Manual Og200c (S)

OG200C(S)
Instruction Manual
TeamTec Incinerator
OG200C/OG200CS
TG5.2
1
OG200C(S)
2
OG200C(S)
Copyright © 2017 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 TeamTec AS.
Version Date Purpose Written

Rev 0 17.02.2016 TAB
Rev A 16.11.2016 Updated manual EEM
Rev B 15.02.2017 Updated manual PSC
Rev C 10.07.2017 Appendix G, new drawing JEG
Rev D 16.08.2017 Revised the setting list KK
Rev. E 28.11.2017 Updated VFD settings LAF
Rev F 08.11.2018 Updated Function Solid Waste tabular and Setting List CS
Rev G 04.02.2019 Refurbished CS
Updated Combined sludge and water program Updated
Regular maintenance check list with WDP Updated Test
Rev H 07.03.2019 CS
of Safety and Alarms
Rev I 09.07.2019 Minor updates in tables and text. KHS

Rev J 31.07.2019 Minor updates in tekst CS
Rev K 02.08.2019 Updated text Alarm system CS
Rev L 29.08.2019 Updated to new Table of Content CS
Rev M 19.12.2019 Updated Test of Safety and Alarms CS
Updated Operator Procedure, Maintenance manual,
Rev N 23.01.2020 CS
User Login, Alarm List, Test of Safety and Alarms
Rev O 03.03.2020 Updated the maximum steam/air pressure high CS
3
ADDENDUMS, CORRECTIONS AND NOTES
Addendums, corrections and notes

This document describes how to operate (Part I) and maintain (Part II) the OG200C(S)
incinerator. The base incinerator type is OG200C, but some of the drawings might have
additional letter codes as below that describe the extra equipment 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 tank
Z CCS – centralized control station twin display
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)).
4
LIST OF CONTENTS
Table of contents
ADDENDUMS, CORRECTIONS AND NOTES..................................................................................... 4
TABLE OF CONTENTS............................................................................................................................ 5
PART I: OPERATOR MANUAL...............................................................................................................9
INTRODUCTION.......................................................................................................................................10
INSTRUCTION MANUAL, PURPOSE AND SCOPE...........................................................................................10
SERVICE NETWORK FOR TEAMTEC INCINERATORS................................................................................... 10
SAFETY MARKINGS...............................................................................................................................11
GENERAL USE AND SAFETY INSTRUCTIONS.............................................................................. 11
ACRONYMS AND TERMS..................................................................................................................... 12
TECHNICAL DESCRIPTION AND MAIN DATA................................................................................ 13
OVERALL SYSTEM FUNCTION DESCRIPTION...............................................................................................13
Combustion chamber...........................................................................................................................13
Main data/Performance data: Incinerator (combustion chamber)............................................................... 14
Burner (fixed on combustion chamber).............................................................................................................14
Sludge dosage pump (fixed on combustion chamber).................................................................................. 15
Sludge filling pump (if dual sludge tank system).............................................................................................15
Diesel oil preheater (fixed on combustion chamber)......................................................................................15
Diesel oil booster pump (optional)..................................................................................................................... 15
Electrical control panel incinerator (normally fixed on combustion chamber)........................................... 15
Operator panel (User terminal/display fixed to control panel), description................................................ 16
Operator panel, main data...................................................................................................................................17
Flue gas fan (bulkhead or deck mounted)........................................................................................18
Main data/Performance data: Flue gas fan......................................................................................................18
Flue gas damper...................................................................................................................................18
Main data/Performance data: Flue gas damper..............................................................................................18
Sludge service tank..............................................................................................................................19
Sludge settling tank with heater (optional)....................................................................................... 19
Sludge burning capacity.......................................................................................................................................20
Sludge burning control......................................................................................................................................... 20
Main data/Performance data: Sludge tank.......................................................................................................21
Sludge circulating pump. (installed on sludge tank).......................................................................................21
CONTROL PROGRAM DESCRIPTION AND OPERATOR INSTRUCTIONS.............................. 22
GENERAL PROGRAM OVERVIEW................................................................................................................. 22
INCINERATOR CONTROL CABINET, OPERATOR PANEL DESCRIPTION........................................................ 23
General overview of the touch screen...............................................................................................23
Screens seen in the incinerator control panel display.................................................................... 24
Structure..................................................................................................................................................................24
Pop-up menu Start -Stop..................................................................................................................................... 25
Information pop-up................................................................................................................................................25
Burner screen.........................................................................................................................................................26
Settings tanks.........................................................................................................................................................26
Hour counters.........................................................................................................................................................27
Setup menu............................................................................................................................................................ 27
Backlight menu...................................................................................................................................................... 28
Time and date menu.............................................................................................................................................28
Program information............................................................................................................................................. 28
Consumption.......................................................................................................................................................... 29
Consumption setup............................................................................................................................................... 29
Alarm system......................................................................................................................................................... 29
The alarm Screen..................................................................................................................................................30
GENERAL OPERATOR INSTRUCTIONS......................................................................................................... 31
Garbage management.........................................................................................................................31
Types of waste that can be burned................................................................................................... 31
Solid and liquid waste that is prohibited to burn.............................................................................. 31
General use- and safety instructions.................................................................................................32
5
INTRODUCTION
Emergency stops..................................................................................................................................32
In the incinerator room......................................................................................................................................... 32
Outside the incinerator room...............................................................................................................................32
Important to know, before you start using the incinerator: When emergency stop is used, or at black
out.............................................................................................................................................................................32
THE SLUDGE BURNING PROGRAM.............................................................................................................. 33
Description.............................................................................................................................................33
General sludge burning use- and safety instructions..................................................................... 33
Operator procedure..............................................................................................................................34
THE SOLID WASTE BURNING PROGRAM......................................................................................................35
Description.............................................................................................................................................35
Batch loading......................................................................................................................................................... 35
Sluice feeding.........................................................................................................................................................35
General solid waste burning use- and safety instructions............................................................. 35
THE COMBINED SOLID WASTE AND SLUDGE BURNING PROGRAM............................................................. 37
Description.............................................................................................................................................37
THE SLAGGING PROGRAM...........................................................................................................................37
Description.............................................................................................................................................37
PART II: MAINTENANCE MANUAL.....................................................................................................39
MAINTENANCE INSTRUCTIONS.................................................................................................................... 40
Preventive maintenance system........................................................................................................ 40
REGULAR MAINTENANCE CHECK LIST.......................................................................................41
Recommended Minimum spare parts............................................................................................................... 45
One year wear and tear parts OG200/400C, TG5.2...................................................................................... 45
Recommended on board repair parts, OG200/400C, TG5.2....................................................................... 46
MAINTENANCE, REPAIR TASKS AND PROCEDURES....................................................................................47
General tool list..................................................................................................................................... 47
Incinerator..............................................................................................................................................47
Chamber................................................................................................................................................................. 47
Refractory cracks where bricks have split in two or more pieces...........................................................47
Bad looking refractory surface?.....................................................................................................................47
Slag is building up on the refectory surface................................................................................................47
Parts of bricks have fallen out........................................................................................................................48
Instructions for use of repair substance for refractory.............................................................................. 48
Combustion chamber refractory exchange................................................................................................. 48
In doubt?............................................................................................................................................................ 49
Restriction bricks replacement...................................................................................................................... 49
Door gasket replacement................................................................................................................................50
Safety door interlock switch replacement....................................................................................................51
Greasing of door hinges..................................................................................................................................51
Greasing of sluice bearings............................................................................................................................51
Burner maintenance and repair..........................................................................................................................52
General information......................................................................................................................................... 52
Burner diesel nozzle assembly and repair.................................................................................................. 53
Reassembly of burner nozzle assembly......................................................................................................55
Burner Blast tube Replacement.................................................................................................................... 58
Ignition cables replacement........................................................................................................................... 60
Reassembly of ignition cables....................................................................................................................... 61
Photo Resistor replacement...........................................................................................................................62
Ignition transformer replacement.................................................................................................................. 63
Oil burner damper motor replacement......................................................................................................... 64
Diesel oil pump maintenance and repair..................................................................................................... 68
Diesel oil pressure adjustment...................................................................................................................... 71
Burner pump shaft seal replacement........................................................................................................... 75
Burner diesel pressure regulation kit replacement.................................................................................... 77
Spline coupling replacement..........................................................................................................................80
Sludge dosage pump maintenance and repair............................................................................................... 82
Sludge dosage pump maintenance and repair procedures....................................................................86
Sludge valve...........................................................................................................................................................93
Control cabinet.......................................................................................................................................................94
PLC repair or replacement............................................................................................................................. 94
6
LIST OF CONTENTS
Replacing the PLC power source in the control cabinet...........................................................................99

