Job Name: Pennram 2200 lb/hr Thermal Plant

User Reference Manual for Job #219019

Revised November 24, 2021
Page 1 of 28

PHCA-2200 SOLID/LIQUID WASTE INCINERATOR

Pennram Job 219019
November 24, 2021

Pennram Diversified Manufacturing Corporation

P.O. Box 695 Williamsport Pennsylvania 17703 0695 USA
(570) 327-2802 fax (570) 326-5650 e-mail: pennram@pennram.com
Plant Locations: 1315 West Third St., Williamsport, PA 17701
234 Park Dr., Montgomery, PA 17752

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 2 of 28

INCINERATOR CHARGING / LOADING THE WASTE FEED CONVEYOR

Load the incinerator in such a manner as to limit the operational capacity of the system
1000 kgs (2000 lbs.) per hour. The hopper should be loaded with an average of 154 kgs. of
waste per 12 minute cycle. The auto charge sequence is set in motion by closing the hopper
lid. The waste feeder will charge the incinerator when the charge cycle timer times out at
zero minutes and zero seconds, and the temperature interlocks are satisfied.

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

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

The auto charge sequence is set in motion by closing of all the waste feed interlocks. These
interlocks include the load timer, hopper lid closed indication, and minimum secondary
temperature of 1600°F-1800°F (871°C-982°C), and access doors proven closed.

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

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

INCINERATOR OPERATION

PANEL CONTROLS

INCINERATOR START KEY SWITCH

Rotating of the SYSTEM START key engages the control system and initiates
the purge cycle. Before the system will start the following interlocks must be
satisfied:
1) The primary and secondary chamber access door must be proven closed.
2) The automatic waste feeder fire door must be proven closed.
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 3 of 28

3) The automatic waste feeder hopper lid must be proven open.

4) The SYSTEM START key operated switch is rotated momentarily.

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

1) The combustion air blower(s) starts.
2) The incinerator completes the PURGE cycle and begins to PREHEAT.

INCINERATOR MANUAL STOP PUSH BUTTON

Pressing of the SYSTEM STOP button will manually disengage the incinerator
control system. The feeder will not be disengaged if in mid-cycle. This button is
normally not used.
PRIMARY BURNER RESET PUSH BUTTON
SECONDARY BURNER RESET PUSH BUTTON
Allows corresponding burner programmer to be reset in the event of a burner
flame failure.

PRIMARY BURNER ON/OFF/AUTO SWITCH

SECONDARY BURNER ON/OFF/AUTO SWITCH
This switch is usually in the AUTO position; in the OFF position the burner will
not run; in the ON position the burner will run continuously limited only by
temperature and fuel and combustion air proving interlocks.

HYDRAULIC SYSTEM AUTO/MANUAL SWITCH

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

ASH RAM EXTEND/RETRACT SWITCH

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

CHARGE RAM EXTEND/RETRACT SWITCH

This switch provides manual operation of charge ram by the operator (ram will
not extend unless fire door is fully open as indicated by the pilot lamp on the
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 4 of 28

graphic display). The HYDRAULIC SYSTEM AUTO/MANUAL SWITCH must

be in the manual position to operate this switch.

FIRE DOOR OPEN/CLOSE SWITCH

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

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

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

These push buttons provide manual operation of the hopper lid by the operator.

HYDRAULIC SYSTEM EMERGENCY SHUTDOWN PUSH/PULL BUTTON

Push in for hydraulic pump shutdown, pull out for normal operation.

HYDRAULIC PUMP OFF/ENABLE SWITCH LOCK

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

COMBUSTION AIR BLOWER ON/OFF/AUTO SWITCH

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

HOPPER SPRAY PUSH TO ACTIVATE PUSHBUTTON

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

HYDRAULIC SYSTEM AUTO DRIVE SEQUENCE (WASTE FEED CYCLE):

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

1) on screen charge timer counting down and locking at zero.
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 5 of 28

2) closing of the waste hopper lid by the operator

3) closing of incinerator feed interlocks, which may include temperature limits, purge
cycle, and burner controls.
4) hydraulic system switch in the AUTO position.

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

ASH RAM EXTENDS

The ash ram extends until the full extend limit switch is activated, or until
the stroke timer, set by touch screen entry at the control panel, times out, or when the
pressure limit, set by touch screen entry at the control panel, is exceeded for 3 seconds,
which ever occurs first. A full stroke of the ash ram is usually not required. Hints: if
ash ram stoke is too long, unburned material may exit ash conveyor, if stroke is too short
chamber will fill with ash.

