K1704 Manual

Instruction Manual
TeamTec Incinerator
OG400 CAIS
Yard : Hyundai Mipo
Hull No.: 2451

2452
2451
Ship name : N/B Hyundai Mipo Ulsan 2452
Serial / project No.: K1704
Date : 09.12.2013
OG200/400C
Copyright  2003 TeamTec AS. All rights reserved.

No part of this manual may be reproduced, transmitted, stored in a database or translated into
any language or in any form without explicit and written permission of TeamTec AS.
Version Date Purpose Written
Rev 0 04.02.2011 KK
Updated Hour counter, alarm list, test of control functions,

Rev A 31.03.2011 KK
test of safety and alarms.
Updated sludge displays, and added burn-in. Combined
Rev B 16.06.2011 KK
OG400C into this manual.
Added date to guarantee certificate, and updated SW,
Rev C 07.07.2011 KK
Sludge and Burn-in menu.
Rev D 28.11.2011 Corrected Motor in part list for sludge dosage pump. KK
Rev E 07.11.2012 Corrected Spare parts list KK
Rev F 05.12.2012 Steam/air supply for sludge and water was 20Kg/h KK
OG200/400C 3
OG200/400C
4 OG200/400C
ADDENDUMS, CORRECTIONS AND NOTES
Addendums, corrections and notes

This document describes, from a user point of view, how to operate and maintain the OG200/400C
incinerator. The incinerator type is OG200/400C, but some of the drawings might have additional letter
codes that describe the extra equipment on your incinerator.
All TeamTec incinerators are made according to EC Type-Examination Certificate MED-B, and are
found to comply with the requirements in the following regulations/standards:
Annex A.1, item NO. A1/2.7 and Annex B, Module B in the Directive. Marpol 73/78 as amended, Annex
VI Regulation 16(2)(a), IMO Res. MEPC.76 (40).
Generally, for a design or type approval certificate, it is allowed to make minor modifications to the
equipment. Minor modifications are changes that will not affect the incinerators function or design. The
incinerator type is still the same, and all main functions are identical to the type approved unit and will be
covered by the certificates. The type stamped on the incinerator is the same as we have on the certificate,
but some of the drawings might have letter codes to describe the extra equipment (minor modification) on
your incinerator. All possible letter codes are:
Code Feature description

A Ampere meter for flue gas fan
B Diesel oil booster pump
C Standard - Computerized automation/control (PLC)
D Dual sludge tank
F Auto feeding of solid waste (Stoker, Shredder)
G Stirrer for solid waste
I Water injection
K Cooling of control cabinet
L Sludge tank level readout in display panel
M Flue gas fan motor heater
P Sludge transfer pump
R Roof mounted sluice
S Sluice for solid waste
T Diesel oil transfer pump
W Incinerator for solid waste only
X Large single door opening
Z CCS - centr. Control station twin display
OG200/400C 5
ADDENDUMS, CORRECTIONS AND NOTES
6 OG200/400C
TABLE OF CONTENTS
Table of contents
ADDENDUMS, CORRECTIONS AND NOTES .................................................................................... 5
ACRONYMS AND TERMS .................................................................................................................... 13
THE INCINERATOR “10 COMMANDMENTS” ................................................................................ 15
GARBAGE MANAGEMENT ................................................................................................................. 17
INCINERATION OF SOLID AND LIQUID WASTE ............................................................................................... 17
SOLID AND LIQUID WASTE THAT IS PROHIBITED TO BE BURNED................................................................... 17
SOLID WASTE HANDLING ............................................................................................................................ 18
BATCH LOADING ......................................................................................................................................... 18
SLUICE FEEDING .......................................................................................................................................... 18
SLUDGE CAPACITY...................................................................................................................................... 18
INTRODUCTION .................................................................................................................................... 19
INSTRUCTION MANUAL, PURPOSE AND SCOPE.............................................................................................. 19
SERVICE NETWORK FOR TEAMTEC INCINERATORS. ..................................................................................... 19
MAIN DATA ............................................................................................................................................ 21
PERFORMANCE DATA .................................................................................................................................. 21
Incinerator (combustion chamber)......................................................................................................... 21
Burner (fixed on combustion chamber) .................................................................................................. 22
Diesel oil booster pump (optional) ........................................................................................................ 22
Flue gas fan (bulkhead mounted) ........................................................................................................... 23
Flue gas damper .................................................................................................................................... 23
Sludge tank ............................................................................................................................................. 24
Water tank (Optional) ............................................................................................................................ 24
Sludge circulating pump (installed on sludge tank) ............................................................................... 24
Sludge filling pump (if dual sludge tank system)(Optional) ................................................................... 24
Sludge transfer pump (optional on dual sludge tank system)(Optional) ................................................ 24
Sludge dosing pump (fixed on combustion chamber) ............................................................................. 24
Water dosage pump (Optional) .............................................................................................................. 25
Diesel oil preheater (fixed on combustion chamber) ............................................................................. 25
Electrical control panel incinerator (fixed on combustion chamber) .................................................... 26
Frequency inverter for flue gas fan (Optional) ...................................................................................... 26
SHIPS SYSTEM INTERFACE REQUIREMENT.................................................................................................... 27
Electrical ................................................................................................................................................ 27
Diesel oil ................................................................................................................................................ 27
Flue gas duct .......................................................................................................................................... 27
Sludge and Steam or Air ........................................................................................................................ 27
Water and Steam or Air (Optional) ........................................................................................................ 28
Sludge tank (1100L / 1700L / 2000L / 3000L option) ............................................................................ 28
Water tank (435 l) (Optional) ................................................................................................................ 28
TECHNICAL DESCRIPTION ............................................................................................................... 29
OVERALL SYSTEM FUNCTION DESCRIPTION ................................................................................................. 29
Water injection (Optional) ..................................................................................................................... 29
Combustion chamber ............................................................................................................................. 29
Flue gas fan............................................................................................................................................ 30
Sludge service tank with heater.............................................................................................................. 30
Sludge settling tank with heater (optional). ........................................................................................... 30
Water tank (Optional). ........................................................................................................................... 30
SLUDGE CONTROL ....................................................................................................................................... 31
Introduction............................................................................................................................................ 31
Temperature limits ................................................................................................................................. 31
Burner stage ........................................................................................................................................... 31
Control ................................................................................................................................................... 32
OPERATOR PANEL ............................................................................................................................... 33
OG200/400C 7
TABLE OF CONTENTS
General .................................................................................................................................................. 33

POP-up select program ......................................................................................................................... 35
Pop-up Start -Stop .................................................................................................................................. 35
Information pop-up ................................................................................................................................ 35
Burner .................................................................................................................................................... 36
Setting tanks ........................................................................................................................................... 36
Hour counters ........................................................................................................................................ 37
Setup....................................................................................................................................................... 37
Login ...................................................................................................................................................... 38
Wrong user pop-up................................................................................................................................. 38
Change values ........................................................................................................................................ 38
Settings burner ....................................................................................................................................... 39
Settings alarms ....................................................................................................................................... 40
Settings sludge (1/4) ............................................................................................................................... 41
Settings sludge (2/4) ............................................................................................................................... 42
Settings sludge (3/4) ............................................................................................................................... 43
Settings sludge (4/4) ............................................................................................................................... 44
Settings solid waste (1/2) ....................................................................................................................... 45
Settings solid waste (2/2) ....................................................................................................................... 46
Settings solid waste and sludge .............................................................................................................. 47
Settings sludge with water...................................................................................................................... 48
Settings loading/slagging and stop ........................................................................................................ 49
Burn-in ................................................................................................................................................... 50
Incinerator configuration ....................................................................................................................... 51
Backlight ................................................................................................................................................ 51
Time and date ......................................................................................................................................... 51
Program information ............................................................................................................................. 52
Consumption .......................................................................................................................................... 52
Consumption setup ................................................................................................................................. 52
Alarm system .......................................................................................................................................... 53
The alarm Screen ................................................................................................................................... 53
Alarm List............................................................................................................................................... 54
Setting list............................................................................................................................................... 56
Settings frequency inverter ALTIVAR 31 ............................................................................................... 59
PROGRAM DESCRIPTION .................................................................................................................. 63
OVERALL PROGRAM FUNCTION DESCRIPTION .............................................................................................. 63
General .................................................................................................................................................. 63
Flue Gas Fan ......................................................................................................................................... 64
Function Sludge program ...................................................................................................................... 64
Function Sludge program with water Injection ..................................................................................... 66
Function solid waste program ............................................................................................................... 67
Function Solid waste and sludge program ............................................................................................. 68
MAINTENANCE INSTRUCTION ........................................................................................................ 69
PREVENTIVE MAINTENANCE ........................................................................................................................ 69
Service hours: ........................................................................................................................................ 69
Daily....................................................................................................................................................... 69
Weekly (100 hours) ................................................................................................................................ 69
Monthly (400 hours)............................................................................................................................... 70
6 monthly (2500 hours or 182 days) ...................................................................................................... 70
Yearly (5000 hours or 365 days) ............................................................................................................ 70
INSPECTION ................................................................................................................................................. 71
Combustion chamber: ............................................................................................................................ 71
Diesel oil pump: ..................................................................................................................................... 71
Flue gas fan: .......................................................................................................................................... 71
Sludge dosage pump: ............................................................................................................................. 71
Water dosage pump: .............................................................................................................................. 71
8 OG200/400C
TABLE OF CONTENTS
CLEANING AND LUBRICATION ..................................................................................................................... 72

Ashes: ..................................................................................................................................................... 72
Photo resistor: ....................................................................................................................................... 72
Diesel oil burner: ................................................................................................................................... 72
Diesel oil pump: ..................................................................................................................................... 72
Flue gas fan: .......................................................................................................................................... 72
Door hinges: .......................................................................................................................................... 72
Sluice: .................................................................................................................................................... 72
Pusher: ................................................................................................................................................... 72
Sludge burner: ....................................................................................................................................... 72
Water injection: ..................................................................................................................................... 72
DISASSEMBLY, REPAIR, REPLACEMENT AND REASSEMBLY .......................................................................... 73
Flue gas fan............................................................................................................................................ 73
To replace the impeller: ...................................................................................................................................... 73
Disassembly................................................................................................................................................... 73
Repair ............................................................................................................................................................ 73
Replacement .................................................................................................................................................. 73
Reassembly .................................................................................................................................................... 73
To adjust the clearance between impeller and fan house ............................................................................... 73
Performance verification ............................................................................................................................... 73
Mounting of bearings with tapered bore ............................................................................................................. 74
SPARE PARTS ......................................................................................................................................... 75
RECOMMENDED MINIMUM SPARE PARTS ..................................................................................................... 75
ONE YEAR WEAR AND TEAR PARTS OG200/400C/CI, TG5 ......................................................................... 76
RECOMMENDED ONBOARD REPAIR PARTS ................................................................................................... 77
STORAGE AND INSTALLATION ....................................................................................................... 78
PREPARATION FOR SHIPMENT ...................................................................................................................... 78
STORING AT YARDS WAREHOUSE ............................................................................................................... 78
PRESERVATION FROM INSTALLATION TO START UP OF EQUIPMENT ............................................................. 78
PRESERVATION IN CASE OF LONG TIME STORING AFTER INSTALLATION ...................................................... 78
PRE-COMMISSIONING .................................................................................................................................. 79
Mechanical completion check list. ......................................................................................................... 79
Pre-check of live equipment. .................................................................................................................. 79
TEST OF FUNCTION AND SAFETY DEVICES ................................................................................................... 80
TEST OF CONTROL FUNCTIONS .................................................................................................................... 86
OPERATION INSTRUCTIONS............................................................................................................. 92
PRIOR TO START .......................................................................................................................................... 92
SLAGGING ................................................................................................................................................... 92
SOLID WASTE ............................................................................................................................................. 92
SLUDGE ....................................................................................................................................................... 92
SOLID WASTE SLUDGE ................................................................................................................................ 93
SLUDGE AND WATER .................................................................................................................................. 93
EMERGENCY STOP ....................................................................................................................................... 94
In the incinerator room. ......................................................................................................................... 94
Outside the incinerator room. ................................................................................................................ 94
When emergency stop is used, or at black out. ...................................................................................... 94
TROUBLE SHOOTING .......................................................................................................................... 96
APPENDIX A: PLC .............................................................................................................................. 100
GENERAL .................................................................................................................................................. 100
BASE UNIT ................................................................................................................................................ 101
INSTALLING A MEMORY MODULE ............................................................................................................. 102
REPLACING THE BATTERY ......................................................................................................................... 103
DIN RAIL MOUNTING ............................................................................................................................... 104
DIAGNOSTICS ............................................................................................................................................ 105
APPENDIX B: OPERATOR PANEL ................................................................................................. 108
OG200/400C 9
TABLE OF CONTENTS
GENERAL .................................................................................................................................................. 108

TECHNICAL DATA ...................................................................................................................................... 109
APPENDIX C: OIL BURNER ............................................................................................................. 110
SERVICING AND ADJUSTMENT ................................................................................................................... 110
............................................................................................................................................................. 110
............................................................................................................................................................. 110
Dismantling .......................................................................................................................................... 110
Cleaning and adjustment...................................................................................................................... 110
Re-assembly ......................................................................................................................................... 110
DIESEL OIL PRESSURE ADJUSTMENT .......................................................................................................... 110
AIR ADJUSTMENT ...................................................................................................................................... 111
DO NOZZLES ............................................................................................................................................. 111
Standard nozzle .................................................................................................................................... 111
Maintenance ......................................................................................................................................... 111
Capacities ............................................................................................................................................ 112
APPENDIX D: OIL PUMP .................................................................................................................. 114
APPLICATIONS ........................................................................................................................................... 114
PUMP OPERATING PRINCIPLE ..................................................................................................................... 114
Bleed .................................................................................................................................................... 114
Cut-off: ................................................................................................................................................. 114
TECHNICAL DATA ...................................................................................................................................... 115
General ................................................................................................................................................ 115
Hydraulic data ..................................................................................................................................... 115
PUMP DIMENSIONS .................................................................................................................................... 116
PIPE DIMENSIONS ...................................................................................................................................... 116
INSTALLATION .......................................................................................................................................... 116
START UP .................................................................................................................................................. 117
PRESSURE REGULATION ............................................................................................................................ 117
SYSTEMATIC MAINTENANCE ..................................................................................................................... 117
PARTS LIST ................................................................................................................................................ 118
APPENDIX E: FREQUENCY INVERTER ATV12 .......................................................................... 120
SPECIFICATION .......................................................................................................................................... 120
Teamtec H055M2 ................................................................................................................................. 120
TECHNICAL CHARACTERISTICS.................................................................................................................. 121
ACCESSING TERMINAL BLOCKS ................................................................................................................. 122
Power Terminals .................................................................................................................................. 122
Control Terminals ................................................................................................................................ 122
Programming ....................................................................................................................................... 124
TeamTec Control Settings .................................................................................................................... 126
FAULTS – CAUSES – REMEDIES ................................................................................................................. 131
Drive does no start, no fault displayed ................................................................................................ 131
APPENDIX F: FREQUENCY INVERTER ATV61 .......................................................................... 136
SPECIFICATION .......................................................................................................................................... 136
Teamtec WU75N4 ................................................................................................................................ 136
TECHNICAL CHARACTERISTICS.................................................................................................................. 137
Power cable ......................................................................................................................................... 138
Motor cable .......................................................................................................................................... 138
Power Terminals .................................................................................................................................. 139
Control Terminals ................................................................................................................................ 140
Programming: ...................................................................................................................................... 142
FAULTS CAUSES – REMEDIES .................................................................................................................... 146
Starter does not start, no fault displayed ............................................................................................. 146
 Wire break 4-20 mA control signal cable.................................................................................... 146
 Faults, witch cannot be reset automatically ................................................................................ 147
Faults, which can not be reset automatically (continued) ................................................................... 148
Faults that can be reset with the automatic restart function, after cause has disappeared ................. 149
10 OG200/400C
TABLE OF CONTENTS
Faults that can be reset with the automatic restart function, after the cause has disappeared
(continued) ........................................................................................................................................... 150
Faults that can be reset as soon as their cause disappears ................................................................. 151
APPENDIX G: SLUDGE BURNER .................................................................................................... 152
CLEANING OF SLUDGE BURNER ................................................................................................................. 152
PROCEDURE FOR ADJUSTING THE SLUDGE BURNER ................................................................................... 152
APPENDIX H: SLUDGE DOSAGE PUMP ....................................................................................... 154
DIMENSION ............................................................................................................................................... 154
DISMANTLING AND ASSEMBLY DIAGRAM, ................................................................................................. 155
Exploded view ...................................................................................................................................... 155
MOTOR FOR PUMP. .................................................................................................................................... 155
PARTS LIST ART. NO. 2007672 .......................................................................................................... 156
INSTALLATION .......................................................................................................................................... 157
Installation and Safety Recommendations ........................................................................................... 157
General ................................................................................................................................................ 157
STORAGE ................................................................................................................................................... 157
Short-term storage ............................................................................................................................... 157
Long-term storage ................................................................................................................................ 157
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING. ........................................................................... 157
ELECTRICAL .............................................................................................................................................. 158
IMPORTANT ............................................................................................................................................... 158
General safety ...................................................................................................................................... 158
Start-up procedure ............................................................................................................................... 158
DRYRUNNING ............................................................................................................................................ 158
Mechanical seals, all pumps. ............................................................................................................... 159
Guards ................................................................................................................................................. 159
Warning/control device ........................................................................................................................ 159
Pump operating temperature ............................................................................................................... 159
MAINTENANCE OF WEARING COMPONENTS ............................................................................................... 159
Rotor and stator ................................................................................................................................................ 159
DIAGNOSTIC CHART .................................................................................................................................. 160
APPENDIX I: SLUDGE VALVE. ....................................................................................................... 162
A 6324/1101/7003. 0-1 bar. G 3/4"...................................................................................................... 162
Valve .................................................................................................................................................... 163
APPENDIX J: SLUDGE CIRCULATION PUMP.............................................................................. 164
GENERAL INFORMATION ........................................................................................................................... 164
Noise level ............................................................................................................................................ 164
DRAWING .................................................................................................................................................. 165
PARTS LIST ................................................................................................................................................ 165
COMMISSIONING ....................................................................................................................................... 165
MAINTENANCE .......................................................................................................................................... 166
Maintenance instructions following a prolonged shutdown ................................................................ 166
Removing the pump .............................................................................................................................. 166
Dismantling and assembly instructions of the mechanical seal ........................................................... 167
Dismantling ...................................................................................................................................................... 167
Assembly .......................................................................................................................................................... 167
Fitting of stationary ring ................................................................................................................................... 168
APPENDIX K: WATER DOSAGE PUMP.......................................................................................... 170
DIMENSION ............................................................................................................................................... 170
DISMANTLING AND ASSEMBLY DIAGRAM, ................................................................................................. 171
MOTOR FOR PUMP. .................................................................................................................................... 171
PARTS LIST ART. NO. 2007740 .......................................................................................................... 172
INSTALLATION .......................................................................................................................................... 173
Installation and Safety Recommendations ........................................................................................... 173
General ................................................................................................................................................ 173
STORAGE ................................................................................................................................................... 173
OG200/400C 11
TABLE OF CONTENTS
Short-term storage ............................................................................................................................... 173

Long-term storage ................................................................................................................................ 173
IMMEDIATELY PRIOR TO INSTALLATION AND STARTING. ........................................................................... 173
ELECTRICAL .............................................................................................................................................. 174
IMPORTANT ............................................................................................................................................... 174
General safety ...................................................................................................................................... 174
Start-up procedure ............................................................................................................................... 174
DRY RUNNING ........................................................................................................................................... 174
Mechanical seals, all pumps. ............................................................................................................... 175
Guards ................................................................................................................................................. 175
Warning/control device ........................................................................................................................ 175
Pump operating temperature ............................................................................................................... 175
MAINTENANCE OF WEARING COMPONENTS ............................................................................................... 175
Rotor and stator ................................................................................................................................................ 175
DIAGNOSTIC CHART .................................................................................................................................. 176
12 OG200/400C
ACRONYMS AND TERMS
ACRONYMS AND TERMS

Acronym / term Description
ACK Acknowledge
CCP Combustion chamber pressure
CCT Combustion chamber temperature
D.O. Diesel Oil
DEC Decrease
EMC Electro Magnetic Compatibility
ESC Escape
FGF Flue gas fan
FGT Flue gas temperature
HMI Human machine interface
HYS Hysteresis
INC Increase
LCD Liquid crystal display
LED Light emitting diode
MAX Maximum
MIN Minimum
PID A proportional–integral–derivative controller
PLC Programmable logic controller
PREV Previous
RPM Revolutions per minute
SAF Secondary air fan
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
WDP Water Dosage Pump
Acronym / term Definition

