manual

Installation and operating instruction

Weishaupt Electric & Media Oil Preheaters

83001802 - 1/2005

Contents

1 2 3 4

1 General instructions

2 Safety information

3 Technical description 3.1 Permissible applications

6 6

4 Electric oil preheater type EV2 4.1 Safety instructions 4.2 Function 4.3 Electrical connection 4.4 Safety instructions for initial commissioning 4.5 Commissioning 4.6 Technical data EV2

7 7 7 8 9 9 11

5 Electric oil preheater type WEV2.2/01 and WEV3/01 5.1 Safety instructions 5.2 Function 5.3 Electrical connection 5.4 Safety instructions for initial commissioning 5.5 Commissioning

12 12 12 13 14 14

6 Media oil preheater type MV9C and MV10A 6.1 Safety instruction 6.2 Function 6.3 Media fittings 6.3.1 Connection variations 6.3.2 Fittings 6.4 Safety instructions for initial commissioning 6.5 Commissioning 6.5.1 Hot water and thermal fluid operation 6.5.2 Steam operation 6.5.3 Ratings and pressure loss diagram 6.6 Technical data MV 6.7 Saturated steam and condensate line

17 17 17 18 18 20 22 22 22 23 24 25 26

Appendix Viscosity - temperature diagram

27 27

General instructions
Hand over and operating instructions The contractor is responsible for passing the operating instructions to the plant operator prior to hand-over. He should also inform the plant operator that these instructions should be kept with the heating appliance. The address and telephone number of the nearest service centre should be entered on the reverse of the operating instructions. The plant operator must note that an agent of the contractor or other suitably qualified person must inspect the plant at least once a year. To ensure regular inspections, -weishaupt- recommends a service contract. The contractor should instruct the plant operator in the use of the equipment prior to hand-over and inform him as and when necessary of any further inspections that are required before the plant can be used. Guarantee and liability Weishaupt will not accept liability or meet any guarantee claims for personal injury or damage to property arising as a result of one or more of the causes below: This symbol is used to mark instructions, which, if not followed, could result in damage to, or the destruction of the equipment and environmental damage. Failure to use the equipment as intended Improper assembly, commissioning, operating or servicing of the equipment. Operating the appliance with defective safety equipment, or with non-recommended or nonfunctioning safety and protection devices Failure to follow the information in the Installation and Operating Instructions Alterations made to the construction of the equipment by the plant operator Fitting additional components not tested or approved for use with the equipment. Alterations made to the equipment by the plant operator (e.g. motor ratio - rating and speed) Alterations made to the combustion chamber, which hinders constructive, predetermined flame formation Inadequate monitoring of parts liable to wear and tear Improperly executed repairs Acts of God Damage caused by continued use despite the occurrence of a fault Use of incorrect fuel Obstruction or damage of the supply lines Use of non-original -weishaupt- spare parts

These installation and operating instructions are an integral part of the equipment and must be kept permanently on site. are to be used by qualified personnel only. contain the relevant information for the safe assembly, commissioning and servicing of the equipment. are for the attention of all personnel working with the equipment.

Explanation of notes and symbols This symbol is used to mark instructions, which, if not followed, could result in death or serious injury.
DANGER

This symbol is used to mark instructions, which, if not followed, could result in life threatening electric shock.
DANGER

ATTENTION

1. 2. 3.

This symbol is used to mark procedures, which you should follow. Procedures with more than one step are numbered. This symbol is used when you are required to carry out a test. This symbol is used to list points. This symbol indicates detailed information.

Abbreviations Tab. Table Ch. Chapter

2 Safety information
Dangers when using the equipment Weishaupt products are manufactured in accordance with the relevant existing standards and guidelines and the recognised safety laws. However, improper use of the equipment could endanger life of the user or a third party, or result in damage to the plant. To avoid unnecessary danger, the equipment is only to be used: for its intended purpose under ideal safety conditions with reference to all the information in the installation and operating instructions in accordance with inspection and service work Faults, which could affect the safe operation of the burner, should be rectified immediately. Personnel training Only competent personnel may work on the appliance. Competent personnel according to this operating manual are persons who are familiar with the installation, mounting, setting and commissioning of the product and have the necessary qualifications such as: Training, instruction or authorisation to switch electrical circuits and electrical devices on and off, to earth them and to mark them in accordance with the safety standards. Organisational measures Everyone working on the plant should wear the necessary protective clothing. All safety devices should be checked regularly. Informal safety measures In addition to the installation and operating instructions, local codes of practice should also be adhered to. Special attention should be paid to the relevant installation and safety guidelines given. All safety and danger notices should be kept in a legible condition. Safety measures in normal operation The unit gets dangerously hot during operation. Do not touch. Only use the equipment when all the safety devices are fully functional. At least once a year the equipment, including the safety devices, should be checked for signs of visible damage and to ensure that the safety devices are operating correctly. More frequent safety check may be required depending on plant conditions.