ASH RAM RETRACTS FULLY

FIRE DOOR OPENS

CHARGE RAM EXTENDS FULLY

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

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

FIRE DOOR CLOSES

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

CHARGE RAM fully retracts.

HOPPER LID opens (automatic).

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 6 of 28

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

20-100 psi of water pressure is acceptable.

WASTE FEEDER(LOADER) DISABLED ALARM

ALARM feature is designed to alert the operator that the waste feeder has jammed
and is not successfully correcting the problem on it’s own. If waste feeder DISABLED
alarm is annunciated, the HYDRAULIC SYSTEM switch is switched to the
MANUAL position, which should immediately be followed by correcting the waste
feeder problem using manual hydraulic switches.

Note: In a waste feeder disabled alarm situation, the first priority should be to secure the fire
door in the closed position.

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

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

INCINERATOR CONTROL SYSTEM SEQUENCE

The operator will check level of the fuel tank and waste oil tank(if applicable) and pilot gas
bottle, to be sure sufficient pilot fuel is present to operate the incinerator. Pilot fuel usage is
generally less than 1/2 gallon (1.8 l) per day.

The operator will check that the fire door is closed, check that the primary chamber access
door is closed, check that the secondary chamber access door is closed, and check that the

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 7 of 28

waste feeder hopper lid is open. The system will not start if these minimum conditions are
not proven. The operator then switches the hydraulic system switch to the auto position.

The operator rotates the SYSTEM START key.

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

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

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

lamp. The preheat cycle is temperature controlled and is maintained until the secondary
chamber temperature reaches 1600-1800°F. At this time the incinerator is ready to accept
waste. The combustion air dampers close during the preheat cycle.

The INCINERATE lamp will illuminate after the preheat cycle and after the first load of
waste is injected into the incinerator.
The high pressure BURNER COMBUSTION AIR BLOWER provides combustion air and
atomizing air to the secondary diesel burners and the primary diesel burner and to the waste
oil injectors, and to the primary chamber combustion air manifold. This high pressure
combustion air blower cycles on during the purge cycle and cycles off two hours after the last
load of waste is injected into the incinerator.

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

The PRIMARY COMBUSTION AIR PRESSURE CONTROL VALVE operates on a time

delay following the closing of the fire door after each charge. The primary air pressure may
be manually adjusted by moving the linkage of the flow control valve. This modulating
butterfly damper valve may be initially set to provide 5.0” w.c. high/ 0.0” off manifold air
pressure and may require an increase in pressure for improved ash quality or a decrease in
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 8 of 28

pressure for smoke control. The primary combustion air pressure control valve modulates to
the closed position when the primary chamber rises above 1700°F and remains at the closed
position until the primary chamber temperature cools to 1650°F. The primary combustion air
valve opens when the incinerator is off line for additional cooling purposes.

The SECONDARY COMBUSTION AIR is controlled with a motorized modulating butterfly

damper which modulates according to the 4-20mA PLC output, 0-100% as indicated on
screen, and opens as secondary exhaust temperature increases. The temperature increase is
a result of, and an indicator of, an increased presence of fuel derived from the waste.
Approximately 80% of the waste placed in the incinerator is oxidized in the secondary
chamber. Carbon “vapors” driven from the waste in the primary chamber are oxidized in the
secondary chamber. The process has potential to produce temperatures in the 3000°F. range
especially when the excess air is controlled. This SECONDARY COMBUSTION AIR is
controlled with a motorized modulating butterfly damper which modulates open as the
temperature in the secondary chamber increases. The damper is fully open during the purge
cycle.. The air pressure in the secondary combustion air manifold is biased (higher pressure)
during a timed period following each charge of waste into the incinerator. The purpose of bias
air is to burn the peak flow of hydrocarbons which vaporize from the waste upon initial
placement into
the incinerator. Later in the cycle less air is needed and the motorized air damper returns to
the normal modulated setting. The BIAS air setting is set on screen, generally at 30%. A
higher value can be inputed to conserve fuel, and a lower value is inputted in the event smoke
occurs after the bias air timer times out (on screen).

