Plate crimping
The plates are sealed with a double
sheet metal fold ensuring good
exchanger rigidity and minimizing
leakage.
Recirculation bypass
With the exchanger recirculation
bypass option the AHU recirculation
mixing box is not required with
resulting cost savings.
Content
2Performance control___________8
3Structure____________________9
3.1Exchanger package in design S
3.2Exchanger package in design F
3.3Plate connection
3.4Casing
4Model Range________________10
4.1Designs
4.2Series
4.3Construction type
4.4Exchanger sizes
4.5Plate spacing
4.6Exchanger width
5Options____________________13
5.1Bypass
5.2Control damper
5.3Recirculation bypass
5.4Leakage test
5.5Horizontal installation
5.6Adapter for actuator
5.7Stronger packing
5.8Block of four, supplied loose
8Exchanger dimensions________21
9System design_______________27
9.1Hoval CASER design program
9.2Design data
9.3Positioning of unit and system layout
9.4Cost-effective design
9.5Performance control
9.6Recirculation bypass
9.7Sound attenuation
9.8Corrosion
9.9Dirt build-up
9.10Condensation in the warm air stream
9.11Solvent resistance
9.12Operation and function reliability
11Commissioning and
Maintenance_______________30
11.1Commissioning
11.2Maintenance
12Specification texts___________31
Appendix_____________________32
Explanation of Symbols
6Application Limits,
Specification of Material________18
6.1Application limits
6.2Specification of material
At a Glance
Three designs
Hoval manufactures 2 designs to satisfy the technical demands on the exchanger package (dimensions, plate spacing, rigidity). The design selection
depends on the air flowrate and the application.
Design S
For 'normal' applications in air handling installations with air flowrates up to about 50000 m/h.
Design F
For applications in process technology and in
air handling installations with air flowrates up to
100000 m/h.
At a Glance
Reliable in operation
Hoval plate heat exchangers have no moving
parts. Their function requires no electrical connection. There are therefore no extra running costs
and operation is always guaranteed: 100% reliability.
Many years of operation in numerous applications
have proved that Hoval plate heat exchangers are
extraordinarily resistant to dirt build-up. Therefore
no special maintenance is required.
Hoval CASER
Reliable data
Hoval plate heat exchangers are independently
tested time and again (for example at the building
technology testing laboratory of the University of
Lucerne). All technical data are based on these
measurements. This means that they are reliable
data for planners, installers and operators.
[W/mK]
1 = 2
[W/mK]
k
[W/mK]
Aluminium
0.125
200
40
19.9998
Aluminium
0.250
200
40
19.9995
Stainless
steel
0.125
15
40
19.9967
Plastic
0.250
0.2
40
19.5122
Material
Table 1: Plate thickness and material have only a slight effect on the efficiency.
1.2 Leakage
Components of air handling units, for example dampers,
ducts or casings, are not normally 100% leakproof. This
is mainly because it is not necessary to ensure the correct
function and it would be very expensive. In practical use,
however, leakage must not exceed technically justifiable limits. Therefore, test specifications and limits (EN
1751) exist for certain components, such as dampers. For
heat recovery units, there is no such data at the moment.
Nevertheless, actual values are known from tests.
A difference has to be made between the following:
Leakage to outside (external)
Leakage between supply air and exhaust air (internal)
While sealing to outside normally does not cause any
problems (it is above all a question of assembly quality),
the internal leakage mainly depends on the system and
exchanger construction. As an approximate value for the
internal leakage of Hoval plate heat exchangers a maximum
of 0.1% of the nominal air flowrate can be used (at 250 Pa
pressure difference).
The leak tightness of Hoval plate heat exchangers is far
better than other manufacturers' data. Nevertheless, it must
be noted that exchangers are not 100% leakproof unless
special measures are taken.
The two air streams are separated in the Hoval plate heat
exchanger and transmission of humidity is therefore not
possible. This is a special advantage when humidity is
removed with the warm air, e.g. in swimming pools, drying
processes,etc.
With the cross-flow heat exchanger, the air streams are not
heated and cooled evenly. This means that the temperatures
vary along the cross section of the air stream. The computer
graphic, calculated by the finite element method, shows this.
Because of the temperature variation the verification of the
temperature efficiency under operating conditions is practically impossible. For this reason, the performance of representative Hoval plate heat exchangers has been empirically
tested, measured and agreed by independent test institutes
to safeguard the consultant, installer and operator. The
technical data of Hoval plate heat exchangers are certified by
Eurovent.
t [C]
30
t [C]
30
25
t 12
t2
1.4 Condensation
25
20
20
15
15
10
10
5
5
0
0
-5
t1
-5
-10
-10
-15
-15
- 20
t2
t 11
-20
t2
h
h
cold
warm
Cold corner
Fig. 4: Under extreme conditions the exchanger can ice up, starting at the 'cold
corner'.
