Instruction Manual

TeamTec Incinerator
OG400C/OG400CS
TG5.2
OG200/400C
Copyright  2003 TeamTec AS. All rights reserved.
No part of this manual may be reproduced, transmitted, stored in a database or translated into
any language or in any form without explicit and written permission of TeamTecAS.

Version Date Purpose Written

Rev 0 17.02.2016 TAB
Rev A 16.11.2016 Updated manual EEM

O 4 0 0 C /O G 4 0 0 C S 3
 ADDENDUMS, CORRECTIONS AND NOTES

Addendums, corrections and notes

This document describes, from a user point of view, how to operate and maintain the OG200/400C
incinerator. The incinerator type is OG200/400C, but some of the drawings might have additional letter
codes that describe the extra equipment on your incinerator.

All TeamTec incinerators are made according to EC Type-Examination Certificate MED-B, and are
found to comply with the requirements in the following regulations/standards:
Annex A.1, item NO. A1/2.7 and Annex B, Module B in the Directive. Marpol 73/78 as amended, Annex
VI Regulation 16(2)(a), IMO Res. MEPC. 244(66) adopted April 4th 2014 (Replacing MEPC.76(40)).

Generally, for a design or type approval certificate, it is allowed to make minor modifications to the
equipment. Minor modifications are changes that will not affect the incinerators function or design. The
incinerator type is still the same, and all main functions are identical to the type approved unit and will be
covered by the certificates. The type stamped on the incinerator is the same as we have on the certificate,
but some of the drawings might have letter codes to describe the extra equipment (minor modification) on
your incinerator. All possible letter codes are:

Code Feature description

A Ampere meter for flue gas fan
B Diesel oil booster pump
C Standard - Computerized automation/control (PLC)
D Dual sludge tank
F Auto feeding of solid waste (Stoker, Shredder)
G Stirrer for solid waste
I Water injection
K Cooling of control cabinet
L Sludge tank level readout in display panel
M Flue gas fan motor heater
P Sludge transfer pump
S Sluice for solid waste
T Diesel oil transfer pump
W Incinerator for solid waste only
Y Twin sludge tanks
Z CCS – centralized control station twin display

O400C/OG400CS 4
 TABLE OF CONTENTS

Table of contents
ADDENDUMS, CORRECTIONS AND NOTES......................................................................................4
ACRONYMS AND TERMS..................................................................................................................... 10
SAFETY MARKINGS.............................................................................................................................. 11
GENERAL USE AND SAFETY INSTRUCTIONS............................................................................... 11
GARBAGE MANAGEMENT.................................................................................................................. 12
INCINERATION OF SOLID AND LIQUID WASTE............................................................................................... 12
SOLID AND LIQUID WASTE THAT IS PROHIBITED TO BE BURNED..................................................................12
SOLID WASTE HANDLING............................................................................................................................. 13
BATCH LOADING...........................................................................................................................................13
SLUICE FEEDING........................................................................................................................................... 13
SLUDGE CAPACITY............................................................................................................................... 13
INTRODUCTION......................................................................................................................................14
INSTRUCTION MANUAL, PURPOSE AND SCOPE.............................................................................................. 14
SERVICE NETWORK FOR TEAMTEC INCINERATORS...................................................................................... 14
CHINA........................................................................................................................................................ 14
MAIN DATA.............................................................................................................................................. 15
PERFORMANCE DATA....................................................................................................................................15
Incinerator (combustion chamber)..........................................................................................................15
Burner (fixed on combustion chamber)................................................................................................... 15
Diesel oil booster pump (optional)..........................................................................................................16
Flue gas fan (bulkhead mounted)............................................................................................................ 16
Sludge tank.............................................................................................................................................. 17
Sludge circulating pump. (installed on sludge tank)............................................................................... 17
Sludge filling pump (if dual sludge tank system).....................................................................................17
Sludge dosage pump (fixed on combustion chamber)............................................................................. 17
Water dosage pump (Optional)............................................................................................................... 17
Diesel oil preheater (fixed on combustion chamber).............................................................................. 18
Electrical control panel incinerator (fixed on combustion chamber)..................................................... 18
Flue gas damper...................................................................................................................................... 18
SHIPS SYSTEM INTERFACE REQUIREMENT.................................................................................................... 19
Electrical................................................................................................................................................. 19
Diesel oil..................................................................................................................................................19
Flue gas duct........................................................................................................................................... 19
Sludge and Steam or Air..........................................................................................................................19
Water and Steam or Air (Optional)......................................................................................................... 19
Sludge tank. (1100 / 1700 / 2000 / 3000l option).................................................................................... 19
Water tank. (435 l) (Optional).................................................................................................................20
TECHNICAL DESCRIPTION.................................................................................................................21
OVERALL SYSTEM FUNCTION DESCRIPTION..................................................................................................21
Combustion chamber...............................................................................................................................21
Flue gas fan............................................................................................................................................. 21
Sludge service tank with heater............................................................................................................... 21
Sludge settling tank with heater (optional)..............................................................................................22
Water injection (Optional).......................................................................................................................22
Water tank (Optional)..............................................................................................................................22
SLUDGE CONTROL........................................................................................................................................ 23
Introduction............................................................................................................................................. 23
Temperature limits...................................................................................................................................23
Burner stage............................................................................................................................................ 23
Control.....................................................................................................................................................24
OPERATOR PANEL................................................................................................................................ 25

OG400C/OG400CS 5
 TABLE OF CONTENTS

General.................................................................................................................................................... 25
SCREENS....................................................................................................................................................... 26
Structure.................................................................................................................................................. 26
Pop-up Start -Stop................................................................................................................................... 27
Information pop-up..................................................................................................................................27
Burner......................................................................................................................................................28
Setting tanks.............................................................................................................................................28
Hour counters.......................................................................................................................................... 29
Setup........................................................................................................................................................ 29
Login........................................................................................................................................................30
Wrong user pop-up.................................................................................................................................. 30
Change values..........................................................................................................................................30
Settings burner.........................................................................................................................................31
Settings alarms........................................................................................................................................ 32
Settings sludge (1/5)................................................................................................................................ 33
Settings sludge (2/5)................................................................................................................................ 34
Settings sludge (3/5)................................................................................................................................ 35
Settings sludge (4/5)................................................................................................................................ 36
Settings sludge (5/5)................................................................................................................................ 37
Settings solid waste (1/2).........................................................................................................................38
Settings solid waste (2/2).........................................................................................................................39
Settings sludge with water....................................................................................................................... 40
Settings solid waste and sludge............................................................................................................... 41
Settings loading/slagging and stop..........................................................................................................42
Burn-in.....................................................................................................................................................43
Backlight..................................................................................................................................................44
Time and date.......................................................................................................................................... 44
Program information...............................................................................................................................45
Consumption............................................................................................................................................45
Consumption setup.................................................................................................................................. 45
Alarm system............................................................................................................................................46
The alarm Screen.....................................................................................................................................46
Alarm List................................................................................................................................................ 46
Setting list................................................................................................................................................ 49
Settings frequency inverter ALTIVAR 12.................................................................................................52
PROGRAM DESCRIPTION....................................................................................................................53
OVERALL PROGRAM FUNCTION DESCRIPTION.............................................................................................. 53
General.................................................................................................................................................... 53
Flue Gas Fan/Damper.............................................................................................................................54
Function Sludge program........................................................................................................................54
Function solid waste program.................................................................................................................57
Function Solid waste and sludge program.............................................................................................. 58
MAINTENANCE INSTRUCTION..........................................................................................................59
PREVENTIVE MAINTENANCE......................................................................................................................... 59
Service hours:.......................................................................................................................................... 59
REGULAR MAINTENANCE PROCEDURES......................................................................................... 60
INSPECTION...................................................................................................................................................63
Combustion chamber:..............................................................................................................................63
Diesel oil pump:.......................................................................................................................................63
Flue gas fan:............................................................................................................................................63
Sludge dosage pump:...............................................................................................................................63
CLEANING AND LUBRICATION...................................................................................................................... 64
DISASSEMBLY, REPAIR, REPLACEMENT AND REASSEMBLY.......................................................................... 65
Repair of refractory................................................................................................................................. 65
Restriction Bricks replacement................................................................................................................66
Flue gas fan............................................................................................................................................. 67
Replace flue gas fan impeller:..................................................................................................................................67
Disassembly.........................................................................................................................................................67
Repair...................................................................................................................................................................67

6 OG / 4 0 0 C /O G 4 0 0 C S
 TABLE OF CONTENTS

Replacement........................................................................................................................................................ 67
Reassembly.......................................................................................................................................................... 67
To adjust the clearance between impeller and fan house...................................................................................68
Performance verification..................................................................................................................................... 68
Mounting of bearings with tapered bore..................................................................................................................69
Flue Gas Damper Motor......................................................................................................................... 70
SPARE PARTS.......................................................................................................................................... 73
RECOMMENDED MINIMUM SPARE PARTS..................................................................................................... 73
1 YEAR WEAR AND TEAR PARTS OG200/400C, TG5.2................................................................................74
RECOMMENDED ON BOARD REPAIR PARTS,..................................................................................................75
OG200/400C, TG5.2....................................................................................................................................75
STORAGE AND INSTALLATION.........................................................................................................76
PREPARATION FOR SHIPMENT.......................................................................................................................76
STORING AT YARDS WAREHOUSE................................................................................................................76
PRESERVATION FROM INSTALLATION TO START-UP OF EQUIPMENT............................................................ 76
PRESERVATION IN CASE OF LONG TIME STORING AFTER INSTALLATION......................................................76
PRE-COMMISSIONING....................................................................................................................................77
Mechanical completion check list............................................................................................................77
Pre-check of live equipment.................................................................................................................... 77
TEST OF SAFETY AND ALARMS.................................................................................................................... 78
OPERATION INSTRUCTIONS.............................................................................................................. 84
PRIOR TO START........................................................................................................................................... 84
SLAGGING.....................................................................................................................................................84
SOLID WASTE............................................................................................................................................... 84
SLUDGE.........................................................................................................................................................84
SOLID WASTE SLUDGE.................................................................................................................................85
SLUDGE AND WATER................................................................................................................................... 85
EMERGENCY STOP........................................................................................................................................ 86
In the incinerator room............................................................................................................................86
Outside the incinerator room.................................................................................................................. 86
WHEN EMERGENCY STOP IS USED, OR AT BLACK OUT................................................................................. 86
TROUBLE SHOOTING........................................................................................................................... 87
APPENDIX A: PLC..................................................................................................................................90
GENERAL...................................................................................................................................................... 90
BASE UNIT....................................................................................................................................................91
INSERTING SD CARD.................................................................................................................................... 93
REPLACING THE BATTERY............................................................................................................................ 94
DIAGNOSTICS................................................................................................................................................96
APPENDIX B: OPERATOR PANEL.....................................................................................................98
GENERAL...................................................................................................................................................... 98
TECHNICAL DATA......................................................................................................................................... 99
APPENDIX C: OIL BURNER...............................................................................................................101
SERVICING AND ADJUSTMENT.................................................................................................................... 101
Dismantling........................................................................................................................................... 101
Cleaning and adjustment....................................................................................................................... 101
Re-assembly........................................................................................................................................... 101
DIESEL OIL PRESSURE ADJUSTMENT...........................................................................................................101
BURNER BLAST TUBE REPLACEMENT........................................................................................................ 102
Reassembly of blast tube:...................................................................................................................... 103
Oil Burner damper motor replacement................................................................................................. 104
Reassembly of the oil burner damper motor......................................................................................... 105
AIR ADJUSTMENT........................................................................................................................................106
DO NOZZLES...............................................................................................................................................106
Standard nozzle......................................................................................................................................106

OG400C/OG400CS 7
 TABLE OF CONTENTS

Maintenance.......................................................................................................................................... 106
Capacities.............................................................................................................................................. 107
Burner nozzle assembly repair.............................................................................................................. 108
Reassembly of burner nozzle assembly..................................................................................................109
Ignition cables replacement...................................................................................................................111
Photo Resistor replacement...................................................................................................................113
Ignition transformer replacement..........................................................................................................114
APPENDIX D: DIESEL OIL PUMP.................................................................................................... 115
APPLICATIONS............................................................................................................................................ 115
PUMP OPERATING PRINCIPLE...................................................................................................................... 115
Bleed...................................................................................................................................................... 115
Cut-off:...................................................................................................................................................115
TECHNICAL DATA....................................................................................................................................... 116
General.................................................................................................................................................. 116
Hydraulic data.......................................................................................................................................116
PUMP DIMENSIONS......................................................................................................................................117
PIPE DIMENSIONS........................................................................................................................................117
INSTALLATION............................................................................................................................................ 118
START UP.................................................................................................................................................... 118
PRESSURE REGULATION..............................................................................................................................118
SYSTEMATIC MAINTENANCE.......................................................................................................................118
PARTS LIST................................................................................................................................................. 119
Oil Burner Fuel Pump replacement...................................................................................................... 120
Burner Pump Shaft Seal replacement....................................................................................................122
Burner pressure regulation kit replacement..........................................................................................124
Spline coupling replacement................................................................................................................. 127
APPENDIX E: FREQUENCY INVERTER ATV12........................................................................... 129
SPECIFICATION............................................................................................................................................129
TECHNICAL CHARACTERISTICS...................................................................................................................130
ACCESSING TERMINAL BLOCKS.................................................................................................................. 131
Power Terminals....................................................................................................................................131
FAULTS – CAUSES – REMEDIES..................................................................................................................132
Drive does no start, no fault displayed..................................................................................................132
APPENDIX F: SLUDGE BURNER......................................................................................................134
CLEANING OF SLUDGE BURNER.................................................................................................................. 134
PROCEDURE FOR ADJUSTING THE SLUDGE BURNER....................................................................................134
APPENDIX G: SLUDGE VALVE........................................................................................................ 135
Valve...................................................................................................................................................... 136
APPENDIX H: SLUDGE DOSAGE PUMP.........................................................................................137
DIMENSION................................................................................................................................................. 137
DISMANTLING AND ASSEMBLY DIAGRAM,..................................................................................................138
PARTS LIST ART. NO. 21270............................................................................................................... 139
INSTALLATION............................................................................................................................................ 140
Installation and Safety Recommendations.............................................................................................140
General.................................................................................................................................................. 140
STORAGE.................................................................................................................................................... 140
Short-term storage.................................................................................................................................140
Long-term storage................................................................................................................................. 140
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING............................................................................ 140
ELECTRICAL................................................................................................................................................141
General safety........................................................................................................................................141
Start-up procedure.................................................................................................................................141
DRY RUNNING.............................................................................................................................................141
MECHANICAL SEALS, ALL PUMPS............................................................................................................... 142
Guards................................................................................................................................................... 142

8 OG / 4 0 0 C /O G 4 0 0 C S
 TABLE OF CONTENTS

Warning/control device......................................................................................................................... 142

Pump operating temperature.................................................................................................................142
MAINTENANCE OF WEARING COMPONENTS................................................................................................142
Rotor and stator...................................................................................................................................................... 142
DIAGNOSTIC CHART....................................................................................................................................143
APPENDIX I: SLUDGE CIRC. PUMP.................................................................................................144
APPENDIX J: WATER DOSAGE PUMP........................................................................................... 150
DIMENSION................................................................................................................................................. 150
DISMANTLING AND ASSEMBLY DIAGRAM,..................................................................................................151
PARTS LIST ART. NO. 2007740........................................................................................................... 151
APPENDIX K: REFRACTORY........................................................................................................... 153
INTRODUCTION........................................................................................................................................... 153
CALDE PATCH INSTRUCTION.......................................................................................................................154
LIST OF DRAWINGS.............................................................................................................................156
INCINERATOR..................................................................................................................................................156
FLUE GAS...................................................................................................................................................... 156
SLUDGE TANK.................................................................................................................................................156
ELECTRICAL DIAGRAMS.................................................................................................................................... 156

OG400C/OG400CS 9
 ACRONYMS AND TERMS

ACRONYMS AND TERMS

Acronym/term Description
ACK Acknowledge
CCP Combustion chamber pressure
CCT Combustion chamber temperature
D.O. Diesel Oil
DEC Decrease
EMC Electro Magnetic Compatibility
ESC Escape
FGF Flue gas fan
FGT Flue gas temperature
HMI Human machine interface
HYS Hysteresis
INC Increase
LCD Liquid crystal display
LED Light emitting diode
MAX Maximum
MIN Minimum
PID A proportional–integral–derivative controller
PLC Programmable logic controller
PREV Previous
RPM Revolutions per minute
SCP Sludge circulation pump
SDP Sludge dosing pump
SFP Sludge Filling Pump
SLT Sludge settling tank
SST Sludge service tank
STP Sludge transfer pump
SW Solid Waste
USR User

Acronym/term Definition
The difference noted in a sensor's output as a response to an increasing or
Hysteresis
decreasing input signal of the same value

OG400C/OG400CS 10
 SAFETY

Safety markings
The contents of this manual use marking based on ISO 3864-1, with the following
differentiation:

: a hazard with a high risk of injury or death if not avoided

: a hazard with a medium risk of injury or death if not avoided

: a hazard with a low risk of minor or moderate injury if not avoided

: Item needing special attention

General use and safety instructions

 Incinerator should be inspected in the morning on a daily basis, and

cleaned as required. Burning chamber air inlets, air outlets and burner parts should be
kept clean.

 Never turn off the main power before the chamber temperature is down below 170°C.

 Never load glass, lithium batteries or spray cans in the incinerator – nor
large quantities of oily rags or filter cartridges. This may damage the flue gas stack and
refractory.

 Inspect the cooling jacket every 6 months (open the cover plates) and clean as required
with steam or hot water.

 Read the instruction manual, and never change any settings.

 In case of abnormal operation, contact TeamTec.

 When doing maintenance on any of the incinerator components always

make sure that the power is switched off.

 Do never throttle the air/steam needle valve more than ¾ turn closed. If the pressure
increases above green area, clean the sludge burner nozzle.

 If experiencing any problem with high temperature in combustion chamber, flue gas or
control of sludge dosing, replace the dosing pump stator.

 Do not transfer sludge to the service tank during sludge burning in a single tank system
(can damage the refractory).

 As a minimum, heat the sludge over night, without starting the circulating pump. Next
morning drain off the free water and start the sludge programs

OG400C/OG400CS 11
GARBAGE MANAGEMENT

Garbage management
TeamTec recommend working out guidelines for an on-board garbage management plan.
Personnel responsible for operation of the incinerator shall be trained and capable of
implementing the guidance follows by the instruction manual.
Waste incineration on board sea going ships and offshore platforms is world wide regulated by IMO
MARPOL 73/78, RESOLUTION MEPC 76(40), STANDARD SPECIFICATION FOR SHIPBOARD
INCINERATORS, adopted on 25.september 1997, and IMO MARPOL ANNEX VI REGULATION 16
and APPENDIX IV adopted on 26. September 1997 and IMO Res. MEPC. 244(66) adopted April 4th
2014 (Replacing MEPC.76(40)).

Incineration of solid and liquid waste

In accordance with the above regulation the following solid and liquid waste can be burned in
an IMO certified shipboard incinerator:

Plastic, Cardboard, Wood

Rubber, Cloth, Oily Rags, Lub. Oil Filters,
Diesel Engine Scavenge Scraping
Paint Scraping
Food waste, etc.
Sludge Oil, Waste Lub. Oil
Hospital Waste, Female Hygienic Binds

Solid and liquid waste that is prohibited to be

burned
Material, which contains more than traces of HEAVY METAL and of refined
petroleum products containing halogen compounds is prohibited to being incinerated. Light
bulbs contain heavy metal and are prohibited to incinerate.
Under shipboard operational waste the following materials have a density placing them in the
category of HEAVY METAL:

MERCURY
LEAD
NICKEL
VANADIUM
ZINC
IMO Annex VI regulation 16 prohibits incineration on ship of certain products, such as
contaminated packaging materials and polychlorinated biphenyls (PCBs).

Do not incinerate metals as soda and food can plates, flatware, serving
spoons/tray, hardware (nuts & bolts), structural pieces, wire rope, chains etc, glass such as
bottles, jars, drinking glasses etc., flammable materials such as bottles or cans containing
flammable liquids or gasses and aerosol cans. Do not incinerate heavy load with plastics or
bulk food waste.

Read instruction/warning label on garbage door.

