PTR/ATRA^I Furnace Manual

1. HOW THE FURNACE WORKS

1.1 WHATTHE FURNACE IS USED FOR

1.2 HOW THE FURNACE WORKS

1.3 WHATTHE FURNACE SHOULD NOT BE USED FOR

1.4 ADVANTAGES

1.5 LIMITATIONS

1.6 PATENTED CONTROLLED PYROLYSIS® SYSTEM

1.7 TIME AND TEMPERATURE ADJUSTMENTS

1.8 LOCAL CODES

1.9 AIR PERMITS

1.10 SELECTION OF FURNACE SIZE

1.11 DRAWINGS AND ILLUSTRATIONS

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1. HOW CONTROLLED PYROLYSIS® CLEANING

FURNACES WORK
1.1 WHATTHE FURNACE IS USED FOR
Three common applications for Controlled Pyrolysis® Cleaning Furnaces
are 1)Painting and Powder Coating, 2)Automotive Parts, 3)Electric Motors

PTR Models

PTR Model Controlled Pyrolysis(S) Cleaning Furnaces are designed to

remove limited amounts of cured paint coatings from metal parts using
pyrolysis and heat at 700-800 degrees F (371-427° C). See Figure 1-1.
Typical metalpartswhich canbe cleaned are steeljigs, hangers, fixtures, and
hanging trees used to hold parts during paint operations on conveyorized
painting and powder coating lines.

Fig. 1-2 Paint hangers being loaded for furnace cleaning

Historically, the cleaning of dirty paint hangers and hooks has been ac
complished with chemical methods, using acid, caustic, or organic chemical
solvents. Disposal of the spent solvents containing the paint residues or
sludge has become more expensive because of environmental concerns and
liability problems relating to disposal ofhazardous chemical wastes. Because
the cleaning is done with heat instead of chemicals. Controlled Pyrolysis^
Furnaces eliminate many or all of the problems of excessive cost, safety,
toxicity, and waste disposal associated with chemical stripping methods.

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Explosion Relief
Door
Limit Controller
Thermocouple Furnace Thermocouple Monitors
Inside Furnace Temperature
Power Connection

Main Control
Box Stack Thermocouple
Monitors Stack Temperature
Front Door At Afterburner Exit

Secondary fUpper) Burner

Afterburner) Consumes Smoke
from Cleaning Process

Water Spray
System

Gas Inlet to
Burners

Primary (Lower)
Burner Heats
Furnace

R0311-02.DWC

Water Inlet

Fig. 1-1 Furnace Side View Showing Basic Controls

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ATR Models

ATR Model Controlled Pyrolysis® Cleaning Furnaces are designed to

remove limited amounts of oil and grease residues from automotive metal
partsusingpyrolytic heatat 600-800 degrees F (315-427o C)' Typical metal
parts which can be cleanedare heads, blocks, crankshafts, all cast iron parts,
and most aluminum parts. The fiimace can also be used to debond brake
shoes; to strip alternators, generators and starters and to clean water pumps

Historically, the cleaningof dirty,greasy heads, blocks, and other automotive

parts has been accomplished with chemical methods, using acid, caustic, or
organicchemicalsolvents. Disposal of the spent solvents containing the oily
residues and sludge has become more expensive because of environmental
concerns and liability problems relating to disposal of hazardous chemical
wastes. Because the cleaning is done with heat instead of chemicals, Con-
trolled Pyrolysis Furnaces eliminate many or all of the problems of exces
sive cost, safety, toxicity, and waste disposal associated with chemical
stripping methods.

VPI Models

VPI Controlled Pyrolysis Cleaning Furnaces are designed specifically for

the electric motor rewinding industry to safely and economically remove the
cured varnish, epoxy, or other organic material from electric motor stators
so the old wire can be stripped from the stator slots and new windings
installed. "T" frames and aluminum frames can be safely processed in this
fiimace. Other metal parts which can be cleaned are end bells, connection
covers, and any other painted or greasy parts.

Historically the stripping of stators has been done with heat: wood fires, gas
torches, open gas bumers, burn-off or bum-out fumaces or ovens often
uncontrolled as to results and as to environmental concems of smoke and
odor. In the early 1970's, pollution laws started to control the smoke and
odors from burning stators for stripping, and some shops tumed to chemicals:
first trichlorethylene, a vapor-degreaser solvent which would soften most
vamishes used in electric motors if the stator is left submerged in its hot
vapors for several hours.

The coming ofbetter vamishes such as epoxy that "trichlor" would not soften,
coupled with increasing knowledge about the harmful effects on workers
exposed to such solvents meant that vapor-degreasing solvents were becom
ing ineffective and even dangerous to workers health. Other chemicals such
as methylene chloride, a cold-stripper, could remove epoxy and all but the

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most resistantvarnishes. Howeverthe toxicity, noxious odors, and the rising

costs of disposal of spent solutions has greatly restricted the use of these
chemicals as well as acids, caustics, and others.

Because the cleaning is done with heat instead of chemicals. Controlled

Pyrolysis® Furnaces eliminate many or all ofthe problems ofexcessive cost,
safety, toxicity, and waste disposal associated with chemical stripping
methods. Cleaning with heat in a controlled furnace atmosphere and with
controlled furnace temperatureshas been proven completely safe for stators
for 25 years, and is the most cost-effective method of parts cleaning in many
industries including the electric motor rewinding business.

1.2 HOW THE FURNACE WORKS

Heat Cleans the Metal Parts by Vaporizing the Paint Residues or Other
Combustible Material on the Parts to Smoke.

Controlled Pyrolysis Cleaning Furnaces are highly specialized ovens

typically operating at 800°F (427°C) for PTR Models, 600 to 800°F (315 to
427°q for ATR Models, or 750-800°F (399 to 42fC) for VPI Models. The
cleaning process carriedoutby the furnace consists of heating the metal parts
up to the process temperature and maintaining process temperature long
enough to clean the parts. As the furnace temperature rises above about
600-700^ (315-371°C), the heat will pyrolyze (thermally decompose) the
paint residues, varnish, epoxy, oil, grease, etc. to smoke and other volatile
gases. The organic residues are literally vaporized off of the metal parts,
leaving them free of any organic material. Any inorganic pigments in the
paint or other organic coating are unaffected by the heat and remain inside
the furnace on the parts and can usually be easily removed by tapping,
brushing, or washing. If necessary, any inorganic materials remaining on
the parts can easily be removed by Jet Washer, Pressure Washer, Steel Shot
or Glass Beads, usually used for engine heads and blocks.