6
1.10 Hygiene
Hoval plate heat exchangers were subjected to hygiene
conformity testing at the ILH Berlin (institution of air hygiene).
Test criteria were the hygiene-relevant requirements for
applications in general air conditioning systems and in hospitals. All hygienic requirements were met.
Notice
The pressure difference depends on the position of
fans. Overpressure on one side and underpressure
on the other side add up.
45
a
0P
250
40
35
30
00
20
25
50
15
00
Pa
20
15
10
10
00 P
a
500 Pa
Plate spacing in mm
Diagram 1: Pressure drop increase due to internal pressure difference for exchangers
design S
Performance control
2 Performance control
The Hoval plate heat exchanger operates as a temperature
moderator between the two air streams. The direction of the
heat transmission is of no consequence, i.e. depending on
the temperature difference between extract and fresh air,
either heat recovery or cool recovery takes place. Therefore
performance control of the Hoval plate heat exchanger is
not necessary when the extract air temperature is identical
to the desired room temperature. In this case, the fresh air
is always either heated or cooled through the plate heat
exchanger in the direction of the set temperature.
In many cases, however, heat gains are present in the
ventilated space (people, machinery, lighting, solar, process
plants), which increase the room temperature, so that the
extract air temperature is higher than the set temperature. In
this case, at full performance of the heat exchanger, check at
which outside temperature heat-up begins, and if this cannot
be tolerated, the performance of the heat exchanger must be
controlled.
Example
In an industrial building the room air is heated from 18C
to 24C through lighting and machinery. The temperature
efficiency t is 66 %. At which outside temperature t21 is
the space heated only by heat recovery without additional
heating?
t22( tt11 )
=
t
21
( 1t)
Fresh air
t21, RH21
Extract air
t11, RH11
Exhaust air
t12, RH12
Supply air
t22, RH22
Fig. 7: Function diagram and air conditions
Structure
3 Structure
Model Range
4 Model Range
3.4 Casing
The exchanger package is fitted into a casing of corner
sections and side walls. The specially developed aluminium
sections offer many advantages:
The corners of the exchanger package are sealed into the
sections with a sealing compound. This technique ensures
optimum integration of the package into the casing.
Other components can be bolted or riveted directly to
the hollow sections without affecting the rigidity of the
exchanger or damaging the exchanger package.
At the corners the sections are flattened by 45, which
facilitates installation of the plate heat exchanger and
reduces the diagonal dimension.
The side walls are bolted to the corner sections. This creates
flat surfaces for connecting ducts or other components.
In addition, the returned edge of the side wall allows easy
installation of a side sealing all round, facilitating integration
into a casing.
4.1 Designs
Depending on usage and air flowrate different design possibilities of Hoval plate heat exchangers are available:
Design S
This design mainly covers 'normal' applications in air
handling installations.
Design F
These exchangers have been developed for higher air
flowrates. Plate size and plate spacing are therefore bigger
than with design S
4.2 Series
5 different material types are available to suit a wide variety
of applications:
Series V
The exchanger package consists of aluminium plates, the
casing of aluminium extrusions and side walls of Aluzinc
sheet steel. The exchangers are silicone-free.
Series T
The construction is identical to series V, however, a hightemperature silicone is used for sealing of the corner
sections. Thus the exchangers are resistant to temperatures
up to 200C.
Series G
The basic materials correspond to those of series V,
however, the complete exchanger (exchanger package and
casing) is coated.
Series C
The basic materials correspond to those of series V; the
casing is coated but the exchanger package is not.
Series D
The basic materials correspond to those of series V; the
exchanger package is coated but the casing is not.
Series Q
The basic materials of the twin exchanger correspond to
those of series V, however, one of the two exchangers is
coated (exchanger package and casing).
Model Range
Fig. 14: Classic arrangements of twin exchangers with air flows passing through
(The total efficiency can easily be calculated with the CASER design program.)
Fig. 15: For unequal mass flow rates check parallel flow or counter flow arrangements.
(For more detailed information about calculating the total efficiency, please contact
Hoval customer service.)
