Heat exchangers UK

Heat exchanger for heat pump

Condenser for heat pump

The condenser is the heat pump exchanger on its secondary circuit. The hot refrigerant in the condenser transfers heat to the heating water. The hot refrigerant enters the exchanger in the vapor phase and is cooled, condensed and subcooled after condensation. The heat transferred to the heating water comes mainly from the change of state (i.e. condensation of the refrigerant). One of the heat exchanger calculation parameters for a heat pump is the condensing temperature of the refrigerant.

Overview of condensers by capacity

The list shows plate heat exchangers often used as condensers:

  • SWEP B8TH, B8LASH (for capacities of 3–10 kW, B8LASH is asymmetric; connections are combo ¾"); the exchanger is suitable as a condenser for the Sinclair Split ASGE air conditioning unit when being rebuilt to a heat pump,
  • SWEP B26H, B26FH (asymmetric exchanger 5–20 kW designed for heat pumps; it has soldering connections towards the primary, external thread ISO G 1" towards the secondary circuit),
  • SWEP B25TH, B85H, B86H (for capacities 10–50 kW, air conditioning; connections combo 1" or combo 1 ¼"),
  • SWEP B18H, B185H, B16DW (for natural gas, CO2 CO2 catalog PDF up to 140 bar; connections according to customer's request),

The asymmetric exchanger has narrower channels in the internal circuit (designed for refrigerant). There is usually about 10 times more flow on the water side than on the refrigerant side. So asymmetric heat exchanger is optimized for air conditioning and heat pumps.

Combo 1". Click for complete drawing
Click on the image to compare the standard connection against combo connection. Some SWEP heat exchangers are equipped with connections combo ¾", combo 1" or combo 1 ¼"

The SWEP B25TH version is popular among technicians because it has pure solder connections on the refrigerant side. SWEP B85H and B86H have a higher efficiency compared to B25TH, their connections are combo: the connections are externally threaded and also provide inner pipe for soldering (see picture, click to open the connection's drawing). B86H achieves the highest efficiency, but it also has the highest pressure losses. Pressure losses can be reduced by increasing the number of plates.

All SWEP heat exchangers have stainless steel connections and a silver solder containing at least 45% silver has to be used.

Heat exchangers for heat pumps

Overview of condensers for heat pumps, i.e. the exchanger serves as a refrigerant condenser. The pressure losses for the water circuit (heating) are shown within the table. The condenser calculation is for the R410A refrigerant on the primary side, the water on the secondary side has gradient of .

Capacity Exchanger type Pressure drop
5 kW B26FHx18 4 kPa
10 kW B26Hx24 9 kPa
15 kW B26Hx40 8 kPa
20 kW B85Hx50 17 kPa
30 kW B85Hx70 20 kPa

The design pressure of the exchanger can be read from the graph in its product sheet. The pressures of individual refrigerants can be read from tables commonly available on the Internet. For clarity, the pressures in bar for commonly used refrigerants R410A, R407C and R32 are summarized in the table:

64 °C42412946484652
66 °C44433046484652
68 °C47453246484652
70 °C48473346484651

Heat pump freezing, heat exchanger failure

The exchanger rupture most often happens in these two cases:

SWEP B26FH heat exchanger for R410A heat pump
  • The operating pressure of the refrigerant is higher than the design pressure of the exchanger. The system must include a high pressure switch. This switches off the compressor when the working pressure is exceeded (e.g. in the event of a fault).
  • The heat exchanger must not get frozen. There is a risk of freezing media inside condenser when the heat pump is running in reverse. Reverse operation is started for a few minutes to defrost the evaporator. The refrigerant in the condenser can have a temperature of -20 °C Therefore, under unfavorable circumstances, there is a risk of water freezing in the condenser. Even if the water at exchanger outlet has 3 °C, inside the heat exchanger might be a space with temperature below freezing point. Freezing is prevented by the correct use of temperature sensors (regulation), the use of antifreeze or electric heating of the heat exchanger during defrosting. To prevent the heat exchanger from freezing, it is necessary to maintain full flow rate on the water side: 1) the heat pump must be equipped with a flow switch, 2) use a constant speed setting on the circulation pump, 3) the valves on the radiators must be open.

Freezing water in the heat exchanger means damaging the heat exchanger and usually also the overall damage to the heat pump (water might get into the refrigerant circuit). That's why SWEP also supplies a special version of the most commonly used SWEP B26H heat exchanger for R410A refrigerant: the modified B26FH version has no channels in the corner at the refrigerant inlet, where the exchanger is most susceptible to freezing. This reduces the overall risk of the "heat pump freezing".

Evaporator for heat pump

The evaporator is the heat pump exchanger on its primary circuit. In this exchanger, the cold liquid refrigerant evaporates. The system is usually set so that the expansion valve in front of the evaporator reduces the pressure. This reduces the boiling temperature. The evaporator refrigerant temperature is set to a temperature of about 0 °C, but it may be less. Heat must be supplied to the refrigerant in order for the refrigerant to evaporate. This is taken, for example, from the ambient air or from the ground (and later transferred to the heating water in the condenser). Most of the energy that is thus transferred from the environment to the refrigerant is stored in the change of state.

For small applications, the classic SWEP plate heat exchanger can be used. The refrigerant inlet connection should never be larger than the refrigerant outlet connection. For proper operation, the recommended refrigerant speed of 10 to 25 m/s at the inlet and 5 to 10 m/s at the outlet (2.5 to 5 m/s if the connection is horizontal) should be ensured; this also prevents oil accumulation in the heat exchanger.

High performance pumps require more plates in the exchanger. If more than 30 plates are needed for the evaporator, it is usually necessary to select a specialized type of plate heat exchanger (V-type, P-type, F-type or Q-type). V-series heat exchangers are classic heat exchangers equipped with a system for even distribution of refrigerant (e.g. V25, V80). Without this measure, with a larger number of plates, the refrigerant would only flow through the plates closest to the inlet. The exchanger would not have the expected efficiency and could get frozen. The distribution system is not an obstacle if such exchanger is used also as a condenser.

Exchanger without distribution system used as evaporator
Classic heat exchanger without distribution system used as an evaporator. For larger capacity, a specialized exchanger (evaporator) is used. Most often it is SWEP V and P series.

Specialized types (i.e. most of V-series heat exchangers and especially P-type and other evaporators) are not in stock and must be manufactured.

Separation exchanger for heat pump

The separation exchanger is used, for example, to separate the antifreeze circuit from the heating water circuit. Then a mixture with glycol can be used outside and there is only heating water in the heating circuit inside the building. The separation exchanger can also be used to separate the heat pump from dirty or aggressive media.

To maintain the efficiency of the heat pump, it is necessary to bring the temperatures of both circuits as close as possible. For most of these applications, we usually recommend SWEP E8Tx40, which is the largest plate heat exchanger in the low-pressure range.

Flow rate Exchanger type Pressure loss
1 m3/h E8THx20, B85Hx20 12, 12 kPa
2 m3/h E8THx40, B85Hx30 15, 19 kPa
3 m3/h B10THx50, B85Hx40 6, 23 kPa
5 m3/h B85Hx60 30 kPa
10 m3/h B85Hx120 33 kPa
Overview of plate exchangers for circuit separation