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FireLake P77-3-SC30 Installation And Operator's Manual

Incinerator
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Model P77-3-SC30
Incinerator
Three Burner, Two Thermocouple, AutoPreheat, Upper Burner Modulation, Individual
Lower Burner On/Off, Water Spray, Hi-Hi Shutdown, Chart Recorder (optional)
Installation and Operators Manual
Note exact model you purchase may look different than image due to design options.
WARRANTY WARNING
1. Tampering with orifices in the burner without factory consent will void warranty.
2. Factory has cured the incinerator but in the future any repairs of the lining may
need to undergo a cure process, consult your dealer.
3. Cracks in lining are normal and allow stress relief.
All Installations Must Be In Accordance With State and Local Codes and it is the
Contents
responsibility of the owner and installer to assure all codes are met
P77-3 SC30 Manual 9.27.2019
Page 1

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Summary of Contents for FireLake P77-3-SC30

  • Page 1 Model P77-3-SC30 Incinerator Three Burner, Two Thermocouple, AutoPreheat, Upper Burner Modulation, Individual Lower Burner On/Off, Water Spray, Hi-Hi Shutdown, Chart Recorder (optional) Installation and Operators Manual Note exact model you purchase may look different than image due to design options.
  • Page 2 PERSONAL PROTECTIVE EQUIPMENT FOR CRUSHING, HEAT , ABRASION, AND DUST P77-3 SC30 Manual 9.27.2019 Page 2...
  • Page 3 P77-3 SC30 Manual 9.27.2019 Page 3...
  • Page 4 Will vary but may range up to 125lb./hr. If on-site testing is required it is the responsibility of the purchaser and your Firelake dealer can assist in the process. Outside installation is recommended with a minimum metal roof and three-sided metal shelter, provided a minimum of four (4) foot clearance from any combustible material.

  • Page 5: Packing List

    PACKING LIST Primary Chamber Components Primary Chamber w/ top & door assembly including weight box with arms. Connector Stack 3 foot tall, may be attached to primary chamber Toggle Clamp Ash door Toggle Clamp Door Stack Components 4’ x 18” Painted Steel Lined Stack section with coupler for thermocouple 18”...

  • Page 6: Site Information

    SITE INFORMATION LACEMENT AND ONSTRUCTION RECOMMENDATIONS • The incinerator is designed for indoor or outdoor installation on a concrete slab. • For ease of operation and to protect the equipment we suggest the unit be installed in a three or four sided shelter with roof. Allow service space to load and unload and service the burners and controls.
  • Page 7 Weight box and swing arms behind main chamber Photo applies to P50 or P77 Main Chamber Stack Cap bolted on stack flange P77-3 SC30 Manual 9.27.2019 Page 7...
  • Page 8 Secondary Chamber aligned on connector stack. Photo applies to P50 or P77 Main Chamber with SC30 Secondary Chamber P77-3 SC30 Manual 9.27.2019 Page 8...
  • Page 9 COMBUSTIBLE ROOF CONSTRUCTION (MINIMUM REQUIREMENT SHOWN) ACTUAL PENETRATION DESIGN AND SUPPORTS MAY BE DIFFERENT FOR GIVEN SITE. Figure 3: Combustible Roof Construction Diagram P77-3 SC30 Manual 9.27.2019 Page 9...
  • Page 10 Chambers, Stack, Control Box Assembly P50/P77-3 SC30 Read through the complete manual before attempting assembly 1. Confirm all assemblies are present before attempting assembly. Refer to picture. Major components would be three burners, a control box, secondary chamber, main chamber, door arms and weight box, stack cap and stacking.
  • Page 11 ALL FLANGE CONNECTIONS Purpose: create air tight flange to flange connection and continue a refractory lining from stack to stack. IF mastic is used and pushes out seam smooth to match interior wall. Mastic is also called “furnace cement” “mud”. P77-3 SC30 Manual 9.27.2019 Page 11...
  • Page 12 P77-3 SC30 Manual 9.27.2019 Page 12...

