Pennram ESS™

JOB NAME: Eco Burn / EcoRom LLC

Ploiesti, Romania

Project ID - 1500 lbs/hr Medical Waste Plant

INCINERATOR MODEL # PHCA-1500-2100

SERIAL # 208181

System:
Incinerator PHCA -1500-2100 rated at 2100 lbs/hr or 955 kg/hr of 8500 btu waste &
rated at 1500 lbs/hr 681 kg/hr of 12000 btu medical waste
Heat Exchanger - input rated at 21,000 cfm / 595 m3 @ 760°C
output rated at 9,038 cfm / 256 m3 @ 171°C
7,603,000 btu/hr net heat transfer
Bag House - rated 10,500 cfm /297 m3 @ 190°C
maximum temperature 218°C

Wet Scrubber rated 11,000 cfm / 311 m3 @ 80°C

liquid tank capacity 451 gallons / 1.7 m3

Induced Draft Fan rated 13,000 cfm / 368 m3 @ 80°C & 18” w.c. static pressure
1572 rpm
outlet velocity 22.8 m/second
 1
INCINERATOR CHARGING / LOADING THE WASTE FEEDER

Load the incinerator in such a manner as to limit the operational capacity of the
system to 681 kgs (1500 lbs.) per hour average medical waste. The hopper should be
loaded with an average of 136 kgs. of waste per 12 minute cycle. The auto charge
sequence is set in motion by closing the hopper lid. The waste feeder will charge the
incinerator when the charge cycle timer times out at zero minutes and zero seconds,
and the temperature interlocks are satisfied.

NOTE: A “full weight” charge may not fill the hopper of the waste feeder.

Mix different types of waste when possible. Avoid placing glass into the incinerator if
possible. If this is unavoidable, save waste which is known to contain glass waste for
the end of the operational day. This procedure will help prevent molten glass from
adhering to the refractory liner of the incinerator due to a buffer of ash between the
glass and the refractory liner.

The auto charge sequence is set in motion by closing of all the waste feed interlocks.
These interlocks include the load timer, hopper lid closed indication, and minimum
secondary temperature of 1600°F-1800°F, access doors proven closed, heat
exchanger temperature interlocks, scrubber pH and water level interlocks, and APC
system temperature.

CAUTION
Keep hands and other body parts clear of ash rams, ash conveyor, and waste feeder
when the hydraulic system is in operation.

CAUTION
Lock out HYDRAULIC PUMP ENABLE SWITCH and remove key before servicing waste
feeder hopper door(lid), ash conveyor, ash rams, fire door, or charging ram.

INCINERATOR OPERATION

BEFORE start up manually run the ash conveyor forward for one minute to clear any
buildup of ashes from the tank bottom and to confirm ash conveyor operation.

PANEL CONTROLS

INCINERATOR START KEY SWITCH

Rotating of the SYSTEM START key engages the control system and initiates
the purge cycle. Before the system will start the following interlocks must be
satisfied:
 1) The primary and secondary chamber access door must be proven closed.
2) The automatic waste feeder fire door must be proven closed.
3) The automatic waste feeder hopper lid must be proven open.
4) The SYSTEM START key operated switch is rotated momentarily.

The start up sequence is as follows after the pressing SYSTEM START:

1) The combustion air blower(s) starts.
2) The incinerator completes the PURGE cycle and begins to PREHEAT.
3) The ID fan and heat exchanger cooling fan will start.
4) The scrubber tank will add water as required.
5) The bypass stack cap will automatically close with limits proven. The
position
of the stack cap is proven both “closed” and “not open” for various process
interlocks.
2

INCINERATOR MANUAL STOP PUSH BUTTON

Pressing of the SYSTEM STOP button will manually disengage the incinerator
control system. The feeder will not be disengaged if in mid-cycle. This button is
normally not used. Note that the incinerator is always, during normal operation
in
itʼs shutdown sequence. However this shutdown sequence is reset with each
waste
feed cycle.

PRIMARY BURNER No. 1 RESET PUSH BUTTON

PRIMARY BURNER No. 2 RESET PUSH BUTTON
SECONDARY BURNER No. 3 RESET PUSH BUTTON
SECONDARY BURNER No. 4 RESET PUSH BUTTON
Allows corresponding burner programmer to be reset in the event of a burner
flame failure.

PRIMARY BURNER No. 1 ON/OFF/AUTO SWITCH

PRIMARY BURNER No. 2 ON/OFF/AUTO SWITCH
SECONDARY BURNER No. 3 ON/OFF/AUTO SWITCH
SECONDARY BURNER No. 4 ON/OFF/AUTO SWITCH
This switch is usually in the AUTO position; in the OFF position the burner will
not run; in the ON position the burner will run continuously limited only by
temperature and fuel and combustion air proving interlocks.

HYDRAULIC SYSTEM AUTO/MANUAL SWITCH

In the MANUAL position, the charge ram, fire door, hopper lid, and ash ram
switches
are operational, and the waste feeder will not cycle automatically. In the AUTO
position, the waste feeder will cycle automatically (with the appropriate interlocks
proven); And the charge ram, fire door, and ash ram switches are disengaged.
The ash
conveyor and hopper lid control switches will operate in the auto or manual
position.
 The ash conveyor, however, will not operate during the waste feed cycle.

ASH CONVEYOR OFF / ENABLE SWITCH

This switch will enable to the ash conveyor to operate in the Auto, Forward, or
Reverse mode when in the ENABLE position. In the OFF position the ash
conveyor
will not operate. The belt conveyor runs in the forward direction anytime the ash
conveyor is operating.

ASH CONVEYOR FORWARD/ AUTO/ REVERSE SWITCH

IN THE AUTO position the ash conveyor will cycle forward only, for a timed
period as
set by panel mounted timer TD-8 located inside the control panel. The auto ash
conveyor cycle occurs after the waste feed sequence is complete and the hopper
lid
has opened. In the FORWARD position the ash conveyor will move forward, if
enabled, and no other limits stop the movement. In the REVERSE position the
ash
conveyor will move backward, if enabled, and no other limits stop the movement.
The ash conveyor will not operate during the waste feed cycle. The belt
conveyor
runs in the forward direction anytime the ash conveyor is operating.

UPPER ASH RAM EXTEND/RETRACT SWITCH

LOWER ASH RAM EXTEND/RETRACT SWITCH
This switch provides manual operation of the ash rams by the operator. The
HYDRAULIC SYSTEM AUTO/MANUAL SWITCH must be in the manual
position to operate this switch.

CHARGE RAM EXTEND/RETRACT SWITCH

This switch provides manual operation of charge ram by the operator (ram will
not extend unless fire door is fully open as indicated by the pilot lamp on the
graphic display). The HYDRAULIC SYSTEM AUTO/MANUAL SWITCH must
be in the manual position to operate this switch.

FIRE DOOR OPEN/CLOSE SWITCH

This switch provides manual operation of fire door by the operator (fire door will
not close unless charge ram is retracted to "clear" or “retract” position as
AUTO/MANUAL SWITCH must be in the manual position to operate this switch.