2
Electrical safety Before starting work - isolate plant and protect against reactivation, check voltage is isolated, the unit is earthed, and protected from adjacent equipment that might still be under voltage! Work on the electrical supply should be carried out by a qualified electrician. Electrical components should be checked during servicing. Loose connections and heat damaged cables should be dealt with immediately. The control panel should be locked at all times. Access should be restricted to authorised key holder personnel. Should it be necessary to carry out work on live parts, country specific safety regulations must be observed and tools to EN 60900 must be used. A second person should be present to switch off the mains supply in an emergency. Maintenance and fault rectification Allow the unit to cool prior to servicing and maintenance work to avoid injury through high temperatures. Necessary installation, service and inspection work should be carried out at the specified time. Inform the operator before beginning any service work. For all service, inspection and repair work, electrically isolate the equipment and ensure the mains switch cannot be accidentally switched back on. Cut off the fuel supply. If, during servicing or testing, control seal joints have to be opened, these have to be thoroughly cleaned to ensure tight sealing when re-assembling. Damaged seals must be replaced. Carry out a soundness test! Flame monitoring devices, limit controls, correcting elements and all other safety devices must be commissioned by, and may only be replaced by, the manufacturer or an authorised agent. Screwed connections, which have been loosened, must be re-tightened without cross-threading. Following service work, all safety devices should be tested to ensure they are functioning correctly. Alterations to the construction of the equipment No alterations to the equipment are to be made without the approval of the manufacturer. All conversions require written confirmation from Max Weishaupt GmbH. Any parts not in perfect working order should be replaced immediately. No additional components may be fitted, which have not been tested for use with the equipment. Use only -weishaupt- replacement and connection parts. Parts from other manufacturers are not guaranteed to be suitable to meet the necessary operational and safety requirements. Waste disposal All materials used should be handled and disposed of correctly, with due regard to the environment.

3 Technical description

On burners for use with medium and heavy residual fuel oils the oil has to be preheated to the temperature required for atomisation. Oil preheating can be carried out electrically or with heating medium, as well as with a combination of electric and media heaters. Hot water, low and high pressure steam or thermal fluid oil are used as heating media.

3.1 Permissible applications

Weishaupt oil preheaters are suitable: for residual fuel oils: In their standard version for a viscosity up to 50 mm2/s at 100C (approx. 570 mm2/s at 50C) In special versions for a viscosity of up to 60 mm2/s at 100C (approx. 700 mm2/s at 50C) for installation on Weishaupt medium and heavy residual oil burners for a maximum oil temperature of 160 C Any other application is only permitted with prior written agreement of Max Weishaupt GmbH. The oil preheater must only be used within the ratings given on the name plate. The oil preheater is not suitable for operation out of doors. The oil preheater must not be operated outside of its permitted temperature range.

4 Electric oil preheater type EV2

4.1 Safety instructions
Electrically isolate plant Prior to commissioning and service switch off the mains switch and the safety switch. Failure to comply could cause death or serious injury by electric shock.
DANGER

4
Allow oil preheater to cool Allow the oil preheater to cool prior to commissioning and service work. The hot surfaces and the hot oil could lead to burns if touched.
DANGER

4.2 Function
Heat exchanger The heat produced by electrical energy is conducted by a copper plate to the oil pipe coil. The oil preheater has a large heat exchange surface with relatively small oil volume. It is therefore possible to heat the fuel oil up to the necessary atomising temperature within a short period of time. The heat distribution prevents localised overheating. The fuel oil will not carbonise. The maximum achievable oil temperature at the nozzle is approximately 150 C and depends on the oil throughput and the temperature of the fuel oil inlet. Temperature controller The oil outlet temperature is set at the temperature controller 1. This operates the heat elements via a contactor. The temperature controller is equipped with an integrated temperature switch for burner release. The switch point for the release contact is 30 K below the temperature set point. Temperature switch To ensure stable operating behaviour the oil preheater has been fitted with two temperature switches for burner release and these are switched in sequence. The burner is only released once both temperature switches have reacted. The temperature switch 3 is connected to the heat exchanger via compensation plate. This ensures that the burner starts only once the minimum operating temperature of the oil preheater has been reached. (Prerequisite: The second temperature switch has also switched). This reduces temperature deviations following fuel release. Temperature limit switch The temperature limit switch 2 reacts, if the fuel oil temperature exceeds the set value. The temperature limit switch acts, either directly (EV2A) or indirectly via a safety relay (EV2B, EV2C and EV2D) on the heat elements. Reset is carried out mechanically direct at the temperature limit switch. Electric oil preheater EV2A 3 2 1

Electric oil preheater EV2B, EV2C and EV2D 3 2 1

1 Temperature controller with integrated temperature switch for burner release. 2 Temperature limit switch 3 Temperature switch on compensation plate

4
4.3 Electrical connection
Connection diagram EV2A 230V/1~N N L1

1 3

2 3a

4
1 2 3 4 5 6

6 6A

6A

1500W

10 EV2A

Connection diagram EV2B, EV2C and EV2D 3 1 4

1 2 3 4 5 6

3a

400V/3~N N L1 L2 L3 6A (EV2B/EV2C) 10A (EV2D)

6A

V2 U2 W2

W1 V1 U1

U1 1500W

U2

V1 1500W

V2

W1 1500W

W2

EV2B
U1 2200W U2 V1 2200W V2 W1 W2 2200W

10

8 7

EV2C
U1 U2 U1 U2 V1 V2 V1 V2 W1W2 W1W2 2200W 2200W 2200W 2200W 2200W 2200W
V2 U2 W2 W1 V1 U1

EV2D
1 2 3 3a 4 5
8

11

Temperature controller Temperature limit thermostat Temperature control contact Temperature switch (compensation plate) Terminal strip Control circuit (burner control box, burner release)

6 Fuse 7 Indicating lamp ON 8 Contactor 9 Safety contactor 10 Heating element 11 Bridge loops for 220V- 290V/3~

4
4.4 Safety instructions for initial commissioning
The initial commissioning of the oil preheater must only be carried out by the supplier, manufacturer or their appointed agent. During this initial commissioning, all regulating, control and safety devices must be checked to ensure correct operation and, if it is possible to adjust them, it should be checked that they have been set correctly. Furthermore the correct fusing of the circuits and the measures for contact protection of electrical equipment and of all wiring must be checked.

