Preheeter Instr

manual
Installation and operating instruction
Weishaupt Electric & Media Oil Preheaters
83001802 - 1/2005
Contents
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

5.2 Function
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
6.5 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
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.
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.
Explanation of notes and symbols

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

which, if not followed, could result in life
threatening electric shock.
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:
DANGER
ATTENTION

which, if not followed, could result in damage
to, or the destruction of the equipment and
environmental damage.
This symbol is used to mark procedures,

which you should follow.
1.
2.
3.
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
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
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.
3Technical 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

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
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.
Electric oil preheater EV2A

3
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.
Electric oil preheater EV2B, EV2C and EV2D

3
2 1
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.
1 Temperature controller with integrated temperature

switch for burner release.
2 Temperature limit switch
3 Temperature switch on compensation plate
4
Connection diagram EV2A
1 3
2 3a
1
2
3
4
5
6
6A
1500W
230V/1~N
N L1
6A
10
EV2A
Connection diagram EV2B, EV2C and EV2D

3
3a
1
2
3
4
5
6
V2
6A (EV2B/EV2C)
6A
10A (EV2D)
U1
W2
W1
1500W
V1
V2
1500W
U2
1500W
V1
400V/3~N
N L1 L2 L3
V1
W2
U2
W1
U2
U1
EV2B
W1
W2
2200W
V2
2200W
2200W
U1
8 7
10
EV2C
2200W
2200W
2200W
2200W
2200W
2200W
U1 U2 U1 U2 V1 V2 V1 V2 W1W2 W1W2
EV2D
1
2
3
3a
4
5
8
Temperature limit thermostat
Temperature control contact
Temperature switch (compensation plate)
Terminal strip
Control circuit (burner control box, burner release)
V2
W1
U2
V1
W2
U1
11
6 Fuse
7 Indicating lamp ON
8 Contactor
9 Safety contactor
10 Heating element
11 Bridge loops for 220V- 290V/3~
4
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).
Temperature controller and limit control EV2A

Reset button
50
50
100
Fill oil preheater with oil

Ensure the oil preheater is filled with oil prior to the first
heat-up procedure.
200
100
200
150
150
If the oil preheater is heated up empty it could

damage the heating elements.
ATTENTION
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.
Temperature controller and limit control EV2B, EV2C, EV2D
DANGER
50
100
200
150
Reset button
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.
200
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.
150
50
Note
100
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.
Temperature limit control
9
4
Ratings diagram EV2
Oil throughput [kg/h]
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
EV2D
EV2C
EV2B
EV2A
40
50
60
70
80
90
100
110
120
Temperature increase t [K]

Pressure loss EV2
4,0
3,5
Pressure loss [bar]
3,0
2,5
EV
2C
2D
EV
2,0
1,5
2B
EV
1,0
EV
0,5
2A
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
Burner oil throughput [kg/h]

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 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
EV2B/01
EV2C
50
100
150
EV2D
Oil throughput kg/h
Heat rating
kW
2.2
Oil pressure
max. bar :
30
30
30
30
Oil content
cm3
240
800
800
1600
approx. kg :
15
15
24
Weight
4.5
270
6.6
13.2
Dimensions EV2
a
202
Oil outlet
M20 x 1.5
55
98
430
100
50
Oil inlet
Oil preheater
type
Dimension in mm
a
b
c
EV2A/01
105
305
162
65
G1/4
EV2B/01
135
305
172
112
G1/4
EV2C
135
310
172
112
G3/8
EV2D
195
310
172
184
G3/8
11
5Electric oil preheaters type WEV2.2/01 and WEV3/01

DANGER

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).
Electric oil preheater WEV2.2/01

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.
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
50
100
200
61
U1
U1
V1
U2
W1
V2
V1
62 63 64 65
W2
150
66
W1
Electric oil preheaters WEV3.1/01 and WEV3/01
W1
V1
U1
B1
V2
U2
W2
61
62 63 64 65
50
66
100
W2
W1
V2
V1
U1
U2
W2
W1
200
150
1 Temperature limit control

