Incinerator Model A1600 -Oil Operators Manual Important Failure to cure refractory Before using will void warranty (See refractory curing procedure) Tampering with orifices in the burner will void warranty Revised July 2006
Owners Manual For Oil Fired Incinerator Models A1600 Index CE certification Page 3 Overview of Incinerator Page 4 Specifications Page 5 Service / installation sheet Page 6 Site plan / fitting Page 7 Assembly Instructions Page 8 Commissioning & start up procedures Page 9 Operator instructions Page 9 Refractory Curing Procedure Page 10 Inspection & Servicing Page 11 Maintenance Programme Page 12 Recommended Housing Plan Page 13 Fitting Chimney through roof (dia.) Page 14 Warranty Page 15 1
Features Overview Designed for economical performance. Up to 750 kg capacity. Low profile for easy loading and ash removal. Refractory lined to retain heat for efficient operation. Fuel Efficiency Rapid incineration means low fuel consumption. Higher burn rate than smaller models. Thick refractory lining in main chamber retains heat, increasing efficiency. Quality Built to Last Heat resistant aluminized steel. Stainless steel stack. Backed by over 30 years of incineration experience. 2
Specifications Summary All installations must be in accordance with state and local codes. WASTE CHAMBER Chamber capacity (Type IV waste - animals) 750 kg Chamber volume 1.18 m 3 Chamber size Width 180 cm (outside) Height 330 cm Including weights Length 311 cm Door opening 200 x 77 cm Height to top of stack 3.1 m BURNERS Operation Oil burner Diesel 2 x burners ELECTRICAL SERVICE Standard - 220 volt, 50 HZ, 10 amp We reserve the right to alter specifications without prior notice Installation Must be installed in accordance with local codes and ordinances, subject to regulatory agencies. Stack test data is available from the distributor for permit application. If on-site testing is required, it is the responsibility of the purchaser and can be arranged through the distributor. Outside installation is recommended with a simple metal roof or three-sided metal shelter, providing a minimum four foot clearance from any combustible material. Inside installations may have special insurance requirements. Factory must be advised. 3
Inciner8 Incinerator Model A1600 Installation Location: Installed by: Date: Sold By: Service Record Date Comments 4
Site Information 1. The A1600 incinerators are designed to be in a covered installation on a concrete slab, which should be smooth and impervious to aid in cleaning around the incinerator area. Drainage or some bunding around the incinerator area is ideal to avoid any waste materials running off the concrete slab. 2. The A1600 may be installed in a three-sided shelter, but must comply with local building and fire codes for clearances from combustible walls and materials, with ample ventilation (also allow for wind direction). A minimum clearance of 1.25m around the incinerator is recommended for service and maintenance. 3. The incinerator should be sited away from animals, feed or bedding areas. For health and safety reasons the incinerator area should be kept locked at all times when not supervised. Please note that it is essential to use an authorised technician for the electrical and fuel installation and inspection Electrical Service 220 Volt, 50/60 HZ, 10 Amp 1. Electrical service can be supplied by plugging into the cord set. NOTE: Polarity must be maintained or the burners will not operate. If burners lock out after approximately 5 seconds and the blower continues to operate, then the polarity is incorrect. It should be corrected at the power source, not in the incinerator control. Fuel Assemble the tubing, oil filter, cut-off cock and fittings between the tank and burner. (NB tubing between the oil tank and burner to be supplied by the customer) Oil Tank Since tanks vary in size and fixtures, additional piping may be needed. It is important that a filter be provided in the line between the tank and the incinerator. There must be a flow and return pipe with two pipe system If the flow outlet is on the underside of the tank, extend a threaded nipple about 5cm into the tank to avoid problems from dirt / condensation in the bottom of the tank Please note that single pipe installation is advisable using a tiger loop. 5
Assembly Instructions Site 1. Position the incinerator on the concrete slab as needed for fuel and electrical hook up. Primary Chamber 1. (IT IS VERY IMPORTANT THAT THE DOOR IS NICELY BALANCED AND MAKES A FIRM SEAL AROUND THE WHOLE CASE WHEN CLOSED SHUT FAILURE TO DO THIS CAN RESULT IN THE INGRESS OF COLD AIR ALLOWING DAMAGE TO THE REFRACTORY LINING WHEN HOT) 2. Slide out counterbalance arm and secure in place with the 3 x bolts supplied. Slide out counterbalance arm and bolt into place (See above, before and after) Stack / Chimney Burner 1. Slide on the stainless steel stack over the chimney outlet on the secondary chamber and bolt into place. 1. Attach the 2 x burners at each burner port. 2. Attach the burner plugs to the relevant plug on the control box, i.e AA to AA, BB to BB 3. Connect the pipe work including pressure gauge. 4. Place the steel burner covers over each burner. Temperature Probes 1. Slide the temperature probes in each location (2) Location 1 is at the rear, top of the secondary chamber. 2. Location 2 is approx 60cm below the control box 6
Control Box 1. Connect the electrical control box to a power supply. (Use a qualified electrician) 2. Place the box on the mounting plate Control box settings Timer 1-10 minutes Timer 2-6 hours (Includes 40 minute secondary chamber pre warm) Timer 3-9 hours (Includes 40 minute secondary chamber pre warm) Timer 4-12 hours (Includes 40 minute secondary chamber pre warm) 7 NB Once the cycles have finished the burner fans will remain on for 8 hours for cool down.
