®
Packaged Domestic Hot Water Generator
with Plate-Type Heat Exchanger and Storage Tank
Energy Source: Boiler Water
®
ENG I NEERED DUP L E X A L L OY
AquaPLEX® Duplex Stainless Steel Tank with 25-year Corrosion Warranty
Up to 6,000,000 Btuh Output
150 to 900 Gallon Storage Tanks
Single-wall Brazed Plate Heat Exchangers
Double-wall Plate-and-Frame Exchangers
Domestic Water Temperature to 180°F
Skid-mounted with Factory Pre-assembled Piping
®
A
S
M
E
A
S
M
E
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HLW
Engineered Water Heating Solutions®
®
Hot Water Outlet
ASHRAE compliant
insulation
TempTrac® Electronic
Operating Control
Boiler Water Supply
Clean-in-Place
Fittings
AquaPLEX® Storage Tank
Operating Thermostat
Boiler Water Return
Flow Diffusers
Y-strainer
Circulator
Plate-type
Heat Exchanger
Cold Water Inlet
Heat Transfer Characteristics of Plate Heat Exchangers
Due to their unique heat transfer characteristics,
plate-type heat exchangers excel when applied in lowtemperature boiler water loops. A plate-type exchanger, when supplied with 145°F boiler water, can produce
140°F domestic hot water while reducing boiler water
return temperature to 100°F or lower. The is highly
beneficial in condensing boiler systems where efficiency improves with reductions in both supply and return
water temperature.
By comparison, u-tube heat exchangers are typically sized for a 20°F difference between the entering
boiler water temperature and the desired domestic hot
water outlet temperature. In addition, the boiler return water cannot be lower than the domestic hot water outlet temperature. For example, to produce 140°F
domestic hot water, a u-tube exchanger would require
160°F entering boiler water and return boiler water
would be no less than 141°F; temperatures above the
ideal range for condensing boilers.
Domestic Water
Outlet 140°F
Boiler Water
Inlet 145°F
Domestic Water
Inlet 40°F
Boiler Water
Outlet 100°F
Inside the plate exchanger, counter-flows of boiler and domestic water maximize the temperature differentials and allow
the temperatures of the opposing liquids to “cross” with boiler
return water becoming colder than domestic outlet water.
Sequence of Operation
Domestic Hot
Water to Building
Demand for hot water causes a temperature drop in
the storage tank as cold makeup water displaces the hot
water in the tank. The tank thermostat senses this temperature drop and signals the operator to energize the
circulator. Cold domestic water flows through the heat
exchanger, captures heat from the boiler water and returns
to the storage tank. Flow diffusers reduce the velocity of
water leaving and returning to the storage tank from the heat
exchanger. This eliminates turbulence in the storage tank
and preserves the natural temperature stratification, allowing delivery of 80% of the storage tank’s capacity at the desired set point temperature.
Boiler
Water
Supply
When tank temperature returns
to the desired set point, the circulator
is de-energized. If the installation includes an optional boiler water control
valve, the electronic operator will energize and de-energize the valve.
140
Heated Domestic Water
Back to Tank
Boiler
Water
Return
Domestic
Cold Water
Makeup
Boiler Water Control Options
Hot Water Outlet
Hot Water Outlet
Storage
Tank
Storage
Tank
Heat
Exchanger
Boiler Water Supply
Heat
Exchanger
Boiler Water Supply
Boiler Water Return
Boiler Water Return
Cold Water Inlet
Cold Water Inlet
No Boiler Water Control Valve
2-Way Boiler Water Control Valve
Constant boiler water flow through the heat exchanger is acceptable because heat transfer to the
domestic water is controlled entirely by the circulator between the tank and heat exchanger. Constant
flow at the water heater is also a logical choice for
boiler loops equipped with VFD pump controls
because domestic hot water is a year-round
requirement in continual need of boiler water flow.
If the water heater is not utilized as the constant
flow bypass in a VFD-equipped boiler loop and boiler flow is to be allowed only during a domestic water
call for heat, the plate heat exchanger can be equipped
with a motorized 2-way valve. In this configuration,
the boiler water 2-way valve and the circulator are
controlled by the TempTrac operator.