The difference noted in a sensor's output as a response to an increasing or
Hysteresis
decreasing input signal of the same value
OG200/400C 13
ACRONYMS AND TERMS
14 OG200/400C
THE INCINERATOR “ 10 COMMANDMENTS”
The incinerator “10 commandments”
 Keep the incinerator chamber inlet outlet and burner parts clean. Inspect daily before start
in the morning, and clean as required.
 Do never throttle the air/steam needle valve more than ¾ turn closed. If the pressure
increases above green area, clean the sludge burner nozzle.
 Do never turn off the main power before the chamber temperature is down below 170°C.
 If experiencing any problem with high temperature in combustion chamber, flue gas or
control of sludge dosing, replace the dosing pump stator.
 Do not transfer sludge to the service tank during sludge burning in a single tank system
(can damage the refractory).
 As a minimum, heat the sludge over night, without starting the circulating pump. Next
morning drain off the free water and start the sludge program.
 Never load glass, lithium batteries or large quantities of spray cans in the incinerator –
nor large quantities of oily rags or filter cartridges. This may damage the flue gas fan.
 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 unless instructed by
TeamTec, Norway
 In case of abnormal operation, contact TeamTec
OG200/400C 15
THE INCINERATOR “ 10 COMMANDMENTS”
16 OG200/400C
GARBAGE MANAGEMENT
Garbage management
TeamTec recommend working out guidelines for an onboard garbage management plan.
Personnel responsible for operation of the incinerator shall be trained and capable of
implementing the guidance follows by the instruction manual.
Waste incineration on board sea going ships and offshore platforms is world wide regulated by
IMO MARPOL 73/78, RESOLUTION MEPC 76(40), STANDARD SPECIFICATION FOR
SHIPBOARD INCINERATORS, adopted on 25.september 1997, and IMO MARPOL ANNEX
VI REGULATION 16 and APPENDIX IV adopted on 26. September 1997.
Incineration of solid and liquid waste

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

Rubber, Cloth, Oily Rags, Lub. Oil Filters,
Diesel Engine Scavenge Scraping
Paint Scraping
Food waste, etc.
Sludge Oil, Waste Lub. Oil
Hospital Waste, Female Hygienic Binds
Destruction of Contaminated water
Solid and liquid waste that is prohibited to be burned

Material, which contains more than traces of HEAVY METAL and of refined petroleum
products containing halogen compounds is prohibited to be incinerated. Light bulbs contain
heavy metal and are prohibiting incinerating.
Under shipboard operational waste the following materials have a density placing them in the
category of HEAVY METAL:
MERCURY
LEAD
NICKEL
VANADIUM
ZINC
IMO Annex VI regulation 16 prohibits incineration on ship of certain products, such as

contaminated packaging materials and polychlorinated biphenyls (PCBs).
Do not incinerate metals as soda and food can plates, flatware, serving spoons/tray,
hardware (nuts & bolts), structural pieces, wire rope, chains etc, glass such as bottles, jars,
drinking glasses etc., flammable materials such as bottles or cans containing flammable
liquids or gasses and aerosol cans. Do not incinerate heavy load with plastics or bulk food
waste. Read instruction/warning label on garbage door.
Loading of glass will result in a rock hard slag, which is difficult to remove from the refractory
lining.
OG200/400C 17
GARBAGE MANAGEMENT
Solid Waste handling

OG200/400C is intended for incineration/burning of sludge and solid waste onboard ships or
other marine installations. For batch loading the incinerator capacity is 400l/charge IMO class 2
wastes.
Class 2 refuse, consists of approximately even mixture of rubbish and garbage by weight. This
type of waste is common to passenger ships occupancy, consisting of up to 50% moisture, 7%
incombustible solids and has a heating value of about 10.000 kJ/kg as fired.
Be aware that plastics has high calorific value, about 36.000 kJ/kg and must only be incinerated
in small amounts at the same time.
Batch loading
Do not attempt to clean the combustion chamber without activating the slagging mode on the
touch screen display, to prevent injury to personnel due to insufficient ventilation.
Each morning, providing that the combustion chamber temperature is lower that 170°C, slag
and ashes should be removed. Partly burnt garbage shall remain in the chamber. This garbage
will be fully incinerated at the next sequence of incineration. The air inlet openings in the
bottom of the combustion chamber must be regularly cleaned. This is important in order to let
the combustion air come into the chamber.
Load the combustion chamber with garbage of type IMO class 2. If high calorific garbage is
loaded, a smaller quantity must be loaded per charge.
Sluice feeding
If sluice is installed, solid waste can be fed into the 55 litre sluice at temperatures between
700°C and 1050°. Fill the trash in a garbage paper bag, open the sluice lid/sluice door and put
the bag into the sluice. Do not jam the trash bag into the sluice or overfill it. Close the lid /
sluice door and rotate the sluice by the handle on the sluice. The recommended waiting time
between each time the sluice can be operated is 210 seconds. After the waiting time has elapsed,
the sluice is ready for a new load.
Sludge Capacity
The incinerator is certified according to MEPC 76(40) which determines the sludge to contain
20% water.
A high water content up to 50% water content will result in a higher capacity than what is
mentioned in the certificate. As an example, the sludge with 40% water content will have lower
calorific value than IMO sludge, hence higher hydraulic capacity.
A water content higher than 50% requires a pilot burner (support burner). This reduces the
available capacity for burning of sludge
.
18 OG200/400C
INTRODUCTION
Introduction
Instruction manual, purpose and scope
This user manual is made according to guidelines in the Norwegian Standard NS 5820
The manual will guide the reader/user gradually to an understanding required for safe operation
and maintenance of the incinerator system.
It is important for the user to have a good understanding of the incinerator function, to avoid
malfunction caused by operational errors.
The guarantee will be invalid if problems and/or caused by operational errors or mistreatment.
Service network for TeamTec incinerators.

Please note that our office is the single point of contact for your service, spares and
upgrading requirements:
TeamTec AS
Nyvei 41
P.O.Box 203
4902 Tvedestrand
Norway
Tel.: +(47) 37 19 98 00
Telefax: +(47) 37 19 98 90
E-mail: office@teamtec.no
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
OG200/400C 19
INTRODUCTION
20 OG200/400C
MAIN DATA
Main data
Performance data
Incinerator (combustion chamber).
Type: OG200 C(S)
400.000 Kcal/h (465KW)

Capacity:
541.900 Kcal/h (630KW) with water injection
70 l/h IMO sludge oil (w. water injection) IMO sludge (20% water)
127 l/h Water consumption (w. water injection) From Bilge water tank
Corresponding to: 53 l/h IMO sludge oil (without water injection) IMO sludge (20% water)
Solid waste max. 400 litre per charge or 55 IMO class 02 waste
l/charge continuous feeding
Type: OG400 C(S)
512.000 Kcal/h (596KW)

Capacity:
625.300 Kcal/h (727KW) with water injection
81 l/h IMO sludge oil (w. water injection) IMO sludge (20% water)
140 l/h Water consumption (w. water injection) From Bilge water tank
Corresponding to: 74 l/h IMO sludge oil (without water injection) IMO sludge (20% water)
Solid waste max. 400 litre per charge or 55 IMO class 02 waste
l/charge continuous feeding
Combustion chamber Max. 1200 °C

temperature: Working. 870-1150 °C
Flue gas Max. 350°C
temperature:
Working. 250 - 340 °C
Surface temperature: 15°C above ambient temperature.
Electrical power, From ship distribution

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

7,5/8,6 kW
power consumption. electrical control panel
Negative pressure: 10-28 mmWC In combustion chamber
Total weight: 3210kg
Outline dimension: 1697 x 1900 x 1960 (L x W x H) See dimension drawing
OG200/400C 21
MAIN DATA
Burner (fixed on combustion chamber)
Two nozzles: 2.5 gph

Capacity: 18-28 l/h
60° and 4.5 gph 45°
Diesel Oil viscosity Max. 13 cSt at 40°C
Burner air blower

Max. 1,500 m2/h
each:
Working press. 16 bar

Oil pump:
Max 21 bar.
El. Motor 1.43/1.38 Amp.

2800/3400 rpm.
Rated current: 380/440 V 50/60 Hz, 0.55/0.63kW
Ignition transformers: 230V / 10,000V
Weight (each): 30 kg
Outline dimension: 845 x 539 x 387 (L x W x H) See dimension drawing.
Diesel oil booster pump (optional)
Capacity: 110 l/h At 14 bar.
El.motor: See Burner motor
Connections: 1/4"
Weight: 12 kg.
Outline dimension: 422x170x200(L x W x H) See dimension drawings.
22 OG200/400C
MAIN DATA
Flue gas fan (bulkhead mounted)
OG200C: DN 300 H2
Designed to withstand
Type: OG400C: DN 350 H2 max temperature of
450°C
One stage centrifugal fan.
OG200C: 8000 m³/h at 300°C At 150 mmWC total back

Capacity:
OG400C: 9500 m³/h at 300°C pressure.
Flue gas duct

DN 400/400
dimensions
El. motor: 380/440V, 7.5/8.6W

1465/1768 rpm variable
Current rating 17.2/15.8A
Weight: 326 kg
Outline dimension: 1020 x 1040 x 1030 (L x W x H) See dimension drawing.
Control speed: 0-1800 rpm
Flue gas damper
Type: Welded steel damper with actuator
OG 200C: DN 300/400
Size:
OG 400C: DN 350/400
Drive force 20Nm

Actuator motor: GBB 131.1E 24V 5VA Travel time for 90° is
150sec 50Hz.
Weight: 68/71 kg
Dimension between
300 mm See dimension drawing.
flanges:
OG200/400C 23
MAIN DATA
Sludge tank
Volume: Net: 1,100/1,700 or 2,000/3,000 litres.
Cylindrical tanks 1 bar

Test pressure:
Rectangular tanks 0.2 bar
Internal coated with one layer of

Corrosion Protection:
Carboline E-19primer, thickness 40 microns
Flange rating: NP 16
Weight: 490 / 566 or 605/750 kg.
Outline dimension: (L x W x H) See dimension drawing.
Water tank (Optional)
Volume: Net: 435 litres.
Test pressure: Rectangular tanks 0.2 bar
External coated with one layer of Carboline E-19

primer, thickness 70-80 μ.
one top coat Carboline Carboxane 2000,
Colour: RAL 6019 (light green)
Corrosion Protection:
dry film thickness: 70 - 100 μ.
Internal coated with one layer of Carbozinc 858
primer, thickness :40 μ
top layer: Carbomastic 18 FC, thickness: 175 μ
Flange rating: NP 16
Weight: 424 Kg
Outline dimension: (826 x 1026x 2188) See dimension drawing.
Sludge circulating pump (installed on sludge tank)
Type; TeamTec sludge circ. pump
Capacity: 6 m3/h at 1.9 bar discharge pressure.
El. motor: 4.8/4.7 Amp

2880/3480 rpm
Current rating 380/440 V, 50/60 Hz, 2.2/2.55 kW,
24 OG200/400C
MAIN DATA
Sludge filling pump (if dual sludge tank system)(Optional)
Type; See sludge circulating pump
Sludge transfer pump (optional on dual sludge tank system)(Optional)
Type; See sludge circulating pump
Sludge dosing pump (fixed on combustion chamber)
Type: TeamTec RDCZ 432 screw pump
El. Motor: 0,37kW IP55

885 rpm
Current rating 1,9A 220V 50Hz
Control speed: 0 – 1200 rpm
Water dosage pump (Optional)
Type: TeamTec RDCZ 432 screw pump
El. Motor: 0,55kW IP55

1380 rpm
Current rating 1.6A 380V 50Hz
Control speed: 0 – 1000 rpm
Diesel oil preheater (fixed on combustion chamber)
380/440V, 50/60Hz, 1.5/2.0 kW

Rating:
2.3/2.6 Amp
OG200/400C 25
MAIN DATA
Electrical control panel incinerator (fixed on combustion chamber)
A Sarel panel of protected steel.

Type: 800x600x300mm
Enclosure rating IP 55
Weight: 56 kg
Frequency inverter for flue gas fan (Optional)
Enclosure rating IP 54
Weight: 22 kg.
Outline dimension 286 x 255 x 525 (L x W X H) See dimension drawing
26 OG200/400C
MAIN DATA
Ships system interface requirement.
Electrical
Refer to Cable Arrangement drawing.
Diesel oil
Equipped with a closing valve Connection.

DN 15 flange, max
Diesel oil supply line Recommended filter mesh 40µm
pressure 1.5 bar
Max. suction lift 3500mm
DN 15 flange, max
Diesel oil return line Connection.
pressure 1.5 bar
Flue gas duct
Incinerator flue gas

Duct DN 400
damper
Flue gas damper to OG200C: DN 300

Duct
flue gas fan OG400C: DN 350
Flue gas fan to open OG200C: DN 300

Duct
air. OG400C: DN 350
Sludge and Steam or Air
Connection DN 15 flange
Steam /air supply line Pressure 6 - 8 bar

for burner atomising. Consumption: Steam approx. 20kg/h
Compressed air approx. 20kg/h
Drain from spill

Connection DN 25
collector.
OG200/400C 27
MAIN DATA
Water and Steam or Air (Optional)
Steam /air supply line Pressure 6 - 8 bar
for water injection
atomising. Consumption: Steam approx. 20kg/h
Compressed air approx. 20kg/h
Drain from spill

Connection DN 25
collector.
Sludge tank (1100L / 1700L / 2000L / 3000L option)
Filling Connection DN 50 flange

Overflow line Connection DN 65 flange
Supply and return Connections DN 25 flange
line for incinerator
Air vent. Connection DN 65 flange
Drain. Connection DN 32 flange
Sample points. Connections 3/8" BSP
Connection 1/2" BSP

Heating: Steam Consumption approx. 50kg/h
Max. pressure 10 bar
Consumption 2 m³/h
Heating: Thermal oil
Max. pressure 10 bar
Max. temperature 180°C
Water tank (435 l) (Optional)
Filling Connection DN 32 flange

Overflow line Connection DN 40 flange
Supply line for Connection DN 15 flange
incinerator
Air vent. Connection DN 50 flange
Drain Connection DN 50 flange
Detailed information regarding the system is found on the Piping & Instrument Diagram given in the
Drawings section.
28 OG200/400C
TECHNICAL DESCRIPTION
Technical description
Overall system function description
The TeamTec Incinerator type OG200/400C is designed for on board incineration of ship's waste oil, solid
refuse and destruction of bilge water. The system consists of 5 main parts:
 Combustion chamber with diesel oil burner, sludge burner, pilot fuel heater and electric control panel.
 Flue gas fan with flue gas damper or frequency inverter (Optional).
 Sludge service tank with circulating pump and heater.
 Sludge settling tank with filling pump and heater (Optional).
 Water injection (Optional).
Water injection (Optional)

The incinerator is equipped with a separate water injection unit including a frequency controlled water dosage
pump. The purpose of this pump is to inject water, containing small quantities of oil remnants, into the
combustion chamber by a special designed TeamTec nozzle system.
When burning sludge with injected water, the sludge burning capacity increases, NOx in flue gas duct reduces
and it is an easy way to get rid of problem water. Dumping oily water directly into the sea can harm marine
life, and is illegal. Various ports are facing new local regulations on ship emissions, including discharges of
ballast water, grey water, bilge water, and deck runoff, among others. Disposal of the contaminated water in the
incinerator is an easy and effective solution to a complex problem.
Combustion chamber
The combustion chamber consists of a cylindrical chamber. The trash is ignited by burner in the chamber. The
combustion chamber is equipped with an inspection, which can be opened only while the incinerator is not
burning. The control system will prevent the door from being opened before the set temperature for cooling is
reached.
The flue gas outlet is located at the top of the left chamber for most efficient use of the flames. The flames
from the burners follow a corkscrew pattern towards the bottom and continue rotation upwards in the centre of
the combustion chamber. Remnants of particulate matters in the gas flow are neutralised by the burner, making
the combustion ecologically safe. As the fumes exits the chamber, cooling air drawn from the lower part of the
casing is mixed with the flue gas to bring the temperature down to approx. 330°C before it pulled out by the
flue gas fan and blown out the stack to atmosphere.
The burning process is monitored by the PLC and scanned by a photo resistor in the burner. The temperatures
are also monitored/regulated automatically by the PLC control system.
Two sight glasses are equipped, for the operator to be able to inspect the amount of trash in the chamber and
the function of the system.
The combustion chamber is of steel construction, lined with specially designed refractory blocks. Between the
steel and refraction there is a 50mm layer of insulation. The refractory material is made of a low cement/high
alumina quality being slag resistant and having very good thermal shock resistance. A double steel casing with
a cooling air jacket forms the outside of the combustion chamber.
The combustion chamber is equipped with a, three-stage diesel oil burner and a steam/air atomising nozzle for
sludge burning. Under the burner assembly, a bracket/drip tray for sludge burning equipment is mounted.
The Diesel Oil burner has 3 stages, automatically controlled by the PLC. In addition there are four stages for
sludge burning, using steam or compressed air for atomising. The sludge burner allows particles up to 4 mm to
pass through. The D.O. burner is monitored by the PLC and has a built in primary air fan and diesel oil pump.
The main electrical control panel is normally fitted on the incinerator and it contains circuit breakers, starters,
frequency inverters, PLC and operator panel. A separate frequency inverter for flue gas fan control is optional,
and are to be installed close to the fan. 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.
OG200/400C 29
Flue gas fan

The purpose of the flue gas fan is transportation of the flue gas from the combustion chamber and the fan
creates negative pressure in the furnace. The same fan draws ambient air through the cooling jacket on the
combustion chamber and the hot gas from the furnace is diluted with the cooling air at the flue gas outlet on the
combustion chamber in order to reduce the temperature 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
Sludge service tank with heater

The TeamTec Sludge tank is meant to function as a daily service tank for sludge to the incinerator. A heater,
controlled by a thermostat, will keep the sludge temperature around the set point (80 to 90°C). (With
temperatures above 60°C, regulations require tank to be insulated or guarded with metal screen).
Drain valves (sample points) are mounted on the tank to check the sludge level in the tank. A level transmitter
on the tank provides PLC to generate a animated tank level readout on operator panel (display on incinerator
control panel), and right amount of sludge burned.
A circulating pump is mounted on the tank. The pump transports the sludge to the incinerator and a return line
to the tank is provided, a god mixing of the sludge and water is guaranteed. A low level switch on the tank will
stop the incinerator, the circulating pump and heating when the level has reached a minimum. An indicating
light for heating is placed on the junction box on the tank.
Do not transfer sludge to the service tank during sludge burning
Sludge settling tank with heater (optional).

