AURORA 1081 BP Series

®
Optional ASME
Certified

BRAZED PLATE HEAT EXCHANGERS Optional

European Code

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 BRAZED PLATE HEAT EXCHANGERS

AURORA 1081 BP Series

®

Brazed Plate Heat Exchangers

Higher Performance
Increased Efficiency
More Versatility

Model AP – For Domestic Hot Water Heating Applications.

Brazed Plate heat exchangers are ideal and offer a compact, high output capacity for Domestic Hot A
B
Water heating applications. These heat exchangers offer substantial advantages over shell & tube,
tank & coil, U-tube bundles and other older technologies when used in both hot water boiler (AP
C
series) and steam applications (APSMO series). These advantages include the unit being easier to
install, rig and maintain at 1/5 the size and weight with a faster response and long life use. D
Brazed Plate models are excellent for both new construction and replacement applications.
Three types of piping installations are typical:
Recirc to Tank Only: A recirc pump to the hot water tank is typical in most residential and light E

commercial applications.
Recirc Loop in Building: A recirc loop is used, with or without a hot water storage tank, for many
commercial and industrial applications.
Instantaneous: Instantaneous hot water heating can be used in a few installations.
Piping. F

Tee(s) on the output side of the HX are recommended for convenience in case future chemical
G
descaling and cleaning is required.

Controls.
Typical control of the pumps (Recirc to Tank only) should use an aqua stat in the A. Easy to Insulate
hot water storage tank to maintain set point temperature (i.e. 130˚F). B. Proplerly Sized Connections
Vacuum Breaker 130°F out
C. Compact
Pressure and
D. Stud Bolts for Installation and Mounting
Hot Water Temperature Relief

Storage Tank
Value
E. High Performance Heat Transfer Surface
Storage
PRV Tank Note: Storage tanks F. Strong, Rugged Connections
over 120 gals. or 200,000 BTU
12" from floor
must have ASME Certification. G. Totally Sealed Construction
Brass Tank Drain

2
 BRAZED PLATE HEAT EXCHANGERS

Pump Features

Controls for Recirc Loops. Diagram 1 – Recirc to Tank

For recirculated domestic hot water systems (i.e. apartments, 180°F 130°F
Bronze Pump

hospitals, factories and office buildings), a motorized three-

130°F max

Hot See Diagram

way mixing valve is REQUIRED on the boiler side and should be PRV
Bronze Pump
Water Below

180°F 130°F Tank

modulated based on water temperature leaving the heat exchanger
100°F 130°F max

Hot
into the domestic water loop. The hot water loop pump runs
Tee(s) for servicing, See Diagram
150°F chemical descaling, and drain line Below
Bronze Pump Water
PRV
Boiler Tank
continuously; this maintains the hot water set point for the loop 180°F 130°F100°F
PRV = Pressure Relief Valve 130°F max

and storage tank. The recirc pump should flow 100% of the return 150°F
Tee(s) for servicing,
Hot
chemical descaling, and drain line
See Diagram
Below
Water
loop water through the heat exchanger, then to the storage tank
PRV
Boiler Tank
100°F
PRV = Pressure Relief Valve
Modulating 3 way valve
(if required; depends on boiler capacity) at all times to minimize Building Loop

Diagram 2 – Recirc to Building Loop

130°F
Tee(s) for servicing,
180°F
150°F chemical descaling, and drain line 130°F max
scaling and maximize BTUH output. City water inlet is recommended Boiler Bypass/
Hot
Modulating 3 way Balancing
PRV = Pressure Relief Valve Water See Diagram
before the heat exchanger and after the pump to maximize the heat
valve
Valve
130°F
PRVBuilding Loop Tank Below
180°F (optional)

exchanger capacity.
130°F max

Bypass/
Hot
Balancing Domestic Water
Bronze Pump See Diagram

Controls for Instantaneous Water Heating.

150°F
Modulating 3 way valve Valve
Hot Water City Water
PRV Loop
Building Tank Below
Boiler 130°F (optional)
180°F (Re-circ)
130°F max

A three-way tempering valve is required and an anti-scalding safety Bypass/

Balancing
150°F Domestic
Tee(s) for servicing
and chemical descaling
Hot
Water
Bronze Pump See Diagram
City Water
device must be installed. The boiler pump should run continuously. Tank
Valve Hot Water PRV Below
Boiler (optional)
(Re-circ)
3 Way

Controls for Steam Systems.

