Operating Manual UK S-Series
Contents
1. FAMILIARISE YOURSELF WITH SHUT DOWN PROCEEDURES NEVER LEAVE OPERATING EQUIPMENT UNATTENDED SAFEGUARD STOCKPILED MATERIAL IN OPERATING ZONE KEEP ENGINE DECK FREE FROM SPILLED FUEL AND DEBRIS KEEP AREA AROUND BURNER FREE FROM DEBRIS BE AWARE OF AND PREVENT FIRE HAZARDS AT ALL TIMES REMEMBER SAFETY OF THE MACHINE WORKSITE AND YOUR SITE SURROUNDINGS IS YOUR RESPONSIBILITY 2 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL INDEX PRINCIPLE OF AIR CURTAIN INCINERATION Page 1 GENERAL DESCRIPTION OF S SERIES Page 2 SAFETY CONSIDERATIONS eene Page 5 HOW TO SET UP THE MACHINE eee Page 8 SITE PREPERATION Page 10 LOADING AND STARTING FIRE Page 13 HOW TO FEED A PIRE aa e a atra tarea tla eaae Page 17 SHUTDOWN taa ie ac Led Page 18 ASH REMOVAL 4 22 rante pie uh n ito rk Rene er tak bna Page 19 TROUBLESHOOTING tu dikriet akku Page 20 MAINTENANCE AND CARE OF THE UNIT Page 21 SERVICING SPECIFICATIONS eee Page 22 ENGINE COWLING REMOVAL ika rta naeh ruentis Page 24 LIFTING POINTS LADDER GUARD amp EMBER SCREEN MOUNTING HOLES na aede hates doe dene a eae Page 25 3 K2. and the soil conditions are not too soft If you are going to excavate the ash out then consider where you will dump it In all cases you will need to let the ash cool down before moving it IMPORTANT NEVER EXCAVATE A TRENCH UNDER THE MACHINE TO ENLARGE THE BURNING CHAMBER AS THE UNDERSIDE OF THE BURNER CAN BE DAMAGED BY DIRECT CONTACT WITH THE FIRE THIS WILL INVALIDATE THE WARRANTY 10 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SITE PREPERATION Faster operation through staging the wood piles Air Burners Fireboxes were designed primarily as a pollution control device but oper ated correctly they will burn clean wood faster than open burning To achieve the best throughput the fire must remain at the highest temperature possible You achieve this by remembering three rules 1 Don t smoother the fire with too much or use very dense material 2 Load with small amounts and keep a level load in the firebox 3 Separate the best burnable wood and use it to maintain a hot fire The basic principle of operation is not too different from any fire You use your best wood to get it started and if the fire dies down you use this again to bring it back up The big difference is that you need to prevent high moisture content and dense materi als from bringing the fire temperature down The temperature drops smoke increases and your burn rate sl
3. ash with a thin layer of dirt to minimize fly ash Connect appropriate cables or chains to the pad eyes or the pull block on the front of the machine and pull the firebox forward The ash will pile up and fall out the back of the unit Be cautious for the remaining hot embers Wet the ash pile down remove un burned chunks of wood and then dispose of it or make it safe EXCAVATING Ash can also be removed by reaching in with an excavator from the rear doors and digging the ash out Smother the hot ash with soil beforehand or use a mist spray of water to reduce fly ash Remember to use the appropriate breathing apparatus and be cautious of the remaining hot embers and flying hot ash Take appropri ate precautions with the excavated hot ash it will remain hot for several days 19 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL TROUBLESHOOTING 1 Fire will not start Material in fire box has too much air space To correct load heavy material to make the lower material pack down Use torches and light from the bottom so the fire burns up 2 Fire burning at one end Load heavy materials directly on top of the burning area This causes the flames to fan out in an effort to reach the top of the pile As the fire begins to spread keep material piled on top of the flames until the entire firebox is burning 3 Fire smoking too much The most common re
4. not have a floor and should not be located over combusti bles such as dry grass or peat moss In addition hot embers will escape from the unit and depending on the wind will land on the ground around the unit The unit should not be located within 30 meters of any stored combustible mate rials The waste material to be burned during the day s operation can be stored within the 30 meter perimeter to facilitate loading The operator must monitor the loading pile to insure embers do not ignite the loading pile The combustible ma terials to be stored for burning at a later date must be stored outside the 30 me ter perimeter or in accordance with the chart on page 6 of this manual which suggests adjustments for wind speed The unit should not be operated when the wind speeds reach 20 MPH as the potential to carry hot embers is significantly increased As an operator you should always be aware of wind speed and direction In creased wind speed will affect the integrity of the air curtain and will cause hot embers to travel farther See the wind speed chart regarding suggested set back on page 6 5 KHL Version 11 11 2008 4 5 6 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL NEVER use highly combustible materials to light the unit Highly combustible materials such as petrol diesel etc ignite at an explosive rate which may cause serious injury or death The sa