Commissioning and start up procedures 1. It is imperative that the refractory has been cured (see page 10 for details) 2. All pipe work must be checked for leak tightness and should be free from dirt and debris. Welding slag needs to be removed and the pipe work should be completely clear of any obstruction. 3. It is important that the burner is set correctly by adjusting the air / fuel flow. When looking at the burner flame it should not be producing black smoke at the ends of the flames, small adjustments should be made to lean the flame so that it is clean. The above should also be checked after periods of shutdown. OPERATOR INSTRUCTIONS Curing of the refractory is essential prior to burning the first load of waste. 1. The incinerator should not be modified in any way not in keeping with the manufacturers instructions, this will not only void warranty but will possibly fail to meet ABPR (UK) 2. Dedicated tools should be used for use with the incinerator only, and not be used elsewhere. 3. REMOVE ASHES before loading the incinerator. 4. NOW LOAD THE INCINERATOR. 5. Select the required time (nos. 2-4, see above) to ignite the burner, (Number 1 is for commissioning only) 6. The secondary burner will operate for about 40 minutes, then the primary burner will ignite. (Ensure that the temperature is reading 850 deg C or above, otherwise Restart the process. 7. Dependant on which time setting has been selected (also dependant on size of load to incinerate) 8. Lock the unit door to ensure that no one can inadvertently access the chamber during the burn 9. An optional temperature cut off device can be fitted where needed. 10. The burners will AUTOMATICALLY SHUT OFF when the chosen burn time is completed. The fan should remain on for a period of time (normally 8 hours) after the burn cycle or when the primary chamber is less than 50 deg C or less 11. For the best results BURN DAILY TO A WHITE ASH 12. Do not store carcasses in the incinerator chamber. Singe and burn does not constitute an approved pre-incineration storage process. 13. In case of any form of breakdown, shut down the burner immediately (if possible leave fan running). 8
Refractory Curing Procedure Curing process should be done using control panel settings DAY 1 Start Burner using number 1 timer position Allow cooling for 10 minutes ON 50 minutes REPEAT THIS 12 (TWELVE) TIMES. I.E. OVER A 12 HOUR PERIOD DAY 2 Start Burner using number 2 timer position Allow cooling for 6 Hours ON 6 Hours The unit is now ready to operate normally Total Burner Time 8 hours There will be hairline cracks and minor scaling of the refractory when curing is completed. This is a normal result of the curing process 9
Inspection Procedures Periodic inspection and servicing of the units is required to maintain optimum operation We recommend the following schedule: - Assuming the unit has been installed and tested by a suitably qualified gas/ electrical engineer. 1 st service (post installation check up) after 50 hours of operation Regular service/ inspection 1000 hours or annually, whichever is the sooner. Service / Inspection procedures should include.. 1. Check for leaks in all pipe-work and gas supply 2. Check for leak tightness of the unit ensuring all waste gas travels up the chimney output 3. All safety shut off valves and safety guards should be inspected. 4. A temperature and combustion analysis should be performed to ensure that there is no deterioration of incinerator performance. 5. Timers should be calibrated to ensure that they reflect a true reading and ensure that the safety cut off applies. 10
Incinerators - Recommended Maintenance Programme Main Chamber Open the chamber door and check around the rim of the chamber for leakage, this is normally easily visible as there may be blackening beyond the area where the door seats. If there is blackening and therefore leakage, then the fire cord around the door / lid should be checked and replaced if damaged. Close the door and inspect for any signs of gaps when tightly closed. Adjustments may need to be made to the locking catch to tighten the seal, also the counterbalance weights may need to be adjusted so that they allow the lid to sit firmly, (normally the lid should be balanced, allowing easy opening and closing with one hand). Check for leak tightness of the unit ensuring all waste gas travels up the chimney output Check the integrity of the main chamber refractory lining. When the unit is cool, it is normal to see hairline cracks; these disappear when the unit is hot. Any large chips or cracks can be simply filled with an approved fire cement (approved to 1500 deg C). Check the burner outlet hole and make sure that the area is clear from any debris and that the integrity of the refractory liner is good. Check all around the outside of the chamber for any bent or buckled steel (this can arise from corroded internal refractory lining. Any damage needs