Tee(s) for servicing Tempering
and chemical descaling Valve Anti-scald
Domestic 130°F Bronze Pump
150°F device
City Water
Hot Water
Boiler
A modulating steam valve and proper steam trapping is required.
130°F max
(Re-circ)
180°F 3 Way
Tee(s) for servicing PRV Tempering City Water

Diagram 3 – Instantaneous
and chemical 130°F
descaling Valve Anti-scald

Start-up.
50°F device
City Water
130°F max
Tee(s) for servicing,
180°F 150°F Domestic Hot Water3 Waychemical descaling, and drain line
The bypass/balancing valve should be adjusted at full load to Boiler
(Instantaneous)
130°F
50°F
PRV
Tempering
Valve
City Water
Anti-scald
device
obtain the proper return water temperature to the boiler.
City Water
130°F max
Tee(s) for servicing,
180°F 150°F Domestic Hot Water chemical descaling, and drain line
(Instantaneous) PRV City Water
Boiler
For applications with a recirc domestic hot water loop, the 50°F
City Water

modulating three-way valve should be adjusted so that it 150°F Domestic Hot Water
Tee(s) for servicing,
chemical descaling, and drain line

maintains proper domestic water temperature and does not hunt Boiler
(Instantaneous)

or overshoot. Slow to medium response rate is recommended.

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 BRAZED PLATE HEAT EXCHANGERS

Potable Water and Chemical Applications

Model APDW – For Domestic Hot Water based on water temperature leaving the heat exchanger into the
domestic water loop. The hot water loop pump runs continuously;
Heating Applications. this maintains the hot water set point for the loop and storage
The APDW model is a Double Wall, Vented Heat Exchanger designed
tank. The recirc pump should flow 100% of the return loop water
to meet local and state plumbing codes for double separation of
through the heat exchanger, then to the storage tank (if required;
potable water from boiler water and other non-potable fluids. As
depends on boiler capacity) at all times to minimize scaling and
a cost effective, full range heat exchanger, the APDW model is a
maximize BTUH output. City water inlet is recommended before
true Double Wall Vented design with double wall plates and double
the heat exchanger and after the pump to maximize the heat
seal fluid ports, both of which have positive leak detection. The
exchanger capacity.
APDW model also has full thickness 316L copper brazed plates for
longer product usage and reliability. Compact and easy to install,
Controls for Instantaneous Water Heating.
the APDW model is ideal for new construction or shell & tube
A three-way tempering valve is required and an anti-scalding safety
replacement. Optional ASME Code.
device must be installed. The boiler pump should run continuously.
Piping. Controls for Steam Systems.
Tee(s) on the output side of the HX are recommended for convenience
A modulating steam valve and proper steam trapping is required.
in case future chemical descaling and cleaning is required.
Start-up.
Controls. The bypass/balancing valve should be adjusted at full load to
Typical control of the pumps (Recirc to Tank only) should use
obtain the proper return water temperature to the boiler.
an aqua stat in the hot water storage tank to maintain set point
temperature (i.e. 130˚F). For applications with a recirc domestic hot water loop, the
modulating three-way valve should be adjusted so that it maintains
Controls for Recirc Loops. proper domestic water temperature and does not hunt or overshoot.
For recirculated domestic hot water systems (i.e. apartments, Slow to medium response rate is recommended.
hospitals, factories and office buildings), a motorized three-way
mixing valve is required on the boiler side and should be modulated

4
 BRAZED PLATE HEAT EXCHANGERS

Potable Water and Chemical Applications

Model APDW Model APSMO –

Diagram 1 – Recirc to Tank
180°F 130°F
Bronze Pump
Bronze Pump
For Swimming Pools and Spas.
Piping: Pools and Spas always have high water flow rates, from 30-
130°F max
180°F 130°F Bronze Pump
130°F max
180°F 130°F Hot See Diagram