11
Model Range
Plate
spacing
Design S
040
050
060
070
085
100
120
140
170
200
240
-A
2.3
2.0
2.0
2.0
2.0
2.5
3.2
2.0
2.0
-C
2.0
2.0
2.0
2.0
2.0
2.0
AD
2.5
3.0
3.0
-D
2.3
2.5
3.0
3.0
AR
3.0
3.2
3.9
3.2
3.9
-R
3.0
3.2
3.9
2.5
3.2
3.2
3.9
2.5
3.2
AS
3.5
3.5
AX
3.2
5.1
4.4
4.8
5.1
4.4
4.8
-X
3.2
4.2
4.3
5.1
4.4
4.8
4.3
5.1
4.4
4.8
AY
5.4
5.4
AL
4.4
4.7
5.3
6.3
6.3
6.3
5.3
6.3
6.3
6.3
-L
4.4
4.7
5.3
6.3
6.3
6.3
5.3
6.3
6.3
6.3
AW
6.3
6.3
6.3
-W
6.3
6.3
6.3
Structure
Table 2: Clear plate spacings for design S (nominal values in mm)
Plate
spacing
Design F
100
120
140
160
200
240
-C
5.6
-D
5.6
7.2
-R
4.6
5.6
5.6
7.2
9.3
-S
7.2
7.2
-X
5.6
8.3
9.3
9.3
12.0
-L
5.6
7.2
10.3
11.3
12.0
-W
7.2
9.3
Structure
Table 3: Clear plate spacings for design F (nominal values in mm)
12
Options
5 Options
S-040 to S-060
S-070 to S-240
F-100 to F-240
5.1 Bypass
If performance control of the plate heat exchanger is necessary, a bypass is built into the casing besides the plate
package. This can be on the side or in the middle.
Notice
To ensure good flow conditions, installation in the
middle is strongly recommended for total widths of
1500mm and more.
Attention
In bigger exchangers reinforcing bar spacers are fitted
in the bypass; do not use these spacers for lifting the
exchanger!
25
13
Options
80%
60%
40%
20%
0%
0
10
20
30
40
50
60
70
80
90
Damper position []
Diagram 3: Exchanger efficiency depending on the damper position:
0 = Face damper closed / bypass damper open
90 = Face damper open / bypass damper closed
With the opposed face and bypass dampers the overall pressure drop and thus the overall air flowrate remains relatively
constant also in intermediate positions, which is proved
by the measured values (Testing Laboratory for Building
Technology of the Lucerne University).
750
100%
500
250
0
0
20
40
60
80
Damper position []
18
Diagram 4: Drag coefficient of the damper ( value) depending on the damper position
(0 = closed / 90 = open)
16
Torque [Nm]
14
12
10
8
6
4
2
0
500
1000
1500
2000
2500
3000
3500
4100
14
Options
Face damper
Bypass damper
Recirculation damper
Fig. 21: Plate heat exchanger with side recirculation bypass
Recirculation damper
Supply air
Bypass
damper
Fresh air
Extract air
Face damper
Exhaust air
Face damper
Fresh air
Bypass damper
Recirculation damper
Supply air
Exhaust air
15
Options
Leakage test - 2P
The air flow that is not channelled through the bypass is
sealed off.
Fig. 22:
Leakage test 2P
Notice
For horizontally installed exchangers the width B
in the unit type reference becomes the exchanger
height.
Leakage test - 7P
The air flow that is channelled through the bypass is
sealedoff.
B
Fig. 23:
Leakage test 7P
Leakage test - 4P
Both air flows are sealed off.
The leakage test is not available for exchangers of series T.
Notice
Exchangers for horizontal installation should always
be checked on all 4 sides.
16
Options
Design F
250
170
Fig. 27: Using the adapter Hoval dampers can be driven with conventional rotary
actuators.
Design S
Table 5: Adapter dimensions (in mm) and positioning on the damper with even or odd
number of gear wheels
17
6 A
pplication Limits, Specification of Material
6.1 Application limits
Design
Dampers
Series
Temperature
Width
mm
V, G, C, D, Q
- 4090
- 40200
V, G, C, D, Q
- 40100
- 40200
V, T, G, C, D, Q
- 4080
20041001)
20041002)
5041003)
1)S-040
18
Pa
max. 2500
max. 1500
max. 1000
max. 1000
max. 2000
max. 1500
max. 1000
max. 1000
max. 500
max. 1500
Plate exchanger
Series
Plates
Aluminium
Aluminium
Aluminium epoxycoated
Aluminium
Aluminium epoxycoated
Side walls 1)
Corner sections
Aluminium
Aluminium
Sealing
Casing
Damper blades
Galvanised sheet
steel
Galvanised sheet
steel
Galvanised sheet
steel, powder-coated
red (RAL 3000)
Galvanised sheet
steel, powder-coated
red (RAL 3000)
Galvanised sheet
steel
Polypropylene
Polypropylene
Polypropylene
Polypropylene
1)Except
2)Aluzinc
Notice
In series Q twin exchangers, one of the two
exchangers corresponds to series V and the other
exchanger is series G.
