FireLake P77-3-SC30 Page 1 Installation And Operator'S Manual Download

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P77-3 SC30 Manual 9.27.2019 Page 1

Model P77-3-SC30

Incinerator

Three Burner, Two Thermocouple, AutoPreheat, Upper Burner Modulation, Individual

Lower Burner On/Off, Water Spray, Hi-Hi Shutdown, Chart Recorder (optional)

Installation and Operators Manual

Note exact model you purchase may look different than image due to design options.

Contents

WARRANTY WARNING

1. Tampering with orifices in the burner without factory consent will void warranty.

2. Factory has cured the incinerator but in the future any repairs of the lining may

need to undergo a cure process, consult your dealer.

3. Cracks in lining are normal and allow stress relief.

All Installations Must Be In Accordance With State and Local Codes and it is the

responsibility of the owner and installer to assure all codes are met

Summary of Contents for P77-3-SC30

Page 1: ...fferent than image due to design options Contents WARRANTY WARNING 1 Tampering with orifices in the burner without factory consent will void warranty 2 Factory has cured the incinerator but in the future any repairs of the lining may need to undergo a cure process consult your dealer 3 Cracks in lining are normal and allow stress relief All Installations Must Be In Accordance With State and Local ...

Page 2: ...P77 3 SC30 Manual 9 27 2019 Page 2 PERSONAL PROTECTIVE EQUIPMENT FOR CRUSHING HEAT ABRASION AND DUST ...

Page 3: ...P77 3 SC30 Manual 9 27 2019 Page 3 ...

Page 4: ...zed accordingly Natural Gas 7 W C with burners operating Liquid Propane 11 W C with burners operating FUEL OIL SET RATE OF THREE BURNERS ACTUAL BURN IS LESS CONTROL TURNS THEM ON AND OFF Fuel Oil 3 burners x 3 gph 9 GPH Burners pumps move not burn approx 3x flow in two pipe operation TOTAL WEIGHT 18 500 lbs approximate varies with features PAD REQUIREMENTS MINIMUM 6 W x 11 L x 6 Thick Concrete PAI...

Page 5: ...actory and placed in fill box at end of door arms Sand or gravel is typical and weight used should be tuned to allow a slow rise of the door and remain open on its own This incinerator must be assembled and connected to utilities by persons qualified to assure proper operation The Operator must read this manual and understand the operation and safety before attempting use Ash must be routinely rem...

Page 6: ...d service the burners and controls Allow ample cross ventilation to prevent the room from exceeding 130F The shelter must comply with local building and fire codes for clearances from combustible walls and materials A minimum clearance of 4 around the incinerator is recommended for service and maintenance For recommended construction of a metal chimney through a combustible roof see the Combustibl...

Page 7: ...P77 3 SC30 Manual 9 27 2019 Page 7 Weight box and swing arms behind main chamber Photo applies to P50 or P77 Main Chamber Stack Cap bolted on stack flange ...

Page 8: ...P77 3 SC30 Manual 9 27 2019 Page 8 Secondary Chamber aligned on connector stack Photo applies to P50 or P77 Main Chamber with SC30 Secondary Chamber ...

Page 9: ... 3 SC30 Manual 9 27 2019 Page 9 COMBUSTIBLE ROOF CONSTRUCTION MINIMUM REQUIREMENT SHOWN ACTUAL PENETRATION DESIGN AND SUPPORTS MAY BE DIFFERENT FOR GIVEN SITE Figure 3 Combustible Roof Construction Diagram ...

Page 10: ...h bolts washers nuts 7 Field installer and customer are to determine if there is a need and arrange for reinforcement of chambers and stack to meet local weather seismic codes 8 Mount the Suspended Control Box with arms away from the incinerator and out of traffic routes Umbilicals of wiring have been factory assembled and rolled up inside or under the Control Box These umbilicals will need to be ...

Page 11: ...ALL FLANGE CONNECTIONS Purpose create air tight flange to flange connection and continue a refractory lining from stack to stack IF mastic is used and pushes out seam smooth to match interior wall Mastic is also called furnace cement mud ...

Page 12: ...P77 3 SC30 Manual 9 27 2019 Page 12 ...

Page 13: ...on the terminal strip as factory labels indicate Have a Disconnect mounted near the Control Box Unroll factory cables and attach labeled wires to smaller boxes on incinerator where matching factory labels indicate Note that burners fire only Fuel Oil or Gas not interchangeable Read the section for your style burner WATER SERVICE PROTECT FROM FREEZING A WATER SPRAY BOX IS FACTORY ATTACHED TO THE IN...

