Filter Press PKF 140 NG
Operating Instructions
4033, 4034, 4035
Version 12/2018
© 2018
Putsch GmbH & Co. KG
Frankfurter Straße 5 – 21
58095 Hagen
Phone:
+49 (0) 2331 399-0
Fax:
+49 (0) 2331 399-3600
E-Mail:
info@putsch.com
Internet
www.putsch.com
Translation of the original operating instructions.
All rights reserved. The contents of this document of parts thereof may
not be replicated, distributed, electronically processed, saved or analysed in any other way without the written permission of Putsch GmbH &
Co. KG.
2
Operating Instructions PKF 140 NG
4033, 4034, 4035
Table of contents
Table of contents
1
2
3
Concerning this document ..............................................................................................................6
1.1
Owner Group and Operator ................................................................................................6
1.2
EU-Guide lines and norms ..................................................................................................6
1.3
Graph description ................................................................................................................7
1.4
Drawings and documents ...................................................................................................8
Safety requirements and advisements ..........................................................................................9
2.1
Intended operational use of the unit ...................................................................................9
2.2
Requirement of installation location ....................................................................................9
2.3
Warning signs ...................................................................................................................10
2.4
Personal protective equipment (PSA) ...............................................................................12
2.5
Hazardous material ...........................................................................................................13
2.6
Responsibility of the machine owner and organizational responsibilities and measures .13
2.7
Qualification and selection of operating personnel ...........................................................14
2.8
Transportation ...................................................................................................................14
2.9
Installation .........................................................................................................................15
2.10
Operation ..........................................................................................................................15
2.11
Maintenance .....................................................................................................................15
2.12
Hydraulic and pneumatic ..................................................................................................16
2.13
Electric ..............................................................................................................................17
2.14
Safety devices ...................................................................................................................18
2.15
Disposal ............................................................................................................................19
2.16
Warranty and Liability .......................................................................................................19
Assembly and function of the PKF 140 NG ........................................................................................20
3.1
Overview ...........................................................................................................................20
3.2
Breakdown of components ...............................................................................................21
3.3
Filter plates .......................................................................................................................25
3.4
Filter cloths ........................................................................................................................35
3.5
Chute covers .....................................................................................................................38
3.6
Safety doors ......................................................................................................................38
3.7
Compressed air unit ..........................................................................................................39
3.8
Pneumatic installation .......................................................................................................40
3.9
Cloth washing machine (AWM) ........................................................................................40
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Operating Instructions PKF 140 NG
3
Table of contents
3.10
4
5
6
7
8
9
4
Control cabinet ..................................................................................................................42
Scope of delivery and set up.........................................................................................................43
4.1
Scope of delivery ..............................................................................................................43
4.2
Installation .........................................................................................................................44
Installation.......................................................................................................................................46
5.1
Connection of the piping and control valves .....................................................................46
5.2
Assembly and Disassembly of filter plates .......................................................................52
5.3
Installation of the Automatic Cloth Washing Machine ......................................................54
5.4
Installation of the safety doors ..........................................................................................56
5.5
Connection to the air pressure station ..............................................................................56
5.6
Connection of the pneumatic equipment ..........................................................................56
Method of operation of the press filter ........................................................................................57
6.1
Filtration cycle – technological operation ..........................................................................57
6.2
Conditions for a proper operation .....................................................................................58
6.3
Automatic cycles ...............................................................................................................59
6.4
Basic description of the automatic cycle ...........................................................................61
6.5
