KUHN GDSTP-24025-MAN-0002 P1 Manual

Kwp wash press

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Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual

GDSTP-24025-MAN-0002_P1

KWP Wash Press

Page 1 of 65

Q-Pulse Id VM364

Active 29/10/2013

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Summary of Contents for KUHN GDSTP-24025-MAN-0002 P1

Page 1 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual GDSTP-24025-MAN-0002_P1 KWP Wash Press Page 1 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 2: Description And Technical Data
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data Description and Technical Data We reserve the right to make technical modifications Goodna STP KWP Washpress Page 2 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 3: Product Description
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data Product Description Use as directed The KWP wash press is intended exclusively for washing, compressing and dewatering recycled materials already separated from waste disposal processes, especially screenings from public sewage treatment plants. The machine is not intended for other types of application.
Page 4 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data Layout 1.2.1 Graphical representation We reserve the right to make technical modifications Goodna STP KWP Washpress Page 4 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 5: Operational Description
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data Operational Description 1.3.1 Task The KWP wash press was designed and built for washing, compressing and dewatering solid matter (screenings). Basically, the machine consists of a feed hopper; the combined conveyor, washing and press screw;...
Page 6: Technical Specifications
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data Technical Specifications 1.4.1 KWP Wash Press Type: KWP 300/1000 Serial number: 1.4.2 Dimensions and technical specifications Max. throughput (raw screenings): Degree of dewatering of the screenings (depending on raw material and design of the driving pipe): 40 - 45 % TS...
Page 7 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Description and Technical Data 1.4.3 Geared motor Make: Siemens Type: Number of phases: Output P: Current consumption I: Voltage U: Frequency f: Starter: Y DR (S100) Method of protection: IP 56 Insulation class: 1.4.4 Solenoid valves...
Page 8: Safety Notes
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes Safety Notes We reserve the right to make technical modifications Goodna STP KWP Washpress Page 8 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 9 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes General Safety Indications Duty of due care of the operator This machine was designed and built having due regard to an analysis of safety hazards and after careful selection of mandatory harmonized standards, as well as other technical specifications.
Page 10: Explanation Of The Safety Symbols Used
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes Explanation of the Safety Symbols Used 1.2.1 Safety symbols on the machine These symbol must refer to the hazards ensuing from the machine. Biohazardous materials The medium processed by the machine falls under the category of “Biohazardous materials“.
Page 11 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes 1.2.2 Safety Symbols in these Operating Instructions These symbol must, above all, draw the attention of the reader to the text of the adjacent safety indications. Caution Places with this label point to possible risk of accident and injury.
Page 12 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes Basic Safety Measures 1.3.1 Keep information available Keep these operating instructions by the machine. Ensure that everyone who has to work on the machine can view the operating instructions at all times. In addition to the operating instructions, the operator must also provide user manuals as defined in the Work Conditions Act and the Work Equipment Use Regulation.
Page 13: In Normal Mode
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes After the machine is switched on, it works via the control unit in automatic mode. It can lead to an automatic run at any time. 1.3.4 In normal mode Do not remove or deactivate any safety device while the machine is running.
Page 14: Modifications To The Machine
For safety reasons, do not undertake any unauthorized modifications on the machine. This also applies to welding work on load-bearing parts. All planned modifications must be approved by Kuhn GmbH in writing. Use only original spare parts. If third-party parts are used, there is no guarantee that they were designed and manufactured according to load and safety specifications.
Page 15: Requirements For Operating Personnel
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Safety Notes Requirements for operating personnel All people who work on the machine must read the operating instructions and confirm with their signature that they have understood them. 1.4.1 Operating personnel Only people who are trained, instructed and authorized to operate the machine may do so.
Page 16: Maintenance Instructions
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions Maintenance Instructions We reserve the right to make technical modifications Goodna STP KWP Washpress Page 16 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 17: Maintenance
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions Maintenance Safety Indications for Maintenance When maintaining the wash press make sure to comply with following safety indications to prevent mortal injuries to people, machine damage and other property damage.
Page 18 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions Inspections and Preventive Maintenance 1.2.1 Daily 1.2.1.1 Checking operability During operation observe whether: ■ unusual running noises can be heard ■ oil is leaking from the gearbox ■ the hinge is tight.
Page 19 ■ If the press output and throughput diminish, assume that the screw is worn. In this case, disassemble the screw and check for dimensional accuracy. Consult Kuhn GmbH when doing so. 1.2.3 Semi-annually or every 600 operating hours 1.2.3.1 Checking fastenings and screw connections ■...
Page 20 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions Cleaning, lubrication, maintenance 1.3.1 Weekly or after 30 operating hours 1.3.1.1 Cleaning ■ Switch off the machine using the main switch and secure against unintentional reclosing. ■ Clean the outside of the machine using a suitable cleaning device. Caution! It is imperative that the solenoid valves and other electrical equipment are not directly cleaned with the water jet but with a brush, etc.
