................................................................................................19
Contents

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
© Danfoss | DCS (ms) | 2019.07 BC172686461130en-000201 | 3
Introduction
Safety alert notices
This user guide is a guide for installation,
commissioning and maintenance of plate type
heat exchangers supplied by Danfoss.
It is meant for those who are responsible for the
installation, the use and maintenance of the heat
exchangers. We recommend that you read this
user guide carefully before commencing any
work.
This user guide is applicable for all plate type
heat exchangers produced and supplied by
Danfoss.
Danfoss can not be held responsible or liable for
damage as a result of incorrect installation, use
and/or maintenance of Danfoss plate type heat
exchanger or damage caused by as not
complying with the instructions in this user guide.
Please note that our plate type heat exchangers
are specially designed and built for the maximum
design conditions (pressures, temperatures,
capacities and type of uids) provided by the
customer and stated on the nameplate.
The following must always be observed when
installing or servicing plate heat exchangers:
• Comply with national/local safety regulations
• Ensure that the heat exchanger is
unpressurized
• Ensure that the heat exchanger is cooled down
to a temperature below 40 °C (104 °F)
Warning symbols refer to safety alert notices.
Warning/safety notices should be observed
carefully to prevent:
Personal injury caused by:
• Wrong transport/lifting
• Burning/freezing as a result of touching
parts with extreme temperatures.
• Burning/freezing/poisoning as a result
of uncontrolled release of pressurized
media
• Contact with chemicals
• Touching sharp edges of e.g plates or
cassettes
Equipment damage caused by:
• Wrong transport/lifting
• Liquid hammering
• External forces
• Corrosion
• Chemical action
• Erosion
• Material fatigue
• Thermal and/or mechanical shock
• Freezing
• Blocking of the heat exchanger due to
particles
Sudden pressure peaks beyond the maximum
operating pressure (or pressure surges) which
can occur during start-up or stopping of the
system can severely damage the heat exchanger
and should be prevented. Danfoss can not be
held responsible for any damage as a result of
any operation deviating from the original design
conditions.

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
4 | BC172686461130en-000201 © Danfoss | DCS (ms) | 2019.07
General Identification of the heat exchanger
All plate type heat exchangers supplied by
Danfoss are provided with a name plate
positioned on the front (head) of the heat
exchanger.
Fig. 1. Nameplate examples. (*) Danfoss Quality approval confirms PHE has passed leak test procedure
On this plate main technical details of the heat
exchanger are specied.
Before installation please make sure that the
intended application is compliant with the name
plate application data and use limitations.
Single plate heat exchanger Nameplate
Semi-welded plate heat exchanger Nameplate
Month/year of production
Month/year of production
Type designation
Type designation
Serial number
Serial number
Assembly (A) measure nominal
Tolerance -1.5%
Max. pressure drop
Min./max. working temp.
Inlet - outlet connections
Max. working pressure
Max. allowed test pressure
Total internal volume
Fluids per side
Assembly (A) measure min.
Inlet - outlet connections
Max. working pressure
Max. allowed test pressure
Total internal volume
Fluids per side
Max. pressure drop
Assembly (A) measure max.
Min./max. working temp.
1727
MADE IN DENMARK
Plate heat exchanger type
S19
IRF76804
12-2018
Serial No. Marking
Month and year
Manufactured by Danfoss A/S, 6430 Nordborg, Denmark
Do not exceed above values at any time.
Please read instruction manual before
installation, operation and maintenance.
MM-YY
159
A-measure min.
mm
Inlet > outlet
Max. working pressure
Max. test pressure
Volume
Fluid
Ref. Side
F4 - F1
16 16
20,820,8
23,523,5
WaterWater
Bar
Bar
Ltr.
F3 - F2
/
/
/
/
/
/
Brine side
F1
F4
F3
F1
B1
B2
B4
B3
F2
A-measure
16
Max. dierential pressure
Bar
-
A-measure max.
mm
80
Max. working temperature
°C
0
Min. working temperature
°C
(*)
MADE IN DENMARK
Plate heat exchanger type
SW19A-IG
76803
159
16
0 80
02-2019
Serial No.
A-measure Nominal*
Max. dierential pressure
Min. working temperature
Inlet > outlet
Max. working temperature
Marking
Month and year
Max. working pressure
Max. test pressure
Volume
Fluid
Manufactured by Danfoss A/S, 6430 Nordborg, Denmark
Ref. Side
F4 - F1
16
20,8
23,5
NH₃
MM-YY
/
/
/
/
/
/
mm
Bar
°C°C
F1
F4
F3
F1
B1
B2
B4
B3
F2
A-measure
1727
(*)
Do not exceed above values at any time.
A-measure min.:
A-measure Nominal - 1.5%
Please read instruction manual before
installation, operation and maintenance.
16
20,8
23,5
PropGlycol
Bar
Bar
Ltr.
F3 - F2
Brine side