NOTE: Fire door and ram switches are intended to be used for servicing and for
occasional use by operators as needed, they are not intended to be used to
“force feed” the incinerator.

HOPPER LID OPEN/CLOSE BUTTONS (or remote control device buttons)

These push buttons provide manual operation of the hopper lid by the operator.
HYDRAULIC SYSTEM EMERGENCY SHUTDOWN PUSH/PULL BUTTON
Push in for hydraulic pump shutdown, pull out for normal operation.

HYDRAULIC PUMP OFF/ENABLE SWITCH LOCK

This switch prevents the waste feeder, and all hydraulic functions from being
operated during off-use hours by switching to OFF and removing the key.

STACK CAP PUSH TO OPEN MUSHROOM

This mushroom button is normally pulled out for normal operation. The button is
pushed in to open the emergency bypass stack cap, to bypass the heat
exchanger, baghouse, wet scrubber, ID fan, and scrubber exhaust stack.

MAIN - LOW PRESSURE COMBUSTION AIR BLOWER ON/OFF/AUTO SWITCH

This switch is usually in the AUTO position; in the OFF position the blower will
not run; in the ON position the blower will run continuously regardless of system
status or control interlocks. This blower supplies combustion air to the primary
and
secondary combustion air injection manifolds.

BURNER - HIGH PRESSURE COMBUSTION AIR BLOWER ON/OFF/AUTO SWITCH

This switch is usually in the AUTO position; in the OFF position the blower will
not run; in the ON position the blower will run continuously regardless of system
status or control interlocks. This blower supplies combustion air and atomizing
air
to the diesel /Diesel burners and gaseous fuel pilot burners.

INDUCED DRAFT FAN ON/OFF/AUTO

This switch is usually in the AUTO position; in the OFF position the blower will
not run; in the ON position the blower will run continuously regardless of system
status or control interlocks so long as the baghouse temperature is not over limit.
This blower pulls gases thru the stack system, thru the heat exchanger, thru the
bag house, thru the wet scrubber, and forces the cleaned waste gases
up the final exhaust stack. Due to the high starting load this blower motor is
operated by a variable frequency drive which will ramp up the acceleration over a
30
second period from 5 hz to the maximum frequency as determined by field set
up.
Actual flow thru this blower is limited by a butterfly valve in the blower outlet
modulated according to primary chamber negative pressure (vacuum)
4

COOLING FAN ON/OFF/AUTO

This switch is usually in the AUTO position; in the OFF position the blower will
not run; in the ON position the blower will run continuously regardless of system
status or control interlocks. This blower provides a constant but modulated
flow of ambient air to the heat exchanger which is cooling the incinerator gases
prior to entry to the bag house. Due to the high starting load this blower motor is
 operated by a variable frequency drive(VFD) which will ramp up the acceleration
over a 30
second period from 5 hz to the operating frequency as determined by the
temperature of the bag house inlet. The bag house temeprature controller
outputs a 4-20mA signal to the VFD to maintain a constant 150°-180°C bag house
temperature.

LIQUOR PUMP No. 1 ON/OFF/AUTO

LIQUOR PUMP No. 2 ON/OFF/AUTO
In the AUTO position the liquor pump will operate when the incinerator is in
operation, so long as the low water level safety switch in the scrubber is
satisfied. In
the ON position the liquor pump will operate continuously so long as the water
level
switch in the scrubber is satisfied. In the off position the liquor pump will not
operate.

CAUSTIC PUMP ON/OFF/AUTO

In the AUTO position the caustic pump will operate when the scrubber liquor pH
controller is indicating a pH value of 6 or lower. The pump will operate until the
pH value is above 7. In the ON position the caustic pump will operate
continuously. This on position is for testing purposes only. Do not leave the
chemical
pump on the on position. In the off position the caustic pump will not operate.

WASTE OIL INJECTOR PUMP ON/OFF/AUTO SWITCH

This switch is usually in the AUTO position, where as the pump operation is
interlocked to minimum & maximum incinerator temperature status and other
interlocks; in the OFF position the WASTE OIL INJECTOR PUMP will not run;
When in the ON position the WASTE OIL INJECTOR PUMP will run for a timed
maximum of 120 seconds, regardless of system status or control interlocks.
This pump supplies waste oil to the incinerator secondary waste oil injector. A
low level switch located at the tank will stop pump operation if waste oil tank level
is low.

DRAFT CONTROL DAMPER CLOSE / AUTO/ OPEN

This switch is usually in the AUTO position which permits the position of the draft
control damper on the ID Fan outlet to automatically adjust according to
incinerator
nagative pressure of negative 0.1”w.c. - 0.2”w.c. control pressure range. This
switch
allows the operator to force the draft damper full open or full closed for testing
purposes.

CAUTION: Use breaker switch(es) located inside the control panel to disconnect
power to burners, pumps, or blowers before servicing equipment.

ANNUNCIATOR TEST PUSHBUTTON

This button, when pushed in, will sound the audible alarm and cause all the
 annunciator lamps to illuminate.

ANNUNCIATOR SILENCE PUSHBUTTON

This button, when pushed in, will silence the audible alarm. Any additional alarm
conditions will again sound the audible alarm.

5
HOPPER SPRAY PUSH TO ACTIVATE PUSHBUTTON
This button, when pushed in, will energize the waste hopper water spray solenoid
valve. The hopper spray may be manually activated by opening the bypass valve
which is parallel to the waste hopper water spray solenoid valve.

HYDRAULIC SYSTEM AUTO DRIVE SEQUENCE (WASTE FEED CYCLE):

The auto forward sequence is set in motion by a combination of several factors:

1) charge timer counting down and locking at zero.
2) closing of the waste hopper lid by the operator
3) closing of incinerator feed interlocks, which may include temperature limits,
purge
cycle, stack cap proven closed, scrubber interlocks, bag house temperature
interlocks, and burner controls.
4) hydraulic system switch in the AUTO position.

The Sequence
HOPPER LID CLOSES - by operator using control panel button
SYSTEM proves all feed interlocks including time, temperature, and door status
interlocks mentioned above.

LOWER ASH RAM EXTENDS

The lower ash ram extends until the full extend limit switch LS6 is activated, or
until
the stroke timer TD-6 (inside control panel) times out, which ever occurs first. A
full
stroke of the ash ram is usually not required.

LOWER ASH RAM RETRACTS FULLY

UPPER ASH RAM EXTENDS

The upper ash ram extends until the full extend limit switch LS8 is activated, or
until
the stroke timer TD-7 (inside control panel) times out, which ever occurs first. A
full
stroke of the ash ram is usually not required.

UPPER ASH RAM RETRACTS FULLY

FIRE DOOR OPENS

CHARGE RAM EXTENDS FULLY
The waste feeder control system senses the force being applied to drive the
charge
ram forward, if this force surpasses a preset limit, the AUTO UNJAMMING
sequence is engaged, reversing the ram for a timed period and then returning the
waste feeder to the AUTO FORWARD sequence. The auto reverse sequence is
initiated when the charge ram reaches the full extend position.

CHARGE RAM RETRACTS to a position "CLEAR OF FIRE DOOR" and stops.