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

As an option to use the ships bilge/grey water tank, it is possible use a water service tank. The Water tank can
be filled from either the bilge holding tank or the grey water tank. This system is utilizing the existing water
discharge pumping system in order to fill a water tank to be located adjacent to the incinerator.
The water tank has filling, overflow and ventilation connection. The incinerator has frequency controlled water
dosing pump unit, with suction lift at 3500mm. The water is connected to the incinerator with DN 15 flange
connection.
The water tank has two level switches. A high level switch to stop the filling pump and a low level switch, with
dual contact set, to start the filling pump and to stop the water injection if switch is activated for more than two
minutes. This is to prevent the water dosage pump to run dry. A suitable tank is available from TeamTec.
30 OG200/400C
Sludge control
Introduction
The automatic sludge control logic is designed for burning a maximum amount of sludge, consuming a
minimum amount of diesel, and maintaining a combustion chamber temperature above 870°C (CCT stop
burner diesel oil), see operator panel - settings sludge program page 2/4. Sludge quality is an important factor
for the sludge burning process. The system is capable to handling sludge with a high content of water, but this
might however result in a higher consumption of diesel oil.
Temperature limits
680°C Start sludge burner.
640°C Temperature decrease to this level stop sludge burner and increase sludge quality
counter with 2.
660°C Temperature decrease to this level, after temperature have been above 690°C,
decrease the sludge dosage pump rpm with 50 and increase sludge quality counter
with 2.
690°C Temperature increase to this level increase the sludge dosage pump rpm with 70.
700°C Alarm level for low combustion chamber temperature, if combustion chamber
temperature has been above 850°C.
840°C Starts a diesel support burner in addition to the condition at 870°C and increase the
sludge quality counter with 2. Decrease the sludge dosage pump rpm with 140.
870°C Temperature allowing burning sludge alone. Temperature increase to this level the
increase the sludge dosage pump rpm with 140.
890°C Above this temperature the sludge quality counter will step down one every minute.
900°C Sluice is available in Sludge/Solid waste program.
1000°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 every 30 second if Sludge/Solid waste program is running.
1050°C Water injection starts.
1150°C Temperature increase to this level and above, decrease the sludge dosage pump rpm
with 4 every 30 second. Water injection control temperature. Water amount injected
to combustion chamber will increase if CCT is above this level, and decrease if CCT
below this level.
Burner stage
 STAGE NO 3 Diesel oil nozzles no. 1 + 2.
 STAGE NO 4 Diesel oil nozzle no. 1 and sludge.
 STAGE NO 5 Diesel oil nozzle no. 2 and sludge.
 STAGE NO 6 Diesel oil nozzles no 1 + 2 and sludge
 STAGE NO 7 Sludge burner alone.
OG200/400C 31
Control
At first start up a sludge burner program, the sludge burner start when combustion chamber temperature rise
above 680°C, the operator panel will indicate burner stage 5, the sludge dosage pump will be given start speed
190 rpm, and will run at this speed for 60 seconds. During the 60 seconds, burner step 5 will be fixed.
Figure: Sludge quality control.
Assuming the sludge is of a good quality the temperature will start to rise. If the temperature raise is >=0°C
over 30 seconds, the sludge dosing pump increase 2 rpm. There will be a sampling of temperature each 30 sec.
and provided there is a temperature raise, a new step of 2 rpm will take place.
If the sludge quality is still good, the sludge dosing pump will be given a new step increase of 70 rpm when
temperature rises above 690°C. The burner stage will be 4. When temperature raise above 870°C the sludge
dosing pump will again be given a new step increase 60 rpm and the burner stage will be 7.
If the sludge contain too much water or chemicals, the temperature is likely to fall below 640°C and the sludge
dosing pump stop. Burner will change to stage 3, and the sludge quality counter will increase with 2 (after an
attempt to stage 5). When temperature rises above 680°C the sludge burner will start again. The burner stage
will then depend of sludge quality number. The sludge quality number is an indication of the quality of the
sludge. A high sludge quality number indicates a sludge with high water content, and burner will use more
diesel oil.
The low temperature alarm, 700°C, will first be activated if temperature has been above 870°C.
32 OG200/400C
OPERATOR PANEL
Operator Panel
General
The operator panel is a touch sensitive screen enabling the operator to enter information to the incinerator
control system. The screen is also displaying information from the control system to the operator. The panel is
connected to A PLC, controlling the combustion process. A description of the screens follows. The main
picture is displayed at start up and is possible to access by pressing “main” from most other screens. The screen
will display equipment according to scope of delivery from TeamTec AS
The Main picture has animated feedback to
the operator. The pumps and fans turn green 1
when running. The level switches are 2
animated up or down according to the level.
A level indication is animated at the sludge 3
tanks. There are written numbers displaying
4
actual measured values positioned
approximately according to physical
position at the incinerator. In addition to the
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
11
12
1: Press in the middle of burner to access screen “Burner”

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.
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 (2 pcs).
10: Press “Slag” button to start loading / slagging program.
11: Press “Setup” button to access screen “Setup” for selection of specific setup screen.
12: Press “Start” button to access pop-up for start / change program.
(The appearance of the screen may differ based on the choice of optional equipment)
OG200/400C 33
OPERATOR PANEL
Structure
Logic control system consists of an “Overview” screen and several sub-screens in the order as described below:
Main
Burner Hour counters
Settings tanks Consumption Setup consum.
Start/stop pumps Water tank

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

Tanks
Login
Restore
Factory
Burn-in Settings
Display backlight
Date time
Prog. info
Consumption Setup consum.
Water tank
Hour
General: From all screens it is possible to stop the incinerator by pressing “Stop” It is also possible to access
“Main”, Setup” and “Alarm from all screens.
34 OG200/400C
OPERATOR PANEL
POP-up select program

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

To start and stop equipment press the actual
icon on the main screen and a pop-up window
will allow you to start or stop pumps and
heaters. The following figure shows an
example for heating service tank. The pop-
up’s will close after selection of “Start” or
“Stop”. Select “Cancel” to close pop-up if you
don’t want to change status of the equipment.
Start – stop heating sludge service tank:

Low level switch in sludge service tank must
be activated.
Start – stop heating sludge settling tank:
Low level switch in sludge settling tank must
be activated.
Start – stop sludge filling pump: Low level
switch in sludge settling tank must be
activated and high level in sludge service tank can not be activated. Sludge burning program must not be
activated.
Start – stop sludge circulation pump: Low level switch in sludge service tank must be activated. If a program
burning sludge is activated it is not possible to stop the pump by this control. In that case choose a program not
burning sludge or stop the incinerator
Start – stop sludge transfer pump: High level switch in sludge settling tank must not be activated.
Information pop-up
An information pop-up gives information to
the user about irregularities between user
actions and incinerator status. Read the
message and press “Ack”.
The following messages may appear as
information messages:
 High temperature sludge settling tank
 Not possible to start heater low level

in sludge settling tank
 Not possible to start sludge transfer

pump high level in sludge settling
tank
 Not possible to start sludge filling pump low level in sludge settling tank
 Not possible to start sludge filling pump high level in sludge service tank
 Not possible to start sludge filling pump when sludge program is running
OG200/400C 35
OPERATOR PANEL
 Not possible to start sludge circulation pump low level in sludge service tank
 Not possible to start heater low level in sludge service tank
 Not possible to start sludge program - low level sludge service tank
 Not possible to start sludge with water 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
 High temperature water tank
 Sludge dosage pump is worn out – stator must be replaced
 Low level water tank – check water tank
 Sludge service tank level decreases too fast – Stop draining
 Low level sludge service tank – cooling
 Heating of refractory is finished. Let the incinerator cool down for 10 Hours1
Burner
Display actual values and status on motors,
actuators and sensors. No adjustments or
settings on this screen – view only.
Setting tanks
Displays tanks physical attributes and sludge
mass for correct sludge consumption.
1
Program revision A or later
36 OG200/400C
OPERATOR PANEL
Hour counters
Display last run and total hours. Press “Next”
button to access screen “Hour counters 2”
Setup
Some functions require the operator to login in
order to access a screen or to alter a value in
the setup. This normally indicates that the
operator needs training in order to be aware of
the consequences of his actions.
Select the setup screen you want to access. If
not logged in as user “usr”, values on different
setup screens are “view only”.
OG200/400C 37
OPERATOR PANEL
Login
Pressing “Setup” will give access to “Login”.
Wrong user pop-up

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

alphanumeric keyboard will pop-up:
Press “User” button and type in user name usr
and press “return” to accept user name. Press
“Password” button and type in password 2468 and press return to accept password.
Press return to close Login pop-up. The user is now logged in as user “usr” and is allowed to change settings.
Settings will automatically change back to factory settings every 15 minutes, regardless if logged in as usr.
Change values
Plot the value that should be changed. A numeric pop-up will appear:
The present value is displayed on the line. Type in a new value and press return to
accept, or press “ESC” to cancel.
38 OG200/400C
OPERATOR PANEL
Settings burner
If not logged in as user “usr”, values on
different setup screens are “view only”.
Buttons “Prev.” and “Next” is used in a
circular shift function between a number of
setting screens.
Text Description
Burner damper opening. Adjusts the amount of air supplied to the

Burner damper burner step x
combustion process by the burner motor fan.
Correction of burner damper opening related to combustion

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

Factor SDP burner damper reg.
pump (SDP) speed. Used internally by the control system.
OG200/400C 39
OPERATOR PANEL
Settings alarms
Text Description
Alarm max time dieselheater The maximum time the dieselheater is activated the first time after
start start incinerator. The dieselheater requires extra time at start-up.
Alarm max time dieselheater The maximum time the dieselheater is activated during
run incinerating.
Alarm max. CCT Maximum combustion chamber temperature (CCT).
Minimum combustion chamber temperature (CCT). Used as

Min. operating CCT
reference to “Alarm CCT below min. oper.”
Maximum temperature drop combustion chamber temperature

Alarm CCT below min. oper.
(CCT). Related to “Min. operating CCT”.
Alarm max. FGT Maximum flue gas temperature (FGT).
Alarm min. CCP (Draught

Minimum combustion chamber pressure (CCP).
failure)
40 OG200/400C
OPERATOR PANEL
Settings sludge (1/4)

circular shift function between a number
of setting screens.
Text Description
Set burning time2 Set total burning time for sludge program
Yes - if sludge burning without diesel oil support burner is allowed

Sludge alone3
No - if sludge burning with diesel oil support burner is required
Setpoint combustion chamber pressure (CCP) when starting a

CCP start sludge
sludge program
Maximum combustion chamber pressure (CCP). Used internally as

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

Min. CCP run sludge
a limit in the control system
Minimum sludge temperature before starting sludge program. This

Min. sludge temp run sludge value is also calculating alarm sludge temperature. See alarm
settings.
The maximum temperature drop in sludge temperature. Related to

Alarm sludge temp. low
“Min sludge temp run sludge”.
The maximum temperature increase in sludge temperature. Related

Alarm sludge temp. high
to “Min sludge temp run sludge”.
Minimum combustion chamber temperature (CCT) before starting

Min. CCT run sludge
sludge.
CCT low hysteresis – stop Maximum drop combustion chamber temperature (CCT) – stop
sludge. sludge dosage system.
2
Can be changed by user
3
OG200/400C 41
OPERATOR PANEL

setting screens.
Text Description
Time after start sludge dosage pump (SDP) before making

Time start sludge before adjust
adjustments – to ensure a stable process before adjusting sludge.
Time between reading combustion chamber temperature (CCT) and

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

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

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

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

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

Maximum CCT
reducing sludge.
Hys max. CCT – stop dec Maximum drop combustion chamber temperature (CCT) before
sludge stop reducing sludge.
Set point for Combustion Chamber Pressure (CCP) is -12mmWC

Set CCP running Step 4 & 5 during burner stage 4 & 5 as long as the Combustion Chamber
Temperature is below 800°C
Set min CCP for Minimum set point for Combustion Chamber Pressure (CCP) as
temp.regulating long as the Combustion Chamber Temperature is above 800°C
42 OG200/400C
OPERATOR PANEL

setting screens.
Text Description
Maximum flue gas temperature (FGT) before decreasing

Max. FGT – start adjust CCP
combustion chamber pressure (CCP)
Hys max. FGT – stop adjust Maximum drop flue gas temperature (FGT) before stop decreasing
CCP combustion chamber pressure (CCP)
Time between check flue gas temperature (FGT) before making

Time check FGT adjust CCP
further increase in combustion chamber pressure (CCP)
Maximum flue gas temperature(FGT), increase combustion

FGT max. inc. CCP
chamber pressure(CCP).
Max. FGT – start adjust SDP Maximum flue gas temperature (FGT) decrease sludge dosage
RPM pump (SDP) RPM.
Hys FGT – stop adjust SDP Minimum drop flue gas temperature (FGT) before stop decreasing
RPM sludge dosage pump (SDP) RPM.
Min. CCT scale CCP run Minimum combustion chamber temperature (CCT) in scaling
sludge range for adjusting combustion chamber pressure (CCP)
Max. CCT scale CCP run Maximum combustion chamber temperature (CCT) in scaling
sludge range for adjusting combustion chamber pressure (CCP)
Combustion chamber pressure (CCP) when burning both diesel

CCP running burnerstep 6
nozzles and sludge nozzle.
SDP comp. decrease diesel oil Increasing sludge when changing burner step from 5 to 4, or 6 to 5.
SDP comp. stop diesel oil Increasing sludge when changing burner step from 4 to 7.
OG200/400C 43
OPERATOR PANEL

setting screens.
Text Description
Decreasing SDP RPM every 30 second if combustion temperature

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

SDP RPM increase
CCT increases or equal.
Min. RPM SDP Minimum allowed speed sludge dosage pump.
Max. RPM SDP Maximum allowed speed sludge dosage pump.
Manual setpoint SDP RPM Adjust sludge dosage pump manually.
Sludge quality counter Sludge quality counter number.
Purging start sludge Time for purging sludge nozzle before opening sludge.
Purging stop sludge – CCT Minimum combustion chamber temperature (CCT) for stop
below purging sludge nozzle.
Setpoint heat tracing Setpoint for heat tracing temperature on sludge line.
Hystersis heat tracing Hysteresis for setpoint, heat tracing temperature on sludge line.
Alarm low level Sludge service Activate if alarm is needed when sludge service tank low level
tank switch is activated.
44 OG200/400C
OPERATOR PANEL
Settings solid waste (1/2)

setting screens.
Text Description
Set burning time4 On, makes it possible to program a fixed burning time
CCP start-up solid waste Minimum combustion chamber pressure (CCP) before start burner
program at start solid waste program
Maximum combustion chamber pressure (CCP) when running

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

CCP min. solid waste program
waste
Max combustion chamber temperature (CCT), decrease burner

Maximum CCT
stage
4
OG200/400C 45
OPERATOR PANEL
Settings solid waste (2/2)

setting screens.
Text Description
Time check CCT increase Time for checking temperature increase/decrease.
Max. FGT start adjustment Maximum flue gas temperature (FGT) before start adjusting
CCP combustion chamber pressure (CCP).
Hysteresis FGT stop adjusting Minimum drop flus gas temperature (FGT) before stop adjusting
CCP combustion chamber pressure (CCP)
CCP inc when FGT above Value for increasing combustion chamber pressure (CCP) when
setpoint flue gas temperature (FGT) is above set point
CCP dec when FGT below Value for decrease combustion chamber pressure (CCP) when flue
setpoint gas temperature (FGT) is below set point
Time between reading flue gas temperature (FGT) before making

Time check FGT adjust CCP
adjustments to combustion chamber pressure (CCP).
Max. FGT start adjust burner Maximum flue gas temperature (FGT) before start adjusting
step burner step.
Hysteresis FGT stop adjust Minimum drop flue gas temperature (FGT) before stop adjusting
burner step burner step.
Time check FGT adjust burner Time between reading flue gas temperature (FGT) before making
step adjustment to burner step.
46 OG200/400C
OPERATOR PANEL
Settings solid waste and sludge

Text Description
Maximum combustion chamber temperature (CCT) – reduce

Max. CCT SW & sludge
sludge when running solid waste and sludge program.
Hysteresis max. CCT SW & Minimum drop combustion chamber temperature (CCT) – stop
sludge reducing sludge when running solid waste and sludge program.
OG200/400C 47
OPERATOR PANEL
Settings sludge with water

Text Description
Setpoint combustion chamber temperature for water injection to

CCT enable Water injection
start.
Maximum combustion chamber temperature when water injection

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

CCT min. for Water injection
is enabled.
Max. RPM WDP Maximum Water dosage pump RPM.
Start RPM WDP Start RPM Water dosage pump.
Min. RPM WDP Minimum Water dosage pump RPM.
Increase of Water dosage pump RPM every 60 second until “Max

Increase RPM WDP
RPM WDP” is reached
48 OG200/400C
OPERATOR PANEL
Settings loading/slagging and stop

Text Description
Set point for combustion chamber pressure (CCP) when running

CCP running cooling
“Stop” program (cooling).
FGF RPM when CCT below Set point for flue gas fan (FGF) speed when running below “Stop”,
stop5 combustion chamber temperature (CCT) – Loading/slagging speed.
Off – After emergency stop the flue gas fan needs to be restarted by
pushing “STOP” button on display.
Auto start of FGF after stop6
On – After emergency stop the flue gas fan automatically starts if
temperature is above 220°C.
Start/Stop cooling - hystersis Setpoint start and stop of cooling incinerator
Hystersis start/stop cooling Hystersis start and stop of cooling incinerator
5
Only visible if frequency controlled flue gas fan is installed.
6
Can be changed by user.
OG200/400C 49
OPERATOR PANEL
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 setpoint Setpoint for combustion chamber temperature CCT, running

(view only) Burn-in program
Hys. chang. burner step Hysteresis for temperature setpoint, when changing burner step.
Burnerstep (view only) Actual burnerstep
50 OG200/400C
OPERATOR PANEL
Incinerator configuration
The button “Restore factory settings” can be
used to restore settings to factory
specifications.
If assistance from TeamTec is required, you

might be asked for the incinerator
configuration listed on the screen
Backlight
No user name and password required.
Time and date

No user name and password required. Press
button “Set new time & date” after new time
and date has been entered. This will transfer
the new time and date values to the control
system.
OG200/400C 51
OPERATOR PANEL
Program information
Values are view only. If assistance from
TeamTec is required, you might be asked for
the type and version listed on the screen.
Consumption
Display consumption for this run, last run and
total. Press “Setup consumption” to access
setup screen.
Consumption setup
52 OG200/400C
OPERATOR PANEL
Alarm system
If the control system encounters any irregularities the system will give an alarm and shut down the incinerator.
When an alarm occurs, the internal audible alarm activates and the alarm signal is given to ships alarm system.
The "ALARM" screen will pop-up at the operator panel display and the most recent alarm(s) will be displayed
at the top of the list. The “ALARM” screen will display active alarms as well as the alarm history. A total of
128 alarms (active and history) can be displayed. When additional alarms occur, the oldest alarms will be
deleted from the alarm history list.
The alarm Screen

Highlighted line (yellow letters) indicates the selected line. When “Ack” button is pressed, the selected alarm is
acknowledged.
Alarms Status:
Symbols indicating alarm status
Symbol Status
! Active Not accepted
*! Active Accepted
* Not active Accepted

Buttons for handling alarm system.
BUTTON TEXT Description
Ack Acknowledge an alarm.
Double arrow up Move the line (alarm) selection to top of list or screen.
Move the line (alarm) selection down one line. If the alarm list contains
Arrow down more alarms than can be displayed on the screen, the list will move one
line at a time each time the button is pressed.
Switch off audible alarm. The audiable alarm will not reengage until all
Audio Off
the alarms have been inactive and an new alarm appears
Leave alarm screen. If one or more alarms is still active or not

Close acknowledged, a red symbol is displayed on the “Alarm” button on the
“Main” screen.
OG200/400C 53
OPERATOR PANEL
Alarm List
The Alarm-list contains information about which alarms that are available. The reference refers to electrical
drawings.
ALARM TEXT Set point Active Ref. Description
One or more failure(s) occurred

Failure frequency
All time +5-U1 in frequency inverter for Flue
inverter FGF7
gas fan.

Failure frequency
All time -U6 in frequency inverter for Sludge
inverter SDP
dosage pump.

Failure frequency
All time +25-U1 in frequency inverter for Water
inverter WDP8
dosage pump
Flue gas temperature above

Flue gas temp. FGT high 375°C All time -U4
maximum setpoint temperature.
Comb. chambr. temp. CCT above maximum

1200°C All time -U2
CCT high temperature.
Comb. chambr. temp. Running CCT falling below normal

850°C -U2
CCT low Sludge operation temperature
Thermal failure - motor

x A9 All time -F1, to – F9 Protection relay cut out.
overload
Micro switch in door lock not

Door not closed  Running -Y3, -Y4
closed.
Draught failure - CCP Combustion chamber pressure

-5 mmWC Running -A11
low falling below set point.
600 sec. Running/ Heater element active more

Diesel oil temp. low +2-S2
1200 sec. Start up than set point time
Safety thermostat released.

Diesel oil temp. high 90°C Running +2-S3
(Require manual reset)
Diesel oil press. Low 11 bar Running +2S1 Diesel oil pump press low.
Flame failure ~ Running +2-R1 Poor or no flame.
Control voltage more than +/-

Voltage low – high 220V 10% All time -K9
10% out of normal.
Steam/air press. - sludge Steam / air pressure sludge

1,5 bar Sl. prog. -S5
low low.
7
Only visible if frequency controlled flue gas fan is installed
8
Only visible if water injection is installed
9
See motor rating
54 OG200/400C
OPERATOR PANEL
Steam/air press. - sludge Steam / air pressure sludge

4,5 bar Sl.prog. -S5A
high high
Sludge pressure low.

Sludge pressure low 0.1 bar Sl. prog. -S6
Sludge temperature low 50°C Sl. prog. -U3 Sludge temperature low.
Sludge temperature high 95°C All time -U3 Sludge temperature high.
Sludge service tank Safety thermostat released.

110°C All time +3A.1-S1
temp. high10 (require manual reset)
Sludge
Steam/air press. - water Steam / air pressure water
1,5/4,5 bar w/water +25 S4/S5
low/high11 low/high.
Prog.
Open circuit in sensor (broken)

Circuit failure FGT ~ All time -U4 or short circuit in amplifier for
flue gas temperature.
Communication failure Communication failure between

~ All time A1 & A2
PLC-Display PLC and display

or short circuit in amplifier for
Circuit failure CCT ~ All time -U2
combustion chamber
temperature.