5. transport skid electric motor drive NOTES All weights and dimension are approximate Subject to change without notice 2 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL GENERAL DESCRIPTION S SERIES When delivered to a job site the S Series machine is ready for use as soon as it is off loaded The entire system is built on a skid type base frame which is designed for easy movement over the ground The forward equipment deck supports a four cylinder die sel engine fuel tank drive system and the fan When viewed from the front of the unit the patented air disbursement manifold is mounted on the left top side of the combus tion chamber The back of the firebox is fitted with refractory lined doors that allow ash removal and access to the only when it is empty firebox The diesel engine is coupled through a clutch drive PTO Power Take Off that turns the fan The high velocity air is sent down the manifold through the vanes and directed to the outlet nozzles A balanced and distributed air flow is directed across the top of the box and then down into the combustion zone The curtain of air acts as a lid over the fire box trapping a large percentage of the es caping particulate matter smoke and causing it to burn down even further under the curtain before finally escaping through the curtain as a hot gas The air from the noz zles travels across the f
6. 15 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL LOADING AND STARTING THE FIREBOX HOT START A hot start uses the embers from the previous days burning operation after the ash has been emptied The more ash in the firebox that you start with the LESS room you have for burning new materials First insure there are enough embers remaining to generate enough heat to get the new waste materials burning If the waste materials do not light you can use a propane torch in the lighting hole If the material does not light the firebox must be emptied be fore trying a cold start HOT START LIGHTING Similarly to a cold start you begin with your best and most burnable materials 1 Load the firebox to about one third or half way with the best wood The wood should begin burning as soon as you start loading 2 Engage the fan at 1 100 RPM This should help fan the flames and spread the fire If you experience heavy smoke then reduce the RPM or disengage the fan Be cautious not to blow out the fire 3 As the fire begins to heat up increase the speed to 2000 RPM maximum 16 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL HOW TO FEED A FIRE It will generally take 30 to 60 minutes for the fire to build to a point where the tempera tures are sufficient for the unit to be operati
7. ANUAL S 40 in operation Rear Doors Open IMPORTANT Notice how soil is placed all around the inside bottom to close anv openings under the skids that mav be caused bv uneven terrain This will prevent smoke from escaping 4 Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SAFETY CONSIDERATIONS READ ALL SECTIONS OF THIS MANUAL BEFORE YOU BEGIN BURNING OPERATIONS The S Series machine operator is dealing with fire on a daily basis and it is very impor tant that each and every individual involved with the machine be alert and practice very rigid safety precautions Read and understand this manual before you start When you are running the S Series unit you are responsible for assuring that it is op erated in the safest possible manner at all times If you notice something wrong cor rect it immediately and if you cannot correct it find someone who can and or shut down the machine Basic Safety Points 1 2 3 The unit should be placed on cleared level ground The unit should be placed on level ground to facilitate loading dumping and moving of the unit The rear doors weigh over 900kgs each and should not be opened if the unit is inclined on any axis more than 5 degrees The unit should be placed such that no combustible material is stored within a minimum 30 meter clearance in any direction The S Series units do
8. Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine Operating Manual UK European S Series Air Burners Equipped With Kubota V2003 TE Diesel Engine Self Contained Refractory Walled Air Curtain Burner The green wood processing machines KINGWVELL HOLDINGS LIMITED UK DEALER Phone 01376 550989 Cordons Farm Depot U Long Green enquiries kingwell holdings co uk Cressing www kingwell holdings co uk Braintree Essex CM77 8DL US Factory and Main Office Air Burners LLC 4390 Cargo Way Palm City FL 34990 Phone 772 220 7303 or 888 566 3900 FAX 772 220 7302 E mail info airburners com Web www airburners com 1998 2005 Air Burners LLC The words Air Burners and the Air Burners Logo are Registered Trademarks of Air Burners LLC All Rights Reserved Subject to change without notice KHL Version 11 11 2008 1 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SAFETY FIRST READ THIS MANUAL BEFORE OPERATING THE EQUIPMENT OPERATE MACHINE ONLY IN ACCORDANCE WITH THIS MANUAL MAKE SURE YOU HAVE THE ABILITY TO PUT OUT SPOT FIRES CARRY OUT A RISK ASSESMENT BEFORE OPERATIONS ONLY TRAINED OPERATORS TO USE THIS EQUIPMENT ALWAYS USE THE MACHINE RESPONSIBLY ONLY USE THE BURNER IN SUITABLE CONDITIONS AND LOCATION DO NOT USE THE MACHINE IF IT IS DAMAGED OR DEFECTIVE ADHERE TO MACHINE MAINTENANCE SCHEDULES
9. E FIREBOX COLD START To minimise start up smoke you can Use your driest materials Ensure your materials do not retain dirt or sand COLD START LIGHTING 1 The air should be off The engine should be Running but the PTO should be disengaged 2 For best results and quickest light up start the fire from the bottom because fire will soread up much better than it will soread down 3 Use a propane torch or dry rags on poles to light the fire 4 The fire can be started from under the rear doors and from the access door in the forward panel on the manifold side of the unit Access door for lighting Wait until the fire has strengthened and flames are reaching the top of the firebox Then engage the air at 1 100 RPM As the fire burns stronger increase the air approximately 200 RPM every 15 minutes up to a maximum of 2000 RPM Don t increase the air too quickly as you can blow the fire out If you add air and the smoke gets heavy then reduce the RPM and let the fire catch up Once it clears up you can slowly increase the air again Sometimes it is helpful to fan the fire during the start up phase You accomplish this by increasing the RPM for 3 to 8 minutes then decreasing it i e 1 400 RPM up to 2 000 RPM and back down to 1 400 RPM This sometimes helps to spread the fire throughout the material How much air to add and when to add it during startup will vary with the type of materials being burned
10. HL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL S 40 Series 4 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL PRINCIPLE OF AIR CURTAIN INCINERATION OPERATION Air curtain burners are designed primarily as a pollution control device Using a diesel engine driven fan these machines generate a curtain of air that is blown over the top of the fire This curtain of air acts as a trap over the top of a thermo ceramic lined fire box The wood debris is loaded into the firebox and then ignited Usually with a pro pane torch or clean rags Once the fire has gained strength the air curtain is turned on The air curtain traps most of the smoke particles and causes them to re burn under the air curtain where the temperatures exceed 1 000 C These machines do not inject any fuels into the fire the fire is sustained only by adding more wood debris The air from the air curtain is not heated The only fuel used in the continuous operation is that of the diesel engine driving the fan Air Burners 1 Manifold and nozzles that create the air curtain over the refractory lined firebox 2 Refractory lined wall to retain and increase burning temperatures 3 Material being burned and agitated by air curtain 4 High velocity air curtain or lid over fire 5 Continued ai
11. anual for Engine Service Details Engine should be serviced every 200 hours of operation Description Air Burners P N Manufacturer s P N NAPA P N Air Filter primary 5000 1334 Donaldson P827653 6671 Air Filter safety 5000 1335 Donaldson P829332 6672 Oil Filter 5000 1327 Kubota 70000 74035 1068 Fuel Filter 5000 1299 Kubota 16631 43560 3393 Fuel Water Separator Filter 5000 1297 Racor R20P 3614 V Belt Engine 5000 1341 Kubota 15469 97010 259425 Electrical System Fuse 40A Amp ID Green Style MAXI 5000 0302 NAPA BK7821079 BK7821079 Optima Battery Red Top 12V CCA 800 AH 50 5000 0199 OPTIMA SC34A Engine Oil 15W40 Diesel Grade Low Silicon Anti Freeze Green Units are shipped from factory with 50 50 mixture green antifreeze water Bearing Lubricant NLGI Grade 2 Engine Coolant Fuel Tank Capacity Min 265 Litres Rev 0307a 22 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SERVICING SPECIFICATIONS Draining of Motor Oil To facilitate the draining of motor oil in the Kubota Diesel Engine Model V 2003 TE an oil drain valve and drain hose has been added The image below shows the drain valve installed on a V 2003 TE engine It can be reached through the lower rear access door and is located on the radiator side of the engine block behind the fuel tank The position of the pet cock as it is installed on the engine block may vary the lever may