Page 14: ...n the tank and the incinerator The Return fuel line allowing fuel back to the tank must be open for free flow Placing valves or other devices in this line is not suggested as accidental dead heading and resistance can ruin oil pumps 3 The fuel supply outlet to the burners may come from the underside of the storage tank or be pulled up through a dip tube from the top If problems from condensation a...

Page 15: ...WARD BE SURE ARRANGEMENT MEETS LOCAL CODE AND NEVER EXCEED PUMP INLET PRESSURE X A TEE IS USED ON LINES SHOWN TO CONNECT THE THIRD BURNER LOCATED AT THE OPPOSITE END OF THE CREMATOR THE THIRD BURNER IS NOT SHOWN FOR CLARITY ALTERNATE METHOD USE TWO FILTERS IN PARALLEL FROM THE TANK USE ONE FILTER TO FEED THE LOWER BURNERS AND ONE TO THE UPPER BURNER ...

Page 16: ...drip leg to protect burners Purge and leak test all lines before running unit TIP Never exceed 14 inches water column in gas lines or it may seize the valves or regulators Use the gauge s supplied or install one of your choice REGULATOR 1 Use a properly sized regulator which maintains reduced pressure under static conditions when no gas is flowing Dead end lock up 2 For best results install regula...

Page 17: ...de Space conduit away from hot metal surfaces to prevent melting TIP if controller shows SnSr or similar display the thermocouple is not wired proper the red or yellow wire failed or the inner ceramic element is failed To confirm the controller is working shut off power to incinerator put jumper wire across screws where red yellow attach to controller If a temperature is now shown on the controlle...

Page 18: ...ss Excessive opening may create unwanted positive pressure in the chamber and possible smoke to escape the seals Air Shutter indicator Upper burner is normally set to 10 Lower burner normally set to 8 Waste conditions may need field adjustment to allow more air to the burn process Excessive opening may create unwanted positive pressure in the chamber and possible smoke to escape the seals ...

Page 19: ...0 000 Open NAT 50 None 1 200 000 Model Mid Continent Model J 83 Pilot Burner Air Shutter Fuel Orifice Orifice BTUH Half LP 58 15 64 350 000 Half NAT 55 11 32 350 000 Figure 1 Air Shutter Midco burner Gas Flow Adjustment Midco burner remove nut turning inner screw clockwise reduces flow Some burners have a 2 nd orifice that limits flow ask your dealer if concerns about flame size ...

Page 20: ...ches along top of waste so flue gases can reach stack or poor combustion and burner damage may occur 5 Start incinerator by setting the digital timer for the desired burn time and press ON Experience dictates time 6 Upper burner starts preheating and will climb in temperature to preset value Lower burners come on when preheat value is reached 7 Lower burners may cycle on off to save fuel and contr...

Page 21: ... OF BURN TIME PRESS START THIS WILL START THE BURNER A FULL LOAD OR COLD CHAMBER START MAY NEED 8 HOURS DEPENDING ON MANY FACTORS LIKE FROZEN ANIMALS OUTSIDE TEMPERATURE FATTY CONTENT OF LOAD EXPERIENCE WILL SHOW HOW TO PREDICT THE TIME AND ACHIEVE A BURN AS COMPLETE AS DESIRED TIP SHOULD THE TIMER NOT RESPOND TO TOUCH SHUT OFF POWER A FEW TIMES AND SEE IF THAT RESETS TIMER ...

Page 22: ...P77 3 SC30 Manual 9 27 2019 Page 22 MAIN CONTROL PANEL Indicator Lights typ Manual Toggles typ Breakers typ Opt Chart Recorder FDC Control typ Main Timer On Off ...

Page 23: ...angles may be used by operator to adjust preheat SCROLL RESET should only be used to view or change programming Only trained programming persons should reprogram and only when they are CERTAIN the change will not harm the apparatus or surroundings DISPLAYS PROGRAMMED SETPOINTS SP1 SP2 SP3 ...

Page 24: ... spray Output indicators for SP1 SP2 SP3 SP indicators are either illuminated or not depending on if each SP value is met or not met at the time DETAILED SEQUENCE OPERATION Starting the timer starts the upper burner and preheats the upper chamber When preheat is reached output 2 on upper FDC goes live and starts the lower burners When the lower burners fire they often force cooler chamber air up a...

Page 25: ...Note on some models any FDC output not used can be utilized by the customer This is a dry light duty amp load contact As the waste burns the temperatures rise and then taper back over time When the Timer expires or power is turned to OFF all burners will stop firing Note on gas burners a thermal sensor monitors temperature in the burner body When the burner power is off for any reason and heat tri...