Frequency inverter for the sludge dosage pump..................................................................................... 100
Flue gas fan......................................................................................................................................................... 103
Replace the flue gas fan thermocouple and temperature transmitter................................................. 103
Replace flue gas fan V-belts........................................................................................................................104
Greasing or replacement of flue gas fan bearings.................................................................................. 105
Replacing the flue gas fan impeller:........................................................................................................... 106
Flue gas damper.................................................................................................................................108
Flue gas damper motor servicing and repair.................................................................................................108
Sludge circ. pump...............................................................................................................................111
Trouble shooting for malfunction of the incinerator plant.............................................................116
APPENDIX A: STORAGE, PRESERVATION AND INSTALLATION.......................................... 119
PREPARATION FOR SHIPMENT.................................................................................................................. 119
STORING AT YARDS WAREHOUSE............................................................................................................ 119
PRESERVATION FROM INSTALLATION TO START-UP OF EQUIPMENT...................................................... 119
PRESERVATION IN CASE OF LONG TIME STORING AFTER INSTALLATION................................................119
SHIPS SYSTEM INTERFACE REQUIREMENT.............................................................................................. 120
Electrical.............................................................................................................................................. 120
Diesel oil.............................................................................................................................................. 120
Flue gas duct...................................................................................................................................... 120
Sludge and steam or Air....................................................................................................................120
Water and Steam or Air (Optional).................................................................................................. 120
Sludge tank. (1100 / 1700 / 2000 / 3000l option).......................................................................... 121
PRE-COMMISSIONING................................................................................................................................122
Mechanical completion check list.................................................................................................... 122
Pre-check of live equipment............................................................................................................. 122
APPENDIX B: USER LOGIN............................................................................................................... 123
LOGIN.........................................................................................................................................................123
WRONG USER POP-UP.............................................................................................................................. 123
SETTINGS BURNER....................................................................................................................................124
SETTINGS ALARMS.................................................................................................................................... 125
SETTINGS SLUDGE (1/5)...........................................................................................................................126
SETTINGS SLUDGE (2/5)...........................................................................................................................127
SETTINGS SLUDGE (3/5)...........................................................................................................................128
SETTINGS SLUDGE (4/5)...........................................................................................................................129
SETTINGS SLUDGE (5/5)...........................................................................................................................130
SETTINGS SOLID WASTE (1/2)..................................................................................................................131
SETTINGS SOLID WASTE (2/2)..................................................................................................................132
SETTINGS SOLID WASTE AND SLUDGE..................................................................................................... 133
SETTINGS LOADING/SLAGGING AND STOP............................................................................................... 133
BURN-IN.....................................................................................................................................................134
INCINERATOR CONFIGURATION.................................................................................................................134
COMPLETE LIST OF SETTINGS IN THE OPERATOR DISPLAY AND FREQUENCY INVERTER IN THE CONTROL
CABINET (FACTORY SETTINGS)................................................................................................................ 135
Settings frequency inverter ALTIVAR 12 (Found in incinerator control panel)........................ 138
APPENDIX C: ALARM LIST................................................................................................................139
APPENDIX D: TEST OF SAFETY AND ALARMS.......................................................................... 141
DRAWINGS.............................................................................................................................................147
LIST OF DRAWINGS............................................................................................................................ 148
7
8
OPERATOR MANUAL
PART I: OPERATOR MANUAL
9
INTRODUCTION
Introduction
Instruction manual, purpose and scope
The manual will guide the reader/user gradually to an understanding required for safe operation
(Part I) and maintenance (Part II) 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 user/operator should therefore always familiarize
themselves with both parts of the manual, before starting to use the equipment.
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
Email: [email protected]
[email protected]
General office email: [email protected]
China
Manufacturer: CSSC NanJing Luzhou Environment Protect Co.,Ltd
Address: LISHUI STREET,BINJIANG ECONOMIC DEVELOPMENT ZONE,JIANGNING
DISTRICT,NANJING
Postal Code: 211162
Tel: +86-(0)25-86723713
Fax: +86-(0)25-86723747
E-Mail: [email protected]
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
10
GENERAL SAFETY INSTRUCTION
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 daily 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.
11
ACRONYMS AND TERMS
ACRONYMS AND TERMS

Acronym/term Description
ACK Acknowledge
CCP Combustion chamber pressure
CCT Combustion chamber temperature
DO Diesel Oil
DEC Decrease
EMC Electro Magnetic Compatibility
ESC Escape
FGF Flue gas fan
FGT Flue gas temperature
HMI Human machine interface
HYS Hysteresis. The allowable amount the measured
value can differ from the desired set point before
correcting measures are activated.
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
12
TECHNICAL DESCRIPTION AND MAIN DATA
Technical description and main data
Overall system function description

The TeamTec Incinerator type OG200C is designed for on board incineration of ship's waste oil
and solid refuse. The system consists of 4 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)
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/ash door, 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 center of the
combustion chamber. Remnants of particulate matters in the gas flow are neutralized 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
atomizing 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 atomizing. 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.
13
TECHNICAL DESCRIPTIAND MAIN DATA
Main data/Performance data: Incinerator (combustion chamber).
Type: OG200 C(S)
Capacity: 400.000/482.0001 Kcal/h (465/5602 kW)
53 l/h IMO sludge oil (without water IMO sludge (20% water)
injection)
Corresponding to:
Solid waste max. 400 litre per charge or
IMO class 02 waste
55 l/charge continuous feeding
Max. 1200 °C
Combustion chamber
temperature: Working. 870-1150 °C
Flue gas temperature: Max. 350°C
Working. 250 - 340 °C
Surface temperature:
15°C above ambient temperature.
Electrical power, rated From ship distribution

15 kW (Flue gas fan included.)
consumption: system.
Flue gas fan El. power From incinerators

7,3/8,7 kW
consumption. electrical control panel
Negative pressure: 10-28mmWC In combustion chamber
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: Max. 1,500 m3/h
Oil pump: Working press. 16 bar

Max 21 bar.
El. Motor 1.4/1.45 Amp. 2730/3310 rpm.

Rated current: 380/440 V 50/60 Hz, 0.53/0.64kW
Ignition transformers: 230V / 10,000V

Weight (each): 30 kg
Outline dimension: 845 x 539 x 387 (L x W x H) See dimension drawing.
1
USCG Capacity
2
USCG Capacity
14
Sludge dosage pump (fixed on combustion chamber)

Type: TeamTec RDCZ 432 screw pump
El. Motor: 0,35kW IP55 900/1080 rpm

Current rating 1,31A 220V 50/60Hz
Control speed: 0 – 1200 rpm
Sludge filling pump (if dual sludge tank system)

Type: See sludge circulation pump appendix
Diesel oil preheater (fixed on combustion chamber)

Rating: 380/440V, 50/60Hz, 1.5/2.0 kW
2.3/2.6 Amp
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 drawing
Electrical control panel incinerator (normally 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)
15
Operator panel (User terminal/display fixed to control panel), description

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
The function of the panel is:
• Selecting of burner mode, setting of all variables as temperature, time etc.
• Display running condition, temperature, pressure, alarm, oil consumption, timer etc.
User functions are described in a later chapter.
16
Operator panel, main data
USB
Battery/SD Card Ethernet
The operator panel is an Ethernet only display with 2 USB port, and consist of a color (640X480)
graphics display. Color terminals support a fixed palette of 256 standard VGA colors. All colors
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

Product certification compliance with European Union Directives. EMC tests satisfies EN 50081-
1-2:1993 and EN 61000-6-2:1999
17
Flue gas fan (bulkhead or deck mounted)

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 below 350°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.
Main data/Performance data: Flue gas fan

Type: Designed to withstand max
DN 300 H2
temperature of 450°C
One stage centrifugal fan.
Capacity: At 150mmWC total back

8000 m³/h at 300°C
pressure.
Flue gas duct

DN300
dimensions
El.motor: 1460/1740 rpm

380/440V, 7.3/8.7kW
Current rating
15.5/15.5A
Weight: 326 kg See dimension drawing.
Outline dimension: 1020 x 1040 x 1030 (L x W x H) See dimension drawing.
Flue gas 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.
Main data/Performance data: Flue gas damper

Type: Welded steel damper with actuator
Size:
DN400/DN300
Actuator motor: Drive force 20Nm. Travel
time for 90° is 150/125sec
50/60Hz.
Weight: 68/71 kg See dimension drawing.
Dimension between 300 mm See dimension drawing.

flanges:
18
Sludge service tank

The Teamtec sludge tank functions as a daily service tank for sludge to the incinerator,
preparing one batch of sludge for incineration.
A heater, controlled by a thermostat, will keep the sludge temperature around the set point (80
to 90°C). An indicating light for heating is placed on the junction box on the tank. (Since surface
temperatures are above 60°C, class regulations require tank to be insulated.).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank.
Level transmitter may also be installed, giving this live in the display.
A level transmitter on the tank provides PLC to generate an animated tank level readout on
operator panel (displayed on the incinerator control panel), and right amount of sludge burned.
A powerful sludge circulating pump is mounted on the tank to ensure a uniform fluid with
predictable heat value. The pump transports a portion of the sludge to the incinerator and a
return line to the tank is provided, but most of the sludge is circulated directly back in the tank.
The balance between the two circle lines is controlled by a valve, set from factory.
A low-level switch on the tank will stop the incinerator, the circulating pump and heating, when
the level has reached a minimum.
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.
19
Sludge burning capacity

The incinerator certified capacity according to MEPC 244(66) 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, thus the sudden drop in the below curve.
Sludge burning control

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 in appendix. 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 result in a higher consumption of diesel oil.
20
Crucial temperature limits used by the PLC:
680°C Start sludge burner.

