*User's Guide to Hot Oil Heater

1. Overview

This is an oil heating device that uses an automatic burner to heat the heat transfer oil so
that the heated oil (approx. 180 ℃) is circulated by a circulating pump from the asphalt
storage bin and the metering bin, through the spray pump, the asphalt tank and the
bunker C tank, to the double piping in the middle to heat the asphalt oil or the bunker C
oil up to a specified temperature.

1) Features

A. This device enables you to get a high temperature with a low pressure.
B. High thermal efficiency is ensured by good circulation of the heat transfer oil, and
the service life of the heater is extended because the device has no scale.
C. You can freely adjust the heating temperature and the calorie.
D. Attached devices include a thermometer, a pressure gauge, an oil tank level switch, a
thermostat, and an alarm bell.

2) Specification
Description 45 60
Calorie (Kcal/Hr) 450,000 600,000
Operating temperature
180 ~ 200 180 ~ 200
(℃)
Exterior size (mm) 4700 x 1920 x 2800 5000 x 1970 x 3000
Weight (Kg) ≒3,500 ≒4,000
Heating capacity (ℓ) 1,100 1,500
2. Check list for commission

1) Check the direction of motor revolution (wiring)

Circulatory motor pump - right-handed rotation from the motor

2) Oiling
Don't forget to oil the bearing parts in the circulatory pump before operating.
For further description on lubricating oils, see the section "Oiling."

3) Install the fire extinguisher.

This device uses mineral oil as its heat transfer oil to heat up to the point near the
flashing point. Don't forget to place a fire extinguisher near the heater to prevent
unexpected fire accident. (Two fire extinguisher for an oil heater)

3. How to fill hot oil

Oiling cap - Keep away
from water

1) Before oiling
If any water is in the main tank and
the sub tank, open the drain valve
located in the bottom of the tanks to
drain water to the last drop. Never fill
oil if it rains. Take care not to allow
rain to fall into the tank if you have
to. Heating oil while there is water
causes accident. Especially, ensure the
oiling cap is kept away from rain
water.

2) How to fill new oil

If it is the first time you fill the tank, fill it with about 2,000 lit of oil.

After oiling, circulate the oil inside the heater to remove the oil in the pipes through the
air vent installed in the middle of the pipe. (Open the tank valve to remove air.)

4. How to operate the burner control panel

1) Adjusting and setting instruments

A. Automatic Thermostat (panel thermometer)

This sets the temperature of hot oil and has a built-in thermometer. Set the
temperature at 180℃ for the upper limit and 160℃ for the lower limit.
B. Thermostat (abnormal temperature detector)

This is activated only when the above automatic thermostat fails and acts as a
safeguard.

Temperature is set to 200℃. If oil is heated up to this point, the burner power switch
is automatically turned off. Pressing the Reset button after oil temperature is
lowered will re-start heating.

C. Float Switch
If the oil level is lowered to a specified level, this stops burner and an beefs
an alarm.

2) Before Starting the Burner

A. Warning!
- Remove air from the pipe before you run the burner.

B. Setting the instruments

ⓐ Secondary air adjustment dial and low combustion cock

Set the secondary air adjustment dial to 8 - 10, depending on burner
combustion state. Set opening of the low combustion adjustment cock at 4
- 5 (in most cases).
ⓑ Timer
Set the secondary timer in the control panel at around 10 seconds.

C. How to use the burner (for both Auto and Timer modes)

The burner does not operate if the above instrument is abnormal.

To start operating, ensure all switches are off and the do the followings in order.

a. Set the Auto-Manual toggle switch to Auto.

b. Turn on the selector switch of the circulatory pump and the burner.
c. Then the Trans and the 1st Oil Sol V/V starts, and the flame detection system
(CDS) is activated, and then after 10 seconds the Trans and the 2nd Oil Sol V/V is
activated.
d. After the burner entered into high-temperature combustion, the hot oil thermostat
keeps burning up to the upper limit of temperature and stops if this limit is reached.
After this, the burner restarts burning at the lower limit of temperature. This cycle
repeats.