Page 21 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions 1.3.2.3 Cleaning ■ Switch off the machine using the main switch and secure against unintentional reclosing. ■ Cleaning the wash and press water trough ■ Cleaning the compaction zone (use a brush if there is hard dirt) ■...
Page 22 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions 1.3.3 Semi-annually or every 600 operating hours 1.3.3.1 Check the oil level of the gearbox ■ Switch off the machine using the main switch and secure against unintentional reclosing.
Page 23 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions 1.3.5 Every 3 years or after 10,000 operating hours 1.3.5.1 Replace oil in gearbox Caution! Gearbox case and oil can be hot. There is risk of burning. When changing the oil clean the gearbox case thoroughly by means of oil flooding to remove oil sludge, abrasion and old oil residues.
Page 24 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions 1.3.6 Maintenance schedule Page Machine Part Activity Time in OI Daily Entire machine Checking operability Clean outside Weekly Entire machine (30 op. hrs.) Remove deposits Check for concentricity and smooth running Screw, bearing unit Assess press output and throughput slotted screen bottom...
Page 25: Lubricant Table
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions 1.3.7 Lubricant Table Examples of lubricants Desig- nation Lubricant under DIN 51502 Degol Energol Falcon SPARTA Renolin Klüberoil Mobilgear Optigear OMALA Ersolan TRIBOL BG220 GR-XP220 CLP220 CLP220 GEM 1 BM220 1100 Mineral oils...
Page 26 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Maintenance Instructions Repairs Specialists from the respective department shall perform repairs on the wash press. If spare parts are needed, use only the spare parts indicated in chapter 11 of these operating instructions.
Page 27: Installation Instructions
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions Installation Instructions We reserve the right to make technical modifications Goodna STP KWP Washpress Page 27 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 28: Environmental Requirements For Installation
Kuhn technicians. In the event the machine operator installs the machine, this should be done only by specialists and strictly according to Kuhn regulations. Follow the rules contained in these operating instructions. Take note of the following hazards when installing the machine: ■...
Page 29 Solenoid valve block After taking the parts out of the packaging check the supplied kit against the parts list and delivery note. Immediately report damaged or missing parts to Kuhn GmbH. 1.3.3 Taking out accessories Remove all separately enclosed accessories such as pins, bolts, etc. from the wash press and place these parts nearby within easy reach.
Page 30 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions Assembly and installation 1.4.1 Adjustment at the installation site Use an industrial truck or hoisting device designed for the weight of the wash press. Securely fasten the load suspension devices and slings on existing load fastening points and place the machine on the installation site.
Page 31 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions 1.4.4 Installing wash water supply Connect the wash water supply for the washing and rinsing to the water distribution through a flexible delivery hose. Comply with the following conditions: ■...
Page 32 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions 1.4.6 Connecting explosion protected solenoid valves Perform the electric connection of the solenoid valves according to the connection layout below. There is another connection layout in the connector box of the solenoid valves. Explosion junction box Made of steel Type 8118 / 121-807...
Page 33: Connecting Motor
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions 1.4.7 Connecting motor The terminal box of motors with 1 rpm has a connection plate with 6 terminals. Perform the electric connection of the motor according to the connection layout below.
Page 34 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions 1.4.8 Warning and information signs Adjacent warning and information signs are mounted on the machine: Switching notice Automatic startup Immediately replace unrecognizable, damaged or missing signs. Biohazard CE sign Indications for disposing of packaging material 1.5.1 For the sake of the environment...
Page 35 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Installation Instructions We reserve the right to make technical modifications Goodna STP KWP Washpress Page 35 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 36: General Arrangement Drawings
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual General Arrangement Drawings General Arrangement Drawings We reserve the right to make technical modifications Goodna STP KWP Washpress Page 36 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 37 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual CPWP: GOODNA STP - STAGE 4A 24025 - PTA EQUIPMENT TAG # - WPR-0220-010, 020 WASHPRESS GENERAL ARRANGEMENT Page 37 of 65 Q-Pulse Id VM364 Active 29/10/2013 VEN-0220-3101...
Page 38 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Process and Instrumentation Drawing Process and Instrumentation Drawing We reserve the right to make technical modifications Goodna STP KWP Washpress Page 38 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 39 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual CPWP: GOODNA STP - STAGE 4A 24025 - PTA EQUIPMENT TAG # - WPR-0220-010, 020 WASHPRESS PIPING & INSTRUMENTATION DIAGRAM Page 39 of 65 Q-Pulse Id VM364 Active 29/10/2013 VEN-0220-3110...
Page 40 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Process Control Strategy Process Control Strategy Goodna STP KWP Washpress We reserve the right to make technical modifications Page 40 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 41: Normal Operation
Process Control Strategy 1. Description The Kuhn KWP300/1000 washpresses are mounted at ground level and receive the flow from the common sluice containing captured band screen and drum screen material. The material is washed and compacted and transferred via the press pipe to a bagging unit and storage bin (supplied by others).
Page 42: Continuous Operation
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Process Control Strategy Screw Forward / MV1 Open Repeat steps 3 - 5 twice Screw Forward / MV1 Open Screw Forward Screw Stopped / MV 4 Open 20-30 3. Continuous Operation If at the conclusion of the normal operation wash cycle, the water level is still at level above the L1 setting, or if the level reaches the high level setting (suggested initial setting, H1: 700mm above screw) at any stage then wash press continuous operation starts...