Basic description of the semi-automatic cycle ..................................................................66
6.6
Filtration operation ............................................................................................................68
6.7
Filter chamber discharge ..................................................................................................70
Commissioning of the PKF ...........................................................................................................72
7.1
Control panel HMI .............................................................................................................72
7.2
Pressure sensor for hydraulic and compressed air ..........................................................84
7.3
Check points before each start-up ....................................................................................84
7.4
Mechanical test runs .........................................................................................................85
7.5
First time commissioning ..................................................................................................88
Operation.........................................................................................................................................91
8.1
Modes of operation ...........................................................................................................91
8.2
Automatic operation ..........................................................................................................92
8.3
Semi-automatic operation .................................................................................................93
8.4
Manual operation ..............................................................................................................94
8.5
Operation of the PKF under extreme conditions ..............................................................95
Washing of the filter cloths (option) .............................................................................................97
9.1
Washing procedure ...........................................................................................................97
9.2
Actuator steps ...................................................................................................................97
Operating Instructions PKF 140 NG
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Table of contents
10
11
12
13
Actions during interruption .........................................................................................................100
10.1
Indication for interruption ................................................................................................100
10.2
Restarting after actuating the emergency stop or after power failure .............................101
Control and maintenance ............................................................................................................103
11.1
Control and maintenance during the campaign ..............................................................103
11.2
Control and maintenance of the hydraulic unit ...............................................................106
11.3
Changing of the hydraulic oil ..........................................................................................112
11.4
Adjustment of the hydraulic unit ......................................................................................115
Technical data ..............................................................................................................................121
12.1
General technical data ....................................................................................................121
12.2
Operational and functional requirements for electrical and control systems ..................122
12.3
Approved oil types ..........................................................................................................123
Operation interruption and disposal ..........................................................................................124
13.1
Short term operation interruption ....................................................................................124
13.2
Control and maintenance prior to long operation interruptions.......................................124
13.3
Disposal ..........................................................................................................................126
Automatic Program PKF 140 NG
Appendix 1
Operating parameters
Appendix 2
Maintenance plan PKF 140 NG
Appendix 3
Changing of Overhang-Membranes
Appendix 4
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Operating Instructions PKF 140 NG
5
1 Concerning this document
1
Concerning this document
These operational instructions are part of the PKF 140 NG and describe
the safe and proper operation for all operational steps.
We reserve changes and improvements because of in the interest of
technical advancements.
Operators must thoroughly read and understand this operating manual
for the PKF 140 NG prior to operating this equipment. All directions and
information for the installation and operation as well as maintenance
and operation have to be followed. For damages due to non-compliance
of the instructions the manufacturer is not liable.
1.1
•
The PKF 140 NG is only to be operated by following these instructions.
•
The operational instructions have to be located near the PKF 140
NG and at all times available for the operator.
•
Operational instructions have to stay with the unit in the event the
unit is sold.
Owner Group and Operator
This manual is created for the Owner and operator of the Filter Press
and their technically capable personnel.
The PKF 140 NG can only be operated by personnel, instructed in the
proper use of the unit.
1.2
EU-Guide lines and norms
The machine/equipment is in accordance with the following EU-Guide
lines and norms:
6
•
DIN EN ISO 12100 Safety of machines – general principle for design, risk assessment, and risk reduction.
Part 1: Basic nomenclature and terminology.
Part 2: Technical guidelines
•
DIN EN ISO 13849-1 Safety of the machine - safety related parts of
the control systems.
Part 1: General principles of design
•
DIN EN ISO 13857 Safety of the machine – safety distance of the
operator to prevent serious bodily harm to the upper and lower body
•
DIN EN 60204-1 Safety of the machine – electrical components of
the machine. Part 1: General principles of design
•
2006/42/EG Guideline of the European parliament and advisory
committees for the requirements of members of the European Union
for Machines.
Operating Instructions PKF 140 NG
4033, 4034, 4035
1 Concerning this document
1.3
1.3.1
Graph description
Used symbols and signs
The following symbols are used in this operating instructions:

Requirement to be fulfilled prior to any action.
1. Multiple action steps are required in consecutive order.
 Single step of action
•
Summary.
IMPORTANT
Information to comprehend, aids and the optimization of working procedures.