Loading of glass will result in a rock hard slag, which is difficult to remove from the refractory
lining.

12 OG/400C/OG400CS
 GARBAGE MANAGEMENT

Solid Waste handling

OG200/400C is intended for incineration/burning of sludge and solid waste on-board ships or
other marine installations. For batch loading the incinerator capacity is 400L/charge IMO class
2 wastes.

Class 2 refuse, consists of approximately even mixture of rubbish and garbage by weight. This
type of waste is common to passenger ships occupancy, consisting of up to 50% moisture, 7%
incombustible solids and has a heating value of about 10.000 kJ/kg as fired.

Be aware that plastics has high calorific value, about 36.000 kJ/kg and must
only be incinerated in small amounts at the same time.

Batch loading

Do not attempt to clean the combustion chamber without activating the

slugging mode on the touch screen display, to prevent injury to personnel due to insufficient
ventilation.

Each morning, providing that the combustion chamber temperature is lower than 170°C, slag
and ashes should be removed. Partly burnt garbage shall remain in the chamber. This garbage
will be fully incinerated at the next sequence of incineration. The air inlet openings in the
bottom of the combustion chamber must be regularly cleaned. This is important in order to let
the combustion air come into the chamber.

Load the combustion chamber to maximum 2/3 height with garbage of type IMO class 2. If high
calorific garbage is loaded, a smaller quantity must be loaded per charge.

Sluice feeding
If sluice is installed, solid waste can be fed into the 55 litre sluice at temperatures between
700°C and 1050°. Fill the trash in a garbage paper bag, open the sluice lid/sluice door and put
the bag into the sluice. Do not jam the trash bag into the sluice or overfill it. Close the lid /
sluice door and rotate the sluice by the handle on the sluice. The recommended waiting time
between each time the sluice can be operated is 210seconds. After the waiting time has elapsed,
the sluice is ready for a new load.

Sludge Capacity
The incinerator is certified according to MEPC 244(66) which determines the sludge to contain
20% water.
A high water content up to 50% water content will result in a higher capacity than what is
mentioned in the certificate. As an example, the sludge with 40% water content will have lower
calorific value than IMO sludge, hence higher hydraulic capacity.

A water content higher than 50% requires a pilot burner (support burner). This reduces the
available capacity for burning of sludge.

OG400C/OG400CS 13
INTRODUCTION

Introduction
Instruction manual, purpose and scope
This user manual is made according to guidelines in the Norwegian Standard NS 5820
The manual will guide the reader/user gradually to an understanding required for safe operation
and maintenance of the incinerator system.
It is important for the user to have a good understanding of the incinerator function, to avoid
malfunction caused by operational errors.
The guarantee will be invalid if problems and/or caused by operational errors or mistreatment.

Service network for TeamTec incinerators.

Please note that our office is the single point of contact for your service, spares and
upgrading requirements:
TeamTec AS
Nyvei41
P.O.Box 203
4902 Tvedestrand
Norway

Tel.: +(47) 37 19 98 00
E-mail: office@teamtec.no

China

Manufacturer: CSSC NanJing Luzhou Environment Protect Co.,Ltd

Address: Xinjian Zhong Hua Men wai NanJing , Jiangsu Province

Tel: +86-(0)25-86723713

Fax: +86-(0)25-86723747
E-Mail: services@nj-lzep.com

Please note that our main strategy is to offer our customers the best service and quality
spare parts wherever and whenever they need them. To reach this goal we have
established a stock of spare parts and trained service personnel in major ports throughout
the world.

For more information please visit our web pages:www.teamtec.no

14 OG/400C/OG400CS
 MAIN DATA

Main data
Performance data
Incinerator (combustion chamber).

Type: OG400 C/OG400CS

Capacity: 596/6161 KW (512,000/530,0002 Kcal/h)

71kg/h (74 l/h) IMO sludge oil IMO sludge (20% water)
Corresponding to: Solid waste max. 400 litre per charge(52kg per IMO class 02 waste
charge) or 55 l/charge continuous feeding

Combustion chamber Max. 1200 °C

temperature: Working. 870-1150 °C
Flue gas Max. 350°C
temperature:
Working. 250 - 340 °C
Surface temperature: 15°C above ambient temperature.

Electrical power, From ship distribution

15 kW (Flue gas fan included.)
rated consumption: system.

Flue gas fan El. From incinerators

7,5/8,6 kW
power consumption. electrical control panel

Negative pressure: 10-28mmWC In combustion chamber

Total weight: 2561/2664kg

Outline dimension: 1412 x 1944 x 1897 (L x W x H)

See dimension drawing.
1356 x 1885 x 1898 (L x W x H)

Burner (fixed on combustion chamber)

Capacity: 18-28l/h Two nozzles: 2.5 gph60°

and 4.5 gph 45°

Diesel Oil viscosity Max. 13 cSt at 40°C

Burner air blower each: Max. 1,500 m2/h

Oil pump: Working press. 16 bar

Max 21 bar.

El. Motor 1.43/1.38 Amp. 2800/3400 rpm.

Rated current: 380/440 V 50/60 Hz, 0.55/0.63kW

1
USCG Capacity
2
USCG Capacity

OG400C/OG400CS 15
MAIN DATA

Ignition transformers: 230V / 10,000V

Weight (each): 30 kg

Outline dimension: 845 x 539 x 387 (L x W x H) See dimension drawing.

Diesel oil booster pump (optional)

Capacity: 110 l/h At 14 bar.

El.motor: See Burner motor

Connections: 1/4"

Weight: 12 kg.

Outline dimension: 422x170x200(L x W x H) See dimension drawings.

Flue gas fan (bulkhead mounted)

Type: Designed to withstand max
DN 350 H2
temperature of 450°C
One stage centrifugal fan.

Capacity: 9500 m³/h at 300°C At 150mmWC total back

pressure.

Flue gas duct dimensions DN350

El.motor: 1465/1768 rpm

380/440V, 7.5/8.6W
Current rating
17.2/15.8A

Weight: 326 kg

Outline dimension: 1020 x 1040 x 1030 (L x W x H) See dimension drawing.

16 OG/400C/OG400CS
 MAIN DATA

Sludge tank
Volume: Net: 435, 700, 1100, 1700, 2000, 3000
litres.

Test pressure: Cylindrical tanks 0.8 bar

Rectangular tanks 0.25 bar

Corrosion Protection: Internal coated with one layer of

Carboline E-19 primer, thickness
minimum 70 microns

Flange rating: PN 16

Weight: See dimension drawing.

Outline dimension: See dimension drawing.

Sludge circulating pump. (installed on sludge tank)

Type; 40WYXH-6-20 sludge circulation pump

Capacity: 6 m3/h at0.2mpa discharge pressure.

El. motor: 4.7/4.07 Amp 2840/3470 rpm

Current rating 380/440 V, 50/60 Hz, 2.2/2.5 3kW

Sludge filling pump (if dual sludge tank system)

Type; See sludge circulation pump

Sludge dosage pump (fixed on combustion chamber)

Type: TeamTec RDCZ 432 screw pump

El. Motor: 0,37kW IP55 885/1062 rpm

Current rating 1,9A 220V 50/60Hz

Control speed: 0 – 1200 rpm

Water dosage pump (Optional)

Type: TeamTec RDCZ 432 screw pump

El. Motor: 0,55kW IP55 1380 rpm

Current rating 1,6A 380V 50Hz

Control speed: 0 – 1000 rpm

OG400C/OG400CS 17
MAIN DATA

Diesel oil preheater (fixed on combustion chamber)

Rating: 380/440V, 50/60Hz, 1.5/2.0 kW
2.3/2.6 Amp

Electrical control panel incinerator (fixed on combustion chamber)

Type: Painted steel control cabinet 800x600x300mm

Enclosure rating IP 55

Weight: 56 kg (included in the total weight of the

incinerator)

Flue gas damper.

Type: Welded steel damper with actuator

Size: DN400/DN350

Actuator motor: Drive force 20Nm. Travel

time for 90° is 150/125sec
50/60Hz.

Weight: 68/71 kg

Dimension between 300 mm See dimension drawing.

flanges:

18 OG/400C/OG400CS
 MAIN DATA

Ships system interface requirement.

Electrical.
Refer to Cable Arrangement drawing.

Diesel oil.
Diesel oil supply line Equipped with a closing
valve. DN 15 flange, max pressure
Connection: 1.5 bar
Recommended filter, mesh
40µm
Max.suction lift 3500mm
Diesel oil return line Connection. DN 15 flange, max pressure
1.5 bar

Flue gas duct.

Incinerator to flue gas fan Duct DN400/DN350
Flue gas fan to open air. Duct DN400/DN350

Sludge and Steam or Air.

Steam /air supply line for sludge Connection DN 15 flange
atomising. Pressure 6 - 8 bar
Consumption: Steam approx. 20kg/h
Comp. air approx. 20kg/h
Drain from spill collector. Connection DN 25

Water and Steam or Air (Optional)

Steam /air supply line for sludge Connection DN 15 flange
atomising. Pressure 6 - 8 bar
Consumption: Steam approx. 20kg/h
Comp. air approx. 20kg/h
Drain from spill collector. Connection DN 25

Sludge tank. (1100 / 1700 / 2000 / 3000l option)

Filling Connection DN 50 flange
Overflow line Connection DN 65 flange
Supply and return line for incinerator Connections DN 25 flange
Air vent. Connection DN 65 flange
Drain. Connection DN 40 flange
Water drain. Connection DN 25 flange
Sample points. Connections 1/2" BSP
Spare Connection DN 50 flange
Heating: Steam Connection 1/2" BSP
Consumption approx. 50kg/h
Max. pressure 8 bar
Heating: Thermal oil Connection DN 15 flange
Consumption 2 m³/h
Max. pressure. 10 bar
Max. temperature 180°C

OG400C/OG400CS 19
MAIN DATA

Detailed information regarding the system is found on the Piping & Instrument Diagram given in the
Drawings section.

Water tank. (435 l) (Optional)

Filling Connection DN 32 flange
Overflow line Connection DN 40 flange
Supply line for incinerator Connection DN 15 flange
Air vent. Connection DN 50 flange
Drain Connection DN 50 flange

Detailed information regarding the system is found on the Piping & Instrument Diagram given in the
Drawings section

20 OG/400C/OG400CS
 TECHNICAL DESCRIPTION

Technical description
Overall system function description
The TeamTec Incinerator type OG200/400C is designed for on board incineration of ship's waste oil and solid
refuse. The system consists of 5 main parts:

 Combustion chamber with diesel oil burner, sludge burner, pilot fuel heater and electric control panel.
 Flue gas damper.
 Sludge service tank with circulating pump and heater.
 Sludge settling tank with filling pump and heater.(Optional)
 Water injection (Optional)

Combustion chamber
The combustion chamber consists of a cylindrical chamber. The trash is ignited by burner in the chamber. The
combustion chamber is equipped with an inspection, which can be opened only while the incinerator is not
burning. The control system will prevent the door from being opened before the set temperature for cooling is
reached.
The flue gas outlet is located at the top of the chamber. The flames from the burners follow a corkscrew
pattern towards the bottom and continue rotation upwards in the centre of the combustion chamber. Remnants
of particulate matters in the gas flow are neutralised by the burner, making the combustion ecologically safe.
As the fumes exits the chamber, cooling air drawn from the lower part of the casing is mixed with the flue gas
to bring the temperature down to approx. 330°C before it pulled out by the flue gas fan and blown out the stack
to atmosphere.
The burning process is monitored by the PLC and scanned by a photo resistor in the burner. The temperatures
are also monitored/regulated automatically by the PLC control system.
Two sight glasses are equipped, for the operator to be able to inspect the amount of trash in the chamber and
the function of the system.
The combustion chamber is of steel construction, lined with specially designed refractory blocks. Between the
steel and refraction there is a 50mm layer of insulation. The refractory material is made of a low cement/high
alumina quality being slag resistant and having very good thermal shock resistance. A double steel casing with
a cooling air jacket forms the outside of the combustion chamber.
The combustion chamber is equipped with a, three-stage diesel oil burner and a steam/air atomising nozzle for
sludge burning. Under the burner assembly, a bracket/drip tray for sludge burning equipment is mounted.
The Diesel Oil burner has 3 stages, automatically controlled by the PLC. In addition there are four stages for
sludge burning, using steam or compressed air for atomising. The sludge burner allows particles up to 4 mm to
pass through. The D.O. burner is monitored by the PLC and has a built in primary air fan and diesel oil pump.
The main electrical control panel is normally fitted on the incinerator and it contains circuit breakers, starters,
frequency inverters, PLC and operator panel. The electric panels are built according to international standards
for marine equipment. The operator panel, which is located at the side of the control panel, has a LCD display
touch screen for selecting burner program modes and for monitoring the burning process.

Flue gas fan

The purpose of the flue gas fan is transportation of the flue gas from the combustion chamber and the fan
creates negative pressure in the furnace. The same fan draws ambient air through the cooling jacket on the
combustion chamber and the hot gas from the furnace is diluted with the cooling air at the flue gas outlet on the
combustion chamber in order to reduce the temperature below350°C. The cooling air drawn trough the cooling
jacket will keep the surface temperature of the combustion chamber lower than 15°C above ambient
temperature

Sludge service tank with heater

The TeamTec Sludge tank is meant to function as a daily service tank for sludge to the incinerator. A heater,
controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).

OG400C/OG400CS 21
TECHNICAL DESCRIPTION

Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. A level transmitter
on the tank provides PLC to generate an animated tank level readout on operator panel (display on incinerator
control panel), and right amount of sludge burned.
A circulating pump is mounted on the tank. The pump transports the sludge to the incinerator and a return line
to the tank is provided, a god mixing of the sludge and water is guaranteed. A low level switch on the tank will
stop the incinerator, the circulating pump and heating when the level has reached a minimum. An indicating
light for heating is placed on the junction box on the tank.
Do not transfer sludge to the service tank during sludge burning

Sludge settling tank with heater (optional)

The TeamTec Settling tank is meant to function as a daily tank to heat, separate and drain water from the
sludge. A transfer pump can be used to fill the tank, and be connected to the "high level" switch, which stops
the pump when the tank is full.
A heater, controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. The lowest one is
meant to use for draining off the water. A level transmitter on the tank provides PLC to generate a tank level
readout on operator panel (display on incinerator control panel).
A filling pump is mounted on the tank. The pump transports the sludge to the sludge service tank. A low level
switch on the tank will stop the filling pump and heating when the level has reached a minimum. It is not
possible to transfer sludge to the service tank during sludge burning
An indicating light for heating is placed on the junction box on the tank.

Water injection (Optional)

The incinerator is equipped with a separate water injection unit including a frequency controlled water dosage
pump. The purpose of this pump is to inject water, containing small quantities of oil remnants, into the
combustion chamber by a special designed TeamTec nozzle system.

When burning sludge with injected water, the sludge burning capacity increases, NOx in flue gas duct reduces
and it is an easy way to get rid of problem water. Dumping oily water directly into the sea can harm marine life,
and is illegal. Various ports are facing new local regulations on ship emissions, including discharges of ballast
water, gray water, bilge water, and deck runoff, among others. Disposal of the contaminated water in the
incinerator is an easy and effective solution to a complex problem.

Water tank (Optional).

As an option to use the ships bilge/grey water tank, it is possible use a water service tank. The Water tank can
be filled from either the bilge holding tank or the gray water tank. This system is utilizing the existing water
discharge pumping system in order to fill a water tank to be located adjacent to the incinerator.

The water tank has filling, overflow and ventilation connection. The incinerator has frequency controlled water
dosing pump unit, with suction lift at 3500mm. The water is connected to the incinerator with DN 15 flange
connection.

The water tank has two level switches. A high level switch to stop the filling pump and a low level switch, with
dual contact set, to start the filling pump and to stop the water injection if switch is activated for more than two
minutes. This is to prevent the water dosage pump to run dry. A suitable tank is available from TeamTec.

22 OG/400C/OG400CS
 TECHNICAL DESCRIPTION

Sludge control
Introduction
The automatic sludge control logic is designed for burning a maximum amount of sludge, consuming a
minimum amount of diesel, and maintaining a combustion chamber temperature above 870°C (CCT stop
burner diesel oil), see operator panel - settings sludge program page 2/4. Sludge quality is an important factor
for the sludge burning process. The system is capable to handling sludge with a high content of water, but this
might however result in a higher consumption of diesel oil.

Temperature limits
680°C Start sludge burner.
640°C Temperature decrease to this level stop sludge burner and increase sludge quality
counter with 2(see sludge quality control Page 30).
660°C Temperature decrease to this level, after temperature have been above 690°C,
decrease the sludge dosage pump rpm with 40 and increase sludge quality counter
with 2.
690°C Temperature increase to this level increase the sludge dosage pump rpm with 40.
700°C Alarm level for low combustion chamber temperature, if combustion chamber
temperature has been above 850°C. Sluice is available in Solid waste program.
840°C Starts a diesel support burner in addition to the condition at 870°C and increase the
sludge quality counter with 2. Decrease the sludge dosage pump rpm with 100.
870°C Temperature allowing burning sludge alone. Temperature increases to this level an
increase of the sludge dosage pump rpm with 100.
890°C Above this temperature the sludge quality counter will step down by one every
minute.
900°C Sluice is available in Sludge &Solid waste program.
1000°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 rpm every 30 second if Sludge &Solid waste program is running.
1050°C Sluice is not available in Sludge & Solid waste or Solid waste program.
1050°C Water injection control temperature. Water amount injected to combustion chamber
will increase if CCT is above this level, and decrease if CCT below this level.
1110°C Water injection starts.
1150°C Temperature increase to this level and above, decreases the sludge dosage pump rpm
with 4rpm every 30 second.

Burner stage
 STAGE NO 3 Diesel oil nozzles no. 1 + 2.

 STAGE NO 4 Diesel oil nozzle no. 1 and sludge.

 STAGE NO 5 Diesel oil nozzle no. 2 and sludge.

 STAGE NO 6 Diesel oil nozzles no 1 + 2 and sludge

 STAGE NO 7 Sludge burner alone.

OG400C/OG400CS 23
TECHNICAL DESCRIPTION

Control
At first start up a sludge burner program, the sludge burner starts when combustion chamber temperature rises
above 680°C, the operator panel will indicate burner stage 5, the sludge dosage pump will be given start speed
200 rpm, and will run at this speed for 60 seconds. During the 60 seconds, burner step 5 will be fixed.

Figure: Sludge quality control.

Assuming the sludge is of a good quality the temperature will start to rise. If the temperature raise is >=0°C
over 30 seconds, the sludge dosing pump increase 3 rpm. There will be a sampling of temperature each 30 sec.
and provided there is a temperature raise, a new step of 3 rpm will take place.
If the sludge quality is still good, the sludge dosing pump will be given a new step increase of 50 rpm when
temperature rises above 690°C. The burner stage will be 4. When temperature raise above 870°C the sludge
dosing pump will again be given a new step increase 220 rpm and the burner stage will be 7.
If the sludge contains too much water or chemicals, the temperature is likely to fall below 640°C and the sludge
dosing pump stop. Burner will change to stage 3, and the sludge quality counter will increase with 2 (after an
attempt to stage 5). When temperature rises above 680°C the sludge burner will start again. The burner stage
will then depend of sludge quality number. The sludge quality number is an indication of the quality of the
sludge. A high sludge quality number indicates a sludge with high water content, and burner will use more
diesel oil.
The low temperature alarm, 700°C, will first be activated if temperature has been above 870°C.

24 OG/400C/OG400CS
 OPERATOR PANEL

Operator Panel
General
The operator panel is a touch sensitive screen enabling the operator to enter information to the incinerator
control system. The screen is also displaying information from the control system to the operator. The panel is
connected to a PLC, controlling the combustion process. A description of the screens follows. The main picture
is displayed at start up and is possible to access by pressing “main” from most other screens. The screen will
display equipment according to scope of delivery from TeamTecAS
The Main picture has animated feedback to the
operator. The pumps and fans turn green when 1
running. The level switches are animated up or down
according to the level. A level indication is animated 2
at the sludge tanks. There are written numbers
displaying actual measured values positioned 3
approximately according to physical position at the
incinerator. In addition to the buttons at the lower part 4
of the panel, it is possible to press on an item on the
screen to open a different screen or dialogue box. The 5
list below describes the possible options:
6

10
1: Press in the middle of burner to access screen “Burner”
2: Press either of the two figures to access screen “Setting tanks” 11
3: Press heating symbol to access pop-up screen for start/stop heating sludge service tank.
4: Press heating symbol to access pop-up screen for start/stop heating sludge settling tank. 12
5: Press pump symbol to access pop-up screen for start/stop sludge filling pump (SFP).
6: Press pump symbol to access pop-up screen for start/stop sludge circulation pump
(SCP).
7: Press “Stop” button to stop incinerator.
8: Press “Alarm” button to access alarm screen.
9: Press “Hour” button to access screens for hour counting.
10: Press “Slag” button to start loading / slagging program.
11: Press “Setup” button to access screen “Setup” for selection of specific setup screen.
12: Press “Start” button to access pop-up for start / change program.