Fig. 1-3 Typical paint hangers, before and after cleaning

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Smoke from the Parts Is Consumed by an Afterburner to Eliminate Pollution

Thesmokeand pyrolysis gasescreated by vaporization of the paintcoatings,

oil grease, varnish, etc., are drawn through an afterburner chamber which
operates at1400-1600°F (760-871°C) with residence times of1/2 second or
greater. The hydrocarbon smoke and pyrolysisgases are completely burned
inside the afterburner section for effective pollution control. The hot stack
gases discharged to the atmosphere consist primarily of water vapor and
carbon dioxide which are invisible, odorless, and harmless. Thus the stack
discharge is smokeless and odorless.

When Furnace Has Cooled, Parts Can Be Removed

After all of the organic residues are vaporized off of the metal parts and no
further smoke is entering the afterburner chamber, this is an indication that
the cleaning cycle is ending. After the oven cycle timer times out and the unit
cools down below 300-400°F, the furnace door(s) may beopened so that the
metal parts will cool down more rapidly so they may be removed.

The Bum-Off Furnace can not remove the inorganic pigments that give a
paint or coating its color. A common example is the white pigment, titanium
dioxide. This inert pigment will be unaffected by the heat which vaporizes
the paint coating off the metal parts. The pigments will fall to the floor as an
ash during the cleaning process, although a small amount may adhere to the
metal parts. If the cleaned part is a paint hanger or hook, no further cleaning
is normally necessary as enough of the pigment will come off in the washer
not to give a problem. However, if a reject painted metal part is cleaned in
the furnace before repainting, it may be necessary to brush or wipe the last
film of pigment off the part under running water to get it clean enough to
repaint.

The Bum-Off Fumace can not remove fiberglass fibers, heavy metals, rust,
or dirt residues. Some type of secondary cleaning operation such as a Jet
Washer, Glass Beading, etc. is required to remove these inorganic residues.

For electric motor stators, the wire is the slots should be very loose with only
ashes remaining. All insulation should be gone (except the fiberglass insula
tion on the lead wires will remain as it is not combustible). The stator slots
should be clean, and the coils should have most of the enamel removed from
the individual wires.

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1.3 WHAT THE CLEANING FURNACE SHOULD NOT

BE USED FOR.
Parts such as drip racks, spray booth gratings, etc., that have dangerous or
excessive amounts of uncured paint on them must not be pyrolyzed in this
fiimace until the paint has been cured by putting the parts through a bake
oven to evaporate the solvent in the uncured paint. Do not use the furnace
for curing of varnished or painted parts, or other parts which may
contain large amounts of volatile solvents. Do not use the furnace for
processing parts with uncured paint on them. This fiimace does not have
a forced exhaust (because of high temperatures involved in pyrolysis) so it
cannot handle excess amounts of solvents that may evaporate at less than
400^ (200°C). Such solvent vapors may fill the furnace at or near room
temperature with an explosive mixture which can be ignited when the fumace
is turned on. Altematively, the rapid evolution of such vapors during initial
heat-up of the furnace may overwhelm the capacity of the afterburner and
lead to a fire in the fumace or exhaust stack.

<S)
Controlled Pyrolysis Bum-Off Fumaces are not incinerators. The fur
nace should be used only to reclaim metal parts for salvage and/or rebuilding
by removing conventional hydrocarbon coatings (paint/powder coatings,
oil/grease coatings) from metal parts. Do not use the fumace as an
incinerator to dispose of waste materials or medical or pathological or
nuclear materials.

DANGER: Do not clean any sealed container, pipe, tank, or other vessel
containing any material which may expand when heated and mpture
the vessel. This includes water-jacketed stators, heat exchangers,
coolers, oil-jacketed pipes, or any other sealed vessel. Plugs, caps, or seals
must be removed to prevent explosive forces from rupturing the vessel,
destroying the furnace, destroying the building, and ii\juring or killing
people.

Do not process wet paint, paint sludge, waste powder from powder
coating operations, paint filters, nitrocellulose paints, solvents, thinners,
waste plastic or polymer, PVC (polyvinyl chloride), lead or rubber
coated scrap wire or parts, wood, paper, trash, waste oil, waste grease,
oUfilters, ammunition, explosives, fertilizer, or anything else which may
overload the furnace and cause a fire or explosion. The furnace is not
designed as an incinerator. It is designed to clean and reclaim metal
parts.

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Do not process sludge from hot tanks, cold tanks, trichlor tanks, parts
washers, or jet washers.

Do not use the furnace to process automotive parts or other parts which
have just been rinsed in a volatile solvent such as gasoline, kerosene, or
similar highly volatile solvent

Do not process coatings that contain chlorine (example, PVC), fluorine

(example. Teflon® Du Pont Co.), sulfur, orelements other than carbon,
hydrogen, and oxygen as they will form dangerous, toxic, and corrosive
acids which will destroy the flimace walls. Processing such materials
may also violate Federal or State air pollution laws by producing "Acid
Rain". Nitrocellulose paints "Gun-Cotton", or similar materials can
ignite and bum violently and must not be processed.

Do not process parts made of magnesium or magnesium alloys. Parts

manufactured of these materials may be ignited by the burning of the
paint or other hydrocarbon coatings covering them. Once ignited, these
alloys can not be extinguished by conventional means.

Motor shops using both a solvent-stripping method (either hot

trichlorethylene vapors or methylene chloride cold stripper) should
carefully analyze their stripping procedures to make sure they are not
wasting time and money by un-necessarily solvent-stripping stators and
then processing the stripped wire in the furnace, which amounts to a
double process. In addition, these chemical strippers contain chlorine
which is very harmful around gas-buraing equipment

Consult factory before processing varnish drip pans from curing ovens,
varnish racks or carts; oU-soaked transformers; epoxy-encapsulated
coU ends; and other out-of-the-ordinary materials.