  • Page 13: Assembly Instruction

    ETAILED SSEMBLY NSTRUCTION LECTRICAL ERVICE HIS INCINERATOR HAS BEEN BUILT TO OPERATE ON ONE OF THE FOLLOWING POWER SUPPLIES EVER CONNECT A V TO A V SYSTEM OR A V TO V SYSTEM 115 volts, 60hz, 30 amp or 220 volts, 50hz, 15 amp for diesel units 115 volts, 60hz, 20 amp or 220 volts, 50hz, 10 amp for gas units •...

  • Page 14: Fuel Supply

    UPPLY Fuel Oil Models OIL TANK: 1. Since tanks vary in size and fixtures, you may need to make adaptations to use the parts supplied. Placing the tank to allow gravity flow to burners is ideal but limit line pressure head to 3 psi (nfpa rule) or no more than 10 psi (pump vendor limit) at the burner pumps.
  • Page 15 FUEL OIL CONNECTIONS “X” TIP: TANK LOCATION - HAVING FUEL GRAVITY FLOW IS BETTER THAN HAVING BURNER PUMPS SUCK FUEL UPWARD. BE SURE ARRANGEMENT MEETS LOCAL CODE AND NEVER EXCEED PUMP INLET PRESSURE. “X” A TEE IS USED ON LINES SHOWN TO CONNECT THE THIRD BURNER LOCATED AT THE OPPOSITE END OF THE CREMATOR.

  • Page 16: Pressure Gauge

    Place a manual gas valve near burner. • Allow for disconnecting lines, use proper fittings to facilitate service if needed. Typical pipe assembly. Some customers have Firelake factory build the gas train thus may be different than shown. P77-3 SC30 Manual 9.27.2019 Page 16...
  • Page 17 Thermocouples Screw thermocouple in opening (apply never-seize on threads or similar antilocking paste) and only hand tighten in port. Connect wires and conduit. Connection: yellow wire to the + side and red wire to the – side. Space conduit away from hot metal surfaces to prevent melting. TIP: if controller shows SnSr or similar display the thermocouple is not wired proper, the red or yellow wire failed, or the inner ceramic element is failed.
  • Page 18 OIL BURNER SETTINGS & AIR ADJUSTMENTS Air Band indicator is normally set to 0. Waste conditions may need field adjustment to allow more air to the burn process. Excessive opening may create unwanted positive pressure in the chamber and possible smoke to escape the seals.
  • Page 19 GAS BURNER SETTINGS & AIR ADJUSTMENTS Gas Flow Adjustment (Midco burner), remove nut, turning inner screw clockwise reduces flow. Some burners have a 2 orifice that limits flow, ask your dealer if Figure 1: Air Shutter (Midco burner) concerns about flame size. Model: Mid Continent Model J-121 Pilot...
  • Page 20 Operating Instructions Safety cannot be overemphasized when charging the incinerator. The following heat resistant garments should be worn when charging or unloading: Insulated gloves. Full length face shield. Full length sleeves for arm protection. Unprotected persons are not to be in area when charging. 1.
  • Page 21 DIGITAL TIMER OPERATION INDICATOR LIGHT RUN TIME UP/DOWN TIME ADJUSTMENT START/STOP START BURNER BY SETTING THE TIMER FOR THE DESIRED HOURS OF BURN TIME. PRESS START, THIS WILL START THE BURNER. A FULL LOAD OR COLD CHAMBER START MAY NEED 8 HOURS DEPENDING ON MANY FACTORS LIKE FROZEN ANIMALS, OUTSIDE TEMPERATURE, FATTY CONTENT OF LOAD.