850°C Sluice availability is opened in Solid waste program.
870°C Temperature allowing burning sludge alone.
900°C Sluice availability is opened in Sludge &Solid waste program.
1050°C The sluice is no longer available.
1150°C Temperature limit for combustion chamber.
Main data/Performance data: Sludge tank
Volume: Net: 435, 700, 1100, 1700, 2000, 3000

liters.
Test pressure: Cylindrical tanks 0.8 bar

Rectangular tanks 0.25 bar
Corrosion Protection: Internal coated with one layer of SDH-8

primer, thickness 150 microns
Flange rating: PN 16
Weight and COG: See dimension drawing.
Outline dimension: See dimension drawing.
Sludge circulating pump. (installed on sludge tank)

Type; 40WYXH-6-20
Capacity: 6 m3/h at 2.0 bar discharge pressure.
El. motor: 380/440V, 50/60Hz, 2.2/2.53kW, 4.5/5A 2840/3470 rpm

Current rating
21
CONTROL PROGRAM DESCRIPTION AND
OPERATOR INSTRUCTIONS
Control program description and operator instructions

General program overview
The Teamtec Incinerator type OG200C（S）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:
• “Sludge”
• “Solid waste & Sludge”
• “Solid Waste”
• “Slagging”
The different programs will be explained in detail in later chapters, as well as a number of
different menus and available information, including user guidance.
22
PERATOR INSTRUCTIONS
Incinerator control cabinet, operator panel description

General overview of the touch screen
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 sub-menus. The screen will display equipment
according to the scope of delivery.
The Main picture has animated feedback to
the operator. The pumps and fans turn green 1
when running. The level switches are
animated up or down according to the level. 2
Online level indication is shown on the sludge
tank. Actual measured values positioned are 3
displayed approximately according to physical
position at the incinerator. In addition to the 4
buttons at the lower part of the panel, it is
possible to press on an item on the screen to 5
open a different screen or dialogue box. The
list below describes the possible options: 6
10
1: Press in the middle of burner to access screen “Burner” 11

2: Press either of the two figures to access screen “Setting tanks”
3: Press heating symbol to access pop-up screen for start/stop heating sludge service tank. 12
4: Press heating symbol to access pop-up screen for start/stop heating sludge settling tank.
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, depending on model and configuration.)
23
Screens seen in the incinerator control panel display

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
Water tank
pumps and
heating
Select/start
programs
Setup Burner
Hour counters Alarms
Alarm Service Trend
Sludge I/O
Solid waste
Information
The control system Pop-up SW Sludge
will activate these
screens. Service Sludge and
Pop-up Water
Load/slag &
stop
Conf. Setting Water tank

Tanks
Login
Restore
Burn-in Factory
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.
24
Pop-up menu to select
program
This appears after pressing Start in the
Main menu. Select program to start. The
pop-up will close after selection of
program. Select “Cancel” to close pop-
up if you do not want to start or change
program.
Description of the program selection
alternatives are given in chapter
program description.
Pop-up menu 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 will close after
selection of “Start” or “Stop”. Select
“Cancel” to close pop-up if you do not
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 (ensuring sludge level above switch). 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
25
transfer pump high 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
• 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
• WARNING! Sluice overload or blocked – check sluice
• 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 screen
Appears when touching the burner.
The menu displays actual values and
status on motors, actuators and sensors
No adjustments or settings on this
screen – view only.
Settings tanks
Displays tanks physical attributes and
sludge mass for correct sludge
consumption.
26
Hour counters
Displays last run and total hours. Press
“Next” button to access screen “Hour
counters 2”
Page 2/2. Displays last run and total

hours. Press “Prev” button to access
screen “Hour counters 1”
Setup menu
Some functions require the operator to
login to access a screen or to alter a
value in the setup. This normally
indicates that the operator needs
training 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 the different setup screens are
“view only”.
For further information on login and
settings, refer to Appendix B on “User
login and changing of settings in
operator display”.
27
Backlight menu
No user name and password required.
Time and date menu

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.
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.
28
Consumption
Displays 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”.
*Setpoint WDP capacity is only appearing if water injection is

configured
29
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
* Not active Accepted
Buttons for handling alarm system.
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 a new alarm appears
Main 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.
30
General operator instructions

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 worldwide regulated by
IMO MARPOL 73/78, RESOLUTION MEPC 244(66) adopted April 4th, 2014 (Replacing
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.
Types of waste that can be burned

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, Oil filters,
Diesel engine scavenge scrapings
Paint scrapings
Food waste etc.
Sludge oil, Waste lubrication oil
Hospital waste, Female hygienic waste
Solid and liquid waste that is prohibited to burn

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).
31
General use- and safety instructions
• Incinerator should be inspected in the morning daily 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.
• 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.
• Read the operator- and maintenance manual, and never change any settings. Know the
regular maintenance tasks in the maintenance manual under part II as a minimum. It is
recommended to know it completely.
• Main switch on the control panel is switched to position "ON". The operator panel is
energized, and the Process picture will show in the display.
Emergency stops
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).
Important to know, before you start using the incinerator: 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 loss of health and life.
32
The sludge burning program
Description
The incinerator is designed and approved to burn sludge according to IMO specifications.
The incinerator starts heating up using the diesel oil burner. The diesel oil burner goes through
different steps. See maintenance 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 frequency-controlled sludge dosage pump (SDP) starts. As
the temperature increases and temperature set-points are reached, the diesel oil burner will
adjust to other burner steps to save diesel and increasing sludge oil. At 870 degrees the sludge
program requires burner step 7 from the burner program, and diesel oil will be cut off completely
to run sludge only.
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.
The low sludge tank level will activate the low-level switch and 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 coal on the burner tip.
Controlling temperature in chamber/fan, and pressure in the combustion chamber is achieved

by calculations in the control system, based on input from the same, by adjusting:
1 – Flue gas damper opening (FGD).
2 – Diesel oil burner steps
3 – Speed sludge dosage pump (SDP).
General sludge burning use- and safety instructions
• Know the regular maintenance tasks in the maintenance manual under part II as a
minimum. It is recommended to know it completely.
• As a minimum, heat the sludge overnight, without starting the circulating pump. Next
morning, drain off the free water and start the sludge programs.
• If experiencing any problem with high temperature in combustion chamber, flue gas or
control of sludge dosing, replace the dosing pump stator.
• Inspect the cooling jacket every 6 months (open the cover plates) and clean as required
with steam or hot water. Any sign of oily sludge here, is a notification of lack of
maintenance, and represents a fire hazard.
• Never transfer sludge to the service tank during sludge burning (can damage the
refractory).
33
Operator procedure
1. Fill up the sludge tank 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
color to indicate that the heater is on and the temperature is controlled locally by the
thermostat
2. Start the filling pump by pressing the pump symbol and choose start pump. The symbol
will change color 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.
3. Activate the heater on the service tank. This is done by pressing the heater symbol on
the operator panel. Choose start heater and the heater symbol will change color to
indicate that the heater is on and the temperature is controlled locally by the thermostat
4. Drain off water from the service tank. (The sludge should be settled overnight before
water is drained off). Remember, longer settling time = better settling!
5. Start the service tank circulation pump by pressing the pump symbol and choose start
pump. The symbol will change color 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!
6. Check the atomizing -air supply pressure to be 6 - 8 bar. (The manual regulating valve
for air atomizing 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 before starting the incinerator!)
7. 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.
8. When the low level in sludge tank, or the key "STOP" is pushed, the burner will stop,
and the cooling down sequence starts.
When the temperature in the combustion chamber has decreased to 170°C, the flue gas fan will
stop, and door locks will be energized.
34
The solid waste burning program
Description
The program is based on a regular daily routine, where a batch of solid waste is loaded directly
into the chamber before start of the program. From here, waste is loaded through the sluice.
The incinerator PLC will detect how much heat is released from the waste itself, and adjust
accordingly:
1 – Flue gas damper opening (FGD).
2 – Diesel oil burner steps
The program will urge to save diesel, when possible.
Batch loading
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 open. Clean, if
necessary.
Load the combustion chamber to maximum 2/3 height with garbage of mixed waste. This is
approximately 500 liters.
If high calorific garbage is loaded, a smaller quantity must be loaded per charge. Make sure to
mix higher calorific waste, like plastics and cardboard, with food waste. This will make
incineration more efficient.
Sluice feeding
If a sluice is installed, solid waste can be fed into the 55-liter sluice at temperatures between
850°C and 1050°C. 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 210 seconds. After the waiting time has elapsed, the
sluice is ready for a new load.
General solid waste burning use- and safety instructions
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.
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.
35
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.
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.
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.
Know the regular maintenance tasks in the maintenance manual under part II as a minimum. It
is recommended to know it completely.
Operator procedure
1. Fill the combustion chamber 2/3 full of waste (approx. 500 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” 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.
36
The combined solid waste and sludge burning program
Description
The Solid waste and sludge program heat up the combustion chamber according to the solid
waste program, and switches to burn sludge from the service tank when ready. However, the
maximum combustion chamber temperature kept lower than approximately 950°C to enable the
operator to feed solid waste continuously.
Operator procedure
1. Perform settling and sludge preparation in the service tank 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.
The slagging program

Description
This program is used to run the flue gas fan during ash removal, combustion chamber
inspections and other situations were personnel enters the chamber. The program will also
open the flue gas damper completely. This program will ensure maximum vacuum in the
chamber and will extract dust and smoke. Consequently, the incinerator room will also be
purged with fresh air from outside.
Operator procedure
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 (even when the
temperature is below 170°C).
3. Open the ash door and remove ashes and slag/Inspect the chamber from the inside.
Partly burned cans, can remain in the chamber. These will disappear eventually.
NOTE! Combustion air inlet openings at "floor" level must be opened, if
blocked.
37
38
MAINTENANCE MANUAL
PART II: MAINTENANCE MANUAL
39
MAINTENANCE MANUAL
Maintenance instructions
Preventive maintenance system
Preventive maintenance periods are
programmed in the control system based on
running hours of the diesel oil burner, apart
from the regular checks found below. The
preventive maintenance tasks groups are:
• Weekly (100 h),
• Monthly (400 h),
• 6 monthly (2500 h) and
• Yearly (5000 h).