As epoxy materials have their own self-contained oxygen source needed

for combustion, epoxy-encapsulated stators are more difflcult to process
than conventional insulations. To minimize the chances of run-away
temperatures, epoxy-encapsulated stators should have both coil-ends
cut off if the connection data on the windings is avaUable. If data is not
available, cut offjust one coil-end and then crack-up or break loose with
a hammer any encapsulation possible on the lead-in end.

Do not process aluminum frame stators in the same load with epoxy-en
capsulated stators because if the epoxy ignites, it may be close enough
to an aluminum frame to overheat it. Aluminum frames should be placed

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near the bottom of the furnace cart to keep them out of the flames of
other stators should one ignite.

1.4 ADVANTAGES

Proper use of furnace can result in several economic advantages in addition

to the obvious advantage of air pollution control.

PTR Furnaces 1. "Prepping" or prior cleaning of the parts before loading them into the
furnace is not normally necessary.

PTR Furnaces 2. Metal hangers,jigs, trees, and fixtures used to hold parts on conveyorized
painting systems can be cleaned very economically by pyrolysis. Such
cleaning is especially useful in electrostatic paint operations where a good
electrical contact for paint wrap-around is essential. Also, possible hazard
ous sparking between the part and the metal hanger is eliminated when the
hangers are kept clean.

PTR Furnaces 3. Painted parts themselves can be cleaned by pyrolysis if proper secondary
removal of pigment is possible physically and economically. Care must be
taken when cleaningaluminum parts to make sure no ignition takes place in
the fiimace as aluminum melts at 1200°F, much lower than most metals.
Temperatures of800°F (427°C) will anneal and soften aluminum, perhaps
too much for re-use. Always test aluminum parts at lower temperatures to
determine if it is safe to clean them.

VPI Furnaces 4. Electric motor stators can be stripped by hand without any power tools.
Statorslotscan be cleaned quickly by handwith compressed air. "T"frames
and aluminum frames can be safely reclaimed. End bells, junction box
covers, andothercomponents canbesafelycleaned whileyouare processing
stators. Nameplatesare not harmed, so they do not have to be removed.

VP! Furnaces Many shops completely eliminate sandblasting because the stator slots are
free of any residue, and the use of steam cleaners can be drastically reduced
because many parts clean better and easier with heat.

VPI Furnaces Thestripped wire with theenamel removed may command a premium scrap
price. Scrap wire recovery can also be increased by processing stators that
were formerly scrapped with the wire in them.

AIR Furnaces 5. Engine heads and blocks come out of the furnace dry and ready for steel
shot, glass bead peening, or Jet Washers with biodegradable detergents.

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ATR Furnaces Safe for aluminum. Heads, blocks, water pumps, oil pans, valve covers, and
other components can be safely cleaned using standard furnace controls with
no technical modifications. The furnace can be used for stress relieving and
pre-heating parts before welding ifthe temperature required is800®F orless.

Carbon deposits are loosened by the cleaning process inside the furnace,
allowing less shot peening time and laborious hand grinding to remove the
carbon on engine heads and blocks. In many cases, the hand grinding
operations associated with cleaning heavy carbon build-up can be eliminated.

All Furnaces 6. Solvents and acids for stripping of parts can be significantly reduced or
eliminated along with the tanks, heaters, fumes, and other safety problems
associated with such chemical cleaning methods.

All Furnaces 7. Open stripping tanks with their odors and ignitable fumes can be
eliminated.

All Furnaces 8. Most sandblasting can be eliminated.

All Furnaces 9. Dumping of harmful chemicals, neutralizing and transporting of used

chemicals to liquid waste sites and handling by employees can all be
eliminated by "cleaning (stripping)with heat".

All Furnaces 10. Skin and eye irritation from solvents or acids used in stripping can be
eliminated along with protectivegloves, aprons, etc.

All Furnaces 11. A pre-set Cycle Timer means no attendant is necessary to supervise
processing.

All Furnaces 12. Thefurnaceis completely piped,wired,and testedat thefactoryto reduce

installation cost to the minimum.

All Furnaces 13. The patented Controlled Pyrolysis System for the furnace prevents
"uncontrollable fires" and thepossibility of partwarpage or otherdamage.

All Furnaces 14. In the unlikely event of an explosion or ignition inside the fiimace
pressurizing it, the Top Relief door(s) provide explosion relief and then
automatically close to seal air from the furnace. There are no spring loaded
doors to blow open and remain open to let air ignite the hot parts.

All Furnaces 15. The loading cart and outside tracks are furnished. There are no acces
sories to buy.

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All Furnaces 16. The light-weight high temperaturestack sections (chimney pieces) allow
quick and easy erection of the exhaust stack. Overhead hoists, cranes, or
rigging are normally not needed.

All Furnaces 17. Operating and safety controls required by most state and local codes are
standard. Special requirements such as Factory Mutual standards and In
dustrial Risk Insurers standards are available at extra cost where required by
the insurance underwriter.

1.5 LIMITATIONS

PTR Furnaces This furnacecannotremovethe pigmentthat gives a paint or coating its color
if that pigment is inert, such as the most common white pigment, titanium
dioxide. Ti02 falls to the floor as an ash after burning, but a small amount
may adhere to the part. If the part is a paint hanger, no further cleaning is
usually necessary as enough of the TiOz will normally come off in the washer
not to give a problem. However, if a reject painted part is cleaned in the
furnace before repainting, it may be necessary to brush or wipe the last film
of Ti02 off the part under running water to get it clean enough to repaint.

PTR Furnaces Some aluminum parts can be cleaned in the furnace while others can not.
Generally, this depends on the required cleaning temperature as well as the
geometry of the parts themselves. Some aluminum parts may tend to warp
or distort at the furnace cleaning temperatures. Temperatures of 800°F and
above will anneal and soften many aluminum alloys. When in doubt, it is a
good idea to test a few sample parts to see how they are affected by the
cleaning process.