Page 26: ...rip legs for moisture and debris drain off 2 Check oil filter for accumulation of water rust sludge and replace as needed 3 Check condition of hinges pins on door weights 4 Replace paper in chart recorder if one is being used MONTHLY 1 Check for gas or oil leaks in fittings 2 Check for loosened bolts in chamber stack and loader 3 Clean and repaint any worn areas before surfaces get corroded YEARLY...

Page 27: ...eck gas pressure while the burner is burning LP gas 11 WC or NAT gas 7 WC FUEL OIL MODELS No spark at electrodes 1 Be sure there is no obstruction in the end of the burner tube and there is no soot build up on the retention head electrodes or nozzle 2 Check all electrical connections 3 Transformer may be burned out Listen or look to see if there is an arc across the electrodes Replace transformer ...

Page 28: ...P77 3 SC30 Manual 9 27 2019 Page 28 MIDCO BURNER J121 DS EXPLODED VIEW ...

Page 29: ...ormer 115 1 50 60 Primary 24V 30VA Or Transformer 220 24V 50 60 Hz 35VA K 101419 3 4 NPT Gas Valve 24 Volt L 31574 Electrode spark or flame 2 required M 101427 Electrode Wires Boots and Strain Reliefs N 33133 Ignitor Assembly O 31579 101426 Motor 115 1 50 60 Hz Or Motor 220 1 60 Hz P 33112 Ignitor Regulator 1 8 NPT Q 33120 Thermal Switch R 33151 DSI Electronic Control Board S 33118 Input Adjuster ...

Page 30: ...P77 3 SC30 Manual 9 27 2019 Page 30 MIDCO BURNER J83 DS EXPLODED VIEW See parts list on following page ...

Page 31: ...d Tube Kit PROPANE I 31581 Main Gas Port and Tube Kit NATURAL J 33129 101420 Transformer 115 1 50 60 Primary 24V 30VA Or Transformer 220 24V 50 60 Hz 35VA K 33109 3 4 NPT Gas Valve 24 Volt L 33121 Electrode spark or flame 2 required M 33138 Electrode Wires Boots and Strain Reliefs N 33131 Ignitor Assembly O 33126 101426 Motor 115 1 50 60 Hz Or Motor 220 1 60 Hz P 33112 Ignitor Regulator 1 8 NPT Q ...

Page 32: ...P77 3 SC30 Manual 9 27 2019 Page 32 BECKETT BURNER AF EXPLODED VIEW See parts list on following page ...

Page 33: ... 57210 FF Connector tube assembly 8 101472 GG Motor 110V 220V 57208 call HH Blower wheel use only RWB replacement 57204 II Coupling 32340 JJ Primary Control 110V 220V 101279 call KK Cad cell detector 57209 LL Flange universal adjustable incl gasket 32365 MM Gasket only 32320 NN Transformer 110V 220V 10170910 call OO Retention head 32335 PP Electrode kit F head air tubes longer than 9 101474 QQ Air...

Page 34: ...P77 3 SC30 Manual 9 27 2019 Page 34 BECKETT BURNER SF EXPLODED VIEW See parts list on following page G G F E D B C A ...

Page 35: ...209 Flame Detector D 101270 101262 SF Burner Motor 120v 60hz AF Burner Motor 220v 50hz E 101265 Blower Wheel F 101263 Flexible Coupling G 101264 Fuel Pump Not Shown 101272 Solenoid Valve 120v 60hz Not Shown 101267 Solenoid Valve 220v 50hz Not Shown 101332 F310 Retention Head Not Shown 101472 Connector Tube Assembly Not Shown 101471 Air Tube Assembly Not Shown 101473 Nozzle Line Electrode Assembly ...

Page 36: ...P77 3 SC30 Manual 9 27 2019 Page 36 ...

Page 37: ...P77 3 SC30 Manual 9 27 2019 Page 37 MIDCO BURNER INTERNAL WIRING ORANGE L1 ...

Page 38: ...P77 3 SC30 Manual 9 27 2019 Page 38 INCINERATOR WIRING DIAGRAM ...

Page 39: ...P77 3 SC30 Manual 9 27 2019 Page 39 ...

Page 40: ...P77 3 SC30 Manual 9 27 2019 Page 40 ...

Page 41: ...P77 3 SC30 Manual 9 27 2019 Page 41 LINKAGE DIAGRAM ...

Page 42: ...Setting SEt _ _ _ _ Scroll LocK nonE Scroll inPt y_tC Scroll unit 0F Scroll dP no dP Scroll SP1L 0 Scroll SP1H 2498 Scroll SHiF 0 Scroll FiLt 0 5 Scroll Pb 0 Scroll out1 rEYr Scroll o1 tY rELY Scroll o1 Ft oFF Scroll o1HY 90 Greater value lessens burner 1 cycling Scroll rAmP nonE Scroll out2 Py Lo Scroll O2 tY rELY Scroll O2 Ft oFF Scroll O2HY 90 Greater value lessens burner 2 cycling Scroll AL Fn...