d. If the burner operates abnormally, the Reset button in the burner control relay (KMP-
200) is activated (pulled out) and the burner stops. Turn off the burner switch, check
each instrument of the burner, and then push the Reset button to restart the burner.
a. Abnormal combustion of the burner

a) The burner does not even catch fire

- Check for defects in the ignition transformer, the solenoid valve, the control relay, or
CDS
- Check for defects in the fuel pump or the coupling
- Check for damage or defects in the ignition rod or the diffuser

b) The burner catches fire but does not enter into high combustion
- Check for defects in the 2nd Timer
- Check if the 2nd Air Damper is opened too much. In the winter, try setting the scale to
a lower point.
- Check if CDS monitoring glass is smeared with soot or if the relay has any defect.

c) Other failures
- Check if the diesel fueling lines are blocked
- Check if diesel oil contains water
- Check if the nozzle is blocked
- Check if the oil filter is blocked

B. Emergency stop made by safety device

a) Abnormal high temperature

- Check if the temperature setting is correct.
- If the auto thermostat does not work normally, immediately replace it.

b) Lowered level
- Check if any pipe leaks oil.
- Too hot oil may cause the level to be lowered.

e. How to heat oil

After you have ensured that oil circulates fully, air is removed, and no oil leaks, restart
the burner to heat oil with the circulatory pump running.
At this time, do not heat it to the upper limit of temperature at once but increase the
temperature gradually as shown in the diagram below. Re-check if any part is abnormal
while you increase the temperature.
 Diagram
( 도 표 )
℃
200℃
Oil Temperature

일 170℃
180℃
온
130℃
도
140℃

100℃

버 너 동 작 시 간 ( TIME )
Time ( Burner )

f. Normal Operation

a) General Cautions

- Ensure that all instruments are correctly set.

- Check the lubricant of the burner and the circulatory pump.
- Check occasionally if the burner combustion is normal.
- Ensure that the oiling cap is closed.
- Occasionally check if the oil temperature, pump pressure, and load to the motor are
normal.
- Any abnormal sound heard while heating oil means that oil contains air. Stop the
burner immediately and remove the air.
- During initial commissioning of the burner after installation, often clean the strainer.

b) Start

- Start the circulatory pump.

- Check the warning lamps of the instruments.
- Start burner to ignite.

c) Stop

Turn off the power switch of the burner, circulate oil for about 5 minutes, and then stop
the circulatory pump.

d) How to deal with power failure

Turn off the asphalt feed pump switch.
Turn off the power switch of the hot oil heater. To restart it, you have to repeat the
procedure from the start.

5. Handling heat transfer oil

1) It is very difficult to remove moisture from inside the system and requires much time.
Therefore you'd better prevent water from flowing in. If any moisture remains, you need
to continue circulating oil and heat it up to 110℃, discharge the vapor, and then heat it
to the required temperature. In addition, you need to have a safety device in
preparation for possible pump failure and over heating and a by-pass connected and
installed.

2) Overheated heater is the main cause of oil damage. To prevent this damage, the
heater is designed to activate the built-in circulatory pump at a surface speed of 2 ~ 2.5
m/sec.

3) It is critical to keep the temperature of coating at 320℃ or below by minimizing the

unequal transfer of heat.

4) Heating the mineral oil at 300℃ causes its volume to increase by approx. 20% at
ambient temperature. Therefore we have taken the change in oil volume filled in the
entire system into designing of the expanded size of the tank.

5) The fact that hot oil contacts the air can be called the temporal destruction of oil due
to oxidation, so it is required to prevent oxidation of oil by proper engineering and
operating.

6) Properly designed and used heat transfer oil will have considerably longer service life.
Especially when you refilled new oil or replaced the entire oil, you need to perform trial
operation and heat transfer analysis for about one week, and after that, every 6 months
of regular analysis is recommended.

7) As the heat transfer oil is some kind of mineral oil and its heat transfer property is
deteriorated by the following two factors, you need to take care.

a. Heat pyrolyzes or destructs the hydrocarbon molecule and turns big molecules into
small ones, which become a flammable substance or an unstable, insoluble sediment.
Note that, especially at 320℃ or higher, pyrolysis proceeds rapidly.

b. The oil itself is oxidized or the hydrocarbon reacts with oxygen in the air. This
phenomenon develops very slowly even at an ambient temperature, and the higher the
temperature is, the faster the reaction is. As the oxide of the oil increases, sludge is
made and its viscosity is increased.
6. Installing and Plumbing the Heat Transfer Circulatory Pump

1-1. Installing
1) Check the coupling gap and height of the pump motor with a gauge, place a liner (a
metal plate or a thin copper plate) under the pump motor, and fine tune it to align the
center of the shaft.
2) Alignment must be made within 5/100mm.
3) After completing alignment, tighten the fastening bolts of the pump motor and ensure
that there is no movement.
4) Especially when you do plumbing the shaft center might move. So you must check it
after plumbing.
5) The main cause of vibration in the pump, rotary equipment, lies in the misalignment
of the shaft or its bearing. It is recommended to check it while you are operating the
system.

