Hydra Plate Heat Exchanger

Operating & Maintenance Manual.

MHS Boilers Ltd 35 Nobel Square

Burnt Mills Industrial Estate Basildon Essex

SS13 1LT 01268 591010 Telephone 01268 728202 Fax

WWW.MHSBOILERS.COML ???

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CONTENTS:

I – GENERAL DESCRIPTION

II – WORKING

1 – CONCEPT

2 – PRECAUTIONS TO BE TAKEN

III – TECHNICAL CHARACTERISTICS AND SET UP

1 – HYDRAULICS

2 –ELECTRICS

3 –MG 94 REGULATION

IV – PLATE EXCHANGER

V – STARTING THE HYDRA

VI – MAINTENANCE

VII – GUARANTEE

VIII – SPARE PARTS

IX – TROUBLE SHOOTING X- INSTALLING THE PRIMARY PUMP X1 – INSTALLING THE 3-WAY DIVERTER VALVE

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I – GENERAL DESCRIPTION

The Hydra machines consist of a plate exchanger that is fixed on a base and to which a regulated primary water system and a secondary system are connected. The primary system mainly consists of a pump and a 3-way diverter valve that is temperature controlled. The secondary system includes a temperature sensor and pressure relief valve set at 7 Bar.

SECONDARY SYSTEM

PRIMARY SYSTEM

PUMP

DIVERTER VALVE

EXCHANGER

CONTROL PANEL

The HYDRA is designed to comply with current regulations. The HYDRA can be easily dismantled for any maintenance operations. It is delivered ready for connection to the system.

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II – WORKING

1 – Concept It takes 15 sec for the 3-way diverter valve to turn on/off completely. When the secondary water temperature is below set point, the 3-way valve opens to divert

primary water through the plate. When the secondary water reaches set point temperature, the valve will close to divert the primary water directly to the primary return connection.

To provide thermal protection against legionella, we recommend that the plate be pasteurised

at least once a week. This can be performed manually by adjusting the control stat. This component is supplied adjustable from 30°C to 90°C. This process can be automated by removing the link between terminal 8&9 on the control panel. See section 2 “Electrics” for more information. The HYDRA plate heat exchangers are all pressure tested at the factory prior to delivery.

2 – PRECAUTIONS TO BE TAKEN The HYDRA must be installed on a stable and

flat base.

We recommend that you allow at least a 500mm clearance all around the HYDRA.

The maximum working pressure of the HYDRA is

7 bar. The maximum primary and secondary temperatures are :

Primary = 105°C Secondary = 80°C

Initial primary system water cleansing and treatment is essential to avoid problems with

operation and the service life of the plate heat exchanger. We also recommend that a strainer be included in the primary flow pipe-work and the cold water supply to the HYDRA to protect the plate heat exchanger from debris accumulation during service.

It is recommended that the total hardness of the system water is maintained at :

- THwater<20°f. = <200ppm CaC03

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III – TECHNICAL CHARACTERISTICS SET UP

1 –HYDRAULICS

H.W. Supply

Primary Flow

INSTALLATION Connections to the HYDRA (See illustrations) IMPORTANT: To ensure that the specified output of the HYDRA is not compromised, it is recommended that the primary and secondary pipe work is not smaller than the connections to the unit. Specific calculations should be completed if high resistance is suspected and it may be necessary to increase the pipe diameter to ensure that the output of the Hydra is not compromised.

Primary Return

d

Cold Fee

1. Dia of Primary Flow 2. Dia of Primary Return 3. Dia of Cold Feed 4. Dia of H.W. Supply

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MODELE POWER LENGTH WIDTH HEIGTH A B C D E F G HYDRA 70 730 260 930 380 220 66 68 265 166 99 HYDRA 85 730 260 930 380 220 66 68 265 166 99 HYDRA 110 730 260 930 380 220 66 68 265 166 99 HYDRA 140 730 260 930 380 220 66 68 265 166 99 HYDRA 170 730 260 930 380 220 66 68 265 166 99 HYDRA 210 730 260 930 380 220 66 68 265 166 99 HYDRA 250 730 260 930 380 220 66 68 265 166 99 HYDRA 280 730 260 930 380 220 66 68 265 166 99 HYDRA 310 730 260 930 380 220 66 68 265 166 99 HYDRA 360 730 260 930 380 220 66 68 265 166 99 HYDRA 440 730 260 930 380 220 66 68 265 166 99 HYDRA 470 765 260 930 380 220 66 68 265 166 99 HYDRA 550 765 260 930 380 220 66 68 265 166 99 HYDRA 600 765 260 930 380 220 66 68 265 166 99