As the exhaust temperature rises from 1600°F toward 2000°F, the secondary combustion air
control damper modulates from 5% open to fully open. Since the secondary diesel
burners are modulated off by the mid 1850’s°F, then continually rising temperatures indicate
an increase in carbon vapor volume being generated in the primary chamber. As such more
oxygen is required to oxidize the vapor. The opposite is so as the temperature in the
secondary chamber is reduced, less air is needed. These values may be adjusted for
optimum performance and are set on screen.

The incinerator is so equipped with two(2) fixed or full modulating heavy oil burners.

The SECONDARY BURNER is of the full modulating type which modulate according to the
exhaust temperature of the secondary chamber, see chart below. The secondary burner is
disabled one hour after waste feeding stops. The fuel/air mixture and rate of input is
continuously modulated to provide process heat as required to the secondary combustion
chamber to maintain the minimum exhaust temperature. The burner may cycle off during

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 9 of 28

the incineration process if the waste is generating sufficient heat to maintain minimum
temperatures.

The PRIMARY BURNER is of the on / off type which actuate according to the exhaust
temperature of the primary chamber, see chart below The primary burner cycles off while
the fire door is open and for a timed following each charge of waste into the primary chamber.
After the fire door closes and with all other limits satisfied the primary burner ignites after a
1 minute delay. The burner cycles off when any access door is opened and while the ash ram
is not proven fully retracted. The primary burners are disabled one hours after waste feeding
stops.

SOLID WASTE CHARGING is locked out if any of the following conditions exist:
A. Primary chamber climbs above 2000°F. (Primary high temperature lockout)
B. Ash ram is not home.
C. Secondary chamber climbs above 2000°F. (Secondary high temperature lockout)
D. Secondary chamber falls below 1600° F. (Secondary low temperature lockout)
E. Charge timer has not engaged.
F. Hydraulic pump controls in manual or off.
G. System is off line.
H. Any incinerator door is open.
I. Air proving interlock open

BURNER OPERATION INFORMATION

The primary burner and secondary burners have full modulation of fuel and combustion air.
Both burners operate in an identical manner. The main fuel is ignited by a proven gaseous
fueled pilot flame. The pilot flame is ignited by an electrical arc fired by the ignition
electrode (spark plug) installed on the burner housing. The electrical arc ignites the pilot.
The flame is proven by means of an ultra violet light scanner installed on the burner housing.
The scanner can only “see” the flame while the pilot or fuel valve is open. The pilot flame is
cut off after a 20 second delay to conserve bottle gaseous fuel.

The purple colored UV scanner device senses a flame signal to the Honeywell burner
controller installed in the control panel. The flame signal may be tested by inserting a DC
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 10 of 28

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

The combustion air and fuel are modulated from high to low fire with a Honeywell damper
motor coupled to the combustion air butterfly valve based on a 4-20mA analog signal
originating in the corresponding temperature controller. An air oil ratio regulator is
installed in the diesel fuel train to the burner. This regulator is controlled by the combustion
air pressure at the burner via a stainless steel air impulse pressure sensing tube which is
connected to the burner housing at one end and to the air oil ratio regulator’s diaphragm at
the other end. As the combustion air pressure increases the fuel pressure follows
maintaining a proper ratio with approximately 5:1 turndown capability.

Pilot gas flow is controlled by the pilot gas regulator and pilot gas needle valve. The pilot air
shall remain fully open at all times. The pilot gas needle valve is adjusted to form a “pencil
“ shaped blue pilot flame. The pilot flame should be maintainable at any burner combustion
air pressure.

Atomizing air flow shall remain fully open at all times.

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

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

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

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

ANNUNCIATOR ALARMS AND CORRECTIVE MEASURES:

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 11 of 28

BURNER FLAME FAILURE:

Burner has failed to light. Press corresponding BURNER RESET button up to three times
waiting a minute before pressing a 2nd or third time. Confirm the alarm goes off and the
burner attempts to re-light after pressing the RESET button. Turn off the burner using the
control panel switch and wait one minute before resetting a second or third time. If burner
still fails to light, check pilot gas supply and confirm valve at pilot fuel tank is open, check
visual pilot operation, check electronic eye of UV scanner for dirt, check for pilot gas pressure
and flow, check for pilot air pressure and flow, gas pressure or air pressure interlocks, check
diesel fuel tank level, check diesel pump operation, check diesel pressure interlock,
check flame signal for 1.25-5.0 vdc, remove ignition spark plug from pilot assembly and check
for spark (do not hold spark plug during test), or seek service.