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
© Danfoss | DCS (ms) | 2019.07 BC172686461130en-000201 | 5
General
(continued)
Each heat exchanger comes with a data list
specifying key components and relevant
Datalist (example)
Drawing (example)
Calculated parameters Unit Ref Side Brine Side
Flow Type Co-Current
Load kW 350,00
Inlet temperature °C -7,59 -1,00
Evaporating temperature °C -8,00
SuperHeating K 0,00
Outlet temperature °C -8,00 -5,00
Inlet/Outlet quality 0,000/0,667
Mass flow rate kg/h 1464,4 83899,1
Volumetric flow rate L/min 1346,458
Total pressure drop kPa 5,03 93,71
Pressure drop - In port kPa 0,63 5,20
Total area m 26,60
Surface margin % 8,7
LMTD K 4,48
HTC(Available / Required) W/m-K 3189/2935
Heat flux kW/m 13,158
Abs.Evaporating pressure bar 3,15
Port velocity m/s 0,09(Inlet)/15,22(Outlet) 3,23
Shear stress Pa 5,41 109,07
Properties of fluid Unit Ref Side Brine Side
Fluid Ammonia Ethylene glycol(25,00%)
Liquid viscosity mPa-s 0,1855 3,6207
Liquid density kg/m 649,1 1039,1
Liquid heat capacity kJ/kg-K 4,575 3,755
Liquid thermal conductivity W/m-K 0,583 0,451
Vapor viscosity mPa-s 0,0088
Vapor density kg/m 2,6
Vapor heat capacity kJ/kg-K 2,570
Vapor thermal conductivity W/m-K 0,023
Specification: Unit Ref Side Brine Side
HEX Type: – SW40A-72-TM
Number of plates: – 72
Max.number of plates in current frame: – 84
Grouping: – (35TM)/(36TM)
Plate thickness / material: – 0,5mm / EN1.4301(AISI304)
Main Gasket / Ring Gasket: – NITRIL HT (H) / CHLOROPRENE
Connection: – DN 100 Flange cl. AISI316 PN16 DN 100 Flange cl. AISI316 PN16
Counter Flange – Yes Yes
Frame type / color: – C2L / RAL3020
Certification/Approval type: – PED
Volume: L 26,28 28,7
Weight: kg 253,74
Min. wall temperature °C -7 -6,56
Design Temp. (Max/Min): °C 50/-12
Design Pressure(Max) Ref./Brine: bar 16/16
Customer: Contact person:
Project: E-mail:
HEX Type: SW40A-72-TM Engineer: IR
Unit: 1 (Parallel) Code: – Date: 04-03-2019 16:28:08
accessories as per specic customer order, heat
exchanger dimensions, and an assembly drawing.
Fig. 2. Standard documentation datalist and drawing (examples)