  • Page 22: Main Control Panel

    MAIN CONTROL PANEL Indicator Lights typ Manual Toggles typ Breakers typ ( Opt) Chart Recorder FDC Control typ Main Timer On/Off P77-3 SC30 Manual 9.27.2019 Page 22...
  • Page 23 FDC TEMPERATURE CONTROL OPERATION DISPLAYS PROGRAMMED SETPOINTS (SP1, SP2, SP3) UP & DOWN arrows (triangles) may be used by operator to adjust preheat. SCROLL & RESET should only be used to view or change programming. Only trained programming persons should reprogram, and only when they are CERTAIN the change will not harm the apparatus or surroundings.
  • Page 24 SP value is shown in green. SP1 will always be shown by default, other SP values can be viewed by clicking recycle button bottom left pad (oval loop ). While a given SP is visible that SP value may be changed with arrow up and down pads beside the recycle pad.
  • Page 25 • During the burn if the temperature in the waste chamber exceeds programming for SP1 on lower FDC the “B1” burner fuel will be shut off until the temperature drops 90 degrees (90 degrees difference is the maximum the control can be set for on any FDC output).

  • Page 26: Maintenance Schedule

    MAINTENANCE SCHEDULE DAILY Check burners for smooth ignition. Check gas pressure before and during operation. Check fuel tank level. Clean inlet to fans, remove debris, bugs from burner housing area. Keep unnecessary tools and materials from incinerator area. Never store combustibles on or near the incinerator. Check primary chamber for wear.

  • Page 27: Troubleshooting

    TROUBLE SHOOTING & LP M ODELS No spark at electrodes 1. Is burner blower operating? Possible defective blower motor. 2. Clean electrodes and pilot igniter assembly. Apply heat if moisture is present. 3. Check electrode position. See drawing in Midco manual for proper adjustment. 4.
  • Page 28 MIDCO BURNER (J121-DS) EXPLODED VIEW P77-3 SC30 Manual 9.27.2019 Page 28...
  • Page 29 PARTS LIST: MIDCO burner (J121-DS) Part Number Description 33116 Manifold 31603 Flange Gasket 31586 Blower Wheel 33140 Ground Barrier Kit 31581 Main Gas Port and Tube Kit – PROPANE 31582 Main Gas Port and Tube Kit – NATURAL 33129 Transformer 115/1/50-60 Primary, 24V-30VA 101420 Transformer 220/24V 50/60 Hz, 35VA 101419...
  • Page 30 MIDCO BURNER (J83-DS) EXPLODED VIEW See parts list on following page. P77-3 SC30 Manual 9.27.2019 Page 30...
  • Page 31 PARTS LIST: MIDCO BURNER (J83-DS) Part Number Description 33116 Manifold 33117 Ignitor Gas Inlet Block, Tube and Ignitor Tip Assembly 31603 Flange Gasket 33125 Blower Wheel 34292 Ignitor Control Piping NATURAL -- #55 Drill (.052) 34290 Ignitor Control Piping PROPANE -- #58 Drill (.042) 33140 Ground Barrier Kit...
  • Page 32 BECKETT BURNER (AF) EXPLODED VIEW See parts list on following page. P77-3 SC30 Manual 9.27.2019 Page 32...
  • Page 33 PARTS LIST: BECKETT BURNER (AF) Item Description Part Number Air band assembly – 8 slot 32322 Air shutter – 8 slot 52321 Escutcheon plate 32323 Pump A2VA7116 (Suntec) 110V 32341 220V 10176130 Pump elbow 57210 Connector tube assembly – 8” 101472 Motor 110V...
  • Page 34 BECKETT BURNER (SF) EXPLODED VIEW See parts list on following page. P77-3 SC30 Manual 9.27.2019 Page 34...
  • Page 35 PARTS LIST: BECKETT BURNER (SF) Item Part Number Description 101255 Ignition Transformer 120v/60hz 101266 Ignition Transformer 220v/50hz 101273 Primary Safety Control 120v/60hz 101268 Primary Safety Control 220v/50hz 57209 Flame Detector 101270 SF Burner Motor 120v/60hz 101262 AF Burner Motor 220v/50hz 101265 Blower Wheel 101263...
  • Page 36 P77-3 SC30 Manual 9.27.2019 Page 36...
  • Page 37 MIDCO BURNER INTERNAL WIRING ORANGE L1 P77-3 SC30 Manual 9.27.2019 Page 37...
  • Page 38 INCINERATOR WIRING DIAGRAM P77-3 SC30 Manual 9.27.2019 Page 38...
  • Page 39 P77-3 SC30 Manual 9.27.2019 Page 39...
  • Page 40 P77-3 SC30 Manual 9.27.2019 Page 40...
  • Page 41 LINKAGE DIAGRAM P77-3 SC30 Manual 9.27.2019 Page 41...

