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manual Installation and operating instruction W eishaupt Electric & Media Oil Preheaters 8300 18 02

manual

Installation and operating instruction

manual Installation and operating instruction W eishaupt Electric & Media Oil Preheaters 8300 18 02 -

Contents

1
1

1 General instructions

4

2
2

2 Safety information

5

3
3

3 Technical description

6

3.1

Permissible applications

6

4
4

4

Electric oil preheater type EV2…

7

4.1 Safety instructions

7

 

4.2 Function

7

4.3 Electrical connection

8

4.4 Safety instructions for initial commissioning

9

4.5 Commissioning

9

4.6 Technical data EV2…

11

5
5

5

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

12

5.1 Safety instructions

12

 

5.2 Function

12

5.3 Electrical connection

13

5.4 Safety instructions for initial commissioning

14

5.5 Commissioning

14

6
6

6

Media oil preheater type MV9C and MV10A

17

6.1 Safety instruction

17

 

6.2 Function

17

6.3 Media fittings

18

 

6.3.1 Connection variations

18

6.3.2 Fittings

20

 

6.4 Safety instructions for initial commissioning

22

6.5 Commissioning

22

 

6.5.1 Hot water and thermal fluid operation

22

6.5.2 Steam operation

23

6.5.3 Ratings and pressure loss diagram

24

 

6.6 Technical data MV

25

6.7 Saturated steam and condensate line

26

A
A

Appendix Viscosity - temperature diagram

27

27

3

1
1

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.

Explanation of notes and symbols

DANGERwith the equipment. Explanation of notes and symbols T his symbol is used to mark instructions,

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

This symbol is used to mark instructions, which, if not followed, could result in life
This symbol is used to mark instructions,
which, if not followed, could result in life
threatening electric shock.
DANGER
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.
ATTENTION
This symbol is used to mark procedures,
which you should follow.
1.
Procedures with more than one step are
2.
numbered.

3.

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

Ta b.

Table

Ch.

Chapter

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:

• 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 non- functioning 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

4

2 Safety information

2
2

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.

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.

Personnel training Only competent personnel may work on the appliance.

Maintenance and fault rectification

Competent personnel according to this operating manual are persons who are familiar with the installation, mounting, setting and commissioning of the product and

Allow the unit to cool prior to servicing and maintenance work to avoid injury through high temperatures.

have the necessary qualifications such as:-

Necessary installation, service and inspection work

should be carried out at the specified time.

 

Training, instruction or authorisation to switch electrical circuits and electrical devices on and off, to earth them

Inform the operator before beginning any service work.

and to mark them in accordance with the safety standards.

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.

Organisational measures

If,

during servicing or testing, control seal joints have to

Everyone working on the plant should wear the necessary protective clothing.

be opened, these have to be thoroughly cleaned to ensure tight sealing when re-assembling.

All safety devices should be checked regularly.

Damaged seals must be replaced. Carry out a soundness test!

Informal safety measures

Flame monitoring devices, limit controls, correcting

Screwed connections, which have been loosened,

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.

elements and all other safety devices must be commissioned by, and may only be replaced by, the manufacturer or an authorised agent.

must be re-tightened without cross-threading.

All safety and danger notices should be kept in a legible condition.

Following service work, all safety devices should be tested to ensure they are functioning correctly.

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.

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.

5

3
3

3Te chnical 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 mm 2 /s at 100°C (approx. 570 mm

In special versions for a viscosity of up to

60 mm

2 /s at 50°C)

2

/s at 100°C (approx. 700 mm 2 /s at 50°C)

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.

6

4 Electric oil preheater type EV2…

4
4

4.1 Safety instructions

Electrically isolate plant

Allow oil preheater to cool

DANGER
DANGER

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.

Allow the oil preheater to cool prior to commissioning and service work. The hot surfaces
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
Electric oil preheater EV2A
3 21
3
21

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 150º C and depends on the oil throughput and the temperature of the fuel oil inlet.

Te mperature 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 30º K below the temperature set point.

Te mperature 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.