FIRE DOOR CLOSES

If fire door fails to fully close, the auto recycle sequence is engaged, reopening
the
fire door and recycling the ram. The auto recycle sequence will remain engaged
until the obstruction is cleared and the cycle is completed.

CHARGE RAM fully retracts.

HOPPER LID opens (automatic).

6
HYDRAULIC SYSTEM AUTO DRIVE SEQUENCE, continued:

ASH CONVEYOR runs FORWARD FOR A TIMED PERIOD (TD-8), if enabled.

MIST SPRAY
MIST SPRAYERS (six units installed in the waste hopper) are cycled under the
following conditions:
1) sprayers remain engaged for a timed cycle following the
closing of the fire door
2) sprayers are engaged by operator pressing the HOPPER SPRAY PUSH
TO
ACTIVATE PUSHBUTTON
3) sprayers are activated by a temperature sensor built into the wall of the
waste hopper which triggers the water spray solenoid valve above
160°F
4) sprayers may be activated by opening the bypass valve in the water
line

20-100 psi of water pressure is acceptable.

WASTE FEEDER(LOADER) DISABLED ALARM

ALARM feature is designed to alert the operator that the waste feeder has
jammed
and is not successfully correcting the problem on itʼs own. If waste feeder
DISABLED
alarm is annunciated, the HYDRAULIC SYSTEM switch is switched to the
MANUAL position, which should immediately be followed by correcting the waste
feeder problem using manual hydraulic switches.
Note: In a waste feeder disabled alarm situation, the first priority should be to secure
the fire door in the closed position.

Note: Hydraulic directional valves may be actuated manually if necessary by

pressing the “button” which is approximately 1/8” in diameter and is
located in the center of each hydraulic directional valve solenoid.

INCINERATOR CONTROL SYSTEM SEQUENCE

The operator will check that the fire door is closed, check that the primary chamber
access door is closed, check that the secondary chamber access door is closed, and
check that the waste feeder hopper lid is open. The system will not start if these
minimum conditions are not proven. The operator then switches the hydraulic
system switch to the auto position.

The operator rotates the SYSTEM START key.

After all limits are proven the MAIN combustion air blower, burner combustion air
blower will start and begin the PURGE cycle. The burner combustion air blower will
not shut off until the incinerator shuts itself off at the end of the dayʼs operation. The
MAIN combustion air blower will shut off at the end of the purge cycle and will not
restart until the initial load of waste is injected into the incinerator.

The bag house and wet scrubber ID fan and heat exchanger cooling fan begin
operation at this time.
7
INCINERATOR CONTROL SYSTEM SEQUENCE, continued:

During the PURGE cycle the primary and secondary combustion air manifold
dampers(2) open for approximately three minutes prior to ignition of the incineratorʼs
burners. The preheat cycle immediately follows the purge cycle.

In the event the primary temperature is above 1000°F at the time of start up the purge
cycle will be skipped. An example of this condition would be following a generator
test or following a power generator shutdown.

The PREHEAT cycle is indicated by the PREHEAT/ LOW TEMPERATURE LOCKOUT

lamp. The preheat cycle is temperature controlled and is maintained until the
secondary chamber temperature reaches 1000°C. At this time the incinerator is ready
to accept waste. The combustion air dampers close during the preheat cycle.
The INCINERATE lamp will illuminate after the preheat cycle and after the first load of
waste is injected into the incinerator.

The high pressure BURNER COMBUSTION AIR BLOWER provides combustion air and
atomizing air to the three secondary chamber burners and the two primary chamber
burners and to the waste oil injector. This high pressure combustion air blower
cycles on during the purge cycle and cycles off four hours after the last load of waste
is injected into the incinerator.

The low pressure MAIN COMBUSTION AIR BLOWER provides combustion air to the
secondary chamber air manifold, and all of the primary chamber air manifolds. This
combustion air blower cycles on during the purge cycle, off during the preheat cycle,
back on after the first load of waste is injected into thge primary chamber, and cycles
off four hours after the last load of waste is injected into the incinerator.

The PRIMARY COMBUSTION AIR PRESSURE CONTROL VALVE operates on a time

delay following the closing of the fire door after each charge. The primary air
pressure may be manually adjusted by moving the linkage of the flow control valve.
This modulating butterfly damper valve may be initially set to provide 4.0” w.c.
manifold air pressure and may require an increase in pressure for improved ash
quality or a decrease in pressure for smoke control. The primary combustion air
pressure control valve modulates to low pressure / off when the primary chamber
rises above 925°C and remains at the low pressure position until the primary chamber
temperature cools to 900°C. The primary combustion air valve opens when the
incinerator is off line for additional cooling purposes and to help eliminate glowing
embers.

The SECONDARY COMBUSTION AIR is controlled with a motorized modulating

butterfly damper which modulates according to the position of the BIAS AIR
POTENTIOMETER and opens as secondary exhaust temperature increases. The
temperature increase is a result of, and an indicator of, an increased presence of fuel
derived from the waste. Approximately 80% of the waste placed in the incinerator is
oxidized in the secondary chamber. Carbon “vapors” driven from the waste in the
primary chamber are oxidized in the secondary chamber. The process has potential
to produce temperatures in the 3000°F. range especially when the excess air is
controlled.

8
INCINERATOR CONTROL SYSTEM SEQUENCE, continued:

The SECONDARY COMBUSTION AIR is controlled with a motorized modulating

butterfly damper which modulates open as the temperature in the secondary chamber
increases. The damper is fully open during the purge cycle.. The air pressure in the
secondary combustion air manifold is biased (higher pressure) during a timed period
following each charge of waste into the incinerator. The purpose of bias air is to burn
the peak flow of hydrocarbons which vaporize from the waste upon initial placement
into
the incinerator. Later in the cycle less air is needed and the motorized air damper
returns to the normal modulated setting.

SECONDARY COMBUSTION AIR

As the exhaust temperature rises from 870°C toward 1100°C, the secondary
combustion air control damper modulates from 5% open to fully open. Since the
secondary diesel
burners are modulated off by the mid 1030s°C, then continually rising temperatures
indicate an increase in carbon vapor volume being generated in the primary chamber.
As such more oxygen is required to oxidize the vapor. The opposite is so as the
temperature in the secondary chamber is reduced, less air is needed.

SECONDARY COMBUSTION AIR/ BIAS AIR SIGNAL

The air pressure in the secondary combustion air manifold is biased (higher pressure)
open during a timed period following each new charge of waste into the incinerator.
The purpose of bias air is to burn the peak flow of hydrocarbons which vaporize from
the waste upon initial placement into the incinerator. This initial peak of hydrocarbon
vapor generation will require extra oxygen (air) before either the oxygen cell or
thermocouple have time to react and adjust the secondary air damper. This is the
purpose of the bias air signal. The bias air value is controlled by the position of the
BIAS AIR POTENTIOMETER which is located inside the control panel.

The incinerator is so equipped with four(4) air atomized full modulating natural gas /
diesel burners. The burners are numbered 1 thru 4. The numbers assigned are
based on flow through the incinerator. Primary burner no. 1 is located near the
feeder. Primary burner no. 2 is located in the center of the chamber. The secondary
burners are accessed from the platform. Secondary burner no. 3 is located on the
end above the ash conveyor. Secondary burner no. 4 is located nearest to the stack
exhaust connection.