Circuit failure SDP temp. ~ All time -U3 or short circuit in amplifier for
sludge temperature.
Low level sludge service Sl. Prog. Sludge below low level switch
~ +3A-S1
tank in more than 5 sec.
Communcation failure No connection between PLC

~ All time A1/A2
PLC-Display12 and display.
10
sludge tank w/el. heater
11
Only visible if water injection is installed
12
Program revision B or later
OG200/400C 55
OPERATOR PANEL
Setting list
50Hz 60Hz
Settings burner 50Hz 60Hz
Sluice Sluice
Burner damper burner step 1 18 % 18 % 18 % 15 %
Burner damper burner step 3 37 % 37% 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 min. oper. 150 °C
Alarm max FGT 375 °C
Alarm min CCP (Draught failure) -5 mmWC
Settings sludge
Sludge alone Yes
CCP start sludge -28 mmWC
Max. CCP run sludge -28 mmWC
Min CCP run sludge -12 mmWC
Min. sludge temp run sludge 80 °C
Alarm sludge temp. low, below normal 30 °C
Alarm sludge temp. high, above normal 15 °C
Min. CCT for run sludge 680 °C
CCT low hysteresis – stop sludge 40 °C
Purging start sludge 5 Sec.
Purging stop sludge – CCT below 300 °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 temperature regulation -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
56 OG200/400C
OPERATOR PANEL
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
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 * rpm
Sludge quality counter [0-18]
Purging start sludge 10 Sec.
Purging stop sludge – CCT below 300 °C
Setpoint heat tracing13 75°C
Hysteresis heat tracing14 5°C
Alarm low level Sludge service tank Off
Settings solid waste
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
Max. RPM WDP 1000 rpm
Start RPM WDP 600 rpm
Min. RPM WDP 200 rpm
Increase RPM WDP 5 rpm
Settings solid waste and sludge

Max CCT SW & Sludge 900 °C
Hysteresis max CCT SW & Sludge 10 °C
Settings loading/slagging & stop
13
Visible if heat tracing installed
14
Visible if heat tracing installed
OG200/400C 57
OPERATOR PANEL
CCP running cooling -18 mmWC

FGF rpm when CCT below stop15 500 rpm
Auto start of FGF after emergency stop Off
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 0.00210 l/r
Setpoint SDP capacity 0.00220 l/r
SDP capacity 0.00220 l/r16
Accepted deviation SDP capacity 80%
Settings Tanks TG5

Max tank level Volume below low level Tank area Sludge density
435 L 500000 mm² 0.96 Kg/L
703 L 217,9 L. 750000 mm² 0.96 Kg/L
1107 L 219,5 L 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
15
Only visible if frequency controlled FGF
16
Changes after 3 hours continious sludge burning
58 OG200/400C
OPERATOR PANEL
Settings frequency inverter ALTIVAR 31
drC code +25-U1 (Water)17

FCS InI
bFr 50 Hz
UnS 380 V
nCr 1.6 A
nSP 1380
COS 0.82
Uft n
tUn POn*
SEt code +25-U1(Water)

ACC 1.0
dEC 0.1
HSP 50
ItH 1.6
UFr 40
FLG 33
Ctl code +25-U1(Water)

Fr1 AI3
FUn code +25-U1(Water)

AdCAdC no
drC Code +25-U1(Water)

SCS Str 1
Save settings before incinerator leaves TeamTec

*Press button until display changes to nO.
17
Only available if water injection is installed
OG200/400C 59
OPERATOR PANEL
CONF code +1-U6 Sludge

FCS InI
bFr 50 Hz
dEC 0.1 sec
HSP 60
nPr 0.37 kW
nCr 1.9 A
A11t 0A
FULL - drC code +1-U6 Sludge

Ctt PErF
nPr 0.37 kW
UnS 220 V
nCr 1.9 A
nSP 885
UFr 50
FLG 33
tUn YES
CONF - code +1-U6 Sludge

SCS YES*
drC Code +1-U6 Sludge

Non rFr
Save settings before incinerator leaves TeamTec

*Press button until display changes to nO.
60 OG200/400C
OPERATOR PANEL
-U1
Menu 1.3 Settings
Flue gas fan
Acceleration 5.0 Sec
Deceleration 10.0 Sec
Low speed 0 Hz
High Speed 60 Hz
Mot. therm. current 17.2 A
Current limitation 17.2 A
-U1
Menu 1.4 Motor control
Flue gas fan
Standard mot. freq. 50 Hz
Rated motor power 7.5 kW
Rated motor voltage 380 V
Rated mot. current 17.2 A
Rated motor speed 1455 rpm
Max. frequency 60 Hz
Auto tuning Yes
-U1
1.5 Inputs/outputs CFG
Flue gas fan
2 wire type Level
AI2 configuration  AI2 min. value 4.0 mA
AO1 assignement I motor
AO1 conf.  AO1 min. value 4.0 mA
-U1
1.6 Command
Flue gas fan
Ref. 1 channel AI2 (enter two times)
Stop key priority No (press 2 sec.)
OG200/400C 61
OPERATOR PANEL
-U1
1.7 Application funct.
Flue gas fan
Auto DC injection Continous
-U1
1.8 Fault management
Flue gas fan
Fault reset LI5
Motor thermal prot.  Overload fault mgt Fallback spd.
Drive overheat Overtemp fault mgt Fallback spd
4-20mA loss  AI2 4-20 mA loss Fallback spd.
Fallback speed 15 Hz
-U1
1.12 Factory settings
Flue gas fan
Config source Config1
Save config Yes (hold for 5 sec)
Remember AUTO TUNING.

Save settings before incinerator leaves TeamTec.
62 OG200/400C
PROGRAM DESCRIPTION
Program description
Overall program function description
The TeamTec Incinerator type OG200/400C is controlled by a Programmable logic controller (PLC) witch
handles both the operating functions and the alarm system. The Human Machine Interface (HMI) is a touch
screen operator terminal. The operator terminal allows the user to view and monitor the process and to give
input to the process by choosing appropriate program to the desired task.
The Incinerator has 5 programs to select from; “Sludge”, ”Sludge and Water18”, “Solid waste & Sludge”,
“Solid Waste” and “Slag”. Some functions are general and controlled in the same way regardless of choice of
program.
General
The diesel oil burner heats up the incinerator. The burner runs in different steps, each program calculates the
required burner step and the burner responds accordingly by controlling the diesel oil valves, the burner air
damper the burner motor and the ignition electrodes.
The airflow through the burner is adjusted by the burner damper to different air flow at different steps on the
burner. The damper opening is corrected for the actual pressure in the combustion chamber (CCP) and the
actual speed of the sludge dosing pump (SDP)
The burner has the following steps:

0 - Burner stopped.
1 – Nozzle 1
2 – Nozzle 2
3 – Nozzle 1 and 2
4 – Nozzle 1 and sludge.
5 – Nozzle 2 and sludge.
6 – Nozzle 1 and 2 and sludge.
7 – Sludge only
18
Only available if water injection is installed
OG200/400C 63
PROGRAM DESCRIPTION
The actual burner step is displayed in the operator terminal.
Sludge with Solid waste and

Program: Sludge Solid waste
water sludge
Burner step 0 X X X X
Burner step 4 X X X Not possible
Combination of possible burner steps in different programs:
Flue Gas Fan

The flue gas damper (FGD) controls the combustion chamber pressure (CCP). If frequency controlled flue gas
fan is installed, the flue gas fan (FGF) speed controls the speed, 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. The flue gas fan inverter uses a PID controller to determine the Flue gas fan speed
according to the given set point.
Function Sludge program

The incinerator is designed and approved to burn sludge according to IMO specifications. See technical
specifications for information about sludge and quantities to be handled by your incinerator.
The incinerator starts heating up using the diesel oil burner. The diesel oil burner is controlled in different
steps. See description of burner for details.
For operation instruction see page 94.
After sludge program is started there is two criteria that needs to be fulfilled before incinerating starts; Sludge
temperature above 80°C and Diesel oil temperature above 60°C.
When the combustion chamber temperature (CCT) has reached set point “min CCT for run Sludge”(680°C),
the steam line will flush for 10 seconds to drain out condensate water before starting up the sludge burner. The
sludge dosage pump (SDP) starts. If the temperature increases after 60 seconds, the diesel oil burner reduces
“CCT inc sludge – dec diesel oil”(690°C). If temperature decreases below 640°C, sludge burning stops and
retries with a higher burnerstep at “min CCT for run Sludge”(680°C) if sludge quality counter is above the
initial value for increasing sludge burner step. At set point “CCT stop burner diesel oil” (870°C), the sludge
program requires burner step 7 from the burner program and runs sludge only if selected in the sludge settings.
64 OG200/400C
PROGRAM DESCRIPTION
The sludge dosage pump (SDP) is controlled by a frequency inverter.

Sludge dosage pump (SDP) will increase sludge dosing if combustion chamber temperature (CCT) is equal or
rising, 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) and flue gas temperature below
maximum setpoints.
Low sludge tank will result in a normal stop of the program or alarm if it is selected in alarm settings. When
sludge burner stops, the sludge solenoid valve closes the sludge while the steam/air solenoid flushes the sludge
nozzle until the temperature in the combustion chamber is lower than 300°C in order to avoid building up of
coke on the burner tip.
The temperature and pressure in the combustion chamber is controlled by calculations in the control system.
The calculation involves:

Set points for temperature in chamber (CCT).
Set points for pressure in chamber (CCP).
Set points for diesel oil burner.
Set points for sludge temperature.
Set points for sludge dosage pump (SDP).
Actual combustion chamber temperature (CCT).
Actual combustion chamber pressure (CCP).
Actual flue gas temperature (FGT).
Actual speed sludge dosage pump (SDP).
Actual sludge temperature.
The calculations controls:
1 – Combustion chamber pressure (CCP).

2 – Combustion chamber temperature (CCT).
3 – Flue gas temperature (FGT).
By adjusting:
1 – Flue gas fan damper(FGD)/ Flue gas speed.

2 – Diesel oil burner steps
5 – Speed sludge dosage pump (SDP).
All checks of temperature are made in time intervals. After each change in state or function, further
adjustments are not made until time interval has elapsed.
At the end of each time interval (30sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
OG200/400C 65
PROGRAM DESCRIPTION
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again.
Combustion chamber pressure:

At the start of sludge program, the initial combustion chamber pressure (CCP) (app. -28 mmWC) must be
reached in order to start burner.
The CCP set point is controlled by the combustion chamber temperature (CCT), flue gas temperature (FGT)
and burner step.
Function Sludge program with water Injection

The “Sludge and Water” program is identical to the sludge program except for the addition to water injection.
If “Sludge and Water” is active the water dosage pump (WDP) is started when combustion chamber
temperature (CCT) reach “CCT enable bilge”(1050°C).
The control system will adjust the sludge dosage pump (SDP) to keep the combustion chamber temperature
(CCT) at “CCT max. for water injection”(1150°C). The maximum water dosage pump (WDP) RPM starts at
200/600 rpm and increases by “Increase RPM WDP” (5 rpm) every 60 second, until “Max. RPM WDP”
(600/1200) RPM is reached. Water dosage pump (WDP) RPM is controlled as a function of the combustion
chamber temperature (CCT), see illustration.
If combustion chamber temperature (CCT) drops below “CCT min. for water injection”(840°C), the water
dosage pump (WDP) stops.
WDP[RPM]
1200
1000
800
WDP[RPM]
600 WDP[RPM]
400
200
0
840 860 880 900 920 940 960 980 1000 1020 1040 1060 1080 1100 1120 1140 1150
CCT[°C]
66 OG200/400C
PROGRAM DESCRIPTION
Function solid waste program
Note: All references to settings and values are for explanation only. The values on your incinerator or
application may be different.
The program assumes a batch load of waste in the incinerator and will have initial speed and pressure set points
to facilitate enough combustion air to handle this (CCP=28 mmWC, burnerstep 1).
All checks of temperature are made in time interval. After each change in state or function, further adjustments
are not made until time interval has elapsed.
At the end of each time interval (40 sec), the change in combustion chamber temperature (CCT) is calculated.
Depending of temperature raise (or drop), adjustments are made, according to calculations, to components that
will influence the combustion chamber temperature (CCT), and the present combustion chamber temperature
(CCT) is stored.
At the end of next time interval new calculations are made with reference to stored and actual combustion
chamber temperature (CCT) and components adjusted again according to tabular below.
Delta CCT Delta step 1 Delta Delta Delta step Delta step
step 2 step 3 4 5
CCT < -1C°
STEP CCT -1 to + 3 to +10 to > +17C°
+3C° +10C° +17C°
> 1000C° P +1 0 -2 -4 -5
4 B 0 -1 -1 -1 -2
900 - 1000C° P +2 +1 0 -2 -2
3 B +1 0 -1 -1 -1
700 – 900C° P +4 +3 +2 0 -2
2 B +1 +1 +1 0 0
< 700C° P +8 +6 +4 +2 -1
1 B +1 +1 +1 +1 0
P = Combustion chamber pressure (-mmWC)
B = Burnerstep
Delta CCT = Temperature rise after 40 seconds.
The diesel oil burner heats up the incinerator. The burner starts and runs in 3 steps (burner step 1-3). Change in
burner steps are made in time intervals as described above.
When combustion chamber temperature (CCT) reaches set point 1000 °C, the diesel oil burner reduces one
step, and further increase in combustion chamber temperature (CCT), reduces burner to step 1.
At the end of time interval (see description above), corrections are made to combustion chamber pressure
(CCP), according to calculations involving a combination of actual temperature in combustion chamber (CCT)
and the temperature raise (or drop) since last correction.
Combustion chamber pressure is also controlled by the flue gas temperature (FGT). At flue gas temperature
(FGT) above set point (330 °C), the control system overrides calculations made in time interval (as described
above).
OG200/400C 67
PROGRAM DESCRIPTION
Function Solid waste and sludge program

The Solid Waste and sludge Program heats up the combustion chamber according to the solid waste program
and when the Incinerator is ready to burn sludge the functions of the sludge program is applied. The maximum
combustion chamber temperature is then reduced to app. 900°C in order to enable the operator to feed solid
waste (if a sluice is fitted).
68 OG200/400C
MAINTENANCE INSTRUCTION
Maintenance instruction
Preventive maintenance
Preventive maintenance periods are defined in the
control system apart from the daily checks. The
control system counts the running hours of the diesel
oil burner. Each group is connected to a list of service
points required to perform. The preventive
maintenance is divided into four groups: Weekly,
monthly, 6 monthly and yearly. Based on experience
the intervals correspond to respectively 100h, 400h,
2500h and 5000h programmed with a service interval
“Hours service”. 6 monthly and yearly service is also
triggered by standby time on the incinerator. When
the actual running hours since last performed
maintenance exceeds the service interval the control
system calls for service by a pop up screen.
6 months and yearly service banner will appear, regardless of running hours, when 180/365 days has elapsed.
It is then required to follow the appropriate procedure. When the maintenance has been carried out press
“Done” and “Hours since last service” is reset. If not logged in as user “usr”, values on different setup screens
are “view only”. Also the “Done” buttons are only visible if user “usr” has logged in.
Service hours:
When “Hours since last service” is above
setting “Hours service”, a red banner is
activated in line for the item. By pressing
“Done”, the hour counter “Hours since
last service” is reset to 0 and the red
banner is turned off.
Daily
1. Inspect the combustion chamber. Remove all ash and slag before loading and starting the incinerator.
2. NOTE: The combustion chamber air inlets in the bottom must always be cleaned.
3. Check diesel oil pressure. Normal reading 16 bar.
4. Check sludge pressure. Normal reading 0.2 bar.
Weekly (100 hours)

1. Clean photo resistor on the Diesel oil Burner. Visually inspect the flame scrod and blast tube for
deposits. Clean if necessary.
2. Check that combustion air inlets and cooling air inlets on the incinerator casing are free from
obstructions. Clean if necessary.
3. Visually inspect the flue gas outlet for deposits, clean if necessary.
OG200/400C 69
Monthly (400 hours)

1. Check fan belts and tensions. Make sure there are no abnormal vibrations, noise or bearing
temperatures.
2. Check refractory condition. Check for pieces falling out or big cracks.
3. Clean diesel oil burner, blast tube flame scrod and ignition electrodes.
4. Dismantle, clean and adjust sludge oil burner.
5. Dismantle, clean and adjust water injection nozzle19.
6. Check spark arrester (if installed) and clean if necessary.
6 monthly (2500 hours or 182 days)

1. Clean the filter in the diesel oil pump. Clean the filter in the diesel oil supply line
2. Replace the rubber stator on sludge oil dosage pump and check the rotor for wear. It should have a
smooth polished surface.
3. Grease the flue gas fan bearings.
4. Check the ventilation on the Flue Gas Fan frequency inverter20.
5. Visually check the thermocouple for combustion chamber.
6. Lubricate the sluice bearings (if incinerator has sluice). See Sluice Assembly drawing.
7. Lubricate door hinges and check the door gaskets for proper sealing. Use chalk on the edges of the
door opening. Close the door. Open and check that the door gasket had contact with the edge all the
way around the opening. If not adjust the door.
8. Open the inspection hatches on the lower side of the incinerator cooling panel. Clean as required with
steam or hot water.
Yearly (5000 hours or 365 days)

1. Check paintwork. Make sure the paint is not chipped or scratched.
2. Check the control and alarm system according to "Test of function and safety devices"
3. Check all safety devices and calibrate if necessary.
4. Check all valves, pumps and solenoid valves for leakage. Repair if necessary
5. Replace nozzles for D.O. burner with new ones.

6. Replace the stator on water dosage pump21
19
If water injection is installed
20
If frequency controlled flue gas fan is installed
21
70 OG200/400C
Inspection
ITEM ACTION
Monthly check: Check visually the refractory inside the combustion

chamber. If pieces of refractory have fallen out so the insulation or steel is
visible, then use of the incinerator must be discontinued until a repair has
Combustion chamber:
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!
Daily check: Check visually for leakage. The pressure is to be checked

daily. If pressure drops below 16 bar and cannot be adjusted by means of
the adjustment screw, clean the filter. (Ref. Appendix D )
To clean the filters, proceed as follows:
Close the valves on supply and return line to D.O. pump. Remove all 8
Diesel oil pump:
bolts at the end the pump opposite the drive-side. Remove the end cover
and the cover gasket.
The filter is now visible and can be pulled out without the use of tools.
Clean the filter in diesel oil and blow dry with compressed air. Reassemble
and adjust the pressure to 16 bar.
Monthly check: Check the fan belts for sufficient tightness. Correct
Flue gas fan:
deflection is 10 mm using a force of approx. 3 kg. weight load.
Weekly check: Check visually for leakage. Turn the shaft by hand to check
Sludge dosage pump:
it is moving freely.
Weekly check: Check visually for leakage. Turn the shaft by hand to check
Water dosage pump22:
it is moving freely.
22
OG200/400C 71
Cleaning and lubrication
ITEM ACTION
The slag must be removed daily before starting up the incinerator. Make
Ashes: sure that trash has been incinerated completely and that the fire is dead
and ashes cold. Use a hoe for this purpose.
The photo resistor should be cleaned by means of a damp cloth every

Photo resistor:
week.
Caution: The main switch must be in OFF position whenever working with
the burner.
For dismantling and re-assembly, see Appendix C. The blast tube, flame
Diesel oil burner: scrod and diesel nozzle should be cleaned every month. This can be
cleaned with Kerosene, White Spirit or Marine Diesel Oil and a brush. The
electrodes should be wiped off with a cloth dipped in one of the above
mentioned agents.
The filter must be cleaned every 6 month. For dismantling and re-
Diesel oil pump:
assembly, see Appendix D.
The grease in the bearings must be changed every six months. Make sure
the bearings are clean before they are re-greased. Pay special attention to
reinstalling of the top half of the housing to its respective base after re-
Flue gas fan:
greasing. The top halves must not be mixed, each top half is made unique
to the base.
Also check the tension of the V-belts.
Door hinges to be greased every six months. Use ordinary ball bearing
Door hinges:
grease.
The sluice bearings must be lubricated every month. Use a graphite grease
type Esso Beacon Q2 or equal.
Sluice: 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.
Lubricate the bearings for the pusher with a grease gun every 6-month.
Pusher:
Use heat resistant type (Esso Beacon EP2 or equal).
The sludge burner should be cleaned every month, if necessary.