1.3.2
Abbreviations
In this document the following abbreviations are used:
Abbreviation
Definition
AWM
Automatic Washing Machine
HMI
Human Machine Interface
PKF
Filter Press
PSA
Personnel Protective Equipment
Tab. 1:
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Abbreviation content
Operating Instructions PKF 140 NG
7
1 Concerning this document
1.4
8
Drawings and documents
Document Content
Identification Number
General drawing
SK5-14790/1A
Specification beet/ refinery
SK5-17218/1
Space requirements
SK5-14336/2
Base frame
SK5-13701/2
Foundation drawing
SK5-14059/2A
Transportation drawing
SK5-17209
Safety door drawing
SK5-15820/2B
Piping installation drawings
SK5-15264D
Work on plate packets
SK5-15265D
Hydraulic circuit diagram
5-17679.16-10B
Control scheme compressed air
station
SK5-15895.28
Control system for AWM
SK5-17631.10
Proposal preparation
SK5-17315
PID
SK5-18149/5
Pipe arrangement plan
M5-18149
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
2
Safety requirements and advisements
The PKF 140 NG is designed and built according to the applicable technical requirements. If the PKF 140 NG is properly installed with the associated safety devices it should not create a dangerous setting.
 Safety and danger advises in these operational instructions must be
observed as well as the safety symbols.
If the machine is not installed and operated properly the following possible dangers could occur.
2.1
•
Injury possibilities due to non-qualified work on the hydraulic and
electrical system.
•
Injury possibilities due to contact at pinch-points and mechanical
moving parts.
Intended operational use of the unit
The PKF 140 NG is only for the filtration of slurries in the industrial environment. Any other installation or use is not in accordance with the design.
The following usage application for the PKF 140 NG is authorized:
•
In the sugar industry for separation of lime cake and sugar juice.
•
In other industries for slug/mud separation.
The manufacturer is not liable for damages resulting from all further
improper use. The risk is on the operator.
2.2
Requirement of installation location
The installation of the machine must allow easy operation, access and
removal of equipment.
The machine design is not explosion proof and should not be installed in
an explosion or hazardous area.
The foundation and steel construction have to be adequately designed
by the owner.
For inspection and maintenance there must be an adequate working
space around the machine. See chapter 1.4, pg. 7.
The installation area must be proper lighted.
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Operating Instructions PKF 140 NG
9
2 Safety requirements and advisements
2.3
Warning signs
Warnings in these operating instructions indicate specific hazards and
measures call for avoiding the danger.
Warnings are in 4 steps:
DANGER
Danger to life!
Failure to follow these measures may cause severe injury or death.
WARNING
Warning for personnel!
Failure to follow these measures may cause severe injury or death.
CAUTION
Warning for personnel!
Failure to follow these measures may cause light personal injury.
ATTENTION
Property damage!
Failure to follow these measures may result in property damage and
production interruption.
10
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
2.3.1
Manufacturing Identification Plate
The plate is located on the control cabinet.
fig. 1:
2.3.2
Manufacturing Identification Plate
Safety identification markings on the machine
Safety Labels
Identification
Location
Caution!
Above the operator
panel and on all distribution panels
Danger due to electrical potential
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No entry for unauthorized personnel
On the panel doors
and on the safety devices
No entrance allowed
On top of chute covers
Disconnect main power before opening any
section of the machine.
Before working on the
machine the sign
should be placed on
the PKF 140 NG so
that it is visible.
Operating Instructions PKF 140 NG
11
2 Safety requirements and advisements
2.4
Personal protective equipment (PSA)
The use of personal protective equipment is part of the safety concept of
the machine and is required.
Identification
Sign
Requirement
Hard hat required.
Safety glass required.
Safety footwear required.
Safety gloves required.
Ear protection required.
 During work on the filters or during operation of the PKF, required
protective equipment should be worn.
 The personal protective equipment must be functional and needs to
fit properly.
12
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
2.5
Hazardous material
The owner of the PKF is required and obligated to inform the operator of
the danger of the hazardous material and the associated protective
measure for the environment and the individual operator.
Hazardous
Material
Possible Danger
Exposure Treatment
Hydraulic oil
Skin rash due to long and
repeated exposure
Remove soiled clothing
and rinse with plenty of
clear water.