The SECONDARY BURNERS are of the full modulating type which modulate according
to the exhaust temperature of the secondary chamber, see chart below. The
secondary burners are disabled two hours after waste feeding stops. The fuel/air
mixture and rate of input is continuously modulated to provide process heat as
required to the secondary combustion chamber to maintain the minimum exhaust
temperature. The burners may cycle off during the incineration process if the waste
is generating sufficient heat to maintain minimum temperatures.

The PRIMARY BURNERS are of the full modulating type which modulates according to
the exhaust temperature of the primary chamber, see chart below The primary
burners cycle off while the fire door is open and for a timed following each charge of
waste into the primary chamber. After the fire door closes and with all other limits
satisfied the primary burner no. 3 ignites after a 1 minute delay, burner no. 2 ignites
after a 1-1/2 minute delay, and burner no. 3 ignites after a 2 minute delay. The
burners cycles off when any access door is opened and while either ash ram is not
proven fully retracted.. The primary burners are disabled two hours after waste
feeding stops.
 9
INCINERATOR CONTROL SYSTEM SEQUENCE, continued:

Control Parameter Normal Modulation Range OFF at / ON at limits

Primary Burner No. 1 650°C to 700°C 745°C 720°C
Primary Burner No. 2 650°C to 700°C 775°C 745°C

Secondary Burner No. 3 1000°C to 1015°C 1032°C 1021°C

Secondary Burner No. 4 1000°C to 1015°C 1020°C 1010°C

SOLID WASTE CHARGING is locked out if any of the following conditions exist:
A. Primary chamber climbs above 1100°C. (Primary high temperature lockout)
B. Bag house climbs above 205°C.
C. Secondary chamber climbs above 1100°C. (Secondary high temperature lockout)
D. Secondary chamber falls below 1000° C. (Secondary low temperature lockout)
E. Charge timer has not engaged.
F. Hydraulic pump controls in manual or off.
G. System is off line.
H. Stack cap is open
I. Any incinerator door is open.
J. Wet scrubber low water
K. Wet Scrubber low pH

BURNER OPERATION INFORMATION

All the primary burners and secondary burners have full modulation of fuel and
combustion air. All four burners operate in an identical manner. The main fuel is
ignited by a proven gaseous fueled pilot flame. The pilot flame is ignited by an
electrical arc fired by the ignition electrode (spark plug) installed on the burner
housing. The electrical arc ignites the pilot. The flame is proven by means of an ultra
violet light scanner installed on the burner housing. The scanner can only “see” the
flame while the pilot or fuel valve is open.

The purple colored UV scanner device senses a flame signal to the Honeywell burner
controller installed in the control panel. The flame signal may be tested by inserting a
DC volt meter lead(s) into the positive(+) and negative(-) test jacks on the Honeywell
flame controller installed in the control panel. A steady signal of 1.25 vdc to 5.0 vdc is
acceptable. If a low signal is present (under 1.25vdc) or no signal is present. Check the
appropriate scanner relays for operation. Check wiring. Check the scanner eye for dirt
(wipe only with clean tissue, do not touch the eye.) Check for spark at the ignition
electrode.

The combustion air and fuel are modulated from high to low fire with a Honeywell
damper motor coupled to the combustion air butterfly valve and natural gas butterfly
flow control valve based on a 4-20mA analog signal originating in the corresponding
temperature controller.
Pilot gas flow is controlled by the pilot gas regulator and pilot gas butterfly valve. The
pilot air shall remain fully open at all times. The pilot gas butterfly valve is adjusted to
form a small pilot flame. The pilot flame should be maintainable at any burner
combustion air pressure.

An air purge is supplied to the UV scanner tube to prevent dirt and heat from contacting
the UV scanner lens.

See specific operating data for the burners and temperature controls at the end of this
section. 10
INCINERATOR CONTROL SYSTEM SEQUENCE, continued:

After the dayʼs waste is consumed, the operator closes the hopper lid and switches
the hydraulic system to manual. Two hours after doing so, the burners will be
disabled. Two hours later the incinerator combustion air blower will cycle off. The
incinerator system, 4 hours after the last load of waste is injected into the primary
chamber is now off line.

The COOLING CYCLE lamp will illuminate the final 2 hours of operation.

AIR to AIR HEAT EXCHANGER OPERATION- Gas cooling:

The clear waste gases (products of combustion) exit the incinerator relatively clean,
smoke free, but at a high temperature, in excess of 1000°C. In order that the
emissions from the incinerator are able to meet the EU and US EPA clean air
regulations, filtration devices are employed. The maximum inlet temperature of these
devices is 200°C. As such as the gases exiting the incinerator are at a much higher
temperature than what is allowable in the filtration process, gas cooling is required.
The extreme heat is radiated thru the shell of the ductwork to the air to air heat
exchanger. The gas temperature is lowered to approximately 750°C by the intial
radiation duct work. The air to air heat exchanger is fabricated of high grade nickel
alloy. The exchanger section flows ambient cooling air as required to reduce the waste
gas temperature to a controlled 150°-180°C as measured at the bag house inlet. A
variable frequency drive(VFD) unit reacts to the incoming bag house temperature to
control the speed and flow from the cooling air blower. Waste gases thus exit the air to
air heat exchanger at a control temperature. The cooling air is heated in the process
to approximately 375°C and exhausted to the atmosphere. The base of the air to air
heat exchanger is supported by a clean out holding box in whcih gases are turned 180°
and in which large particles are collected and deposited in the box. The box and air
to air heat exchanger are equipped with access doors for cleaning purposes.
Frequency of cleaning is suggested initially each two weeks, until operation determines
the frequency of cleaning required. Thi cleaning cycle varies from site to site. An
interconnecting unlined stainless steel duct then routes the cooled waste gases to the
baghouse inlet.
BAGHOUSE DUST COLLECTOR SYSTEM

The baghouse dust collector uses special fabric filters to collect approximately 95-99%
of remaining microscopic and larger dust particles and heavy metals that pass through
the air to air heat exchanger. The bag house is operated at a temperature sufficient to
prevent condensation of acid compounds in its interior surfaces. The dust collector
contains approximately 260 pcs of a fabric “bag” which is 15cm in diameter and 180cm
in length.
The gases pass through the exterior side of the bags and exit at the end of the interior
side. Filtered particles collect on the outside of the bags. A rotary screw air
compressor and air dryer supply compressed air to teh baghouse for bag cleaing. On
a user adjustable timer control automatic reverse pulse of compressed air is applied to
the inside of the bags to clean the collected dust from the outside surface of the bags.
This reverse pulse dust drops to the base of the baghouse hopper. Once each day a
manual slide valve is opened to drop the collected dust into a drum for proper disposal.

11
INCINERATOR CONTROL SYSTEM SEQUENCE, continued:

WET SCRUBBER OPERATION

The purpose of the scrubbing system is to remove acid producing compounds from
the waste gas stream. This scrubbing apparatus is required under this contract
according to emission performance data.