Te mperature 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 EV2B, EV2C and EV2D

3 21
3
21

1 Temperature controller with integrated temperature switch for burner release.

2 Te mperature limit switch

3 Te mperature switch on compensation plate

7

4
4

4.3 Electrical connection

Connection diagram EV2A

230V/1~N N L1 1 3 2 3a 45 6 6 1 ϑ ϑ 2 6A
230V/1~N
N L1
1
3
2
3a
45
6
6
1
ϑ
ϑ
2
6A
6A
3
4
5
6
ϑ
ϑ
10
8
7
EV2A
1500W

Connection diagram EV2B, EV2C and EV2D

400V/3~N

3a 3 2 1 4 5 69 N L1 L2 L3 1 6A (EV2B/EV2C) 2
3a
3
2
1
4
5
69
N L1 L2 L3
1
6A
(EV2B/EV2C)
2
6A
3
4
10A (EV2D)
ϑ
ϑ
5
6
ϑ
ϑ
V2
W1
U2
V1
W2
U1
U1
U2
V1
V2
W1
W2
EV2B
U1
U2
V1
V2
W1
W2
10
8
7
EV2C
U1
U2
U1
U2
V1
V2
V1
V2
W1
W2
W1
W2
V2
W1
U2
V1
W2
U1
11
EV2D
2200W
2200W
2200W
1500W
2200W
2200W
1500W
2200W
2200W
2200W
1500W
2200W

1 Temperature controller

2 Temperature limit thermostat

3 Temperature control contact

3a Temperature switch (compensation plate)

6 Fuse

7 Indicating lamp ‘ON’

8 Contactor

9 Safety contactor

4

Terminal strip

10 Heating element

5

Control circuit (burner control box, burner release)

11 Bridge loops for 220V- 290V/3~

8

4
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.

4.5 Commissioning

Furthermore the correct fusing of the circuits and the measures for contact protection of electrical equipment and of all wiring must be checked.

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.

ATTENTIONis filled with oil prior to the first heat-up procedure. If the oil preheater is heated

If the oil preheater is heated up empty it could damage the heating elements.

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

Temperature controller and limit control EV2A

Reset button ➁ ➀ 0 0 °C 50 °C 50 100 100 200 200 150
Reset button
0
0
°C
50
°C
50
100
100
200
200
150
150

DANGER➀ 0 0 °C 50 °C 50 100 100 200 200 150 150 Danger of getting

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

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.

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 and limit control EV2B, EV2C, EV2D

➀ 0 °C 50 100 200 150 Reset button ➁ 0 °C 50 100 200
0
°C
50
100
200
150
Reset button
0
°C
50
100
200
150

Temperature controller

Temperature limit control

9

4
4

Ratings diagram EV2…

Oil throughput depending on t at maximum rating

360 340 320 300 EV2D 280 260 240 220 200 180 160 EV2C 140 120
360
340
320
300
EV2D
280
260
240
220
200
180
160
EV2C
140
120
EV2B
100
80
60
EV2A
40
20
40
50
60
70
80
90
100
110
120
Oil throughput [kg/h]

Te mperature increase t [K]

Pressure loss EV2…

4,0 3,5 3,0 2,5 2,0 1,5 1,0 0,5 0 20 40 60 80 100 120
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
EV2D
EV2B
EV2A
EV2C
Pressure loss [bar]

Burner oil throughput [kg/h]

The value for type EV2A has been determined with medium fuel oil M (viscosity 37 mm 2 /s at 50° C) Oil inlet temperature:

20° C

Note

Due to the different oil throughputs and the varying inlet viscosities, the data given relating to the pressure losses of the preheaters

Oil outlet temperature:

95° C

should be used as guide values.

The values for type EV2B to EV2D have been determined with fuel oil S (viscosity 450 mm 2 /s at 50° C)

Oil inlet temperature:

60° C

Oil outlet temperature:

150° C

For values above the oil preheater’s nominal rating the oil inlet temperature has to be increased accordingly.

10

4
4

4.6 Technical data EV2…

Oil preheater type

 

EV2A/01

EV2B/01

EV2C

EV2D

Oil throughput

kg/h

:

50

100

150

270

Heat rating

kW

:

2.2

4.5

6.6

13.2

Oil pressure

max. bar :

30

30

30

30

Oil content

cm 3

:

240

800

800

1600

Weight

approx. kg :

8

15

15

24

Dimensions EV2…

202 98 b c
202
98
b
c
a 55 100 50 d e Oil inlet
a
55
100
50
d
e
Oil inlet

430

Oil outlet M20 x 1.5

Oil preheater

Dimension in mm abcde

type

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

5
5

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

5.1 Safety instructions

Electrically isolate plant

Allow oil preheater to cool

DANGERElectrically isolate plant Allow oil preheater to cool Prior to commissioning and service switch off the

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.