(The appearance of the screen may differ based on the choice of optional equipment)

OG400C/OG400CS 25
 OPERATOR PANEL

Screens
Structure
Logic control system consists of an “Overview” screen and several sub-screens in the order as described below:

Main

Burner Hour counters

Settings tanks Consumption Setup consum.

Start/stop pumps Water tank

and heating

Select/start
programs

Setup Burner

Hour counters Alarms

Alarm Service Trend

Sludge I/O

Solid waste
Information
The control system Pop-up
will activate these SW Sludge
screens. Service
Pop-up
Sludge and Water

Load/slag & stop

Conf. Setting Water tank

Tanks

Login
Restore
Factory
Burn-in Settings

Display backlight

Date time

Prog. info

Consumption Setup consum.

Water tank

Hour

General: From all screens it is possible to stop the incinerator by pressing “Stop” It is also possible to access
“Main”, Setup” and “Alarm from all screens.

26 OG/400C/OG400CS
 OPERATOR PANEL

POP-up select program

Select program to start. The pop-up will close
after selection of program. Select “Cancel” to
close pop-up if you don’t want to start or
change program.
Description of the program selection
alternatives are given in chapter program
description.

Pop-up Start -Stop

To start and stop equipment press the actual
icon on the main screen and a pop-up window
will allow you to start or stop pumps and
heaters. The following figure shows an
example for heating service tank. The pop-
up’s will close after selection of “Start” or
“Stop”. Select “Cancel” to close pop-up if you
don’t want to change status of the equipment.
Start – stop heating sludge service tank:
Low level switch in sludge service tank must
be activated.
Start – stop heating sludge settling tank:
Low level switch in sludge settling tank must
be activated.
Start – stop sludge filling pump: Low level
switch in sludge settling tank must be
activated and high level in sludge service tank cannot be activated. Sludge burning program must not be
activated.
Start – stop sludge circulation pump: Low level switch in sludge service tank must be activated. If a program
burning sludge is activated it is not possible to stop the pump by this control. In that case choose a program not
burning sludge or stop the incinerator
Start – stop sludge transfer pump: High level switch in sludge settling tank must not be activated.

Information pop-up
An information pop-up gives information to the
user about irregularities between user actions and
incinerator status. Read the message and press
“Ack”.
The following messages may appear as
information messages:

 High temperature sludge settling tank

 Not possible to start heater low level in

sludge settling tank

 Not possible to start sludge transfer

pump high level in sludge settling tank

 Not possible to start sludge filling pump low level in sludge settling tank

 Not possible to start sludge filling pump high level in sludge service tank

 Not possible to start sludge filling pump when sludge program is running

OG400C/OG400CS 27
OPERATOR PANEL

 Not possible to start sludge circulation pump low level in sludge service tank

 Not possible to start heater low level in sludge service tank

 Not possible to start sludge program - low level sludge service tank

 Not possible to start solid waste - sludge program - low level sludge service tank

 Not possible to start program - Door not closed - please close door

 Not possible to start program –Alarm is active - please check Alarms

 Waiting.... flame in chamber

 Waiting for correct sludge temperature

 Sludge dosage pump is worn out – stator must be replaced

 Sludge service tank level decreases too fast – Stop draining

 Low level sludge service tank – cooling

 Battery power is low, or no battery is detected.

 Heating of refractory is finished. Let the incinerator cool down for 10 Hours

Burner
Display actual values and status on motors,
actuators and sensors. No adjustments or
settings on this screen – view only.

Setting tanks
Displays tanks physical attributes and sludge
mass for correct sludge consumption.

28 OG/400C/OG400CS
 OPERATOR PANEL

Hour counters
Display last run and total hours. Press “Next”
button to access screen “Hour counters 2”

Page 2/2. Display last run and total hours.

Press “Prev” button to access screen “Hour
counters 1”

Setup
Some functions require the operator to login in
order to access a screen or to alter a value in
the setup. This normally indicates that the
operator needs training in order to be aware of
the consequences of his actions.
Select the setup screen you want to access. If
not logged in as user “usr”, values on different
setup screens are “view only”.

OG400C/OG400CS 29
OPERATOR PANEL

Login
Pressing “Setup” will give access to “Login”.

Wrong user pop-up

All screens can be accessed by all users. To
change settings, the user has to log in as user
“usr” with password “2468”. To log in, select
“Setup” and then “Login”. If the user tries to
change a value without logging in to the
operating terminal, this screen will pop-up:

Press the “name” tab to activate the login sequence: An

alphanumeric keyboard will pop-up and type in user name usr
and press “enter” to accept user name. Press “Password” button
and type in password 2468 and press return to accept password.
The user is now logged in as user “usr” and is allowed to change
settings. Settings will automatically change back to factory
settings every 15 minutes, regardless if logged in as usr.

Change values
Plot the value that should be changed. A numeric pop-up will appear:
The present value is displayed on the line. Type in a new value and press return to
accept, or press “ESC” to cancel.

30 OG/400C/OG400CS
 OPERATOR PANEL

Settings burner
If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.

Text Description

Burner damper burner Burner damper opening. Adjusts the amount of air supplied to the
step x combustion process by the burner motor fan.

Factor CCP burner Correction of burner damper opening related to combustion chamber
damper reg. pressure (CCP). Used internally in the control system.

Factor SDP burner Correction of burner damper opening in related to sludge dosage pump
damper reg. (SDP) speed. Used internally by the control system.

OG400C/OG400CS 31
OPERATOR PANEL

Settings alarms
If not logged in as user “usr”, values on
different setup screens are “view only”.

Text Description

Alarm max time diesel The maximum time the diesel heater is activated the first time after start
heater start incinerator. The diesel heater requires extra time at start-up.

Alarm max time diesel The maximum time the diesel heater is activated during incinerating.
heater run

Alarm max. CCT Maximum combustion chamber temperature (CCT).

Minimum operating Minimum combustion chamber temperature (CCT). Used as reference to

CCT “Alarm CCT below minimum operation temp”

Alarm CCT below Maximum temperature drop combustion chamber temperature (CCT).
minimum operation Related to “Minimum operating CCT”.
temp

Alarm max. FGT Maximum flue gas temperature (FGT).

Alarm min. CCP Minimum combustion chamber pressure (CCP).

(Draught failure)

Alarm minimum diesel Adjust minimum diesel oil pressure

oil pressure

32 OG/400C/OG400CS
 OPERATOR PANEL

Settings sludge (1/5)

If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number
of setting screens.

Text Description

CCP start sludge Set point combustion chamber pressure (CCP) when starting a sludge
program

Max. CCP run sludge Maximum combustion chamber pressure (CCP). Used internally as a limit
in the control system

Min. CCP run sludge Minimum combustion chamber pressure (CCP). Used internally as a limit
in the control system

Min. sludge Minimum sludge temperature before starting sludge program. This value is
temperature running also calculating alarm sludge temperature. See alarm settings.
sludge

Alarm sludge The maximum temperature drop in sludge temperature. Related to “Min
temperature low sludge temperature running sludge”.

Alarm sludge temp. The maximum temperature increase in sludge temperature. Related to “Min
high, above normal sludge temperature running sludge”.

Min. CCT for run Minimum combustion chamber temperature (CCT) before starting sludge.
sludge

CCT low hysteresis – Maximum drop combustion chamber temperature (CCT) – stop sludge
stop sludge. dosage system.

OG400C/OG400CS 33
OPERATOR PANEL

Settings sludge (2/5)

If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.

Text Description

Time start sludge Time after start sludge dosage pump (SDP) before making adjustments – to
before adjust ensure a stable process before adjusting sludge.

Time check CCT after Time between reading combustion chamber temperature (CCT) and making
adjust adjustments to the process

CCT inc between The minimum increase in combustion chamber temperature (CCT) needed
adjust – inc sludge at time check before making adjustment to process.

CCT inc sludge – dec Minimum combustion chamber temperature (CCT) before decreasing diesel
diesel oil oil and increasing sludge.

Hysdec sludge – inc Maximum drop combustion chamber temperature (CCT) before decreasing
diesel oil sludge and increasing diesel oil.

CCT stop burner Minimum combustion chamber temperature (CCT) before stop diesel oil
diesel oil and further increase sludge.

Hys burner restart Maximum drop combustion chamber temperature (CCT) before restart
diesel oil burner diesel oil and decrease sludge.

Maximum CCT Maximum combustion chamber temperature (CCT) before reducing sludge.

Hys max. CCT – stop Maximum drop combustion chamber temperature (CCT) before stop
dec sludge reducing sludge.

Set CCP running Step Set point for Combustion Chamber Pressure (CCP) is -15mmWC during
4&5 burner stage 4 & 5 as long as the Combustion Chamber Temperature is
below 800°C

Set min CCP for Minimum set point for Combustion Chamber Pressure (CCP) as long as the
temp.regulating Combustion Chamber Temperature is above 800°C

34 OG/400C/OG400CS
 OPERATOR PANEL

Settings sludge (3/5)

If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.

Text Description

Max. FGT – start Maximum flue gas temperature (FGT) before decreasing combustion
adjust CCP chamber pressure (CCP)

Hys max. FGT – stop Maximum drop flue gas temperature (FGT) before stop decreasing
adjust CCP combustion chamber pressure (CCP)

Time check FGT Time between check flue gas temperature (FGT) before making further
adjust CCP increase in combustion chamber pressure (CCP)

FGT max. inc. CCP Maximum flue gas temperature(FGT), increase combustion chamber
pressure(CCP).

Max. FGT – start Maximum flue gas temperature (FGT) decrease sludge dosage pump (SDP)
adjust SDP RPM RPM.

Hys FGT – stop adjust Minimum drop flue gas temperature (FGT) before stop decreasing sludge
SDP RPM dosage pump (SDP) RPM.

Min. CCT scale CCP Minimum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)

Max. CCT scale CCP Maximum combustion chamber temperature (CCT) in scaling range for
run sludge adjusting combustion chamber pressure (CCP)

CCP running burner Set point combustion chamber pressure (CCP) running burner step 6
step 6

OG400C/OG400CS 35
OPERATOR PANEL

Settings sludge (4/5)

If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.

Text Description

SDP compensation – Increasing sludge when changing burner step from 5 to 4, or 6 to 5.

decrease diesel oil

SDP compensation – Increasing sludge when changing burner step from 4 to 7.

stop diesel oil

SDP RPM decrease Decreasing SDP RPM every 30 second if combustion temperature
CCT >Max. CCT run sludge – dec sludge(1/4).

SDP RPM increase Increasing SDP RPM every 30 second if combustion temperature CCT
increases or equal.

Min. RPM SDP Minimum RPM for sludge dosage pump (SDP).

Max. RPM SDP Maximum RPM for sludge dosage pump (SDP).

Manual set point SDP Adjust sludge dosage pump manually.

RPM

Sludge quality counter Sludge quality counter number. See Page 29.

Purging start sludge Time for purging sludge nozzle before opening sludge.

Purging stop sludge – Minimum combustion chamber temperature (CCT) for stop purging sludge
CCT below nozzle.

Alarm low level Activate if alarm is needed when sludge service tank low level switch is
Sludge service tank activated.

36 OG/400C/OG400CS
 OPERATOR PANEL

Settings sludge (5/5)

If not logged in as user “usr”, values on different
setup screens are “view only”. Buttons “Prev.”
and “Next” is used in a circular shift function
between a number of setting screens.

Text Description

Alarm set point Adjust setpoint for minimum steam/air pressure

minimum steam/air
pressure

Alarm set point Adjust setpoint for maximum steam/air pressure

maximum steam/air
pressure

Alarm set point Adjust setpoint for minimum sludge pressure

minimum sludge
pressure

Alarm set point Adjust setpoint for maximum sludge pressure

maximum sludge
pressure

OG400C/OG400CS 37
OPERATOR PANEL

Settings solid waste (1/2)

If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number of
setting screens.

Text Description

Set burning time On, makes it possible to program a fixed burning time

CCP start-up solid Minimum combustion chamber pressure (CCP) before start burner at start
waste program solid waste program

CCP max. solid waste Maximum combustion chamber pressure (CCP) when running solid waste
program

CCP min. solid waste Minimum combustion chamber pressure (CCP) when running solid waste
program

Maximum CCT Max combustion chamber temperature (CCT), decrease burner stage

38 OG/400C/OG400CS
 OPERATOR PANEL

Settings solid waste (2/2)

If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number of
setting screens.

Text Description

Time check CCT Time for checking temperature increase/decrease.

increase

Max. FGT start Maximum flue gas temperature (FGT) before start adjusting combustion
adjustment CCP chamber pressure (CCP).

Hysteresis FGT stop Minimum drop flus gas temperature (FGT) before stop adjusting
adjusting CCP combustion chamber pressure (CCP)

CCP inc when FGT Value for increasing combustion chamber pressure (CCP) when flue gas
above set point temperature (FGT) is above set point

CCP dec when FGT Value for decrease combustion chamber pressure (CCP) when flue gas
below set point temperature (FGT) is below set point

Time check FGT Time between reading flue gas temperature (FGT) before making
adjust CCP adjustments to combustion chamber pressure (CCP).

Max. FGT start adjust Maximum flue gas temperature (FGT) before start adjusting burner step.
burner step

Hysteresis FGT stop Minimum drop flue gas temperature (FGT) before stop adjusting burner
adjust burner step step.

Time check FGT Time between reading flue gas temperature (FGT) before making
adjust burner step adjustment to burner step.

OG400C/OG400CS 39
 OPERATOR PANEL

Settings sludge with water

If not logged in as user “usr”, values on different
setup screens are “view only”.

Text Description

CCT enable Water Setpoint combustion chamber temperature for water injection to start.
injection

CCT min. for Water Minimum combustion chamber temperature when water injection is
injection enabled.

Setpoint water Setpoint combucstion chamber temperature for control of water injection.
injection Control

Maximum CCP Maximum combustion chamber pressure (CCP) for running sludge with
running sludge with water.
water

Max. RPM WDP Maximum Water dosage pump RPM.

Min. RPM WDP Minimum Water dosage pump RPM.

Increase RPM WDP Increase of Water dosage pump RPM every 60 second until “Max RPM
WDP” is reached

Setpoint steam/air Minimum pressure to trigger the alarm for pressure low water
pressure min

Setpoint steam/air Maximum pressure to trigger the alarm for pressure high water
pressure max

40 OG/400C/OG400CS
 OPERATOR PANEL

Settings solid waste and sludge

If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number of
setting screens.

Text Description

Max. CCT SW & Maximum combustion chamber temperature (CCT) – reduce sludge when
sludge running solid waste and sludge program.

Hysteresis max. CCT Minimum drop combustion chamber temperature (CCT) – stop reducing
SW & sludge sludge when running solid waste and sludge program.

OG400C/OG400CS 41
OPERATOR PANEL

Settings loading/slagging and stop

If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number of
setting screens.

Text Description

CCP running cooling Set point for combustion chamber pressure (CCP) when running “Stop”
program (cooling).

Auto start of FGF after The flue gas fan atomically starts after the emergency stop is released, if
emergency stop CCT above 220°C.

Stop when CCT below Maximum combustion chamber temperature (CCT) to stop “Stop program”
– cooling.

Hys. stop CCT open Maximum increase combustion chamber temperature (CCT) after stop to
door allow opening of door(s)

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 OPERATOR PANEL

Burn-in
If not logged in as user “usr”, values on
different setup screens are “view only”.
Burn-in program is used for burning in
refractory after long storage periods or
refractory replacement. It runs automatically
for 10 hours, increasing CCT from 200°C to
600°C. A message will appear when refractory
is ready.

Text Description

Temperature set point Set point for combustion chamber temperature CCT, running Burn-in
(view only) program

Hys. chang. burner Hysteresis for temperature set point, when changing burner step.
step

Burner step (view Actual burner step

only)

OG400C/OG400CS 43
OPERATOR PANEL

Incinerator configuration
The button “Restore factory settings” can be
used to restore settings to factory
specifications.
If assistance from TeamTec is required, you
might be asked for the incinerator
configuration listed on the screen

Backlight
No user name and password required.

Time and date

No user name and password required. Press
button “Set new time & date” after new time
and date has been entered. This will transfer
the new time and date values to the control
system.

44 OG/400C/OG400CS
 OPERATOR PANEL

Program information
Values are view only. If assistance from
TeamTec is required, you might be asked for
the type and version listed on the screen.

Consumption
Display consumption for last run and total.
Press “Setup consumption” to access setup
screen.

Consumption setup
If not logged in as user “usr”, values on
different setup screens are “view only”.

OG400C/OG400CS 45
OPERATOR PANEL

Alarm system
If the control system encounters any irregularities the system will give an alarm and shut down the incinerator.
When an alarm occurs, the internal audible alarm activates and the alarm signal is given to ships alarm system.
The "ALARM" screen will pop-up at the operator panel display and the most recent alarm(s) will be displayed
at the top of the list. The “ALARM” screen will display active alarms as well as the alarm history. A total of
128 alarms (active and history) can be displayed. When additional alarms occur, the oldest alarms will be
deleted from the alarm history list.

The alarm Screen

Highlighted line (yellow letters) indicates the selected line. When “Ack” button is pressed, the selected alarm is
acknowledged.

Symbols indicating alarm status

Alarms Status:

Symbol Status
! Active Not accepted
*! Active Accepted
Buttons for handling alarm system.
* Not active Accepted

BUTTON TEXT Description

Ack Acknowledge an alarm.
Audio Off Move the line (alarm) selection down one line. If the alarm list contains
more alarms than can be displayed on the screen, the list will move one
line at a time each time the button is pressed.
Close Switch off audible alarm. The audible alarm will not reengage until all the
alarms have been inactive and an new alarm appears
Leave alarm screen. If one or more alarms is still active or not
acknowledged, a red symbol is displayed on the “Alarm” button on the
“Main” screen.

Alarm List
The Alarm-list contains information about which alarms that are available. The reference refers to electrical
drawings.

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ALARM TEXT Setpoint Active Ref. Description

Failure frequency inverter All time -U4 One or more failure(s) occurred
SDP in frequency inverter for Sludge
dosage pump.
Failure frequency inverter All time +25-U1 One or more failure(s) occurred
WDP3 in frequency inverter for water
dosage pump.
Flue gas temp. FGT high 375°C All time -U4/-F14 Flue gas temperature above
maximum setpoint temperature.
Comb. chambr. temp. CCT 1200°C All time -F15 CCT above maximum
high temperature.
Comb. chambr. temp. CCT 850°C Running -F15 CCT falling below normal
low operation temperature
Thermal failure - motor x A4 All time -F2 - F9 Protection relay cut out.
overload
Door not closed  Running -Y4 Door not locked
Draught failure - CCP low -5mmWC Running -A11 Combustion chamber pressure
falling below set point.
Diesel oil temp. low 600 sec. Running -S2 Heater element active more than
1200 sec. Start up set point time
Diesel oil temp. high 90°C Running -S3 Safety thermostat released.
(Require manual reset)
Diesel oil press. Low 11 bar Running +2-U10 Diesel oil pump press low.
Diesel oil press. High 20 bar Running +2-U10 Diesel oil pump press high.
Flame failure ~ Running +2-R1 Poor or no flame.
Voltage low – high 220V All time -K9 Control voltage more than +/-
10% 10% out of normal.
Steam/air press. - sludge low 1,5bar Sl. prog. -U8 Steam / air pressure sludge low.
Steam/air press. - sludge 4,5bar Sl.prog. -U8 Steam / air pressure sludge high
high
Sludge pressure low 0.05 bar Sl. prog. -U11 Sludge pressure low.