12. ason for a smoking fire is too much dirt or dense materials going into the fire box and reducing the heat You must make sure the wood waste material is free from large amounts of dirt Load from your best wood pile to bring the tempera ture back up and keep load amounts small and regular You may have overloaded the box or loaded the box too fast Too much material will smother the fire Stop loading and let the fire catch up The material you are loading may have a very high moisture content You can either load at a slower rate or mix the wetter material with dryer material If you are letting the fire burn down or the load in the box is less than 1m deep you may need to turn the air down by reducing the engine RPM 4 Smoke from one area of the box The area is probably not burning well Add smaller material from your best wood pile to this area to help build the fire As the smoke clears add heavier material again 5 Smoke from under the base rails or bottom of panels Loose dirt was not properly shoveled around inside of box to seal between panel bot toms and the ground To fix shovel dirt around the outside where the smoke is escap ing Once the ash inside builds up this will stop 20 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL MAINTENANCE AND CARE 1 Daily check list CLEAN AIR FILTER EVERY DAY BLOCKED FILTER NO WARRANTY Engine coo
13. be towards the bottom Lift the lever and turn to open the valve When closing the oil drain valve make sure that the lever latches securely in the closed position as shown below The air curtain burners are shipped with a drain hose already attached to the nipple of the drain valve as shown below Collect the spent motor oil in an appropriate con tainer outside the engine cowling for proper disposal V2003 TE Oil Drain Valve NOTE All routine engine maintenance and service can be performed through the access doors and openings provided This includes adding and draining the motor oil and en gine coolant changing of air fuel and oil filters etc The engine cowling should only be removed for major engine work 23 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL Removal of Engine Cowling Removal is not required for routine engine maintenance and service 1 Remove all bottom rail bolts nuts and washers reach behind to hold nut with wrench There are three on each side front and back Also remove the single bolt and washer to the left of the PTO lever It s nut is welded to the bracket 2 Reach through the front access door and loosen the two 2 set screws nearest the PTO the other two are plugged and need not be loosened from the sleeve that connects the PTO lever rod to the PTO Use an Allen wrench 3 16 Then remove the leve
14. d This is the preferred position It is also acceptable to have the wind blow into the manifold It is not recommended to have the wind come from either end of the machine as this will tend to disrupt the air curtain B PRE OPERATION CHECKS Air filter for cleanliness VERY IMPORTANT CHECK EVERY DAY Engine oil level Engine coolant level and antifreeze rating Diesel fuel level Check fuel gauge Battery cable switch connection The unit is shipped from the factory with the man ual battery disconnect in the disconnect position 6 Radiator cleanliness Check for blockages amp debris IMPORTANTI NEVER START OR STOP THE ENGINE WITH THE FAN DRIVE EN GAGED AS THIS MAV BREAK THE DRIVE COUPLING THE AIR FLOW WILL THEN STOP AND THE MACHINE WILL OVERHEAT 8 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL HOW TO SET UP THE MACHINE C STARTING Kubota V2003 TE Ensure that the power take off clutch lever is disengaged Turn the speed control knob clockwise to en sure engine speed is at idle Close battery disconnect switch located on one of the terminal of the battery If needed turn key switch counterclockwise to the PREHEAT position for a few seconds Turn the key switch clockwise to the RUN po sition The gauges will register to confirm that power is supplied to the panel Start the engine by turning t
