Immergas Victrix Pro Plate Heat Exchanger Kit Installation Guide
This document provides instructions for the installation of Immergas plate heat exchanger kits for Victrix Pro boilers.
General Warnings
All Immergas products are protected with suitable transport packaging and must be stored in a dry place protected from the weather. This manual contains technical information for installing the Immergas kit. For other installation-related issues, such as workplace safety and environmental protection, comply with current regulations and good practice. Improper installation can lead to problems for people, animals, and objects. Always read the provided instructions carefully. Installation and maintenance must be performed by qualified personnel in compliance with regulations and manufacturer instructions.
The plate heat exchanger hydraulically separates the primary and secondary circuits, protecting the boiler.
ATTENTION: All safety alerts apply to environmental, health, and safety regulations.
The hazard symbol ! indicates a dangerous situation that may lead to moderate or serious injury and death. The symbol i indicates a dangerous situation that may lead to property damage if not avoided.
Sudden pressure peaks can damage the plate heat exchanger and should be prevented.
Safety Precautions
Follow these points during installation, operation, and maintenance. Always respect local safety regulations.
- ATTENTION: Before maintenance, ensure exchangers are pressure-less and cooled below 40°C to prevent burns.
- ATTENTION: Use gloves when handling the plate exchanger to prevent injury from sharp edges. Ensure compliance with all human and environmental protection laws and regulations.
Before Installation
- Open the packaging carefully. Check that all components are included and undamaged.
- Maximum working pressure and temperature limits are marked on the label and must not be exceeded.
- Always check the product identification label to ensure the exchanger is suitable for operating conditions. Do not exceed the parameters indicated on the label during installation and operation.
Lifting and Handling
- ATTENTION: Use appropriate hoisting equipment to prevent personal injury. Use straps for lifting the plate exchanger.
- ATTENTION: Maintain a safety separation of 3 meters when lifting the plate exchanger to prevent personal injury.
- ATTENTION: Use safety gloves to prevent personal injury from sharp edges when handling the plate exchanger.
Installation Guidelines
- For lifting, place straps as shown in the diagram, lift in a vertical position, lower slowly, and remove straps.
- Install the plate exchanger so that fluid flows are in opposite directions.
- Connect the brazed plate heat exchanger. Ensure all required safety equipment for pressure vessel regulations is installed.
- When connecting the pipe system, ensure no loads (including torque effects) are transferred from the piping to the heat exchanger. Isolate the pipe system from pressure pulsations, vibrations, and thermal shocks.
- Use mounting brackets fitted at the bottom of the heat exchanger for support. The exchanger is not designed to withstand excessive forces from earthquakes, wind, fire, vibration, or improper piping.
- The system designer or end-user is responsible for protecting the heat exchanger and reducing damage risk.
- A safety valve should be installed between the heat exchanger and shut-off valves on the secondary side. Failure to do so may result in damage due to thermal expansion.
- Pipes must be connected to prevent stress from thermal expansion from harming the exchanger. Use brackets to prevent torsion stress on connections.
Operation
For maximum heat transfer efficiency, the media should flow counter-current. Install filters on the secondary circuit to prevent clogging by mechanical particles.
Avoid media corrosive to the brazed plate heat exchanger materials.
ATTENTION: Flow rate changes must be implemented slowly to protect the exchanger from sudden temperature and pressure variations.
In case of hard water, limescale may deposit if the water temperature is above 60°C.
Close Down
Incorrect operation can lead to water hammer damages.
Close Down Sequence:
- Close the hot side by slowly adjusting the control valve. Keep full flow on the cold side.
- When the control valve is fully shut down, switch off the pump.
- Slowly close down the cold side and stop the pump.
- Close all shut-off valves.
- If the plate heat exchanger will be closed down for a long time, it should be drained. Drain if there is a risk of freezing the heat transfer media due to low ambient temperature. Damages from frozen media are not covered by warranty.
- Before putting the plate heat exchanger back into operation, flush it with fresh water to prevent chemicals from entering the system circuits.
Utilization
ATTENTION: This product should be dismantled and components sorted for recycling or disposal, following local regulations.
For further information, contact the Authorized After-Sales Technical Assistance Centre.
Technical Data
| Model | System litres content | Expansion vessel capacity (litres) | N° plates | System-side heat exchanger maximum pressure (bar) | Maximum power (kW) | Weight of the heat exchanger only (kg) |
|---|---|---|---|---|---|---|
| N°2 Victrix Pro 35 V2 | 25 | 4 | 15 | 30 | 400 | 31.3 |
| N°3 Victrix Pro 35 V2 | 34 | 4 | ||||
| N°4 Victrix Pro 35 V2 | 43 | 8 | ||||
| N°5 Victrix Pro 35 V2 | 52 | 8 | ||||
| N°2 Victrix Pro 55 V2 | 26 | 4 | ||||
| N°3 Victrix Pro 55 V2 | 35 | 4 | 16 | 90 | 400 | 31.3 |
| N°4 Victrix Pro 55 V2 | 45 | 8 | ||||
| N°5 Victrix Pro 55 V2 | 54 | 8 | ||||
| N°2 Victrix Pro 80 V2 | 27 | 4 | ||||
| N°3 Victrix Pro 80 V2 | 37 | 4 | 16 | 90 | 400 | 31.3 |
| N°4 Victrix Pro 80 V2 | 46 | 8 | ||||
| N°5 Victrix Pro 80 V2 | 56 | 8 |
Pressure Drop Graphs
Graphs showing pressure drop for various Victrix Pro models under different temperature differentials (ΔT) and flow rates.