When the actual running hours since last performed maintenance exceeds the service interval
the control system calls for service by a pop-up screen.
6 monthly and yearly service is also triggered by standby time on the incinerator.
Follow the appropriate procedure when notified. When “Hours since last service” is above
setting “Hours service”, a red banner is activated in line for the item. Once maintenance has
been carried out, press “Done” and “Hours since last service” is reset. The red banner is turned
off.
If not logged in as user “usr” (Ref appendix), values on different setup screens are “view only”.
Also, the “Done” buttons are only visible if user “usr” has logged in.
Following the preventive maintenance
tasks will as a minimum consume
parts according to below list of “One-
year wear and tear parts”.
Detailed instructions and

information on all maintenance
tasks can be found in the “Teamtec
incinerator service video” provided.
Service hour counter
Make sure the incinerator has finished the cooling down procedure before the main
power is turned off.
If otherwise not specified, no testing of equipment needed before turning incinerator

system back on again after maintenance task is completed.
40
MAINTENANCE MANUAL
REGULAR MAINTENANCE CHECK LIST

Task No. Task Title Maintenance Equipment Details
interval needed
1 Inspection of Daily - Remove all ash

combustion and slag before
chamber loading and
starting the
incinerator
2 Clean Daily - -
combustion
chamber air inlets
3 Check diesel oil Daily - Normal reading
pressure and 16 bar. Deviation
check for any normally related
leakage to clogged filter,
so cleaning this is
first task of
troubleshooting.
Check visually for

leakage.
4 Check sludge Daily - Normal reading
pressure 0.2 bar
5 Clean photo Weekly (100 Rag -
resistor on burner hours)
6 Inspect flame Weekly (100 Rag Clean if
scrod and blast hours) necessary
tube
7 Check Weekly (100 Rag Check that there
combustion air hours) Flashlight are obstructions.
inlets and cooling Clean if
air inlets necessary.
8 Visually inspect Weekly (100 Rag Clean if
the flue gas outlet hours) Flashlight necessary
from inside the
chamber for
deposits
9 Check sludge Weekly (100 Check visually for
dosage pump hours) leakage. Turn the
shaft by hand to
check it is moving
freely.
10 Check water Weekly (100 Check visually for
dosage pump hours) leakage. Turn the
shaft by hand to
check it is moving
freely.
41
MAINTENANCE MANUAL

interval needed
11 Check fan belts Monthly (400 - Make sure there

condition and hours) are no abnormal
tension. Replace vibrations, noise
if worn, tighten if or bearing
necessary. temperatures.
Correct deflection
is 10 mm using a
force of approx. 3
kg. weight load.
12 Check refractory Monthly (400 - Check visually the
condition. Repair hours) refractory inside
is necessary. the combustion
chamber. If
pieces of
refractory have
fallen out so the
insulation or steel
is visible, 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!
13 Clean diesel oil Monthly (400 Rag Blast tube, flame
burner hours) scrod and ignition
electrodes to be
cleaned
14 Dismantle and Monthly (400 14mm wrench See service video
clean sludge oil hours) 19mm wrench
burner 27mm wrench
Vise
Compressed air
15 Dismantle and Monthly (400 14mm wrench See service video
clean water hours) 19mm wrench
nozzle 27mm wrench
Vise
Compressed air
16 Check spark Monthly (400 Brush Clean if
arrester hours) Flashlight necessary
42
MAINTENANCE MANUAL

interval needed
16 Clean the filters in 6 monthlies (2500 Soft brush See tasks
diesel oil pump hours or 182 Fuel oil description. New
and diesel oil days) cover gasket
supply line must be installed.
17 Replace rubber 6 monthlies (182 13 mm wrench See service
stator on sludge days) video
oil dosage pump
18 Replace rubber 6 monthlies (182 13 mm wrench See service
stator on water days) video
dosage pump
19 Check sludge 6 monthlies (2500 - Should have a
dosage pump hours or 182 smooth polished
rotor days) surface
20 Check water 6 monthlies (2500 - Should have a
dosage pump hours or 182 smooth polished
rotor days) surface
21 Grease the flue 6 monthlies (2500 10 mm wrench See service
gas fan bearings hours or 182 16 mm wrench video
days) 30 mm wrench
Ball bearing
grease
22 Visually check the 6 monthlies (2500 - -
thermocouple for hours or 182
combustion days)
chamber
23 Lubricate the 6 monthlies (2500 Grease gun See service
sluice bearings hours or 182 General purpose video
days) grease
24 Lubricate door 6 monthlies (2500 Grease gun. See service
hinges hours or 182 General purpose video
days) grease
25 Check door 6 monthlies (2500 Chalk Use chalk on the
gasket hours or 182 edges of the door
days) 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.
26 Clean inside the 6 monthlies (2500 10mm wrench Open the
steel cooling hours or 182 inspection covers
jacket of the days) on the lower side
chamber through of the incinerator
the inspection cooling panel.
covers Clean as
required with
steam or hot
water.
43
MAINTENANCE MANUAL

interval needed
27 Check Paintwork Yearly (5000 - Make sure the
hours or 365 paint is not
days) chipped or
scratched
28 Check the Yearly (5000 - See task
control and alarm hours or 365 description
system days)
according to
"Test of function
and safety
devices"
29 Check all safety Yearly (5000 - See task

devices and hours or 365 description under
calibrate if days) Appendix D.
necessary
30 Check all valves, Yearly (5000 Repair if

pumps and hours or 365 necessary
solenoid valves days)
for leakage
31 Replace nozzles Yearly (5000 Allen key, 3 mm See service

for D.O. burner hours or 365 Allen key, 4 mm video
with new ones. days) 14 mm wrench
16 mm wrench
19 mm wrench
27 mm wrench
Screwdriver,
flathead, 6 mm
32 Replace flue gas Yearly (5000 See task
fan V-belts hours or 365 description
days)
33 Change door Yearly (5000 See task
gasket hours or 365 description
days)
34 Change sludge Yearly (365 days) To be done at
dosage pump the same time as
rotor changing the
stator, the
universal joint,
the stuffing box
gasket, and the
seal plate
gasket.
35 Change water Yearly (365 days) To be done at
dosage pump the same time as
rotor changing the
stator, the
universal joint,
the stuffing box
gasket, and the
seal plate
gasket.
44
MAINTENANCE MANUAL
Remember: Following the preventive maintenance tasks will as a minimum consume parts
according to below list of “One-year wear and tear parts”.
Recommended Minimum spare parts

Article / Name 17910 / Minimum Spare Parts, OG200/400C, TG5.2
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.
One year wear and tear parts OG200/400C, TG5.2

Article / Name 20521 / One year wear and tear parts, OG200/400C,
TG5.2
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.
Typical repair and maintenance tasks and procedures are described in detail elsewhere in the
manual.
It is advised to keep the following kit of parts on board to be prepared for unwanted downtime.
16066* only for OG200CS / OG400CS
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MAINTENANCE MANUAL
Recommended on board repair parts, OG200/400C, TG5.2

Article / Name 20689 / Recommended on board repair parts, OG200/400C,
TG5.2
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.
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MAINTENANCE MANUAL
Maintenance, repair tasks and procedures
General tool list
For most maintenance and repair tasks, it is enough 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
Incinerator
Chamber
Refractory cracks where bricks 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.
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.
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.
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MAINTENANCE MANUAL
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.
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.
Instructions for use of repair substance for refractory
The main power switch must be turned off before starting this maintenance task. Check that the
incinerator combustion chamber is cold.
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 individually, meaning no substance should cement 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. The substance 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. The substance 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, if
necessary.
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.
Combustion chamber refractory exchange

In worst case, where the refractory is beyond repair, it may be necessary to exchange the
refractory. Fear not, the procedure is fast and does not require hot work, as the chamber is
bolted, and the refractory consists of interlocking modular blocks. It is the inner lining of the
incinerator consists of a heat resistant material which is called refractory. This material can
withstand temperatures up to 1500°C, and its function is to protect and insulate the ceramic
insulation between the refractory and the air-cooled metal jacket of the chamber. 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 5-8 years on a sludge burning incinerator.
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If a new refractory must be installed
Contact [email protected] for a new refractory kit. A certified Teamtec service engineer will
be required for the replacement. The after sales department will assist in providing global
support.
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 ( [email protected] or [email protected] or
[email protected] or [email protected]).
Restriction bricks replacement
The 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 others are loose.
3. Replace with new ones. No cement needed!
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Door gasket replacement
1. Remove the old door gasket with a screw driver or similar.