4.5 Commissioning
Check oil inlet temperature Determine minimum inlet temperature into the oil preheater for the required oil throughput and adjust if necessary (see ratings diagram). Determine pressure loss Determine pressure loss using the oil throughput and increase the pump pressure accordingly (see pressure loss diagram). Fill oil preheater with oil Ensure the oil preheater is filled with oil prior to the first heat-up procedure. If the oil preheater is heated up empty it could damage the heating elements.
ATTENTION

Temperature controller and limit control EV2A Reset button

C 0 50

C 0 50

100 200 150 200 150

100

Check hydraulic connections Ensure the correct type of hydraulic connections are used. Danger of getting burnt! Leaking connections can allow hot oil to escape, which can lead to burns.
DANGER

Temperature controller and limit control EV2B, EV2C, EV2D

C 0 50

Set temperature controller Set controller to the required atomising temperature (see Appendix Viscosity - Temperature chart). The oil outlet temperature can deviate from the value set at the temperature controller by 10 K. Therefore the oil outlet temperature should be measured, and if necessary the temperature controller setting should be corrected accordingly. Note The temperature controller should always be set below the limit control and should not exceed 160 C to ensure that the limit control does not switch during normal operation and thus initiate a lockout.

100 200 150

Reset button

50

100 200 150

Check and set temperature limit control To check the operation of the temperature limit control set it below the value set at the controller. The limit control must switch before the controller shuts off. The temperature limit control should then be set approx. 40 K above the value set at the regulator and the reset button should be pressed.

Temperature controller Temperature limit control

9

4
Ratings diagram EV2 Oil throughput depending on t at maximum rating 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 40 50 60 70

EV2D

Oil throughput [kg/h]

EV2C

EV2B

EV2A

80

90

100

110

120

Temperature increase t [K] Pressure loss EV2 4,0 3,5 3,0 Pressure loss [bar] 2,5
EV 2C

EV

2D

2,0 1,5 1,0 0,5 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 Burner oil throughput [kg/h]
EV 2A
EV 2B

The value for type EV2A has been determined with medium fuel oil M (viscosity 37 mm2/s at 50 C) Oil inlet temperature:__________________________ 20 C Oil outlet temperature: ________________________ 95 C The values for type EV2B to EV2D have been determined with fuel oil S (viscosity 450 mm2/s at 50 C) Oil inlet temperature:__________________________ 60 C Oil outlet temperature: ______________________ 150 C For values above the oil preheaters nominal rating the oil inlet temperature has to be increased accordingly.
10

Note

Due to the different oil throughputs and the varying inlet viscosities, the data given relating to the pressure losses of the preheaters should be used as guide values.

4
4.6 Technical data EV2
Oil preheater type EV2A/01 Oil throughput kg/h Heat rating Oil pressure Oil content Weight kW : : 50 2.2 30 240 8 EV2B/01 100 4.5 30 800 15 EV2C 150 6.6 30 800 15 EV2D 270 13.2 30 1600 24

max. bar : cm3 :

approx. kg :

Dimensions EV2 202 a

Oil outlet M20 x 1.5 55 98 430 100 b 50

e Oil inlet

Oil preheater type EV2A/01 EV2B/01 EV2C EV2D

Dimension in mm a b c 105 135 135 195 305 305 310 310 162 172 172 172

d 65 112 112 184

e G1/4 G1/4 G3/8 G3/8

11

5 Electric oil preheaters type WEV2.2/01 and WEV3/01

5.1 Safety instructions

Electrically isolate plant Prior to commissioning and service switch off the mains switch and the safety switch. Failure to comply could cause death or serious injury by electric shock.
DANGER

Allow oil preheater to cool Allow the oil preheater to cool prior to commissioning and service work. The hot surfaces and the hot oil could lead to burners if touched.
DANGER