Notice
A hygiene certificate of ILH Berlin (institution of air
hygiene) confirms the exchangers suitability for use in
general air handling systems as well as in hospitals.
19
20
Exchanger dimensions
8 Exchanger dimensions
The following drawings show various designs and exchanger
sizes. The dimensions given are those relevant for connection of the plate heat exchanger. Details of type sizes made
up of four exchanger packages have been omitted.
21
Exchanger dimensions
Design S
Exchanger size
040
050
060
070
085
100
120
140
170
200
240
Height, length
H=L
367
467
567
690
840
990
1190
1380
1680
1980
2380
Diagonal
506
648
789
963
1175
1387
1670
1939
2363
2787
3353
Reinforcing section
only for S-200, S-240
m)
(m
50
B
)
mm
00 mm)
4
1
B x.
0
ma 205
60: max.
0
:
- S 40
040 S-2
(S- 070 (Sb=
Detail A
Exchanger sizes: 040, 050, 060
Detail A
Exchanger sizes: 070, 085, 100, 120, 140, 170, 200, 240
H=L
20
H=L
12
D
.7
Damper contact
surface
12
5.5
12
.7
Damper contact
surface
28.5
46
19.5
37
8.5
Exchanger dimensions
Design F
H=L
Diagonal
120
140
160
200
240
968
1168
1387
1567
1936
2336
1349
1632
1942
2196
2718
3284
24
20
50
Height, length
100
36
Exchanger size
Detail A
25
)
mm
(
m)
50
m
0
B
20
=
2
b
x.
ma
(
B
Exchanger dimensions
Side bypass BS
Middle bypass BM
Design S
E = 25 mm 040 050 060 070 085 100 120 E = 25 mm 040 050 060 070 085 100 120
Design F
BS
15
15
BM
15
Design S
Design F
E = 25 mm 200 240
E = 25 mm 200 240
15
BS
15
Table 10: Dimensional drawings for exchangers with bypass (in mm)
24
BM
15
Exchanger dimensions
040
050
060
070
Design F
100
120
140
160
085
120
040
050
060
070
100
120
140
160
BS
085
100
120
B
BM
Design S
140
170
140
170
BS
BM
Design S
200
240
200
240
Design F
200
240
200
240
BS
B
BM
Table 11: Dimensional drawings for exchangers with bypass and dampers (in mm)
25
Exchanger dimensions
040
050
060
070
085
100
120
140
170
200
240
Dimension X
42
42
42
34
16
34
34
37
37
34
34
Dimension Y
24
24
24
36
61
36
36
31
31
36
36
56.5
Exchanger size
Detail B
16
Design S
Design F
Exchanger size
100
120
140
160
200
240
Dimension X
16
26
28
16
Dimension Y
53
49
59
53
53
49
170
Recirculation damper
Face damper/Bypass
damper
26
System design
9 System design
Notice
You can download the Hoval CASER design program
free of charge from our home page (hrs.hoval.com).
V11
[m3/s]
t11
[C]
RH11 [%]
V21
[m3/s]
t21
[C]
RH21 [%]
Hoval CASER
Fresh air
t21, RH21
Extract air
t11, RH11
Exhaust air
t12, RH12
Supply air
t22, RH22
Fig. 28: Function diagram and air conditions
27
System design
9.8 Corrosion
Series V of Hoval plate heat exchangers has proved satisfactory for installation into air handling equipment. If corrosion
is expected e.g. in swimming pools, kitchens, and certain
industrial applications series G (corrosion-protected) is
used. The Hoval technical department will advise which
series is suitable for specific applications.
28
10.1 Transport
The plates should always be vertical during transport.
The exchangers may be lifted at the side walls, yet to
avoid damage the tensile direction must be vertical
(parallel to the side wall). Also lifting facilities (hooks,
loops, etc.) may be bolted to the returned edge of the side
wall for transportation.
The reinforcing sections on the side walls may also be
used for lifting when present.
Do not lift the exchanger at the aluminium corner section.
This might cause damage to the corner sealing (leakage).
Do not lift the exchanger at the reinforcing bar spacers of
the bypass.
The following general items are applicable: Do not lift the
exchanger at a single point but always suspend it by a
crane beam (Fig. 29).
29
The examples below show some possibilities for the installation of Hoval plate heat exchangers into air handling units:
56.5
16
11.2 Maintenance
Only periodic visual checks are necessary. If dampers are
fitted, test their movement. After initial 3-monthly inspection
intervals, checks can be carried out every 12 months.