Grease
Irritation of eyes
Rinse eyes immediately
with clear water.
Tab. 2:
2.6
Hazardous material
Responsibility of the machine owner and
organizational responsibilities and measures
Safety and accident prevention measures are the responsibility of the
PKF 140 NG owner.
 Precisely define the operation maintenance and responsibility of the
PKF 140 NG.
 Designate one person responsible for the safe operation and coordination of all work on the PKF 140 NG.
 The operation instruction needs to be close and adjacent to the PKF
140 NG filter press. All work is to be done by only authorized personnel who have read and understand the operational manual.
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Operating Instructions PKF 140 NG
13
2 Safety requirements and advisements
 In addition to the original instructions, all other binding regulations
for accident prevention and environmental protection should be observed. These responsibilities pertain to hazardous material and the
availability to wear personal protective equipment.
 Update operating instruction to supervisory and reporting requirements and instructions for operating characteristics, e.g. in terms of
work organization, work processes and staff efficiency.
 The owner must at least have training sessions two times per year
for operators.
 The owner must ensure
2.7
–
in case of a power failure that all electrical, hydraulic, and
pneumatic connections to be disconnected and
–
after re-establishing the electrical power supply no uncontrolled
movements of the equipment is possible.
Qualification and selection of operating personnel
All work for the installation, commissioning, operation, maintenance, and
preventive maintenance and correction of operation interruptions must
be performed by trained personnel.
Qualified personal is familiar with the construction and installation of the
machine and proven trained in the
2.8
•
Operation and maintenance of PKF 140 NG
•
Handling of lifting devices
•
Handling of all safety equipment
•
First aid training
Transportation
 Unloading of transportation only to be carried out by trained personnel
 For the transport or parts of the equipment only lifting devices with
adequate capability to be used.
 Lifting devices only to be used on approved and marked lifting
points (page 45, Fig. 16)
 Individual part and larger components are to be carefully secured
with appropriate lifting devices.
 Stay clear of suspended load.
14
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
2.9
Installation
The owner must insure the correct installation of the unit according to
their supplied installation plan.
It is recommended to utilize Putsch specialist to insure the correct installation of the PKF 140 NG. The included installation drawing is binding
for the installation of the PKF 140 NG.
 For working heights above local codes use appropriate steps, lifts,
or ladders.
After the completion of construction, and before commissioning, the
PKF 140 NG must be certified by Putsch personnel.
2.10
Operation
The PKF 140 NG is only allowed to operate in technically correct conditions under the requirements of the operating manuals, operating installation and maintenance instruction.
 before each individual start-up that following items should be
checked:
–
Appropriate connections of all power units, piping, and control
valves.
–
No leakage.
–
Safety devices in place and functional.
 Prior to starting the machine, ensure no personnel is in danger.
 No personnel is allowed during machine operating between the
safety devices and moving parts. Possible pinch points.
 At least once per shift, observe and check for possible damages
and leaks and report observation immediately to a supervisor.
2.11
Maintenance
All work including the operation, adjustments, production adjustments,
maintenance, repair, connect and disconnect procedures of PKF 140
NG, must comply with the operation instruction.
 Maintenance and repair work only to be performed at idle machine
condition.
 Operating personnel to be informed timely about the upcoming
maintenance and repair work.
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Operating Instructions PKF 140 NG
15
2 Safety requirements and advisements
 Prior to any work the PKF 140 NG needs to be emptied, switched
off and pressure released.
 The following measures to prevent accidental reconnecting of electrical power:
–
main switch to 0 position
–
secure with padlock, hide key
–
set up warning sign in front or on the machine.
 During maintenance above normal working heights use appropriate
steps, lifts, or ladders.
 During work on the PKF 140 NG secure the closing of shut-off
valves to prevent opening and accidental burning of working personnel with hot juice.
 Never step on chute covers.
 Only trained or certified electrician to work on electrical components.
 Prior to every start-up, all covers, connections, and safety devices
must be installed according to the documents and to tests their functions.