Sludge pressure high 1.00 bar Sl. prog -U11 Sludge pressure high.
Sludge temperature low 50°C Sl. prog. -F16 Sludge temperature low.
Sludge temperature high 95°C Sl. prog. -F16 Sludge temperature high.
Sludge service tank temp. 110°C Sl. Prog. +3A-S4 Safety thermostat released.
high5 (require manual reset)
Circuit failure FGT ~ All time -A4 Open circuit in sensor (broken)
or short circuit in amplifier for flue
gas temperature.
Circuit failure CCT ~ All time -A2 Open circuit in sensor (broken)
or short circuit in amplifier for
combustion chamber

3
Optional equipment
4
See motor rating
5
sludge tank w/el. heater

OG400C/OG400CS 47
OPERATOR PANEL

ALARM TEXT Setpoint Active Ref. Description

temperature.
Circuit failure SDP temp. ~ All time -A2 Open circuit in sensor (broken)
or short circuit in amplifier for
sludge temperature.
Low level sludge service tank ~ Sl. Prog. +3A-S1 Sludge below low level switch in
more than 5 sec.
Communication failure PLC- ~ All time A1-A2 No communication between PLC
HMI and HMI.

48 OG/400C/OG400CS
 OPERATOR PANEL

Setting list

Settings burner 50Hz 50Hz 60Hz 60Hz

Sluice Sluice
Burner damper burner step 1 32 % 32 % 27 % 27 %
Burner damper burner step 2 33 % 33 % 30 % 30 %
Burner damper burner step 3 45 % 45 % 38 % 38 %
Burner damper burner step 4 28 % 28 % 25 % 25 %
Burner damper burner step 5 30 % 30 % 27 % 27 %
Burner damper burner step 6 100 % 100 % 100 % 100 %
Burner damper burner step 7 55% 55% 50% 50%
Factor CCP burner damper reg. 0.150
Factor SDP burner damper reg. 0.050
Settings alarms
Alarm low level Sludge service tank Off
Alarm max time dieselheater start 600 Sec.
Alarm max time dieselheater run 480 Sec.
Alarm max CCT 1200 °C
Min.operating CCT 850 °C
Alarm CCT below minimum operating temp 150 °C
Alarm max FGT 375 °C
Alarm min CCP (Draught failure) -5 mmWg
Alarm minimum diesel oil pressure 11 bar
Alarm maximum diesel oil pressure 20 bar
Settings sludge
CCP start sludge -35 mmWg
Max. CCP run sludge -35 mmWg
Min CCP run sludge -10 mmWg
Min. sludge temp run sludge 80 °C
Alarm sludge temp. low, below normal 30 °C
Alarm sludge temp. high, above normal 15 °C
Min. CCT for run sludge 680 °C
CCT low hysteresis – stop sludge 40 °C
Time start sludge before adjust 60 Sec.
Time check CCT after adjust 30 Sec.
CCT inc between adjust – inc sludge 0 °C
CCT inc. sludge – dec. diesel oil 690 °C
Hysdec sludge – inc diesel oil 30 °C
CCT stop burner diesel oil 870 °C
Hys restart burner diesel oil 30 °C
Maximum CCT 1150 °C
Hys max CCT – stop dec sludge 0 °C
Set CCP running step 4 & 5 -12 mmWC
Set min CCP for temperature regulation -12 mmWC
Max. FGT – start adjust CCP 330 °C
Hys max FGT – stop adjust CCP 0 °C
Time check FGT adjust CCP 30 Sec.
FGT max inc CCP -3 mmWC
Max FGT start adjust SDP RPM 340 °C
Hys FGT – stop adjust SDP RPM 1 °C
Min CCT scale CCP run sludge 800 °C
Max CCT scale CCP run sludge 1200 °C
CCP running burner step 6 -35 mmWC
SDP compensation – decrease diesel oil 40 rpm
SDP compensation – stop diesel oil 100 rpm
SDP RPM decrease 4 rpm
SDP RPM increase 2 rpm

OG400C/OG400CS 49
 OPERATOR PANEL

Min. RPM SDP 200 rpm

Max. RPM SDP 1200 rpm
Manual setpoint SDP rpm * rpm
Sludge quality counter *[2-18]
Purging start sludge 10 Sec.
Purging stop sludge – CCT below 300 °C
Alarm low level Sludge service tank Off
Setpoint heat tracing6 75°C
Hysteresis heat tracing7 5°C
Alarm setpoint minimum steam/air pressure 1.5 bar
Alarm setpoint maximum steam/air pressure 4.5 bar
Alarm setpoint minimum sludge pressure 0.05 bar
Alarm setpoint maximum sludge pressure 1.00 bar
Settings solid waste
CCP start-up solid waste program -35 mmWg
CCP max. solid waste program -28 mmWg
CCP min solid waste program -10 mmWg
Maximum CCT 1150 °C
CCT min. for start solid waste (sluice) 700 °C
Time check CCT increase 40 sec
Max. FGT start adjustment CCP 330 °C
Hysteresis FGT stop adjusting CCP 2 °C
CCP inc when FGT above setpoint 1 mmWg
CCP dec when CCP below setpoint 2 mmWg
Time check FGT adjust CCP 30 Sec.
Max. FGT start adjust burner step 340 °C
Hysteresis FGT stop adjust burner step 5 °C
Time check FGT adjust burner step 60 Sec

6
Visible if heat tracing installed
7
Visible if heat tracing installed

50 OG/400C/OG400CS
 OPERATOR PANEL

Settings solid waste and sludge

Max CCT SW & Sludge 1000 °C
Hysteresis max CCT SW & Sludge 10 °C
Settings loading/slagging & stop
CCP running cooling -18 mmWg
Auto start of FGF after emergency stop On
Start/Stop cooling – hysteresis 220 °C
Hysteresis start/stop cooling 50 °C
Setup consumption
Nozzle 1 specification 20.82 l/h
Nozzle 2 specification 24.6 l/h
Setpoint SDP capacity 0.0022 l/r
SDP capacity 0.0022 l/r
Accepted deviation SDP capacity 80%

Settings
Tanks
TG5
Sludge
Max tank level Volume below low level Tank area density
435 L 500000 mm² 0.96 Kg/L
703 L 217,9 L. 750000 mm² 0.96 Kg/L
1107 L 219,5 L 1020703mm² 0.96 Kg/L
1692 L 277,0 L 1517468 mm² 0.96 Kg/L
2071 L 277,0 L 1517468 mm² 0.96Kg/L
2938 L 622,0 L 1517468 mm² 0.96 Kg/L
3812 L 622,0 L 1985565 mm² 0.96Kg/L
4945 L 550,0 L 1985565 mm² 0.96 Kg/L

OG400C/OG400CS 51
OPERATOR PANEL

Settings frequency inverter ALTIVAR 12

Parameter U4 – +25-U1
SDP
CONF>FULL>SET-
ACC Acceleration [s] 3.0 1
dEC Deceleration [s] 0.1 0.1
HSP High Speed [Hz] 60 50
itH Mot therm current [A] 1.1 1.6
CONF>FULL>DRC-
BFR Standard motor freq [Hz] 50 50
UNS Rated Motor Volt [V] 380 380
CTT Motor Control Type uuC UF9
SPG Speed prop gain [%] 33 N/A
UFR IR Compensation [%] 40 40
CONF>FULL>DRC->ASY-
NPR Rated motor power [kW] 0.8 2.15
COS Motor Cos phi 0.73 0.85
NCR Rated motor current [A] 2.9 4.8
TUNU Auto tuning usage Ctt Ctt
AUT Automatic autotune Yes Yes
CONF>FULL>CTL-
Fr1 Ref 1 channel Ndb AI3
CONF>FULL>FUN->ADC-
Stt- Stt Type of Stop nSt nSt
AdC Auto DC Injection no no
CONF>FULL>I_O>Ai3-
CrL3 AI3 min Value [A] 4 4
CrH3 AI3 max Value [A] 20 20
CONF>FULL>CoN->Md1-
Add Modbus address 2
Tbr Baud rate [Kbps] 19 2
tFo Format 8E1
Tto Time out [s] 30

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Program description
Overall program function description
The TeamTec Incinerator type OG200/400C is controlled by a Programmable logic controller (PLC) which
handles both the operating functions and the alarm system. The Human Machine Interface (HMI) is a touch
screen operator terminal. The operator terminal allows the user to view and monitor the process and to give
input to the process by choosing appropriate program to the desired task.
The Incinerator has 5 programs to select from; “Sludge”, “Solid waste & Sludge”, “Sludge with Water8”,
“Solid Waste” and “Slag”. Some functions are general and controlled in the same way regardless of choice of
program.

General
The diesel oil burner heats up the incinerator. The burner runs in different steps, each program calculates the
required burner step and the burner responds accordingly by controlling the diesel oil valves, the burner air
damper the burner motor and the ignition electrodes.
The airflow through the burner is adjusted by the burner damper to different air flow at different steps on the
burner. The damper opening is corrected for the actual pressure in the combustion chamber (CCP) and the
actual speed of the sludge dosing pump (SDP)

The burner has the following steps:

0 - Burner stopped.
1 – Nozzle 1
2 – Nozzle 2
3 – Nozzle 1 and 2
4 – Nozzle 1 and sludge.
5 – Nozzle 2 and sludge.
6 – Nozzle 1 and 2 and sludge.
7 – Sludge only

8
Optional Water injection

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MAINTENANCE INSTRUCTION

The actual burner step is displayed in the operator terminal.

Combination of possible burner steps in different programs:

Program: Sludge Sludge with Solid waste Solid waste

water and sludge

Burner step 0 X X X X

Burner step 1 X X X X

Burner step 2 X X X X

Burner step 3 X X X X

Burner step 4 X X X Not possible

Burner step 5 X X X Not possible

Burner step 6 X X X Not possible

Burner step 7 X X X Not possible

Flue Gas Fan/Damper

The flue gas damper (FGD) controls the combustion chamber pressure (CCP). Flue gas damper open or closes,
the combustion chamber pressure (CCP) changes, and thereby also alter the amount of combustion air drawn
into the combustion chamber from the outside.
The chosen program will call for different Combustion chamber pressure set points at different conditions and
stages of the program.

Function Sludge program

The incinerator is designed and approved to burn sludge according to IMO specifications. See technical
specifications for information about sludge and quantities to be handled by your incinerator.
The incinerator starts heating up using the diesel oil burner. The diesel oil burner is controlled in different steps.
See description of burner for details.
When the combustion chamber temperature (CCT) has reached set point “min CCT for run Sludge” (680°C),
the steam line will flush for 10 seconds to drain out condensate water before starting up the sludge burner. The
sludge dosage pump (SDP) starts. As the temperature increases, the diesel oil burner reduces “CCT inc sludge
– dec diesel oil” (690°C) and finally stops in order to save diesel. At set point “CCT stop burner diesel oil”
(870°C), the sludge program requires burner step 7 from the burner program and runs sludge only.
The sludge dosage pump (SDP) is controlled by a frequency inverter.
Sludge dosage pump (SDP) will increase sludge dozing until combustion chamber temperature (CCT) has
reached set point” Max CCT run Sludge” (1150°C) or flue gas temperature (FGT) raises above “Max FGT –
start adjust SDP RPM (340°C). The control system will then adjust sludge dosage pump (SDP) to keep
combustion temperature (CCT) steady.
Low sludge tank will result in a normal stop of the program. When sludge burner stops, the sludge solenoid
valve closes the sludge while the steam/air solenoid flushes the sludge nozzle until the temperature in the
combustion chamber is lower than 300°C in order to avoid building up of coke on the burner tip.

The temperature and pressure in the combustion chamber is controlled by calculations in the control system.

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The calculation involves:

Set points for temperature in chamber (CCT).
Set points for pressure in chamber (CCP).
Set points for diesel oil burner.
Set points for PID regulators.
Set points for sludge temperature.
Set points for sludge dosage pump (SDP).
Actual combustion chamber temperature (CCT).
Actual combustion chamber pressure (CCP).
Actual flue gas temperature (FGT).
Actual speed sludge dosage pump (SDP).
Actual sludge temperature.

The calculations controls:

1 – Combustion chamber pressure (CCP).

2 – Combustion chamber temperature (CCT).
3 – Flue gas temperature (FGT).

By adjusting:

1 – Flue gas damper opening (FGD).

2 – Diesel oil burner steps
5 – Speed sludge dosage pump (SDP).

All checks of temperature are made in time intervals. After each change in state or function, further
adjustments are not made until time interval has elapsed.
At the end of each time interval (30-60 sec. - adjustable), the change in combustion chamber temperature (CCT)
is calculated. Depending of temperature raise (or drop), adjustments are made, according to calculations, to
components that will influence the combustion chamber temperature (CCT), and the present combustion
chamber temperature (CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again.

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MAINTENANCE INSTRUCTION

Combustion chamber pressure:

At the start of sludge program, the initial combustion chamber pressure (CCP) (app. -35 mmWC) must be
reached in order to start burner.
The CCP set point is controlled by the combustion chamber temperature (CCT), flue gas temperature (FGT)
and burner step.
The CCP set point is also controlled by the flue gas temperature (FGT). At flue gas temperature (FGT) above
set point (330 °C), the control system overrides calculations made in time interval.

56 OG/400C/OG400CS
 MAINTENANCE INSTRUCTION

Function solid waste program

Note: All references to settings and values are for explanation only. The values on your incinerator or
application may be different.
The program assumes a batch load of waste in the incinerator and will have initial speed and pressure set points
to facilitate enough combustion air to handle this (CCP=28 mmWC, burnerstep 1).
All checks of temperature are made in time interval. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (40 sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again according to tabular below.

Delta CCT Delta step 1 Delta Delta Delta step Delta step
step 2 step 3 4 5
CCT < -1C°
STEP CCT -1 to + 3 to +10 to > +17C°
+3C° +10C° +17C°

> 1000C° P +1 0 -2 -4 -5
4 B 0 -1 -1 -1 -2
860 - 1000C° P +2 +1 0 -2 -4
3 B +1 0 0 -1 -1
700 – 860C° P +4 +3 +2 0 -2
2 B +1 +1 +1 0 0
< 700C° P +8 +6 +4 +2 0
1 B +1 +1 +1 +1 0
P = Combustion chamber pressure (-mmWC)
B = Burnerstep
Delta CCT = Temperature rise after 40 seconds.
The diesel oil burner heats up the incinerator. The burner starts and runs in 3 steps (burner step 1-3). Change in
burner steps are made in time intervals as described above.
When combustion chamber temperature (CCT) reaches set point 1000°C, the diesel oil burner reduces one step,
and further increase in combustion chamber temperature (CCT), reduces burner to step 1.
At the end of time interval (see description above), corrections are made to combustion chamber pressure
(CCP), according to calculations involving a combination of actual temperature in combustion chamber (CCT)
and the temperature raise (or drop) since last correction.
Combustion chamber pressure is also controlled by the flue gas temperature (FGT). At flue gas temperature
(FGT) above set point (330 °C), the control system overrides calculations made in time interval (as described
above).

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Function Solid waste and sludge program

The Solid Waste and sludge Program heats up the combustion chamber according to the solid waste program
and when the Incinerator is ready to burn sludge the functions of the sludge program is applied. The maximum
combustion chamber temperature is then reduced to app. 950°C in order to enable the operator to feed solid
waste (if a sluice is fitted).

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Maintenance instruction
Preventive maintenance
Preventive maintenance periods are defined in the
control system apart from the daily checks. The
control system counts the running hours of the diesel
oil burner. Each group is connected to a list of service
points required to perform. The preventive
maintenance is divided into four groups: Weekly,
monthly, 6 monthly and yearly. Based on experience
the intervals correspond to respectively 100h, 400h,
2500h and 5000h programmed with a service interval
“Hours service”. 6 monthly and yearly service is also
triggered by standby time on the incinerator. When
the actual running hours since last performed
maintenance exceeds the service interval the control
system calls for service by a pop up screen.
It is then required to follow the appropriate procedure. When the maintenance has been carried out press
“Done” and “Hours since last service” is reset. If not logged in as user “usr”, values on different setup screens
are “view only”. Also the “Done” buttons are only visible if user “usr” has logged in.

Service hours:
When “Hours since last service” is above
setting “Hours service”, a red banner is
activated in line for the item. By pressing
“Done”, the hour counter “Hours since last
service” is reset to 0 and the red banner is
turned off.

Detailed instructions and information on

all maintenance tasks can be found in the
“Teamtec incinerator service video”
provided.

Turn of main power before starting any maintenance tasks.

If otherwise not specified, no testing of equipment is needed before turning incinerator system back on
again after maintenance task is completed

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MAINTENANCE INSTRUCTION

REGULAR MAINTENANCE PROCEDURES

Performing these procedures will consume parts equivalent to a “One year wear and tear parts” kit from
manufacturer, specified later in this manual.

Task No. Task Title Maintenance Equipment Details

interval needed

1 Inspection of Daily - Remove all ash and

combustion slag before loading
chamber and starting the
incinerator
2 Clean comb. Daily - -
Chamber air inlets
3 Check diesel oil Daily - Normal reading 16
pressure bar
4 Check sludge Daily - Normal reading 0.2
pressure bar
5 Clean photo resistor Weekly (100 hours) Rag -
on burner
6 Inspect flame scrod Weekly (100 hours) Rag Clean if necessary
and blast tube
7 Check combustion Weekly (100 hours) Rag Check that there are
air inlets and Flashlight obstructions. Clean
cooling air inlets if necessary.
8 Visually inspect the Weekly (100 hours) Rag Clean if necessary
flue gas outlet for Flashlight
deposits
9 Check fan belts and Monthly (400 hours) - Make sure there are
tensioners no abnormal
vibrations, noise or
bearing temperatures
10 Check refractory Monthly (400 hours) - Check for pieces
condition falling out or big
cracks
11 Clean diesel oil Monthly (400 hours) Rag Blast tube, flame
burner scrod and ignition
electrodes to be
cleaned
12 Dismantle, clean Monthly (400 hours) Allen key, 4 mm See service video
and adjust sludge oil 14mm wrench
burner 19mm wrench
27mm wrench
Vise
Compressed air
13 Check spark arrester Monthly (400 hours) Rag Clean if necessary
Flashlight

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 MAINTENANCE INSTRUCTION

Task No. Task Title Maintenance Equipment Details

interval needed
14 Clean the filters in 6 monthly (2500 Soft brush See description
diesel oil pump and hours or 182 days) Fuel oil below
diesel oil supply
line
15 Replace rubber 6 monthly (2500 13mm wrench See service video
stator on sludge oil hours or 182 days)
dosage pump
16 Check sludge 6 monthly (2500 - Should have a
dosage pump rotor hours or 182 days) smooth polished
surface
17 Grease the flue gas 6 monthly (2500 10mm wrench See service video
fan bearings hours or 182 days) 16mm wrench
30mm wrench
Ball bearing grease
18 Visually check the 6 monthly (2500 - -
thermocouple for hours or 182 days)
combustion
chamber
19 Lubricate the sluice 6 monthly (2500 Supplied grease See service video
bearings hours or 182 days) gun
General purpose
grease
20 Lubricate door 6 monthly (2500 Supplied grease See service video
hinges hours or 182 days) gun. General
purpose grease
21 Check door gasket 6 monthly (2500 Chalk Use chalk on the
hours or 182 days) edges of the door
opening. Close the
door. Open and
check that the door
gasket had contact
with the edge all
the way around the
opening. If not
adjust the door.
22 Clean inside 6 monthly (2500 10mm wrench Open the
inspection hatch hours or 182 days) inspection hatches
on the lover side of
the incinerator
cooling panel.
Clean as required
with steam or hot
water.

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MAINTENANCE INSTRUCTION

Task No. Task Title Maintenance Equipment needed Details

interval
23 Check Paintwork Yearly (5000 hours - Make sure the
or 365 days) paint is not
chipped or
scratched
24 Check the control Yearly (5000 hours - -
and alarm system or 365 days)
according to "Test
of function and
safety devices"

25 Check all safety Yearly (5000 hours - -

devices and or 365 days)
calibrate if
necessary

26 Check all valves, Yearly (5000 hours Repair if necessary

pumps and or 365 days)
solenoid valves for
leakage

27 Replace nozzles Yearly (5000 hours Allen key, 3 mm See service video
for D.O. burner or 365 days) Allen key, 4 mm
with new ones. 14mm wrench
16mm wrench
19mm wrench
27mm wrench
Screwdriver,
flathead, 6 mm

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 MAINTENANCE INSTRUCTION

Inspection
ITEM ACTION
Combustion chamber: Monthly check: Check visually the refractory inside the combustion chamber. If
pieces of refractory have fallen out so the insulation or steel is visible, then use of
the incinerator must be discontinued until a repair has been carried out. Pay
attention to residue on the walls. If this is over 20 mm thick, remove this by means
of a wire brush and a paint-scraper. Do not use a hammer!