5.2 Function
Heat exchanger The heating oil is heated to the required atomising temperature by electric heating elements via pipe coils cast in an aluminium alloy plate. Due to the even and rapid transfer of heat, local overheating is prevented. Via the bridging loop of the terminal strip 4, the electrical connection of the heating elements 3 (Ch. 5.3) can be star switching (e.g. 400 V mains voltage) or delta switching (e.g. 230 V). Temperature limit control The temperature limit control 1 switches, if the oil temperature exceeds the set value and acts on the control voltage of the contactor, as well as the safety contactor and thus switches the heating elements off. Restart is only possible once the temperature limit control has been reset. Temperature controller The required oil temperature is set on the digital controller DR 100 with PID control behaviour (setting range 20 170 C) fitted in the control panel. In Standby an automatic set value reduction by -30 K is initiated via the potential free contact 6, this reduces the losses as well as the loading of the preheater at burner shutdown. The switch point for the release contact is set automatically by the controller DR 100 to 5 K below the set value. The oil temperature is determined by a Pt100 resistance temperature sensor 2 and compared to the set value. If the oil temperature in the preheater is less than the selected set value, the release contact 5 in the controller is opened and the contactor 9 is activated. The safety contactor 8 is activated by the limit control (normal operation) and the oil preheating is in operation. Once the minimum oil temperature in the oil preheater (10 K below the set value) has been reached, the release contact 5 of the controller (terminals 11/12) is closed. Once the oil temperature reaches the value set at the controller, the heating is switched off by the contactor. The controller is designed in such a way, that if a short circuit of the the sensor line or the sensor occurs, the sensor monitoring switches off the heating via the contactor and opens the release contact. If the heating of the preheater stops during operation, and if the fixed temperature differential of the set value is not achieved, the release switch of the controller opens and the burner shuts down.
W2 U2 V2
C 0 50

Electric oil preheater WEV2.2/01

100 200 150

61

62 63 64 65

66

U1

V1

U1

U2 W1

V2

V1

W2

W1

Electric oil preheaters WEV3.1/01 and WEV3/01

W1

V1

U1

B1

0 50

61

62 63 64 65

66
100

W2

W1 V2 V1 U1 U2

V2 W2

U2 W1 A

W2 B

200

150

1 Temperature limit control 2 Resistance temperature sensor PT100

12

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5.3 Electrical connection
Connection diagram WEV2.2/01 * Other voltages available on request

PE N L1 L2 L3

U1 V2 Y V1 W2 Z W1 U2 X 61 62 63 64

U1 V2

V1 W2

W1 U2

X
11 12 6 7 L1 9 1 3 N 10

Controller DR 100

K2

* 380 - 500V~
U1 V2 Y V1 W2 Z W1 U2 X

K1

* 220 - 290V~

Connection diagram WEV3.1/01 and WEV3/01 * Other voltages available on request

PE N L1 L2 L3

U1 V2 Y V1 W2 Z W1 U2 X A B 61 62 63 64

U1 V2 Y V1 W2 Z W1 U2 X
11 12 6 7 L1 9 1 3 N 10

Controller DR 100

K2

* 380 - 500V~
U1 V2 Y V1 W2 Z W1 U2 X

K1

* 220 - 290V~

1 2 3 4 5

Temperature limit control Temperature sensor PT100 Heating element Terminal strip Control circuit (burner control box, burner release)

6 7 8 9 0

Potential free contact (set value change over) Fuse carriers Safety contactor Contactor Indicating lamp ON
13

5
5.4 Safety instructions for initial commissioning
The initial commissioning of the oil preheater must only be carried out by the supplier, manufacturer or their appointed agent. During this initial commissioning, all regulating, control and safety devices must be checked to ensure correct operation and, if it is possible to adjust them, it should be checked that they have been set correctly. Furthermore the correct fusing of the circuits and the measures for contact protection of electrical equipment and of all wiring must be checked.

5.5 Commissioning
Check oil inlet temperature Determine minimum inlet temperature into the oil preheater for the required oil throughput and adjust if necessary (see ratings diagram). Determine pressure loss Determine pressure loss using the oil throughput and increase the pump pressure accordingly (see pressure loss diagram). Fill oil preheater with oil Ensure the oil preheater is filled with oil prior to the first heat-up procedure. If the oil preheater is heated up empty it could damage the heating elements.
ATTENTION

Temperature controller DR 100

1 5

2 6

3 7

4 8

-weishaupt-

147 . 0
145.6

Check hydraulic connections Ensure the correct type of hydraulic connections are used.

K1 K2

Danger of getting burnt! Leaking connections can allow hot oil to escape, which can lead to burns.
DANGER

9 10 11 12 L1 N

Set temperature controller DR 100 The set value SP1 should be set to the required atomising temperature (see Appendix Viscosity temperature chart). Documentation relating to the set value setting is enclosed with controller. Note The temperature controller DR 100 should always be set below the limit control and should not exceed 160 C to ensure that the limit control does not switch during normal operation and thus initiates a lockout.

Temperature limit control

0 50

Check and set temperature limit control To check the operation of the temperature limit control set it below the value set at the controller. The limit control must switch before the controller shuts off. The temperature limit control should then be set approx. 40 K above the value set at the DR 100 controller and the reset button should be pressed.

100 200 150

14

5
Ratings diagram WEV Oil throughput depending on t at maximum rating 1600 1500 1400
W

1300 Oil throughput [kg/h] 1200 1100 1000 900 800 700 600 500 400 300 200 100 20

WE

EV

EV

V2

30

0 3/

3.1

.2/

/0

01

40

50

60

70

80

90

100

Temperature increase t [K] Pressure loss WEV 3,0

2,5 Pressure loss [bar]

2,0

1,5
EV 2 0 .2/

1,0

1 3/0 1 EV 3.1/0 W V WE

0,5

0 0 100 200 300 400 500 600 700 800 900 1000 Burner oil throughput [kg/h] The values of types WEV2.2/01 to WEV3/01 have been determined with fuel oil S (viscosity 450 mm2/s at 50 C) Oil inlet temperature:__________________________ 60 C Oil outlet temperature: ______________________ 150 C For values above the oil preheaters nominal rating the oil inlet temperature has to be increased accordingly. Note Due to the different oil throughputs and the varying inlet viscosities the data given relating to the pressure losses of the preheaters should be used as guide values.