2. Remove all the old sealing compound used to fix the gasket to the steel, to get an even
and smooth track.
3. Apply new sealing compound in an even string around the door perimeter.
4. Insert the new gasket. Start and end in the middle in the lower part of the door and cut
the gasket to exact length.
5. Give the gasket a series of gentle and even punches all the way around the door
perimeter to settle it in the sealing compound, for example using the handle of a mallet.
6. Remove any excess sealing compound, close the door, and leave it closed until the
compound has settled.
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Safety door interlock switch replacement
Tools needed:
- Flathead screw driver.
- Torx screw driver set
- Allen key set
Approx. time required: 0,5 hour
Disassembly
1. Switch off the power and make sure it cannot be switched

on again while the unit is under repair.
2. Unscrew the screws holding the lid.
3. Take pictures of the wire connections for reference.
4. Loosen the wires and pull out the cables.
5. Loosen the switch from the chamber using an Allen key.
Repair
It is not possible to repair a damaged safety interlock switch to reliable state.
Replacement
1. Install the new switch on the chamber.
2. Thread and re-attach the wires according to reference pictures.
3. Replace the lid.
Greasing of door hinges
Use ordinary ball bearing grease. Consult service video for execution.
Greasing of sluice bearings
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.
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Burner maintenance and repair

General information
While the diesel oil burner heats up the incinerator, the burner runs in different steps controlled
by the selected program, simultaneously 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 for the Sludge burning program, the actual speed of the sludge dosing
pump (SDP)
The actual burner step is displayed on the operator terminal.
Combination of possible burner steps in different programs:
Diesel Sludge Solid waste Solid

Burner Sludge
nozzles in nozzle in and sludge waste
step: program
operation operation program program
0 X X X
1 1 X X X
2 2 X X X
3 1+2 X X X
4 1 Yes X X N/A
5 2 Yes X X N/A
6 1+2 Yes X X N/A
7 Yes X X N/A
The complete (red) burner housing should never be dismantled from the incinerator for
any maintenance or replacement!
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MAINTENANCE MANUAL
Burner diesel nozzle assembly and repair
(Demo pictures only. The (red) burner housing 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. Pull out the photo cell.
2. Remove the inspection cover.
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3. Remove the nozzle line from burner.
4. Loosen the two screws marked at the picture to dismantle the electrodes and the flame
scrod and then unscrew the D.O. nozzles!
7842
12329
5. Clean or replace as parts as needed. 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.
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DO nozzles data
Incinerator Nozzle 1 Nozzle 2 Std. pressure DO temp.
OG120C 2.5 GPH 60° - 16 bar 50°C
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
GS900CX 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
GS1000CX 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
For special cases other nozzles may be used.
Maintenance
Burner nozzle cannot be repaired.
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 is 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.
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Sludge diesel burner maintenance
Cleaning of sludge burner

Check the sludge burner frequently, minimum every month, and if necessary clean it.
1. Loosen nut (A) and pull out the external pipe (B)
2. Clean the external (B) and internal (C) pipes
3. Re‐assemble the sludge burner in reverse order
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Burner Blast tube Replacement
(Demo pictures only. The complete burner should never be dismantled from the incinerator for
any maintenance or replacement.)
Tools needed:
- Hammer and chisel
2. Remove the nozzle line.
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3. Unscrew the two screws shown at the picture. Use a hammer and chisel gently to
loosen the blast tube if stuck. Do not hit the red casting, as this is made of brittle
material.
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
Note: The blast tube should be adjusted for the two screws mentioned in point 3 to be in
the middle of the sliding track.
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Ignition cables replacement
(Demo pictures only. The burner should never be dismantled from the incinerator for any
maintenance or replacement.)
Tools needed:
2. Remove the nozzle line.
3. Pull out the cables from the ignition transformer.
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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
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Photo Resistor replacement
Tools needed:
- Screwdriver set
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 screws to hold them in place
3. Put the photo resistor back into its socket
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Ignition transformer replacement
Tools needed:
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.
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Oil burner damper motor replacement
maintenance or
replacement.)
Tools needed:
- Screwdriver set
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 to get it free.
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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 screws 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 splint back in
6. Put back and tighten the two set screws
PS! Make sure that the shaft is in approx. mid position when assembling, and that the damper
flap is in closed position.
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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.
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Capacities
Oil burner nozzle capacities in l/h at various pressures.3
Rated flow 4 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
3
Sp gr 0,85 @ 25°C and viscosity 1,3°E @ 20°C
4
Pressure = 100 P.S.I.
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Diesel oil pump maintenance and repair

General pump data and information
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
• 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.
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Technical data for burner diesel pump

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 μ 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 Nm
Pump capacity Power consumption
Bar Bar
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Burner diesel 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
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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.
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.
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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 (shall always be installed!) 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
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MAINTENANCE MANUAL
Burner diesel fuel pump replacement
Tools needed:
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.
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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
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Burner pump shaft seal replacement
Tools needed:
- Lug spanner
3. Measure the distance shown at the below picture to positioning the spline coupling
correctly when reassembling. Should be 10mm
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MAINTENANCE MANUAL
4. Untighten the set screw and remove the spline coupling.
5. Use a felt pen to mark position of the nut with a line from nut to housing. 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
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MAINTENANCE MANUAL
Burner diesel pressure regulation kit replacement
Tools needed:
- 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.
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MAINTENANCE MANUAL
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.
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7. When starting the incinerator again, the pressure must be regulated to 16 bar by
adjusting at the screw as shown at picture below.
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Spline coupling replacement
Tools needed:
3. Unscrew the 4 bolts and pull out the motor.
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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.
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Sludge dosage pump maintenance and repair
Dimensions
Check also assembly drawing in the Drawings section.
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Dismantling and assembly diagram, exploded view
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Parts list Art. No. 2007672
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 15684 Rotor 1
2220 15748 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 15691 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
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MAINTENANCE MANUAL
General recommendations
When handling harmful or objectionable materials, adequate ventilation must be provided in

order to disperse vapors.
The pump may have high surface temperature.
Beware electrical hazards.
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.
If, the pump has been left standing for an appreciable time, 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.
Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasives,
speed, pressure etc.
When pump performance has reduced to an unacceptable level one or possibly both items will
need replacing.
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MAINTENANCE MANUAL
Sludge dosage pump maintenance and repair procedures
This procedure covers replacement of bonded rubber stator, rotor for dosage pump, universal
joint, mechanical seal, seal plate gasket, stuffing box gasket
Tools needed:
- Flat screw driver
- Pin punch tool
1. Cover the area under the dosage pump with plastic and cover the plastic with rags to
collect oil.
2. Close sludge valves.
3. Unscrew the sludge supply line on the pressure side.
4. Unscrew the four hex bolts and remove end cover.
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5. At this stage, it is possible to replace the rubber stator, and reassemble.
6. Unscrew and remove the sludge supply AND return pipes connected to the dosage
pump.
7. Unscrew and remove the thermocouple.
8. Loosen the two hex socket bolts to loosen the pump shaft from the motor shaft. There is
a third hex socket grub bolt between the two tightening bolts. This will loosen the clamp
from the shafts when tightened.
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MAINTENANCE MANUAL
9. Remove the stator.

10. Carefully remove the rubber seal ring and the steel ring on both ends of the universal
joint rubber guard. Remove the rubber guard.
11. At this stage of changing the mechanical seal, it is recommended to change both the
universal joint, the rotor and all gaskets.
12. Remove the retaining pin on the stub shaft side with a pin punch tool and remove the
universal joint.
13. Split the mechanical seal housing by unscrewing the two hex nuts.
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14. Unscrew the three hex socket set screws and dismantle the shaft parts.
15. Carefully remove the seal plate, and gently push out the mechanical seal.
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16. Reassemble in reverse order with a bit of oil for lubrication. The shiny side of the white
mechanical seal shall face outwards.
17. Fix assembly with the three hex socket screws with 120 mm as shown in below
picture.
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18. Reconnect the shaft to the universal joint with the retaining pin. Grease the universal
joint and reassemble the remaining parts in reverse order.
19. Reassemble the shaft assembly and the housing with a new seal plate
gasket.
20. Install new stator. Suction cone side to face the
pump.
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MAINTENANCE MANUAL
21. Install the pump on the motor. Reattach all pipes and tighten all nuts before fixing the
stub shaft to the motor. Notice how the two axles are positioned.
Loosen the grub hex socket bolt once in correct position. Tighten the two fixing hex
socket bolts, and finally remember to slightly tighten the grub hex socket bolt to keep it
from vibrating loose.
22. Clean the drip tray and reinstall all guards.
23. To prime the pump before starting the incinerator, start the sludge circulation pump in
the incinerator control display. Failure to prime the pump will cause damage.
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Sludge valve
Article 12560, 0-1 bar, 3/4": Two of these valves are in the drip tray in the sludge dosage
assembly. It ensures that sludge is not injected through the sludge burner, without
atomizing air or atomizing steam present.
Valve housing Brass

Cove Red brass
Inner parts AISI 430F
Sealing device Teflon, Viton and Silicone
Control medium Steam 180°C or compressed air, 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 consists of:
Pos. no. Nos. Description

1 (302 1 Spindle
2 (304) 1 Disc washer
3 (306) 1 Seal
4 (309) 1 Bolt
5 (310) 1 O-ring
6 (311) 2 Ring
7 (312) 1 O-ring
8 (313) 1 O-ring
9 (316) 1 Deflector
10 (317) 1 Face plate
11 (318) 1 Spring
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MAINTENANCE MANUAL
Control cabinet
PLC repair or replacement
General information
The Standard PLC contain of 4 units. See below figures.
1 2 3 4
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)
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MAINTENANCE MANUAL
Base Unit
1. Status LEDs
2. Output removable screw terminal block
3. Clip-on lock for 35 mm (1.38in.)
4. Ethernet port
5. 220Vac 50/60 Hz 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. Cartridge slot 1
14. Cartridge slot 2
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MAINTENANCE MANUAL
15. Protective cover

16. Locking hook (lock not included)
17. Removable analogue inputs cover
18. Battery holder
Inserting SD card
When new program is received from Teamtec, this must 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.
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MAINTENANCE MANUAL
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.
Rail Mounting of PLC
A
C
Dimension:
A – 90 mm (3.5 in.)
B – 29.4 mm (1.157 in.)
C – 27.4 mm (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.
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MAINTENANCE MANUAL
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.
Troubleshooting
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I/O Status Indicators on the LCD
Indicator Color 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)
Replacing the PLC power source in the control cabinet
1. Use a flat head screw driver to pull out the locking device in the lower base of the module,
shown on the picture above.
2. Move wiring from old to new module, one wire at the time to identical location.
3. Insert new module on the rail.
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Frequency inverter for the sludge dosage pump

Repair or replacement
Control
terminals
Power
terminals
Power Terminals
The power terminals must be connected before connecting the control terminals!
Maximum connection
AWG 10 / 5 mm2
capacity:
Tightening torque: 1.2 Nm
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MAINTENANCE MANUAL
Faults – Causes – Remedies

Drive does not 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 freewheel 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.
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Flue gas fan

Ref. Flue gas fan assembly drawing
Replace the flue gas fan thermocouple and temperature transmitter
Tools needed:
- adjustable spanner.
- flathead screw driver
Approx. time required: 0,5 hour
Disassembly
1. Consult assembly drawing 19442.