15. e box for lighting should be kept just below the manifold nozzles Your goal is to develop a good hot base fire and to maintain a good hot fire throughout your burning operation This will give you the cleanest burn and the most through put There is always smoke on start up as all of the material in the box contains moisture compared to later in the burn operation when only the new material you are loading contains moisture Plus the air curtain cannot be fully engaged until the fire has strengthened or you run the risk of blowing out the fire Remember we recommend the following tips for efficient burning operations High moisture content material will need lots of dry fuel to co fire it Let material dry out before burning if possible Never burn anything except clean wood waste and plant fibre based material Large items like stumps and logs will need splitting to burn efficiently Break up long items to avoid bridging the fire Avoid smothering the fire with large sheet material break it up first Keep soil and similar material out of the firebox to prevent smothering Always keep ash levels low and empty every morning Keep area around machine clean to prevent uncontrolled fire damage Take care of the manifold and lining efficiency will be lost if damaged 14 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL LOADING AND STARTING TH
16. e loads may smother the fire for a short period before it ignites this will slow the burning down in crease smoke and reduce your daily throughput 7 The load in the box should not go higher than 30cm below the manifold If the material is piled higher it will begin to break the air curtain and emit smoke The fire should be loaded continuously throughout the day in order to maintain operat ing temperatures If the fire is not loaded continuously the temperature will drop the through put will go down and smoke will escape BURNING HOT Burning Clean Burning Clean Maximum Efficiency 17 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SHUTDOWN HOW TO BURN FIRE DOWN FOR SHUTDOWN All loading should stop one hour before you intend to put the fire out As the fire burns down maintain the fan speed until the box begins to smoke As the smoke increases reduce the air speed in increments of about 300 RPM This will help to reduce the smoke The air in the manifold needs air flow both to accelerate the burn down and to protect the manifold from warping due to excessive heat DO NOT shut off the air flow while there is still a fire in the firebox Doing so may cause the high temperatures to warp the manifold nozzle assembly etc Your warranty does NOT cover damage due to ex cessive heat Once the fire has burned down and flames are not visible it wi
17. fest method to start the fire in the box is to use materials such as paper rag and kindling wood In the ab sence of these materials or when starting materials with a high moisture con tent use clean untreated timber such as pallets NEVER climb on the unit to view or light the fire Use the ladder built into the unit and never go beyond the top step or use a step ladder or similar platform located at a safe distance from the unit Do not stand along the rails or on top of the S Series unit under any circumstances Shutting the unit down in an emergency Stop loading the unit stop the air flow by disengaging the PTO then shut down the engine Dump soil or sand onto the fire Water should only be used as a last resort as it will damage the refractory panels and invalidate the warranty WIND SPEED VS SAFE DISTANCE Approximate Safe Distance for VERG Speed amp Build Vegetation Trees Stored Materials MPH ings O 125m m m 6 KHL Version 11 11 2008 7 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL Personal Safety Operators need to be aware of the following potential hazards A Flying hot embers and hot air being released from the fire Operators or anyone within a 30m radius of the fire should wear appropriate fire resistant clothing The operator should always wear appropriate PPE and should never wear synthetic mate
18. he key switch all the way clockwise to START then release key switch and warm up the engine at idle speed of 1 000 RPM for 5 to 10 minutes be fore engaging fan at 1 100 RPM Engage the fan by slowly engaging the clutch lever until it locks into place Fir mara MET Engine and fan speed mav now be increased i by turning the speed control knob counter DISENGAGE ENGAGE clockwise to the maximum 2000 RPM tA To stop the engine turn the kev to the off position Alwavs remember to let the engine idle for 5 minutes before shutdown to cool properlv and lubricate the turbo bearings Clutch Lever 9 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SITE PREPERATION GOOD SITE PREPERATION PRACTICES ARE To place the firebox for easy access To sort the waste wood pile To organise the inflow of new wood waste To position work equipment safely When locating the firebox Consider access for your transport to load and unload the firebox Ensure there is enough room to work next to the machine Consider where the waste piles will be located We generally recommend two waste piles explained in next section Consider the wind direction Hot embers will be escaping from the firebox during all burning operations Consider where and how you will empty the firebox If you are going to drag the fire box to empty it ensure there is room