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
6 | BC172686461130en-000201 © Danfoss | DCS (ms) | 2019.07
Design:
Single plate and
Semi-welded
Frame
The heat exchanger consists of a frame plate
(head), a pressure plate (follower), a carrying bar,
a guiding bar and a column. Tie bolts are used to
press the plate package together. The size and
number of bolts depend on the type of heat
exchanger.
The ring gasket material is carefully selected to
match the combination of temperature and
chemical resistance requirements (e.g. NH₃ and
compressor oil on the welded side).
Gaskets
The following gasket types are used in Danfoss
plate type heat exchangers:
• Sonderlock gaskets
• Glued gaskets
• Sonder Snap gaskets (semi-welded plate heat
exchangers, large range)
• Hang-on gaskets (semi-welded plate heat
exchangers)
Single Plates
Single plate pack consists of single plates tted
with a ow gasket on each plate to seal the plate
pack. The number of plates, size and dimension
depend on the thermal output required. The
number of plates determines the total heat
transfer area (surface).
Semi-welded plates (plate cassettes)
A plate cassette consists of two single ow plates
welded together, creating a sealed ow channel.
The cassettes are tted with two individual
gaskets, a ring gasket and a eld gasket, to seal
the plate pack preventing the intermixing of
media. This gasket design allows the use of
dierent gasket materials for the ring and eld
gaskets respectively for best t to the actual
media and temperature conditions.
Fig. 4. ”Hang-on” gasket
Fig. 3. Construction of generic Semi-welded heat exchanger.
Single Plate construction is identical except plates are not paired (welded) into cassettes.
Roller C a rryin g bar
Head
Na m e P late
Tie bolt
Guiding bar
Plate/Cassette
Follower
Column
Anchoring
b ra ck e ts
Roller Carrying bar
Column
Follower
Plate/Cassette
Guiding bar
Tie bolt
Name Plate
Head
Anchoring
brackets

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
© Danfoss | DCS (ms) | 2019.07 BC172686461130en-000201 | 7
Description
(Continued)
Right (R)/ Left (L) plates
Plates are designed in such a way that they can
be used both as right and left plates by
alternately turning them 180°. Semi-welded
cassettes are not turned.
Right and left plates, Single plates:
On a right plate the ow runs from porthole 2 to
3 or reverse from porthole 3 to 2.
On a left plate the ow runs from porthole 1 to 4
or reverse from porthole 4 to 1.
The opening of the corner portholes is described
in a “plate code index”. For instance 1234 means
that all corner portholes are open. Every plate
can be identied by the gasket conguration, the
plate code index, and the plate geometry (e.g.
thermal short or thermal long geometry).
Fig. 5. Single plates: Left and Right plates and flow
Fig. 6. Semi-welded plates (cassettes) have no Left and Right plates. Refrigerant always flows in port 1 and 4
1
2
4
3
R
L
R
1
2
4
3
Cassettes x N
(total number of plates 2xN+2)
Connections:
1, 4: Refrigerant side, *Ring gasket high
2, 3: Brine side, *Ring gasket low
Flow arrows shown are only indicative
Connections:
1, 4: Brine 1
2, 3: Brine 2
Flow arrows shown are only indicative
Head
Brine ow Field gasket
Follower
Ring gasket
Refrigerant ow
Ring gaskets h/l*
First plate:
Single plate
with no gaskets
Last plate:
Single plate
without portholes
Single plates x N
Follower
Last plate:
plate without
portholes
Each plate rotated
180° relative to plate
before/after
Standard gasket
Used on all plates
except rst
First plate:
Special gasket
All portholes gasketed)
Head

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
8 | BC172686461130en-000201 © Danfoss | DCS (ms) | 2019.07
Storage
Foundation
Install the heat exchanger on a at foundation
providing sucient support for the frame.
Space
Ensure enough space around the plate heat
exchanger for servicing the unit (renewal of
plates, tightening of the plate pack).
As a rule, free space around the unit should be
1.5 to 2 x the width of the unit. See Fig. 7.
Drip tray
Replaceable plate heat exchangers involve a risk
of leakage.
It is recommended to take this into account while
installing. Preferably install a drip tray underneath
the heat exchanger to prevent leakages onto the
oor and/or harm to electrical equipment.
Screen plate
If the heat exchanger is being used with
temperatures above 60 °C or with aggressive
uids, we advise that you cover the heat
exchanger with a screen plate to prevent the risk
of human exposure to the surface and uids.
If storing the plate heat exchanger for a longer
period of time, i.e. more than one month/30
days, the following precautions should be taken
to prevent unnecessary equipment damage:
Preferably the plate heat exchanger should be
stored inside in dry conditions at room
temperatures around 15 – 20 °C (59 – 68 °F) and
a humidity of maximum 70%.
If this is not possibly, place the plate heat
exchanger in a wooden box provided with a
lining on the inside that will prevent against
moisture penetration.
Rubber gasket material is sensitive to certain
agents and ultraviolet radiation.
• Plate heat exchangers must be stored
in rooms with no ozone producing
equipment such as electric motors or
arc-welding equipment as ozone may
destroy several rubber materials
• Plate heat exchangers should not be
stored together with any organic
solvents or acids in the room
• Do not expose the plate heat exchanger
to ultraviolet radiation
Fig. 7. Ensure enough free space for servicing the plate
heat exchanger
Installation
Min.