2 Resistance temperature sensor PT100
12
5
Connection diagram WEV2.2/01
* Other voltages
available on
request
PE N L1 L2 L3
U1 V2
V1 W2
W1 U2
U1 V2
V1 W2
W1 U2
61 62 63 64
K2
* 380 - 500V~
11 12
U1 V2
V1 W2
W1 U2
6 7 L1 9
1 3 N 10
Controller
DR 100
* 220 - 290V~
K1
Connection diagram WEV3.1/01 and WEV3/01

* Other voltages
available on
request
PE N L1 L2 L3
U1 V2
V1 W2
W1 U2
U1 V2
V1 W2
W1 U2
61 62 63 64
K2
* 380 - 500V~
11 12
U1 V2
V1 W2
W1 U2
* 220 - 290V~
1
2
3
4
5

Temperature sensor PT100
Heating element
Terminal strip
Control circuit (burner control box, burner release)
6 7 L1 9
Controller
DR 100
1 3 N 10
K1
6
7
8
9
0
Potential free contact (set value change over)

Fuse carriers
Safety contactor
Contactor
Indicating lamp ON
13
5
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).
Temperature controller DR 100
Determine pressure loss

Determine pressure loss using the oil throughput and
increase the pump pressure accordingly (see pressure
loss diagram).
-weishaupt-
147 . 0
Fill oil preheater with oil

Ensure the oil preheater is filled with oil prior to the first
heat-up procedure.
145.6
If the oil preheater is heated up empty it could

damage the heating elements.
ATTENTION
K1
K2
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.
9 10 11 12
DANGER
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.
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.
14
50
100
200
150
5
Ratings diagram WEV
Oil throughput depending on t at maximum rating
1600
1500
1400
W
0
3/
1200
1100
1000
EV
1300
900
EV
3.1
WE
V2
800
/0
.2/
01
700
600
500
400
300
200
100
20
30
40
50
60
70
80
90
100
Temperature increase t [K]

Pressure loss WEV
3,0
Pressure loss [bar]
2,5
2,0
1,5
0
.2/
1,0
EV
01
V3/.1/01
E
W V3
WE
0,5
0
0
100
200
300
400
500
600
700
800
900
1000

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 outlet temperature: ______________________ 150 C
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.
For values above the oil preheaters nominal rating the oil
inlet temperature has to be increased accordingly.
15
5
Oil preheater type
WEV2.2/01
Oil throughput kg/h
Heat rating
kW
Oil pressure
max. bar :
Oil content
cm3
Weight
300
WEV3.1/01
500
WEV3/01
500
13.8
17.0
22.4
32
32
32
750
1550
1550
approx. kg :
27
42
42
Dimensions WEV
WEV2.2/01
k
b
Oil inlet G 1/2

h
Oil outlet G 1/2
M 10
d
a
WEV3.1/01
WEV3/01
Oil outlet G 1/2

h
c
f
I
M 10
Oil inlet G 1/2
d
a
Oil preheater
type
Dimensions in mm
a
b
c
WEV2.2/01
610
126
WEV3.1/0.1
WEV3/01
724
140
16
254
42
148
100
112
33
231
12
58
314
43
148
100
110
13
288
12
58
6 Media oil preheaters type MV9C and MV10A

DANGER
DANGER

burners if touched.
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.
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
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.
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
6
6.3 Media fittings
6.3.1 Connection variations
The fittings are selected depending on the type of media
used.
Please note that the dimensions of the fittings are not

determinative when sizing the connection lines.
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.
Version
Fittings
1- Warm water up to 110 C
No. per
preheater
DN
DN
MV9C
MV10A
Ball valve
R 1/2
R 1/2
Ball valve
Regulator for thermal fluid
2
1
15 + 20
20
20
20
Ball valve
Strainer
Reg. valve with thermostat
2
1
1
15
15
15/6
15
15
15/9
Ball valve
2
1
15
15
20
20
Bellows valve
2
1
15
15
20
20
Ball valve
Strainer
2
1
1
15
15
15
20
20
20
Bellows valve
Strainer
2
1
1
15
15
15/6
15
15
15/9
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
WW-outlet
WW-inlet
2. Hot water above 110 180 C