2.12
Hydraulic and pneumatic
Faulty installation can cause spraying of hot liquid (temperature of 80° C
to 90° C), and escaping high pressure air could cause operator injury
and burns.
 All piping, hoses and connections have to be inspected regularly for
leaks, and obvious visible damages, and must be corrected immediately by the appropriate maintenance personnel.
 For exchange of hoses use original manufacturer supplied hoses.
DO NOT REUSE HOSES.
 The machine owner is responsible for the quality of the hydraulic oil
and the quality of the compressed air.
 Pressure lines (hydraulic and air) at the beginning of the repair sequence have to be de-energized prior to maintenance work. Because stored energy could cause movement of the machine and
possible injury.
 Hydraulic and air pressure lines have to be installed professionally
and make sure that the length and quality of the hoses to the appropriate application.
16
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
 Ensure that the filtration pressure does not exceed 7.5 bar (160 psi).
 Pressurize membrane filter plates only when the PKF 140 NG is
closed and the chambers are filled with product.
 Open the plate pack only if the air pressure is below 0,2 bar (3 psi).
At higher pressure the danger may exist to damage the membrane
or cause operator injury.
2.13
Electric
 The electrically equipment has to be installed, checked and maintained according to local codes. Any discrepancies or issues have to
be immediately addressed and accident prevention checked by licensed electrician.
 The energy supply of the PKF 140 NG needs to be disconnected
during operational interruptions.
 All the machine and component parts during inspection and repair
work have to be electrically disconnected and tested.
During work on electrical energized parts, a second qualified person has
to be present to disconnect the power in case of emergency. Furthermore, to perform the following safety measures:
 Secure the work area with a red and white safety chain
 Set up warning sign.
 Exclusively use insulated high voltage safety tool.
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Operating Instructions PKF 140 NG
17
2 Safety requirements and advisements
2.14
Safety devices
The PKF 140 NG has the following safety devices:
2.14.1
•
Emergency stop button
•
Safety doors
Emergency stop button
By activating the emergency stop button
•
the following components of the unit are being de-energized:
–
the drive unit
–
hydraulic valves, control valves
–
pumps
IMPORTANT
The pressure in the closing cylinder stays maintained. Existing membrane pressure is being decreased. (V13 opens)
•
The press continues to stay in automatic or partial automatic mode
as well as automatic mode for the AWM and the present position of
the AWM.
•
Any manually initiated operating steps are being stopped.
Directions to resume operation after activating the emergency stop button, see chapter 10, pg. 100.
2.14.2
Safety Doors
On each side of the PKF 140 NG are safety doors to protect from possible hot liquid spray.
During operation the safety doors must be closed at all times.
The presence of any person in the danger zone between the PKF filter
and the safety doors is prohibited.
18
Operating Instructions PKF 140 NG
4033, 4034, 4035
2 Safety requirements and advisements
2.15
Disposal
The machine and its parts have to be disposed according to local laws
(see chapter 13.3, pg. 126).
 After de-commissioning of equipment all components have to be
disposed properly or recycled appropriately.
2.16
–
Drain all the liquid and store in appropriate containers (motor
and gear drive oil).
–
Separate hazardous waste (electrical components).
–
Separate plastic.
–
Separate metals by grade
Warranty and Liability
The owner is only allowed to implement design components changes
and safety changes on the PKF 140 NG with the permission by Putsch.
Results in changes, Putsch is not liable for personnel or property damage caused due to changes on the PKF 140 NG and other associated
components.
Warranty claims can only be accepted if
4033, 4034, 4035
•
all work on the PKF 140 NG and the maintenance has been performed professionally and documented by qualified personnel and
also
•
only original spare parts, wear parts, filter plates, filter cloths have
been utilized.
Operating Instructions PKF 140 NG
19
3 Assembly and function of the PKF 140 NG
3
Assembly and function of the PKF 140 NG
The PKF 140 NG is a fully automatic operating membrane filter press. It
separates the solids from the slurry and carries away the washed and
dried filter cake.