1-2. Plumbing
1) In no cases, you may apply plumbing stress (power, weight, or bending) to the pump.
3) Take care not to fill air to the induction pipe (air pocket) during plumbing.
3) It is often found that the strainer suffers unexpectedly increased resistance and fails to
suck up. Take care not to make excessive resistance due to excessively small strainer or
strainer holes while you do plumbing.

2. Operation

2-1. Before Commissioning

1) Check the plumbing again to see if it has a welding rod or any foreign substance, if
air flows into the suction pipe or its coupling, and if the gasket in the flange coupling
parts is normal.
2) Check the input power of the motor, and voltage/horse power/revolution in the pump
casing.
3) Turn the coupling to check if any is stuck, check motor wiring, and then power on in
a moment to see if it turns in the right direction. If the revolution is made reversely,
change any two wire connections.
4) Install a coupling cover in order to prevent any accident that might occur when a
glove or clothing is stuck in the coupling or the revolving parts while the system is
running.

2-2. Operating
1) Check if the pump is filled with the gear oil. If not, fill the oil before operating.
2) Close the discharging valve (with induction valve open).
3) Power on the motor and check if any abnormal sound is heard.
4) Slowly open the discharging valve.
6) Take care not to allow the pump to make idling for a long time or run for a long time
with its discharging valve and induction valve is closed. This might cause damage to the
pump and thus an accident.
3. Troubleshooting

3-1 Pumping failure

Problem Action
Can't fill up water in the induction pipe Check if piping is done correctly.
Check if revolution is made in the right
Water fills, but can't pump up.
direction.
Pressure is lowered by wearing of revolution Check the revolution cart and replace if
cart required.
Ensure the induction pipe end is fully
Air comes into the induction pipe.
submerged in the oil.
Discharge the air through the air vent of the
Air comes into the casing.
main system.

3-2. Excessive oil leak in the pump

Problem
Excessive oil leaks in the shaft parts.
Oil leak in the casing joint.
Action
Check if the mechanical seal and rubber ring
is damaged. Apply oil before replacing the
seal.
Check if the gasket is normal and replace it
with new one if necessary.

3-3. Oil shortage

Problem Action
Check the strainer induction pipe and
Induction valve is clogged.
remove any foreign substance.
Reverse revolution fails. Reconnect any two wires of the motor.
Check revolution of the motor using a
Motor RPM
revolution counter.
Check the revolution cart for damage or
Serious wearing inside the pump (revolution
wearing, and replace it with a new one if
cart casing, etc)
required.

3-4. Big noise and vibration

Problem Action
Pump motor shaft is not aligned. Check if it is correctly aligned.
Damaged bearing Replace it with a new one.
Check the revolution cart and the casing ring
Damage in revolution parts (poorly
for contacting and damage, and replace if
balanced)
required. Check if shaft is bent.
Ensure the pipe load is not transferred to the
Loosened fastening bolts
pump.
 Ensure the vibration of the pipe does not
affect the pump.
Tightly fasten the bolts.

3-5. Heated bearing

Problem Action
The shaft is misaligned. Align the shaft and restart.
Wash the bearing and refill it with new
grease by 1/3 to 1/2.
Too much grease is applied.
Excessive amount of grease may cause
overheating.

4. Maintenance

4-1. Regular Check List

Weekly Monthly Yearly

1) Vibration 1) Packing 1) Overhaul
2) Abnormal noise 2) Bearing grease (lubricant) 2) Replace worn parts
3) Leakage in packing 3) Check alignment. 3) Operator training
4) Bearing temperature 4) Accuracy of instruments

4-2. Logging

When replacing a worn part, the operating department must keep a written pump
specification to ensure correct part is purchased.

4-3. Spare parts

Considering the importance of the pump and the severe operating condition such as 24-
hour operation, it is recommended to have a spare pump or use several pumps to
distribute risks.