15

5
Oil preheater type Oil throughput kg/h Heat rating Oil pressure Oil content Weight kW : : 300 13.8 32 750 27 WEV2.2/01 500 17.0 32 1550 42 WEV3.1/01 500 22.4 32 1550 42 WEV3/01

max. bar : cm3 :

approx. kg :

Dimensions WEV WEV2.2/01

b k

i h g

Oil inlet G 1/2 Oil outlet G 1/2

c I

f M 10

d a

WEV3.1/01 WEV3/01
b

Oil outlet G 1/2

h c I f M 10 g

Oil inlet G 1/2

d a

Oil preheater type WEV2.2/01 WEV3.1/0.1 WEV3/01

Dimensions in mm a b c 610 724 126 140 254 314

d 42 43

e 148 148

f 100 100

g 112 110

h 33 13

i 231 288

k 12 12

l 58 58

16

6 Media oil preheaters type MV9C and MV10A

6.1 Safety instructions
Electrically isolate plant Prior to commissioning and service switch off the mains switch and the safety switch. Failure to comply could cause death or serious injury by electric shock.
DANGER

6
Allow oil preheater to cool Allow the oil preheater to cool prior to commissioning and service work. The hot surfaces and the hot oil could lead to burners if touched.

DANGER

6.2 Function
Heat exchanger The compact media oil preheaters are high efficiency heat exchangers with flow according to requirements. The media (hot water, steam or thermal fluid oil) heats the oil flowing through the pipe coils to the required atomising temperature. The oil preheaters guarantee an almost constant oil temperature and therefore good combustion values. Application The universal media oil preheaters can be used alone or in addition to an electric oil preheater. The preheaters are equipped with the fittings required for the relevant media used. The media can be changed at any time by fitting new fittings accordingly. Ratings range See ratings diagram Ch. 6.5.3 Electric preheating If operating with steam or hot water and sufficient temperature is available, or if the start is effected with distillate oil an electric oil preheater is not required. In this case the media oil preheater should be fitted with an additional temperature switch for oil release. If the media temperature is not sufficient to heat the fuel oil adequately, then the electric preheater continues the heating up of the oil. The electric oil preheater heats up the oil to start the plant. If the required media temperature is available, change over to the media preheater takes place. This saves expensive electric energy. Installation position The unit can be installed vertically or horizontally. The condensate outlet (steam) must always be downwards, the water or thermal fluid outlet always upwards.

Installation position and connections Outlet for liquid heating medium

Outlet for steam

Inlet medium

Heating oil outlet

Heating oil inlet

Media preheater with electric oil preheater

Media preheater without electric oil preheater

Included in delivery: 2 Oil hoses 1 Ball valve 1 Thermometer + screwed unions and pipe connections

Included in delivery: 2 Oil hoses 1 Thermometer 1 Temperature controller 1 Temperature controller with change-over contact for burner release + screwed unions and pipe connections
17

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6.3 Media fittings
6.3.1 Connection variations The fittings are selected depending on the type of media used. On installations to TRD 411 a condensate sight glass is necessary when the heating media is returned back into the boiler. This unit is supplied at extra cost. Please note that the dimensions of the fittings are not determinative when sizing the connection lines.

Version

Fittings

No. per preheater 2

DN MV9C R 1/2

DN MV10A R 1/2

1- Warm water up to 110 C

WW-outlet WW-inlet

Ball valve

2. Hot water above 110 180 C

WW-outlet HW-inlet

Ball valve Regulator for thermal fluid

2 1

15 + 20 20

20 20

3.Hot water up to 200 C

WW-outlet HW-inlet

Ball valve Strainer Reg. valve with thermostat

2 1 1

15 15 15/6

15 15 15/9

4. Thermal fluid oil up to 250 C

Thermal fluid oil outlet Thermal fluid oil inlet

Ball valve Regulator for thermal fluid

2 1

15 15

20 20

5. Thermal fluid oil up to 300 C

Thermal fluid oil outlet Thermal fluid oil inlet

Bellows valve Regulator for thermal fluid

2 1

15 15

20 20

6. Thermal fluid oil up to 250 C

Thermal fluid oil outlet Thermal fluid oil inlet

Ball valve Strainer Reg. valve with thermostat

2 1 1

15 15 15

20 20 20

7. Thermal fluid oil 250 300 C

Thermal fluid oil outlet Thermal fluid oil inlet

Bellows valve Strainer Reg. valve with thermostat

2 1 1

15 15 15/6

15 15 15/9

8. Low pressure steam up to 0.5 bar high pressure steam up to 1.5 bar
Condensate outlet Steam inlet

Ball valve Condensate sight glass Steam trap

2 1 1

R 1/2 R 1/2 R 1/2

R 1/2 R 1/2 R 1/2

18

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Version Fittings No. per preheater 2 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 DN MV9C R1/2 R 1/2 R 1/2 R 1/2 R 1/2 15 15 15 15 15 15 15 15/6 15 15 15 15 15/6 15 15 15 15 15/6 15 15 DN MV10A R 3/4 R1/2 R 3/4 R 3/4 R 1/2 R 1/2 15 15 15 15 15 15 15 15 15 15 15 15 15/9 15 15 15 15 15/9 15 15 9. High pressure steam 1.5 15 bar
Condensate outlet HPS inlet