2. Switch off the power and make sure it cannot be switched on again while the unit is under
repair.
3. Unscrew the two screws holding the lid on the thermocouple/the four screws holding the lid
on the temperature transmitter.
4. Loosen the wires and pull out the cables.
5. Loosen the thermocouple from the fan housing using the adjustable spanner/Loosen the
transmitter from the fan housing using a screw driver.
Repair
It is not possible to repair a damaged thermocouple or temperature transmitter to reliable state.
Replacement
1. Adjust the length of the thermocouple going into the fan housing to match the removed
thermocouple, by loosening the nut on the sliding fastener.
2. Install the new thermocouple on the fan housing.
3. Thread and re-attach the wires according to the electrical diagram.
4. Replace the lids.
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MAINTENANCE MANUAL
Replace flue gas fan V-belts

Tools needed:
- A wide screw driver (to not damage the belts)
Approx. time required: 0.5 hour
Disassembly
repair. If unit is switched on during repair, it may cause serious damage and injuries.
2. Unscrew the four bolts holding the protective cover over the V-belts and remove the cover.
3. Use the wide screw driver to force the outer belt out of the track while rotating the pulley.
4. Use the screw driver to move the inner belt to the outer track and beyond to remove it. ONE
track at each pulley at the time!
Repair
It is not advisable to repair V-belts.
Replacement
Install new belts in reverse order of disassembly.
Reassembly
Check the tensioning of the belt’s mid-way between pulleys. It should be 10 mm deflection at 3
kg pressure. If the tensioning needs adjustment, follow the next items 2-5 before replacing the
cover.
1. Use a marker to draw a line where the upper edge of the motor base is located. This is used
as a reference.
2. Loosen the four bolts securing the motor.
3. Adjust the two positioning bolts counter clockwise to tighten the belts to above specification.
Make sure the motor base stays parallel to the marked line. Double check that the two
pulleys are parallel by using a ruler.
4. Once tension is acceptable, tighten the 4 bolts securing the motor.
5. Replace the cover and tighten the cover bolts.
6. Power to the unit can now be restored.
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MAINTENANCE MANUAL
Greasing or replacement of flue gas fan bearings

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.
The grease in the bearings must be changed every six months. Make sure the bearings are
clean before they are re-greased. The following grease brand is recommended:
• Mobilgrease XHP 222
Alternatives:
• Esso Ronex MP-D
• Texaco Thermatex EP2
• Shell Alvania RL 3
• BP Energrease HTG 2
• Mobil Mobilith SHC 220
• Mobil Mobilith SHC 460
• Statoil Uniway LYX 625
• FAMM Ulti-Plex Sunthetic Grease EP
• Total CERAN WR 2
• Total CERAN XM 220
• Elf Multiplex EP 2
• CASTROL LMX
• CASTROL Spheerol SX2
• LITOL 24
• Chevron Multifak EP2
For mounting after re-greasing, the tightening torque for the cup bolts for the incinerator size
OG200C, 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 swiveled 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 which 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.
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Replacing the flue gas fan impeller:

Tools needed:
Disassembly
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.
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MAINTENANCE MANUAL
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.
5. Reconnect all electrical cables to the motor
6. Main power can now be turned back on again
Adjusting 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.)
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Flue gas damper

Flue gas damper motor servicing and repair
(Demo pictures only. The motor can be replaced without dismantling the damper unit from the
stack)
Tools needed:
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.
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4. Unscrew one of the bolts for the bracket shown at the picture below 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.
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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 wires in junction box +6, terminal clamps X1-
1 and X1-3.
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Sludge circ. pump
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。
4.Main Technical Data
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MAINTENANCE MANUAL
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.
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).
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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.

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:____________
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60Hz
50Hz
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Trouble shooting for malfunction of the incinerator plant

Symptom Probable cause Checkout procedure
1. OPERATOR PANEL 1. Faulty main power Check main switch -Q1Check

DEAD. supply. power supply from main
switchboard.
Check switch -S1.
2. Emergency stop switch
open.
Check fuses –F12 and –F13
3. Faulty fuse for pilot
transformer.
Check fuse.
4. Faulty fuse -F13.
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
damper. and 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 nozzle. necessary clean and adjust it.
sludge.
2. Closed or incorrect Adjust valve. (1/2 to 1/1 turn
adjusted air/steam open) NB! only to be
control valve. performed with a clean sludge
burner.
3. Damaged sludge dosing Change stator.

pump stator.
4. Sludge pressure to high. Adjust to correct setting.
(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 Change the valve.
solenoid valve.
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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 Clean inlet. (Bottom grating)
inlet. Clean panel slot
3. Panel cooling slot
clogged with dirt. Put the missing brick back in
place.
4. Throttling bricks fallen
out. See Draft Failure
5. Under pressure to low Replace sensor
6. Faulty temp. sensor. Check transmitter mV input.
Replace, DO NOT ADJUST
7. Faulty temp.
Burning solid waste transmitter. Check frq. inverter circuit
Stop loading, and tray to block
8. Faulty frequency lower four corners
inverter.
9. Loaded too much waste

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

pressure > 3.5 bar
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MAINTENANCE MANUAL
10. DRAUGHT FAILURE 1. Leaking sensor tube. Check sensor tube for
(low under pressure) damage and fixing.
2. Defect pressure sensor Check and replace, DO NOT

ADJUST.
3. Door gasket damaged. Check door gasket
4. Broken flue gas fan Tighten or replace.

belts.
5. Flue gas fan motor Check direction

6. running in wrong
direction.
11. LOW/HIGH VOLTAGE 1. Input voltage to low or Check supply voltage.

to high (+10% to –13%) If this alarm occurs 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 Put the missing brick back in

out. 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.
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APPENDIX A: STORAGE, PRESERVATION AND INSTALLATION
APPENDIX A: Storage, preservation and

installation
Preparation for shipment

The incinerator unit, the flue gas fan, the damper and tanks 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 will be damaged if stored outdoor in wet conditions.
For long time storage, Teamtec recommend placing 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.
The fan, pumps and electrical motors must be rotated monthly.
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, 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, if any.
Turn the electrical motors for fan, pumps and burner slightly.
If possible, the power should be switched on to the control panel to keep the panel dry.
119
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
Connection: pressure 1.5 bar
Recommended filter, mesh
40µm
Max. suction lift 3500 mm
Diesel oil return line Connection. DN 15 flange, max
pressure 1.5 bar
Flue gas duct.

Incinerator to flue gas fan Duct DN400/DN300
Flue gas fan to open air. Duct DN400/DN300
Sludge and steam or Air.

Steam /air supply line for sludge Connection DN 15 flange
atomizing Pressure 6 - 8 bar
approx. 20kg/h
Consumption: Steam
approx. 20kg/h
Comp. air
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
120
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
Detailed information regarding the system found on the Piping & Instrument Diagram as given in
the Drawings section. A detailed installation instruction is given in approval drawings, as well as
the drawing package towards the end of this manual.
121
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 enough 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.
122
APPENDIX B: USER LOGIN
APPENDIX B: User login

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 must 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 can change settings. Settings will
automatically change back to factory
settings every 15 minutes, regardless if
logged in as usr.
123
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.
Settings burner
Buttons “Prev.” and “Next” is used in a
circular shift function between several
setting screens.
Text Description
Burner damper Burner damper opening. Adjusts the amount of air supplied to the
burner step x combustion process by the burner motor fan.
Factor CCP burner Correction of burner damper opening related to combustion

damper reg. chamber pressure (CCP). Used internally in the control system.
Factor SDP burner Correction of burner damper opening in related to sludge dosage
damper reg. pump (SDP) speed. Used internally by the control system.
124
Settings alarms
Text Description
Alarm max time The maximum time the diesel heater is activated the first time
diesel heater start after start incinerator. The diesel heater requires extra time at
start-up.
Alarm max time The maximum time the diesel heater is activated during
diesel heater run incinerating.
Alarm max. CCT Maximum combustion chamber temperature (CCT).