19. irebox creating the air curtain effect then it reflects off the far side ceramic wall adding oxygen to the combustion zone helping to generate a hotter more complete fire This additional agitation helps prevent the fire from starving for oxygen as the ash builds up during burning operations All of this is carefully engineered to provide the correct amount of air at the correct velocity It is sometimes thought that more air flow will actually increase the burn rate This is INCORRECT Modifying the air flow will actually have the opposite effect and reduce the machine s through put Additionally it will reduce the ma chine s ability to meet air quality minimum standards There is a maximum rate at which wood can burn Trying to exceed that rate by adding more air to an air cur tain burner causes two major problems 1 It will cool the fire reducing combustion efficiency creating more smoke carbon dioxide and nitrogen enriched This will begin a circular effect of further reduc ing the oxygen and further reducing combustion efficiency The result is that your through put drops and smoke increases Increasing the air flow beyond design standards will over pressurise the firebox causing larger sized particles to be ejected from the firebox The larger hotter embers ejected will pose a much greater fire hazard 3 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING M
20. lant level and clean radiator fins Diesel fuel level in fuel tank Tap dirt out of air intake housing and check for excessive dirt Oil level Very important for initial 200 hours with new engine 2 Periodic Maintenance moov Change engine oil and oil filter as per the recommended intervals Clean replace fuel filters 2 as needed Clean and inspect air filter and replace as needed Grease both air fan bearings every 100 hours Adjust and grease PTO as per supplied NACD Service Manual Clean debris from radiator core with power washer Low pressure Check alternator V belt and adjust as needed Ommoourp Kubota Diesel Engine V2003 TE is equipped with NACD Clutch Model 411238 AM The clutch size is 7 55 7 5 Using a torque wrench with a socket 1 7 16 to fit the hex on the outside end of the PTO handle the engagement torques measured at cross shaft is 50 58 ft Ibs or 68 79 Nm Always refer to the NACD Service Manual Section 3 5 should adjustments be re quired The cowling will have to be partially removed to gain access to the clutch see page 25 of this Operating Manual for details on how to remove the cowling 21 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SERVICING SPECIFICATIONS Parts List for Routine Service of Kubota Industrial Diesel Engine V2003 TE Also Refer to Engine Manufacturer s Service M
21. ll be safe to shut the en gine and air down Make sure the fire is extinguished or the machine is adequately guarded before you leave the job site Do not spray the refractory walls with water as this will damage them use soil or sand When the burning materials in the fire box have burnt down to ash reduce engine RPM s to 1 100 RPM and disengage the PTO Move the key switch to the OFF position to shut down the engine If you intend to leave embers to smoulder all night ensure the work site is secured or has a constant security guard to prevent anybody from getting near the firebox Al ways apply your ladder lock plate The inside temperatures of the firebox will remain very high most of the night 18 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL ASH REMOVAL HOW TO EMPTY THE S SERIES UNITS The box will operate with a maximum of 1m of ash inside but as the ash gets deeper the efficiency of the unit goes down The box should not be run with over this level of ash inside Always plan to empty the ash every morning after the box has stood over night before burning operations begin This will give you maximum capacity in the fire box and the ash will be easier to handle There are generally two ways to empty the ash by dragging the unit forward or by ex cavating it out using an excavator and bucket DRAGGING Open the back doors and cover the