Diesel oil pump: Daily check: Check visually for leakage. The pressure is to be checked daily. If
pressure drops below 16 bar and cannot be adjusted by means of the adjustment
screw, clean the filter. (Ref. Appendix D )
To clean the filters, proceed as follows:
Close the valves on supply and return line to D.O. pump. Remove all 8 bolts at the
end the pump opposite the drive-side. Remove the end cover and the cover gasket.
The filter is now visible and can be pulled out without the use of tools. Clean the
filter in diesel oil and blow dry with compressed air. Reassemble and adjust the
pressure to 16 bar.

Flue gas fan: Monthly check: Check the fan belts for sufficient tightness. Correct deflection is 10
mm using a force of approx. 3 kg. weight load.

Sludge dosage pump: Weekly check: Check visually for leakage. Turn the shaft by hand to check it is
moving freely.

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Cleaning and lubrication

ITEM ACTION
Ashes: The slag must be removed daily before starting up the incinerator. Make
sure that trash has been incinerated completely and that the fire is dead and
ashes cold. Use a hoe for this purpose.

Photo resistor: The photo resistor should be cleaned by means of a damp cloth every week.

Diesel oil burner: Caution: The main switch must be in OFF position whenever working with
the burner.
For dismantling and re-assembly, see Appendix C. The blast tube, flame
scrod and diesel nozzle should be cleaned every month. This can be
cleaned with Kerosene, White Spirit or Marine Diesel Oil and a brush. The
electrodes should be wiped off with a cloth dipped in one of the above
mentioned agents.

Diesel oil pump: The filter must be cleaned every 6 month. For dismantling and re-assembly,
see Appendix D.

Flue gas fan: The grease in the bearings must be changed every six months. Make sure
the bearings are clean before they are re-greased. Pay special attention to
reinstalling of the top half of the housing to its respective base after re-
greasing. The top halves must not be mixed; each top half is made unique to
the base.
Also check the tension of the V-belts.

Door hinges: Door hinges to be greased every six months. Use ordinary ball bearing
grease.

Sluice: The sluice bearings must be lubricated every month. Use a graphite grease
type Esso Beacon Q2 or equal.
Unscrew the blinding plug and lubricate the nipple. Replace the plug. Also
lubricate the bearing on the opposite side by lubricating the nipple through
the expanded metal.

Pusher: Lubricate the bearings for the pusher with a grease gun every 6-month. Use
heat resistant type (Esso Beacon EP2 or equal).

Sludge nozzle: The sludge nozzle should be cleaned every month, if necessary.
For dismantling and re-assembly, see Appendix.

64 OG/400C/OG400CS
 MAINTENANCE INSTRUCTION

Disassembly, repair, replacement and reassembly

Tool list:
For most maintenance and repair tasks, it is sufficient with the following tools:

 Wrench set, metric

 Allen key set, metric
 Screwdriver set
 Plier set

For detailed instructions of all maintenance tasks, please see the “Teamtec
incinerator service video” supplied by Teamtec

Repair of refractory

Main power switch must be turned off before starting this maintenance task. Check that the
incinerator combustion chamber is cold.

CALDE PATCH PT 88U is delivered in 25 Kg plastic containers and is used for small incinerator brick
repairs, article 11878.

The following working should be applied when using CALDE PATCH PT88U:

1. The surface should be clean(ed) and all loose material should be removed to secure a firm
binding between the repair substance and the bricks.

2. The bricks should be padded one by one, meaning no Calde Patch to bind two bricks together.
3. Do not fill the gaps between the bricks with Calde Patch. The bricks need
the space for heat expansion. Preferably use cardboard between the
bricks when padding the brick edges.

4. If there is some OLD repair substance left on the area that is to be fixed, it is important to add
some water to this part of the area and make it wet BEFORE new repair substance is added to
the spot.

5. CALDE PATCH PT88U consists of proximately 20% water to obtain a plastic substance that
can easily be worked with. The material is VERY sensitive to additional water content.
(Additional water should not be added without consulting to TeamTec AS first).

6. CALDE PATCH PT88U shall be added to the bricks by means of a stopping knife until the right
thickness has been reached. The thickness should be at least 10mm, but not so much it causes
sagging. The material will have to dry for some hours before the next layer is added, if necessary.

7. We advise to dry the material over night by means of an electrical heater (max 50 degrees)
before the incinerator is started up again. I your incinerator have a burn in program; please use
this for 5 to 6 hours the day after padding, before reverting to normal incineration.

OG400C/OG400CS 65
MAINTENANCE INSTRUCTION

Restriction Bricks replacement

Main power switch must be turned off before starting this maintenance task. Check that the
incinerator combustion chamber is cold.

1. There are 4 bricks located at the outlet of the combustion chamber. The 4 bricks are
forming a circle and are self locking.

2. Push one brick up and then the three other are loose.

3. Replace with new ones. No cement is needed!

66 OG/400C/OG400CS
 MAINTENANCE INSTRUCTION

Flue gas fan

Ref. Flue gas fan assembly drawing

Replace flue gas fan impeller:

Tools needed:
- Wrench set, metric
- Allen key set, metric

Approx. time required: 1 hour

Disassembly

1. Switch off the power and make sure it cannot be switched on again while the unit is under
repair.
2. Disconnect the electrical cables to the motor.
3. Remove the 16 bolts pos. 30 on the cover (motor end of the fan housing).
4. Remove the 4 bolts for the bearing stand (fan base).
5. Slide the bearing stand assembly backwards from the fan housing till the impeller is clear of
the housing.
6. Carefully turn the bearing stand assembly to get access to the impeller.
7. The impeller is attached to the shaft with a taper lock hub. On the hub, unscrew the two
hexagon screws. By inserting one of the screws in the third hole (the one not in use), the
impeller will come off the hub when the screw is screwed in.

Repair
It is not advisable to repair an impeller unless one has access to balancing equipment.

Replacement
No special procedure is required except for cleaning the shaft and the hub before the hub is
placed on the shaft.

Reassembly
1. Remove the hexagon screws from the third hole. Insert the taper lock
hub in the impeller and put the two hexagon screws back to their original
position and tighten.
2. Carefully slide the bearing stand assembly back into the fan house.
3. Put the 4 bolts for the bearing stand back and tighten
4. But back the 16 bolts for fastening the bearing base to the fan housing
and tighten.

OG400C/OG400CS 67
MAINTENANCE INSTRUCTION

5. Reconnect all electrical cables to the motor

6. Main power can now be turned back on again

To adjust the clearance between impeller and fan house

1. After working with the fan always check the proper end clearance between impeller and fan
housing.
2. Proceed as follows:
3. Unscrew the top part of both bearings.
4. Unscrew the nuts for the bearing hubs. Now the shaft is loose.
5. Pull the shaft out as far as possible. Put an ink mark on the shaft against the back bearing.
6. Push the shaft in as far as possible. Put an ink mark on the shaft against the same bearing.
7. Pull the shaft half way out so the clearance on both side of the impeller is identical (approx.
10 mm) and secure the nuts on the bearing hubs.
8. Replace the bearing tops.

Performance verification
1. Run the fan in cold and hot condition and listen for noise.
2. Inspect that the fan is able to provide at least 100 mm WC negative pressure in the
combustion chamber. (Cold gas.)

68 OG/400C/OG400CS
 MAINTENANCE INSTRUCTION

Mounting of bearings with tapered bore

For re-lubrication of the bearings, the caps must be demounted. The housing base and cap are
matched during manufacture and are not interchangeable. To prevent mixing, the same
consecutive number is marked on the cap and base of each individual housing.
For mounting after re-greasing, the tightening torque for the cup bolts for the incinerator size
OG200/400C/1000C, housing type SNL 513 are torque 80Nm.
The bearings are mounted with an adaptor sleeve. The bearings have a small internal clearance
and an accurate mounting is very important. When the bearing is properly mounted, the outer
ring can be easily turned, but there should be a slight resistance when the ring is swivelled out.
When mounting a new bearing to the fan’s shaft, the following procedure should be followed:
Before mounting the threads of the nut and the side face of the nut witch is about the bearing
should be greased and the outside diameter of the sleeve should be lightly oiled. The bearing is
then pushed on to the sleeve and the nut screwed on by hand. Check that the bearing is correctly
located on the shaft. Use a hook spanner and turn the nut an angle of 90°. By turning the nut
through this given angle of 90° the bearing will be pressed up on the tapered seating of the
sleeve. Re-position the hook spanner and apply a light hammer blow to the spanner. The bearing
will straighten up on its seating and is correctly fastened to the shaft. Lock the nut but bending
down one of the tabs on the locking washer. The residual clearance of the bearing should be
checked.

OG400C/OG400CS 69
MAINTENANCE INSTRUCTION

Flue Gas Damper Motor

(Demo pictures only. The motor can be replaced without dismantling the damper unit from the stack)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric

Approx. time required: 1 hour

1. Disconnect the cables from the junction box (remember the color combination) and
loosen the lock bolt shown at the picture.

2. Pull out the shaft lock spline shown at the picture.

3. Pull the marked unit out of the motor.

70 OG/400C/OG400CS
 MAINTENANCE INSTRUCTION

4. Unscrew one of the bolts for the bracket shown at the picture below in order to turn
the bracket and free the motor.

5. Picture below is showing all parts in the new damper motor kit. The marked parts
will not be needed, as they are excessive part! Use the previously dismantled
original parts!

6. Enter the marked unit into the motor and lock it with shaft lock shown at point 2.

7. Make sure that the motor can turn 90° by pressing the button marked at the picture
and turn the shaft.

OG400C/OG400CS 71
MAINTENANCE INSTRUCTION

8. Assemble the motor to the damper. The damper flap position is marked with a cut in
the shaft end. Remember to tighten the bolt shown in point 1 and the bracket shown
in point 4.

Connect the wires. Test that the motor is turning correctly. Ex. If the motor turns the flap open when it is
supposed to close, you should change the position for the orange and the violet wires

72 OG/400C/OG400CS
 SPARE PARTS

Spare parts
Recommended Minimum spare parts
Article / Name 17910 / Minimum Spare Parts, OG200/400C, TG5

Art. no. Art. name Quantity Unit

18925 TeamTec Incinerator Service Video (as USB-stick) 1,00 ea.
15748 Bonded Stator, Black mark 1,00 ea.
7587 Photo resistor, QRB 1 A 1,00 ea.

OG400C/OG400CS 73
SPARE PARTS

1 Year wear and tear parts OG200/400C, TG5.2

Article / Name 20521 / One year wear and tear parts,
OG200/400C, TG5.2

Art. no. Art. name Quantity Unit

12329 Nozzle, 2,5 gph 60° S 2,00 ea.
12500 Thermocouple Type N-300 Assembly 1,00 ea.
13530 Glassfibre Rope 15x20 3,75 M
15684 Rotor for Dosage Pump 1,00 ea.
15688 Universal Joint 1,00 ea.
15748 Bonded Stator, Black mark 2,00 ea.
16066 Glassfibre Rope 16x16 2,30 M
17168 Stuffing Box Gasket 1,00 ea.
17691 Sealing Compound, NON DANGEROUS GOODS 1,00 ea.
4979 V-belt, XPA 1360 2,00 ea.
6996 Cover gasket 2,00 ea.
7842 Nozzle, 4,5 gph 45° SS 2,00 ea.

16066* only for OG200CS / OG400CS

74 OG/400C/OG400CS
 SPARE PARTS

Recommended on board repair parts,

OG200/400C, TG5.2

Article / Name 20689 / Recommended on board repair parts,

OG200/400C, TG5.2

Art. no. Art. name Quantity Unit

11632 Flame Scrod 1,00 ea.
11878 Refractory repair substance 25,00 KG
12806 Repair kit for sludge valve A6324 1,00 ea.
15556 Solenoid Valve, G1/4", 220V, 3-Way 1,00 ea.
15687 Seal Plate Gasket 1,00 ea.
15741 Mechanical Seal 1,00 ea.
17168 Stuffing Box Gasket 1,00 ea.
19442 Thermocouple Type "K", Headmounted Transmitter 1,00 ea.
19710 Pressure Transmitter, Sludge Dosage Pump 1,00 ea.
19711 Pressure Transmitter, Steam/Air 1,00 ea.
19712 Pressure Transmitter, Diesel Oil 1,00 ea.
21340 Thermocouple "K" Ø6x115, Cable L=2100 1,00 ea.
5128 Bearing, 2211 EK 2,00 ea.
6154 Sludge Burner Assembly 1,00 ea.
6565 Flue Gas Restriction Ring, Ø220 4,00 ea.
6567 Blast Tube, F-50-45-T 1,00 ea.
6568 Ignition Cable Compl. L=380 2,00 ea.
6981 Nozzle Line 1,00 ea.
6987 Press. regulator kit, 10-21 bars 1,00 ea.
7587 Photo resistor, QRB 1 A 1,00 ea.
8126 Solenoid Valve, G1/4", 220V 1,00 ea.
8153 Ignition Electrode 2,00 ea.
8454 Solenoid Valve, 1/8", 220V 1,00 ea.
8563 Spline Coupling Compl. 1,00 ea.
9272 Shaft seal kit 1,00 ea.

OG400C/OG400CS 75
STORAGE AND INSTALLATION

Storage and installation

Preparation for shipment
The incinerator Unit, Flue Gas Fan, damper and motors are packed for overseas shipment.

Storing at Yards Warehouse

The incinerator Unit must be stored only indoor in a dry warehouse. Sensitive electronic unit and refractory
segments might be damaged if stored outdoor in wet conditions.
For long time storage, TeamTec recommend to place Silica Gel inside the Control Panels.
Once a month, check visually that the Control Panels are not damaged. Special attention must be paid to the
silica gel inside the panels. If there has been humidity in the panel, the Silica Gel must be replaced.
Check that the coating of the steel work is OK. If the coating is damage and the steel is exposed to the
atmosphere, it must be touched up with new paint according to paint spec.
Monthly the fan, pumps and electrical motors must be rotated.

Preservation from installation to start-up of

equipment
After installation the equipment should be preserved and protected for hostile
environment like welding, grinding, handling of heavy equipment, insulation work, water spray washing and
paint spraying.
The equipment is delivered with plastic sheet. The plastic sheeting does not offer protection against hot work.
If the incinerator is exposed to high humidity for a period of time, silica gel must be placed inside the control
panel.

Preservation in case of long time storing after

installation
In addition to the item mention above check that coating is in good condition.
Grease exposed parts of the burner.
Remove slag and ashes from combustion chamber.
Turn the electrical motors for fan, pumps and burner slightly.
If possible, the power should be switched on to the control panel in order to keep the panel dry.

76 OG/400C/OG400CS
 STORAGE AND INSTALLATION

Pre-commissioning
Mechanical completion check list.
Prior to function testing at first start up, the following mechanical completion must be checked.
1. Check that the foundation support and the deck strength are adequate for the incinerator unit. (5. ton)
2. Check that flue gas fan foundation is of a sturdy design for fan to run without vibration.
3. Check that the air inlet to the incinerator room has sufficient capacity.
4. Check that the necessary drainpipe is installed and connected.
5. Check that the incinerator door can be fully opened and locked in the installed locking mechanism.
6. Check that the insulation, flue gas duct and flue gas fan is installed and fixed.
7. Check that the flue gas duct is not welded direct into painted wall penetration. (fire hazard)
8. Check that the refractory brickwork has been dried out with a portable heater for 48 hours at
approximately 100°C.
9. Check that the “Burn In” program has been run for 10 hours. The “Burn In” program starts with a
combustion chamber temperature at 200°C and runs for 10 hours. The Burn In Program is available
from the set up menu in the operator panel when logged in as user.
10. Check the diesel oil line for correct hook up, and make sure that no valve is closed on the return line.
(A blocked return line will result in a leak in the diesel oil pump shaft seal)
11. Check the electrical power supply for correct rated protection at the ship distribution board.
12. Check that all pipes, ducts and cables hooked up have been correctly completed according to
arrangement drawings.
Pre-check of live equipment.

Prior to function test, the following live equipment should be tested.

1. Start the flue gas fan and check for correct rotation direction.
2. Start the diesel oil burner and check for correct rotation direction, and that normal diesel oil pressure
is reached.
3. Check that the operator control panel is live, and indicating normal.
4. Make sure that sludge is filled in the sludge tank to a level above the low level switch before starting
the pump. Start the sludge pump and check for correct rotation direction, and normal pressure
indication.

After having checked out the above items, a function test according to this manual can take place

OG400C/OG400CS 77
STORAGE AND INSTALLATION

Test of Safety and Alarms

No. Test procedure. Observation Accepted

1. FLAME FAILURE Alarm activates and the burner stops.
Pull the photo resistor out and
blind off. Flame failure

2. FLUE GAS TEMP. HIGH At flue gas temperature above alarm set
Adjust alarm set point point, the alarm will activate and the burner
[Alarm max. FGT] stops.
below operating temp. Flue gas temp. FGT high

3. COMB. CHAMBER TEMP. At combustion chamber temperature above

HIGH Adjust alarm set set point alarm will activate and the burner
point stops.
[Alarm max. CCT] Comb. chmbr. temp. CCT high
below operating
temperature.

4. COMB. CHAMBER TEMP. At combustion chamber temperature below

LOW set point [Alarm CCT below min. oper.] the
Start sludge program. alarm will activate and the burner stops.
Adjust alarm set point[Min.
operating CCT] below Comb. chambr. temp. low
actual temperature
then above actual CCT +
[Alarm CCT below min.
oper.]

5. MOTOR OVERLOAD The motor stops, the alarm will activate and
Activate test button at front the burner stops.
of the motor circuit breaker.

Thermal failure - motor overload

78 OG/400C/OG400CS
 STORAGE AND INSTALLATION

No. Test procedure. Observation Accepted

6. DOOR NOT CLOSED Alarm activates and the burner stops.
Start a burner program.
Unlock the waste door by
unlocking the special screw. Door not closed

7. DRAUGHT FAILURE At pressure decrease below alarm set point

Start a burner program. [Alarm max. CCP (Draught failure)]
When fan is running and after 10 sec. the alarm activates and
disconnect the sensor tube the burner stops.
from vacuum controller.
Draught failure - CCP low

8. DIESEL OIL TEMP HIGH At release of safety thermostat-S3 the alarm

Start a burner program. will activate and the burner stops
Adjust down the safety
thermostat -S3 to below set
point for working thermostat - Diesel oil temp. high
S4.
The safety thermostat require manual reset.

9. DIESEL OIL TEMP LOW At start of heating the alarm activates and
Start a burner program. the burner stops.
Adjust alarm set point
[Alarm max. time dieselheater
start]
to "0". Diesel oil temp. low

10. DIESEL OIL PRESSURE At pressure below setting [Alarm minimum

LOW Diesel oil pressure](11 Bar), the alarm
Start a burner program. activates and the burner stops.
Reduce the fuel oil pressure
by adjusting the pump.
Diesel oil press. low

11. DIESEL OIL PRESSURE At pressure above setting [Alarm maximum

HIGH Diesel oil pressure](20 Bar), the alarm
Start a burner program. activates and the burner stops.
Adjust the fuel oil pressure by
adjusting the pump.

Diesel oil press. high

OG400C/OG400CS 79
STORAGE AND INSTALLATION

No. Test procedure. Observation Accepted

12. VOLTAGE LOW/HIGH Relay deactivates at voltage above or below
Adjust upper setpoint down at set point after a time delay (normally 5
relay (-K9) until yellow LED sec.). During time delay, yellow led flashes,
flash. and relay deactivates.

Voltage low - high

LED goes off, and the red LED goes on.

13. STEAM/AIR PRESSURE After 10 sec. alarm activates and the burner
SLUDGE LOW stops.
Adjust [Alarm setpoint
minimum steam/air pressure]
setting to 4.5 bar.
Steam/air press. - sludge low
Start a sludge program.
When running sludge, close
off steam-air supply.