Minimum operating Minimum combustion chamber temperature (CCT). Used as
CCT reference to “Alarm CCT below minimum operation temp”
Alarm CCT below Maximum temperature drops combustion chamber temperature

minimum operation (CCT). 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 Adjust minimum diesel oil pressure

diesel oil pressure
Alarm maximum Adjust maximum diesel oil pressure

diesel oil pressure
125
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 several setting screens.
Text Description
Set burning time Set burning time for incinerator
Sludge alone Enable/Disable sludge alone

CCP start sludge Set point combustion chamber pressure (CCP) when starting a
sludge program
Min. CCP run Minimum combustion chamber pressure (CCP). Used internally
sludge as a limit in the control system
Max. CCP run Maximum combustion chamber pressure (CCP). Used internally
sludge as a limit in the control system
Min. sludge Minimum sludge temperature before starting sludge program.

temperature This value is also calculating alarm sludge temperature. See
running sludge alarm settings.
Alarm sludge The maximum temperature drops in sludge temperature. Related

temperature low to “Min sludge temperature running sludge”.
Alarm sludge temp. The maximum temperature increases in sludge temperature.

high, above normal Related to “Min sludge temperature running sludge”.
Min. CCT for run Minimum combustion chamber temperature (CCT) before starting
sludge sludge.
CCT low Maximum drop combustion chamber temperature (CCT) – stop

hysteresis – stop sludge dosage system.
sludge.
126

setting screens.
Text Description
Time start sludge Time after start sludge dosage pump (SDP) before making
before adjust adjustments – to ensure a stable process before adjusting
sludge.
Time check CCT Time between reading combustion chamber temperature (CCT)
after adjust and adjusting the process
CCT inc between The minimum increase in combustion chamber temperature

adjust – inc sludge (CCT) needed at time check before making adjustment to
process.
CCT inc sludge – Minimum combustion chamber temperature (CCT) before

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

inc diesel oil decreasing sludge and increasing diesel oil.
CCT stop burner Minimum combustion chamber temperature (CCT) before stop
diesel oil diesel oil and further increase sludge.
Hys restart burner Maximum drop combustion chamber temperature (CCT) before
diesel oil restart burner diesel oil and decrease sludge.
Maximum CCT Maximum combustion chamber temperature (CCT) before

reducing sludge.
Hys max. CCT – Maximum drop combustion chamber temperature (CCT) before
stop dec sludge stop reducing sludge.
Set CCP running Set point for Combustion Chamber Pressure (CCP) is -15mmWC
Step 4 & 5 during burner stage 4 & 5 if the Combustion Chamber
Temperature is below 800°C
Set min CCP for Minimum set point for Combustion Chamber Pressure (CCP) as
temp.regulating long as the Combustion Chamber Temperature is above 800°C
127

setting screens.
Text Description
Max. FGT – start Maximum flue gas temperature (FGT) before decreasing
adjust CCP combustion chamber pressure (CCP)
Hys max. FGT – Maximum drop flue gas temperature (FGT) before stop
stop adjust CCP decreasing combustion chamber pressure (CCP)
Time check FGT Time between check flue gas temperature (FGT) before making
adjust CCP further 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
adjust SDP RPM pump (SDP) RPM.
Hys FGT – stop Minimum drop flue gas temperature (FGT) before stop
adjust SDP RPM decreasing sludge dosage pump (SDP) RPM.
Min. CCT scale Minimum combustion chamber temperature (CCT) in scaling

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

CCP run sludge range for adjusting combustion chamber pressure (CCP)
CCP running Set point combustion chamber pressure (CCP) running burner
burner step 6 step 6
128

setting screens.
Text Description
SDP Increasing sludge when changing burner step from 5 to 4, or 6 to

compensation – 5.
decrease diesel oil
SDP Increasing sludge when changing burner step from 4 to 7.

compensation –
stop diesel oil
SDP RPM Decreasing SDP RPM every 30 second if combustion

decrease 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 Adjust sludge dosage pump manually.
SDP RPM
Sludge quality Sludge quality counter number. See Page 29.

counter
Purging start Time for purging sludge nozzle before opening sludge.
sludge
Purging stop Minimum combustion chamber temperature (CCT) for stop

sludge – CCT purging sludge nozzle.
below
Alarm low level Activate if alarm is needed when sludge service tank low level
Sludge service tank switch is activated.
129

setting screens.
Text Description
Alarm set point Adjust set point for minimum steam/air pressure
minimum steam/air
pressure
Alarm set point Adjust set point for maximum steam/air pressure
maximum steam/air
pressure
Alarm set point Adjust set point for minimum sludge pressure
minimum sludge
pressure
Alarm set point Adjust set point for maximum sludge pressure
maximum sludge
pressure
130
Settings solid waste (1/2)

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
waste program burner at start solid waste program
CCP max. solid Maximum combustion chamber pressure (CCP) when running
waste program solid waste
CCP min. solid Minimum combustion chamber pressure (CCP) when running
waste program solid waste
Maximum CCT Max combustion chamber temperature (CCT), decrease burner

stage
131
Settings solid waste (2/2)

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
adjustment CCP combustion chamber pressure (CCP).
Hysteresis FGT Minimum drop flus gas temperature (FGT) before stop adjusting
stop adjusting CCP combustion chamber pressure (CCP)
CCP inc when FGT Value for increasing combustion chamber pressure (CCP) when
above set point flue gas temperature (FGT) is above set point
CCP dec when Value for decrease combustion chamber pressure (CCP) when
FGT below set flue gas temperature (FGT) is below set point
point
Time check FGT Time between reading flue gas temperature (FGT) before
adjust CCP adjusting combustion chamber pressure (CCP).
Max. FGT start Maximum flue gas temperature (FGT) before start adjusting
adjust burner step burner step.
Hysteresis FGT Minimum drop flue gas temperature (FGT) before stop adjusting
stop adjust burner burner step.
step
Time check FGT Time between reading flue gas temperature (FGT) before making
adjust burner step adjustment to burner step.
132
Settings solid waste and

sludge
setting screens.
Text Description
Max. CCT SW & Maximum combustion chamber temperature (CCT) – reduce

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

CCT SW & sludge reducing sludge when running solid waste and sludge program.
Settings loading/slagging
and stop
setting screens.
Text Description
CCP running Set point for combustion chamber pressure (CCP) when running
cooling “Stop” program (cooling).
Auto start of FGF The flue gas fan atomically starts after the emergency stop is
after emergency released, if CCT above 220°C.
stop
Start\stop cooling - Maximum combustion chamber temperature (CCT) to stop “Stop

hysteresis Program” – cooling.
Hysteresis Maximum increase combustion chamber temperature (CCT) after

start\stop cooling stop to allow opening door(s).
133
Burn-in
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 100°C to 600°C. A message
will appear when refractory is ready.
Text Description
Temperature set Set point for combustion chamber temperature CCT, running
point (view only) Burn-in program
Hys. chang. burner Hysteresis for temperature set point, when changing burner step.
step
Burner step (view Actual burner step

only)
Incinerator configuration
The button “Restore factory settings”
can be used to restore settings to
factory specifications.
If assistance from Teamtec is required,
you may be asked for the incinerator
configuration listed on the screen
134
Complete list of settings in the operator display and frequency

inverter in the control cabinet (Factory settings)
Settings burner 50Hz 50Hz 60Hz 60Hz

Sluice Sluice
Burner damper burner step 1 18 % 18 % 18 % 15 %
Burner damper burner step 3 37 % 40% 30 % 30 %
Factor CCP burner damper reg. 0.150
Factor SDP burner damper reg. 0.050
Settings alarms
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 mmWC
Alarm minimum diesel oil pressure 11 bar
Alarm maximum diesel oil pressure 20 bar
Settings sludge
Set burning time “off” 0 min
Sludge alone Yes
CCP start sludge -28 mmWC
Min. CCP run sludge 12 mmWC
Max. CCP run sludge -28 mmWC
Min. sludge temp run sludge 80 °C
Alarm sludge temp. low 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
Hys. dec. 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 10 °C
Set CCP running step 4 & 5 -15 mmWC
Set min CCP for temp. regulating -15 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 -28 mmWC
SDP compensation – decrease diesel oil 60 rpm
135
SDP compensation – stop diesel oil 60 rpm

SDP RPM decrease 2 rpm
SDP RPM increase 2 rpm
Min. RPM SDP 190 rpm
Max. RPM SDP 1000 rpm
Manual setpoint SDP rpm 0 rpm
Sludge quality counter 2 [2-18]
Purging start sludge 5°C
Purging stop sludge – CCT below 300 °C
Alarm low level Sludge service tank Off
Setpoint heat tracing5 75°C
Hysteresis heat tracing6 5°C
Alarm setpoint minimum steam/air pressure 1.0 bar
Alarm setpoint maximum steam/air pressure 3.5 bar
Alarm setpoint minimum sludge pressure 0.05 bar
Alarm setpoint maximum sludge pressure 1.00 bar
Settings solid waste
Set burning time “off” 0 min
CCP start-up solid waste program -28 mmWC
CCP max. solid waste program -28 mmWC
CCP min solid waste program -10 mmWC
Maximum CCT 1150 °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 mmWC
CCP dec when CCP below setpoint 2 mmWC
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
Settings sludge with water
CCT enable water injection 1050 °C
CCT max. for water injection 1150 °C
CCT min for water injection 840 °C
Maximum rpm WDP 1200 rpm
Start rpm WDP 600 rpm
Min. rpm WDP 200 rpm
Increase rpm WDP 5 rpm
5
Visible if heat tracing installed
6
Visible if heat tracing installed
136
Settings solid waste and sludge