Page 43: ..._ _ Scroll LocK nonE Scroll inPt y_tC Scroll unit 0F Scroll dP no dP Scroll SP1L 0 Scroll SP1H 2498 Scroll SHiF 0 Scroll FiLt 0 5 Scroll Pb 100 Scroll ti 0 Scroll td 0 Scroll out1 rEYr Target temperature modulation Scroll o1 tY 4 20 Scroll o1 Ft 25 Scroll Of st 25 Scroll rAmP none Scroll out2 Py Hi Scroll O2 ty rEly Scroll O2 Ft off Scroll O2 HY 90 Greater value lessens prehet cycling Scroll AL Fn...

Page 44: ...P77 3 SC30 Manual 9 27 2019 Page 44 ...

Page 45: ...P77 3 SC30 Manual 9 27 2019 Page 45 FDC Future Design Control Specification Review ...

Page 46: ...AC resistive o Alarm 2 Output 2 Form A Relay 2A 240 VAC resistive Alarm Output C21 C91 One alarm when when Output 2 configured as Alarm 1 o Relay Form A 2A 240 VAC resistive Communications Modbus RS232 RS485 or VDC or mA retransmission o RS232 RS485 Retransmission are mutually exclusive options o C91 1 16 DIN Communications and Control Output 2 are mutually exclusive Transmitter Power Supply isola...

Page 47: ...ace new chart on and align day time screw nut down to hold in place Press pad 3 again Close recorder face The recorder has an indicator light too Field reprogramming is possible by using a provided blank setup chart and following the instructions printed on it Also see complete FDC CHART RECORDER USER MANUAL for recorder to familiarize Refer to information in that manual for Dual Pen Universal Ink...

Page 48: ...3 SC30 Manual 9 27 2019 Page 48 Indicator light Push pads 1 2 3 blank setup chart shown below Finished programmed setup chart values to be entered are Type K on both pens 0000 2400 F 24 8 disabled off chart ...

Page 49: ...er the thermocouple column the red pen will respond to and pad keys move red pen over K and touch 3 on pad You will see the blue pen slightly shift now you need to use the and pads to locate the blue pen over K Touch 3 on the pad and the chart will advance to next column ...

Page 50: ...ill automatically shut off when the upper timer ends 5 For best results burn daily to a white ash Load waste near hot part of flame REFRACTORY CURING PROCEDURE Table 1 REFRACTORY CURING PROCEDURE Procedure Time Start burner and burn for 5 minutes Allow to cool for 15 minutes burn 5 minutes cool 15 minutes burn 15 minutes cool 15 minutes burn 15 minutes cool 15 minutes burn 30 minutes cool 15 minut...

Page 51: ..._____ Hour 3 250 F ____________ _________ Hour 4 250 F ____________ _________ Hour 5 250 F ____________ _________ Hour 6 250 F ____________ _________ Hour 7 300 F ____________ _________ Hour 8 400 F ____________ _________ Hour 9 500 F ____________ _________ Hour 10 600 F ____________ _________ Hour 11 700 F ____________ _________ Hour 12 800 F ____________ _________ Hour 13 900 F ____________ ____...

Page 52: ... workmanship or material and does not apply to grates or thermocouples installed incorrectly or grates which have been abused Controls Recorders and Burners Most of our suppliers warrant their products for at least one year If a part is found to be defective in workmanship or material within one 1 year from date of purchase Firelake Manufacturing LLC will either issue a replacement part or credit ...

Page 53: ...entative thereof or the Warranty will be void 4 Malfunctions or failure resulting from misuse abuse negligence alteration accident or lack of proper maintenance shall not be considered defects under the Warranty 5 This Warranty applies only to systems for animal and medical waste Other applications in industry or commerce are not covered by this Warranty unless prior written acceptance is granted ...

Page 54: ...r returning merchandise pursuant to this Warranty stating the reasons for the request THIS WARRANTY CONSTITUTES THE MANUFACTURER S ENTIRE AND SOLE WARRANTY AND THIS MANUFACTURER EXPRESSLEY DISCLAIMS ANY AND ALL OTHER WARRANTIES INCLUDING BUT NOT LIMITED TO EXPRESS AND IMPLIED WARRANTIES AS TO MERCHANTIBILITY FITNESS FOR PARTICULAR PURPOSES SOLD AND DESCRIPTION OR QUALITY OF THE PRODUCT FURNISHED H...

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