Waste gases exit the baghouse and enter a gas quenching chamber where the
temperature is reduced to 80°C. Scrubber liquor is sprayed into the quench chamber
using several 3/4 npt clog resistant wide angle spray heads rated at 10 gpm each
operating at 30 psi. The scrubbing process begins at this point although the primary
purpose of the gas quenching chamber is for cooling purposes. Excess scrubbing
liquor (scrubber water) drains back to the tank in the same duct as the gases.

Cooled waste gases enter the scrubber tower above the tank and below the separator
plate. The separator plate is the point where acid producing compounds are
neutralized
and separated from the waste gas. The scrubber has one separation plate where
approximately 99% of acid pollutants are removed. The separator plate is perforated
with approximately 1500 directional holes approximately 5mm in diameter. The top
side of the plate is continuously flooded with scrubbing liquor. Waste gases pass up
through the plate from the bottom side and are propelled though the scrubbing liquor.
The liquor level is maintained at about 10cm by 1-1/2 npt clog resistant wide angle
spray head rated at 25 gpm operating at 30 psi. Excess liquor overflows the
separator plate and drains back to the tank.

The pH of the liquor is maintained by an injection of 50% solution of caustic which is

pumped on demand using a common peristaltic pump or “tube” pump. The pH level
of the liquor is maintained at 6 to 7. The process of neutralizing acids creates salts
and increases the density of the liquor, this is further complicated by the evaporation
of water in the liquor. For this reason, the liquor tank is blown down to the drain via a
2” automatic drain valve. The drain valve close time TD9 and open time TD10 are user
adjustable via timers. TD9 controls the valve closed time, typically two hours. Timer
TD10 controls the blowdown valve open time, typically 2-5 minutes. In the event the
temperature of liquor rises above 85°C, fresh water will be introduced to the tank.
Excess water in the tank will pass to the drain via the overflow piping.

Fresh water is introduced into the scrubber as required by float activated switches.
The water feed valve is controlled by a level switch and certain commands from the
PLC.

The cleaned waste gases then are routed to the Induced draft fan inlet and blown up
the stack. Water vapor will condense on the walls of the stack and drain back to the
tank. The outlet of the scrubber stack is equipped with a trap to prevent condensed
water from being “blown” into the surrounding area.

The scrubber liquor to the quench chamber and the separator plate is supplied by
two(2)
3 hp pumps, each capable of delivering 60 gpm at 20 ft. of head. The pump is capable
of passing solids up to 0.375 inches in diameter. The 3/4” spray nozzles will pass
objects up to 0.28 inches in diameter. And the 1-1/2” spray nozzles will pass objects
up to 0.62 inches in diameter.

12
WET SCRUBBER OPERATION, continued:

A motorized butterfly valve is positioned in the final exhaust stack to control the rate
of final exhaust gas flow. The damper motor is responding to changes in pressure in
the primary chamber of the incinerator. During high flow demand periods the draft
damper opens which increases the scrubberʼs capacity for waste gas flow from the
incinerator. And, during lower flow demand periods the draft damper closes which
decreases the scrubberʼs capacity for waste gas flow from the incinerator.

After the dayʼs waste is consumed, the operator switches the closes the hopper lid
and switches the hydraulic system to manual. Two hours after doing so, the burners
will be disabled. Two hours later the scrubber, bag house, and incinerator blowers
will cycle off and the stack cap will open. The incinerator system, 4 hours after the
last load of waste is injected into the primary chamber is now off line.

The COOLING CYCLE lamp will illuminate the final 2 hours of operation.
NOTE: Mixing of caustic soda is not required. Purchase the caustic soda(NaOH)
from a chemical supplier in a 50% solution. When one drum is empty, pull the plastic
suction tubing from the empty drum and place it inside the full drum. Make sure the
tubing goes to the bottom of the drum.

It is recommended that the ph sensor is recalibrated once per week minimum to

prevent damage to teh wet scrubber apparatus.

DO NOT OPERATE THE WET SCRUBBER WITH OUT SUPPLY OF CAUSTIC

SODA(NAOH) OR WITH CAUSTIC SODA IN FROZEN STATE, EQUIPMENT DAMAGE
WILL RESULT. IF REQUIRED, DURING COLD WEATHER APPLY HEAT TO THE
CAUSTIC SODA CONTAINER TO PREVENT FREEZING OF THE CAUSTIC SODA
SOLUTION.

CAUTION: Do not touch the caustic or suction tubing with your bare hands. Chemical
burns will result. Wear gloves, safety glasses and protective clothing when handling
caustic drums or tubing from with in the caustic drum.

NOTE: DARK Visible emission at the stack is usually associated with over charging
the
incinerator, excessive air leakage into the primary chamber, or failed combustion
air delivery components to the secondary chamber. Seek factory assistance in
the
unlikely event that visible emission is experienced on a routine basis.

13
ANNUNCIATOR ALARMS AND CORRECTIVE MEASURES:

PRIMARY BURNER No. 1 FLAME FAILURE:

Primary burner has failed to light. Press PRIMARY BURNER No. 1 RESET button up
to three times waiting 10 seconds before pressing a 2nd or third time. Confirm the
alarm goes off an the burner attempts to relight after pressing the RESET button.
Turn off the burner using the control panel switch and wait one minute before
resetting a second or third time. If burner still fails to light, check pilot gas supply
and confirm valve at pilot fuel tank is open, check visual pilot operation, check
electronic eye of UV scanner for dirt, check for pilot gas pressure and flow, check for
pilot air pressure and flow, gas pressure or air pressure interlocks, check diesel fuel
tank level, check diesel pump operation, check diesel pressure interlock,
check flame signal for 1.25-5.0 vdc, remove ignition spark plug from pilot assembly
and check for spark (do not hold spark plug during test), or seek service.

SECONDARY BURNER No. 2 FLAME FAILURE:

Primary burner has failed to light. Press SECONDARY BURNER No. 3 RESET button
up to three times waiting 10 seconds before pressing a 2nd or third time. Confirm the
alarm goes off an the burner attempts to relight after pressing the RESET button.
Turn off the burner using the control panel switch and wait one minute before
resetting a second or third time. If burner still fails to light, check pilot gas supply
and confirm valve at pilot fuel tank is open, check visual pilot operation, check
electronic eye of UV scanner for dirt, check for pilot gas pressure and flow, check for
pilot air pressure and flow, gas pressure or air pressure interlocks, check diesel fuel
tank level, check diesel pump operation, check diesel pressure interlock,
check flame signal for 1.25-5.0 vdc, remove ignition spark plug from pilot assembly
and check for spark (do not hold spark plug during test), or seek service.

SECONDARY BURNER No. 3 FLAME FAILURE:

Primary burner has failed to light. Press SECONDARY BURNER No. 3 RESET button
up to three times waiting 10 seconds before pressing a 2nd or third time. Confirm the
alarm goes off an the burner attempts to relight after pressing the RESET button.
Turn off the burner using the control panel switch and wait one minute before
resetting a second or third time. If burner still fails to light, check pilot gas supply
and confirm valve at pilot fuel tank is open, check visual pilot operation, check
electronic eye of UV scanner for dirt, check for pilot gas pressure and flow, check for
pilot air pressure and flow, gas pressure or air pressure interlocks, check diesel fuel
tank level, check diesel pump operation, check diesel pressure interlock,
check flame signal for 1.25-5.0 vdc, remove ignition spark plug from pilot assembly
and check for spark (do not hold spark plug during test), or seek service.