Ball valve Ball valve (inlet) Ball valve (outlet) Strainer Pressure controller Pressure gauge Condensate sight glass Steam trap Ball valve Strainer Pressure controller Manometer Condensate sight glass Steam trap Ball valve Strainer Reg. valve with thermostat Pressure gauge Condensate sight glass Steam trap Ball valve Strainer Reg. valve with thermostat Pressure gauge Condensate sight glass Steam trap Ball valve Strainer Reg. valve with thermostat Pressure gauge Condensate sight glass Steam trap

10. High pressure steam 6 25 bar

Condensate outlet HPS inlet

11. High pressure steam 7,5 13 bar*

Condensate outlet HPS inlet

12. High pressure steam 13 25 bar*

Condensate outlet HPS inlet

13. High pressure steam 20 25 bar*

Condensate outlet HPS inlet

* only with preheating without electric. oil preheater Description of fittings Ball valve or bellows valve: Control valve with thermostat:

Controller for hot water and thermal fluid oil or pressure controller for steam:

Strainer:

Condensate sight glass:

Pressure gauge:

Steam trap:

Oil preheater:

19

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6.3.2 Fittings Shut off devices: Ball valve R 1/2 R 3/4 R 1/2 (R 3/4) Ball valve DN15 Ball valve DN20 Bellows valve DN15

DN15

DN20

77

130 Operating pressure max.: 25 bar at 250C

150 Operating pressure max.: 25 bar at 250C

Operating pressure max.: 15 bar at 200C Strainer: Nominal diameter R 1/2 72 R 1/2

130 Operating pressure max.: 13 bar at 300C

Nominal diameter R 3/4 82 R 1/3

Nominal diameter DN15 130 DN15

Operating pressure max.: 15 bar at 200C Pressure controller: Nominal diameter R 1/2

Operating pressure max.: 25 bar at 250C

Operating pressure max.: 25 bar at 250C

Nominal diameter R 3/4

Nominal diameter DN15 130

Nominal diameter DN15

DN15

126,5

126,5

R 1/2

R 3/4

234

DN 15

DN15

55

55

83 Inlet pressure max.: 19 bar at 210C Reduced pressure range: 1.3 4 bar (green spring*) 3.5 10 bar (orange spring) * at inlet pressure < 5 bar Pressure gauge

96 Inlet pressure max.: 19 bar at 210C Reduced pressure range: 1.3 4 bar (green spring*) 3.5 10 bar (orange spring) * at inlet pressure < 5 bar 185 Inlet pressure max.: 20 bar at 230C Reduced pressure range: below 3 bar (blue spring) 3.0 10 bar (red spring)

130

114 Inlet pressure max.: 25 bar at 250C Reduced pressure range: 3.0 10 bar

Nominal diameter R 1/2 A pressure snubber is connected before the pressure gauge. R 1/2

Nominal diameter R 3/4

Nominal diameter DN15

R 3/4

DN 15

165
20

165

100

48

310

157

6
Control valve: Nominal diameter DN15 130 55 22 112 Nominal diameter DN20 150 55 22 112 DN 15

390

DN 20

385

730* 630

R 1

730* 630

385

R 1

* with intermediate piece on HPS 13 to 20 bar and thermal fluid oil Operating pressure max. Type M: 13 bar at 200C Type H: 25 bar at 250 C Set value range with thermostat: 40-160 C Controller for thermal fluid oil Nominal diameter DN15 Nominal diameter DN20

* with intermediate piece on HPS 13 to 20 bar and thermal fluid oil Operating pressure max. Type M: 13 bar at 200C Type H: 25 bar at 250 C Set value range with thermostat: 40-160 C Controller for hot water Nominal diameter DN20

150

DN15

DN20

150

130 Operating pressure max.: 17 bar Supply temperature max.: 320 C Temperature adjustment range: 100 170 C Condensate sight glass Nominal diameter DN15 R 1/2

150 Operating pressure max.: 17 bar Supply temperature max.: 320 C Temperature adjustment range: 100 170 C

150 Operating pressure max.: 22 bar Supply temperature max.: 180 C Temperature adjustment range: 70 145 C Steam trap

Nominal diameter DN15 DN15

Nominal diameter 1/2 84

DN20

150

Nominal diameter DN15 86 150 Operating pressure max.: 25 bar Differential pressure max. 17 bar Operating temperature: 100 K above relevant saturated steam temp. Condensate cooling: 8 K (not adjustable)
21

R 1/2

95 Operating pressure max.: 20 bar at 250C

150 Operating pressure max.: 20 bar at 250C

95 Operating pressure max.: 15 bar Operating temperature: 100 K above relevant saturated steam temp. Condensate cooling: 8 K (not adjustable)