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
© Danfoss | DCS (ms) | 2019.07 BC172686461130en-000201 | 9
Installation
(Continued)
Transport and lifting
WARNING:
To prevent personal injury always use
appropriate hoisting equipment. If you
are to lift the heat exchanger itself,
straps should be used. The straps
should be placed as shown in fig. 8.
Usually the heat exchanger will be supplied
horizontally on a pallet.
The back side of the head will then be secured
to the pallet. This allows the unit to be
transported by means of a forklift truck.
Raising of the unit: see g. 8.
• Remove all tightening elements from the pallet
• Place straps around opposite bolts on each side
of the column (1)
• Lift the unit vertically from the pallet (2)
• Remove the pallet securely (3)
• Slowly lower the heat exchanger to the oor (4)
• Remove the straps at the unit bottom side (5)
• Lift one-sided in an appropriate lifting angle (6)
and follow the raising of the unit carefully.
Avoid any bumps or shocks
• Once the heat exchanger is in upright position
place the straps in the dedicated lifting eyes (7)
and lift the unit to its nal position (8)
• Remove the straps and mount the heat
exchanger securely to the oor
Fig. 8. Lifting instructions
Never lift the heat exchanger using any
other method than described above.
Never use the connections, studs or any
intermediate plates (if fitted) for lifting
(fig. 9).
Fig. 9. Lifting points not allowed
2
4
11
3
6
5
8
7

User Guide |Plate Type Heat Exchangers, Single plate & Semi-welded - Installation, Commissioning and Maintenance
10 | BC172686461130en-000201 © Danfoss | DCS (ms) | 2019.07
Piping system Filtration
If the uid in the plate heat exchanger
contains particles larger than Ø0.5mm an inline
lter should be tted.
Installing the pipe connections
Most plate heat exchangers are intended for
counter-current ow directions, but some
specic applications require co-current ow.
Refer to name-plate for information on each
specic plate heat exchanger.
Danfoss plate type heat exchangers are
provided with various connection types
depending on size, application and
conditions.
Single plate heat exchangers come with
threaded pipe connections or studded
anges ready for counter/blind anges.
Semi-welded heat exchangers come with
factory installed welding anges. The
refrigerant side is hermetically closed by blind
plates and pressurized with nitrogen.
Before connecting any piping to the
plate heat exchanger make sure to
clean and flush the piping system
thoroughly for any foreign objects.
When connecting the piping system to
the plate heat exchanger make sure
that the piping system does not subject
the plate heat exchanger to stress or
strain.
Make sure that the piping system,
connected to the plate heat exchanger,
is secured against pressure peaks/
surges and temperature shocks!
When doing any welding in the flange/
valve/piping system make earthing to
the piping opposite of the plate heat
exchanger. Never use the heat
exchanger for earthing as plates and
gaskets might be severely damaged.
When fitting threaded pipe to the
threaded plate heat exchanger
connection make sure that the
connection do not rotate during
tightening as this might damage
internal ring gaskets. A secure
counter-hold is needed.
For studded flange connection, insert
the gaskets before bolting the blind
flanges to the end plate. Tighten the
bolts evenly - do not over-tighten as
this might damage bolts/threads.
Note:
• Identify actual ow inlets/outlets on the name
plate before commencing piping work
• Heavy piping should be supported. This will
prevent heavy forces on the plate heat
exchanger
• To be able to open/close and dismantle the
plate heat exchanger shut o valves should
be installed in all connections
• Remove anges from the plate heat exchanger
before connecting to the valve/piping system.
• Nitrogen pressurized refrigerant side must be
depressurized through the small valve in the
blind plate before removing the anges
• Always install exible connections on the
follower to prevent vibrations on the plate heat
exchanger. The exible connections also help
prevent expansion of the pipes, which could
be caused by temperature inuence
• Flexible connections must be tted
perpendicular to the header/follower
• Install vents on both sides of the plate heat
exchanger
• The vents should be tted on the highest point
in the direction of the media ow
• The installation must be tted with safety
valves according to current pressure vessel
regulations