Allow the oil preheater to cool prior to commissioning and service work. The hot surfaces
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
Electric oil preheater WEV2.2/01
➀ ➁
0 W2 U2 V2 °C 50 100 200 150 61 62 63 64 65 66
0
W2
U2
V2
°C
50
100
200
150
61
62
63
64
65
66
U1
U2
V2
V1
W2
W1
U1
V1
W1
Electric oil preheaters WEV3.1/01 and WEV3/01 ➀ ➁
Electric oil preheaters WEV3.1/01 and WEV3/01
W1 V1 U1 B1 0 °C 50 61 62 63 64 65 66 100 200
W1
V1
U1
B1
0
°C
50
61
62
63
64
65
66
100
200
W2
W1
V2
U2
W2
B
150
V2
V1
U1
U2
W2
W1
A
B

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).

Te mperature 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.

Te mperature 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.

12

1 Temperature limit control

2 Resistance temperature sensor PT100

5
5

5.3 Electrical connection

Connection diagram WEV2.2/01 * Other voltages available on ➂ request ➀ ➁ PE N L1
Connection diagram WEV2.2/01
*
Other voltages
available on
request
PE N L1 L2 L3
ϑ
ϑ
U1
V2
Y
V1
W2
Z
W1
U2
X
61
62
63
64
K2
U1
V2
Y
V1
W2
Z
W1
U2
X
*
380 - 500V~
11
12
6
7
L1
9
1
3
N 10
U1
V2
Y
V1
W2
Z
W1
U2
X
Controller
K1
DR 100
*
220 - 290V~
Connection diagram WEV3.1/01 and WEV3/01 * Other voltages available on request ➂ ➀ ➁ PE
Connection diagram WEV3.1/01 and WEV3/01
*
Other voltages
available on
request
➀ ➁
PE N L1 L2 L3
ϑ
ϑ
U1
V2
Y
V1
W2
Z
W1
U2
X
A
B
61
62
63
64
K2
U1
V2
Y
V1
W2
Z
W1
U2
X
*
380 - 500V~
11
12
6
7
L1
9
1
3
N 10
U1
V2
Y
V1
W2
Z
W1
U2
X
Controller
K1
DR 100
*
220 - 290V~
1 Temperature limit control
6
Potential free contact (set value change over)
2 Te mperature sensor PT100
7
Fuse carriers
3 Heating element
8
Safety contactor
4 Terminal strip
9
Contactor
5 Control circuit (burner control box, burner release)
0
Indicating lamp ‘ON’

13

5
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.

5.5 Commissioning

Furthermore the correct fusing of the circuits and the measures for contact protection of electrical equipment and of all wiring must be checked.

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.

ATTENTIONis filled with oil prior to the first heat-up procedure. If the oil preheater is heated

If the oil preheater is heated up empty it could damage the heating elements.

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

DANGER
DANGER

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

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.

Temperature controller DR 100

Temperature limit control

0 °C 50 100 200 150
0
°C
50
100
200
150

14

5
5

Ratings diagram WEV…

Oil throughput depending on t at maximum rating

1600 1500 1400 1300 1200 1100 1000 900 WEV2.2/01 800 WEV3.1/01 700 600 WEV 3/01
1600
1500
1400
1300
1200
1100
1000
900
WEV2.2/01
800
WEV3.1/01
700
600
WEV 3/01
500
400
300
200
100
20
30
40
50
60
70
80
90
100
Oil throughput [kg/h]

Te mperature increase t [K]

Pressure loss WEV…

3,0 2,5 2,0 1,5 1,0 0,5 0 0 100 200 300 400 500 600 700
3,0
2,5
2,0
1,5
1,0
0,5
0
0
100
200
300
400
500
600
700
800
900
1000
WEV3/01
WEV3.1/01
WEV2.2/01
Pressure loss [bar]

Burner oil throughput [kg/h]

The values of types WEV2.2/01 to WEV3/01 have been

Note

Due to the different oil throughputs and the

determined with fuel oil S (viscosity 450 mm 2 /s at 50° C)

varying inlet viscosities the data given relating

Oil inlet temperature:

60° C

to the pressure losses of the preheaters

Oil outlet temperature:

150° C

should be used as guide values.

For values above the oil preheater’s nominal rating the oil inlet temperature has to be increased accordingly.