PRV
Water
Hot
130°FBelow
max
See Diagram
Below
50 GPM for a typical residential pool to higher GPMs for commercial
Tank
Water
Hot
applications. Because the APSMO model is a high efficiency heat
100°F PRV See Diagram
100°F
Tank
Water Below
PRV
Tank
exchanger and does not require the full pool GPM flow, a bypass/
100°F Tee(s) for servicing,
150°F chemical
Tee(s) for descaling,
servicing, and drain line
150°F chemical descaling, and drain line
Boiler
Boiler 150°F
Tee(s) for servicing,
PRV = Pressure Relief Valve
chemical descaling, and drain line balancing valve is required to bypass 50%-80% of the pool water.
PRV = Pressure Relief Valve
Boiler
PRV = Pressure Relief Valve
The bypass/balancing valve should be adjusted and permanently
Diagram Modulating
2 – Recirc3towayBuilding Loop
set at startup.
valve
Building Loop
Modulating 3 way valve 130°F
180°F
Modulating
180°F 3 way valve 130°F
Building Loop

Building Loop
130°F max Chemical feeds MUST be downstream from the heat exchanger. A
130°F Hot 130°F max
180°F Bypass/
Balancing
Bypass/
Water
Hot See Diagram
130°F max check valve should be installed to prevent backflow of chemicals
Valve
Balancing PRV HotTank
Water SeeBelow
Diagram
Bypass/
Valve
Balancing
PRV
(optional)
Tank
Water
Below
(optional) See Diagram
into the heat exchanger when the pump is not in operation.
Valve PRV Tank Below

Controls.
(optional)
150°F Domestic Bronze Pump
City Water
150°F Hot Water
Domestic Bronze Pump
Boiler City Water
(Re-circ)
Hot Water
Domestic
Temperature control of the pool should be based on a return water
Bronze Pump
Boiler 150°F
(Re-circ) City Water
Hot WaterTee(s) for servicing
Boiler
(Re-circ) and chemical descaling
Tee(s) for servicing
and chemical descaling
Tee(s) for servicing
temperature stat, controlling (on/off) the boiler and boiler pump.
3 Way
and chemical descaling
130°F
Tempering
3 Way
Valve
Tempering Anti-scald
Temperature control of the 90˚F-100˚F feed to the pool should be
Diagram 3 – Instantaneous 3 Way
Valve device
controlled by permanent adjustment of the bypass/balancing valve.
130°F Anti-scald
Tempering device
Valve 130°F max
130°F Anti-scald
180°F device 130°F max

Start-up.
PRV City Water
180°F 130°F max
50°F PRV City Water
180°F City Water
50°F PRV City Water

150°F
50°F
Domestic Hot Water chemicalCity
City Water
Tee(s) for servicing,
Water
Start up the system and adjust the pool side bypass/balancing
Tee(s) for servicing, and drain line
descaling,
Boiler 150°F (Instantaneous)
Domestic Hot Water
(Instantaneous)
Domestic Hot Water
chemical descaling, and drain line
Tee(s) for servicing, valve so that the pool initially heats up no faster then 2˚F/hr.
Boiler 150°F chemical descaling, and drain line
Boiler
(Instantaneous) After the pool reaches approximately 78˚F-80˚F and the boiler
water enters at 180˚F, adjust the pool side bypass/balancing valve
to obtain 90˚F-100˚F water to the pool. Then, adjust the boiler
Model APSMO bypass/ balancing valve so that approximately 150˚F water returns
to the boiler.
Chemical Feed
90°F
Swimming Pool
Bypass/
Bypass/
NOTE: Install a zinc anode on the swimming pool/spa side piping
Balancing
Valve Balancing Filter
Valve S1
80°F

180°F when using an electronic chlorinator.