VPI Furnaces Thisfurnace can not( nor cananyothers)stripa smallfractional-horsepower

stator as fast as an experienced man can using an open flame burner or gas
torch, perhaps in 20-30 minutes. However, the furnace can strip 5,10, 20 or
perhaps more stators at 1 time, and for the same operating cost. The only
labor required is cutting one coil-end, loading the stators in the furnace, and
unloading at theend of thecycleandvery quicklystrippingthe wire out.The
furnace quite often reduces labor intensive stripping operations to only
5-10% of that formerly used.

VPI Furnaces Stator frames or other parts made of zinc, "pewter", or "die-cast" can not be
burned in this furnace since this material melts between 600 and 800
dependingon the alloy.Fortunately, such stators are from usually very small
motors, on the order of 1/6 HP or smaller. If there is any doubt about the
material being zinc or aluminum, a simple test with concentrated nitric acid
diluted 50/50withwaterwill tell thedifference. (Nitricacid can be obtained

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from chemical supply houses, or in many cases from local electro-platers.)

One drop of this solution on a zinc part will evolve many bubbles and a fast
action; on aluminum there will be no reaction. The part must be clean of
paint or grease for the test to work. If the frame is zinc it must be cold-
stripped, solvent-stripped, or cautiously torch-stripped by hand.

All Furnaces This furnace can not remove or "bum-off' the rust on the parts as rust is an
inorganic material. However, the fumace loosens the rust for easier removal
during secondary cleaning operations.

All Furnaces This furnace is not designedfor use as a solvent-drying oven. It may be used
for water-drying only if desired. The reasons behind the recommendation
that it not be used to cure painted parts or vamished stators are: After use as
a stripping furnace, the fumace floor and walls contain fine particles of ash
which are stirred up when the furnace is operating and may contaminate the
freshly painted or varnished parts, ruiningthem.Also, the exhaustsystemon
the fumace is due to a natural draft set up by the afterbumer instead of a
fan-forced exhaust as on a conventional bake-oven, and may not prove
adequate to remove the solvent fumes at the proper rate. DANGER: At
tempting to use the furnace for solvent drying, or as a curing oven can
lead to a fire or explosion in the fumace. Circulation within the fumace
is also due to naturalconvectionand may have a greater temperature gradient
than required to properly cure paint or varnish.

1.6 PATENTED CONTROLLED PYROLYSIS® SYSTEM

Thisfurnace isequipped with aControlled Pyrolysis System (C.P.S.) which
is a method of measuring and controlling the rate of emission of volatile
material from the parts being processed. The C.P.S. does this by monitoring
the afterburner exhaust temperature. If it rises above a preselected point, a
fine mist water spray is tumed on to cool the emissions before they reach an
ignition temperature. When the temperature drops due to the decreased
amount of volatiles, the water spray is tumed off. Should the volatiles
increase, the water spray will come back on.

This system is automatic and is interlocked so that the lower burner on the
furnace cannot come on if there is insufficient water pressure for the C.P.S.

To insure that the system operates properly, it is mandatory that the

primary and back-up spray nozzles located Just inside the door of the
furnace are tested beforeeach cleaningcycle. For information on testing
the operation of the water spray system, refer to Chapters 4 and 11.

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1.7TIME AND TEMPERATURE ADJUSTMENTS

For PTR Models, experience has shown that most painted or coated parts
will be adequately stripped ata temperature of800°F (427®C). The amount
of time required depends on the weight of combustible material on the parts.
Based upon field experience, typical cleaning cycle times for various size
Controlled Pyrolysis® Fumaces loaded with paint hangers are listed in the
Table 1.Please note these are strictly averages based upon a wide variety of
customers. If your load of metal parts is much larger and more heavily
contaminated with paint residues, cleaning times will be longer. If you have
a very light load of hanger, hooks, or other parts with light residues, the
cleaning time may be shorter.

For VPI Models, experience has shown that most electric motor stators can
be adequately processed at a stator temperature of 750°F (400°C). The
amount of time required depends primarily on the weight of the stator and
the cross-section of its thickest part. The furnace temperature controller
indicates and controls the furnace temperature by the furnace air tempera
ture. The stator temperature will lag behind the air temperature sometimes
for an hour or more if it is a large stator, and the stator temperature must get
to 750°F for the insulation and varnish to be decomposed, so the time for a
good jobwill begreater than just the time ittakes the furnace togetto750°F.

For ATRModels,experience hasshown thatmost cast- iron automotiveparts

will beadequately cleaned atatemperature of750°F (400°C). Valve covers,
pan manifolds, crankshafts, and aluminum heads are usually cleaned at
600°F. The amount oftime required depends on the weight ofcombustible
material on the parts, and the total weight of the metal loaded to the furnace.
The larger your load and the more heavily contaminated it is with oil and
grease residues, the longer your cleaning times will be. If you have a very
lightloadof partswithlightresidues of oilandgrease, thecleaning timemay
be shorter.

Establishingjust how clean a part is can be a very subjective process and

depends on the opinion of the person evaluating the part. Just how clean the
part has to be when it emergesfrom the cleaning furnace also depends to a
degree on the type of post cleaning operation, if any.

Because the cleaningtime is dependenton three major variables, the amount

and weight of metal parts loaded to the furnace, the weight of combustible
residues on the parts, and personal preferences or individual requirements,
cleaning times can vary widely. During the early use of the furnace, use

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caution and be careful to prevent over-loading the furnace until enough

experience is gained to accurately select cycle times for various size loads.

The furnace is equippedwith a 0-12 Hr. adjustable timer to allow time cycle
changes. The timer has two scales, the black figures showing the correct
settings if the electricity supply is 60 hertz and the red figures for 50 hertz
supplies. The temperature indicator-controllers are also dual-frequency
models. All controls and motors are set up at the Factory to operate at the
customer's specified supply frequency.