Max CCT SW & Sludge 900 °C
Hysteresis max CCT SW & Sludge 10 °C
Settings loading/slagging & stop
CCP running cooling -18 mmWC
Auto start of FGF after emergency stop Yes
Start/stop cooling – hysteresis 220 °C
Hysteresis start/stop cooling 50 °C
Setup consumption
Nozzle 1 specification 11.41 l/h
Nozzle 2 specification 22.94 l/h
Setpoint WDP capacity 0.00228 l/r
Setpoint SDP capacity 0.00220 l/r
SDP capacity (floating) 0.00220 l/r
Accepted deviation SDP capacity 80%
Settings Tanks
Volume below low
Max tank level Tank Area Sludge density
level
435 L 500000 mm2 0,96 kg/L
703 L 217,9 L 750000 mm2 0,96 kg/L
1107 L 219,5 L 1020703 mm2 0,96 kg/L
1692 L 277,0 L 1517468 mm2 0,96 kg/L
2071 L 277,0 L 1517468 mm2 0,96 kg/L
2938 L 277,0 L 1517468 mm2 0,96 kg/L
3812 L 622,0 L 1985565 mm2 0,96 kg/L
4945 L 550,0 L 1985565 mm2 0,96 kg/L
137
Settings frequency inverter ALTIVAR 12 (Found in incinerator control

panel)
Parameter U4 – SDP +25-U1
CONF>
ACC Acceleration [s] 3.0 1
dEC Deceleration [s] 0.1 0.1
HSP High Speed [Hz] 60 50
CONF>FULL>DRC-
BFR Standard motor freq [Hz] 50* 50*
UNS Rated Motor Volt [V] 230 380
CTT Motor Control Type PErF PUNP
FLG Speed prop gain [%] 33 N/A
UFR IR Compensation [%] 50 40
NPR Rated motor power [kW] 0.37* 2.15*
NPC Motor parameter choice NPr NPr
NCR Rated motor current [A] 1.9* 4.8*
CONF>FULL>CTL-
Fr1 Ref 1 channel Ndb AI1
CONF>FULL>FUN>Stt-
Stt Type of Stop nSt nSt
CONF>FULL>FUN->ADC-
AdC Auto DC Injection no no
CONF>FULL>I_O>Ai1-
Ai1t AI 1 signal type 0A 0A
CrL1 AI1 min Value [A] 4 4
CrH1 AI1 max Value [A] 20 20
CONF>FULL>CON-
Add Modbus address 2
Tbr Baud rate [Kbps] 19 2
tFo Format 8E1
Tto Time out [s] 30
CONF>Flt->tHt->itH
itH Motor Thermal current [% 1.1 1.6
In]
* According to motor nameplate
138
APPENDIX C: ALARM LIST
APPENDIX C: Alarm list

The Alarm-list contains information about available alarms. The reference refers to electrical
drawings.
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.
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 A7 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 1,0bar Sl. prog. -U8 Steam / air pressure sludge low.
Steam/air press. - sludge 3,5bar 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.
50°C Sl. prog. -F16 Sludge temperature low.
Sludge temperature low
95°C Sl. prog. -F16 Sludge temperature high.

Sludge temperature high
Sludge service tank temp. 110°C Sl. Prog. +3A-S4 Safety thermostat released.
high8 (require manual reset)
~ All time -A4 Open circuit in sensor (broken)

Circuit failure FGT or short circuit in amplifier for flue
gas temperature.
7
See motor rating
8
sludge tank w/el. heater
139
APPENDIX C: ALARM LIST
ALARM TEXT Setpoint Active Ref. Description

Circuit failure CCT ~ All time -A2 Open circuit in sensor (broken)
or short circuit in amplifier for
combustion chamber
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.
140
APPENDIX D: TEST OF SAFETY AND ALARMS
APPENDIX D: 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 or unplug the diesel Flame failure
oil common solenoid.
2. FLUE GAS TEMP. HIGH At flue gas temperature above alarm set point,
Adjust alarm set point the alarm will activate, and the burner stops.
[Alarm max. FGT]
below operating temp. Flue gas temp. FGT high
3. COMB. CHAMBER TEMP. At combustion chamber temperature above set

HIGH Adjust alarm set point point alarm will activate and the burner stops.
[Alarm max. CCT]
below operating temperature. Comb. chmbr. temp. CCT high
4. COMB. CHAMBER TEMP. At combustion chamber temperature below set

LOW point [Alarm CCT below min. oper.] the alarm will
Start sludge program. activate, and the burner stops.
Adjust alarm set point[Min.
Comb. chambr. temp. low
operating CCT] below actual
temperature
then above actual CCT +
[Alarm CCT below min. oper.]
5. MOTOR OVERLOAD The motor stops, the alarm will activate, and the
Activate test button, one by burner stops.
one, at front of the motor
circuit breaker.
Thermal failure - motor overload
141

6. DOOR NOT CLOSED Alarm activates, and the burner stops.
Start a burner program.
Unlock the waste door by Door not closed
unlocking the special screw.
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 the
disconnect the sensor tube burner stops.
from vacuum controller.
Draught failure - CCP low
8. DIESEL OIL TEMP HIGH At release of safety thermostat-S3 the alarm will
Start a burner program. activate, and the burner stops
Adjust down the safety
thermostat -S3 to below set Diesel oil temp. high
point for working thermostat -
S4. The safety thermostat requires manual reset.
9. DIESEL OIL TEMP LOW At start of heating the alarm activates and the
Start a burner program. burner stops.
Adjust alarm set point
[Alarm max. time dieselheater
start] Diesel oil temp. low
to "0".
10. DIESEL OIL PRESSURE At pressure below setting [Alarm minimum Diesel
LOW oil pressure] (11 Bar), the alarm activates, and
Start a burner program. the burner stops.
Reduce the fuel oil pressure
Diesel oil press. low
by adjusting the pump.
11. DIESEL OIL PRESSURE At pressure above setting [Alarm maximum

HIGH Diesel oil pressure] (20 Bar), the alarm activates,
Start a burner program. and the burner stops.
Adjust the fuel oil pressure by
adjusting the pump. Diesel oil press. high
142

12. VOLTAGE LOW/HIGH Relay deactivates at voltage above or below set
Adjust upper setpoint down at point after a time delay (normally 5 sec.).
relay (-K9) until yellow LED During time delay, yellow LED flashes, and relay
flashes. deactivates after time delay has elapsed.
Voltage low - high
13. STEAM/AIR PRESSURE After 10 sec. alarm activates and the burner
SLUDGE LOW stops.
Adjust [Alarm setpoint
minimum steam/air pressure]
setting to 3.5 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] Steam/air press. - sludge high
setting to 1 bar.
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

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
143

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 1°C. Sludge temperature low
18. SLUDGE TEMP HIGH Alarm activates, and the burner stops.
Adjust set point
[Min. sludge temp run sludge]
below actual temperature and Sludge temperature high
adjust alarm set point to 0.
[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 Error Modbus comm. slave 2 SDP
the inverter –U4, wait for
alarm modbus comm.
144

21. SLUDGE SERVICE TANK Alarm activates, and the burner stops.
TEMP HIGH9
Start a sludge program Adjust Sludge service tank temp. high
down safety thermostat +3.1-
S1 below operating The safety thermostat requires manual reset.
temperature.
22. LOW LEVEL SLUDGE After 5 sec. delay the Alarm/Warning activates
SERVICE TANK and burner stops
Activate test lever if
mounted or disconnect cable. Low level sludge service tank
23. CIRCUIT FAILURE FGT Alarm activates and the burner stops
Disconnect wire terminal
Circuit failure FGT
+1-X1-114
24. CIRCUIT FAILURE CCT Alarm activates, and the burner stops.
Disconnect wire from A2
Cartrige AI0 Circuit failure CCT
25. CIRCUIT FAILURE SDP Alarm activates, and the burner stops.
TEMP
Disconnect wire from A2
Circuit failure SDP Temp
Cartrige AI1
9
Sludge tank with el. heater.
145

26. COMMUNICATION FAILURE Alarm activates, and the burner stops.
PLC-DISPLAY
Remove the communication Communication failure PLC-Display
cable between PLC and
display.
27. 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.
146
DRAWINGS
DRAWINGS
147
DRAWINGS
List of drawings
Incinerator
Dwg. No Name of drawing
1011242 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
1011015 Flue Gas Damper Assembly DN400/300
1006998 Flue Gas Damper, Sub. Assy DN400/300
1008644 Flue Gas Fan, Sub. Assy. DN 300 H2
4009251 Main dimensions Flue Gas Fan DN 300 H2
AS300-5 Expansion Compensator DN 300
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
3011031 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
14 8

Manual Og200c (S)

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OG200C(S)

Copyright © 2017 TeamTec AS. All rights reserved.

Version Date Purpose Written

Rev I 09.07.2019 Minor updates in tables and text. KHS

Addendums, corrections and notes

Code Feature description

Replacing the PLC power source in the control cabinet...........................................................................99

PART I: OPERATOR MANUAL

Service network for Teamtec incinerators.

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

: 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 daily and cleaned as

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

• In case of abnormal operation, contact TeamTec.

ACRONYMS AND TERMS

Technical description and main data

Overall system function description

Main data/Performance data: Incinerator (combustion chamber).

Type: OG200 C(S)

Capacity: 400.000/482.0001 Kcal/h (465/5602 kW)

Electrical power, rated From ship distribution

Flue gas fan El. power From incinerators

Negative pressure: 10-28mmWC In combustion chamber

Burner (fixed on combustion chamber)

Diesel Oil viscosity Max. 13 cSt at 40°C

Burner air blower: Max. 1,500 m3/h

Oil pump: Working press. 16 bar

El. Motor 1.4/1.45 Amp. 2730/3310 rpm.

Ignition transformers: 230V / 10,000V

Sludge dosage pump (fixed on combustion chamber)

El. Motor: 0,35kW IP55 900/1080 rpm

Control speed: 0 – 1200 rpm

Sludge filling pump (if dual sludge tank system)

Diesel oil preheater (fixed on combustion chamber)

Diesel oil booster pump (optional)

El.motor: See Burner motor

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

Electrical control panel incinerator (normally fixed on combustion

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

Operator panel (User terminal/display fixed to control panel), description

The function of the panel is:

• Selecting of burner mode, setting of all variables as temperature, time etc.

User functions are described in a later chapter.

Operator panel, main data

Battery/SD Card Ethernet

Orange Flashing Software starting up

- Off Power is turned OFF

Flue gas fan (bulkhead or deck mounted)

Main data/Performance data: Flue gas fan

Capacity: At 150mmWC total back

Flue gas duct

El.motor: 1460/1740 rpm

Weight: 326 kg See dimension drawing.

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