15

5
5

Oil preheater type

 

WEV2.2/01

WEV3.1/01

WEV3/01

Oil throughput

kg/h

:

300

500

500

Heat rating

kW

:

13.8

17.0

22.4

Oil pressure

max. bar :

32

32

32

Oil content

cm 3

:

750

1550

1550

Weight

approx. kg :

27

42

42

Dimensions WEV…

WEV2.2/01

WEV3.1/01

WEV3/01

k b e i Oil inlet G 1/2” h c f g Oil outlet G
k
b
e
i
Oil inlet G 1/2”
h
c f
g
Oil outlet G 1/2”
I M
10
d
a
k b e i Oil outlet G 1/2” h c f g Oil inlet G
k
b
e
i
Oil outlet G 1/2”
h
c f
g
Oil inlet G 1/2”
I
M
10
d
a

Oil preheater

Dimensions in mm b

a

c

 

type

d

ef

g

h

i

k

l

WEV2.2/01

610

126

254

42

148

100

112

33

231

12

58

WEV3.1/0.1

724

140

314

43

148

100

110

13

288

12

58

WEV3/01

16

6 Media oil preheaters type MV9C and MV10A

6
6

6.1 Safety instructions

Electrically isolate plant

Prior to commissioning and service switch off the mains switch and the safety switch. Failure
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
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.
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
Outlet for
liquid heating
medium
Outlet for steam
Inlet
Outlet for liquid heating medium Outlet for steam Inlet Heating oil outlet Heating oil inlet medium

Heating oil outlet

Heating oil inlet

medium

Media preheater with electric oil preheater

inlet medium Media preheater with electric oil preheater Media preheater without electric oil preheater Included in

Media preheater without electric oil preheater

preheater Media preheater without electric oil preheater Included in delivery: 2 1 1 Thermometer + screwed

Included in delivery:

2

1

1 Thermometer

+ screwed unions and pipe connections

Oil hoses

Ball valve

Included in delivery:

2

1

1 Temperature controller

1 Temperature controller with change-over contact for burner release + screwed unions and pipe connections

Oil hoses

Thermometer

17

6
6

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 DN DN pre- heater MV9C MV10A 1- Warm water up to
Version
Fittings
No. per
DN
DN
pre-
heater
MV9C
MV10A
1- Warm water up to 110° C
Ball valve
2
R 1/2”
R 1/2”
WW-outlet
WW-inlet
2.
Hot water above 110 – 180° C
Ball valve
Regulator for thermal fluid
2
15 + 20
20
1
20
20
WW-outlet
HW-inlet
3.Hot water up to 200° C
Ball valve
Strainer
Reg. valve with thermostat
2
15
15
1
15
15
1
15/6
15/9
WW-outlet
HW-inlet
4.
Thermal fluid oil up to 250° C
Ball valve
Regulator for thermal fluid
2
15
20
1
15
20
Thermal fluid oil outlet
Thermal fluid oil inlet
5.
Thermal fluid oil up to 300° C
Bellows valve
Regulator for thermal fluid
2
15
20
1
15
20
Thermal fluid oil outlet
Thermal fluid oil inlet
6.
Thermal fluid oil up to 250° C
Ball valve
Strainer
Reg. valve with thermostat
2
15
20
1
15
20
1
15
20
Thermal fluid oil outlet
Thermal fluid oil
inlet
7. Thermal fluid oil 250 – 300° C
Bellows valve
Strainer
Reg. valve with thermostat
2
15
15
1
15
15
1
15/6
15/9
Thermal fluid oil outlet
Thermal fluid oil
inlet
8.
Low pressure steam up to 0.5 bar
high pressure steam up to 1.5 bar
Ball valve
Condensate sight glass
Steam trap
2
R 1/2”
R 1/2”
1
R 1/2”
R 1/2”
1
R 1/2”
R 1/2”
Condensate
outlet