SECONDARY BURNER No. 4 FLAME FAILURE:

Primary burner has failed to light. Press SECONDARY BURNER No. 4 RESET button
up to three times waiting 10 seconds before pressing a 2nd or third time. Confirm the
alarm goes off an the burner attempts to relight after pressing the RESET button.
Turn off the burner using the control panel switch and wait one minute before
resetting a second or third time. If burner still fails to light, check pilot gas supply
and confirm valve at pilot fuel tank is open, check visual pilot operation, check
electronic eye of UV scanner for dirt, check for pilot gas pressure and flow, check for
pilot air pressure and flow, gas pressure or air pressure interlocks, check diesel fuel
tank level, check diesel pump operation, check diesel pressure interlock,
check flame signal for 1.25-5.0 vdc, remove ignition spark plug from pilot assembly
and check for spark (do not hold spark plug during test), or seek service.

14
ANNUNCIATOR ALARMS AND CORRECTIVE MEASURES, continued:

ASH RAM OUT

The ash ram has failed to return to the full retract position. This condition may cause
permanent damage to the ash ram tubes. Check ash ram directional valves, position
proving switches, and hydraulic pump or e-stop switches. Take the appropriate
action to retract the ash ram from the primary chamber. The primary burner will not
fire while in this condition.

LOADER DISABLED ALARM

This alarm feature is designed to alert operator that loader has jammed or failed the
auto loading sequence in some form. If LOADER DISABLED alarm is annunciated, the
HYDRAULIC SYSTEM switch is switched to the MANUAL position, which should
immediately be followed by correcting loader problem using manual hydraulic
switches. In
a loader disabled situation, the first priority should be to secure the fire door in the
closed position. Then check for obstruction, check limit switches by proving the
physical position of each component and check that the appropriate lamp on the
control panel is illuminated indicating that the limit switch or position sensor is
working. Check hydraulic pump pressure. Check hydraulic pump overload relay.
Check circuit breaker for hydraulic pump. Or Seek service.

SCRUBBER TANK LOW FLUID LEVEL

The liquid level in the scrubber tank is low. This caused the liquor pump to stop
operation, the stack cap to open, and the feed system to lock out. Check output
relays, wiring, water supply pressure, and water supply valves, and water level control
switch.

SCRUBBER LOW pH
The liquor in the scrubber tank is becoming acidic. The caustic pump has stopped
operation or the caustic solution barrel is empty. Check caustic supply barrel level,
output relays, pump tubing, wiring, and pump switch.

SCRUBBER INDUCED DRAFT FAN HIGH TEMP

The inlet temperature of the scrubber fan has exceeded 180°C. This caused the stack
cap to open, and the feed system to lock out. Check the water level floats, fan
temperature probe, scrubber tank drain valve, scrubber liquor pump operation.

CHECK STACK CAP

Stack cap has not fully closed. This prevents the system from running. Check
hydraulic system operation, stack cap open pushbutton position, stack cap limit
switches. Or the stack cap did not fully open when commanded to do so.

LOW DRAFT
The pressure with in the primary chamber is too high. This caused the stack cap to
open, primary burner and combustion air to shut off, and the feed system to lock out.
Check draft damper operation by switching full open and closed. Check that heat
exchanger is not plugged or plugging, cleaning may be required.

ID FAN OVERLOAD
The APC ID fan is supposed to be running, but one or more running interlocks has
opened. The interlocks include high cyclone temperature, motor overload, and the
variable speed drive control. Check for variable speed drive operation. Shut off ID
FAN control panel switch and then turn the switch on again, and attempt to restart
after investigating.

15
ANNUNCIATOR ALARMS AND CORRECTIVE MEASURES, continued:

COOLING OVERLOAD
The COOLING fan is supposed to be running, but one or more running interlocks has
opened. The interlocks include, motor overload, and the variable speed drive control.
Check for variable speed drive operation. Shut off COOLING FAN control panel
switch and then turn the switch on again, and attempt to restart after investigating.

ASH CONVEYOR OVERLOAD

The ash conveyor shaft rotation switch did not/make/break while the ash conveyor
was commanded to run. Check that the needle valve is not closed or closed to far.
Check that the hydraulic system is generating pressure. Check that the hydraulic
directional valve is opening (by observe the hydraulic hoses “jumping” at the
conveyor motors when the conveyor is commanded to run is given). Check that the
conveyor will run reverse then forward again. Forward and reverse operation will
usually clear a jamb.

BAG HOUSE HIGH TEMP

The inlet temperature of the cyclone fan has exceeded 205°C. This caused the stack
cap to open, and the feed system to lock out. Check the operation of the heat
exchanger cooling fan.
 16
MAINTENANCE

DAILY OPERATE ash conveyor one full chain revolution every day

CHECK fly ash level in HEAT EXCHANGER BOX, empty as required.

Open Baghouse hopper slide gates & check fly ash level in hopper
drums empty as required.

WEEKLY: CALIBRATE pH sensor using pH 4, 7, 10 test solutions

CHECK hydraulic system for leaks and CHECK hydraulic fluid level.
DO NOT USE CONVENTIONAL HYDRAULIC FLUID. USE ONLY
FIRE RETARDANT WATER GLYCOL HYDRAULIC FLUID

CLEAN debris from beneath base of fire door

ROD THRU external primary air jets on the lower hearth level, there are
multiple air jets per manifold, there is one air manifold on each side of
the lower hearth. Use 1/2” diameter x 12” length cleaning rod*

CHECK for accumulation of fly ash under and inside heat exchanger.
The
frequency of this check may have to be altered as required after
operation
is established.

MONTHLY: CHECK and change as necessary rope gasket beneath base of fire
door.

CHECK and add ringes to ash conveyor packing as required, do not

overtighten packing. Add antiseize past to ash ram tube surface with
new
packing to prevent sticking and tearing of packing.

VACUUM primary chamber and apply coating of Satanite mortar as

required. Coat the hearth with a sacrificial layer or mortar to prevent
 glass adhesion to the refractory lining. Experience will determine if
this
practice should continue.

ROD THRU internal primary air jets on the two upper hearth level, there
are fifteen air jets per manifold, there are three air manifolds on per
hearth,
there is one air jet in the center and seven jets on either side of center
jet,
On the middle hearth the jets spaced 4” apart,
On the upper hearth the jets spaced 4.75” apart,
use 3/8” diameter x 12” length cleaning rod

CHECK output pressure of primary chamber combustion air manifold

CHANGE as necessary rope gaskets on primary chamber door(1), and

waste feeder door(4)

SEMI- ANNUALLY: GREASE bearings on all blowers:

17
HYDRAULIC SYSTEM NOTES

NOTE: Hydraulic directional valves may be actuated manually if necessary by

pressing the “button” which is approximately 1/8” in diameter and is located in the
center of each
directional valve solenoid. If hydraulic components appear to move in an irregular
fashion, check that speed/flow control valves are not closed or partially plugged. The
debris that occasionally collects in the valve my be flushed to the tank by fully
opening the valve and operating the cylinder. Following flush, readjust the valve until
the cylinder runs at the desired speed. Speed is adjustable in both directions for the
hopper lid cylinder.