to be investigated and resolved internally before making any external repairs or welds. Check all external bolts for corrosion (especially if unit is located outside) and replace where necessary. Discolouration of the stainless chimney stack is normal, although watch for corrosion where the stack meets the steel chamber (especially where units are located inside but the stack is incorrectly fitted through the roof allowing water to run down the outer skin of the chimney) see page 14. Check for leaks in all pipe-work and gas supply All safety shut off valves and safety guards should be inspected. A temperature and combustion analysis should be performed to ensure that there is no deterioration of incinerator performance Timers should be calibrated to ensure that they reflect a true reading and ensure that the safety cut off applies. Check burners for correct setting (see installation manual on set up procedures), the air / fuel mix should be set so that there is no black smoke at the flame tips and there is not excessive fuel use. Where necessary it is possible to remove any corrosion or discolouration (normally on units kept outside) using a wire brush and rust remover. The un its can be re-sprayed in those places (matching heat resistant paint available from Inciner8) Tighten up and inspect any bolts which will have loosened due to settlement, especially where the secondary chamber meets the primary chamber. 11
Model A1600 Suggested Building Layout 5.004 2.003 3.110 0.895 LOADING DOOR 0.707 Secondary Chamber 0.856 0.850 3.550 1.000 3.501 1.800 2.500 3.497 0.240 2.003 Counterbalance Arm 0.152 0.240 5.004 Title: Model A1600 Building Layout Author: Date: V Ferguson 11th July 2006 Sheet: ONE Revision: 3/2
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Limited Warranty Warranty Inciner8 Ltd, warrantor, warrants to the original purchaser of one (1) year or 1000hrs (whichever is earlier) from date of purchase or delivery to original purchaser, products manufactured / supplied by it which are installed and operated according to Warrantor s instructions that are furnished and/or are available to purchaser upon request, and installed according to other applicable federal, state, government and local codes or regulations and upon substantiation that said products were installed correctly, were not abused and are defective. The exact nature of said warranty and exclusive remedy for breach by warrantor is as follows: - Warrantor will repair or replace at Warrantors expense, products found to be defective in workmanship or material. If a problem occurs which the purchaser believes is covered by his warranty, then the purchaser shall contact the seller giving the seller sufficient information to enable a resolution of the problem. Cost of delivery and installation of said parts are not covered under warranty. No product or part thereof may be returned pursuant to this warranty without first receiving specific written permission to do so. All requests should be addressed to the dealer or Inciner8 Ltd, Inciner8 House, Balmoral Drive, Balmoral Business Centre, Southport, PR8 9PZ, United Kingdom, requesting specific authority for returning merchandise pursuant to this warranty with reasons for the request. Limitations Products which are abused or neglected are not covered under this warranty, including overfilling / overheating units, or covering burner outlets (please refer to manual for usage instructions). Warrantor shall not be responsible for the costs of removal or reinstallation of its products and shall not be liable for transportation costs to and from its plant. Further. Warrantor shall not be liable for replacement, repair or refund for component parts not manufactured by it. Failure to cure the refractory (see manual) will immediately void the warranty. Use of parts for modification or repair of the unit or any component not authorised or supplied by Inciner8 Ltd, specifically for this product shall void the warranty. Implied warranties of merchantability and fitness for a particular purpose are limited to the same period of time as this express limited one (1) year warranty or 1000hrs (whichever is earlier) and are specifically disclaimed thereafter. Items Not Covered Under Warranty Nozzles (burner) Fire rope Temperature Probe Inciner8 Ltd shall not be liable for any incidental, consequential, special or contingent damages or expenses arising directly or indirectly from any defect in the product hereby warranted. The warranty shall be VOID if solvents or other highly inflammable fluids such as but not limited to Benzene, methyl ethyl, ketenes, toluene, xylene or naphtha are burned in or mixed with oil for burning in used oil fired burning heaters or furnaces. Inciner8 Ltd is not responsible for any undertaking, representation, or warranty made by any dealer, distribution, or other persons, beyond those expressly set forth in this warranty. 13