MODELE POWER 1 2 3 4 HYDRA 70 DN32 DN32 DN32 DN32 HYDRA 85 DN32 DN32 DN32 DN32 HYDRA 110 DN32 DN32 DN32 DN32 HYDRA 140 DN32 DN32 DN32 DN32 HYDRA 170 DN32 DN32 DN32 DN32 HYDRA 210 DN32 DN32 DN32 DN32 HYDRA 250 DN32 DN32 DN32 DN32 HYDRA 280 DN32 DN32 DN32 DN32 HYDRA 310 DN32 DN32 DN32 DN32 HYDRA 360 DN32 DN32 DN32 DN32 HYDRA 440 DN32 DN32 DN32 DN32 HYDRA 470 DN32 DN32 DN32 DN32 HYDRA 550 DN32 DN32 DN32 DN32 HYDRA 600 DN32 DN32 DN32 DN32

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III – TECHNICAL CHARACTERISTICS SET UP.

2 – ELECTRICS

2 – ELECTRICS The HDRA Plate Heat Exchanger operates using a 240 Volt 50 Hz single-phase supply and should be 10 Amp protected. Polarity should be as follows: Terminal 3 Live Terminal 2 Neutral Terminal 1 Earth The conductors used for supply to the HYDRA should be 2.5mm2 C.S.A. PVC insulated. The HYDRA control panel includes an NC relay for general remote fault indication. The terminal connections for remote fault indication are 6&7. The control characteristics ensure that pump reversal occurs each day to maintain even run times and it also incorporates automatic switching in the case of pump failure. In the event of pump failure the relay would open and continuity between terminals 6&7 would be lost. At the same time a fault lamp would be lit on the HYDRA control panel. The control characteristics of the HYDRA include an automatic pasteurisation facility but this is not activated when the HYDRA is delivered. To activate this facility the link between terminal 8&9 must be removed. If activated, the HYDRA will raise the secondary water temperature to 80°C for a period of one hour, once a week. This is programmed to occur at 2am every Sunday. If activated, it is the installer’s responsibility to issue the relevant safety warning notifications.

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3 –MG 94K REGULATION IT WORKS AUTOMATICALLY. The HYDRA is supplied with user friendly controls. The regulation of the HYDRA is achieved via interaction with two potentiometers fitted in the housing of the diverter valve. The function of the potentiometers is: 1) Control of H.W. Supply temperature. 2) Electronic regulation of the servomotor on the three-way diverter valve. The time interval for

temperature pulse transmissions can be altered allowing reaction time of the motor to be effected. It takes 15 sec for the 3-way diverter valve to turn on /off completely).

Range of adjustment on the potentiometers

a) H.W. supply temperature, “adjustable 30 - 90 °C” b) Time interval for temperature readings, adjustable between 1 - 70 seconds with the default

being 3 seconds.

MANUAL CONTROL If the motor controlling the diverter should fail, a manual control (lever + button) can be used to ensure that H.W. Supply can be maintained Disconnect the electrical supply to the diverter valve motor and adjust the primary water temperature to 70°C. Find a satisfactory intermediate position for the 3-way diverter valve that maintains H.W. Supply. Changing the motor-regulator is achievable within a few seconds without any specific tools. Disconnect the electrics of the motor regulator, unlock the motor on the valve (pulling the lock to the outside) and extract the motor pulling it away from the diverter valve.

IV – PLATE EXCHANGER The plate exchanger is composed of STAINLESS (AISI 316 L) steel plates that are

compressed between two steel plates. The plates are not welded and can easily be dismantled. Seals between the plates make them watertight.

HOW TO REPLACE A PLATE.

yes no

Visual control of the set-

Diagram of the plate stack

1) When the exchanger is to be assembled, the

stainless steel plate with four holes, “opening plate” should fit directly to the rear fixed plate with the fibre seal towards the rear fixed plate.

2) The stainless steel intermediate plates should be

installed back to back and in pairs as detailed in the illustration.

3) Once all the intermediate plates have been installed,

the front mobile plate should be positioned. 4) The connecting bolts securing the front mobile plate

to the rear fixed plate should be inserted. The nuts should be secured finger tight.