Steam inlet

18

6
6
Version Fittings No. per DN DN pre- heater MV9C MV10A 9. High pressure steam 1.5
Version
Fittings
No. per
DN
DN
pre-
heater
MV9C
MV10A
9. High pressure steam 1.5 – 15 bar
2
R1/2”
1
R 3/4”
1
R1/2”
Condensate
1
R 1/2”
outlet
1
R 1/2”
HPS inlet
Ball valve
Ball valve (inlet)
Ball valve (outlet)
Strainer
Pressure controller
Pressure gauge
Condensate sight glass
Steam trap
1
1
R 1/2”
1
R 1/2”
R 3/4”
R 3/4 “
R 1/2”
R 1/2”
10.
High pressure steam 6 – 25 bar
Ball valve
Strainer
Pressure controller
Manometer
Condensate sight glass
Steam trap
2
15
15
1
15
15
1
15
15
Condensate
1
outlet
1
15
15
HPS inlet
1
15
15
11.
High pressure steam 7,5 – 13 bar*
Ball valve
Strainer
Reg. valve with thermostat
Pressure gauge
Condensate sight glass
Steam trap
2
15
15
1
15
15
1
15/6
15
Condensate
1
outlet
HPS inlet
1
15
15
1
15
15
12.
High pressure steam 13 – 25 bar*
2
15
15
1
15
15
1
15/6
15/9
Condensate
outlet
Ball valve
Strainer
Reg. valve with thermostat
Pressure gauge
Condensate sight glass
Steam trap
1
HPS inlet
1
15
15
1
15
15
13.
High pressure steam 20 – 25 bar*
Ball valve
Strainer
Reg. valve with thermostat
Pressure gauge
Condensate sight glass
Steam trap
2
15
15
1
15
15
1
15/6
15/9
Condensate
1
outlet
HPS inlet
1
15
15
1
15
15

* only with preheating without electric. oil preheater

Description of fittings

Ball valve or bellows valve:

Description of fittings B all valve or bellows valve: Controller for hot water and thermal fluid

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

and thermal fluid oil or pressure controller for steam: Strainer: Control valve with thermostat: Condensate sight

Strainer:

Control valve with thermostat:

for steam: Strainer: Control valve with thermostat: Condensate sight glass: Pressure gauge: Steam trap: Oil

Condensate sight glass:

for steam: Strainer: Control valve with thermostat: Condensate sight glass: Pressure gauge: Steam trap: Oil preheater:

Pressure gauge:

Steam trap:

for steam: Strainer: Control valve with thermostat: Condensate sight glass: Pressure gauge: Steam trap: Oil preheater:

Oil preheater:

for steam: Strainer: Control valve with thermostat: Condensate sight glass: Pressure gauge: Steam trap: Oil preheater:

19

6
6

6.3.2 Fittings

Shut off devices:

Ball valve R 1/2” R 3/4”

Ball valve DN15

Ball valve DN20

Bellows valve DN15

77 R 1/2” (R 3/4”)
77
R 1/2” (R 3/4”)

Operating pressure max.:

15 bar at 200°C

130 DN15
130
DN15

Operating pressure max.:

25 bar at 250°C

150 DN20
150
DN20

Operating pressure max.:

25 bar at 250°C

130 DN15 157
130
DN15
157

Operating pressure max.:

13 bar at 300°C

Strainer:

Nominal diameter R 1/2”

72 R 1/2”
72
R
1/2”

Operating pressure max.:

15 bar at 200°C

Nominal diameter R 3/4”

82 R 1/3”
82
R
1/3”

Operating pressure max.:

25 bar at 250°C

Nominal diameter DN15

130 DN15
130
DN15

Operating pressure max.:

25 bar at 250°C

Pressure controller:

Nominal diameter R 1/2”

83 R 1/2” 55 126,5
83
R
1/2”
55
126,5

Nominal diameter R 3/4”

96 R 3/4” 55 126,5
96
R
3/4”
55
126,5

Nominal diameter DN15

130 185 DN 15 130 234
130
185
DN 15
130
234

Nominal diameter DN15

114 DN15 31048
114
DN15
31048

Inlet pressure max.:

Inlet pressure max.:

Inlet pressure max.:

Inlet pressure max.:

19

bar at 210°C

19

bar at 210°C

20

bar at 230°C

25 bar at 250°C

Reduced pressure range:

Reduced pressure range:

Reduced pressure range:

Reduced pressure range:

1.3

– 4 bar (green spring*)

1.3

– 4 bar (green spring*)

below 3 bar (blue spring)

3.0 –10 bar

3.5

–10 bar (orange spring)

3.5

–10 bar (orange spring)

3.0 –10 bar (red spring)

* at inlet pressure < 5 bar

* at inlet pressure < 5 bar

Pressure gauge

A pressure snubber is connected before the pressure gauge.