Page 43: Prohibited Operation
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Process Control Strategy 4. Alarms Alarms signals should be generated should the wash press operation fail to reduce the inlet hopper water level below the L1 setting after the first cycle or if the water level reaches the high level setting and again if the water level rises to the overflow level.
Page 44 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Equipment List and Datasheets Equipment List and Datasheets We reserve the right to make technical modifications Goodna STP KWP Washpress Page 44 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 45 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Quality Records Quality Records We reserve the right to make technical modifications Goodna STP KWP Washpress Page 45 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 46 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Quality Records Product Description Use as directed The KWP wash press is intended exclusively for washing, compressing and dewatering recycled materials already separated from waste disposal processes, especially screenings from public sewage treatment plants. The machine is not intended for other types of application.
Page 47: Ec Declaration Of Conformity
A1:1999 to EN 50014:1997, amendment A2:1999 to EN 50014:1997 The following national and international standards (or parts/clauses therefrom) and specifications were applied: Accident prevention regulation "Machines” of BAM Kuhn GmbH Technische Anlagen Franz-Kuhn-Straße 1-3 D-74746 Höpfingen, Germany March 31st, 2004 ............
Page 48: Warranty And Guarantee
Not included in the scope of the warranty are natural wear and tear as defined in DIN 31 051, No. 4 whose occurrence and scope can not be controlled by KUHN GmbH. To secure warranty, we recommend that the operator: ■...
Page 49 For damage resulting from the use of non-original spares and accessories, Kuhn GmbH rejects all liabilities and guarantees. We reserve the right to make technical modifications Goodna STP...
Page 50 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Quality Records Attachment: Draft Factory Acceptance Test Report We reserve the right to make technical modifications Goodna STP KWP Washpress Page 50 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 51 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual KUHN GmbH, Technische Anlagen Quality test report (workshop) Customer: Thiess Motor power [kW]: Project: Goodna STP Empty weight [kg]: Model: KWP250/1000 Year of construction: 2011 Material: 316 Ti Serial-No.: i.O.
Page 52: Spare Parts
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Spare Parts Spare Parts Page 52 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 53: List Of Spare Parts
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Spare Parts List of spare parts Position Designation Number Type of Part Flat gear motor 1 no. Bearing housing 1 no. Screw 1 no. Spiral brush 1 no. Bearing and packing set 1 set Profile packing of cover and collection pan 1 set...
Page 54: Additional Information
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Spare Parts Additional Information Customer Service Mailing Address Kuhn GmbH Technische Anlagen Franz-Kuhn-Straße 1-3 D – 74746 Höpfingen Telephone and Offices Main telephone +49 (0) 6283 2201-0 Customer service +49 (0) 6283 2201-22...
Page 55 Copyright Any duplication of these operating instructions, as well as extracts therefrom, require the written approval of Kuhn-GmbH. These operating instructions were drawn up carefully and with the goal of making the operation and functioning of our product simple and understandable for the reader.
Page 56 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Transport and Storage Instructions Transport and Storage Instructions Page 56 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 57: Damage In Transit
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Transport and Storage Instructions Transport Safety Indications for Transport When transporting the machine the following special hazards must be taken into account: ■ Protruding sharp edges may lead to cuts. ■...
Page 58: Temporary Storage
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Transport and Storage Instructions Permissible Transport Equipment and Devices 1.4.1 Ground transport Transport the machine only in the original packaging and using suitable ground transportation designed for the load and size of the machine. Do not place any objects on the machine while it is being transported.
Page 59: Startup And Shutdown
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Start Up and Shut Down Start Up and Shut Down We reserve the right to make technical modifications Goodna STP KWP Washpress Page 59 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 60: Special Hazards
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Start Up and Shut Down Startup Safety indication for startup 1.1.1 General Safety Indications To prevent machine damage or mortally dangerous injuries during machine startup, make sure to comply with the following: ■...
Page 61: Performing Basic Settings
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Start Up and Shut Down Performing basic settings Perform the following settings before startup: ■ Check the direction of rotation of the drive motor. If the direction of rotation is correct, the screw flank moves in the direction of discharge pipe.
Page 62: Temporary Shutdown
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Start Up and Shut Down Shutdown Safety Indications for Shutdown When shutting down the machine, it is imperative that you follow the safety indications below. This will prevent mortal injuries, material damage and environmental damage.
Page 63: Troubleshooting
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Trouble Shooting Trouble Shooting We reserve the right to make technical modifications Goodna STP KWP Washpress Page 63 of 65 Q-Pulse Id VM364 Active 29/10/2013...
Page 64 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Trouble Shooting Help during malfunction Safety indications for trouble-shooting To prevent machine damage or mortally dangerous injuries when rectifying malfunction, it is imperative that you comply with the following: ■ Only people who have the needed qualifications may rectify malfunction.
Page 65 Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual Trouble Shooting 1.1.1 Tabular overview of possible faults Fault Possible cause Elimination Check contacts and connections on There is no voltage on the geared motor terminal boxes, junction boxes and in the switch cabinet Motor is faulty Replace motor...