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

Water injection23:
For dismantling and re-assembly, see Appendix.
23
72 OG200/400C
Disassembly, repair, replacement and reassembly

Flue gas fan
Ref. Flue gas fan assembly drawing
To replace the impeller:
Disassembly
1. Switch off the power and make sure it cannot be switched on again while the unit is under
repair.
2. Disconnect the electrical cables to the motor.
3. Remove the 16 bolts pos. 17 (dwg. 1007005) on the cover (motor end of the fan housing).
4. Remove the 4 bolts pos. 33 for the bearing stand (fan base).
5. Slide the bearing stand assembly backwards from the fan housing till the impeller is clear of
the housing.
6. Carefully turn the bearing stand assembly to get access to the impeller.
7. The impeller is attached to the shaft with a taper lock hub. On the hub, unscrew the two
hexagon screws. By inserting one of the screws in the third hole (the one not in use), the
impeller will come off the hub when the screw is screwed in.
Repair
It is not advisable to repair an impeller unless one has access to balancing equipment.
Replacement
No special procedure is required except for cleaning the shaft and the hub before the hub is
placed on the shaft.
Reassembly
Proceed as for disassembly, in opposite manner.
To adjust the clearance between impeller and fan house
1. After working with the fan always check the proper end clearance between impeller and fan
housing.
2. Proceed as follows:
3. Unscrew the top part of both bearings.
4. Unscrew the nuts for the bearing hubs. Now the shaft is loose.
5. Pull the shaft out as far as possible. Put an ink mark on the shaft against the back bearing.
6. Push the shaft in as far as possible. Put an ink mark on the shaft against the same bearing.
7. Pull the shaft half way out so the clearance on both side of the impeller is identical (approx.
10 mm) and secure the nuts on the bearing hubs.
8. Replace the bearing tops.
Performance verification
1. Run the fan in cold and hot condition and listen for noise.
2. Inspect that the fan is able to provide at least 100 mm WC negative pressure in the
combustion chamber. (Cold gas.)
OG200/400C 73
Mounting of bearings with tapered bore

Shaft, hub and Taper-Lock bushings must be complete clean before mounting. These elements
are normally supplied light oiled.
At mounting, make sure the tightening torque is of correct level.
The mounting torque for the various hubs shall be as shown in this table:
Allen wrench
Bushing type Set screw type Torque in NM Fan type
type
1210 / ø30 3/8” x 5/8” 20 5,0 DN 200
1610 / ø40 3/8” x 5/8” 20 5,0 DN 250
2012 / ø50 7/16” x 7/8” 31 6,0 DN 300/350
2517 / ø60 ½” x 1” 49 6,0 DN 400
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 bearings are mounted with an adaptor sleeve. The bearings have a small internal clearance
and an accurate mounting is very important. When the bearing is properly mounted, the outer
ring can be easily turned, but there should be a slight resistance when the ring is swivelled out.
When mounting a new bearing to the fan’s shaft, the following procedure should be followed:
Before mounting the threads of the nut and the side face of the nut witch is about the bearing
should be greased and the outside diameter of the sleeve should be lightly oiled. The bearing is
then pushed on to the sleeve and the nut screwed on by hand. Check that the bearing is correctly
located on the shaft. Use a hook spanner and turn the nut an angle of 90°. By turning the nut
through this given angle of 90° the bearing will be pressed up on the tapered seating of the
sleeve. Re-position the hook spanner and apply a light hammer blow to the spanner. The bearing
will straighten up on its seating and is correctly fastened to the shaft. Lock the nut but bending
down one of the tabs on the locking washer. The residual clearance of the bearing should be
checked.
74 OG200/400C
SPARE PARTS
Spare parts
Recommended minimum spare parts
Name / Article Minimum Spare Parts, OG200/400C/CI, TG5 / Art.No. 17910/17916
Art. no. Art. name Quantity Unit
15748 Bonded Stator 2,0024 stk
7587 Photo resistor, QRB 1 A 1,00 stk
24
1 pcs if no water injection.
OG200/400C 75
SPARE PARTS
One year wear and tear parts OG200/400C/CI, TG5
Name / Article One year wear and tear parts, OG200/400C/CI, TG5 / Art.No.18232/18377
12329 Nozzle, 2,5 gph 60° S 2,00 ea.
13530 Glassfibre Rope 15x20 3,75 M
15684 Rotor 2,0025 ea.
15688 Universal Joint 2,0026 ea.
15748 Bonded Stator, black mark 4,0027 ea.
16066 Glassfibre Rope 16x16 2,30 M
17168 Stuffing Box Gasket 2,0028 ea.
17691 Sealing Compound, NON DANGEROUS GOODS 1,00 ea.
4979 V-belt, XPA 1357 2,00 ea.
6996 Cover gasket 2,0029 ea.
7842 Nozzle, 4.5 gph 45° SS 2,00 ea.
25
1 pcs if no water injection
26
27
28
29
76 OG200/400C
SPARE PARTS
Recommended onboard repair parts
Recommended onboard repair parts, OG200/400C/CI, TG5

Name / Article
Art.No.18221/18378

11632 Flame Scrod 1,00 ea.
11878 CALDE PATCH PT 88 U 25,00 KG
12500 Thermocouple Type "N-300" Assembly 1,00 ea.
12501 Thermocouple Type "K" Assembly 1,00 ea.
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 2,0030 ea.
15741 Mechanical Seal 2,0031 ea.
17168 Stuffing Box Gasket 2,0032 ea.
5128 Bearing, 2211 EK 2,00 ea.
6154 Sludge Burner Assembly 1,00 ea.
6438 Thermocouple with Pocket 1,00 ea.
6565 Flue Gas Restriction Ring Brick, 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_8in. 220V 1,00 ea.
8563 Spline Coupling Compl. 1,00 ea.
9272 Shaft seal kit 1,00 ea.
30
31
32
OG200/400C 77
STORAGE AND INSTALLATION
Storage and installation

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

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

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

In addition to the item mention above check that coating is in good condition.
Grease exposed parts of the burner.
Remove slag and ashes from combustion chamber.
Turn the electrical motors for fan, pumps and burner slightly.
If possible, the power should be switched on to the control panel in order to keep the panel dry.
78 OG200/400C
Pre-commissioning
Mechanical completion check list.
Prior to function testing at first start up, the following mechanical completion must be checked.
1. Check that the foundation support and the deck strength are adequate for the incinerator unit. (5. ton)
2. Check that flue gas fan foundation is of a sturdy design for fan to run without vibration.
3. Check that the air inlet to the incinerator room has sufficient capacity.
4. Check that the necessary drainpipe are 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 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)
10. Check the electrical power supply for correct rated protection at the ship distribution board.
11. Check that all pipes (sludge, steam and water) ducts and cables hooked up have been correctly
completed according to arrangement drawings.
12. Check that the “Burn In” program has been run for 10 hours. The “Burn In” program starts with a
combustion chamber temperature at 300°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.
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.
5. Make sure that water is filled in the water tank to a level above the low level switch.
After having checked out the above items, a function test according to this manual can take place
OG200/400C 79
Test of function and safety devices
No. Test procedure. Observation Accepted
1) FLAME FAILURE Alarm activates and the burner stops.

Start a burner program.
Pull the photo resistor out and blind
off.
Flame failure
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. high
3) COMB. CHAMBER TEMP. HIGH At combustion chamber temperature above set

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

Start SLUDGE program. point and the alarm will activate and the burner
Wait for burner to start. stops.
Adjust alarm set point[Min. operating
CCT] below actual temperature,
then above (actual CCT + [Alarm
CCT below min. oper.])
Comb. chambr. temp. CCT low
5) MOTOR OVERLOAD The motor stops, the alarm will activate and the
Activate test button at front of the burner stops.
motor circuit breaker.
Thermal failure - motor overload
80 OG200/400C
6) DOOR NOT CLOSED Alarm activates and the burner stops.

Unlock the waste door by tightening
the torx screw.
(Allen Bradley device)
Door not closed
7) DRAUGHT FAILURE At pressure below alarm set point

Start a burner program. When fan is [Alarm max. CCP (Draught failure)]
running disconnect the sensor tube and after 10 sec. the alarm activates and the
from vacuum controller. burner stops.
Draught failure - CCP low
8) DIESEL OIL TEMP HIGH At release of safety thermostat-S3 the alarm will
Start a burner program. Adjust activate and the burner stops
down the safety thermostat -S3 to The safety thermostat require manual reset.
below set point for working
thermostat -S4.
Diesel oil temp. high
9) DIESEL OIL TEMP LOW At start of heating the alarm activates and the
Adjust alarm set point burner stops.
[Alarm max. time dieselheater start]
to "0".
Diesel oil temp. low
10) DIESEL OIL PRESSURE LOW At pressure switch +2-S1 set point, the alarm
Start a burner program. Reduce the activates and the burner stops.
fuel oil pressure by adjusting the
pump.
Diesel oil press. low
OG200/400C 81
11) VOLTAGE LOW/HIGH Relay deactivates at voltage above or below set

Adjust upper/lower setpoint down/up point after a time delay (normally 5 sec.). Alarm
at relay (-K9) until red LED flash. activates.
When the relay is deactivated, the yellow LED
goes off, and the red LED goes on.
Voltage low - high
12) STEAM/AIR PRESSURE SLUDGE After 10 sec. alarm activates and the burner
LOW stops.
Adjust the steam/air pressure sludge
alarm switch to 1.5 bar.
Start a sludge program.

When running sludge, close off
steam-air supply. Steam/air press. - sludge low
13) STEAM/AIR PRESSURE SLUDGE After 10 sec. alarm activates and the burner
HIGH stops.
Adjust the steam/air pressure high
sludge alarm switch to 4.5 bar.
Close test valve steam/air supply.
When running sludge, close off
steam-air supply. Steam/air press. - sludge high
14) SLUDGE PRESSURE LOW After 10 sec. alarm activates and the burner
Adjust the sludge pressure low stops.
alarm switch to 0.1 bar.
Start a sludge program. Close the

sludge supply.
Sludge pressure low
15) SLUDGE TEMP LOW Alarm activates and the burner stops.
Start a sludge program. Adjust set
point
[Min. sludge temp run sludge]
above actual temperature and
adjust [Alarm sludge temp low] to 0.
Sludge temperature low
82 OG200/400C
16) SLUDGE TEMP HIGH Alarm activates and the burner stops.
Adjust set point
[Min. sludge temp run sludge]
below actual temperature and
adjust [Alarm sludge temp high] to 0.
Sludge temperature high
17) STEAM/AIR PRESSURE WATER After 15 sec. alarm activates and the burner
LOW/HIGH33 stops.
Adjust the steam/air water pressure
low alarm switch to 1,5 bar.
Start sludge with water.

Close steam/air supply.
Steam/air press. - Water
high/low
18) FREQUENCY INVERTER FAILURE After 10 second delay, alarm activates and the
SDP burner stops.
Start a sludge program. Disconnect

the wire at terminal RC on the
inverter.
Frequency inverter failure SDP
WDP34 burner stops.

inverter.
Frequency inverter failure WDP
FGF35 burner stops.

inverter.
Frequency inverter failure FGF
33
34
35
If frequency controlled FGF is installed
OG200/400C 83
21) SLUDGE SERVICE TANK TEMP Alarm activates and the burner stops.
HIGH36
Start a sludge program Adjust down
safety thermostat +3.1-S1 below
operating temperature. The safety thermostat requires manual reset.
Sludge service tank temp. high
22) LOW LEVEL SLUDGE SERVICE After 5 sec. delay the Alarm/Warning activates
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
+1–X1-114
Circuit failure FGT
24) CIRCUIT FAILURE CCT Alarm activates and the burner stops.
Disconnect wire from U2 terminal 4
Circuit failure CCT
25) CIRCUIT FAILURE SDP TEMP Alarm activates and the burner stops.
Disconnect wire from U3 terminal 4
Circuit failure SDP Temp
36
Only available if El.heater installed
84 OG200/400C
26) COMMUNICATION FAILURE PLC- Alarm activates after 40 sec. and the burner
DISPLAY stops.
Disconnect cable between A1 and
A2
Communcation failure PLC-
27) OVERLOAD SETTINGS: Flue gas fan motor :_______Amp.

Burner motor :_______Amp.
Sludge circ. pump :_______Amp.
Diesel oil booster pump :_______Amp.
Diesel oil transfer pump :_______Amp.
Sludge filling pump :_______Amp.
Sludge transfer pump :_______Amp.
28) IGNITION ELECTRODES
29) CENTRING OF FLAME-SCROD
30) PROGRAM BASED FUNCTIONS
31) ALL SETTINGS ACCORDING TO

LIST.
32) UNDERPRESSURE ON DISPLAY

SET TO 0
33) OVERALL INCINERATOR VISUAL

CONTROL
34) TERMINAL CLAMPS
35) FREQUENCY INVERTER

SETTINGS
OG200/400C 85
Test of control functions
No. Test procedure. Observations Display main menu
1. LOADING SLAGGING Flue gas fan start.

Test at low chamber temp. Loading/Slagging
Open the waste door and
push key "Slag" from main
menu.
2. DOOR NOT CLOSED The burner will not start until Not possible to start
Open the door and start a the door is closed. program – Door not
burner program. closed – please close
door
3. SOLID WASTE 1) Flue gas fan starts, and Damper closing…
If available, load solid waste the diesel oil burner
in combustion chamber and starts, indicated
close the door. Push the key visualised in main menu
"Solid Waste" from the start display.
menu display. The main menu display
2) Diesel oil heater activate indicates flue gas
for a time of 2-5 min. prior temperature and running
to start of burning. indication.
DISPLAY:37
3) Program will automatically The main menu display
control burner stage by indicates combustion
the temperature rise, and chamber temperature,
temperature level. combustion chamber
pressure, burner damper
opening and burner stage.
CCP start-up solid waste

program
-28 mmWC
Burner stage 1
4. SLUICE When burning solid waste,
Start “Solid waste” program sluice feeding is
or “solid waste sludge” recommended when
program from the start menu combustion chamber
display. temperature is above 700°C
and less than 1050°C.
5. SL. CIRC PUMP (SCP) Pressure gauge should read Not possible to start
Check sludge tank level. Start approx. 0.2 bar. sludge circulation pump
circulation pump by pushing If low level on sludge tank : low level in sludge
the motor symbol for SCP in service tank
main menu display.
6. SL. TRANSFER PUMP (STP) Start the sludge transfer pump Not possible to start
by pump by pushing the motor sludge transfer pump high
If applicable level in sludge settling
symbol for STP in main menu
display. tank
If high level sludge settling
tank:
37
Display is text at main menu
86 OG200/400C
7. Sl. FILLING PUMP (SFP) Start the sludge filling pump

If applicable by pump by pushing the motor
symbol for SFP in main menu
display.
If low level sludge settling Not possible to start
tank: sludge filling pump low
level in sludge settling
tank
If high level sludge settling
Not possible to start
tank:
sludge filling pump high
level in sludge service
tank
8. SL TANK HEATER The heater element symbol

Start the heater element by will turn red indicating that the
pushing the picture of the sludge tank heater is active
sludge tank heater element in (ON). Thermostat in the tank
the main menu display or start control switching on /off the
heater. Not possible to start
the sludge circ pump. heater low level in sludge
If low level on sludge tank: service/-settling tank
9. SLUDGE a) If not started manually, the Waiting for correct
Check that level in sludge sludge circulation pump sludge temperature
tank is above low level. Push and sludge heater will
the key start. Pressure indicator
"Sludge" from the start menu for sludge pressure should
display. read approx. 0.2 bar and
the sludge temperature
must be above start temp.
80°C (Min. sludge temp. Damper closing…
run sludge)
b) Flue gas fan starts, and
CCP start sludge
the burner starts,
-28mmWg
visualized indicated in
Burner stage 3
main menu.
c) Diesel oil heater will The main menu display
operate 2-5 min. until the indicates flue gas
oil temperature has temperature, combustion
reached normal level. chamber temperature,
combustion chamber
pressure, sludge
temperature, sludge dosing
pump rpm, burner damper
opening and burner stage.
d) At chamber temperature
above 680°C (Min.sludge
temp run sludge) and the
given flushing time, the
sludge dosing pump start
at 190 rpm (Min.RPM
SDP).
Diesel oil nozzle 2 and
sludge nozzle will burn.
e) After sludge flush time,
the burner will step down
OG200/400C 87
to stage 4. Diesel oil

nozzle 1 and sludge
nozzle.
f) The logic control is now
monitoring temperature
increase or decrease, and
controlling burner and
sludge speed (60 sec
fixed start – to ensure a
stable process before
adjusting sludge [Time
start sludge before
adjust]).
g) At combustion chamber
temperature above 870°C
burning sludge alone is The main menu display
allowed provided the indicates burner step 7 at
sludge is sufficient the burner picture.
inflammable.
If low level sludge service

tank:
Not possible to start
sludge program – low level
sludge service tank.
10. SLUDGE WITH WATER a) Control will be the same
Check that level in sludge as for item 9 a to g.
tank is above low level. Push b) At combustion above
the key 1050°C water injection is
"Sludge with water" from the enabled (CCT enable
start menu display. water).
c) If low level water tank
Check level water tank. Start during incinerating, the Low level water tank.
“Sludge with water” from the program changes to The incinerator automatic
start menu display. “Sludge” and a warning change to sludge program.
will occur:
11. SW SLUDGE a) If not started manually,
Check that level in sludge the sludge circulation
tank is above low level. pump and heater will
If applicable load waste in the start. Sludge pressure
chamber and close the door. gauge should read
Push the key approx. 0.2 bar, and the
"Solid Waste Sludge" from the sludge temperature must Waiting for correct sludge
start menu display. be above start temp. at temperature
80°C(Min. sludge temp.
run sludge) The main menu display
Heating up : indicates flue gas
b) Flue gas fan starts, and temperature, combustion
the burner starts, chamber temperature,
visualized indicated in combustion chamber
main menu. pressure, sludge
c) Diesel oil heater will temperature, sludge dosing
operate 2-5 min. until the pump rpm, burner damper
oil temperature has opening and burner stage.
reached normal level
88 OG200/400C
d) Program will automatically

control burner stage
by the temperature rise,
and temperature level.
e) Control will be the same Program Solid Waste and
as for item 9 c to f. Sludge:
Burner is controlled by
solid waste program until
combustion chamber
temperature (Min. CCT for
run sludge) is above 680°C.
From here burner is
controlled by sludge
program but will try to not
exceed 1000°C.
If low level sludge service Not possible to start solid

tank: waste – sludge program –
low level sludge service
tank
12. FLAME IN CHAMBER Start a burner program when Waiting... flame in chamber
there is flame in chamber or
pull out the photo resistor if
incinerator is in ready state.
13. STOP a) Will stop any selected Cooling. Combustion chamber
Push the key "Stop" from the program. pressure -18mmWg
start menu display. At combustion chamber
temperature > 170°C
all function will stop, but.
the flue gas fan will run for
cooling down. The steam/air sludge
b) Combustion chamber solenoid turns green,
above 300°C flushes the indicated in the burner
sludge nozzle after sludge display.
burner stops.
Incinerator ready
c) At combustion chamber
temperature < 170°C
the flue gas fan stop. The
waste door can be
opened.
14. ALARM IN SYSTEM Start a program when there is Not possible to start
incinerator is in Alarm state. program – Alarm is active –
please check Alarms
15. CLEANING OF WATER 1. After testing is completed
INJECTION SYSTEM with water injection,
system must be
preservated with diesel oil.
2. If system has water
booster pump, attach
diesel hose to both inlet
and return on the booster
pump.
OG200/400C 89
3. If system has water tank,

attach diesel to the water
inlet flange on incinerator.
4. Latch terminal clamp
+1X1-129&130(Low level
water tank).
5. Start “sludge with water”
and wait for water pump to
inject diesel oil into
combustion chamber. Stop
when the diesel oil has
been injected(1-2
minutes).
6. Remove latch on terminal
clamps.
7. This procedure is to
prevent corrosion and
internal damage on pipes
and nozzle.
90 OG200/400C
OG200/400C 91
OPERATION INSTRUCTIONS
Operation instructions
Prior to start
1. Main switch on the control panel is switched to position "ON" .The operator panel is
energised and the Process picture will show in the display.
Slagging
1. Check that there are no flames in the incinerator.
2. Push the "SLAG" key, the flue gas fan will run at a fixed speed when the temperature is
below 170°C (+50 hysteresis).
3. Open the ash door and remove ashes and slag, partly burned cans, can remain. These will
burn out eventually.
NOTE! Combustion air inlet openings at "floor" level must be cleaned.
This is important for a free airflow to the combustion chamber.
Solid Waste
1. Fill the combustion chamber half full with waste (max 400l)
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.
4. When the key "STOP" is pushed, the burner will stop, and the cooling down sequence starts.
5. When the temperature in the combustion chamber has decreased to 170°C, the flue gas fan
will stop and door locks energized.
Sludge
1. Fill up the sludge 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 colour
to indicate that the heater is on and the temperature is controlled locally by the thermostat
2. Drain off water from the settling tank. (The sludge should be settled overnight before water
is drained off) . Remember, longer settling time, better settling!
3. Start the filling pump by pressing the pump symbol and choose start pump. The symbol will
change colour to green to indicate that the pump is running. The pump will stop
automatically if the service tank level is high or the settling tank level is low.
4. Start the service tank circulation pump by pressing the pump symbol and choose start pump.
The symbol will change colour to green to indicate that the pump is running. Check the
sludge pressure on the pressure indicator to be in the range of 0.2 bar, adjust if required,
using the by pass valve. Run the circulation pump for at least 1 hour prior to burning sludge!
5. Check the atomising -air /-steam supply pressure to be 6 - 8 bar. If steam is used, the
condensate must be drained off by use of the valve located at sludge equipment drip tray.
6. 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
92 OG200/400C
required for starting the incinerator, the operator panel will display a message explaining the
condition.
7. The manual regulating valve for air / steam atomising located at sludge equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the sludge burner/nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the sludge burner.
8. When the low level in sludge tank, or the key "STOP" is pushed, the burner will stop, and
the cooling down sequence starts.
9. When the temperature in the combustion chamber has decreased to 170°C the flue gas fan
will stop and door locks will be energized.
Solid Waste Sludge

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

1. Make sure the manual valves in the bilge water system are open.
2. Make sure there are water available and that the water tank is filled with water.
3. Follow the sludge procedure, but choose “Sludge and Water” program instead of “sludge”
program.
4. The manual regulating valve for air / steam atomising located at water equipment drip tray
should be from ¾ to 1 turn open. The pressure should be shown in the upper half of the
green area (3.3 bar or 48 PSI) when the water injection nozzle is clean. If pressure rises, do
NOT adjust the valve, but clean the water injection nozzle.
OG200/400C 93
Emergency stop
In the incinerator room.
Turn the main switch at the control panel "OFF".
Outside the incinerator room.