22. ng at maximum efficiency 1 Add material from your best wood pile slowly for the first hour It takes about an hour for the fire to reach minimum temperature Your goal is to achieve an even and hot fire across the unit 2 If you get excessive smoke and ash when you load the wood waste while drop ping the load through the air curtain then you may need to turn the RPM s down temporarily This may especially be required earlier in the burn operation 3 Take caution when loading the unit that the material to be burned is not dumped in the box too quickly causing hot embers to be thrown from the unit 4 If you have an area in the box that is smoking this indicates the temperature is low in that area Add material from the best wood pile to get the fire temperature up Once that area is burning add some of the heavier material 5 The rate at which you load the unit varies depending on moisture content of the materials and the temperature of the fire If you overload the box you will notice an increase in white smoke White smoke is an indication that the temperature is dropping If the smoke increases stop loading until the fire has caught up You can also bring the temperature up by adding materials from the best wood pile 6 For the highest throughput load LESS MORE OFTEN Smaller grapple loads more often will give the materials a better chance to burn and will result in your highest throughput of material Oversized grappl
23. ows down if you over load the machine with material that has a high moisture content or is too bulky While these are ok to burn in the firebox you want to add them to a hot fire so they dry out or ignite quickly To keep the temperature up and to main tain the highest throughput of material you amp should mix the very burnable wood with the less burnable materials throughout the 5 course of the burning operation The most common to accomplish this is to store a pile of the most burnable materials or what we call the two pile svstem BURNING HOT Burning Clean Burning Clean Maximum Efficiency 11 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL SITE PREPERATION The Two Pile System For an efficient operation you would have two piles The first pile or main debris pile is the material less likely to burn well and is located away from the ember path but with good access to your loading machinery The second pile or best material pile is your driest and most burnable wood When you first setup the site the operator should spend some time sorting through the main debris pile pulling out what appears to be your best and most burnable materials This is the material you will start the fire with this is the material that will give you a good hot burning base fire You will also draw from this pile throughout
24. r by pulling it forward 3 Remove the throttle cable from the engine loosen set screw then remove the two jam nuts holding the knob assembly and re move same from cowling 4 Disconnect the electrical harness from the control panel at the Deutsch quick disconnect plug inside the cowling to the left of the front access door behind the location of the black control panel box Do not detach the control panel box from cowling 5 The cowling can now be removed by lifting it slightly and pulling it as indicated by the arrows in the direction away from the air fan Two persons can lift the cowling easily Re install in reverse order 24 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL LIFTING POINTS STAIR GUARD amp EMBER SCREEN MOUNTING HOLES S 200 Series Front Lifting Points 4 Air Burners LA Rear Lifting There are four designated lifting pad eyes for lift ing the S Series units by crane Only lift by at taching cables to these four pad eyes Their lo cations are marked with yellow lifting point labels with up arrows The Ladder Guard is shipped in place secured with a bolt and nut red circle in photo above The bolt must be replaced with a suitable pad lock before the firebox is placed into service The S Series units are equipped with mounting holes for an optional ember
25. r flow over oxygenates fire keeping temperatures high 1 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL GENERAL DESCRIPTION S SERIES The self contained refractory walled air curtain system is manufactured as a fully trans portable combustion system designed to reduce wood waste and vegetation to ash in a safe controlled burning process without excessive particulate emissions The UK European S Series machines are offered in 4 sizes S 10 S 20 Euroburner amp S 40 Euroburner S Series Dimensions Overall Size Fire Box Size Weight LxWxH LxWxH kgs gtr 8 2m x 2 6m x 2 6m 5m x 1 9m x 2 2m 13 600 S 20 Euro 8 3m x 2 2m x 2 3m 4 9m x 1 5m x 1 8m 11 800 burner 5 7m x 2 2m x 2 3m 3 3m x 1 5m x 1 8m 9 300 Diesel Engine Version S Series Kubota V2003 TE Tier2 or equivalent engines Diesel fuel Consumption rated at average operating RPM Drive System PTO amp mechanical direct coupling drive Notes on Through put Through put depends on many factors such as nature and type of wood waste moisture content operator skills elevation and location etc The figures stated here are guidelines only Machines of different dimensions with same through puts denote ability to accept larger material without pre processing into smaller sizes Options Firebox safety screen heat recovery engine deck security hook lift equipment