TABLE I

Typical Cycle Times for Various Size PTR Furnaces

Furnace Size Cycle Times, Hrs. Water Spray Counts, Typical

27 2-3 20-200

52 2-4 200-400

88 2-6 400-600

150 3-6 200-600

260 4-8 400-700

340 6-8 500-800

640 8-10 600-1500

Note: Ifyour furnace is equipped with the Automatic Time Cycle feature
and you are cleaning parts which are not very massive, such as paint hangers
and hooks,a settingof 1 to 2 hourson the Cycle Timer is generally adequate,
as the temperature of these parts will generally follow the temperature of the
furnace fairly closely. If youarecleaning largemassive partssuchas engine
blocks, dies, etc., the actual temperature of the parts may lag behind the
temperature of the furnace considerably. For parts such as these, you will
need to select a longer time on the Cycle Timer in order to insure that the
parts have had time to reach temperature before the Cycle Timer starts. See
Chapter 2 for a more in depth description of how the Automatic Time Cycle
feature operates.

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1.8 LOCAL CODES

Furnaces are equipped to comply with most local building codes, but
sometimes there will be requirements which the factory has no way of
knowing unless told before shipment. If such requirements become known
after receipt of the furnace, please contact the manufacturer before authoriz
ing any work to change anything so that we may fully explain to local
authorities details of our unit, and also for us to understand their require
ments. If the manufacturer was not notified in advance of any special
requirements, then any changes will be at the expense of the customer.

1.9 AIR PERMITS

CONTROLLED PYROLYSIS® FURNACES are Process Equipment that

use state-of-the-art technology to eliminate hazardous chemical cleaners and
their problems in the work place such as disposal after use. Some states
exempt these furnaces, but most require air permits. Our furnaces have been
permitted in every state that requires them. The process of securing a permit
to construct or install and to operate a piece of Process Equipment usually
requires filling out the applicable state forms and providing information
about the process, the equipment, and the location where the equipment is to
be used.

Uponrequestbyourcustomers, wewillfurnishan E.P.A.Air PermitPackage

for your particular state which can be used as the application package for
submittal to the state.The package normally consistsof the appropriate state
formsalongwithsupporting technical documentation suchas expectedstack
emissions, combustion gas flow rates and temperatures, etc. The customer
must supply required information related to the owner of the equipment,
persons responsible, physical location, including plot plans where required,
etc.Thecustomer is ultimately responsible forfullycompleting, signing, and
submitting the completed forms alongwith any necessary filing fees.

1.10 SELECTION OF FURNACE SIZE

Refer to the drawings at the end of this chapter entitled "PRC/PTR Furnace
Frame Cart Dimensions" and"ATRA^I Furnace Cart Interior Frame Dimen
sions"whichshowtheusablecartloadingspacefor the standardfurnacesizes
ranging from 88 to 640 cubic feet in volume.

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Furnaces should be selected by size depending on the size and shape of the
parts to be processed. The parts must fit within the confines of the cart that
is furnished with the furnace. The Factory cart must be used instead of
customer-supplied carts, baskets, or other containers as such other containers
may block the proper flow of air within the furnace and lead to problems in
processing.

Parts to be processed must not be nested or stacked so that they touch each
other over an appreciable area as this retards the decomposition of the
combustible material due to inadequate air flow around the parts. Inadequate
air flow may cause "coking" or transformation of the combustible material
on the parts to hard charcoal (carbon) with the result that the charcoal must
combine with oxygen on the part, perhaps raising the part temperature higher
than it should be. Getting rid of the charcoal in this way is a slower process.
Therefore, if parts are allowed to coke, processing time must be increased.

The quantity of parts to be processed also affect furnace size selection and
cycle time. In cooperation with the customer, the factory will "custom"
design at extra cost a cart suitable to hold and process the customer's parts.
This will require sample parts being sent in (preferred) or drawings of the
parts, quantities to be processed and the time frame of customer's operations
so that a proper cart can be designed. Of particular interest will be the amount
of combustible material on the sample parts. This can be determined by the
factory or by the customer by carefully weighing coated parts before and
after cleaning.

Most companies who use metal hangers for paint spraying operations know
that by conventional means(paint stripping by acid or chemical agents), the
cleaning process is looked upon as a dirty, time consuming, laborious job
not to be done until absolutely necessary. Sometimes this means a 1/2" or
more build-up of paint on the metal hangers before cleaning takes place.
With the use of this fiimace these extra large build-ups of paint can be
cleaned; however, the first loads, until the extra large build-up is off, must
be reduced to less than the normal number of hangers. Once the majority of
the metal hangers have been cleaned by the furnace, then the normal number
of hangers per load can be started.

1.11 DRAWINGS AND ILLUSTRATIONS

Refer to Figure 1-1 for a side view of a typical Controlled Pyrolysis®
Cleaning Furnace, showing thegeneral layoutof thecontrol box,gasburners,
and water spray system.

Page 1-15 Revision 5,2/1/2004

 c:\newq)man\doclall.chp PTR/ATRATI Furnace Manual

Figure 1-4 shows the basic lay-out of the main control box, while Figure 1-5
shows the components of the water spray control system.

Refer to the drawings labeled "ATR, VPI, & PTR Installation Drawing" for
details regarding placement and installation of the furnace.

The drawing labeled "PRC/PTR Furnace Frame Cart Dimensions", shows

the cart sizes for model numbers PTR-27F up to PTR-885.

The drawing labeled "ATRA^I Furnace Cart Interior Dimensions" shows

the cart sizes for model numbers ATR-27F thru ATR-680 and VPI-27F thru
VPI-680.

Revision 5,2/M20QA Page 1 -16

 PTR/ATR/VPI Furnace Manual c:\newq)man\doclaU.chp

Water Spray Totalizer

Afterburner Power Toggle Switch

Pilot Lamp
0 ® #
Stack Temperature/
Water Spray Controller
Primary Burner
Pilot Lamp

Furnace Temperature Cycle Timer, 0—12 Hr.