3.1
Overview
Fig. 2:
1
Head piece
2
AWM
3
Filter plates
4
5
20
3D-view PKF 140 NG
Switch cabinet including control and hydraulic aggregate
10 Side rail
7
Panel view
12 Safety doors
End piece
8
Traverse
13 Main frame
Transport cylinder
9
Main Cylinder
14 Air manifold
6
Operating Instructions PKF 140 NG
11 Chute covers
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.2
3.2.1
Breakdown of components
Head piece
Slurry, wash water and compressed air are introduced to the filter
through the head piece. Filtrate and wash filtrate are discharge through
the head piece also. The head piece is connected with two side rails to
the end piece and traverse.
Fig. 3:
Head piece of the PKF with pipe flanges
1
Flange for slurry inlet
6
2
Flange for
7
- filtrate from pressure plates
- wash water inlet
- Compressed air for drying of 8
filter cake
Distributor for air manifold
Flange for
- filtrate from membrane plates
- wash filtrate
Flange for
- filtrate from membrane plates
- Wash water inlet
- Compressed air for drying of
Filter cake
3
Connecting points for side
rails
4
Flange for
- filtrate from pressure plates
- wash filtrate
9
Air manifold
10 connection for compressed air
5
Ventilation valve V13 for membrane
14 DN 20 for membrane air
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Operating Instructions PKF 140 NG
21
3 Assembly and function of the PKF 140 NG
IMPORTANT
The flange points are the scope of delivery for the machine. All
other the customer must provide.
On the headpiece are flanges located for the supply and discharge of
slurry, wash water, filtrate and wash filtrate. On the flanges 2 and 8 are
designed for compressed air and wash water.
The head piece is connected with two side rails to the hydraulic cylinder.
The side rails are connected with bolts (3) of the head piece.
In the lower portion of the head piece is an air manifold (5) installed
which includes a pressure controller for the different required pressure
stages (first pressing, intermediate pressing, and after pressing).
The vent valve V 13 (9) is utilized for pressure relief of the membrane
plates.
IMPORTANT
In contrast to all other valves in the non-actuated state V13 is open.
The vent valve must be piped to an external room or outside or included
a muffler.
22
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.2.2
Traverse
The traverse is a moving counterpart to the head piece. With the use of a
hydraulic cylinder the filter plate package can be closed with a hydraulic
pressure of 280 bar (4000 psi).
Fig. 4:
Traverse
3
Filter plate
9
Main cylinder
13 Bolts for the rail connection
4
End piece
10 Side rails
15 Energy supply
5
Transport cylinder
11 Main frame
17 Bushing mounting for traverse
8
Traverse
18 Carrier rollers of the end piece
On the side of the traverse (8) are two bolts (13) which utilize to connect
the side rails (10). The traverse is connected with two bushings (17) to
the main frame (11) to allow different expansions between the main
frame and the guide rails.
Guide rails carry the plate package and the traverse. On each side of
the side rails are located hydraulic transport cylinders for the movement
of the plate pack (5).
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Operating Instructions PKF 140 NG
23
3 Assembly and function of the PKF 140 NG
3.2.3
End piece
The filter plates are compressed between the end piece and the head
piece. The end piece transfers the closing forces from the hydraulic
cylinder to the filter plate package.
The end piece moves on carrier rollers on the side rails. On the upper
part of the end plate is a control valve V21 located which is needed for
the discharge of the slurry channel.
24
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.3
Filter plates
The PKF 140 NG is equipped with a plate package with at least 51 filter
plates, including head plate, middle membrane plate and end plate.
Starting with the end plate the standard plate package includes the:
•
Head plate
•
Membrane plate
•
Pressure plate and Membrane plate in sequence
•
Middle Membrane plate
•
Pressure plate
•
Membrane plate and Pressure plate in sequence
•
Endplate
All filter plates are made out of polypropylene. They have handles located on each side on which they suspend on the side rails. The handles
are connected with connecting bars for the transport of the plates.