Nominal diameter R 1/2”

165 R 1/2”
165
R
1/2”

Nominal diameter R 3/4”

165 R 3/4”
165
R
3/4”

Nominal diameter DN15

100 DN 15
100
DN 15

20

6
6

Control valve:

Nominal diameter DN15

130 Ø 22 R 1” * with intermediate piece on HPS 13 to 20 bar
130
Ø 22
R 1”
* with intermediate piece
on HPS 13 to 20 bar
and thermal fluid oil
730*
630
55
112385
DN 15
390

Operating pressure max. Ty pe M: 13 bar at 200°C Ty pe H: 25 bar at 250° C Set value range with thermostat: 40-160° C

Nominal diameter DN20

150 Ø 22 R 1” * with intermediate piece on HPS 13 to 20 bar
150
Ø 22
R 1”
* with intermediate piece
on HPS 13 to 20 bar
and thermal fluid oil
730*
630
55
112385
DN 20
390

Operating pressure max. Ty pe M: 13 bar at 200°C Ty pe H: 25 bar at 250° C Set value range with thermostat: 40-160° C

Controller for thermal fluid oil

Nominal diameter DN15

130 DN15 150
130
DN15
150

Operating pressure max.:

17

bar

Supply temperature max.:

320° C

Temperature adjustment range:

100 … 170° C

Nominal diameter DN20

150 DN20 150
150
DN20
150

Operating pressure max.:

17

bar

Supply temperature max.:

320° C

Temperature adjustment range:

100 … 170° C

Controller for hot water

Nominal diameter DN20

150 DN20 150
150
DN20
150

Operating pressure max.:

22

bar

Supply temperature max.:

180° C

Temperature adjustment range:

70 … 145° C

Condensate sight glass

Nominal diameter DN15

95 R 1/2”
95
R 1/2”

Operating pressure max.:

20 bar at 250°C

Nominal diameter DN15

150 DN15
150
DN15

Operating pressure max.:

20 bar at 250°C

Steam trap

Nominal diameter 1/2”

95 R 1/2” 19 84
95
R 1/2”
19
84

Operating pressure max.:

15

bar

Nominal diameter DN15

150 DN15 86
150
DN15
86

Operating pressure max.:

25

bar

Operating temperature:

100° K above relevant saturated steam temp.

Condensate cooling:

8° K (not adjustable)

Differential pressure max.

17 bar

Operating temperature:

100° K above relevant saturated steam temp.

Condensate cooling:

8° K (not adjustable)

21

6
6

6.4 Safety instructions for initial commissioning

The initial commissioning of the oil preheater must only be carried out by the supplier,
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

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.

Condensate line pressure

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.

Steam pressure in the oil preheater

Pressure in the 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

6.5.3 Ratings and pressure loss diagram

Ratings diagrams (maximum achievable oil temperature with hot water and steam)

achievable oil temperature with hot water and steam) Hot water Saturated steam The HW temperatures and

Hot water

Saturated steam

The HW temperatures and steam pressures must be available at the oil preheater inlet.

MV9C 700 600 500 400 300 200 100 80 90 100 110 120 130 140
MV9C
700
600
500
400
300
200
100
80 90
100
110
120
130
140
150
160
Oil throughput [kg/h]
110°C
0,5 bar
1,0 bar
130°C
2,5 bar
150°C
5,0 bar
170°C
7,5 bar
10
bar
15
bar

Oil temperature max. [°C]

MV10A 1000 900 800 700 600 500 400 80 90 100 110 120 130 140
MV10A
1000
900
800
700
600
500
400
80 90
100
110
120
130
140
150
160
Oil throughput [kg/h]
110°C
0,5 bar
1,0 bar
130°C
2,5 bar
150°C
5,0 bar
170°C
7,5 bar
10
bar
15
bar

Oil temperature max. [°C]

24

6
6

Fuel oil pressure losses MV9C / MV10A

The values have been determined using fuel oil S (max. viscosity 150 mm 2 /s at 50° C and an outlet temperature of 130° C).