WW-outlet
HW-inlet
3.Hot water up to 200 C

WW-outlet
HW-inlet
4. Thermal fluid oil up to 250 C

Thermal fluid oil outlet
Thermal fluid oil inlet

Thermal fluid oil inlet

Thermal fluid oil
inlet
7. Thermal fluid oil 250 300 C

Thermal fluid oil
inlet
8. Low pressure steam up to 0.5 bar

high pressure steam up to 1.5 bar
Condensate
outlet
Steam inlet
18
6
Version
Fittings
9. High pressure steam 1.5 15 bar

Condensate
outlet
HPS inlet
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
No. per
preheater
DN
DN
MV9C
MV10A
Ball valve
Ball valve (inlet)
Ball valve (outlet)
Strainer
Pressure controller
Pressure gauge
Steam trap
2
1
1
1
1
1
1
1
R1/2
R 1/2
R 1/2
R 1/2
R 1/2
R 3/4
R1/2
R 3/4
R 3/4
R 1/2
R 1/2
Ball valve
Strainer
Pressure controller
Manometer
Steam trap
2
1
1
1
1
1
15
15
15
15
15
15
15
15
15
15
Ball valve
Strainer
Pressure gauge
Steam trap
2
1
1
1
1
1
15
15
15/6
15
15
15
15
15
15
15
Ball valve
Strainer
Pressure gauge
Steam trap
2
1
1
1
1
1
15
15
15/6
15
15
15
15
15/9
15
15
Ball valve
Strainer
Pressure gauge
Steam trap
2
1
1
1
1
1
15
15
15/6
15
15
15
15
15/9
15
15
* 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
6
6.3.2 Fittings
Shut off devices:
Ball valve DN20
Bellows valve DN15
77
Operating pressure max.:

15 bar at 200C
DN15
DN20
157
Ball valve DN15
DN15
R 1/2 (R 3/4)
Ball valve R 1/2

R 3/4
130
150

25 bar at 250C

25 bar at 250C
Nominal diameter R 3/4
130
13 bar at 300C
72
82
Nominal diameter DN15

130
R 1/2
R 1/3
DN15
Strainer:

15 bar at 200C

25 bar at 250C

25 bar at 250C
Pressure controller:
310
96
48
DN15
130
DN 15
234
126,5
83
55
R 3/4
55
R 1/2
126,5
130
114
185
Inlet pressure max.:
20 bar at 230C

19 bar at 210C

19 bar at 210C

25 bar at 250C
Reduced pressure range:

1.3 4 bar (green spring*)
3.5 10 bar (orange spring)
* at inlet pressure < 5 bar

1.3 4 bar (green spring*)
3.5 10 bar (orange spring)
* at inlet pressure < 5 bar

below 3 bar (blue spring)
3.0 10 bar (red spring)

3.0 10 bar
Pressure gauge
165
20
DN 15
R 3/4
R 1/2
A pressure snubber is
connected before the
pressure gauge.
165
100
6
Control valve:
130

150
22
R 1
385
390
DN 20
112
55
730*
630
390
385
730*
630
DN 15
112
55
22
R 1
* with intermediate piece

on HPS 13 to 20 bar
and thermal fluid oil
* 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
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
Controller for hot water
150
DN20
DN20
130
150

17 bar

17 bar
150
22 bar
Supply temperature max.:

320 C

320 C

180 C
Temperature adjustment
range:
100 170 C
range:
100 170 C
range:
70 145 C

95
150

20 bar at 250C

20 bar at 250C
19
86
84
Nominal diameter 1/2
R 1/2
R 1/2
DN15
Steam trap
DN15
DN15
150
150
95
15 bar
150
25 bar
Operating temperature:
100 K above relevant
saturated steam temp.
Differential pressure max.

17 bar
Condensate cooling:
8 K (not adjustable)
Operating temperature:
100 K above relevant
saturated steam temp.
Condensate cooling:
8 K (not adjustable)
21
6
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
Hot water and thermal fluid oil operation without

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.