ASH RAM OUT

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

ASH RAM STALL

The ash ram (upper or lower) has failed to make the correct stroke limit. The stroke is being
limited by the hydraulic over pressure limit (825 psi on screen) rather than the time limit or
full extend limit. The over pressure limit is designed to prevent ash ram jam conditions
which may cause damage to the ash rams. Check stroke operation of ash rams by stroking
the ash ram by manual switch control. If the ash ram makes full stroke then check & adjust
the pressure limit switch adjustment (825 psi, on screen) for the appropriate ash ram. If the
ash rams fail to make full stroke and appear to stall then there is an obstruction the ram can
not move. Check inside the primary chamber for this obstruction, such as a glass clinker, the
next time the system is cooled and remove the obstruction.

LOADER DISABLED ALARM

This alarm feature is designed to alert operator that loader has jammed or failed the auto
loading sequence in some form. If LOADER DISABLED alarm is annunciated, the
HYDRAULIC SYSTEM switch is switched to the MANUAL position, which should
immediately be followed by correcting loader problem using manual hydraulic switches. In
a loader disabled situation, the first priority should be to secure the fire door in the closed
position. Then check for obstruction, check limit switches by proving the physical position of
each component and check that the appropriate lamp on the control panel is illuminated
indicating that the limit switch or position sensor is working. Check hydraulic pump
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 12 of 28

pressure. Check hydraulic pump overload relay. Check circuit breaker for hydraulic pump.
Or Seek service.

FUEL TANK LOW FLUID LEVEL /PUMP OFF

The liquid level in the fuel tank is low. This caused the fuel pump to stop (automatic)
operation and caused the burners to lock out due to low fuel pressure. Check fuel tank level
visually. Check the FUEL TRANSFER PUMP operation and switch position. If fuel is in
tank, check output relays, wiring, and low level float switch operation in fuel tank.

MAINTENANCE

EVERY OTHER DAY:

CHECK and CLEAN as required debris from behind the charging ram to
prevent damage to hoses and position sensor.

WEEKLY: OBSERVE that waste feeder operates in a proper and timely fashion.
OBSERVE condition of refractory liner, cracks are normal, missing
pieces of refractory are not, have liner repaired as required.
CHECK position of (5) burner diesel input sensitrol valves•
CHECK hydraulic system for leaks
CLEAN debris from beneath base of fire door
ROD THRU external primary air jets on the lower hearth level, there are
mutiple air jets per manifold, there is one air manifold on each side of
the lower hearth. Use 1/2” diameter x 12” length cleaning rod*
CHECK output pressure of primary chamber combustion air manifold

MONTHLY: CHECK and change as necessary rope gasket beneath base of fire door.
GREASE ash ram wheels.
VACUUM primary chamber and apply coating of Satanite mortar as
required. Coat the hearth with a sacrificial layer or mortar to prevent
glass adhesion to the refractory lining. Experience will determine if this
practice should continue.
ROD THRU internal primary air jets on the two upper hearth level, there
are fifteen air jets per manifold, there are three air manifolds on per hearth,
there is one air jet in the center and four jets on either side of center jet,
The jets spaced 21cm apart, use 3/8” diameter x 15cm length
cleaning rod*, or 3/8 drill. Manifolds (x2) are spaced 122cm apart. Location of
air jets indicated below.

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 13 of 28

CHARGING
OPENING

UPPER AIR JETS

75.70" 48.00" 20.38"
[1923mm] [1219mm] [518mm]

LOWER AIR JETS

51.63" 48.00" 20.13"
[1311.275mm] [1219.2mm] [511mm]

UPPER AIR MANIFOLD JETS

CENTER JET
8.25"
[210mm]

11.75" 8 SPCS. @ 8.250" = 66.00" 11.75"

LOWER AIR MANIFOLD JETS

7.00" CENTER JET
[178mm]

16.75" 8 SPCS. @ 7.000" = 56.00" 12.50"

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 14 of 28

CHANGE SEALS:
B
IF DOOR CAN BE REMOVED THIS JOB IS MUCH EASIER
HOWEVER SEALS CAN BE CHANGED BY RAISING DOOR,
BLOCKING DOOR RAISED POSITION, AND REMOVEING TOP FRONT COVER.

SECURE TOP ROPE GASKET WITH 1-1/4" COURSE THREAD SCREWS.

HEAVILY COAT PORTION OF ROPE TO CONTACT FRAME OR SLIDE IN TRACK

WITH NEVERSEEZE PASTE OR SPRAY. A VERY HEAVY COATING IS BENEFICIAL.