ASH CONVEYOR NOTES

Max continuous hydraulic operating pressure at the motors is 1300 PSI.

IMPORTANT- The ash conveyor chain is designed to run underwater.

To prevent seizing of the chain due to dried solids in the pin assemblies:
•Be certain the conveyor chain moves everyday.
 •If the incinerator is offline for an extended period then have operators run the
conveyor chain at least one full rotation each day, with water in the tank.

•DO not allow chain and tank to totally dry out with out a thorough rinse of the chain
link pins.

LOAD TIMER PROGRAM TD5:

SP = 1100
Dip switch set up:
on: 1, 2, 3, 5, 7 off: 4, 6, 8

18
TEMPERATURE CONTROLLER PROGRAMS
Temperature Controller Program Settings: TIC-1A, TIC-1B PRIMARY

To gain access to configuration mode parameters you must press and hold the “set up”
key and while holding the “set up” key momentarily press the “∆” key. The lower display
will indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates ConF. Now press the “set up” key. The lower display will indicate ULoc, enter
20 using the “∆/V” keys, press the “set up” key again. You are now in the configuration
mode. Us the “set up” ket to enter values and scroll to the next menu item.

To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

PRI TIC-1A(air) PRI TIC-1B(burner)

model 111 711..
 Configuration menu (initial upper display ConF, lower display SLCt)
ULoc 20 20
InPt YC YC
ruL 1373 1373

rLL -240 -240

CtyP SnGL SnGL
CtrL rev? (SP1 on below rev
set point)
ALA1 factory default P Lo
PLA1(sp3) factory default 787°C(1450°F)
(spare) (burner 2 limit)
AHY1(SP3 dif) 1 10

ALA2 P Hi P Lo
PLA2(sp2) 1038°C(1900°F) 760°C(1400°F)
(pri H2O spray limit) (burner 1 limit)
AHY2(SP2 dif) 20 10

LAEn diSA diSA

Inhi none none
USE1 Pri Pri

tyP1 no parameter 4-20

USE2 A2 d A2 d
USE2 A1 d A1 d

diSP 4 4
CLoc 20 20

Setpoint menu: press set up key, change value, enter by pressing set up key again
SP 925°C(1700°F) 704°C(1300°F)
(air limit) (pri burner
modulation)
19
TEMPERATURE CONTROLLER PROGRAMS

Temperature Controller Program Settings: TIC-1A, TIC-1B PRIMARY

To gain access to Set Up mode parameters you must press and hold the “set up” key and
while holding the “set up” key momentarily press the “∆” key. The lower display will
indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates SEtP. Now press the “set up” key. The lower display will indicate ULoc, enter 10
using the “∆/V” keys, press the “set up” key again. You are now in the set up mode. Us
the “set up” ket to enter values and scroll to the next menu item.
To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

PRI TIC-1A(air) PRI TIC-1B(burner)

Set Up menu (initial upper display SEtP, lower display SLCt

ULOC 10 10
FILE 2.0 2.0
OFFS 0 0

PPLJ 0 0
Pb p 0 3.4
ArSt no parameter off(100+)
diF 2.0 no parameter
rAtE no parameter 0.00
biAS 0 0
SPuL 1373 1373

SPLL -240 -240

OPuL 100 100

PLA1(sp3) factory default 787°C(1450°F)

(spare) (burner 2 limit)
AHY1(SP3 dif) 1 10

PLA2(sp2) 1038°C(1900°F) 760°C(1400°F)

(pri air limit) (burner 1 limit)
AHY2(SP2 dif) 20 10

APt diSA diSA

PoEn diSA diSA

SPr diSA diSA
rP Off Off

20
TEMPERATURE CONTROLLER PROGRAMS

Temperature Controller Program Settings: TIC-2A & TIC-2B SECONDARY

To gain access to configuration mode parameters you must press and hold the “set up”
key and while holding the “set up” key momentarily press the “∆” key. The lower display
will indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates ConF. Now press the “set up” key. The lower display will indicate ULoc, enter
20 using the “∆/V” keys, press the “set up” key again. You are now in the configuration
mode. Us the “set up” ket to enter values and scroll to the next menu item.

To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

SEC -TIC-2A(air) SEC -TIC-2B(burner)

model 711 711

Configuration menu (initial upper display ConF, lower display SLCt)

ULoc 20 20
InPt YC YC
ruL 1373 1373

rLL -240 -240

CtyP SnGL SnGL
CtrL dir rev

ALA1 P Lo P Lo
PLA1(sp3) 1226°C(2240°F) 1210°C(2228°F)
(sec high temp) (burner 4 limit)
AHY1(SP3 dif) 3 5

ALA2 P Hi P Lo
PLA2(sp2) 1000°C(1832°F) 1220°C(2210°F)
(low temp lock) (burner 3 limit)
AHY2(SP2 dif) 3 5

LAEn diSA diSA

Inhi none none
USE1 Pri Pri

tyP1 4-20 4-20

USE2 A2 d A2 d
USE2 A1 d A1 d

diSP 4 4
CLoc 20 20

Setpoint menu: press set up key, change value, enter by pressing set up key again
SP 950°C (1740°F) 1200°C (2192°F)
(sec comb (sec burner
air modulation) modulation)
21
TEMPERATURE CONTROLLER PROGRAMS

Temperature Controller Program Settings: TIC-2A & TIC-2B SECONDARY

To gain access to Set Up mode parameters you must press and hold the “set up” key and
while holding the “set up” key momentarily press the “∆” key. The lower display will
indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates SEtP. Now press the “set up” key. The lower display will indicate ULoc, enter 10
using the “∆/V” keys, press the “set up” key again. You are now in the set up mode. Us
the “set up” ket to enter values and scroll to the next menu item.

To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

SEC -TIC-2A(air) SEC -TIC-2B(burner)

Set Up menu (initial upper display SEtP, lower display SLCt

ULOC 10 10
FILE 2.0 2.0
OFFS 0 0

PPLJ 0 0
Pb p 17.1 1.0
ArSt off(100+) off(100+)
diF no parameter no parameter
rAtE 0.00 0.00
biAS 0 0
SPuL 1373 1373

SPLL -240 -240

OPuL 100 100

PLA1(sp3) 1226°C(2240°F) 1210°C(2228°F)

(sec high temp) (burner 4 limit)
AHY1(SP3 dif) 3 5

PLA2(sp2) 1000°C(1832°F) 1220°C(2210°F)

(low temp lock) (burner 3 limit)
AHY2(SP2 dif) 3 5

APt diSA diSA

PoEn diSA diSA
SPr diSA diSA
rP Off Off
 22
TEMPERATURE CONTROLLER PROGRAMS

Temperature Controller Program Settings: TIC-3 BAGHOUSE & TIC-4 SCRUBBER

To gain access to configuration mode parameters you must press and hold the “set up”
key and while holding the “set up” key momentarily press the “∆” key. The lower display
will indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates ConF. Now press the “set up” key. The lower display will indicate ULoc, enter
20 using the “∆/V” keys, press the “set up” key again. You are now in the configuration
mode. Us the “set up” ket to enter values and scroll to the next menu item.