P2
150°F
P1
Boiler

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 BRAZED PLATE HEAT EXCHANGERS

Snow Melt and Radiant Floor Applications

Model AP – Controls.
For Snow Melt Applications. A three-way tempering valve is required to allow for adjustment
Brazed Plate heat exchangers are very cost effective in Snow Melt of the snow melt side and to limit the temperature of the glycol.
applications, providing high output, fast response and separation For radiant tubing in sand, maximum glycol temperature is 140˚F.
of the fluids. Used for boiler water to glycol heat transfer and, in In asphalt and concrete, maximum temperature is typically 150˚F.
some applications, zone isolation, the AP series provides an easy Recommended set point 130˚F for the glycol snow melt side.
solution to Snow Melt systems.
Start-up.
Most Snow Melt systems are boiler water to glycol 10%-40% Adjust the three-way tempering valve to 130˚F or the desired set
(typical), depending on location and weather conditions. The point.
heat exchanger isolates the glycol from the boiler water and
P1

provides an oxygen barrier to the boiler, which protects other Bypass/

130°F
Balancing
components in the boiler system.
180°F
Valve

Snow

Piping.
100°F Melt
150°F Loop
Snow Melt
Heat Exchanger
Boiler
A boiler side bypass/balancing valve is recommended, but not
required. A three-way tempering valve or motorized control valve
on the snow melt side is required. Another strong application is using a domestic hot water heater to
Model AP – provide heat to a radiant floor system bathroom radiant floor, or for
add-on projects. This is easily accomplished using a Brazed Plate
For Radiant Floor Applications. model to isolate the domestic water from the radiant floor loop.
Many radiant floor applications utilize
180°F
Brazed Plate heat exchangers to reduce the overall cost of the Bypass/
P1

radiant floor system installation. This is possible when using Balancing

Valve

cast iron boilers and radiant tubing (with lower

150°F

cost, no oxygen barrier) and for applications where isolation Boiler

of the boiler to radiant floor loops are needed. These actions

simplify installation and minimize costs.

Brazed Plate models also make it possible to interface steam

boilers to radiant floor systems, both low pressure and high
pressure steam systems (up to 300 psi) using the APSMO series.

6
 BRAZED PLATE HEAT EXCHANGERS

Close Approach Applications

Model AP – Temperature Difference (TD) of (Side A or Side B) are defined as:

Entering Temperature minus Leaving Temperature
For Close Approach.
Brazed Plate heat exchangers can be used in applications Example:
whereby the Approach Temperatures can be 10˚F or less and Side A: 95˚F in , 85˚F out = 10˚F TD for Side A
as low as 2˚F, which means the heating (or cooling) source will Side B: 77˚F in , 87˚F out = 10˚F TD for Side B
heat (or cool) the secondary load side to within a 2˚F-10˚F
Optimum Approach Temperature for a Brazed Plate heat exchanger
of the source temperature. This capability allows for a variety
is typically 10˚F for cost effective selections; however, 3˚F and 4˚F
of applications and versatility for utilizing Brazed Plate heat
Approach Temperatures are possible for special applications.
exchangers. Brazed Plate heat exchangers can be used for many
Fluid-to-Fluid applications where a heating (or cooling) source Ideal Temperature Difference (TD) is typically 10˚F and is preferred
is used to transfer heat to a load. in many applications.

Applications Include: Diagram 1Strainer

Strainer
– Standard Piping Arrangement 10˚F and Higher Approach
Strainer

A boiler side bypass/balancing valve is recommended, but not SOURCE SOURCE SideIn A SideSide
In
A B
Side AOut
Side B
Bypass/Balancing
Out
Adjustment
Side B
Bypass/Balancing
Adjustment
Bypass/Balancing
(Boiler,
(Boiler, Heat Pump,SOURCE Heat Pump, In Out LOAD LOAD
required. A three-way tempering valve or motorized control valve Chiller, etc.) (Boiler,
Chiller,
Heatetc.) Bypass
Pump,
Bypass
Adjustment
Adjustment
LOAD
Chiller, etc.) Adjustment Bypass
on the snow melt side is required. Adjustment
Strainer Strainer
Strainer
• Boiler Water to Process
• Chilled Water to Process
• Glycol to Process Water Diagram 2 – Heat Exchanger to Cooling Tower
Side A Side
SideA B Side B
• Process Water to Process Water In In
SideOut
A
Out
Side B
In Out
• Hot Water Heater to Radiant Floor Chilled Chilled
Bypass/ Bypass/
Balancing
Balancing Bypass/
Water / or Process
Water / or Process
• Cooling Tower/Free Cooling to Chilled Water Loop Chilled Valve Valve
Loop Loop Balancing
Water / or Process Valve
Loop