5) The plates should be tightened alternately until the

required distance between the front and rear plates is achieved.

Distance

Distance = number of plates x 3+ 2 IMPORTANT : The distance between the plates should be maintained as equal as possible during tightening of the assembly.

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V – STARTING THE HYDRA

1) The HYDRA must be installed in compliance with W.R.A.S. The Building Regulations G3 and BS7266.

2) Initially the taps should be opened gently to avoid excessive surges in the

hydraulic system. This scenario could displace joints and bring about leaks in the exchanger.

3) When initially filling the system the plates should be checked for leaks. If no

leaks are apparent, the system should be bled of air. If there are leaks between the plates, the assembly must be dismantled and re-assembled. Distance between front and rear plates is important.

4) Open the control panel and turn the fuse switches « off ».

5) Connect the control panel to a 240 volts 50 HZ 10 amperes supply.

6) A light on the control panel confirms power to the appliance.

7) Switch the primary pump on (fuse-switch) bleed it and check it’s working

properly

8) Switch the primary pump off and check the secondary pump in the same way

9) Check the primary water circulates properly. The flow temperature must be around 80°C and the return temperature should be between 35°C and 80°C.

10) Check operation of the 3-way diverter valve work when turned on and off. (adjust

the potentiometer to achieve this if necessary)

11) Open several taps completely to create a significant H.W. Supply demand and bleed the secondary system.

The 3 way diverter valve should position itself and you should be able to determinate a temperature in the secondary system. Following adjustments at the potentiometers it will take a short period of time for the secondary temperature to stabilise. Once the secondary temperature is around 40°C, the primary return temperature should be stable and around 55°C or 60°C (this depends on your adjustments)

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MAINTENANCE Electrics : All electrical connections must be correct polarity, safe and have good continuity. Check the temperature of the secondary water is at the required level (55 ° - 60°C) Check the interval between temperature pulses to ensure the plate is performing correctly (default 3 seconds). HYDRAULICS : Regularly check there are no leaks anywhere, special attention must be taken when checking the joints between the plates of the exchanger. This check should be completed when the plate heat exchanger is both cold and hot. The distance between the front mobile and rear fixing plate should be checked and the securing bolts tightened if necessary. The condition of the primary and secondary water should be checked and remedial works completed if necessary. Plates : If the required system water treatment levels are maintained, there should be no need for maintenance of the plates forming the heat exchanger. Correct adjustment of the two potentiometers should be sufficient to satisfy general maintenance requirements. The pressure drop across the plate should be checked when it is operating at maximum output. The recorded value should be between 1-5mWC. If the pressure drop is greater than this, the plates may be blocked with system debris and the exchanger will need to be taken apart and cleaned. If this is the case, it may be necessary to replace the seals between the plates of the exchanger. If the plates are found to be significantly blocked with debris, they should be replaced. IMPORTANT : A new plate should not be installed on and old exchanger. If this is a requirement, then all the plates must be replaced.

VIII –SPARE PARTS

Erreur ! Liaison incorrecte. REP DESIGNATION REFERENCE A Control Panel 240 v 61400973

B Stainless steel intermediate plate

61400974

B1 Stainless steel 4 opening plate 61400975 B2 Stainless steel plate 61400976 C Simple pump 70 to 210 KW 61400977 C1 Simple pump 250 to 600 KW 61400978 C2 Double pump 70 to 210 KW 61400979 C3 Double pump 250 to 600 KW 61400980 D Brass 3 way tap 61400981 E Primary connection bend 61400982 F Regulator servomotor 61400983 H 7 bar valve 61400984 J Probe + cable 61400985 K Primary lower collector 61400986 L Primary upper collector 61400987 O Q Fixed painted base 61400988 P Mobile painted base 61400989

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X – INSTALLING THE PRIMARY PUMP

Secure the union with the correct size spaner ensuring a water tight seal.

Mount the pump on the plate heat exchanger and screw finger tight.

Take the pump out of its package

Remove the packaging from the plate heat exchanger

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X1 – INSTALLING 3-WAY DIVERTER VALVE

Carefully engage the motor assembley to the anti-roatation lug (4) and the spindle of the three way valve (1). Hold the motor assembly in position and lock with switch (6)

Ensure that the location handle (5) of the diverter valve is in the horizontal position i.e. closed position.

Remove the three-way diverter valve from its package.

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