To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

TIC-3 BAGHOUSE TIC-4 SCRUBBER

model 711 111

Configuration menu (initial upper display ConF, lower display SLCt)

ULoc 20 20
InPt YC YC
ruL 1373 1373

rLL -240 -240

CtyP SnGL SnGL
CtrL dir rev? (SP1 on below set point)

ALA1 default setting default setting

PLA1(sp3) default setting default setting
(spare) (spare)
AHY1(SP3 dif) 1 1

ALA2 P Hi default setting

PLA2(sp2) 149°C(300°F) default setting
(cooling fan limit) (spare)
AHY2(SP2 dif) 5 1

LAEn diSA diSA

Inhi none none
USE1 Pri Pri

tyP1 4-20 4-20

 USE2 A2 d A2 d
USE2 A1 d A1 d

diSP 4 4
CLoc 20 20

Setpoint menu: press set up key, change value, enter by pressing set up key again
SP 155°C(310°F) 91°C(195°F)
(cooling air (ID fan limit
fan speed control)

23
TEMPERATURE CONTROLLER PROGRAMS SECTION G
Page 6

Temperature Controller Program Settings: TIC-3 BAGHOUSE & TIC-4 SCRUBBER

To gain access to Set Up mode parameters you must press and hold the “set up” key and
while holding the “set up” key momentarily press the “∆” key. The lower display will
indicate SLCt. Scroll through the menu by pressing the “∆” key until the upper display
indicates SEtP. Now press the “set up” key. The lower display will indicate ULoc, enter 10
using the “∆/V” keys, press the “set up” key again. You are now in the set up mode. Us
the “set up” ket to enter values and scroll to the next menu item.

To exit you must press and hold the “set up” key and while holding the “set up” key
momentarily press the “∆” key. The lower display will indicate SLCt. Scroll through the
menu by pressing the “∆” key until the upper display indicates OPtr. Now press the “set
up” key. You are now back to display/normal operation.

TIC-3 BAGHOUSE TIC-4 SCRUBBER

Set Up menu (initial upper display SEtP, lower display SLCt

ULOC 10 10
FILE 2.0 2.0
OFFS 0 0

PPLJ 0 0
Pb p 2.1 0
ArSt off(100+) no parameter
diF no parameter 2.0
rAtE 0.00 no parameter
biAS 0 0
SPuL 1373 1373

SPLL -240 -240

OPuL 100 100

PLA1(sp3) default setting default setting

 (spare) (spare)
AHY1(SP3 dif) 1 1

PLA2(sp2) 149°C(300°F) default setting

(cooling fan limit) (spare)
AHY2(SP2 dif) 5 1

APt diSA diSA

PoEn diSA diSA
SPr diSA diSA
rP Off Off

24
Combustion Air/ Burner / Hydraulic Set Up

Secondary combustion air damper linkage adjustment: (purge)

Maximum output: 20 mA full open
Minimum output: 4 mA full closed

Primary combustion air linkage adjustment:

De-energize manifold pressure 0.0”w.c.
Energize manifold pressure 5.0” w.c.

Primary burner No. 1 & combustion air damper linkage adjustment:

located closed to feeder - 1,000,000 btu/hr maximum

Burner model number Eclipse TJ-100, 1,000,000 btu/hr
High fire air ∆P 6.0” w.c. 10,000 cfh flow
Low fire air ∆P 0.2 ” w.c. 1,200 cfh flow
High fire gas ∆P 3.4 ” w.c. 1,000 cfh flow (natural gas)
Pilot signal 5.0 volts DC

Primary burner No. 2 & combustion air damper linkage adjustment:

located center of chamber nearest to ash conveyor - - 1,000,000 btu/hr maximum

Burner model number Eclipse TJ-100, 1,000,000 btu/hr
High fire air ∆P 6.0” w.c. 10,000 cfh flow
Low fire air ∆P 0.2 ” w.c. 1,200 cfh flow
High fire gas ∆P 3.4 ” w.c. 1,000 cfh flow (natural gas)
Pilot signal 5.0 volts DC
Secondary burner No. 3 & combustion air damper linkage adjustment:

located closed to ash conveyor end mounted - 5,000,000 btu/hr maximum

Burner model number Eclipse TJ-500, 5,000,000 btu/hr
High fire air ∆P 5.2 ” w.c. 50,000 cfh flow
Low fire air ∆P 0.3 ” w.c. 10,000 cfh flow
High fire gas ∆P 3.7 ” w.c. 5,000 cfh flow (natural gas)
Low fire gas ∆P 0.1 ” w.c. 500 cfh flow (natural gas)
Pilot signal 5.0 volts DC

25
Combustion Air/ Burner / Hydraulic Set Up

Secondary burner No. 4 & combustion air damper linkage adjustment:

located upper level, side mounted- 5,000,000 btu/hr maximum
Burner model number Eclipse TJ-500, 5,000,000 btu/hr
High fire air ∆P 5.2 ” w.c. 50,000 cfh flow
Low fire air ∆P 0.3 ” w.c. 10,000 cfh flow
High fire gas ∆P 3.7 ” w.c. 5,000 cfh flow (natural gas)
Low fire gas ∆P 0.1 ” w.c. 500 cfh flow (natural gas)
Pilot signal 5.0 volts DC

PERTINENT NOTES:
Hydraulic system relief pressure PCV-1 set at 1200 psi.
Charge ram relief pressure PCV-2 set at 875 psi.
Charge ram reverse pressure switch PS-2 set at 850+/- psi.
Lower Ash ram relief pressure PCV-3 set at 900 psi.
Lower Ash ram reverse pressure switch PS-3 set at 875+/- psi.
Upper Ash ram relief pressure PCV-4 set at 900 psi.
Upper Ash ram reverse pressure switch PS-4 set at 875+/- psi.
Ash Conveyor ram relief pressure PCV-5 set at 1200 psi.
Ash Conveyor ram relief pressure PCV-6 set at 1200 psi.
System Gas pressure 2 psi
Air Pressure proving Switch 7” w.c.
Low Gas Pressure proving Switch 7” w.c.
 High Gas Pressure proving Switch 5 psi
Waste Oil Injector pressure 40 psi

PANEL TIMER SETTINGS:

TD1 primary burner no. 1 pilot timer 30 seconds

TD2 primary burner no. 2 pilot timer 30 seconds
TD3 primary burner no. 3 pilot timer 30 seconds

TD4 secondary burner no. 4 pilot timer 30 seconds

TD5 feed timer (indicating) 14 minutes

TD6 lower ash ram stroke timer 0-60 seconds

TD7 upper ash ram stroke timer 0-60 seconds

TD8 ash conveyor auto run timer 0-60 seconds

TD9 scrubber drain valve blowdown timer 60 minutes

TD10 scrubber drain valve open timer 5 minutes
26