SIDE SEALS ARE SECURED WITH BOLTS UNDER/THRU COMPRESSION PLATE

AND GASKET. 58" STROKE - 1-3/4" ROD - 3.25" BORE 58" STROKE - 1-3/4" ROD - 3.25" BORE drwn w/ rod ext 1/4" Ports position 2 & 6
LOWER DOOR AND UNBOLT HYDRAULIC CYLINDERS AND MOVE OUT OF WAY.
REMOVE SIDE COVERS.
REMOVE COMPRESSION PLATES. 44" hose including
tube
fittings
CLEAN DOOR TRACK OF ANY DEBRIS AND BURRS.
INSTALL NEW ROPE SEAL (BOLTS PUNCH THRU SEAL. tube
ROPE COMPRESSION PLATE
HEAVILY COAT DOOR TRACT AND REASSEMBLE.
DO NOT OVERTIGHTEN COMPRESSION PLATE, OR DOOR WILL NOT MOVE 16.1"
PROPERLY. OR STACK TUBES IF THAT WORKS BEST
13.2"

17.75"

22"

SIDE SEALS

ACCESS COVERS FOR TOP SEALS

TOP SEALS
ACCESS COVERS FOR SIDE SEALS

TOP SEALS

58" STROKE - 1-3/4" ROD - 3.25" BORE drwn w/ rod ext 1/4" Ports position 2 & 6

Ports position 2 & 6 drwn w/ rod ext 1/4" 58" STROKE - 1-3/4" ROD - 3.25" BORE
22" WOOD BLOCK

13"

SIDE SEALS
4" 15"

SEMI- ANNUALLY: GREASE bearings on all blowers:

ANNUALLY: CLEAN hydraulic system oil filter.

CHANGE as necessary rope gaskets on primary chamber door(1), and
waste feeder door(3):
Vacuum flash from the secondary chamber, as required.
Ensure air jets are fully open.

NOTE: Hydraulic directional valves may be actuated manually if necessary by pressing the
“button” which is approximately 1/8” in diameter and is located in the center of each
directional valve solenoid. If hydraulic components appear to move in an irregular
fashion, check that speed/flow control valves are not closed or partially plugged. The debris
that occasionally collects in the valve my be flushed to the tank by fully opening the valve and

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 15 of 28

operating the cylinder. Following flush, readjust the valve until the cylinder runs at the
desired speed.

*experience will dictate the frequency in which this cleaning is required. This cleaning
requires shutdown and cool down.
Notes on ASH CONVEYOR:
Max continuous hydraulic operating pressure at the motors is 1300 PSI.
IMPORTANT- The ash conveyor chain is designed to run underwater. To prevent seizing of
the chain due to dried solids in the pin assemblies:
•Be certain the conveyor chain moves everyday.
•If the incinerator is offline for an extended period then have operators run the conveyor
chain at least one full rotation each day, with water in the tank.
•DO not allow chain and tank to totally dry out with out a thorough rinse of the chain link
pins.

Notes on Refractory Liner:

The refractory liner is cast from time proven (25 years) super duty fire clay refractory rated
for service to 2550°F. This material routinely outperforms refractory rated at higher
temperatures.

The formation of cracks in refractory is completely normal. This occurs due to thermal
expansion. The refractory wall is 1800° on the inside and 200° on the other side. The hot
side of the refractory wall expands a different rate than the cool side. This sets up thermal
cracks from two different coefficients of expansion in the same wall.

The refractory cracks will close when the wall heats up. In addition, this refractory contains
an aggregate of crushed firebrick which mechanically keys the section of refractory to one
another to prevent falling of sections when cracked even 360°. This is in addition to stainless
steel mechanical anchors the secures the refractory to the steel shell.

Filling these cracks will cause additional stress.

To prolong the life of the refractory hearth and to prevent glass materials from adhering to
the refractory hearth. We suggest using a sacrificial coating of Harbison Walker Satanite
mortar on the lower portion of the walls and on the hearth of the primary chamber to extend
the refractory life. Before application the primary chamber must be fully vacuumed. The
powdered Satanite mortar is mixed with water to a thick consistency and applied with a stiff
bristled masonry brush. Mixing is performed using a special mixing tool installed in an
electric drill motor with 1/2” chuck. Application is twice annually, monthly, or as desired.