For identification all plates are color coded with pins:
•
Membrane plates: blue pins
•
Pressure plates: red pins
The pins on the end plate and head plate are color neutral.
In the following description of the filter plates is the view starting at the
head piece to the end piece. An exception is the head piece, viewed
from the inside.
All filter plates have the same opening size for the supply and discharge
of
•
Slurry and filtrate
•
Wash water and wash filtrate
•
Compressed air
These openings are specifically described below.
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Operating Instructions PKF 140 NG
25
3 Assembly and function of the PKF 140 NG
3.3.1
Overhang membrane plates
The overhang membrane plate consists of two frames (2) which are
connected by a carrier (1). In each frame a special membrane (13) is
installed, which has dimples. The two frames are thicker than the membranes and creating with the pressure plate the mud chamber for the
filtrate.
Fig. 5:
26
Membrane plate
Pos.-No.
Name
Function
1
Carrier
Connects the frames of the membrane plate
2
Frame
Creates with the carrier the membrane plate
3
Opening for compressed air
Inlet for membrane air for the
membrane plates
4
Big opening top left
- filtrate out of membrane plates
- wash water
- compressed air for cake drying
5
Openings top, front and
back
- outlet of filtrate
- inlet of wash water and
drying air
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
Pos.-No.
Name
Function
6
Opening center top
Inlet for slurry
7
Slot in frame
Inlet of the slurry into the filter
chamber
8
Cloth locating pins
To hang filter cloths
9
Big opening top right
- filtrate out of pressure plates
- wash water
- compressed air for cake drying
10
Handle
To suspend the filter plates between the side rails
11
Pin, blue
Identification of membrane plate
12
Big opening lower right
- filtrate out of pressure plates
- wash filtrate out of
pressure plates
13
Membrane
14
Openings lower, front
and back
- discharge of filtrate
- discharge of wash filtrate
15
Big opening lower left
- filtrate out of membrane plates
- wash filtrate out of
membrane plates
The slurry is channeled through opening (6) and the slot (7) which is
located below the opening into the filter chamber. The filtrate out of
membrane plates is discharged through the openings (5, 14) out of the
filter chamber into the conduit and is discharged through the openings
(4, 15). The solids remain in the filter chamber and form the filter cake.
The filtrate out of the pressure plates is discharged through the openings on the right side of the plate (9, 12).
Wash water and drying air for the filter cake are induced through the
openings left top (4) and right top (9) and are discharged through the
small openings (5) into the filter chamber. The wash filtrate flows
through the small openings (14) into the conduit and is discharged
through opening (15).
Seal rings are utilized to seal the opening between the filter plates:
•
•
Seal ring 06.29
–
Opening for filtrate and wash filtrate out of the membrane plates
(15)
–
Opening for filtrate and wash filtrate out of the pressure plates
(12)
Seal ring 06.30
–
4033, 4034, 4035
Opening for compressed air for membrane plates (3)
Operating Instructions PKF 140 NG
27
3 Assembly and function of the PKF 140 NG
Fig. 6:
Seal rings
The handles (10) are bolted onto the filter plate to suspend the plate
between the side rails. Also each handle is connected by connecting
plates for the plate transport system.
On top of the filter plates are located the pins to hang the filter cloths.
On the side of the service side of the plates are the blue pins (11) to
identify the membrane plate.
On the middle membrane plate of a plate pack are located special handles which are for connection to the hydraulic cylinder for plate transport
(see Fig. 2, pg. 20).
3.3.2
Alternative membrane plates
There are special membrane plates where only the membranes can be
changed. Multiple membranes can be utilized and changed separately.
28
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.3.3
Pressure plate
The pressure plate is a thick plate with concave sides for the chamber
depth. For a good filtrate discharge the inside has a dimpled surface.
Fig. 7:
4033, 4034, 4035
Pressure plate
Pos.- No.