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.
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
22

The required oil temperature is set by turning the knob of
the thermostat within the set value range of 40 to 160 C.
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
Steam operation without 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.

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.
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.
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.
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.
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
approx. 0 bar
from 1.5 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
15 bar
10 bar
7,5 bar
170C
5,0 bar
150C
2,5 bar
130C
1,0 bar
700
110C
MV9C
0,5 bar
The HW temperatures and steam

pressures must be available at the
oil preheater inlet.
600
500
400
300
200
100
80
90
100
110
120
130
140
150
160
15 bar
10 bar
7,5 bar
170C
5,0 bar
150C
2,5 bar
130C
0,5 bar
MV10A
1,0 bar
Oil temperature max. [C]
900
110C
1000
800
700
600
500
400
80
90
100
110
120
130
Oil temperature max. [C]
24
140
150
160
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
Pressure loss [bar]
2,0
MV9C
1,5
MV10A
1,0
0,5
0
100
200
300
400
500
600
700
800
900
1000
6.6 Technical data MV

Oil preheater
type
Contents
oil coil [dm3]
MV9C
2.6
MV10A
7.5
Contents
cover space [dm3]
Oil pressure
max. [bar]
Medium pressure max.

at 250C [bar]
at 300C [bar]
7.8
40
25
25
18.0
40
25
20
Dimensions MV9C / MV10A

Outlet for liquid heating media
i
Heating media
inlet
Oil inlet
Oil outlet
e
h
b
g
d
c
l
a
Steam outlet
Oil preheater
type
Dimensions in mm
a
b
c
MV9C
640
222
170
108
16
55
G1/2
G1/2
G1/2
M 12
300
MV10A
800
287
250
135
55
84
G1/2
G3/4
G1/2
M 12
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 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.
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.
Saturated steam quantity required
1200
1100
1000
900
800
700
200
DN32
DN25 DN20
DN10
90
80
70
60
50
40
30
20
10
60
50
40
30
t Oil in K
300
DN40
DN15
100
80
Oil throughput in kg/h
400
DN50
150
600
500
Nominal diameter of saturated steam line
300
250
200
Saturated steam in kg/h
2600
2400
2200
2000
1800
1600
1400
20
0,5 0,6 0,8 1,0
Steam pressure in bar
absolute pressure in bar

(end of condensate line)
Nominal diameter
of condensate line
DN10
10
DN15
20
DN20
30
DN25
10
1
1,5
DN32
7
DN40
DN50
0,5
1
2
3
4 5 6 7 8 910
absolute pressure in bar
(condensate before pressure release)
15 20 25
100 110 120 130 140

160
180
200 220
Temperature in C (condensate before pressure release)
26
10
20
30 40 50 60 80100
Condensate flow in kg/h
200
400
600 800
Appendix
Viscosity - temperature chart
Temperature [F]
60
80
100
120
140
160
180
200
220
240
260
280 300
320 340
2000
1000
200
150
120
Max. pump viscosity
600
400
300
60
Viscosity [E]
Viscosity [mm2/s]
40
40
30
100
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
50
40
30
20
Max. oil preheater temperature*
200
B
10
9
8
7
20
10
8
6
4
3
2,5
2
1,8
zzle viscosity
Recommended no
1,6
1,5
6
5
1,4
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
1,5
va
lu
es
1,3
1,2
1,1
Ke
ro
se
ne
1,0
1
0
10
20
30
40
50
60
70
80
90
100 110
120 130
140 150 160 170 180

Temperature [C]
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.
intersect the line Recommended nozzle viscosity. From

this intersection vertically to the temperature axis. There
read the desired preheating temperature of 147 C.
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,
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.
Recommendation
The following maximum viscosities in relation to nozzle size
are to be noted:
Due to the components selected a preheating

temperature of 160C should not be exceeded.
27
Weishaupt products
and service
Max Weishaupt GmbH

D - 88475 Schwendi
Tel.: (07353) 830, Fax.: (07353) 83358
www.weishaupt.de
Print No. 83001802, July 2005
Printed in Germany. All rights reserved.
Neachells Lane, Willenhall, WV13 3RG
Tel: (01902) 609841, Fax: (01902) 633343
Product
Description
Performance
W-Burners
The compact series, proven millions of times over:

Economical, reliable, fully automatic. Gas, oil and
dual fuel burners for domestic and commercial
applications.
Up to 570 kW
Monarch and
industrial burners
The legendary industrial burner:

Tried and tested, long lived, clear construction.
Gas, oil and dual fuel burners for district heat provision.
Up to
10900 kW
multiflam burners
Innovative Weishaupt technology for large burners:

Minimal emission values particularly at ratings
over one megawatt. Oil, gas and dual fuel burners with
patented fuel distribution system.
Up to
12000 kW
WK
industrial burners
Modular powerhouses:
Adaptable, robust, powerful.
Oil, gas and dual fuel burners for industrial plant.
Up to
17500 kW
Thermo Unit
The Thermo Unit heating systems from cast iron or

steel: Modern, economic, reliable.
For environmentally friendly heating.
Fuel: Gas or oil as desired.
Up to 55 kW
Thermo Condens
The innovative condensing boilers with the SCOT system:

Efficient, low in emissions, versatile.
Ideal for domestic heating.
Fuel: Gas.
Up to 240 kW
Solar systems
Free energy from the sun:

Perfectly coordinated components, innovative, proven.
Pleasantly shaped flat roof collectors to support
heating and of domestic water
Water heater /
energy reservoir
The attractive domestic water heating range

includes classic water heaters which are supplied
through a heating system and energy reservoirs which
can be fed through solar systems.
Control technology /
building
management
From control panels to complete building management

systems at Weishaupt you can find the entire
spectrum of modern control technology.
Future oriented, economical and flexible.
Service
Customer service completes the Weishaupt range.

Weishaupt customer service is available 24/7.
Were there when you need us. Everywhere.

Preheeter Instr

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Preheeter Instr

Uploaded by

Copyright:

Available Formats

manual

Installation and operating instruction

Weishaupt Electric & Media Oil Preheaters

4 Electric oil preheater type EV2

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

6 Media oil preheater type MV9C and MV10A

These installation and operating instructions

are to be used by qualified personnel only.

contain the relevant information for the safe assembly,

are for the attention of all personnel working with the

Hand over and operating instructions

Explanation of notes and symbols

The contractor should instruct the plant operator in the use

This symbol is used to mark instructions,

Guarantee and liability

This symbol is used to mark instructions,

This symbol is used to mark procedures,

Procedures with more than one step are

This symbol is used when you are required to

This symbol is used to list points.

This symbol indicates detailed information.

Failure to use the equipment as intended

On burners for use with medium and heavy residual fuel

3.1 Permissible applications

The oil preheater must only be used within the ratings

4 Electric oil preheater type EV2

Allow oil preheater to cool

Electric oil preheater EV2A

The oil preheater has a large heat exchange surface with

Electric oil preheater EV2B, EV2C and EV2D

The temperature switch 3 is connected to the heat

1 Temperature controller with integrated temperature

Connection diagram EV2B, EV2C and EV2D

Furthermore the correct fusing of the circuits and the

Temperature controller and limit control EV2A

Fill oil preheater with oil

If the oil preheater is heated up empty it could

Check hydraulic connections

Temperature controller and limit control EV2B, EV2C, EV2D

The temperature controller should always be

Check and set temperature limit control

Set temperature controller

Oil throughput [kg/h]

Oil throughput depending on t at maximum rating

Temperature increase t [K]

Pressure loss [bar]

Burner oil throughput [kg/h]

Due to the different oil throughputs and the

Oil throughput kg/h

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

5.1 Safety instructions

Allow oil preheater to cool

Electric oil preheater WEV2.2/01

Temperature limit control

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

1 Temperature limit control

Connection diagram WEV3.1/01 and WEV3/01

Temperature limit control

Potential free contact (set value change over)

Furthermore the correct fusing of the circuits and the

Temperature controller DR 100

Determine pressure loss

Fill oil preheater with oil

If the oil preheater is heated up empty it could