Controller

Diagnostic Panel

Limit Controller
Rg401-05.DWC

Fig. 1-4 Lay-out of Main Control Box Components

Bypass Valve
Primary Water Spray
Bypass Valve
Back—up Water Spray
Pressure Relief Valve

Automatic Valve
Primary Water Spray Water Pressure Gage
Normally Open

Automatic
Water Pressure Switch Back—up Water
Spray Valve

Automatic Valve
Primary Water Spray
Normally closed 0
9401-06.DWG

Strainer —^ — Gate Valve

Fig. 1-5 Components of Water Spray System

Page 1 -17 Revision 5,2/1/2004

 RELIEF

•p

I t9V/«0Hz
4
i
El

-1 n (. 28>
A

SIDE VIEW FRDNT VIEW

12* C.30) MINIMUM TO COMBUSTIBLE WALL NOTES:

0) £r:::r-
1. NUMBERS IN BRACKETS < ) OR UNDER COLUMN ' M' METERS.
fl)

I TOP RELIEF
h-» PLAN V EW
00

1-27-97 CORRECTED DIM. G FDR 539

REV. C 12-16-96 SEE EIR 145 (CART ROLL DUTSi
REV. B ADD NEW MODELS 8. UPDATE CHART
REV. A 3-15-95 TITLE BLOCK t NOTES

POLLUTION CONTROL
S mHbX'
PRODUCTS CO. DALUS. TEXAS
CLEARANCE TO ROLL
CART OUT
24*C.6n MINIMUM TO SET CONTROLS «. SERVICE
GENERAL INSTALLATION DRAWING
FOR MODEL DC. PTR. ATR, VPI.
PRC, ARC, VRC FURNACES
NONE RLB 1-9-95

S9501-05
 A B C D E r G A B C D E r G
MODEL MODEL
IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M IN. M

DCl 59 1. SO 66 1. 68 43 1. 09 101 2. 57 28 . 71 10-1/2 . 27 N/A N/A 330 85 2. 16 189 4. 29 88 2. 19 124 3. 15 38 . 97 18-1/2 . 42 188 4. 73

DC2 82 1. 58 46 1. 17 46 1. 17 69 1. 75 28 . 71 10-1/2 . 27 24 . 81 340 109 2. 77 121 3. 07 97 2. 48 141 3. 58 38 . 97 18-1/2 . 42 144 3. 88

DC3 68 1. 73 72 1. 83 55 1. 40 91 2. 31 27 . 69 10-1/2 . 27 54 1. 37 390 109 2. 77 122 3. 10 110 2. 79 162 4. 12 38 . 97 16-1/2 . 42 144 3. 66

0C4 88 1. 73 84 2. 13 81 1. 83 98 2. 44 27 . 89 10-1/2 . 27 57 1. 49 391 109 2. 77 134 3. 40 97 2. 48 147 3. 74 38 . 97 18-1/2 . 42 158 3. 96

B7r 59 1. 50 69 1. 75 43 1. 09 80 2. 03 28 . 71 10-1/2 . 27 54 1. 37 392 121 3. 07 122 3. 10 98 2. 49 148 3. 76 38 . 97 18-1/2 . 42 152 3. 86

52 88 1. 73 72 1. 83 55 1. 40 91 2.31 27 . 89 10-1/2 . 27 54 1. 37 412 79 2. 01 182 4. 12 117 2. 97 153 3. 89 38 . 97 16-1/2 . 42 170 4. 32

71 68 I. 73 84 2. 13 61 1. 55 96 2. 44 27 . 69 10-1/2 . 27 57 1. 49 448 121 3. 07 134 3. 40 98 2. 49 135 3. 43 38 . 97 16-1/2 . 42 164 4. 17

78 68 1. 73 99 2. 52 55 1. 40 91 2.31 27 . 69 10-1/2 . 27 81 2. 06 449 121 3. 07 122 3. 10 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 152 3. 86

88 71 1. 80 85 2. 16 73 1. 85 113 2. 87 28 . 88 15-1/2 . 65 94 2. 39 450 109 2. 77 134 3. 40 110 2. 79 148 3 78 38 . 97 18-1/2 . 42 158 3. 98

111 77 1. 96 87 2. 21 79 2. 01 117 2. 97 26 . 66 15-1/2 . 39 94 2. 39 482 97 2. 46 170 4. 32 98 2. 49 141 3. 58 38 . 97 16-1/2 . 42 186 4. 73

125 88 1. 73 137 3. 48 55 1. 40 95 2. 41 27 . 69 10-1/2 . 27 108 2. 85 504 109 2. 77 134 3. 40 122 3. 10 180 4. 08 38 . 97 18-1/2 . 42 188 4. 27

14] 83 2. 11 83 2. 16 91 2. 36 129 3. 28 26 . 68 15-1/2 . 39 94 2. 39 512 121 3. 07 134 3. 40 110 2. 79 148 3. 76 38 . 97 18-1/2 . 42 164 4. 17

150 83 2. 11 97 2. 46 85 2. 16 123 3. 13 26 . 88 15-1/2 . 39 128 3. 20 539 109 2. 77 170 4. 32 98 2. 49 138 3. 48 38 97 18-1/2 . 42 192 4. 88

177 83 2. 11 97 2. 46 97 2. 46 143 3. 63 26 . 86 15-1/2 . 39 126 3. 20 549 121 3. 07 134 3. 40 118 3. 00 155 3. 94 38 . 97 16-1/2 . 42 164 4. 17

188 83 2. 11 85 2. 16 112 2. 85 ISO 3. 81 26 . 66 15-1/2 . 39 94 2. 39 585 131 3. 33 134 3. 40 110 2. 79 148 3. 76 38 . 97 16-1/2 . 42 170 4. 32

222 85 2. 18 121 3. 07 85 2. 16 117 2. 97 28 . 86 15-1/2 . 39 138 3 51 577 121 3. 07 148 3. 71 110 2. 79 148 3. 78 38 . 97 18-1/2 . 42 178 4. 47

225S 97 2. 46 109 2. 77 89 2. 26 125 3. 18 26 . 66 15-1/2 . 39 (1) < l> 608 121 3. 07 134 3. 40 128 3. 25 166 4. 22 38 . 97 16-1/2 . 42 164 4. 17

228 133 3. 38 93 2. 38 73 1. 85 123 3. 13 28 . 88 15-1/2 . 39 148 3. 71 812 208 5. 23 82 2. 08 117 2. 97 165 4. 19 98 2. 44 40 1. 02 ( 1) < n