Activate the emergency stop. (The switch normally requires manual reset).
When emergency stop is used, or at black out.

Warning: 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.
NOTE! Careful heating-up and cooling-

down is required for preventing
damage to the refractory.
94 OG200/400C
TROUBLE SHOOTING
OG200/400C 95
TROUBLE SHOOTING
Trouble shooting
Symptom Probable cause Checkout procedure
1. OPERATOR PANEL 1. Faulty main power supply. Check main switch -Q1
DEAD. Check power supply from main
switchboard.
2. Emergency stop switch Check switch -S1.
open.
3. Faulty fuse for pilot Check fuses –F11 and –F12
transformer.
4. Faulty fuse -F13. Check fuse.
2. Alarms 1. Described in section Described in section "Alarm

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

when burning on blocked or damaged.
diesel oil.
2. Malfunction of burner air Check the damper function and
damper. position.
3. Burner dirty. Clean burner flame scrod and
blast tube.
4. Poor flame / smoke 1. Damaged or blocked Check the nozzle and if

when burning sludge. sludge nozzle. necessary clean and adjust it.
2. Closed or incorrect Adjust valve. (1/2 to 1/1 turn
adjusted air/steam control open) NB! only to be performed
valve. with a clean sludge burner.
3. Damaged sludge dosing Change stator.
pump stator.
4. Sludge pressure to high. Adjust to correct setting.
(0.2bar)
5. Temperature raising 1. Loaded too much waste Stop loading, and tray to block
"uncontrolled" with high calorific value. lower four corner ventilation
slots.
2. Damaged sludge dosing Change stator.
pump stator.
3. Sludge speed control not Check sludge speed.
working.
4. Leaking diesel oil solenoid Change the valve.
valve.
96 OG200/400C
TROUBLE SHOOTING

6. FLAME FAILURE. 1. Flame sensor dirty. Take out and clean.
2. Flame sensor defect. Replace flame sensor.
3. The nozzles could be Clean or change the nozzles.
blocked or damaged.
4. Incorrect opening Check opening at closed
of burner air damper. damper and correct.
5. Ignition failure. Adjust spark electrodes.
6. Poor flame See section above
7. Defect solenoid valve or Replace valve or coil
coil
7. FLUE GAS TEMP. 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)
HIGH
Burning sludge 2. Panel cooling slot Clean panel slot
clogged with dirt.
3. Throttling bricks fallen Put the missing brick back in
out. place.
4. Under pressure to low See Draft Failure
5. Faulty temp. sensor. Replace sensor
6. Faulty temp. transmitter. Check transmitter mV input.
Replace, DO NOT ADJUST
7. Faulty frequency inverter. Check frq. inverter circuit
Burning solid waste 8. Loaded too much waste Stop loading, and tray to block
with high calorific value. lower four corners
8. COMB. CHMBR. 1. Same as flue gas temp See FLUE GAS TEMP HIGH
TEMP. HIGH high.
2. The outlet blocked with Clean outlet
slag. (Top of chamber)
3. Blocked slot at chamber Clean slots
floor level
9. STEAM/AIR PRESS. 1. To low steam/air Check steam/air supply
LOW/HIGH. pressure <1,5 bar. pressure.
2. To high steam/air Clean the sludge burner. Do
pressure > 4.5 bar not adjust the manual valve
unless the sludge burner is
clean.
10. DRAUGHT FAILURE 1. Leaking sensor tube. Check sensor tube for damage
(low under pressure) and fixing.
2. Defect pressure sensor Check and replace, DO NOT
ADJUST.
3. Door gasket damaged. Check door gasket
4. Broken flue gas fan belts. Tighten or replace.
5. Flue gas fan motor Check direction
running in wrong
direction.
OG200/400C 97
TROUBLE SHOOTING
11. LOW/HIGH VOLTAGE 1. Input voltage to low or to Check supply voltage.

high (+10% to –13%)
If this alarm occur and has
been reset, but supply voltage
is still low/high, the incinerator
will not start.
12. LOW CAPACITY 1. Blocked air cooling inlet. Clean inlet. (Bottom grating)
2. Panel cooling slot Clean panel slot
clogged with dirt.
3. Throttling bricks fallen Put the missing brick back in
out. place.
4. Deposits at flue gas Clean the Flue Gas outlet
outlet
5. Damaged or blocked Check the nozzle and if
sludge nozzle. necessary clean and adjust it.
98 OG200/400C
TROUBLE SHOOTING
OG200/400C 99
APPENDIX A
Appendix A: PLC
General
The Standard PLC contain of 4 units. See Figure 11 and 12.
1 2 3 4
Figure 11
1. Base unit (20 Digital Inputs / 12 Digital outputs)

2. Extension unit, relay output module (16 Digital outputs)
3. Extension unit, analogue input module (4 analogue inputs)
4. Extension unit, analogue (2 analogue inputs / 2 analogue outputs)
100 OG200/400C
APPENDIX A
Base Unit
Figure 12
1. Comm port 2 -9-pin D-Shell RS-232C connector

2. Memory Module connector
3. User 24V
4. Input terminal block
5. LCD Display Keypad (ESC, OK, Up, Down, Left, Right)
6. Battery compartment
7. Expansion bus connector
8. Battery connector
9. Output terminal block
10. LCD Display
11. LED Indicator
12. Comm port 1 – RJ45 connector
13. Comm port 0 – 8-pin mini DIN RS-232C/RS-485 connector
OG200/400C 101
APPENDIX A
Installing a Memory Module
1. Remove the memory module port cover.
2. Align the connector on the memory module with the connector pins on the controller.
3. Firmly seat the memory module into the controller.
102 OG200/400C
APPENDIX A
Replacing the battery

The PLC main unit is equipped with a replaceable battery. The Battery Low indicator on the
LCD display of the controller shows the status of the replaceable battery. When the battery is
low, the indicator is set (displayed as a solid rectangle). This means that either the battery wire
connector is disconnected, or the battery may fail within 2 weeks if it is connected.
IMPORTANT. Replacing the battery when the controller is powered down will lose all user
application memory. Replace the battery when the controller is powered on.
Follow the procedure below to connect the battery wire connector to the battery connector.
1. Insert the replaceable battery wire connector into the controller’s battery connector.
2. Secure the battery connector wires so that it does not block the expansion bys connector
as shown below.
OG200/400C 103
APPENDIX A
DIN Rail Mounting
Dimension:
A – 90mm (3.5 in.)
B – 27.5mm (1.08 in.)
C – 27.5mm (1.08 in.)
1. Hook the top slot over the DIN rail

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

1. Place a flat-blade screwdriver in the DIN rail latch at the bottom of the controller.
2. Holding the controller, pry downward on the latch until the latch locks in the open
position.
3. Repeat step 1 and 2 for the second DIN rail latch.
4. Unhook the top of the DIN rail slot from the rail.
104 OG200/400C
APPENDIX A
Diagnostics
LED Colour Indicates

No input power, or power
Off
POWER error condition.
Green Power on
Not executing the user
Off
program
Executing the user program
RUN Green
in run mode
Memory module transfer
Green flashing
occurring
Off No fault detected
FAULT Red flashing Application fault detected
Red Controller hardware faulted
Off No forces installed
FORCE
Amber Forces installed
OG200/400C 105
APPENDIX A
Status Indicators on the LCD
Input status indicators (20)
Output status indicators (12)
Indicator Colour Indicates

Not transmitting via RS-
Off (empty rectangle)
232/485 port (Channel 0)
COMM 0
Transmitting via RS-232/485
On (solid rectangle)
port (Channel 0)
Not transmitting via Ethernet
port (Channel 1)
COMM 1
Transmitting via Ethernet
port (Channel 1)
Not transmitting via RS-232
port (Channel 2)
COMM 2
Transmitting via RS-232 port
(Channel 2)
Configured communications
(Channel 0)
DCOMM
Default communications
(Channel 0)
Off (empty rectangle) Battery level is acceptable
BAT.LO
On (solid rectangle) Battery low
Off (empty rectangle) Default display mode
U-DISP
On (solid rectangle) Customized display mode
106 OG200/400C
APPENDIX A
I/O Status Indicators on the LCD
Indicator Colour Indicates

INPUTS Off (empty rectangle) Input is not energized
Input is energized (terminal
status)
OUTPUTS Off (empty rectangle) Output is nor energized
Output is energized (logic
status)
Error Conditions
If the LEDS The Following

Probable Cause Recommended Action
indicate: Error Exists
Verify proper line voltage and
No line power
connections to the controller
Not input power
All LEDs off or power supply This problem can occur
error Power Supply intermittently if power supply is
Overloaded overloaded when output loading
and temperature varies
Power and Processor Cycle power. Contact TeamTec if

Hardware Hardware Error the error persists
FAULT LEDs
faulted
on solid Loose Wiring Verify connections to the controller
Power LED on Hardware/Softw
Application
and FAULT are Major Fault Contact TeamTec
fault
LED flashing Detected
Missing or
RUN FORCE
Operating Corrupt
FAULT LEDs Contact TeamTec
system fault Operating
all flashing
System
OG200/400C 107
APPENDIX B
Appendix B: Operator Panel

General
The operator panel is a user friendly operator panel with touch screen. Applications are
controlled by touching screen objects. The panel is connected to the PLC.
Touch screen
Figure 14.
The function of the panel is:

 Selecting of burner mode, setting of all variables as temperature and time etc.
 Display running condition, temperature, pressure, alarm, oil consumption, timer
etc.
See also chapter Operator Panel, page 21, for user functions.
108 OG200/400C
APPENDIX B
Technical data
COMM and
FAULT LEDs
RESET Button Figure 15
The operator panel is a RS-232 only display with 1 USB port, and consist of a colour
(320X240) graphics display. Colour terminals support a fixed palette of 32 standard EGA
colours. All colours in an application is defined when the application is created, and not
selectable at the terminal.
The compact 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 RS-232 serial communication.
The terminal requires 24VDC.
Reset Button resets the terminal.
Display temperature should be less than 55°C. The CPU temperature should be less than 95°C.
The terminal has two LED indicators isolate operating problems:
 COMM indicator (green) for communications
 FAULT indicatior (red) for hardware faults
Red LED Green LED Indication

Blinking Off Last firmware download failed. Reload firmware.
Blinking Blinking Boot loader firmware failed or is missing. Reload firmware.
Windows CE OS firmware failed or is missing. Reload
Blinking On
firmware.
Fatal hardware error occurred. Contact TeamTec to replace
On Off
terminal
Fatal hardware error occurred in Display. Contact TeamTec
On Blinking
to replace terminal
Product certification compliance with European Union Directives. EMC tests satisfies EN
50081-1-2:1993 and EN 61000-6-2:1999
OG200/400C 109
APPENDIX C
Appendix C: Oil burner
Servicing and adjustment
Air damper motor

1
DO press. adjustment screw
Dismantling
DO pump
2
DO pressure gauge 5
1. Pull out the photo cell.
3
2. Remove the cover on top of the burner .
3. Disconnect the ignition cables.
4. Disconnect and pull out the sludge burner.
5. Disconnect and pull out the nozzle line.
Cleaning and adjustment

Ignition electrode
(Figure 1)
Clean the blast tube, flame scrod, ignition Flame scrod
electrodes and sludge burner. Replace
the diesel oil nozzle if necessary.
Blast tube
Note: The smallest nozzle is stage
one. Check the spark gap and the
position of the flame scrod.
Nozzle 2
Nozzle 1
Re-assembly Sludge burner
Reassemble the burner in reverse order. Figure 1
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.
110 OG200/400C
APPENDIX C
Air adjustment
The Burner damper motor is analogue, and will open the damper proportionally to the control voltage applied
by the control system. The only two checks necessary is Closed position and that it operates freely.
To check that the damper is closed make sure that the damper blade is vertical to the opening when the control
system shows 0% opening (after power up, flue gas fan not running).
To check that the damper operates freely, wind up the actuator by using a 4mm hex key on the top of the
damper motor, then release and observe that the damper closed by the spring action.
DO nozzles
Standard nozzle
For special cases other nozzles can be used.
Incinerator Nozzle 1 Nozzle 2 Std. pressure DO temp.

OG200/400C 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
GS1000C 4.5 GPH 45° 6.5 GPH 45° 16 bar 50 °C
Maintenance
Burner nozzle cannot be repaired.
OG200/400C 111
APPENDIX C
Capacities
Oil burner nozzle capacities in l/h at various pressures.38
Rated flow 39 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
38
Sp gr 0,85 @ 25C and viscosity 1,3E @ 20°C
39
Pressure = 100 P.S.I.
112 OG200/400C
APPENDIX C
OG200/400C 113
APPENDIX D
Appendix D: Oil pump

The oil pump incorporates a regulating valve with cut-off function.
Applications
 Light and medium oil
 Nozzle flow up to 110 l/h (2850 rpm, 5 cSt, 10 bar)
 Normally associated with in-line solenoid valve.
 One or two-pipe system
Pump operating principle

The gear-set draws oil from the tank through the built-in filter and
transfers it to the valve that regulates the oil pressure to the nozzle
line. All oil, which does not go through the nozzle line, will be
dumped through the valve back to the return line. The valve also as
a cut-off and bleed function as follows:
Bleed Figure 2
 Two pipe operation

During starting period when the gear-set speed is increasing, all the oil passes through a
special flat on the piston, back to the return.
Once the speed reaches a certain value and the flow can no longer pass through this flat,
then the pressure increases rapidly overcoming the valve spring force and opens the valve
Cut-off:
During the stop sequence, the gear-set speed slows down and the valve closes when the gear-set capacity is
lower than the flow.
The cut -on and cut-off speed depends on the set pressure.
Figure 3
114 OG200/400C
APPENDIX D
Technical data
General
Mounting Flange according to DIN 24220
Connection:
Inlet 1/4" NPTF
Return 1/4 " NPTF
Nozzle outlet 1/8" NPTF
Pressure gauge port 1/8" NPSF
Vacuum gauge port ¼" NPTF
Valve function Pressure regulating cut-off.
Strainer 45 cm² open area 120  opening size.
Shaft 11 mm according to DIN 24220
By-pass plug Inserted for 2 pipe system. To be removed with
3/16" allen key for 1 pipe system.
Weight 4 kg
Rotation Anti-clockwise rotation. Left hand nozzle.
(seen from shaft end).
Hydraulic data
Nozzle pressure range. 10 to 21 bar.
Delivery pressure setting. 16 bar
Viscosity range. 2.8 to 200 cSt
Inlet and return pressure. 1.5 bar max.
Suction height. 0.45 bar max. vacuum to prevent air separation
from oil.
Rated speed. 3600 rpm max.
Oil temperature. Max. 90°C in the pump.
Starting torque. 0.4 N.m
Pump capacity Power consumption
Figure 4 Figure 5
OG200/400C 115
APPENDIX D
Pump dimensions
Pipe dimensions
The tables below give the maximum length (in meters) of suction line as function of 3 variables:
 Lift between fuel unit and tank (H).

 Nozzle capacity.
 Pipe diameter (d)
For normal atmospheric pressure (sea level) and 0.45 bar vacuum.
Only mentioned diameters can be used, bigger pipes are not suitable.
The length indicated (intersection of horizontal lines and columns) assumes the fitting of 4 right
angle bends, 1 stop valve, 1 non return valve. If additional restrictions exist, the length must be
reduced accordingly.
From these tables, the maximum length for other viscosity's can be calculated by simple ratio of
viscosities i.e., multiply the length shown in the table by 20 and divide by the value of the new
viscosity in cSt.
Rated speed: 2850 rpm
Viscosity: 20cSt
Pressure: 12 bar
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 12 27 51 90
1 14 30 57 99
2 17 36 68 118
3 20 42 79 136
4 22 48 90 155
Q (l/h) 150
d (mm)
H (m) 10 12 14 16
0 11 24 46 80
0.5 9 21 41 71
1 8 18 35 61
2 5 12 24 42
3 2 6 13 24
4 0 0 2 5
Installation
The pump is ready for use with 2 pipe systems (i.e. with by-
pass plug fitted, in the return port.)
Figure 6 The inlet and return pressures must not exceed 1.5 bar.
The vacuum must not be more than 0.45 bar to prevent air
116 OG200/400C
APPENDIX D
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.
2. Check the pump filter.
This filter should be cleaned with a soft brush and fuel oil.
Each time, the cover gasket should be changed.
3. Check the tightness of all couplings and unused plugs.
4. Check the shaft coupling.
5. 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.
6. 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.
OG200/400C 117
APPENDIX D
Figure 7
Parts list
Pos. no. Description Article no.
1 Pressure adjusting plug assy "C" 10-21 bars 6985

1.1 Protecting nut + washer 6986
2 Pressure regulator kit, 10-21 bars 6987
3 Drilled nozzle plug and washer (J 1002) 6988
4 Shaft seal kit 9272
4.1 Seal face kit 6439
5 J 3 shaft 6999
5 J 4 shaft 6989
6 Seal cap 6990
7 By-pass plug 6991
8 1/4 NPTF plug (J 1000) 6992
9 1/8 NPTF steel plug (J 1000) 6993
10 J 3 rot. A gear kit 7000
11 Filter 6995
12 Cover gasket 6996
13 Cover + filter kit 6997
* Spanner wrench for shaft seal 6998
118 OG200/400C
APPENDIX D
OG200/400C 119
APPENDIX E
Appendix E: Frequency inverter ATV12

Specification
Teamtec H055M2
Power supply 200/240 V -15% +10%
50/60Hz 5Hz
Motor power rating 0.37kW / 0.5HP
Line current 40 6.7 A
Permanent output 3.5 A
current
Maximum transient 5.3 A
current 41
Power dissipated 41 W
(loss) at normal
load
Dimension (WxHxD) 72x145x122 mm
Weight 1.05 kg
40
Line current: Typical value without additional inductance.
41
Transient current: for 60seconds
120 OG200/400C
APPENDIX E
Technical characteristics
Degree of protection IP 20 without protective vent cover. IP31 other areas.
Vibration and shock 1 gn from 13 to 150 Hz, 15 g for 11 ms
resistance
(EN60068)
Degree of pollution Degree 2 according to UL840. Protect the drive against dust,
corrosive gases, and falling liquid.
Relative maximum 96% without condensation or dripping water (if there is a risk
humidity of condensation provide a heating system).
Ambient air temp. in Operating: -10°C to +60°C (with vent cover removed)
acc. with EN50178 Storage: -25°C to +70°C
Maximum operating 1000 m. without derating. Above this, derate the current by
altitude 1% for each additional 100 m.
Output voltage Maximum voltage equal to mains voltage.
Frequency range 0 Hz to 500 Hz.
Maximum transient 150% of nominal drive controller current for 60 seconds
current
Breaking torque 100% of the nominal motor torque without break resistor
(typical value). Up to 150 % with braking resistor as an
option.
Frequency - Display: 0.1 Hz
resolution - Analog inputs: 0.1 Hz for 100 Hz maximum
Switching frequency Can be adjusted from 2.0 to 16 kHz
Speed controller - Galvanic isolation between power and control circuits
protection and (inputs,
safety outputs, supplies)
- Protection against short-circuits:
 within internal power supplies
 between output phases
 between the output phases and earth
- Protection against input phase loss
- Thermal protection from excessive overheating and
overcurrents
- Under and overvoltage supply
- Overvoltage safe on braking
Motor protection Thermal protection integrated into the drive controller by
calculating I²t. Protection against motor phase loss.
OG200/400C 121
APPENDIX E
Accessing terminal blocks
Control
terminals
Power
terminals
Figure 31
Power Terminals
The power terminals must be connected before connecting the control terminals!
Maximum connection capacity:
Tightening torque: 1.2 Nm
Figure 32
Characteristics and functions of power terminals