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
 Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 16 of 28

XAER
Pressure-fed/Ext. Mix/Narrow Angle Round
DESIGN/SPRAY CHARACTERISTICS
• External mix: allows spraying of
• Narrow spray angle (10°- 30°)
• Precise metering of liquid flow rate
viscous liquids
• Variable atomization

1/4” XAER850A
XA 00 Body; A Hardware
Dimensions are approximate. Check with BETE for critical dimension applications.
AIR ATOMIZING

XA ER Set-up Flow Rates and Spray Dimensions

Pressure-fed, External Mix, Narrow Round Spray Pattern, 1/8" and 1/4" Pipe Sizes
Spray Fluid and 3 PSI Liquid 5 PSI Liquid 10 PSI Liquid 20 PSI Liquid 40 PSI Liquid Spray Dimensions
Pipe Set-up Air Cap PSI PSI PSI PSI PSI PSI A B C D
Size Number Numbers air GPH SCFM air GPH SCFM air GPH SCFM air GPH SCFM air GPH SCFM Liquid Air in in in ft
5 0.8 10 1.2 20 1.8 3 10 2 4 5 8
Fluid Cap 5 0.8 5 0.8 10 1.2 20 1.8 30 2.3 5 20 3 4 4 10
ER 050 FC7 10 0.7 1.2 10 0.8 1.2 20 1.2 1.8 30 1.7 2.3 40 2.4 2.9 5 40 2 4 5 12
& 20 1.8 20 1.8 30 2.3 40 2.9 50 3.5 10 40 2 3 5 16
Air Cap 30 2.3 30 2.3 40 2.9 50 3.5 60 4.0 20 20 3 2 3 14
AC1801 40 2.9 50 3.5 60 4.0 70 4.7 20 40 2 3 4 18
80 5.3 90 5.9 40 60 3 3 4 20
5 0.8 10 1.2 20 1.8 20 1.8 3 10 2 3 3 10
Fluid Cap 5 0.8 10 1.2 20 1.8 30 2.3 30 2.3 5 20 3 3 3 14
ER 150 FC4 10 1.0 1.2 20 1.3 1.8 30 2.0 2.3 40 2.7 2.9 40 4.0 2.9 5 40 2 3 5 16
& 20 1.8 30 2.3 40 2.9 50 3.5 50 3.5 10 40 3 3 4 18
Air Cap 30 2.3 40 2.9 50 3.5 60 4 60 4.0 20 20 3 3 5 13
AC1801 40 2.9 50 3.5 60 4.0 70 4.7 70 4.7 20 40 3 4 4 18
90 5.9 90 5.9 40 60 3 4 6 20
6 0.9 10 1.2 10 1.2 20 1.8 40 2.9 3 10 3 4 4 10
Fluid Cap 10 1.2 20 1.8 20 1.8 30 2.3 50 3.5 5 20 3 3 5 14
ER 250 FC3 20 2.0 1.8 30 2.7 2.3 30 4.0 2.3 40 4.5 2.9 60 6.0 4.0 5 40 3 3 5 14
& 30 2.3 40 2.9 40 2.9 50 3.5 70 4.7 10 40 3 4 5 17
Air Cap 40 2.9 50 3.5 50 3.5 60 4.0 80 5.3 20 20 3 4 4 18
1/8” AC1801 50 3.5 60 4.0 60 4.0 70 4.7 90 5.9 20 40 3 4 5 16
90 5.9 40 60 4 4 5 17
10 3.4 10 3.4 30 7.2 40 8.9 3 10 3 5 6 9
Fluid Cap 15 4.5 20 5.5 20 5.5 40 8.9 50 10.6 5 20 3 4 6 11
ER 350 FC6 20 3.3 5.5 30 4.1 7.2 30 5.7 7.2 50 8.3 10.6 60 11.9 12.2 5 40 3 4 6 16
& 30 7.2 40 8.9 40 8.9 60 12.2 70 13.9 10 40 3 4 6 16
or Air Cap 40 8.9 50 10.6 50 10.6 70 13.9 80 15.6 20 30 3 4 6 15
AC1802 50 10.6 60 12.2 60 12.2 80 15.6 90 16.7 20 60 3 5 7 17
90 16.7 40 60 3 5 6 18
ware and mounting assemblies, and material. See page 74.