The exchanger package can be cleaned as follows:
Remove dust and fibres with a soft brush or with
a vacuum cleaner. Take care when cleaning with
compressed air that the exchanger package is not
damaged. Keep at a distance!
Oils, solvents, etc. can be removed with hot water or
grease solvents, by washing or immersing. Cleaning with
high-pressure devices is possible if:
a flat nozzle 40 is used (type WEG40/04)
the maximum water pressure is 100 bar
Collar
Fig. 31: The damper shaft is easy to install with the bearing and a collar.
30
Attention
When cleaning take care that the exchanger is not
damaged, neither mechanically nor chemically:
Choose harmless cleansing agents.
Clean carefully.
Specification text
12 Specification texts
Hoval cross-flow plate heat exchanger for heat recovery,
consisting of exchanger package and casing: The exchanger
package consists of aluminium plates with pressed-in
spacers; condensate drainage is possible in every direction.
The plates are connected by a fold, which gives a severalfold
material thickness at air entry and exit.
The corners of the exchanger package are sealed into especially rigid aluminium extrusions in the casing with a sealing
compound. The side walls of Aluzinc sheet steel are bolted
tightly to these extrusions.
All performance data is certified by Eurovent and RLT
(TV Sd). Dry temperature efficiencies up to 80% can be
achieved. The exchangers are resistant to up to 2500 Pa
pressure difference between the air streams.
A hygiene certificate of ILH Berlin (institution of air hygiene)
confirms the exchangers suitability for use in general air
handling systems as well as in hospitals.
Options
A side or middle bypass suited to the exchanger package
is built into the casing.
A side or middle recirculation bypass suited to the
exchanger package is built into the casing (in the exhaust
air stream or in the supply air stream, as desired).
Control dampers are positioned on the casing before the
exchanger face and the bypass; resistant to temperatures
up to 80 C. These consist of galvanised sheet steel
(powder-coated for designs G and C). The geared drives
are plastic. Leaktightness class 2 in accordance with
EN1751.
The exchanger is suitable for horizontal installation.
Hoval leakage test.
Adapter for actuator for inside drive of the control
dampers.
Series
Series V (standard):
Aluminium plates, extruded aluminium sections and
Aluzinc sheet steel; silicone-free; resistant to temperature
up to 90C(design S) or 100C(design F).
Series T (high-temperature):
Aluminium plates, extruded aluminium sections and
Aluzinc sheet steel; special sealing agent, resistant to
temperatures up to 200 C.
Series G (corrosion-protected):
All components (Aluminium plates, extruded aluminium
sections and Aluzinc sheet steel) coated; silicone-free;
resistant to temperatures up to 90 C (design S) or 100 C
(design F).
Series C:
Bear aluminium plates, coated extruded aluminium
sections and Aluzinc sheet steel; silicone-free; resistant to
temperatures up to 90C (designS) or 100C (designF).
Series D:
Coated aluminium plates, bare extruded aluminium
sections and Aluzinc sheet steel; silicone-free; resistant to
temperatures up to 90C (designS) or 100C (designF).
Series Q:
In series Q twin exchangers, one of the two exchangers
corresponds to series V and the other exchanger is
seriesG.
Construction types
A distinction is made between the following construction
types:
Individual exchangers (standard)
Twin exchangers: The plate heat exchangers are supplied
individually and are only assembled into a twin exchanger
in the central air conditioning unit.
31
Explanation of Symbols
Symbol
Unit
Term
m2
mm or m
mm
Plate thickness
kJ/kg
Enthalpy
W/m2K
Heat transmission
kg/h
Mass flow=V
Pa
Pressure drop
QHRS
kW
Recuperation power
K or C
Temperature
m3/h
Volume flow
W/m2K
Temperature efficiency
RH
Relative humidity
kg/m3
Specific density
W/mK
Heat conductivity
Drag coefficient
Index
11
21
12
22
Extract air
Fresh air
Exhaust air
Supply air
32
t22t21
t = 100
t11t21
m2
=
m1
International
Hoval Aktiengesellschaft
Austrasse 70
9490 Vaduz, Liechtenstein
Tel. +423 399 24 00
Fax +423 399 27 31
info.klimatechnik@hoval.com
hrs.hoval.com
United Kingdom
Hoval Ltd.
Northgate, Newark
Nottinghamshire
NG24 1JN
Tel. 01636 672711
Fax 01636 673532
heatrecovery@hoval.co.uk
hrs.hoval.com
iv