Terminal Function For ATV12
t Ground terminal All ratings
R/L1 - S/L2/N Power supply 1-phase 100…120 V
R/L1 - S/L2/N 1-phase 200…240 V
R/L1 - S/L2 - T/L3 3-phase 200…240 V
+ output (dc) to the braking module DC Bus (visible
PA/+ All ratings
part on wiring trap)
– output (dc) to the braking module DC Bus (visible
PC/- All ratings
part on wiring trap)
PO Not used
U/T1 - V/T2 - W/T3 Outputs to the motor All ratings
122 OG200/400C
APPENDIX E
Control Terminals
Terminal Function Electrical characteristics

R1A NO contact of the relay Min. switching capacity: • 5 mA for 24 V c Maximum
switching capacity: • 2 A for 250 V a and for 30 V c on
R1B NC contact of the relay inductive load (cos ϕ = 0.4 and L/R = 7 ms) • 3 A for
250 V a and 4 A for 30 V c on resistive load (cos ϕ = 1
R1C Common pin of the relay and L/R = 0) • response time: 30 ms maximum.
COM Common of analog and logic I/Os
• resolution: 10 bits • precision: ± 1% at 25°C (77°F) •
linearity: ± 0.3% (of full scale) • sampling time: 20 ms
AI1 Voltage or current analog input ± 1 ms Analog voltage input 0 to +5 V or 0 to +10 V
(maximum voltage 30 V) impedance: 30 kΩ Analog
current input x to y mA, impedance: 250 Ω
+5 VDC power supply for
5V • precision: ± 5% • maximum current: 10 mA
reference potentiometer
• resolution: 8 bits • precision: ± 1% at 25°C (77°F) •
linearity: ± 0.3% (of full scale) • refresh time: 4 ms
Voltage or current analog output (maximum 7 ms) Analog voltage output: 0 to +10 V
AO1
(collector) (maximum voltage +1%) • minimum output
impedance: 470 Ω Analog current output: x to 20 mA •
maximum output impedance: 800 Ω
• voltage: 24 V (maximum 30 V) • impedance: 1 kΩ,
LO+ Logic output maximum 10 mA (100 mA in open collector) •
linearity: ± 1% • refresh time: 20 ms ± 1 ms.
LO- Common of the logic output (emitter)
LI1 Logic inputs Programmable logic inputs
LI2 • +24 VDC power supply (maximum 30 V)
LI3 • impedance: 3.5 kΩ
• state: 0 if < 5 V, state 1 if > 11 V in positive logic •
state: 1 if < 10 V, state 0 if > 16 V or switched off (not
LI4
connected) in negative logic • sampling time: < 20 ms
± 1 ms.
+ 24 VDC -15% +20% protected against short-circuits
+ 24 VDC supply provided by
+24V and overloads. Maximum customer current available
the drive
100 mA
Figure 33
OG200/400C 123
APPENDIX E
Programming
124 OG200/400C
APPENDIX E
OG200/400C 125
APPENDIX E
TeamTec Control Settings
126 OG200/400C
APPENDIX E
OG200/400C 127
APPENDIX E
128 OG200/400C
APPENDIX E
OG200/400C 129
APPENDIX E
130 OG200/400C
APPENDIX E
Faults – Causes – Remedies

Drive does no start, no fault displayed
 If the display does not light up, check the power to the drive and check the wiring of input AI1.
 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 ATV12 then displays “nSt” in freewheeel
stop mode and “FSt” in stop mode. This is normal since these functions are active at zero so that the
drive will be stopped safely if there is a wire break.
 Check that the run command input(s) have been actuated in accordance with the chosen control mode
(tCC parameter in the I-O menu).
 If an input is assigned to the limit switch function and this input is zero, the drive can only be started
up by sending a command for the opposite direction, see ATV 12 programming manual.
 If the LED on the DC bus is lit and nothing appears on the display, check that there is no short-circuit
on the 24 V power supply.
 If the drive displays “rdY” and refuses to start, check that there is not short circuit on the 24 V power
supply and check the wiring of input AI1 and LI1.
OG200/400C 131
APPENDIX E
132 OG200/400C
APPENDIX E
OG200/400C 133
APPENDIX E
134 OG200/400C
APPENDIX E
OG200/400C 135
APPENDIX F
Appendix F: Frequency inverter ATV6142

Specification
Teamtec WU75N4
Power supply 380 / 480 V -15% +10%
50/60Hz 5Hz
Motor power rating 7.5kW / 10HP
Line current 43 13.3/15.8 A
Permanent output 16/14 A

current(380V/460V
output voltage)
Maximum transient 17.6 A

current 44
Dimension (WxHxD) 260x525x286 mm
Weight 22 kg
Figure 34
42
Only for incinerators with frequency controlled flue gas fan
43
Line current: Typical value without additional inductance.
44
Transient current: for 60seconds
136 OG200/400C
APPENDIX F
Technical characteristics
Degree of protection IP 54 / UL Type 12
Vibration and shock

1 gn from 13 to 200 Hz, 15 g for 11 ms
resistance (EN60068)
Degree of pollution Degree 3 conforming to IEC/EN 61800-5-1.
5…95% without condensation or dripping water conforming to IEC

Relative humidity
60068-2-3
Ambient air temp. in Operating: -10°C to +40°C without derating.

acc. with EN50178 Storage:-25°C to +70°C
Maximum operating 1000 m. without derating. Above this, derate the current by 1% for each
altitude additional 100 m.
Output voltage Maximum voltage equal to mains voltage.
Frequency range 0.5 Hz to 500 Hz.
Maximum transient
120% of nominal drive controller current for 60 seconds
current
30% of the nominal motor torque without braking resistor (typical value)
Breaking torque
Up to 130 % with braking resistor installed as an option,
- Display: 0.1 Hz
Frequency resolution
- Analog inputs: 0.024/50 Hz (11 bits)
Switching frequency Can be adjusted from 2.0 to 16 kHz
- Galvanic isolation between power and control circuits (inputs,

outputs, supplies)
Thermal protection:
- against overheating and of the power stage
Protection against:
Speed controller - short-circuits between motor phases and input phase breaks
protection and safety - overcurrents between output phases and earth
- overvoltages on the DC bus
- a break on the control circuit
- exceeding the limit speed
Safety function for:
- line supply overvoltage and undervoltage and input phase loss, in 3-
phase
Thermal protection integrated in drive via continuous calculation of I2t
taking speed
into account:
b The motor thermal state is saved when the drive is powered down.
Motor protection b Function can be modified via operator dialogue terminals, depending
on the type
of motor (force-cooled or self-cooled).
Protection against motor phase breaks
Standards /
Certification / UL, CSA, DNV, C-Tick, NOM 117 and GOST
Recommendation
OG200/400C 137
APPENDIX F
Power cable
A standard power cable, 3 x 1,5 + E, from control panel to frequency inverter flue gas fan, ATV61, yard
supply. TeamTec recommend a cable type LM-HF 0,6/1 kV or similar type.
Terminal clamp 1 on control panel to L1 on ATV61.

To access the power terminal on frequency inverter for flue gas fan, unlock the power part access flap and
remove it as shown below:
Arrangement of the power terminals:
Motor cable
From U/T1, V/T2 and W/T3 on frequency inverter flue gas fan to motor for flue gas fan, you must use a
shielded motor cable, yard supply. TeamTec recommend a cable type LSM-HF 0,6/1kV or similar type.
Shielded cable for motor connection with shielding connected to ground at both end. The shielding must be
continuous and intermediate terminals must be in EMC shielded metal boxes. Connect the shield to ground at
each end by using EMC Cable Gland. The frequency inverter cabinet is delivered with two EMC cable glands
with nut. M40 is to be used for motor cable. The shield is to be grounded on the EMC cable gland.
Ensure that an EMC-compliant cable gland is
provided at the motor. TeamTec recommend an
EMC Cable gland with nut, M40, IP68.
If using conduit, do not lay the motor, power supply and control cables in the same conduit. Keep the metal
conduits containing the power supply cables at least 8 cm (3 in.) away from the metal conduit containing the
control cables. Keep the non-metal conduits or cable ducts containing the power supply cables at least 30 cm
(12 in.) away from the metal conduits containing the control cables. If necessary for control and power cables
to cross each other, be sure they cross at right angles.
NOTE: EMC-filter, on frequency inverter flue gas fan, is not dimensioned for motor cable length over 15
meters. Depending on the cable lengths it may be necessary to use an output filter.
The motor cables must be at least 0,5 m (20 in.) in length.
138 OG200/400C
APPENDIX F
Accessing terminal blocks
Figure 31
Power Terminals
 Maximum connection 2
 AWG 14 – 2,5 mm
capacity:
 Tightening torque:  3.0 Nm
Figure 32
OG200/400C 139
APPENDIX F
Control Terminals
Figure 33
140 OG200/400C
APPENDIX F
OG200/400C 141
APPENDIX F
Programming:
142 OG200/400C
APPENDIX F
OG200/400C 143
APPENDIX F
144 OG200/400C
APPENDIX F
TeamTec Control Settings
-U1
Menu 1.3 Settings
Flue gas fan
Acceleration 5.0 Sec
Deceleration 10.0 Sec
Low speed 10.0 Hz
High Speed 60 Hz
Mot. therm. current 15.2 A
Current limitation 15.2 A
-U1
Menu 1.4 Motor control
Flue gas fan
Standard mot. freq. 50 Hz
Rated mot. current 15.2 A
Max. frequency 60 Hz
Rated motor power * 7.5 kW
Rated motor voltage * 380V
Rated motor speed * 1455 rpm
Auto tuning Yes
* See motor plate
-U1
1.5 Inputs/outputs CFG
Flue gas fan
2 wire type Level
AI2 configuration  AI2 min. value 4.0 mA
AO1 assignement I motor
AO1 conf.  Ao1 min. value 4.0 mA
-U1
1.6 Command
Flue gas fan
Ref. 1 channel AI2 (enter two times)
Stop key priority No (press 2 sec.)
OG200/400C 145
APPENDIX F
1.7 Application funct. -U1

Flue gas fan
Auto DC injection Continuous
1.8 Fault management -U1

Flue gas fan
Fault reset LI5
Motor thermal prot.  Overload fault mgt Fallback spd.
Drive overheat Overtemp fault mgt Fallback spd
4-20 mA loss  AI2 4-20 mA loss Fallback spd.
Fallback speed 15 Hz
1.12 Factory settings -U1

Flue gas fan
Config source Config1
Save config Yes (hold for 5 sec)
Faults Causes – Remedies

Starter does not start, no fault displayed
 Wire break 4-20 mA control signal cable.
 No run signal present. That 24VDC is present at LI.
 Frequency inverter is in “local” mode. Press F4 to change status.
 Frequency inverter is stopped. Press green “RUN” button.
 Check wiring for power and motor cable.
146 OG200/400C
APPENDIX F
 Faults, witch cannot be reset automatically

The cause of the fault must be removed before resetting by turning off and then back on. AI2F, EnF, SOF, SPF
and tnF faults can also be reset remotely by means of a logic input or control bit ({Fault reset] (rSF)
parameter). EnF, InFA, InFb, SOF, SPF and tnF faults can be inhibited and cleared remotely be means of a
logic input or control bit ([Gault inhibit assign] (InH)).
OG200/400C 147
APPENDIX F
Faults, which can not be reset automatically (continued)
148 OG200/400C
APPENDIX F
Faults that can be reset with the automatic restart function, after cause has
disappeared
These faults can also be reset by turning on and off or by means of a logic input or control bit ({Fault reset]
(rSF) parameter). APF, SnF, COF, EPF1, EPF2, FCF2, LFF2, LFF3, LFF4, nFF, ObF, OHF, OLC, OLF,
OPF1, OPF2, OSF, OtF1|, OtF2, OtFL, PHF, PtF1, PtF2, PtFL, SLF1, SLF2, SLF3, SPIF, SSF, tJF and ULF
faults can be inhibited and cleared remotely by means of a logic input or control bit ({Fault inhibit assign.]
(InH) parameter.
OG200/400C 149
APPENDIX F
Faults that can be reset with the automatic restart function, after the cause has
disappeared (continued)
150 OG200/400C
APPENDIX F
Faults that can be reset as soon as their cause disappears

The USF fault ca be inhibited and cleared remotely by means of a logic input or control bit ([Fault inhibit
assign.] (InH) parameter)
OG200/400C 151
APPENDIX G
Appendix G: Sludge burner
Cleaning of sludge burner

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

 Attach fresh water supply to the Steam/Air connection
 Apply moderate water pressure until water flows steadily trough the nozzle
 Adjust the setscrews (A) until the water forms an even shape that does not bend away from
the centre line.
152 OG200/400C
APPENDIX G
OG200/400C 153
APPENDIX H
Appendix H: Sludge dosage pump
Dimension
Weight:19,5 kg
Figure 34
154 OG200/400C
APPENDIX H
Dismantling and assembly diagram,

Exploded view
Figure 35
Motor for pump.
 0.37Kw- 50Hz -900 Rpm.
Figure 35
OG200/400C 155
APPENDIX H
Parts list Art. No. 2007672
Pos.No Art.nr. Description Qty.

1 15687 Seal Plate Gasket 1
2 17168 Stuffing Box Gasket 1
3 15679 Tie rod 4
4 15683 Mech. Seal housing 1
5 15682 Seal plate 1
6 15681 Straight through end cover 1
7 15680 Pump housing 1
8 15685 Stub shaft 1
9 15684 Rotor 1
10 15748 Bonded stator 1
11 15678 Pump lantern 1
12 15677 Foot 1
13 15739 Hex socket grub screw 1
14 15738 Hex socket set screw 2
15 3206 Spring washer 4
16 2541 Hex nut 4
17 15740 Stud 4
18 15691 Flange mounted geared motors 1
19 5641 Punched washer 10
22 15688 UJ 1
23 16274 Taper plug 1
25 2598 Hex nut 10
26 15735 Hex nut 2
27 15734 Stud 2
28 15690 Retaining pin 1
30 15741 Mech. Seal 1
Figure 36. Revised November 2011.
156 OG200/400C
APPENDIX H
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will
ensure that the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory
conditions. With certain product materials, a hosing down facility with adequate draining will simplify
maintenance and prolong the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do
not allow moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut
hand tight. If a water flush system is to be used do not grease, a small amount of light oil is
recommended for these.
4. See Manufacturers instructions for motor/gearbox/drive instructions for storage procedures.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following
procedures should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the
stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because
damage could be caused to the rotor/stator elements.
Immediately prior to installation and starting.

Before installing the pump please ensure that all plugs and inspection plates are replaced and that excess
grease/oil is removed from the stuffing box. Make sure the pump is not started in dry condition.
OG200/400C 157
APPENDIX H
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where
any doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding.
Normally the pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly
connected. When the motor is being wired and checked for rotation, the start/stop sequence must be
instantaneous to prevent dry running or pressurising upstream equipment. (Check direction arrow on pump
nameplate). The electrical installation should include appropriate isolating equipment to ensure that the pump
unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation.
To eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely
flexed in position. When commissioning the plant, all joints in the system must be checked thoroughly for
leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and
the cause of the malfunction established before operations are recommenced. It is recommended that
depending upon plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge
only be fitted to the pump inlet port, and a pressure gauge fitted to the outlet port, these will then continuously
monitor the pump operating conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide
the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid
will normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been
dismantled and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is
normally somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears
when the pump is running normally against pressure.
Dryrunning
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.
158 OG200/400C
APPENDIX H
Mechanical seals, all pumps.

When a mechanical seal is fitted to the pump it may be necessary to provide a barrier fluid to some part of the
seal. This should be provided in line with the seal manufacturers instructions.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with
their specific instructions.
Pump operating temperature

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

Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasivity, speed, pressure
etc.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.
OG200/400C 159
APPENDIX H
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES

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

1. INCORRECT DIRECTION OF ROTATION REVERSE MOTOR
2. PUMP UNPRIMED BLEED SYSTEM OF AIR / GAS
INCREASE SUCTION HEAD OR REDUCE
3. INSUFFICENT N.P.S.H. AVAILABLE
SPEED / TEMP
INCREASE N.P.S.H. AVAILABLE (SEE 3
4. PRODUCT VAPOURISING IN SUPPLY LINE
ABOVE)
CHECK PIPE JOINTS / GLAND
5. AIR ENTERING SUPPLY LINE
ADJUSTMENT
INSUFFICIENT HEAD ABOVE SUPPLY
6. RAISE VESSEL / INCREASE PIPE SIZE
VESSEL OUTLET
FOOTVALVE / STRAINER OBSTRUCTED OR
7. CLEAN OUT SUCTION LINE / VALVES
BLOCKED
PROOUCT VISCOSITY ABOVE RATED DECREASE PUMP SPEED / INCREASE
8.
FIGURE TEMP
9. PRODUCT TEMP ABOVE RATED FIGURE COOL THE PRODUCT
PRODUCT VSCOSITY BELOW RATED
10. INCREASE PUMP SPEED / REDUCE TEMP
FIGURE
DELIVERY PRESSURE ABOVE RATED
11. CHEC FOR BLOCKAGES IN DELIVERY LINE
FIGURE
12. GLAND OVERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
13. GLAND UNDERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
CHECK FLUID FLOWS FREELY INTO
14. GLAND FLUSHING INADEQUATE
GLAND
15. PUMP SPEED ABOVE RATED FIGURE DECREASE PUMP SPEED
16. PUMP SPEED BELOW RATED FIGURE INCREASE PUMP SPEED
17. BELT DRIVE SLIPPING RE -TENSION BELTS
160 OG200/400C
APPENDIX H
18. COUPLING MISALIGNED CHEOK AND ADJUST ALIGNMENT

CHECK AND TIGHTEN ALL PUMP
19. INSECURE PUMP I DRIVE MOUNTING
MOUNTINGS
20. SHAFT BEARING WEAR I FAILURE REPLACE BEARINGS
21. WORN PUMP ELEMENT FIT NEW PARTS
22. RELIEF VALVE CHATTER CHECK CONDITION OF VALVE / RENEW
23. R.V. INCORRECTLY SET RE -ADJUST SPRING COMPRESSION
24. LOW VOLTAGE CHECK VOLTAGE I /WIRING SIZES
25. PRODUCT ENTERING PACKING AREA CHECK PACKING CONDITION AND TYPE
CHECK AND REPLACE BROKEN
26. DRIVE TRAIN BREAKAGE
COMPONENTS
27. NEGATIVE OR VERY LOII DELIVERY HEAD CLOSE DELIVERY VALVE SLIGHTLY
REVERSE PUMP/RELIEVE PRESSURE /
28. DISCHARGE BLOCKED / VALVE CLOSED
CLEAR BLOCKAGES
REPLACE WORN PARTS / TIGHTEN UP
29. STATOR TURNING
STATOR BOLTS
30. STUFFING BOX EATS - PACKING CHECK FOR WORN SHAFT AND REPLACE
OG200/400C 161
APPENDIX I
Appendix I: Sludge valve.