10 3.4 10 3.4 15 4.5 30 7.2 3 10 4 6 9 14

Fluid Cap 15 4.5 15 4.5 20 5.5 40 8.9 40 8.9 5 20 4 5 6 18
O ORDER: specify pipe size, body style, spray set-up #,

ER 450 FC2 20 5.0 5.5 20 6.4 5.5 30 8.8 7.2 50 13 10.6 50 18 10.6 5 40 4 5 6 21
1/4” & 30 7.2 30 7.2 40 8.9 60 12.2 60 12.2 10 40 5 5 7 22
Air Cap 40 8.9 40 8.9 50 10.6 70 13.9 70 13.9 20 30 5 5 6 20
AC1802 50 10.6 50 10.6 60 12.2 80 15.6 80 15.6 20 60 4 5 7 22
60 12.2 70 13.9 40 60 4 4 7 22
30 7.2 3 20 6 6 9 16
Fluid Cap 15 4.5 20 5.5 40 8.9 40 8.9 50 10.6 5 20 5 6 9 15
ER 550 FC1 20 10 5.5 30 13 7.2 50 18 10.6 50 25 10.6 60 30 12.2 5 40 5 7 7 21
& 30 7.2 40 8.9 60 12.2 60 12.2 70 13.9 10 60 6 6 10 22
Air Cap 40 8.9 50 10.6 70 13.9 70 13.9 80 15.6 20 40 5 6 7 22
AC1802 50 10.6 60 12.2 80 15.6 80 15.6 20 60 5 5 7 22
40 80 4 5 6 22
15 7.2 20 8.8 30 11.7 50 17.2 3 20 5 6 8 17
Fluid Cap 20 8.8 25 10.3 40 14.5 55 18.5 5 30 6 6 6 22
ER650 FC8 25 10 10.3 30 13 11.7 50 18 17.2 60 25 19.8 5 50 5 5 6 22
& 30 11.7 40 14.5 55 18.5 65 21.1 10 60 5 6 7 22
For minor refractory repairs. We suggest use of Harbison Walker Super Hybond Plus plastic
Air Cap 40 14.5 50 17.2 60 19.8 70 22.5 20 50 5 6 6 22
AC1803 50 17.2 55 18.5 65 21.1 80 25.2 20 70 4 5 7 18
refractory to build up missing refractory thickness. Existing refractory needs to be chipped
60
20
19.8
8.8
60
30
19.8
11.7
70
40
22.5
14.5
90
50
27.9
17.2
20
3
90
20
4
6
5
6
7
9
18
19
Fluid Cap 30 11.7 40 14.5 50 17.2 55 18.5 5 30 6 6 8 21
away in such
ER750 a FC9
way
&
that17 the plastic
20 refractory
29 used in the
42 repair will be mechanically
40
50
14.5
17.2
50
60
17.2
19.8
60
65
19.8
21.1
60
65
19.8
21.1
5
10
60
60
6
5
7
5
7
7
22
22
Air Cap 55 18.5 65 21.1 70 22.5 70 22.5 20 50 5 6 8 20
AC1803 60 19.8 70 22.5 80 25.2 80 25.2 20 70 4 5 8 19
Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
70 22.5 80 25.2 90 27.9 90 27.9 20 90 4 6 8 19
17.2 3 40 6 6 7 22
Fluid Cap 40 14.5 55 18.5 65 21.1 5 70 4 5 7 20
ER850 FC5 50 25 17.2 60 29 19.8 70 42 22.5 80 61 25.2 10 80 4 5 7 18
& 55 18.5 65 21.1 80 25.2 90 27.9 10 90 3 4 6 18
Air Cap 60 19.8 70 22.5 90 27.9 20 80 4 4 6 18
AC1803 65 21.1 80 25.2 20 90 3 4 6 19
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 17 of 28

interlocked, or keyed, to the existing refractory surface. Vacuum existing surface before
application of plastic refractory. Then use a hammer to shape and install the plastic
refractory. This material is malleable (like playdoh). Can be fired immediately after
installing. This material is sold in 25 kg /55 lb boxes. 2.3 kg plastic per liter of repair is
required. Or 165 lbs per cubic foot of repair is required. Once opened the box is only good for
a day or so.
The Waste Oil System:
Each chamber has a waste oil injector, rated for a nominal combined 30 gallons per hour.
The flow rate is based on the set up of the Beta Fog air atomized nozzles as seen next page.

The combustion air set up shall allow for as little air as possible in the primary chamber
(lower) waste oil burner. Just enough air to produce a smoky flame is sufficient.

The combustion air set up shall allow for as much air as is needed in the secondary chamber
(upper) waste oil burner, to produce a clean flame. Just enough air to produce a smoky flame
is sufficient.