14. STEAM/AIR PRESSURE After 10 sec. alarm activates and the burner
SLUDGE HIGH stops.
Adjust [Alarm setpoint
maximum steam/air pressure]
setting to 1 bar. Steam/air press. - sludge high
Start a sludge program.
15. SLUDGE PRESSURE LOW After 10 sec. alarm activates and the burner
Adjust [Alarm setpoint stops.
minimum sludge pressure]
setting to 1 bar. Sludge pressure low

Start a sludge program.

Close the sludge supply.
16. SLUDGE PRESSURE HIGH After 10sec. alarm activates and the burner
Adjust [Alarm setpoint stops.
maximum sludge pressure]
setting to 0.1 bar.
Sludge pressure high

Start a sludge program.

80 OG/400C/OG400CS
 STORAGE AND INSTALLATION

No. Test procedure. Observation Accepted

17. SLUDGE TEMP LOW After 10sec. alarm activates and the burner
Start a sludge program. stops.
Adjust set point Alarm activates and the burner stops.
[Min. sludge temp run sludge]
above actual temperature and
adjust alarm set point to 1sec.
[Alarm sludge temp low] Sludge temperature low

18. SLUDGE TEMP HIGH Alarm activates and the burner stops.
Start a sludge program.
Adjust set point
[Min. sludge temp run sludge]
below actual temperature and
adjust alarm set point to 0. Sludge temperature high
[Alarm sludge temp high]

19. FREQUENCY INVERTER Alarm activates and the burner stops.

FAILURE SDP

Withdraw the modbus plug on Frequency inverter failure SDP

the inverter –U4, wait for
alarm modbus comm., insert
the modbus plug again.

20. ERROR MODBUS COMM. Alarm activates and the burner stops.
SLAVE 2 SDP
Withdraw the modbus plug on
the inverter –U4, wait for Error Modbus comm. slave 2 SDP
alarm modbus comm.

OG400C/OG400CS 81
STORAGE AND INSTALLATION

No. Test procedure. Observation Accepted

21. SLUDGE SERVICE TANK Alarm activates and the burner stops.
TEMP HIGH9
Start a sludge program Adjust
down safety thermostat +3.1- Sludge service tank temp. high
S1 below operating The safety thermostat requires manual reset.
temperature.

22. LOW LEVEL SLUDGE After 10 sec. delay the Alarm/Warning activates
SERVICE TANK and burner stops
Activate test lever if
mounted or disconnect Low level sludge service tank
cable.
Start a sludge program.

23. CIRCUIT FAILURE CCT Alarm activates and the burner stops.
Disconnect wire from A2
Cartrige AI0 Circuit failure CCT

24. CIRCUIT FAILURE SDP Alarm activates and the burner stops.
TEMP
Disconnect wire from A2
Cartrige AI1 Circuit failure SDP Temp

9
Sludge tank with el. heater.

82 OG/400C/OG400CS
 STORAGE AND INSTALLATION

No. Test procedure. Observation Accepted

25. COMMUNICATION FAILURE Alarm activates and the burner stops.
PLC-DISPLAY
Remove the communication Communication failure PLC-Display
cable between PLC and
display.

26. OVERLOAD SETTINGS: Flue gas fan motor :_______Amp.

Burner motor :_______Amp.
Sludge circ. pump :_______Amp.
Diesel oil booster pump :_______Amp.
Sludge filling pump :_______Amp.
Sludge transfer pump :_______Amp.

27. IGNITION ELECTRODES

28. CENTRING OF FLAME-
SCROD
29. PROGRAM BASED
FUNCTIONS
30. ALL SETTINGS
ACCORDING TO LIST.
31. UNDERPRESSURE ON
DISPLAY SET TO 0
32. OVERALL INCINERATOR
VISUAL CONTROL
33. TERMINAL CLAMPS
34. FREQUENCY INVERTER
SETTINGS
35. INSULATION TEST

OG400C/OG400CS 83
TROUBLE SHOOTING

Operation instructions

Prior to start
1. Main switch on the control panel is switched to position "ON". The operator panel is
energised and the Process picture will show in the display.

Slagging
1. Check that there are no flames in the incinerator.
2. Push the "SLAG" key, the flue gas fan will run at a fixed speed when the temperature is
below 170°C (+50 hysteresis).
3. Open the ash door and remove ashes and slag, partly burned cans, can remain. These will
burn out eventually.
NOTE! Combustion air inlet openings at "floor" level must be cleaned.
This is important for a free airflow to the combustion chamber.

Solid Waste
1. Fill the combustion chamber half full with waste (max 400 L)
NOTE: The Solid waste program start up sequence assumes a batch load. If the incinerator
is to be heated up without a batch load, choose the sludge program.
2. Close the door.
3. Push the key "START" and choose "SOLID WASTE" from the menu. The flue gas fan will
start and automatically control the pressure in the chamber. If there are conditions not met
required for starting the incinerator, the operator panel will display a message explaining the
condition. If an exact burning time is wanted, it can be activated from the “Settings Solid
Waste (1/3)” menu. After the time has elapsed the incinerator stops, and the cooling down
sequence starts.
4. When the key "STOP" is pushed, the burner will stop, and the cooling down sequence starts.
5. When the temperature in the combustion chamber has decreased to 170°C, the flue gas fan
will stop and door locks energized.

Sludge
1. Fill up the sludge tank10 and activate the heater. This is done by the pressing the heater
symbol on the operator panel. Choose start heater and the heater symbol will change colour
to indicate that the heater is on and the temperature is controlled locally by the thermostat
2. Drain off water from the settling tank. (The sludge should be settled overnight before water
is drained off). Remember, longer settling time, better settling!
3. Start the filling pump by pressing the pump symbol and choose start pump. The symbol will
change colour to green to indicate that the pump is running. The pump will stop
automatically if the service tank level is high or the settling tank level is low.
4. Activate the heater on the service tank. This is done by the pressing the heater symbol on
the operator panel. Choose start heater and the heater symbol will change colour to indicate
that the heater is on and the temperature is controlled locally by the thermostat

10
If no dual tank system, jump to point 4.

84 OG/400C/OG400CS
 STORAGE AND INSTALLATION

5. Drain off water from the service tank. (The sludge should be settled overnight before water
is drained off). Remember, longer settling time, better settling!
6. Start the service tank circulation pump by pressing the pump symbol and choose start pump.
The symbol will change colour to green to indicate that the pump is running. Check the
sludge pressure on the pressure indicator to be in the range of 0.2 bar, adjust if required,
using the bypass valve. Run the circulation pump for at least 1 hour prior to burning sludge!
7. Check the atomising -air /-steam supply pressure to be 6 - 8 bar. If steam is used, the
condensate must be drained off by use of the valve located at sludge equipment drip tray.

8. Push the key "START" and choose "SLUDGE" from the menu. The flue gas fan will start
and automatically control the pressure in the chamber. If there are conditions not met
required for starting the incinerator, the operator panel will display a message explaining the
condition.
9. The manual regulating valve for air / steam atomising located at sludge equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the sludge burner/nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the sludge burner.
10. When the low level in sludge tank, or the key "STOP" is pushed, the burner will stop, and
the cooling down sequence starts.
11. When the temperature in the combustion chamber has decreased to 170°C the flue gas fan
will stop and door locks will be energized.

Solid Waste Sludge

1. Make settling according to the routine described in the sludge program.
2. Follow the Solid waste procedure, but choose “Solid Waste Sludge” program instead of
“Solid Waste” program.

Sludge and Water

1. Make sure the manual valves in the bilge water system are open.
2. Make sure there are water available and that the water tank is filled with water.
3. Follow the sludge procedure, but choose “Sludge and Water” program instead of “sludge”
program.
4. The manual regulating valve for air / steam atomising located at water equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the water injection nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the water injection nozzle.
5. Water injection starts when CCT reaches 1110°C.

OG400C/OG400CS 85
TROUBLE SHOOTING

Emergency stop
In the incinerator room.
Turn the main switch at the control panel "OFF".

Outside the incinerator room.

Activate the emergency stop. (The switch normally requires manual reset).

When emergency stop is used, or at black out

If the combustion chamber temperature is above 220°C, it is important to
start the flue gas fan as soon as possible in order not to damage the incinerator by accumulated
heat in the refractory lining. If setting “Auto start of FGF after emergency stop” is set to “off”,
a manual restart of Flue gas fan is needed. This is done by pressing “Stop” button.

Careful heating-up and cooling-

down is required for preventing
damage to the refractory.

Safety warning: If smoke exits the incinerator to the incinerator room, evacuate the room
immediately. Risk of of loss of health and life.

86 OG/400C/OG400CS
 TROUBLE SHOOTING

Trouble shooting
Symptom Probable cause Checkout procedure

1. OPERATOR PANEL 1. Faulty main power supply. Check main switch -Q1Check
DEAD. power supply from main
switchboard.
2. Emergency stop switch Check switch -S1.
open.
3. Faulty fuse for pilot Check fuses –F12 and –F13
transformer.
4. Faulty fuse -F13. Check fuse.

2. Alarms 1. Described in section Described in section "Alarm

"Alarm system". system".

3. Poor flame / smoke 1. The nozzles could be Change the nozzles.

when burning on blocked or damaged.
diesel oil.
2. Malfunction of burner air Check the damper function and
damper. position.
3. Burner dirty. Clean burner flame scrod and
blast tube.

4. Poor flame / smoke 1. Damaged or blocked Check the nozzle and if

when burning sludge. sludge nozzle. necessary clean and adjust it.
2. Closed or incorrect Adjust valve. (1/2 to 1/1 turn
adjusted air/steam control open) NB! only to be performed
valve. with a clean sludge burner.

Change stator.
3. Damaged sludge dosing
pump stator.
Adjust to correct setting.
4. Sludge pressure to high. (0.2 bar)

5. Temperature raising 1. Loaded too much waste Stop loading, and tray to block
"uncontrolled" with high calorific value. lower four corner ventilation
slots.
2. Damaged sludge dosing Change stator.
pump stator.
3. Sludge speed control not Check sludge speed.
working.
4. Leaking diesel oil solenoid Change the valve.
valve.

OG400C/OG400CS 87
TROUBLE SHOOTING

Symptom Probable cause Checkout procedure

6. FLAME FAILURE. 1. Sludge dosage pump Replace the Stator (Every 6

months)
stator worn out.
2. Flame sensor dirty. Take out and clean.

3. Flame sensor defect. Replace flame sensor.

4. The nozzles could be Clean or change the nozzles.

blocked or damaged.
5. Incorrect opening Check opening at closed
of burner air damper. damper and correct.
6. Ignition failure. Adjust spark electrodes.
7. Poor flame See section above
8. Defect solenoid valve or Replace valve or coil
coil
7. FLUE GAS TEMP. 1. Sludge dosage pump Replace the Stator (Every 6
HIGH months)
stator worn out.
Burning sludge
2. Blocked air cooling inlet. Clean inlet. (Bottom grating)
Clean panel slot
3. Panel cooling slot
clogged with dirt.
Put the missing brick back in
4. Throttling bricks fallen
place.
out.
See Draft Failure
5. Under pressure to low
Replace sensor
6. Faulty temp. sensor.
Check transmitter mV input.
7. Faulty temp. transmitter.
Replace, DO NOT ADJUST
Burning solid waste
Check frq. inverter circuit
8. Faulty frequency inverter.
Stop loading, and tray to block
9. Loaded too much waste lower four corners
with high calorific value.
8. COMB. CHMBR. TEMP. 1. Same as flue gas temp See FLUE GAS TEMP HIGH
HIGH high.

2. The outlet blocked with Clean outlet

slag. (Top of chamber)

3. Blocked slot at chamber Clean slots

floor level

9. STEAM/AIR PRESS. 1. To low steam/air Check steam/air supply

LOW/HIGH. pressure <1,5 bar. pressure.

2. To high steam/air Clean the sludge burner.

pressure > 4.5 bar

88 OG/400C/OG400CS
 TROUBLE SHOOTING

Symptom Probable cause Checkout procedure

10. DRAUGHT FAILURE 1. Leaking sensor tube. Check sensor tube for damage
(low under pressure) and fixing.

2. Defect pressure sensor Check and replace, DO NOT

ADJUST.

3. Door gasket damaged. Check door gasket

4. Broken flue gas fan belts. Tighten or replace.

5. Flue gas fan motor

6. running in wrong Check direction
direction.

11. LOW/HIGH VOLTAGE 1. Input voltage to low or to Check supply voltage.

high (+10% to –13%) If this alarm occur and has
been reset, but supply voltage
is still low/high, the incinerator
will not start.

12. LOW CAPACITY 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)

2. Panel cooling slot clogged Clean panel slot

with dirt.

3. Throttling bricks fallen out. Put the missing brick back in

place.
4. Deposits at flue gas outlet
Clean the Flue Gas outlet
5. Damaged or blocked
sludge nozzle.
Check the nozzle and if
necessary clean and adjust it.

OG400C/OG400CS 89
 APPENDIX A

Appendix A: PLC
General
The Standard PLC contain of 4 units. See Figure 11 and 12.

1 2 3 4

Figure 11

1. Base unit (14 Digital Inputs / 10 Digital outputs / 2 Analog inputs)

2. Extension unit, Cartridge input module (2 Analog inputs)
3. Extension unit, analogue (16 Digital Output)
4. Extension unit, analogue (4 Analog inputs / 2 Analog outputs)

90 OG/400C/OG400CS
 APPENDIX A

Base Unit

Figure 12

1. Status LEDs
2. Output removable screw terminal block
3. Clip-on lock for 35-mm (1.38in.)
4. Ethernet port
5. 220Vac 50/60Hz Power supply
6. USB mini-B programming port
7. Serial line port 1
8. SD Card slot
9. 2 analogue inputs
10. Run/Stop switch
11. Input removable screw terminal block
12. I/O Expansion connector
13. Cartrige slot 1
14. Cartrige slot 2

OG400C/OG400CS 91
APPENDIX A

15. Protective cover

16. Locking hook (lock not included)
17. Removable analogue inputs cover
18. Battery holder

92 OG/400C/OG400CS
 APPENDIX A

Inserting SD card

When new program is received this will be installed from the SD Card slot.
Follow the steps listed to reprogram the plc.

1. Insert the SD card into the SD card slot of the plc

2. Push until you hear it “click”

3. Check the Status LED on the plc, when the SD label is activated the SD card program is
being downloaded to the plc.
4. When the LED switches off and the PLC Run indication is activated, remove the SD card
from the plc. (Step 2-1)

OG400C/OG400CS 93
APPENDIX A

Replacing the battery

The PLC main unit is equipped with a replaceable battery. The Battery Low indicator on the
LED display of the controller shows the status of the replaceable battery. When the battery is
low, the indicator is set. This means the battery may fail within 2 weeks if it is connected.

Replacing the battery when the controller is powered down will lose all user
application memory. Always replace the battery when the controller is powered on!
Follow the procedure 1-3 below to connect the new battery to the plc.

94 OG/400C/OG400CS
 APPENDIX A

DIN Rail Mounting

A
C

Dimension:
A – 90mm (3.5 in.)
B – 29.4mm (1.157 in.)
C – 27.4mm (1.07 in.)

1. Hook the top slot over the DIN rail

2. While pressing the controller down against the top of the rail, snap the bottom of
the controller into position.
3. Leave the protective debris shield attached until you are finished wiring the
controller and any other devices.

To remove your controller from the DIN rail:

1. Place a flat-blade screwdriver in the DIN rail latch at the bottom of the controller.
2. Holding the controller, pry downward on the latch until the latch locks in the open
position.
3. Repeat step 1 and 2 for the second DIN rail latch.
4. Unhook the top of the DIN rail slot from the rail.

OG400C/OG400CS 95
APPENDIX A

Diagnostics

96 OG/400C/OG400CS
 APPENDIX A

I/O Status Indicators on the LCD

Indicator Colour Indicates

INPUTS Off (empty rectangle) Input is not energized
On (solid rectangle) Input is energized (terminal
status)
OUTPUTS Off (empty rectangle) Output is nor energized
On (solid rectangle) Output is energized (logic
status)

OG400C/OG400CS 97
APPENDIX B

Appendix B: Operator Panel

General
The operator panel is a user friendly operator panel with touch screen. Applications are
controlled by touching screen objects. The panel is connected to the PLC.
Touch screen

Figure 14.

The function of the panel is:

 Selecting of burner mode, setting of all variables as temperature and time etc.
 Display running condition, temperature, pressure, alarm, oil consumption, timer etc.

See also chapter Operator Panel, page 26, for user functions.

98 OG/400C/OG400CS
 APPENDIX B

Technical data

USB

Figure 15
Battery/SD Card Ethernet

The operator panel is an Ethernet only display with 2 USB port, and consist of a colour
(640X480) graphics display. Colour terminals support a fixed palette of 256 standard VGA
colours. All colours in an application is defined when the application is created, and not
selectable at the terminal.
The SD flash slot is used to program the display. Normally this will be done by TeamTec
personnel.
The operator panel is connected to the PLC with Ethernet communication.
The terminal requires 24VDC.
Display temperature should be less than 55°C. The CPU temperature should be less than 95°C.
The terminal has one LED indicator that shows listed operations:
Color Indication Description
Green On Offline

In Operation
Orange Flashing Software starting up
Red On Power is turned ON
- Off Power is turned OFF

OG400C/OG400CS 99
APPENDIX B

Product certification compliance with European Union Directives. EMC tests satisfies EN
50081-1-2:1993 and EN 61000-6-2:1999

100 OG/400C/OG400CS
 APPENDIX C

Appendix C: Oil
burner
Servicing and
adjustment
Air damper motor
1
DO pump
Dismantling
DO press. adjustment screw
DO pressure transmitter
2 5
1. Pull out the photo cell.
3
1. Remove the cover on top of the burner.
2. Disconnect the ignition cables.
3. Disconnect and pull out the sludge burner.
4. Disconnect and pull out the nozzle line.

4
Cleaning and
adjustment Ignition electrode

(Figure 1)
Flame scrod
Clean the blast tube,
flame scrod,
Blast tube
ignition electrodes
and sludge burner.
Replace the diesel
oil nozzle if
necessary.
Nozzle 2
Note: The Sludge burner
smallest nozzle is Nozzle 1
Figure 1
stage one. Check
the spark gap and
the position of the flame scrod.

Re-assembly
Re-assembly the burner in reverse order.

Diesel oil pressure adjustment

The oil pressure is adjusted on the oil pump. Remove end cap nut from pump for access to pressure setting
screw.
Turning the regulator screw clockwise increases the pressure setting.
Normal pressure is 16 bar.

OG400C/OG400CS 101
APPENDIX C

Burner Blast tube Replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric
- Hammer and chisel

1. Remove the inspection cover.

102 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX C

2. Remove the nozzle line.

3. Unscrew the two screws shown at the picture.

4. The blast tube is now loose and can be pushed into the combustion chamber.

Note: Due to soot deposits, the blast tube might be stuck. Use a hammer and chisel carefully to get
loosen the blast tube.

Reassembly of blast tube:

1. Clean the blast tube and the hole for it in the burner.
2. Slide the blast tube into position
3. Fasten the two screws holding the tube in place
4. Reattach the nozzle line
5. Put the inspection cover back on and tighten the screws holding it in place
6. Turn main power back on

Note: The blast tube should be adjusted in order for the two screws mentioned in point 3 to be in the
middle of the sliding track.

OG400C/OG400CS 103
APPENDIX C

Oil Burner damper motor replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Screwdriver set
- Allen key set, metric

Approx. time required: 1 hour

1. Untighten the two set screws.

2. Pull of the splint.

3. Pull up the shaft.

4. Push the motor as shown in order to get it free.

104 OG/400C/OG400CS
 APPENDIX C

5. Remove the two covers.

6. The damper motor is connected to terminal 9-10-11-12.

9-red
10-black
11-grey
12-pink

Reassembly of the oil burner damper motor

1. Reconnect the wires for the damper motor in the terminal

2. Put the two covers back, an tighten the scews to hold them in place
3. Slide the motor in place, opposite way of dismantling it
4. Put the shaft for damper back in
5. Put the locking spint back in
6. Put back and tighten the two set screws
7. Turn main power back on

PS! Make sure that the shaft is in approx. mid position when assembling, and that the damper flap is in closed
position.