240 109 2. 69 93 2. 36 95 2. 41 133 3. 38 26 . 66 15-1/2 . 39 126 3. 20 622 109 2. 77 188 4. 22 110 2. 80 148 3. 76 38 . 97 16-1/2 . 42 188 4. 78

243 97 2. 46 97 2. 46 103 2. 82 141 3. 58 26 . 88 15-1/2 . 39 128 3 20 840 121 3. 07 158 4. 01 110 2. 79 148 3. 78 38 . 97 18-1/2 , 42 188 4. 78

280 91 2. 31 121 3. 07 97 2. 46 142 3.61 38 . 97 18-1/2 . 42 138 3. 51 880 121 3. 07 158 4. 01 117 2. 97 154 3. 91 38 . 97 18-1/2 . 42 188 4. 78

290 97 2. 46 121 3. 07 97 2. 46 136 3. 46 38 . 97 16-1/2 . 42 138 3. 51 699 131 3. 33 168 4. 27 98 2. 49 136 3. 46 38 . 97 18-1/2 . 42 204 5. 18

300 85 2. 16 157 3. 99 88 2. 18 124 3. 15 38 . 97 18-1/2 . 42 174 4. 42 714 121 3. 07 164 4. 17 117 2 97 154 3. 91 38 . 97 18-1/2 . 42 194 4. 93
REV. 0 1-27-97 CORRECTED DIM. G rOR 539
308S 9/ 2. 46 109 2. 77 117 2. 97 166 4. 22 38 . 97 18-1/2 . 39 (1) < n 748 121 3. 07 170 4. 32 117 2. 97 154 3. 91 38 . 97 16-1/2 . 42 200 5. 08 REV. C 12-16-96 SEE EIR 145 (CART ROLL OUTS)
REV. 8 11-8-98 ADD NEW MODELS & UPDATE CHART
308 91 2. 31 121 3. 07 110 2. 80 159 4. 04 38 . 97 18-1/2 . 42 138 3. 51 806D 288 8. 78 118 3. 00 117 2. 97 158 3. 98 128 3. 20 50 1. 27 < 1) < 1> REV. A 3-15-95 t i t l e block t NOTES

885 133 3. 38 158 4. 01 132 3. 35 181 4. 60 38 . 97 16-1/2 . 42 194 4. 93

NOTES: POLLUTION CONTROL

( 1) MODELS 225S, 306S 612D, 806D ARE FORK LIFT LOADED. PRODUCTS CO. DALLAS. TEXAS

LUADJNb AREA IN hKUNI •F THE FURNACE JS DLIERMINLIJ

GENERAL INSTALLATION DRAWING
BY INSTALLATION SITE CONFIGURATION.
FDR MODEL DC. PTR, ATR. VPI,
(2) NUMBERS UNDER COLUMN IN. =INCHES PRC, ARC, VRC FURNACES

<3) NUMBERS UNDER COLUMN 'M- =METERS SCAUC NONE OR. by PLB DATB 1 "9-95
DLC. JMOI-Oi
( 4) MODEL DCl IS S•UPPLIED WITH A STATIONARY INTERNAL RACK. LA«(«> CHAV1 IMO. s r a cmm BY DATE

ccc SMOI •05

SHOT 2 or £ 1D«C. NO. S950I-05

I 0)
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 EXHAUST EXHAUSX,
I STACK STACK

12' <300> MIN. TO COMBUSTIBLE WALL

ELECTRICAL

w
PLAN VIEW

CONTROL
BOX

inlet CAS
3/4' NRT

CONTROL BOX

24' (610> MIN. TO SET CONTROLS «. SERVICE BURNERS

SIDE VIEW FRDNT VIEW

A B C 0 F G H
J K NOTE:
MODEL IN. M IN. M IN. M IN. M IN. M N. M IN. M IN. M IN. M IN. M
NUMBERS UNDER COLUMN 'IN' = INCHES
NUMBERS UNDER COLUMN "M' = METERS
54T 46 58 1.47 86 2.19 122 3.10 26 .66 .28 48 1.22 40 1.02 25 .64 65 1.66 NUMBERS IN C ) MILLIMETERS

63T 46 58 1.47 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 25 .64 65 1.66

72T 46 58 1.47 no 2.80 146 3.71 26 .66 .28 48 1.22 46 1.17 25 65 1.66

REV.C 12-12-96 DELETE I «. ADJUST H

73T 46 70 1.78 86 2.19 3.10 26 .28 48 1.22 40 1.02 33 .84 65 1.66
122 REV.B 9-19-96 DELETE ROLL OUT CART

84T 46 70 1.78 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 33 65 1.66 POLLUTION CONTROL

PRODUCTS CO. DALLAS. TEXAS

96T 46 70 1.78 no 2.80 146 3.71 26 .66 .28 48 1.22 46 1.17 33 .84
65 1.66

85T 52 1.78 26 .66 33 .84

INSTALLATIDN DRAWING
32 70 86 2.19 122 3.10 .28 48 1.22 40 1.02 65 1.66
FDR "TALL BGY" FURNACE.
98T 52 32 70 1.78 98 2.50 134 3.40 26 .66 .28 48 1.22 43 1.09 33 65 1.66
NONE R.S. 4-g3-91
112T 52 70 1.78 no 2.80 146 3.71 26 .66 .28 48 1.22 46 1.17 33 .84 65 1.66
19505-01

M PJ
I yQ
NJ CD
o
 CART FRAME DIMENSIONS

width KPTH HEIGHT

MODEL NO. INCHES (METERS) INOCS (METERS) INCHES (METERS)

277 25 (. 64) 39 (.99) 21 (.53)

52 33 (. 84) 45 ( 1. 14) 36 (. 92)

71 33 (. 84) 57 (I. 45) 41 (1.04)

76 33 (. 84) 72 ( 1. 83) 36 (. 92)

86 39 (. 99) 46 ( 1. 22) 46 (1. 17)

III 43 (1. 14) 50 (1. 27) 32 (1. 32)

125 33 (. 84) 110 (2.80) 36 (. 92)