Double-Wall Heat Exchanger Performance
with Different Boiler Water Temperatures
Boiler Water Side
145°F Entering Boiler Water (Supply)
~ 100°F Leaving Boiler Water (Return)
Double-wall heat exchangers
are plate-and-frame design.
ASME Stamp:
Section VIII
Operating Pressure (boiler side):
150 psi (standard)
300 psi (optional)
Operating Temperature (boiler side):
338°F maximum rating
Maximum boiler water
temperature when operating
EZ Plate water heater is 185°F.
Consult PVI for higher boiler
water temperatures.
Connections:
2" NPT Stainless Steel
Gasket Material:
EPDM
Plate Material:
Stainless Steel
DomesƟc Water Side
40°F to 140°F
Heat
Exchanger
Model No.
Boiler Water
Flow
(gpm)
Boiler Water
Pressure Drop
(psi)
Recovery
(gph)
BTU Output
600
10
1.6
270
225,000
900
15
2.1
400
333,000
1200
20
2.5
540
450,000
1800
30
3.0
810
675,000
2400
40
3.0
1080
900,000
3000
50
3.2
1350
1,125,000
3600
60
3.5
1590
1,325,000
4500
75
3.8
1980
1,650,000
5400
90
4.2
2400
2,000,000
7200
120
4.8
3180
2,650,000
Boiler Water Side
160°F Entering Boiler Water (Supply)
~ 88°F Leaving Boiler Water (Return)
DomesƟc Water Side
40°F to 140°F
Heat
Exchanger
Model No.
Boiler Water
Flow
(gpm)
Boiler Water
Pressure Drop
(psi)
Recovery
(gph)
BTU Output
600
10
1.6
450
374,850
900
15
2.1
660
549,780
1200
20
2.5
870
724,710
1800
30
3.0
1260
1,049,580
2400
40
3.0
1710
1,424,430
3000
50
3.2
2160
1,799,280
3600
60
3.5
2580
2,149,140
4500
75
3.8
3180
2,648,940
5400
90
4.2
3900
3,248,700
7200
120
4.8
5160
4,298,280
For performance with other boiler water and domestic water
conditions, refer to PVI web site.
Warranty: 3-year
Domestic side standard temperature
is 180°F max.
Domestic side standard pressure
is 150 psi max.
For higher operating pressure,
consult your PVI representative.
®
Single-Wall Heat Exchanger Performance
with Different Boiler Water Temperatures
Boiler Water Side
145°F Entering Boiler Water (Supply)
~ 105°F Leaving Boiler Water (Return)
Single-wall heat exchangers
are brazed plate design.
ASME Stamp:
Section VIII
Operating Pressure (boiler side):
435 psi max
Operating Temperature (boiler side):
450°F maximum rating
Maximum boiler water
temperature when operating
EZ Plate water heater is 185°F.
Consult PVI for higher boiler
water temperatures.
Connections:
2" NPT Stainless Steel
Brazing Material:
Copper
Plate Material:
Stainless Steel
Warranty: 3-year
Domestic side standard temperature
is 180°F max.
Domestic side standard pressure
is 150 psi max.
For higher operating pressure,
consult your PVI representative.
DomesƟc Water Side
40°F to 140°F
Heat
Exchanger
Model No.
Boiler Water
Flow
(gpm)
Boiler Water
Pressure Drop
(psi)
Recovery
(gph)
600
10
1.6
270
225,000
900
15
2.1
390
325,000
1200
20
2.5
420
350,000
1800
30
3.0
630
525,000
2400
40
3.0
780
650,000
3000
50
3.2
960
800,000
3600
60
3.5
1260
1,050,000
4500
75
3.8
1500
1,250,000
5400
90
4.2
1800
1,500,000
7200
120
4.8
2400
2,000,000
Boiler Water Side
160°F Entering Boiler Water (Supply)
~ 95°F Leaving Boiler Water (Return)
BTU Output
DomesƟc Water Side
40°F to 140°F
Heat
Exchanger
Model No.
Boiler Water
Flow
(gpm)
Boiler Water
Pressure Drop
(psi)
Recovery
(gph)
BTU Output
600
10
1.6
450
375,000
900
15
2.1
690
575,000
1200
20
2.5
750
625,000
1800
30
3.0
1100
920,000
2400
40
3.0
1440
1,200,000
3000
50
3.2
1800
1,500,000
3600
60
3.5
2250
1,875,000
4500
75
3.8
2760
2,300,000
5400
90
4.2
3300
2,750,000
7200
120
4.8
4380
3,650,000
For performance with other boiler water and domestic water
conditions, refer to PVI web site.