OG400C/OG400CS 105
APPENDIX C

Air adjustment

The Burner damper motor is analogue, and will open the damper proportionally to the control voltage applied
by the control system. The only two checks necessary is Closed position and that it operates freely.
To check that the damper is closed make sure that the damper blade is vertical to the opening when the control
system shows 0% opening (after power up, flue gas fan not running).
To check that the damper operates freely, wind up the actuator by using a 4mm hex key on the top of the
damper motor, then release and observe that the damper closed by the spring action.

DO nozzles
Standard nozzle
Incinerator Nozzle 1 Nozzle 2 Std. pressure DO temp.
OG 200C 2.5 GPH 60 4.5 GPH 45 16 bar 50°C
OG 400C 2.5 GPH 60 4.5 GPH 45 16 bar 50°C
GS 500C 3.5 GPH 60 5.5 GPH 45 16 bar 50°C
OG200/400C 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
For special cases other nozzles can be used.

Maintenance
Burner nozzle cannot be repaired.

106 OG/400C/OG400CS
 APPENDIX C

Capacities
Oil burner nozzle capacities in l/h at various pressures.11
Rated flow 12 Pressure in bar
G.P.H. l/h 10 11 12 13 14 15 16
1,50 5,68 6,82 7,12 7,41 7,71 8,00 8,24 8,47
1,65 6,25 7,41 7,82 8,24 8,53 8,82 9,29 9,76
1,75 6,62 7,88 8,29 8,71 9,06 9,41 9,71 10,00
2,00 7,57 9,06 9,47 9,88 10,29 10,71 11,06 11,41
2,25 8,52 10,24 10,71 11,18 11,59 12,00 12,41 12,82
2,50 9,46 11,29 11,82 12,35 12,88 13,41 13,88 14,35
3,00 11,36 13,53 14,18 14,82 15,47 16,12 16,65 17,18
3,50 13,25 15,88 16,65 17,41 18,06 18,71 19,35 20,00
4,00 15,14 18,12 19,00 19,88 20,65 21,41 22,18 22,94
4,50 17,03 20,35 21,35 22,35 23,24 24,12 24,94 25,76
5,00 18,93 22,59 23,71 24,82 25,82 26,82 27,71 28,59
5,50 20,82 24,82 26,06 27,29 28,35 29,41 30,47 31,53
6,00 22,71 27,18 28,47 29,76 30,94 32,12 33,24 34,35
6,50 24,61 29,41 30,59 31,76 33,53 35,29 36,47 37,65
7,00 26,50 31,76 33,53 35,29 36,47 37,65 38,82 40,00
7,50 28,39 34,12 35,88 37,65 38,82 40,00 41,76 43,53
8,00 30,28 36,47 38,24 40,00 41,18 42,35 44,12 45,88

11
Sp gr 0,85 @ 25C and viscosity 1,3E @ 20°C
12
Pressure = 100 P.S.I.

OG400C/OG400CS 107
APPENDIX D

Burner nozzle assembly repair

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric

Approx. time required: 0,5 hour

1. Remove the inspection cover.

2. Remove the nozzle line from burner.

108 OG/400C/OG400CS
 APPENDIX D

3. Loosen the two screws marked at the picture in order to dismantle the electrodes and the flame scrod
and then unscrew the D.O. nozzles!

16788

17304

Reassembly of burner nozzle assembly

1. Screw the D.O. nozzles back in their respective sockets

2. Assemble the ignition electrodes, flame scrod and nozzle line and tighten the 2 set screws.
3. Adjust the ignition electrodes as shown below.
4. Put the burner nozzle assembly back into the burner and tighten the nuts
5. Put the inspection cover back on and tighten the screws to keep it in place
6. Turn main power back on

Note! Adjustment of ignition electrodes and flame scrod needed. The 1 mm indicated is from the top
of the fastening sleeve of the flame scrod to the top of the main body of the burner head. See also
next page.

OG400C/OG400CS 109
APPENDIX D

110 OG/400C/OG400CS
 APPENDIX D

Ignition cables replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric

1. Remove the inspection cover.

2. Remove the nozzle line.

3. Pull out the cables from the ignition transformer.

OG400C/OG400CS 111
APPENDIX D

4. Pull the cables through the glands.

Reassembly of ignition cables

1. Pull the cables through the glands.

2. Reattach the cables to the ignition electrodes
3. Reattach the cables to the ignition transformer
4. Put the burner nozzle assembly back into the burner and tighten the nuts
5. Put the inspection cover back on and tighten the screws to keep it in place
6. Turn main power back on

112 OG/400C/OG400CS
 APPENDIX D

Photo Resistor replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Screwdriver set
- Allen key set, metric

1. Pull out the photo resistor

2. Remove the two covers shown at the below pictures!

3. The photo resistor is connected to terminal 13-14.

Reassembly of the photo resistor

1. Connect the cables for the photo resistor back into the terminal block
2. Put the two covers back, an tighten the scews to hold them in place
3. Put the photo resistor back into its socket

OG400C/OG400CS 113
APPENDIX D

4. Turn main power back on

Ignition transformer replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Allen key set, metric

1. Remove the inspection cover.

2. Pull out the cables from the ignition transformer.

3. Unscrew the two screws marked at the pictures below!

Reassembly of ignition transformer

1. Mount the ignition transformer on the burner by fastening the two screws.
2. Reattach the two cables into the ignition transformer.
3. Put the inspection cover back on and tighten the screws to keep it in place.
4. Turn main power back on.

114 OG/400C/OG400CS
 APPENDIX D

Appendix D: Diesel oil pump

The oil pump incorporates a regulating valve with cut-off function.

Applications
 Light and medium oil
 Nozzle flow up to 110 l/h (2850 rpm, 5 cSt, 10 bar)
 Normally associated with in-line solenoid valve.
 One or two-pipe system

Pump operating principle

The gear-set draws oil from the tank through the built-in filter and
transfers it to the valve that regulates the oil pressure to the nozzle
line. All oil, which does not go through the nozzle line, will be
dumped through the valve back to the return line. The valve also as
a cut-off and bleed function as follows:

Bleed Figure 2

 Two pipe operation

During starting period when the gear-set speed is increasing, all the oil passes through a
special flat on the piston, back to the return.
Once the speed reaches a certain value and the flow can no longer pass through this flat,
then the pressure increases rapidly overcoming the valve spring force and opens the valve
Cut-off:
During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is
lower than the flow.
The cut -on and cut-off speed depends on the set pressure.

Figure 3

OG400C/OG400CS 115
APPENDIX D

Technical data
General
Mounting Flange according to DIN 24220
Connection:
Inlet 1/4" NPTF
Return 1/4 " NPTF
Nozzle outlet 1/8" NPTF
Pressure gauge port 1/8" NPSF
Vacuum gauge port ¼" NPTF
Valve function Pressure regulating cut-off.
Strainer 45 cm² open area 120  opening size.
Shaft 11 mm according to DIN 24220
By-pass plug Inserted for 2 pipe system. To be removed with
3/16" allen key for 1 pipe system.
Weight 4 kg
Rotation Anti-clockwise rotation. Left hand nozzle.
(seen from shaft end).

Hydraulic data
Nozzle pressure range. 10 to 21 bar.
Delivery pressure setting. 16 bar
Viscosity range. 2.8 to 200 cSt
Inlet and return pressure. 1.5 bar max.
Suction height. 0.45 bar max. vacuum to prevent air separation
from oil.
Rated speed. 3600 rpm max.
Oil temperature. Max. 90°C in the pump.
Starting torque. 0.4 N.m

Pump capacity Power consumption

Figure 4
Figure 5

116 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

Pump dimensions

Pipe dimensions
The tables below give the maximum length (in meters) of suction line as function of 3 variables:

 Lift between fuel unit and tank (H).

 Nozzle capacity.
 Pipe diameter (d)
For normal atmospheric pressure (sea level) and 0.45 bar vacuum.
Only mentioned diameters can be used, bigger pipes are not suitable.
The length indicated (intersection of horizontal lines and columns) assumes the fitting of 4 right
angle bends, 1 stop valve, 1 non return valve. If additional restrictions exist, the length must be
reduced accordingly.
From these tables, the maximum length for other viscosity's can be calculated by simple ratio of
viscosities i.e., multiply the length shown in the table by 20 and divide by the value of the new
viscosity in cSt.
Rated speed: 2850 rpm
Viscosity: 20cSt
Pressure: 12 bar

Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 12 27 51 90
1 14 30 57 99
2 17 36 68 118
3 20 42 79 136
4 22 48 90 155

Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 9 21 41 71
1 8 18 35 61
2 5 12 24 42
3 2 6 13 24
4 0 0 2 5

Figure 6

OG400C/OG400CS 117
APPENDIX D

Installation
The pump is ready for use with 2 pipe systems (i.e. with by-pass plug fitted, in the return port.)
The inlet and return pressures must not exceed 1.5 bar.
The vacuum must not be more than 0.45 bar to prevent air separation from oil.
It is recommended to use a separate filter upstream of the pump.
The pump is to be used with cylindrical fitting or conical fittings as appropriate and sealing washers. Other
sealants are not recommended.

Start up
Check that the sense of rotation for pump and motor are the same (an arrow is stamped on the pump body).
In order to purge pumps used on 1 pipe systems, loosen one of the high pressure connections. On 2 pipe
systems, purging is automatic.

Pressure regulation
Remove end cap nut from pump for access to pressure stetting screw. Turning the regulator screw clockwise
increases the pressure.

Systematic maintenance
1. Check the stop valve and in line filters.
1. Check the pump filter.
This filter should be cleaned with a soft brush and fuel oil.
Each time, the cover gasket should be changed.
2. Check the tightness of all couplings and unused plugs.
3. Check the shaft coupling.
4. Check the pump pressure.
Fit a pressure gauge in the fitting provided and run the pump in normal manner.
If the pressure required cannot be obtained, check that the pump is completely purged. If air
bubbles are found in the fuel, check all connections for tightness.
5. Check the pump vacuum.
Fit a vacuum gauge in fitting provided and run the pump in the normal manner, making sure
to fully purge the pump.
The vacuum should not exceed 0.45 bar. If this is the case, check condition of all
components (non return valve, stop valves, filters....).
If the pump does not suck correctly, check for any leaks in the line by retightening all
fittings.

118 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

Figure 7

Parts list
Pos. no. Description Article no.

1 Pressure adjusting plug assy "C" 10-21 bars 6985

1.1 Protecting nut + washer 6986
2 Pressure regulator kit, 10-21 bars 6987
3 Drilled nozzle plug and washer (J 1002) 6988
4 Shaft seal kit 9272
4.1 Seal face kit 6439
5 J 3 shaft 6999
5 J 4 shaft 6989
6 Seal cap 6990
7 By-pass plug 6991
8 1/4 NPTF plug (J 1000) 6992
9 1/8 NPTF steel plug (J 1000) 6993
10 J 3 rot. A gear kit 7000
11 Filter 6995
12 Cover gasket 6996
13 Cover + filter kit 6997
* Spanner wrench for shaft seal 6998

OG400C/OG400CS 119
APPENDIX D

Oil Burner Fuel Pump replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric

1. Disconnect the three D.O. pipes from the pump.

2. Unscrew the two bolts and pull out the pump.

3. Measure the distance shown at the below picture before removing the spline coupling from the old
pump. Should be 10mm.

120 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

4. Untighten the set screw and move the spline coupling to the new pump. Distance between spline
coupling and pump as measured in point 3.

Reassembly of oil burner fuel pump

1. Mount the spline coupling on the pump, distance should be 10mm

2. Put the pump back on the burner, and tighten the 2 bolts to keep it in place
3. Reconnect the 3 D.O, pipes to the pump
4. Turn main power back on

OG400C/OG400CS 121
APPENDIX D

Burner Pump Shaft Seal replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric
- Lug spanner

1. Disconnect the three D.O. pipes from the pump.

2. Unscrew the two bolts and pull out the pump.

3. Measure the distance shown at the below picture in order to positioning the spline coupling correctly
when reassembling. Should be 10mm

122 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

4. Untighten the set screw and remove the spline coupling.

5. Unscrew the nut with the lug spanner by turning it anticlockwise.

6. Pick out all the parts and replace it with the new ones. Picture below shows in which order!

Reassembly

1. Put all the parts back in the pump in the order shown on the picture above
2. Put the lock nut back and tighten by turning it clockwise, tighten with 20Nm force
3. Mount the spline coupling on the pump, distance should be 10mm
4. Put the pump back on the burner, and tighten the 2 bolts to keep it in place
5. Reconnect the 3 D.O, pipes to the pump
6. Turn main power back on

OG400C/OG400CS 123
APPENDIX D

Burner pressure regulation kit replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Screwdriver set

1. Disconnect the D.O. pipe from the pump. Unscrew the two large hexagon nuts.

2. Use a pipe or similar to knock out the cylindered part that remain inside the pump.

124 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

3. All parts (items) positioned in correct order for assembling.

4. Add item 6 and 7 to item 5, as shown at the picture below, and slide the complete unit back in
position in the pump.

5. Enter the nut item 10 to the pump. Notice the direction of the spring washer item 8.

6. Enter the item 1, 2, 3 and 4 to the pump. Notice the direction of item 3.

OG400C/OG400CS 125
APPENDIX D

7. When starting the incinerator again, the pressure has to be regulated to 16 bar by adjusting at the
screw as shown at picture below.

126 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX D

Spline coupling replacement

(Demo pictures only. The burner should never be dismantled from the incinerator for any maintenance or
replacement.)

Turn of main power before starting the maintenance task

Tools needed:
- Wrench set, metric
- Allen key set, metric

1. Disconnect the three D.O. pipes from the pump.

2. Unscrew the two bolts and pull out the pump.

3. Unscrew the 4 bolts and pull out the motor.

OG400C/OG400CS 127
APPENDIX D

4. Measure the distance shown at the below picture before removing the spline coupling. Should be 10mm

5. Untighten the set screws in order to remove the spline couplings.

Reassembly of the spline coupling

1. Put the inner spline coupling back into the fan wheel and tighten the set screws.
2. Put the outer spline coupling on the pump and adjust the distance between them, should be 10mm.
tighten the set screw to keep it in place
3. Put the motor with the fan wheel back on the burner and tighten the 4 bolts.
4. Put the pump back on the burner, and tighten the 2 bolts to keep it in place
5. Reconnect the 3 D.O, pipes to the pump
6. Turn main power back on

128 OG/400C/OG400CS
 APPENDIX E

Appendix E: Frequency inverter ATV12

Specification
Teamtec H055M2
Power supply 200/240 V -15% +10%
50/60Hz 5Hz
Motor power rating 0.37kW / 0.5HP
Line current 13 6.7 A
Permanent output 3.5 A
current
Maximum transient 5.3 A
current 14
Power dissipated 41 W
(loss) at normal
load
Dimension (WxHxD) 72x145x122 mm
Weight 1.05 kg

13
Line current: Typical value without additional inductance.
14
Transient current: for 60seconds

OG400C/OG400CS 129
APPENDIX E

Technical characteristics
Degree of protection IP 20 without protective vent cover. IP31 other areas.
Vibration and shock 1 gn from 13 to 150 Hz, 15 g for 11 ms
resistance
(EN60068)
Degree of pollution Degree 2 according to UL840. Protect the drive against dust,
corrosive gases, and falling liquid.
Relative maximum 96% without condensation or dripping water (if there is a risk
humidity of condensation provide a heating system).
Ambient air temp. in Operating: -10°C to +60°C (with vent cover removed)
acc. with EN50178 Storage: -25°C to +70°C
Maximum operating 1000 m. without derating. Above this, derate the current by
altitude 1% for each additional 100 m.
Output voltage Maximum voltage equal to mains voltage.
Frequency range 0 Hz to 500 Hz.
Maximum transient 150% of nominal drive controller current for 60 seconds
current
Breaking torque 100% of the nominal motor torque without break resistor
(typical value). Up to 150 % with braking resistor as an
option.
Frequency - Display: 0.1 Hz
resolution
- Analog inputs: 0.1 Hz for 100 Hz maximum
Switching frequency Can be adjusted from 2.0 to 16 kHz
Speed controller - Galvanic isolation between power and control circuits
protection and (inputs,
safety outputs, supplies)
- Protection against short-circuits:
 within internal power supplies
 between output phases
 between the output phases and earth
- Protection against input phase loss
- Thermal protection from excessive overheating and
overcurrents
- Under and overvoltage supply
- Overvoltage safe on braking
Motor protection Thermal protection integrated into the drive controller by
calculating I²t. Protection against motor phase loss.

130 OG/400C/OG400CS
 APPENDIX E

Accessing terminal blocks

Control
terminals

Power
terminals

Figure 31

Power Terminals
The power terminals must be connected before connecting the control terminals!

Maximum connection capacity: AWG 10 / 5 mm2

Tightening torque: 1.2 Nm

Figure 32

OG400C/OG400CS 131
APPENDIX E

Faults – Causes – Remedies

Drive does no start, no fault displayed
 If the display does not light up, check the power to the drive and check the wiring of inputs AI1 and
AI2 and the connection to the RJ45 connector.

 The Assignment of the “Fast stop” or “Freewheel stop” functions will prevent the drive from starting
if the corresponding logic inputs are nor powered up. The ATV320 then displays “nSt” in freewheeel
stop mode and “FSt” in stop mode. This is normal since these functions are active at zero so that the
drive will be stopped safely if there is a wire break.

 Check that the run command input(s) have been actuated in accordance with the chosen control mode
(tCC parameter in the I-O menu).

 If an input is assigned to the limit switch function and this input is zero, the drive can only be started
up by sending a command for the opposite direction, see ATV 320 programming manual.

 If the reference channel or the control channel is assigned to Modbus or CANopen, the drive displays
nSt on power-up and remains at stop until the communication bus sends a command.

 If the LED on the DC bus is lit and nothing appears on the display, check that there is no short-circuit
on the 10 V power supply.

 If the drive displays “rdY” and refuses to start, check that there is not short circuit on the 10 V power
supply and check the wiring of inputs AI1 and AI2 and the connection to the RJ45 connector.

132 OG/400C/OG400CS
 APPENDIX E

OG400C/OG400CS 133
APPENDIX F

Appendix F: Sludge burner

Cleaning of sludge burner

Check the sludge burner frequently, minimum every month, and if necessary clean it.

 Loosen setscrews (A), and nut (B) and pull out the external pipe (C).
 Clean the external (C) and internal (D) pipes.
 After cleaning, re-assemble the sludge burner in reverse order.
 Check that internal pipe (D) is centred (concentric) in the external pipe (C), adjust with set-
screw (A) according to the adjustment procedure below.

Procedure for adjusting the sludge burner

 Attach fresh water supply to the Steam/Air connection
 Apply moderate water pressure until water flows steadily trough the nozzle
 Adjust the setscrews (A) until the water forms an even shape that does not bend away from
the centre line.

134 OG/400C/OG400CS
 APPENDIX G

Appendix G: Sludge valve.

A 6324/1101/7003. 0-1 bar. G 3/4"

Figure 错误！未找到引用源。

OG400C/OG400CS 135
APPENDIX G

Valve
Valve housing Brass
Cove Red brass
Inner parts AISI 430F
Sealing device Teflon, Viton and Silicone
Control medium Steam 180°C, max 7 bar. Inlet 1/8 BSP
Medium Oil 90°C, max 1 bar. Inlet/Discharge 3/4 BSP

Repair kit for sludge valve article no. 12806 consist of:

Pos. no. Nos. Description

1 (101) 1 Arm
2 (301) 1 Base plate
3 (302 1 Spindle
4 (303) Piston
5 (304) 1 Disc washer
6 (305) 1 Washer
7 (306) 1 Seal
8 (307) 1 Cylinder
9 (308) 1 Tube bearing
10 (309) 1 Bolt
11 (311) 2 Ring
12 (312) 1 O-ring
13 (313) 1 O-ring
14 (314) 1 Safety ring
15 (315) 1 Nut
16 (316) 1 Deflector
17 (317) 1 Face plate
18 (318) 1 Spring
19 (319) 1 Compression ring

Figure 33

136 OG/400C/OG400CS
 APPENDIX H

Appendix H: Sludge Dosage Pump

Dimension

Weight:19,5 kg

Figure 34

OG400C/OG400CS 137
APPENDIX H

Dismantling and assembly diagram,

Figure 35

138 OG/400C/OG400CS
 APPENDIX H

Parts list Art. No. 21270

Pos.No Art.nr. Description Qty.