Waste oil injection will proportionately reduce diesel consumption.

Some experimentation with varying nozzles and pressures may be necessary due to unknown
viscosity of the waste oil. Multiple nozzles are provided.

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 18 of 28

MAIN SCREEN:

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 19 of 28

PRESS “INPUT STATUS SCREEN” BUTTON TO GET TO:

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 20 of 28

PRESS “ENTER SET UP SCREEN” BUTTON TO GET TO:

Inputed Screen Values: access code A219019 User Code is User

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 21 of 28

PRESS “GOTO GASIFIER INPUT SCREEN” BUTTON TO GET TO:

Inputed Screen Values: access code A219019

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 22 of 28

PRESS “GOTO RAM POSITION ENTRY SCREEN” BUTTON TO GET TO:

Inputed Screen Values: access code A219019

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 23 of 28

PRESS “GOTO OXIDIZER INPUT SCREEN” BUTTON TO GET TO:

Inputed Screen Values: access code A219019

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 24 of 28

PRESS “WASTE OIL SET UP SCREEN” BUTTON TO GET TO:

Inputed Screen Values: access code A219019

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 25 of 28

OTHER SCREENS ACCESSIBLE FROM MAIN SCREEN:

EVENT LOG SCREEN:

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 26 of 28

OUTPUT STATUS SCREEN:

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 27 of 28

Combustion Air/ Burner / Hydraulic Set Up

Secondary combustion air damper linkage adjustment: (purge)

Maximum output: full open
Minimum output: full close

Primary combustion air linkage adjustment:

De-energize manifold pressure 0.0”w.c.
Energize manifold pressure 3.0” w.c.

Primary burner no. 1 fuel & combustion air damper linkage adjustment:

Burner model number N/A 5425-7B (3,260,000 btu/hr)

High fire air & flow 27 ” w.c. 32,600 cfh
Low fire air & flow 1.0 ” w.c. 6,200 cfh
High fire oil pressure psi
Low fire oil pressure on peg psi
Pilot signal 5.0 volts DC
Pilot mix pressure 7” w.c.
Atomizing Air Pressure 25-35” w.c.
Sensitrol valve model & position setting 1813-02C /

Primary burner no. 2 fuel & combustion air damper linkage adjustment:

Burner model number N/A 5425-7B (3,260,000 btu/hr)

High fire air & flow 27 ” w.c. 32,600 cfh
Low fire air & flow 1.0 ” w.c. 6,200 cfh
High fire oil pressure psi
Low fire oil pressure on peg psi
Pilot signal 5.0 volts DC
Pilot mix pressure 7” w.c.
Atomizing Air Pressure 25-35” w.c.
Sensitrol valve model & position setting 1813-02C /

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment
Job Name: Pennram 2200 lb/hr Thermal Plant
User Reference Manual for Job #219019
Revised November 24, 2021
Page 28 of 28

Secondary burner no. 3 fuel & combustion air damper linkage adjustment:

Burner model number N/A 6425-8A (4,200,000 btu/hr)

High fire air & flow 27 ” w.c. 42,000 cfh
Low fire air & flow 2.0 ” w.c. 11,430 cfh
High fire oil pressure psi
Low fire oil pressure psi
Pilot signal 5.0 volts DC
Pilot mix pressure 7” w.c.
Atomizing Air Pressure 25-35” w.c.
Sensitrol valve model & position setting 1813-02D /

Secondary burner no. 4 fuel & combustion air damper linkage adjustment:

Burner model number N/A 6425-8A (4,200,000 btu/hr)

High fire air & flow 27 ” w.c. 42,000 cfh
Low fire air & flow 2.0 ” w.c. 11,430 cfh
High fire oil pressure psi
Low fire oil pressure psi
Pilot signal 5.0 volts DC
Pilot mix pressure 7” w.c.
Atomizing Air Pressure 25-35” w.c.
Sensitrol valve model & position setting 1813-02D /

PERTINENT NOTES:
Hydraulic system relief pressure set at 1250 psi.
Charge ram relief pressure set at 900 psi.
Lower Ash ram relief pressure set at 950 psi.
Upper Ash ram relief pressure set at 950 psi.

System Diesel pressure 25 psi

Air Pressure proving Switch 7” w.c.

Manufacturers of: Incinerators..Hydraulic loaders...Tanks...Control panels...High temp. ducts and dampers...Process Equipment