DN15

19

390

6
6.4 Safety instructions for initial commissioning
The initial commissioning of the oil preheater must only be carried out by the supplier, manufacturer or their appointed agent. During this initial commissioning, all regulating, control and safety devices must be checked to ensure correct operation and, if it is possible to adjust them, it should be checked that they have been set correctly. Furthermore, it should be checked that the hydraulic connections have been made correctly. Danger of getting burnt If touched, the hot surfaces of the individual components and fittings can cause burns.
DANGER

6.5 Commissioning
6.5.1 Hot water and thermal fluid operation Hot water and thermal fluid oil operation with combined electric preheater The media oil preheaters are supplied with the fittings in position 1, 2, 4 or 5 (Ch. 6.3.1) depending on the operating medium used. By setting the relevant closing temperature of the controller fitted in the media outlet, the desired or highest possible oil temperature is attained. The controller senses the media outlet temperature and only releases the heating media once it has cooled to below the closing temperature setting. With hot water, the differential pressure at the controller should be approx. 2 bar, with thermal fluid oil at least 1 bar. The combined electric oil preheater carries out any additional heating which may be required and monitors the oil temperature. Setting the oil temperature The closing temperature of the conroller should be set to approx. 10 K above the required or maximum possible oil temperature. However, the closing temperature must always be below the media inlet temperature, so that the controller closes at burner shutdown (no heat demand on the preheater). The oil temperature attained during operation should be measured and if necessary adjusted at the controller. The setting of the hot water controller is carried out to scale. The external adjusting device of the thermal fluid oil controller (not available with scale) is set to a closing temperature of 150 C as supplied. One rotation of the adjusting screw is equal to 30 K closing temperature alteration. Clockwise rotation ________________________ Increase Anti clockwise rotation ____________________ Decrease Hot water and thermal fluid oil operation without combined electric preheater The media oil preheaters are supplied with the fittings in position 3, 6 or 7 (Ch. 6.3.1)depending on the operating medium used. The desired oil temperature is attained and maintained by a temperature controller without auxiliary energy. This temperature controller consists of a regulating valve with thermostat and sensor. The sensor located in the oil outlet flow monitors the oil temperature and controls the regulating valve in the medium inlet via the thermostat. The regulating valve controls the media flow accordingly. With hot water, the differential pressure at the control valve should be approx. 1 bar, with thermal fluid oil at least 0.5 bar. Setting the oil temperature The required oil temperature is set by turning the knob of the thermostat within the set value range of 40 to 160 C.

22

6
6.5.2 Steam operation With steam operation, care should be taken that dry steam is available at the media fittings.
ATTENTION

Steam operation with combined electric oil preheater The media preheaters are supplied with the fittings in position 8, 9 or 10 (Ch. 6.3.1) depending on the available steam pressure. The desired oil temperature is achieved by the appropriate steam pressure setting of the pressure controller. The condensate that forms is drained via the steam trap, cooled 8 K below the actual saturated steam temperature. It is not possible to adjust the opening temperature of the steam trap. Due to the steam pressure in the oil preheater the condensate is forced into the condensate line via the steam trap. Therefore the pressure in the condensate line must always be lower than the steam pressure in the oil preheater (see Tab. Condensate line pressure). The maximum differential pressure of 17 bar must not be exceeded. Setting the oil temperature Pre-set pressure controller to Ratings diagram (Ch. 6.5.3). The oil temperature attained during operation should be measured and if necessary adjusted at the controller.

Steam operation without combined electric oil preheater The media oil preheaters are supplied with the fittings in position 11, 12, or 13 (Ch. 6.3.1) depending on the available steam pressure. The desired oil temperature is achieved and maintained by a temperature controller without auxiliary energy. This temperature controller consists of a regulating valve and thermostat with sensor. The sensor located in the oil flow outlet monitors the oil temperature and controls the regulating valve in the medium inlet via the thermostat. The regulating valve controls the media flow accordingly. With a steam pressure of up to 13 bar the differential pressure at the regulating valve should be 2 bar, and at 13 to 20 bar it should be approx. 4 bar. If the steam pressure available is between 20 and 25 bar, a pressure reducing valve should be fitted before the regulating valve, because the temperature controller does not work satisfactorily in this pressure range. The condensate that forms is drained via the steam trap, cooled 8 K below the actual saturated steam temperature. It is not possible to adjust the opening temperature of the steam trap. Due to the steam pressure in the oil preheater the condensate is forced into the condensate line via the steam trap. Therefore the pressure in the condensate line must always be lower than the steam pressure in the oil preheater (see Tab. Condensate line pressure). The maximum differential pressure of 17 bar must not be exceeded. Setting the oil temperature The required oil temperature is set by turning the knob of the thermostat within the set value range of 40 to 160 C.

Condensate line pressure Steam pressure Pressure in the in the oil preheater condensate line up to1.5 bar from 1.5 bar approx. 0 bar approx.. 1/3 of the steam pressure in the oil preheater; but maximum 17 bar pressure differential

23

6
6.5.3 Ratings and pressure loss diagram Ratings diagrams (maximum achievable oil temperature with hot water and steam) Hot water Saturated steam The HW temperatures and steam pressures must be available at the oil preheater inlet.