2,5 2,0 MV9C 1,5 MV10A 1,0 0,5 0 100 200 300 400 500 600 700
2,5
2,0
MV9C
1,5
MV10A
1,0
0,5
0
100
200
300
400
500
600
700
800
900
1000
Pressure loss [bar]

Burner oil throughput [kg/h]

6.6 Technical data MV

Oil preheater

Contents oil coil [dm 3 ]

Contents cover space [dm 3 ]

Oil pressure

Medium pressure max.

type

max. [bar]

at 250°C [bar]

at 300°C [bar]

MV9C

2.6

7.8

40

25

25

MV10A

7.5

18.0

40

25

20

Dimensions MV9C / MV10A

Outlet for liquid heating media Heating media inlet i k h b d c l
Outlet for liquid heating media
Heating media
inlet
i k
h b
d
c
l
a
Steam outlet

Oil inlet

Oil outlet e f g
Oil outlet
e f
g

Oil preheater

Dimensions in mm

 

type

ab

c

d

ef

ghi

 

kl

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

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
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.
2600
Saturated steam quantity required
Nominal diameter of saturated steam line
2400
2200
2000
1800
DN50
DN40
DN32
DN25
DN20
300
1600
250
DN15
1400
200
1200
150
1100
DN10
1000
100
900
90
80
800
80
60
700
70
50
600
40
60
30
500
50
20
400
40
300
10
30
5
200
20
0,5
0,6
0,8
1,0
2
3
4
5
6
8
10
20
30
Oil throughput in kg/h
Saturated steam in kg/h
∆t Oil in K

Steam pressure in bar

absolute pressure in bar (end of condensate line) Nominal diameter of condensate line DN10 DN15
absolute pressure in bar
(end of condensate line)
Nominal diameter
of condensate line
DN10
DN15
DN20
DN25
10
1
1,5
2
3
45
7
0,5
1
2
3
4
5
6
7 8 9
10
15
20
25
10
20
30
40 50 60
80100
200
400
600 800
absolute pressure in bar
(condensate before pressure release)
Condensate flow in kg/h
100 110 120 130
140
160
180
200
220

Temperature in °C (condensate before pressure release)

DN32

DN40

DN50

26

Appendix

A
A

Viscosity - temperature chart

Te mperature [°F]

40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
40 60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
2000
200
Maximum value oil S and SA DIN 51 603
150
1000
120
Max. pump viscosity
Average values oil S and SA
600
60
400
300
40
30
200
C
20
100
B
10
8
50
6
40
30
4
3
20
2,5
2
10
1,8
9
A
8
Max. oil preheater temperature*
Recommended nozzle viscosity
1,6
7
1,5
6
Maximum value oil EL DIN 51 603
1,4
5
Average value oil EL
4
1,3
3
1,2
2
1,1
Average values Kerosene
1,5
1
1,0
0 10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160 170 180
Viscosity [mm 2 /s]
Viscosity [E]

Te mperature [°C]

Determination of the preheating temperature The preheating temperature to be determined can be taken from the viscosity - temperature chart. The viscosity

intersect the line “Recommended nozzle viscosity”. From this intersection vertically to the temperature axis. There read the desired preheating temperature of 147° C.

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.

Recommendation The following maximum viscosities in relation to nozzle size are to be noted:

Example

In the area between the oil grade lines use:

Known:

A and B nozzles > 0.85 US-gph

Fuel oil viscosity: 300 mm 2 /s at 50° C

B and C nozzles > 2.00 US-gph and

Required:

over C nozzles > 3.00 US-gph.

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 mm 2 /s, from there parallel to the nearest fuel grade,

* Due to the components selected a preheating temperature of 160°C should not be exceeded.

27

Weishaupt products and service

We ishaupt products and service Max Weishaupt GmbH D - 88475 Schwendi Te l.: (07353) 830,

Max Weishaupt GmbH D - 88475 Schwendi Te l.: (07353) 830, Fax.: (07353) 83358 www.weishaupt.de

Print No. 83001802, July 2005 Printed in Germany. All rights reserved.

Neachells Lane, Willenhall, WV13 3RG Te l: (01902) 609841, Fax: (01902) 633343

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The innovative condensing boilers with the SCOT system:

Up to 240 kW

Efficient, low in emissions, versatile. Ideal for domestic heating. Fuel: Gas.

Solar systems Free energy from the sun:  

Solar systems

Free energy from the sun:

 

Perfectly coordinated components, innovative, proven. Pleasantly shaped flat roof collectors to support heating and of domestic water

W ater heater / energy reservoir T he attractive domestic water heating range includes classic

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

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. W eishaupt customer service is available 24/7. W

Service

Customer service completes the Weishaupt range. Weishaupt customer service is available 24/7. We’re there when you need us. Everywhere.