26. rial around the machine as this type of material can burn and cause injury B Eye and ear protection is recommended around the machine It is good practice to wear approved ear protection when working in close proximity to the fan and engine and eye protection to guard against dust and flying embers C Hot Panels The backs of the thermo ceramic panels and parts of the structure can reach temperatures as high as 260 degrees C Caution should be taken to insure operatives do not come in contact with these hot areas Always wear gloves D Ash and dust can be released during the operation and during cleaning Operators should wear appropriate respirators to protect themselves from dust and fly ash This can be damped down with water spray or soil when emptying the machine 7 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL HOW TO SET UP THE MACHINE A POSITIONING THE UNIT The S Series units are totally self contained and ready to use upon delivery to the work site The units are built on a skid base that is designed to be dragged into position and moved around the site The weights of the various units are given in the General De scription section Ensure cables chains and shackles are certified and tested for these weights With respect to the prevailing wind direction the unit should be positioned such that the wind comes over the back of the manifol
27. screen See Ember Screen Instructions for details regarding units shipped with an optional ember screen 25 KHL Version 11 11 2008
28. sts for the first hour of burning As burning continues the ash will build up and seal off the bottom of the unit We recommend loading the fire box from the opposite side of the air manifold This will prevent accidental damage to the manifold by the loader Load your most burnable material materials from the best wood pile as discussed in the previous section which is the smaller dryer and cleaner wood into the firebox to a level just below the manifold Ensure the entire bottom area of the fire box is covered Use clean dry timber with rags to ignite the fire 13 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL LOADING AND STARTING THE FIREBOX COLD START Larger material should be placed at the top This heavier material will help compress the smaller material which will give you a better start If there are large air spaces be tween the materials in the firebox the heat will not build up as quickly and the fire may be more difficult to light Larger material once burning will become your hot base fire to support continued burning Use your best and driest materials for startup as this will form a strong base for continued burning plus it will start quicker and burn hotter If you will be burning more large objects then it is best to load them after the first hour of burning when the fire is up to full temperature The level of material in the fir
29. the day if you should need to stoke up the fire more on this in the following sections As the firebox operator is drawing from the main debris pile throughout the day he should continue to replenish the best wood pile as necessary This pile only needs to be enough material to stoke up the fire if needed and enough material to get you started the next day BURNING HOT Burning Clean Burning clean Maximum Efficiency E G 3 w 253 12 KHL Version 11 11 2008 Air Burners LLC UK European S Series Air Curtain Burner Kubota V2003 TE Engine OPERATING MANUAL LOADING AND STARTING THE FIREBOX THE GOALS IN STARTING AN S SERIES UNIT ARE To achieve an even fire across the length of the box To start the fire from the bottom of the initial pile To build a hot base fire To feed the machine at the design capacity There are two methods for lighting the unit a cold start and a hot start A cold start means the firebox is clean and has no hot embers left from a previous burn A hot start uses heat from the previous day s burn COLD START Unit should be on level ground the fan should be off but the engine can be running to bring it up to operating temperature To prevent smoke from escaping under the box shovel dirt along the inside bottom edges of the panels It will only need enough to prevent the smoke from escaping un derneath the unit This is generally only a concern on hard ground and it usually only la
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