®
®
ENGINEER ED D U PLEX A LLO Y
EZ Plate water heaters use a storage tank that is
fabricated from AquaPLEX duplex stainless steel. It is
an engineered alloy that combines two different types of
stainless steel; austenitic and ferritic, to create a material
that captures the advantages of both. After the tank is
completely fabricated, it is immersion pickle-passivated; a process that returns the duplex stainless steel to its
original pristine condition.
AquaPLEX is naturally immune to corrosion in
hot potable water regardless of temperature and as a
result requires no additional lining or any type of anode protection. Because there is no corrosion, an anode
rod, whether sacrificial or impressed current, simply has
nothing to do. Unlike 316L stainless steel, the addition
of a ferritic grain structure renders the duplex stainless
steel immune to chloride stress corrosion cracking; a
known failure mode of 316L stainless steel in hot potable water. These properties allow PVI to provide an
unprecedented 25-year tank corrosion warranty.
Additionally, because there is no lining AquaPLEX
tanks are maintenance-free and the water contacting surfaces are non-porous and do not absorb water.
AquaPLEX can also withstand temperature elevation and
hyper-chlorination methods if it’s ever necessary to
eliminate bacteria from the building’s water system.
Storage Tank is Equipped
with Lead-Free Bronze Fittings
All connections to the AquaPLEX tanks are made
through removable cast-bronze fittings. This design
avoids using lined steel fittings that are often the starting
point for corrosion inside a water heater. There is also
no galvanic corrosion because the bronze fittings are
galvanically neutral to the AquaPLEX tank.
Bolt-on
Bronze
Fitting
O-ring
Gasket
More than one-quarter million of these
removable bronze fittings are in service!
Tank Wall
Packaged Heater Dimensions
Maximum Dimensions of Factory Packaged Heater
Tank Size (gallons)
Maximum Heater
Model No.
Height (H)
Width (W)
Depth (D)
150
4500
65
60
61.5
175
4500
71
60
61.5
215
4500
78
60
61.5
250
4500
63
77.5
69
300
4500
75
77.5
69
400
7200
87
77.5
69
500
7200
78
87
80
600
7200
90
87
80
750
7200
83
98
90.5
900
7200
95
98
90.5
For larger tank sizes, consult your PVI representative.
Standard Equipment
•
•
•
•
•
•
•
•
•
•
AquaPLEX storage tank. ASME stamped HLW
for 150 psi MAWP
Double-wall plate-and-frame or single-wall brazed-plate
heat exchanger, ASME stamped
ASME-rated pressure relief valve (on heat exchanger)
ASME-rated temperature and pressure relief valve
(on storage tanks)
Clean-in-place valves for heat exchanger
Bronze y-strainer with blow down valve on domestic water
to the heat exchanger
Bronze circulating pump
Programmable electronic operating control with digital
temperature readouts (BAS connectable via Modbus RTU)
Immersion temperature limiting device (high limit control)
Drain Valve
D
Optional Equipment
•
Electronic low water cutoff
•
Manual-reset, immersion temperature limiting device
•
•
•
•
H
Temperature and pressure gauges
2-way boiler water control valve
Y-strainer for boiler water
Higher operating pressures for storage tanks and heat
exchangers (consult PVI representative)
W
®
Configuring an EZ Plate® Model Number
(_ _ _ _)
L
(_ _ _ _) A-TRPF (plate-and-frame, double wall)
A-TRBP (brazed plate, single wall)
Storage tank size in gallons
150
175
215
250
300
400
500
600
750
900
(consult PVI representative for larger storage tanks
or horizontal tank configuration)
“L” designates AquaPLEX storage tank
Heat exchanger model number
600
900
1200
1800
2400
3000
3600
4500
5400
7200
Example model number: 1800 L 300A-TRPF
Plate-and-Frame heat exchanger number 1800 connected to a
300 gallon AquaPLEX storage tank.
®
PV 8650
1-2016
Engineered Water Heating Solutions®
www.pvi.com