A 6324/1101/7003. 0-1 bar. G 3/4"
Figure 37
162 OG200/400C
APPENDIX I
Valve
Valve housing Brass
Cove Red brass
Inner parts AISI 430F

Sealing device Teflon, Viton and Silicone
Control medium Steam 180°C, max 7 bar. Inlet 1/8 BSP
Medium Oil 90°C, max 1 bar. Inlet/Discharge 3/4 BSP
Repair kit for sludge valve article no. 12806 consist of:
Pos. no. Nos. Description

1 (101) 1 Arm
2 (301) 1 Base plate
3 (302 1 Spindle
4 (303) Piston
5 (304) 1 Disc washer
6 (305) 1 Washer
7 (306) 1 Seal
8 (307) 1 Cylinder
9 (308) 1 Tube bearing
10 (309) 1 Bolt
11 (311) 2 Ring
12 (312) 1 O-ring
13 (313) 1 O-ring
14 (314) 1 Safety ring
15 (315) 1 Nut
16 (316) 1 Deflector
17 (317) 1 Face plate
18 (318) 1 Spring
19 (319) 1 Compression ring
Figure 38
OG200/400C 163
APPENDIX J
Appendix J: Sludge circulation pump

General information
Centrifugal pumps are suitable for pumping:
Hot and cold water.
Clean and slightly contaminated liquids.
thermal salt water, sea water, lyes and all types of oils.
The pump MUST NOT be used to pump the following:
Explosive media!
Liquids containing abrasive substances or long fibres!
Media containing aggressive chemicals which could damage the pump
material!
Technical data
Capacity 6 m³/h at 1.9 bar discharge

380/440V, 50/60Hz, 2.2/2.55 kW
El. motor
2880/3480 rpm
El. coupling 380/440V Star
Weight 32 kg
Connections Suction: DN 40, Discharge: DN 40
Noise level
The maximum noise level is generally determined by the drive motors via air, magnet and bearing
noises. The system does not exceed the permissible limit curves for electric motors as specified by
VDE 0530 part 9/12.84. Lowest noise generation during operation is close to Q OPT
164 OG200/400C
APPENDIX J
Drawing
Figure 39
Parts list
Pos. no. Nos. Description Article no.
1 1 Pump House Milled Dimensions 1006672

2 1 Impeller for Sludge Pump 3008633
3 1 Pump House Bracket 1006664
4 1 Mechanical Seal 11166
5 1 Motor 11599
6 1 Nut, hex 12118
7 1 Washer 12119
8 1 Gasket 12134
9 1 Plug 12105
10 1 Split Pin 15031
11 4 Stud Bolt 12272
12 8 Net, hex 2544
13 4 Bolt, hex 863
15 12 Washer 2410
OG200/400C 165
APPENDIX J
Commissioning
Before commissioning, the pump should be inspected and a functional check carried out. In
particular, the following points should be checked:
 Is the motor circuit-breaker correctly set?
 Are the valves required for operation open?
 Checking the direction of rotation. (Looking at the motor fan, it should rotate in a
clockwise direction.)
CAUTION When commissioning, the pump and intake line should be vented and primed with
pumping liquid before starting up! The shut-off valve in the intake and discharge lines must be fully
open.
Maintenance
Maintenance instructions following a prolonged shutdown
Preserve the mechanical shaft seal with glycerine. To do so, squirt onto the motor shaft several
times through the leakage opening on the back panel.
NOTE Before switching on the pump after a prolonged shutdown, rotate the motor shaft several
times by hand on the fan.
Removing the pump

Before removing the pump, the motor connection cables should be disconnected from the terminal
box by a qualified electrician.
All shut-off valves in the intake and discharge lines must be closed.
With hot pumping media, the pump casing must have cooled down to the ambient
temperature.
The pump unit must be pressureless and empty. For this purpose, open the vent device and
drain plug.
7. Maintenance
166 OG200/400C
APPENDIX J
Dismantling and assembly instructions of the mechanical seal

Dismantling
Close intake and discharge valves.
Disconnect motor from power supply and release leads from terminals.
The pump unit must be pressureless and empty.
Sectional drawing look at page 165
1. Undo fastening bolts of motor and foundation.

2. Remove fastening screws from casing and rear wall (3).
3. Lift released rear wall (3) assembly off casing.
4. Undo impeller nut (13) (RH thread) using socket wrench.
5. Force impeller (2) off shaft.
6. Remove the shaft key (f) from shaft slot.
7. Lift seal ring (a+b).
8. Undo fastening bolts of motor and rear
wall (3).
9. Lift off rear wall (3) in alignment along shaft.
Figure 40
10. Remove stationary ring (c+d) from rear
wall (3).
Clean the shaft from sediments and contamination by using very fine structured emery cloth. Check
all dismantled components for damage and renew defective parts.
Assembly
Before re-assembling
check all parts on damages and wear,
if necessary, replace by original spare parts,
clean the parts.
NOTE If the seal- or stationary ring of the seal is damaged, change the complete mechanical seal.
OG200/400C 167
APPENDIX J
Fitting of stationary ring

When pressing in the pressure sensitive stationary ring, ensure that
uniform pressure is exerted.
no foreign bodies are applied to the sliding surface.
NOTE To facilitate fitting, the outer faces of the O-ring can be moistened with a parting or anti-
friction agent such as for example water, glycerine or soap. CAUTION - do not use oil!
1. Stationary ring (c) with O-ring (d) press into the rear wall (3) by hand (first of all O-ring
then stationary ring).
CAUTION When pressing in the stationary ring (c), ensure that the pin safety (e)
device against twisting is fixed in the slot of the stationary ring.
2. Carefully push rear wall (3) along the motor shaft on to the centering of the motor.
CAUTION Do not damage the stationary ring on the thread or shoulder of the shaft or
push it crooked in its seating!
3. Bolt rear wall (3) and motor.
4. Push seal ring (a) with O-ring (b) carefully over the shoulder of the motor shaft along to the
fitted stationary ring.
CAUTION Ensure that the O-ring is not damaged!
5. Insert the shaft key (f) into the slot of shaft and seal ring (a).
6. Push impeller (2) onto the shaft and fasten it by the impeller nut (13).
7. Insert the rear wall (3) to the casing and fix it with the screws.
CAUTION Check free running of impeller (2) by turning fan!
8. Reconnect motor electrically! Ensure clockwise rotation (see item 5.7 Checking the
direction of rotation)
NOTE Start up pump unit (see Commissioning page 165)
168 OG200/400C
APPENDIX J
Performance curves
2880 rpm 50 Hz 3480 rpm 60 Hz
TeamTec circ pump capasity
3,00
2,50
2,00
60Hz
Pressure [bar]
50Hz
1,50
1,00
60Hz
0,50 50Hz
0,00
0,00 5,00 10,00 15,00 20,00 25,00 Flow [m3/h] 30,00
OG200/400C 169
APPENDIX K
Appendix K: Water Dosage Pump
Dimension
Weight:19,5 kg
Figure 41
170 OG200/400C
APPENDIX K
Dismantling and assembly diagram,
Figure 42
Motor for pump.

 0.55Kw- 1.6A - 50Hz -1395 Rpm.
Figure 35
OG200/400C 171
APPENDIX K
Parts list Art. No. 2007740
Pos.No Art.nr. Description Qty.
1 15689 Gland Guard 1

2 15687 Seal Plate Gasket 1
3 15679 Tie rod 4
4 15683 Mech. Seal housing 1
5 15682 Seal plate 1
6 15681 Straight through end cover 1
7 15680 Pump housing 1
8 15685 Stub shaft 1
9 15684 Rotor 1
10 15748 Bonded stator 1
11 15678 Pump lantern 1
12 15677 Foot 1
13 15739 Hex socket grub screw (for part no. 4400) 1
14 15738 Hex socket set screw (for part no. 4400) 2
15 3206 Sping washer (for part no.42) 4
16 2541 Hex nut (for part nr. 41) 4
17 15740 Stud (for part no. 40) 4
18 15749 Flange mounted geared motors 1
19 5641 Punched washer (for part nr. 16) 10
20 15736 Spring washer (for part no. 08) 2
21 15741 Mech. Seal 1
22 15688 UJ 1
23 16274 Taper plug (for part no. 5010) 1
24 2598 Hex nut (for part no. 15) 10
25 15737 Spring washer (for part no. 7710, 1200 & 5310) 10
26 15735 Hex nut (for part no. 07) 2
27 15734 Stud (for part no. 5861 & 5452) 2
28 15690 Retaining pin 1
Figure 43
172 OG200/400C
APPENDIX K
Installation
Installation and Safety Recommendations
In common with other items of process plant a pump must be installed correctly to ensure satisfactory and safe
operation. The pump must also be maintained to a suitable standard. Following these recommendations will
ensure that the safety of personnel and satisfactory operation of the pump is achieved.
General
When handling harmful or objectionable materials, adequate ventilation must be provided in order to disperse
dangerous concentrations of vapours. It is recommended that wherever possible pumps should be installed with
provision for adequate lighting, thus ensuring that effective maintenance can be carried out in satisfactory
conditions. With certain product materials, a hosing down facility with adequate draining will simplify
maintenance and prolong the life of pump components.
Storage
Short-term storage
Where a pump has to be stored for 6 months or less then the following steps are advised:
1. Store pump inside wherever possible or if this is not feasible then provide protective covering. Do
not allow moisture to collect around the pump.
2. Remove the drain plug, if fitted. Any inspection plates fitted should also be removed to ensure that the
suction housing could drain and dry completely.
3. Loosen the packing gland and inject sufficient grease into the stuffing box. Tighten the gland nut
hand tight. If a water flush system is to be used do not grease, a small amount of light oil is
recommended for these.
4. See Manufacturers instructions for motor/gearbox/drive instructions for storage procedures.
Long-term storage
If the pump is to be kept in storage for more than six months then in addition to the above the following
procedures should be carried out regularly (every 2 - 3 weeks if possible):
1. If practicable rotate the pump at least three quarters of one revolution to avoid the rotor setting in the
stator.
2. Note, however, that the pump is not to be rotated for more than two revolutions each time because
damage could be caused to the rotor/stator elements.
Immediately prior to installation and starting.

Before installing the pump please ensure that all plugs and inspection plates are replaced and that excess
grease/oil is removed from the stuffing box. Make sure the pump is not started in dry condition.
OG200/400C 173
APPENDIX K
Electrical
Electrical connection should only be made using equipment suitable for both rating and environment. Where
any doubts exist regarding the suitability of equipment, supplier should be consulted before proceeding.
Normally the pump should be installed with starting equipment arranged to give direct on line starting.
Earthing points will be provided on electric drives (if supplied) and it is essential that these are correctly
connected. When the motor is being wired and checked for rotation, the start/stop sequence must be
instantaneous to prevent dry running or pressurising upstream equipment. (Check direction arrow on pump
nameplate). The electrical installation should include appropriate isolating equipment to ensure that the pump
unit is safe to work on.
Important
The pump must never run against a closed inlet or outlet valve, as this could result in mechanical failure.
General safety
Great care must be taken to protect all electrical equipment from splashing when hosing down.
All nuts and bolts, securing flanges and base mounting fixtures must be checked for tightness before operation.
To eliminate vibration, the pump must be correctly aligned with the drive unit, and all guards must be securely
flexed in position. When commissioning the plant, all joints in the system must be checked thoroughly for
leakage.
If, when starting, the pump does not appear to operate correctly, the plant must be shut down immediately and
the cause of the malfunction established before operations are recommenced. It is recommended that
depending upon plant system operation, either a combined vacuum and pressure gauge, or a vacuum gauge
only be fitted to the pump inlet port, and a pressure gauge fitted to the outlet port, these will then continuously
monitor the pump operating conditions.
Start-up procedure
Pumps must be filled with liquid before starting. The initial filling is not for priming purposes, but to provide
the necessary lubrication of the stator until the pump primes itself. When the pump is stopped, sufficient liquid
will normally be trapped in the rotor/stator assembly to provide lubrication upon re-starting.
If, however, the pump has been left standing for an appreciable time, moved to a new location, or has been
dismantled and re-assembled, it must be refilled with liquid and given a few turns before starting. The pump is
normally somewhat stiff to turn by hand owing to the dose rotor/stator fit. However, this stiffness disappears
when the pump is running normally against pressure.
Dry running
Never run the pump in a dry condition even for a few revolutions, the stator will be
damaged immediately. Continual dry running could produce some harmful or damaging
effects.
174 OG200/400C
APPENDIX K
Mechanical seals, all pumps.

When a mechanical seal is fitted to the pump it may be necessary to provide a barrier fluid to some part of the
seal. This should be provided in line with the seal manufacturers instructions.
Guards
In the interests of safety, all guards must be replaced after necessary adjustments have been made to the pump.
Warning/control device
Prior to operating the pump, if any warning or control devices are fitted these must be set in accordance with
their specific instructions.
Pump operating temperature

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

Rotor and stator
The wear rate on these components is dependent on many factors, such as product abrasivity, speed, pressure
etc.
When pump performance has reduced to an unacceptable level one or possibly both items will need replacing.
OG200/400C 175
APPENDIX K
Diagnostic chart
SYMPTOMS POSSIBLE CAUSES

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

1. INCORRECT DIRECTION OF ROTATION REVERSE MOTOR
2. PUMP UNPRIMED BLEED SYSTEM OF AIR / GAS
INCREASE SUCTION HEAD OR REDUCE
3. INSUFFICIENT N.P.S.H. AVAILABLE
SPEED / TEMP
INCREASE N.P.S.H. AVAILABLE (SEE 3
4. PRODUCT VAPORISING IN SUPPLY LINE
ABOVE)
CHECK PIPE JOINTS / GLAND
5. AIR ENTERING SUPPLY LINE
ADJUSTMENT
INSUFFICIENT HEAD ABOVE SUPPLY
6. RAISE VESSEL / INCREASE PIPE SIZE
VESSEL OUTLET
FOOT VALVE / STRAINER OBSTRUCTED
7. CLEAN OUT SUCTION LINE / VALVES
OR BLOCKED
PRODUCT VISCOSITY ABOVE RATED DECREASE PUMP SPEED / INCREASE
8.
FIGURE TEMP
9. PRODUCT TEMP ABOVE RATED FIGURE COOL THE PRODUCT
PRODUCT VISCOSITY BELOW RATED
10. INCREASE PUMP SPEED / REDUCE TEMP
FIGURE
DELIVERY PRESSURE ABOVE RATED CHECK 9890

11.
FIGURE FOR BLOCKAGES IN DELIVERY LINE
12. GLAND OVERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
13. GLAND UNDERTIGHT ADJUST GLAND SEE O & M INSTRUCTIONS
CHECK FLUID FLOWS FREELY INTO
14. GLAND FLUSHING INADEQUATE
GLAND
15. PUMP SPEED ABOVE RATED FIGURE DECREASE PUMP SPEED
16. PUMP SPEED BELOW RATED FIGURE INCREASE PUMP SPEED
17. BELT DRIVE SLIPPING RE -TENSION BELTS
176 OG200/400C
APPENDIX K
18. COUPLING MISALIGNED CHECK AND ADJUST ALIGNMENT

CHECK AND TIGHTEN ALL PUMP
19. INSECURE PUMP I DRIVE MOUNTING
MOUNTINGS
20. SHAFT BEARING WEAR I FAILURE REPLACE BEARINGS
21. WORN PUMP ELEMENT FIT NEW PARTS
22. RELIEF VALVE CHATTER CHECK CONDITION OF VALVE / RENEW
23. R.V. INCORRECTLY SET RE -ADJUST SPRING COMPRESSION
24. LOW VOLTAGE CHECK VOLTAGE I /WIRING SIZES
25. PRODUCT ENTERING PACKING AREA CHECK PACKING CONDITION AND TYPE
CHECK AND REPLACE BROKEN
26. DRIVE TRAIN BREAKAGE
COMPONENTS
27. NEGATIVE OR VERY LOW DELIVERY HEAD CLOSE DELIVERY VALVE SLIGHTLY
REVERSE PUMP/RELIEVE PRESSURE /
28. DISCHARGE BLOCKED / VALVE CLOSED
CLEAR BLOCKAGES
REPLACE WORN PARTS / TIGHTEN UP
29. STATOR TURNING
STATOR BOLTS
30. STUFFING BOX EATS - PACKING CHECK FOR WORN SHAFT AND REPLACE
OG200/400C 177
DRAWINGS
DRAWINGS
178 DRAWINGS
List of drawings
Project: K1704
Incinerator
Dwg.no. Rev. Name of drawing.
2009245 B P&ID OG400CI/CIS, Steam H. DO tank, therm loose
1009048 B Main Dimensions OG200/400CIS
1010109 Combustion Chamber Assy. 200/400CIS with water flow meter
1008973 B Combustion Chamber Mounting Drawing OG200/400C
1008073 A Oil Burner F-50-45-T, OG200/400C
1007868 B Oil Burner F-50-45-T, Sub Assy. w/ Three-Way Test.
1008970 B Refractory and Insulation OG200/400C
1009273 Sludge Oil Dosage Valve Assembly, OG200/400C.
1009038 D Door Assy. CO 1310x510 with Sluice
2008096 D Steam Inlet Assembly w/Dual Valve w/Three-Way Test Cock
2008097 B Sludge Inlet Assembly
3010169 Sounding Cock
Flue gas
Dwg. no. Rev. Name of drawing.
4006931 C Main Dimensions Flue Gas Fan DN 350 H2
1007664 A Flue Gas Fan Assy. DN 350, w/ Pl and Insul. H2, 60 Hz
1006993 B Flue Gas Fan Assy. DN 350, H2, 60Hz
3007250 E Flue Gas Damper DN 400/350
1007001 B Flue Gas Damper DN 400/350
1007000 Flue Gas Damper, Sub. Assy. DN 400/350
14653 Expansion Compensator DN 350, L=400
Sludge Tank
1010147 Main Dimensions Waste Oil Service Tank 1100L Net.
1010149 A Sludge Tank Assy. 1100L Steam Heating w/Level Gauge/Sounding
Diesel Oil Tank

1010191 Main dimensions, Diesel oil tank 400L Net.
1010190 B Diesel Oil Tank 400L Net
4006299 B Filter for Diesel Oil. DN 10-3/8''
Water Tank
1009915 Main Dim., Water Tank 435L Net., Steam Heat.,Level Indicator
1009914 Water Tank Assy. 435 L, w/Steam Heating, Level Indicator
Electrical diagrams
4008939 Cable Arrangement OG200/400CAI, 380/440V - 220V, Flowmeter
1010120 Control Panel OG200/400CAI, 380/440V - 220V, Flowmeter
1010121 Mounting Plate OG200/400CAI, 380/440V - 220V, Flowmeter
3010574 Electrical Diagram, OG200/400CAI, 380/440V - 220V, Flowmeter
4007918 A Terminal Diagram Diesel Oil Burner F-50-45-T with Analog Motor
2006948 C Control Panel 380/440V-220V, Sl.Tank w/Steam Heater
2006949 B Mounting Plate w/El.Components Sludge Tank w/Steam Heating
3007895 E Electric Diagram Sludge Tank w/Steam Heating
3006996 G Thermocouple with Transmitter for Flue Gas
2008535 Control Panel, Water injection St.heat 380/440V-220V
4008419 A Cable Arr. Water Tank w/Steam Heating, 380/440V - 220V
2008536 A Mounting Plate, Water injection St.heat 380/440V-220V
3009866 C El. Diagram Water Tank w/Steam Heating, 380/440V - 220V
3009835 Junction Box for High- & Low Level Switch Diesel Oil Tank
4006721 C Terminal Diagram Diesel Oil Tank w/High and Low Level Switch
4006619 A Emergency Stop Switch

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Instruction Manual

Yard : Hyundai Mipo

Hull No.: 2451

Serial / project No.: K1704

Copyright  2003 TeamTec AS. All rights reserved.

Version Date Purpose Written

Updated Hour counter, alarm list, test of control functions,

Addendums, corrections and notes

Code Feature description

General .................................................................................................................................................. 33

CLEANING AND LUBRICATION ..................................................................................................................... 72

GENERAL .................................................................................................................................................. 108

Short-term storage ............................................................................................................................... 173

ACRONYMS AND TERMS

Acronym / term Definition

The incinerator “10 commandments”

 In case of abnormal operation, contact TeamTec

Incineration of solid and liquid waste

Plastic, Cardboard, Wood

Solid and liquid waste that is prohibited to be burned

IMO Annex VI regulation 16 prohibits incineration on ship of certain products, such as

Solid Waste handling

Service network for TeamTec incinerators.

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

Incinerator (combustion chamber).

Type: OG200 C(S)

400.000 Kcal/h (465KW)

Type: OG400 C(S)

512.000 Kcal/h (596KW)

Combustion chamber Max. 1200 °C

Electrical power, From ship distribution

Flue gas fan El. From incinerators

Negative pressure: 10-28 mmWC In combustion chamber

Total weight: 3210kg

Outline dimension: 1697 x 1900 x 1960 (L x W x H) See dimension drawing

Burner (fixed on combustion chamber)

Two nozzles: 2.5 gph

Diesel Oil viscosity Max. 13 cSt at 40°C

Burner air blower

Working press. 16 bar

El. Motor 1.43/1.38 Amp.

Ignition transformers: 230V / 10,000V

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

Diesel oil booster pump (optional)

Capacity: 110 l/h At 14 bar.

El.motor: See Burner motor

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

Flue gas fan (bulkhead mounted)

OG200C: 8000 m³/h at 300°C At 150 mmWC total back

Flue gas duct

El. motor: 380/440V, 7.5/8.6W

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

Control speed: 0-1800 rpm

Flue gas damper

Type: Welded steel damper with actuator

Drive force 20Nm

Volume: Net: 1,100/1,700 or 2,000/3,000 litres.

Cylindrical tanks 1 bar

Internal coated with one layer of

Weight: 490 / 566 or 605/750 kg.