• Engine Water to Process

Strainer Strainer
Heat Exchanger
• High Pressure (300psi) Isolation to Heat Exchanger
to Cooling
Heat
to Cooling Tower Tower
Exchanger
Strainer

  Low Pressure (150psi) Equipment to Cooling Tower

Diagram 3 – High Pressure Isolation
• Sea Water to Process (APSMO Series)
Side A Side
SideA B Side B
In In Out
SideOut
Approach Temperature = Side A (Source) Entering Temperature In
A Side B
Out

(˚F) minus Side B (Load) Leaving Temperature (˚F) High Pressure High Pressure
Loop Loop
High Pressure
Low Pressure
Loop
Low Pressure
Loop
Low Pressure
< 450psi < 450psi < 150psi < 150psi
Loop Loop
< 450psi < 150psi
Example:
Side A: 95˚F in , 85˚F out High Pressure
Isolation
High Pressure
Isolation
High Pressure
Side B: 77˚F in , 87˚F out = 8˚F Approach (Interceptor)
(Interceptor)Isolation
(Interceptor)

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 BRAZED PLATE HEAT EXCHANGERS

Model AP Accessories

Mounting Brackets: BKT10X20 AND FR10X20

Mounting of any Brazed Plate unit can be
accomplished by:
1. Using a bar across the face of the unit
2. Mounting to a steel strut
3. Using a mounting bracket. Mounting brackets are designed for easy use
where applicable. BKT and FR models are all stainless steel.

Part
BKT10X20 FR10X20 BKT5X20 BKT5X12
BKT5X12 AND BKT5X20
Number
Plate Count 10-100 PL 110-220 PL All All
A 5.500 3.500
B 13.625 8.625
C 14.875 9.750
D 3.000 7.000
E 4.000 8.000
MATL. TH’K 14 GA 10 GA 14 GA 14 GA
MATERIAL: SA-240, 304 SS

Bracket Model Type

BKT5x12 Mounting Bracket

for AP4H, APDW4, APSMO5x12

BKT5x20 Mounting Bracket

for AP57H, APDW5, APSMO5x20

BKT10x20 Mounting Bracket

for AP10H, APDW10, APSMO10x20

FR10x20 Rugged Floor Mounting Frame

for AP57H, APDW5, APSMO5x20, 90-200 plates BKT5x12 BKT5x20 BKT10x20 FR10x20

8
 BRAZED PLATE HEAT EXCHANGERS

Model AP Accessories

“Y” Strainers: Model Female Pipe

Connection
Mesh
Strainer
GPM
at 1 psi PD
GPM
at 2 psi PD
A water strainer is required for proper protection of the Brazed Plate STR3/4 3/4" FPT 20 mesh 18 26
fluid side for chillers, condensers and fluid-to-fluid units. These STR1 1" FPT 20 mesh 28 40

strainers are cast bronze, female pipe thread connections and rated STR1-1/4 1-1/4" FPT 20 mesh 42 60
STR1-1/2 1-1/2" FPT 20 mesh 70 100
for 400 psi working pressure at 150˚F.
STR2 2" FPT 20 mesh 110 140
STR2-1/2 2-1/2" FPT 20 mesh 140 190
STR3 3" FPT 20 mesh 180 260
STR4 4" FPT 20 mesh 300 420
Note: Please contact Aurora Applications Engineering ([email protected]) for higher working
pressure models or stainless steel versions.

Zinc Anode:
A zinc anode is required for all APSMO models used in swimming
pools with electronic chlorinators and for ALL applications where
Model Female Pipe
galvanic corrosion is possible. A zinc anode is not provided with Connection

APSMO fluid-to-fluid models. ANODE 3/8 3/8" FPT

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 BRAZED PLATE HEAT EXCHANGERS

Replacement Heat Exchangers

Model AP – Step 4: Multiply:

#Tubes____ x Diameter of tube_____(inches) x 3.14 x Tube
For Replacement Heat Exchangers. Length_____(inches) x .0069 (ft2/in2) x 1.2 Safety factor =
There are two simple ways to select a Brazed Plate Heat Exchanger
______Sq. Feet of Heat Transfer Surface
to replace a Shell & Tube Heat Exchanger. Both methods provide
exact or improved performance selection. Step 5: Select the corresponding Brazed Plate model based on
the Sq. Feet column above.
Method A. Heat Transfer Surface Method.
This method uses a near exact way of matching the heat transfer Step 6: Installation – The fluid pressure drop of the new
surface area of the heat exchanger, which defines the nominal installation must closely match (+/- 20%) that of the former
performance of the unit. Because Brazed Plate units perform Shell & Tube installation so that the pump performance and
20%-80% better than Shell & Tube Heat Exchangers on a heat fluid flow remain the same. Make sure bypass/balancing valves
transfer surface basis, a 20%-80% safety factor is embedded in are installed on all fluid circuits to the heat exchanger (boiler
this method. This approach works for almost any type of fluid- and secondary side while excluding steam lines). Adjust for
to-fluid and steam-to-fluid heat exchangers. proper pressure drop across the heat exchanger, which should
match the pressure drop across the (former) Shell & Tube heat
Step 1: Count the number of tubes in the Shell & Tube Heat
exchanger.
Exchanger. # of tubes = ______

Step 2: Measure the external diameter of the tube(s). OD

H
Diameter of bare tube is: (.25", .375", .5", .625", .75", .875" or LENGT es)
i h
n c
______). If the tubes have fins or protrusions, call your Aurora (_____
Pump sales representative.
Tube Diameter
Step 3: Measure the length of the tube(s) from end sheet to (_____ inch)
end sheet. Length of tubes = ______ inches. If U-tube bundle,
use overall length of U-tube bundle. _____ # of Tubes

10
 BRAZED PLATE HEAT EXCHANGERS

Replacement Heat Exchangers

Method B. Design Condition Method. Hydronic Models

(AP4H)
Square Feet
Surface
Hydronic Models
(AP57H)
Sq Feet
Surface
The standard design and selection method of a heat exchanger AP4H-8 2.3 AP57H-20 23.6
is based on “Design Conditions.” This heat exchanger can either AP4H-10 3.1 AP57H-24 28.9
be selected from one of the charts in the A-01-20-1000-1080 AP4H-12 3.8 AP57H-30 36.8
AP4H-14 4.6 AP57H-40 49.9
Selection Data pages or computer selected. The following
AP4H-16 5.4 AP57H-50 63.0
information is required for a computer selection: AP4H-20 6.9 AP57H-60 76.1
AP4H-24 8.4 AP57H-70 89.3
Hot Side A 10.7 AP57H-80 102.4
AP4H-30
Fluid ________(Water, or, %Glycol, or Fluid Type) 10.7 AP57H-90 115.5
Temperature In ________˚F (or ˚C) AP4H-36 13.0 AP57H-100 128.6

Temperature Out ________˚F (or ˚C) AP4H-40

14.6 AP57H-110 141.8
14.6 AP57H-120 154.9
Flow Rate ________GPM (or L/min)
18.4 AP57H-130 168.0
Fouling Factor (.0001 standard) Maximum Allowable AP4H-50
18.4 AP57H-140 181.1
Pressure Drop ________psig AP4H-60 22.2 AP57H-150 194.3
AP4H-70 26.1 AP57H-160 207.4
Cold Side B AP4H-80 29.9 AP57H-170 220.5
Fluid ________(Water, or, %Glycol, or Fluid Type) Note: For Steam, CuNi-Cupronickel and Brass Shell AP57H-180 233.6
& Tube Replacements, or Swimming Pool water
Temperature In ________˚F (or ˚C) and installations with questionable water quality,
AP57H-190 246.8
AP57H-200 259.9
Temperature Out ________˚F (or ˚C) substitute Aurora Pump APSMO series for the AP
model number.
Flow Rate ________GPM (or L/min)
Fouling Factor (.0001 standard) Maximum Allowable
Pressure Drop ________psig
Total Heat Transfer __________________BTUH (or KW)

Note: The Brazed Plate unit will be 1/2 to 1/5 the size and weight of the Shell & Tube heat exchanger
while still offering the same performance and design conditions.

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 ST ER E D Q U
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ALI
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ISO 9001

TY SYSTEM
LIC
IN
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ST
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19 17

800 AIRPORT ROAD, NORTH AURORA, ILLINOIS 60542 WWW.AURORAPUMP.COM

Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice.
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