0,5 bar

1,0 bar

2,5 bar

5,0 bar

130C

150C

110C

7,5 bar

170C

700 600 Oil throughput [kg/h] 500 400 300 200 100

80

90

100

110

120

130

140

10 bar

150

15 bar 160 15 bar 150 160

MV9C

Oil temperature max. [C]

0,5 bar

1,0 bar

2,5 bar

5,0 bar

130C

150C

7,5 bar

170C

1000 900 Oil throughput [kg/h] 800 700 600 500 400 80 90 100 110 120 130 140 Oil temperature max. [C] 110C

24

10 bar

MV10A

6
Fuel oil pressure losses MV9C / MV10A The values have been determined using fuel oil S (max. viscosity 150 mm2/s at 50 C and an outlet temperature of 130 C). 2,5

2,0 Pressure loss [bar]

MV9C

1,5 MV10A 1,0

0,5

0 100 200 300 400 500 600 700 800 900 1000 Burner oil throughput [kg/h]

6.6 Technical data MV

Oil preheater type MV9C MV10A Contents oil coil [dm3] 2.6 7.5 Contents cover space [dm3] 7.8 18.0 Oil pressure max. [bar] 40 40 Medium pressure max. at 250C [bar] at 300C [bar] 25 25 25 20

Dimensions MV9C / MV10A Outlet for liquid heating media i k Heating media inlet Oil inlet Oil outlet

e h b

f g

d c l a

Steam outlet Oil preheater type MV9C MV10A Dimensions in mm a b c 640 800 222 287 170 250

d 108 135

e 16 55

f 55 84

g G1/2 G1/2

h G1/2 G3/4

i G1/2 G1/2

k M 12 M 12

l 300 300
25

6
6.7 Saturated steam and condensate lines
Application example for the diagram below An oil preheater type MV10A is used to preheat 900 kg/h residual oil from 60 C to 130 C. Saturated steam with10 bar pressure is available. At the end of the condensate line a pressure of 0 bar (1 bar absolute pressure) will exisit. Saturated steam quantity required With an oil throughput of 900 kg/h and a t oil of 70 K a saturated steam quantity of 68 kg/h is required. Nominal diameter of saturated steam line For a saturated steam quantity of 68 kg/h and a pressure of 10 bar (11 bar absolute pressure ) the saturated steam line must be DN 15. Nominal diameter of the condensate line With 11 bar absolute pressure and a condensate cooling of 8 K the condensate temperature prior to the pressure release amounts to 175 C. Based on this temperature and with 1 bar absolute pressure at the end of the condensate line, the condensate line at 68 kg/h condensate flow must be DN 25.

2600 2400 2200 2000 1800 1600 1400 1200 1100 1000 900 800 700 600

Saturated steam quantity required

Nominal diameter of saturated steam line

300 250 200 150 100 80 60 50 40 Saturated steam in kg/h 30 Oil throughput in kg/h 20

DN50

DN40

DN32

DN25 DN20 DN15 DN10

90 80 70 60 50 40 t Oil in K 30

500 400 300

10

200

20 0,5 0,6 0,8 1,0 Steam pressure in bar 2 3 4 5 6 8 10 20 30

absolute pressure in bar (end of condensate line)

Nominal diameter of condensate line

DN10

DN15

DN20

DN25

10 1 1,5 2 3 4 5 7

DN32

DN40

DN50

0,5

1 2 3 4 5 6 7 8 910 absolute pressure in bar (condensate before pressure release)

15 20 25

10 20 30 40 50 60 80100 Condensate flow in kg/h

200

400

600 800

100 110 120 130 140 160 180 200 220 Temperature in C (condensate before pressure release) 26

Appendix
Viscosity - temperature chart
Temperature [F] 40 Viscosity [mm2/s] 2000 1000 600 400 300 200 100 50 40 30 20
Ma xim um va Av lue er ag oil ev S an alu dS es A oil DI S N an 51 dS 60 A 3 C

A
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 200 150 120 60 40 30 Max. oil preheater temperature* 20 10 8 6 4 3 2,5 2 1,8 1,6 1,5
M ax im A um va lu Av e er oi ag lE e LD va IN lu e 51 oi lE 60 L 3
Av er ag e

Max. pump viscosity

B
10 9 8 7 6 5 4
zzle viscosity Recommended no

1,4 1,3

1,2

va lu es

1,1
Ke ro se ne

1,5

1 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 Temperature [C]

1,0

Determination of the preheating temperature The preheating temperature to be determined can be taken from the viscosity - temperature chart. The viscosity of the fuel oil available must be known at a reference temperature. It should be noted that the thermostat must be set higher on account of the heat loss between oil preheater and nozzle. Example Known: Fuel oil viscosity: 300 mm2/s at 50 C Required: Preheating temperature in C Procedure to be followed: From the viscosity reference temperature of 50 C vertically up to the intersection with the viscosity of 300 mm2/s, from there parallel to the nearest fuel grade,

intersect the line Recommended nozzle viscosity. From this intersection vertically to the temperature axis. There read the desired preheating temperature of 147 C. Recommendation The following maximum viscosities in relation to nozzle size are to be noted: In the area between the oil grade lines use: A and B nozzles > 0.85 US-gph B and C nozzles > 2.00 US-gph and over C nozzles > 3.00 US-gph. * Due to the components selected a preheating temperature of 160C should not be exceeded.

27

Viscosity [E]

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