Ml 51 (1.30) 48 (1. 22) 64 (1.63)

ISO 51 (1.30) 60 (1. 53) 58 (1.47)

177 51 (1.30) 60 (1. 53) 70 (1.76)

188 51 (1.30) 50 (1. 27) 85 <2. 16)

222 51 (1.30) 84 (2. 14) 58 ( 1. 47)

226 99 ( 2. 52) 56 (1. 42) 46 ( 1. 17)

240 77 (I. 96) 56 ( 1. 42) 65 ( 1. 65)

243 63 (1.60) 60 ( 1. 52) 76 (1. 93)

260 57 (I. 49) 84 (2. 14) 68 (1. 73)

290 63 (1. 60) 84 (2. 14) 68 (I. 73)

300 31 (1.29) 120 (3 03) 58 (1. 47)

308 37 (1. 49) 84 (2. 14) 80 ( 2.03)

330 51 (1.30) 132 ( 3 03) 36 (1. 47)

340 75 (I. 91) 84 (2. 14) 68 ( 1. 73)

390 75 (1. 91) 84 (2. 14) 80 (2.03)

391 75 (1.91) 96 (2 44) 68 (1. 73)

392 67 (2.21) 84 (2 14) 68 (1.73)

412 45 (1. 43) 124 (3. 15) 86 (2. 19)

448 67 (2. 21) 96 ( 2. 44) 68 (1. 73)

449 87 (2. 21) 84 (2. 14) 80 (2.03)

450 73 (1. 91) 96 ( 2. 44) 80 ( 2. 03)

462 63 (1.60) 132 (3. 35) 68 ( 1. 73)

304 73 (1.91) 96 ( 2. 44) 92 ( 2. 38)

312 67 (2.21) 96 (2. 44) 80 (2.03)

339 75 (1. 91) 132 (2. 35) 68 (1. 73)

549 87 (2.21) 96 (2. 44) 86 (2. 19)

565 97 (2. 46) 96 ( 2. 44) 80 (2.03)

577 87 (2. 21) 108 ( 2. 75) 80 (2.03)

608 87 (2. 21) 96 (2. 44) 98 (2. 49)

622 75 (1. 91) 128 ( 3 25) 80 (2.03)

640 87 (6. 21) 120 (3. 05) 80 (2.03)

POLLUTION CONTROL PRODUCTS CO.
2677 niECWOOD ST. DiOLAS, IX 75220
680 87 (2. 21) 120 (3. 05) 86 (2. 19)
•nw C-CHART
699 97 (2. 46) 130 (3. 30) 68 ( 1. 73) S, 9-19-96 PRC/PTR FURNACE
714 87 (2. 21) 126 ( 3 20) 86 (2. 19) NOTES 19502-13
FRAME CART DIMENSIONS
748 87 (2. 21) 132 ( 2. 35) 86 (2. 19) I. TOP LOADING M. 27 IS SUPPLIED WITH A STATIONARY INTERNAL RACK.
e«im«L9502-13 NONE RLB P4T12*" 13~95
883 99 ( 2. 52) 120 ( 3 03) 101 (2. 57) THE RACK IS 27'W. X 27'D. X 32'H.

Ftri>«i»9-i9-96 >Hgr 1 or 1 |pwa. wa L95Q2—13

I p
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•"-» (D
 SQUARE OPENING
CHIMNEY SECTION
INSUUTED CHIMNEY SECTION
ADJUSTABLE PUSHING
1-1/2"(38) CRIMP FITS
INSIDE SECTION ABOVE.
EACH SECTION MAKES
(D UP TO 34-1/2"(876).
I
ro
bo
TYPICAL VIEW A-A
36"
(920)
RAIN CAP
STORM COLUR ,
Slide Down Over
60" MIN.
(1520)
NOTES: 4-HOLES 1/4" DIA.
2"(51) INSUUTION EVENLY SPACED TO
(*) REFERS TO MODEL 26D-680 IGG OR OLDER
MASTIC SEALER KAOWOOL SLEEVE SECURE SECTIONS
FURNACES HAVING G2T OR J-8D/81/82 BURNERS
TOGETHER.
KAOWOOL
NUMBERS IN BRACKETS ( ) OR 60" MIN. \ l.
UNDER COLUMN 'M' = MILLIMETERS ADJUSTABLE PUSHING
(1520) KAOWOOL
DIM. C REFERENCES A SQUARE OPENING
THROUGH THE INSTALUTION STRUCTURE'S ROOF. OUTER MATERIAL
26 GA. STAINLESS STEEL
INSTALLER:
SQUARE WEIGHT/INSUUTED SECTION
FOR ANY LENGTH LESS THAN 36"(.92)
CUT CHIMNEY SECTION AT BOTTOM. OPENING 36 LBS. (16.33 KG.)
SQUARE
OPENING
A B C
MODELS
IN. M. IN. M. IN. M.
DC-1/27 INSUUTED STACK
8 200 12 300 19 480 36"(.91) LONG SECTIONS «tv.B •-»«-<» tacto rviMciz wtm ueisee on o-n
DC-2/SP-13
SNAPS TOGETHER MV.C i-»-w
DC-3, DC-4, FASTENS WITH SCREWS IttV.B I-IT-M *00[D VIIW A-A * MUOt OUMt
netjk n-s-t« cw i o (Euinmre nomii mnitium
52-150, TALLBOYS 10 250 14 360 21 530
SCTR 6-15
POLLUTION CONTROL
(•>260-680 PRODUCTS CO.
FLAT ROOFS PITCHED ROOFS DAUAS. TEXAS
WITH J-8X OR 12 300 16 410 23 580
G2T BURNERS
EXHAUST STACK TYPICAL INSTALUTION
260 & UP FOR ALL FURNACES, INSTALLED THRU
WITH J-121-3 14 360 18 460 25 630 NON-COMBUSTIBLE ROOFS ONLY
BURNERS
FURNACES WITH
RLE: 1950301 D.DWC
LCI500 OR 0-57 16 406 20 508 27 686 UYER: STACINST ua_
BURNERS PLOT DATE: 8-24-05 19503-01