  • Page 42: Reference Sheet

    REFERENCE SHEET LOWER FDC 4100 Input from thermocouple in burn chamber Hold [Scroll] Button(arrow in oval shape) 5 Seconds to display menu, press UP/DOWN buttons while within each parameter to change setting. Use Scroll to move to next parameter. Push [ R ] button when done to save settings.
  • Page 43 REFERENCE SHEET UPPER FDC 4100 Modulating Input from thermocouple above secondary Hold [Scroll] Button(arrow in oval shape) 5 Seconds to display menu, press UP/DOWN buttons while within each parameter to change setting. Use Scroll to move to next parameter. Push [ R ] button when done to save settings.
  • Page 44 P77-3 SC30 Manual 9.27.2019 Page 44...
  • Page 45 FDC (Future Design Control) Specification Review P77-3 SC30 Manual 9.27.2019 Page 45...
  • Page 46 • Power Input: 90-264VAC 50/60hz 11-26VAC / 11-36VDC optional • Input sample rate - 5 scans/second • Input Resolution - 18 Bit [262,144] click here for 18 Bit descr. • Inputs - Universal Thermocouple & RTD Linear mA/VDC inputs available as special order •...

  • Page 47: Chart Recorder (Optional)

    CHART RECORDER (optional) A Chart Recorder (when ordered as an option) in the control box records the temperature of each thermocouple. The recorder is factory programmed. A toggle switch is there to cut power to the recorder if desired. • Charts operate 24/7. Each week the chart needs to be replaced or the ink will overlap past data.
  • Page 48 Indicator light. Push pads 1,2,3 blank setup chart shown below Finished programmed setup chart , values to be entered are Type K on both pens, “0000”, “2400”, “F”, “24”, “8”, disabled (off chart). P77-3 SC30 Manual 9.27.2019 Page 48...
  • Page 49 TIP: When programming the chart over the thermocouple column the red pen will respond to < and > pad keys, move red pen over “K” and touch “3” on pad. You will see the blue pen slightly shift, now you need to use the < and > pads to locate the blue pen over “K”.
  • Page 50 Curing of the refractory has been factory done. If any new refractory is added later it is essential to cure prior to burning the first load of waste. See "REFRACTORY CURING PROCEDURE" table. 1. Remove ashes before loading the incinerator. 2.
  • Page 51 Curing Log Each operation takes 1 hour prior to temperature change. If the unit has steam releasing from the refractory hold that temperature until the steam dissipates and then continue. SET TEMP ACTUAL TEMP. OPERATOR Hour 1 250° F ____________ _________ Hour 2 250°...
  • Page 52 Grates & Thermocouples Incinerator grates and thermocouples are not manufactured by Firelake Manufacturing, LLC and are therefore exempt under our regular warranty on the opposite side of this page. Firelake Manufacturing, LLC will, however, warrant grates and thermocouples used on Professional Incinerators for a period of ninety days (3 months) form date of installation.

  • Page 53: Conditions And Limitations

    If such a defect is found by the Firelake to exist within the one-year period, Firelake will, at its option, (a) repair or replace such product free of charge, F.O.B.

  • Page 54: Warranty Procedure

    (Tel.) 320-275-3391 (Fax) 320-275-2779 Thank You The employees of Firelake Mfg., LLC would like to thank your for your recent purchase. If a problem should arise, your distributor can supply the necessary information to help you. P77-3 SC30 Manual 9.27.2019...

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