- Graph 1: Δ20° Primary / Δ15° Secondary for Victrix Pro 35-55-60-68-80 V2.
- Graph 2: Δ15° Primary / Δ10° Secondary for Victrix Pro 35-55-60-68-80 V2.
- Graph 3: Δ20° Primary / Δ15° Secondary for Victrix Pro 100-120-150-180 V2.
- Graph 4: Δ15° Primary / Δ10° Secondary for Victrix Pro 100-120-150-180 V2.
Technical Data (Kit 3.033679)
| Model | System litres content | Expansion vessel capacity (litres) | N° plates | System-side heat exchanger maximum pressure (bar) | Maximum power (kW) | Weight of the heat exchanger only (kg) |
|---|---|---|---|---|---|---|
| N°2 Victrix Pro 100 V2 | 75 | 8 | 16 | 100 | 850 | 65 |
| N°3 Victrix Pro 100 V2 | 100 | |||||
| N°4 Victrix Pro 100 V2 | 125 | 12 | ||||
| N°5 Victrix Pro 100 V2 | 150 | |||||
| N°2 Victrix Pro 120 V2 | 77 | 8 | 16 | 100 | 850 | 65 |
| N°3 Victrix Pro 120 V2 | 103 | |||||
| N°4 Victrix Pro 120 V2 | 129 | 12 | ||||
| N°5 Victrix Pro 120 V2 | 155 | |||||
| N°2 Victrix Pro 150 V2 | 81 | 8 | 16 | 100 | 850 | 65 |
| N°3 Victrix Pro 150 V2 | 109 | 12 | ||||
| N°4 Victrix Pro 150 V2 | 137 | |||||
| N°5 Victrix Pro 150 V2 | 165 | |||||
| N°2 Victrix Pro 180 V2 | 89 | 8 | 16 | 100 | 850 | 65 |
| N°3 Victrix Pro 180 V2 | 121 | 12 | ||||
| N°4 Victrix Pro 180 V2 | 153 | |||||
| N°5 Victrix Pro 180 V2 | 185 | 18 |
Installation Diagrams
Diagrams illustrating the mounting dimensions for Victrix Pro 35-55-80 V2 and Victrix Pro 100-120-150-180 V2 boilers with right and left hydraulic connections.
Assembly Instructions (Victrix Pro 35-55-80 V2)
- Assemble the automatic air vent valve (14) on pipe (12), interposing O-ring (5), and tighten the free connection with brass plug (10), using sealing material.
- Assemble valve (7) and hose connector (6) on pipe (13), tighten cap (9) with gaskets (1).
- Connect pipe (11) to pipe (13) on the return line (R) of boiler (14), interposing gaskets (3).
- Connect pipe (12) on the delivery line (M) of boiler (14), interposing gasket (3).
- Connect pipes (12) and (13) to the plate heat exchanger (4), interposing gaskets (2), as shown in Fig. 8.
- After the first temperature test, check all pipe tightness.
- Connections with caps 9 and 10 are for expansion vessel and boiler circuit filling. Refer to the data table for expansion vessel sizing.
- For left-side free outputs, follow figure 9.
Attention: Victrix Pro V2 boilers have IPX5D insulation and can be installed outdoors with appropriate kits. Protect kits from weather if installed outdoors.
Boilers must be installed with their original safety kits. The manufacturer is not liable if the installer uses unapproved or improperly used kits.
Assembly Instructions (Victrix Pro 100-120-150-180 V2)
- Assemble the automatic air vent valve (4) on manifold (7), interposing O-ring (3), and tighten the free connection with brass plug (17), using sealing material.
- Assemble valve (13) and hose connector (14) on manifold (8), tighten plug (16) with gaskets (12).
- Connect manifold (8) to the return pipe (R) of boiler (21), interposing gasket (9), and using screws (18), washers (20), and nuts (19).
- Secure the plate exchanger (6) to the support bracket (10) using nuts (15).
- Connect manifold (8) to the plate heat exchanger (6), interposing gasket (11).
- Connect manifold (7) to the delivery pipe (M) of boiler (21), interposing gasket (9), and using screws (18), washers (20), and nuts (19).
- Connect the plate heat exchanger (6) to manifold (7), interposing gasket (11).
- Position insulation (5) on delivery (M) and return (R) of boiler (21).
- Secure the support bracket (10) to the ground using screws (1) and plugs (2), as shown in Fig. 18.
- After the first temperature test, check all pipe tightness.
- Connections with caps 16 and 17 are for expansion vessel and boiler circuit filling. Refer to the data table for expansion vessel sizing.
- For left-side free outputs, follow figure 19.
Attention: Victrix Pro V2 boilers have IPX5D insulation and can be installed outdoors with appropriate kits. Protect kits from weather if installed outdoors.
Boilers must be installed with their original safety kits. The manufacturer is not liable if the installer uses unapproved or improperly used kits.