8190 15689 Gland Guard 1

8120 15687 Seal Plate Gasket 1
7710 15679 Tie rod 4
5861 15683 Mech. Seal housing 1
5452 15682 Seal plate 1
5310 15681 Straight through end cover 1
5010 15680 Pump housing 1
4400 15685 Stub shaft 1
2500 21267 Rotor 1
20 21268 Bonded stator 1
1200 15678 Pump lantern 1
0760 15677 Foot 1
46 15739 Hex socket grub screw (for part no. 4400) 1
45 15738 Hex socket set screw (for part no. 4400) 2
43 3206 Spring washer (for part no.42) 4
42 2541 Hex nut (for part nr. 41) 4
41 15740 Stud (for part no. 40) 4
40 15749 Flange mounted geared motors 1
36 5641 Punched washer (for part nr. 16) 10
34 15736 Spring washer (for part no. 08) 2
30 15741 Mech. Seal 1
20 15688 UJ 1
19 16274 Taper plug (for part no. 5010) 1
16 2598 Hex nut (for part no. 15) 10
15 15737 Spring washer (for part no. 7710, 1200 & 5310) 10
08 15735 Hex nut (for part no. 07) 2
07 15734 Stud (for part no. 5861 & 5452) 2
5862 15690 Retaining pin 1

Figure 36

OG400C/OG400CS 139
APPENDIX H

Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will
ensure that the safety of personnel and satisfactory operation of the pump is achieved.

General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory
conditions. With certain product materials, a hosing down facility with adequate draining will simplify
maintenance and prolong the life of pump components.

Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do
not allow moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut
hand tight. If a water flush system is to be used do not grease, a small amount of light oil is
recommended for these.
4. See Manufacturers instructions for motor/gearbox/drive instructions for storage procedures.

Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following
procedures should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the
stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because
damage could be caused to the rotor/stator elements.

Immediately prior to installation and starting.

Before installing the pump please ensure that all plugs and inspection plates are replaced and that excess
grease/oil is removed from the stuffing box. Make sure the pump is not started in dry condition.

140 OG/400C/OG400CS
 APPENDIX H

Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where
any doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding.
Normally the pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly
connected. When the motor is being wired and checked for rotation, the start/stop sequence must be
instantaneous to prevent dry running or pressurising upstream equipment. (Check direction arrow on pump
nameplate). The electrical installation should include appropriate isolating equipment to ensure that the pump
unit is safe to work on.

The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.

General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation.
To eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely
flexed in position. When commissioning the plant, all joints in the system must be checked thoroughly for
leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and
the cause of the malfunction established before operations are recommenced. It is recommended that
depending upon plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge
only be fitted to the pump inlet port, and a pressure gauge fitted to the outlet port, these will then continuously
monitor the pump operating conditions.

Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide
the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid
will normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been
dismantled and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is
normally somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears
when the pump is running normally against pressure.

Dry running
Never run the pump in a dry condition even for a few revolutions, the stator will be damaged
immediately. Continual dry running could produce some harmful or damaging effects.

OG400C/OG400CS 141
APPENDIX H

Mechanical seals, all pumps.

When a mechanical seal is fitted to the pump it may be necessary to provide a barrier fluid to some part of the
seal. This should be provided in line with the seal manufacturers instructions.

Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.

Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with
their specific instructions.

Pump operating temperature

The range of temperatures the pump surfaces will develop is dependent upon factors such as product
temperature and ambient temperature of the installation. There may be instances where the external pump
surface can exceed 50°C.

Maintenance of wearing components

Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasivity, speed, pressure
etc.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.

142 OG/400C/OG400CS
 APPENDIX H

Diagnostic chart
SYMPTOMS POSSIBLE CAUSES
1 NO DISCHARGE 1.2.3.7.26.28.29.
2 LOSS OF CAPACTY 3.4.5.6.7. &: 9.10. 11.13. 16.17.21.22.23.29.
3 IRREGULAR DISCHARGE 3.4.5.6.7.8.13.15.29.
4 PRIMING LOST AFTER START 3.4.5.6.7.8.13.15.
5 PUMP STALLS AT START UP 8.11.24.
6 PUMP OVERHEATS 8.9.11.12.18.20.
7 MOTOR OVERHEATS 8.11.12.15.18.20.
8 EXCESSIVE POWER ABSORBED BY PUMP 8.11.12.15.18.20.
9 NOISE AND VIBRATION 3.4.5.6.7.8.9.11.13.15. 18.s~19. 20.22.23.27.
10 PUMP ELEMENT WEAR 9.11..
11 EXCESSIVE GLAND OR SEAL WEAR 12.14.25.30.
12 GLAND LEAKAGE 13.14.
13 SEIZURE 9. 11.12.20.

LIST OF CAUSES REMEDIAL ACTIONS

1. INCORRECT DIRECTION OF ROTATION REVERSE MOTOR
2. PUMP UNPRIMED BLEED SYSTEM OF AIR / GAS
3. INSUFFICENT N.P.S.H. AVAILABLE INCREASE SUCTION HEAD OR REDUCE SPEED / TEMP
4. PRODUCT VAPOURISING IN SUPPLY LINE INCREASE N.P.S.H. AVAILABLE (SEE 3 ABOVE)
5. AIR ENTERING SUPPLY LINE CHECK PIPE JOINTS / GLAND ADJUSTMENT
6. INSUFFICIENT HEAD ABOVE SUPPLY VESSEL OUTLET RAISE VESSEL / INCREASE PIPE SIZE
7. FOOTVALVE / STRAINER OBSTRUCTED OR BLOCKED CLEAN OUT SUCTION LINE / VALVES
8. PROOUCT VISCOSITY ABOVE RATED FIGURE DECREASE PUMP SPEED / INCREASE TEMP
9. PRODUCT TEMP ABOVE RATED FIGURE COOL THE PRODUCT
10. PRODUCT VSCOSITY BELOW RATED FIGURE INCREASE PUMP SPEED / REDUCE TEMP
11. DELIVERY PRESSURE ABOVE RATED FIGURE CHEC FOR BLOCKAGES IN DELIVERY LINE
12. GLAND OVERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
13. GLAND UNDERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
14. GLAND FLUSHING INADEQUATE CHECK FLUID FLOWS FREELY INTO GLAND
15. PUMP SPEED ABOVE RATED FIGURE DECREASE PUMP SPEED
16. PUMP SPEED BELOW RATED FIGURE INCREASE PUMP SPEED
17. BELT DRIVE SLIPPING RE -TENSION BELTS
18. COUPLING MISALIGNED CHEOK AND ADJUST ALIGNMENT
19. INSECURE PUMP I DRIVE MOUNTING CHECK AND TIGHTEN ALL PUMP MOUNTINGS
20. SHAFT BEARING WEAR I FAILURE REPLACE BEARINGS
21. WORN PUMP ELEMENT FIT NEW PARTS
22. RELIEF VALVE CHATTER CHECK CONDITION OF VALVE / RENEW
23. R.V. INCORRECTLY SET RE -ADJUST SPRING COMPRESSION
24. LOW VOLTAGE CHECK VOLTAGE I /WIRING SIZES
25. PRODUCT ENTERING PACKING AREA CHECK PACKING CONDITION AND TYPE
26. DRIVE TRAIN BREAKAGE CHECK AND REPLACE BROKEN COMPONENTS
27. NEGATIVE OR VERY LOII DELIVERY HEAD CLOSE DELIVERY VALVE SLIGHTLY
28. DISCHARGE BLOCKED / VALVE CLOSED REVERSE PUMP/RELIEVE PRESSURE / CLEAR
BLOCKAGES
29. STATOR TURNING REPLACE WORN PARTS / TIGHTEN UP STATOR BOLTS
30. STUFFING BOX EATS - PACKING CHECK FOR WORN SHAFT AND REPLACE

OG400C/OG400CS 143
APPENDIX I

Appendix I: Sludge circ. Pump

Model 40WYXH-6-20
Marine Sludge Oil Circulation Pump

Operation Instruction

Tiantai Shan Water Pump Factory, Taizhou City, Zhejiang Province

Address：No.71 Jiatu Street, Jietou Town, Tiantai County, Zhejiang Province
Post Code：317205
Telephone：（0576）3030350 3030258
Fax：（0576）3032032

144 OG/400C/OG400CS
 APPENDIX I

1.General information
Model 40WYXH-6-20 marine sludge oil circulation pump is a
motor-driven horizontal sludge oil pump (Reference to as residual oil
pump hereinafter).
Pumps of this series are suitable for delivering heavy oil and sludge
oil with temperature up to 90℃. This is a piece of equipment optimal
for completion of incinerator in water treatment plant.
1.1Type designation
40 WY XH ─ 6 ─ 20
Pressure at rated flow0.20Mpa
Rated flow 6m3/h
Circulation pump
Sludge oil（residual oil）
Inlet and outlet dia40mm
2.Structure and Features
2.1Structure （See fig.）
A. Pump of this series is composed of casing, impeller, locking bolts,
sealing device, motor and etc.
B. Pump of this series is a horizontal pump with the motor at rear
and pump in front coupled together. The pump uses semi-open
impeller which is directly connected to motor output shaft.
C. Inlet and outlet of the pump shall be connected to external with
standard four-step four-hole flanges.
2.2 Features
Pumps of this series feature high discharge power, good sealing
performance, thermal resistance, high efficiency and energy saving.
3.Selection of Main Part and Component Materials
a. Pump casing, rear pump casing and impeller are made of ductile
cast iron.
b. Metal bellow mechanical sealing ring is used as shaft seal。

OG400C/OG400CS 145
APPENDIX I

4.Main Technical Data

Type 40WYXH-6-20
Item Unit
Flow m3/h 6
Pressure mpa 0.2
Power supply v/Hz 380/50 440/60
Motor power kw 2.2 2.53
Motor speed r/min 2840 3470
Dia. of inlet and outlet mm 40
Weight kg
Outline（L×W×H） mm 454×225×240
5. Installation Instructions (See Fig. For dimension
The pump is a non-self-suction type and media is sludge oil with solid
granulates or heavy oil. Therefore, centerline of pump casing must be
below medium level and suction and discharge pipes must have size
larger than inlet and outlet with minimal bends. Otherwise, pumping
performance shall be affected.
Pump base plate shall be secured with bolts. There shall have four
pump casing fixing bolts at pump discharging side 90°apart, which can
be undone for adjustment.
6.Operation and Maintenance Instructions
Prior to initial start, pump motor shall be checked for conformance of
power supply to be connected with power system of the motor.
Open valves in suction and discharge pipelines and start the motor. At
start up direction of pump rotation shall be checked to see if it is in line
with that indicated on pump casing, or it shall be changed.
If there is any leakage with the pump, stop the pump immediately to
make checks and close valves so as not to burn the motor. When
necessary, seal ring shall be replaced. Normal leakage from the
mechanical seal shall be less then 10ml/h.
The pump shall not be run empty so as not burn seal ring.

146 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX I

When the pump is not to be operated for al long time, it shall be

dismantled for cleaning. Special attention shall be paid when disassembling
that both faces of mechanical seal shall not be damaged. A suitable amount
of lubricant shall be applied at assembling for proper storage.
7.Disassembling and assembling
7.1Disassembling
a. Removal the four securing nuts(15) and take off pump casing(1).
b. Undone lock nuts (2) and pull out impeller (4). Take out flat key (5).
c. Remove three fixing screws (14) for rear pump casing (14) and pull
out rear casing (13) together with mechanical seal ring(7). And remove the
mechanical seal ring from rear pump casing for replacement or repair.
d. Remove 3 screws (9) fixing the gland and take off the gland (10) and
you will be able to fill lubricant into the bearings.
e. Remove the retainer from motor shaft (11) by means of circlip pliers.
Remove 3 fixing screws on motor enclosure and pull out the enclosure with
bearing for replacement and cleaning.
7.2. Assembling
a. Assemble in the reverse order of assembling.
b. Both faces of the mechanical seal ring shall be cleaned up before
being installed. Never strike so as not to damage the sealing ring.。
8. Spare Parts Delivered with the pump (see packing list for details)
a. “o”-type ring each for two sizes
9. Document Delivered with the pump
a. A copy of pump inspection certificate
b. A copy of operation instructions
c. Motor operation instructions & quality certificate 1 copy each
d. Packing list 1 copy.

OG400C/OG400CS 147
APPENDIX I

Packing list

S/N Description Type and size Q’ty Unit Remarks

1 Marine sludge oil
40WYXH-6-20 1 set
circulation pump
2 O seal ring 20×2.6 GB1235-76 1 pc spare
3 O seal ring 130×3.1GB1235-76 1 pc spare
4 Document

Inspection:____________ Packing:____________Date:____________

148 OG / 4 0 0 C /O G 4 0 0 C S
 APPENDIX I

OG400C/OG400CS 149
APPENDIX J

Appendix J: Water Dosage Pump

Dimension

Weight:19,5 kg

Figure 37

OG400C(S) 150
 APPENDIX J

Dismantling and assembly diagram,

Figure 38

Parts list Art. No. 2007740

Pos.No Art.nr. Description Qty.

1 15689 Gland Guard 1

2 15687 Seal Plate Gasket 1
3 15679 Tie rod 4
4 15683 Mech. Seal housing 1
5 15682 Seal plate 1
6 15681 Straight through end cover 1
7 15680 Pump housing 1
8 15685 Stub shaft 1
9 15684 Rotor 1
10 15748 Bonded stator 1
11 15678 Pump lantern 1
12 15677 Foot 1
13 15739 Hex socket grub screw (for part no. 4400) 1
14 15738 Hex socket set screw (for part no. 4400) 2
15 3206 Sping washer (for part no.42) 4
16 2541 Hex nut (for part nr. 41) 4
17 15740 Stud (for part no. 40) 4

OG400C/OG400CS 151
APPENDIX J

18 15749 Flange mounted geared motors 1

19 5641 Punched washer (for part nr. 16) 10
20 15736 Spring washer (for part no. 08) 2
21 15741 Mech. Seal 1
22 15688 UJ 1
23 16274 Taper plug (for part no. 5010) 1
24 2598 Hex nut (for part no. 15) 10
25 15737 Spring washer (for part no. 7710, 1200 & 5310) 10
26 15735 Hex nut (for part no. 07) 2
27 15734 Stud (for part no. 5861 & 5452) 2
28 15690 Retaining pin 1

Figure 39

OG400C(S) 152
 APPENDIX K

APPENDIX K: Refractory
Introduction
The inner lining of the incinerator consists of a heat resistant material called refractory. This material can
withstand temperatures up to 1500°C, and its function is to protect and insulate the insulation behind. The
refractory lifetime will vary depending on the use of the incinerator and if maintenance of the incinerator has
been performed regularly according to instructions given in the maintenance chapter. If the incinerator has been
well serviced over the years, there will be less wear on the refractory, and the refractory lifetime will be 7-10
years.

Defining incinerator refractory condition

Refractory cracks where brick have split in two or more pieces:

In case micro cracks have developed, splitting a brick into two or more pieces, there are no reasons for repair or
worry. Note however, that if parts of the refractory fall out or there has been other wear, action is required as
described below.

Parts of bricks have fallen out:

If parts of a bricks have fallen out, there is reason for concern. If the insulation or steel plate behind is exposed,
the repair must be done immediately, and before further use of the incinerator. If only small parts are coming
loose and there is remaining refractory protecting the insulation plate behind, repair material should be added
during next cleaning of the chamber.

Slag is building up on the refectory surface:

There are general two types of slag.

The first is a glass-like, hard slag, looking like the surface of the moon. This type of slag is normally building
up in a thin layer, and should not be removed.

The second type of slag is the soft ash type of slag that builds up in a heavy layer, and should be gently
removed during the daily ash removal routine.

Bad looking refractory surface:

There are often questions of “bad” looking refractory surface.

Parts of refractory can chip off, for example if air at room temperature is leaking in to the chamber from the
door gasket or if sludge containing water is transferred to the sludge service tank during sludge burning. In the
latter case, water in the sludge will then become steam at 100°C. Both room air and steam are very chilly for
1100°C refractory, cooling the refractory surface very rapidly, but not the core. The huge temperature
difference between surface and core of refractory will then create a lot of tension forces, for which concrete has
little strength to withstand, and the result in these scenarios is chipping.

Refractory is very slowly wearing down from day one of operation (faster if handbook procedures and
instructions are not followed to the point), but the look of the surface can be disregarded. The important
parameter is if 30% of the thickness or more of the brick dimension is lost, repair material should be added in
order to rebuild the brick to original dimension.

In doubt:
Feel free to ask Teamtec main office to give an opinion. Good quality digital photos, taken from different
distances and angels are required (spares@teamtec.no or service@teamtec.no ).

OG400C/OG400CS 153
APPENDIX K

Calde patch instruction

CALDE PATCH PT 88U is delivered in 25 Kg plastic containers and is used for small incinerator brick repairs.

The following working should be applied when using CALDE PATCH PT88U:

The surface should be clean(ed) and all loose material should be removed to secure a firm binding between the
repair substance and the bricks.

The bricks should be padded one by one, meaning no Calde Patch to bind two bricks together.
Do not fill the gaps between the bricks with Calde Patch. The bricks need the space for heat expansion.
Preferably use cardboard between the bricks when padding the brick edges.

If there is some OLD repair substance left on the area that is to be fixed, it is important to add some water to
this part of the area and make it wet BEFORE new repair substance is added to the spot.

CALDE PATCH PT88U consists of proximately 20% water to obtain a plastic substance that can easily be
worked with. The material is VERY sensitive to additional water content. Water should not be added without
consulting to TeamTec AS first.

CALDE PATCH PT88U shall be added to the bricks by means of a stopping knife until the right thickness has
been reached. The thickness should be at least 10mm. The material will have to dry for some hours before the
next layer is added.

We advise to dry the material over night by means of an electrical heater (max 50 degrees) before the
incinerator is started up again. If your incinerator has a burn in program, please use this for 5 to 6 hours the day
after padding to cure in the repair substance.

OG400C(S) 154
 DRAWINGS

DRAWINGS

OG400C/OG400CS 155
DRAWINGS

List of drawings
Incinerator
Dwg. no Name of drawing
1011248 Piping & Instrument Diagram OG200C/CS, Steam Heating
116711 Combustion Chamber Assy. OG200/400C
116740 Combustion Chamber Assy. OG200/400CS
1008973 Combustion Chamber Mounting Drawing OG200/400C
116711M Combustion Chamber Main Dimension. OG200/400C
116740M Combustion Chamber Main Dimension. OG200/400CS
119827 Oil Burner F-50-45-T, 220V With Analog Motor
119512 Oil Burner F-50-45-T, 220V with Sludge Burner, Sub Assy.
1008970 Refractory and Insulation OG200C/CS
119640 Sludge Oil Dosage Valve Assembly,
116726 Garbage Door Assembly
116742 Door Assy.CO1310×510 with Sluice
3010075 Running Instructions OG200/400C
3010073 Running Instructions OG200/400CS

Flue gas
Dwg. no Name of drawing
1011017 Flue Gas Damper Assembly DN400/300
1007000 Flue Gas Damper, Sub. Assy DN400/300
1008645 Flue Gas Fan, Sub. Assy. DN 300 H2
3010975 Main dimensions Flue Gas Fan DN 300 H2
AS350-5 Expansion Compensator DN 350

Sludge Tank
Dwg. no Name of drawing.
116831 Sludge Tank Assembly1100 L Net Steam Heating
116831M Main Dimension Sludge Tank 1100L Net Stem heating

Electrical diagrams
Dwg. no Name of drawing
2009906 Cable Arrangement for OG200C/CS
1011269 Control Panel 380/440V - 220V for OG400C/CS
1010728 Mounting Plate with El.Components 380/440V-220V, OG200C/CS
3010840 Electric Diagram 380/440V-220V Teamtec Incinerator OG200C/CS
4007918 Terminal Diagram Diesel Oil Burner F-50-45-T with Analog Motor
1010920 Control Panel Sludge Tank w/Steam Heating
2009668 Mounting Plate w/El.Components Sludge Tank w/Steam Heating
3010933 Electric Diagram Sludge Tank w/Steam Heating

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