Name
Function
3
Opening for compressed air
Inlet for membrane air for the
membrane plates
4
Big opening top left
- filtrate out of membrane plates
- wash water
- compressed air for cake drying
5
Openings top, front and - outlet of filtrate
back
- inlet of wash water
6
Opening center top
Slurry inlet
7
Slot in frame
Slurry inlet into the filter chamber
8
Cloth locating pins
To hang filter cloths
9
Big opening top right
- filtrate out of pressure plates
- wash water
- compressed air for cake drying
Operating Instructions PKF 140 NG
29
3 Assembly and function of the PKF 140 NG
Pos.- No.
Name
Function
10
Handle
To suspend filter plates between
the side rails
11
Pin, red
Identification of pressure plate
12
Big opening lower right
- filtrate out of pressure plates
- wash filtrate out of
pressure plates
14
Openings lower, front
and back
– discharge of filtrate
Big opening lower left
- filtrate out of membrane
plates
- wash filtrate out of
membrane plates
15
- discharge of wash filtrate
The slurry is channeled through opening (6) and the slot (7) which is
located below the opening into the filter chamber. The filtrate is discharged through the openings (5, 14) out of the filter chamber into the
conduit and is discharged through the openings (9, 12). The solids remain in the filter chamber and form the filter cake. The filtrate out of the
membrane plates is discharged through the openings on the left side of
the plate (4, 15).
Wash water and drying air for the filter cake are induced through the
openings left top (4) and right top (9) and are discharged through the
small openings (5) into the filter chamber. The wash filtrate flows
through the small openings (14) into the conduit and is discharged
through opening (15).
The handles (10) are bolted onto the filter plate to suspend the plate
between the side rails. Also each handle is connected by connecting
plates for the plate transport system.
On the top of the filter frame are pins to secure the filter cloths. On the
operator side is a red pin (11) for the identification of the pressure plate.
30
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.3.4
Head plate
The head plate consists of a thick plate with a depression on the inside.
The outside of the filter plate is smooth.
Fig. 8:
4033, 4034, 4035
Head plate
Pos.-No. Name
Function
3
Opening for compressed
air
Inlet for membrane air for the
membrane plates
4
Big opening top left
- filtrate out of pressure plate
- wash water
- compressed air for cake drying
5
Openings top, front and
back
- outlet of filtrate
- Inlet of wash water and
drying air
6
Opening center top
Slurry inlet
7
Slot in frame
Slurry inlet into the filter chamber
8
Cloth locating pins
To hang filter cloths
Operating Instructions PKF 140 NG
31
3 Assembly and function of the PKF 140 NG
Pos.-No. Name
Function
9
Opening top right
- filtrate out of membrane plates
- wash water
- compressed air for cake drying
10
Handle
To suspend the filter plates
between the side rails
11
Pin, grey
Identification of head plate
12
Opening lower right
- filtrate out of membrane
plates
- wash filtrate out of
membrane plates
14
Openings lower, front and - discharge of filtrate
back
- discharge of wash filtrate
15
Opening lower left
- filtrate out of pressure
plates
- wash filtrate out of pressure
plates
16
Connecting opening
Bolting the head plate to the
head piece
17
Loop
To fasten the head cloths
The slurry is channeled through opening (6) and the slot (7) which is
located below the opening into the filter chamber. The filtrate is discharged through the openings (5, 14) out of the filter chamber into the
conduit and is discharged through the openings (4, 15). The solids remain in the filter chamber and form the filter cake. The filtrate out of the
membrane plates is discharged through the openings on the left side of
the plate (9, 12).
Wash water and drying air for the filter cake are induced through the
openings left top (4) and right top (9) and are discharged through the
small openings (5) into the filter chamber. The wash filtrate flows
through the small openings (14) into the conduit and is discharged
through opening (15).
Prior to installing the head plate with the smooth side to the head piece,
seal rings have to be installed on the openings 4, 6, 9, 12 and 15.
The handles (10) are bolted onto the head plate to suspend the plate
between the side rails. Also each handle is connected by connecting
plates for the plate transport system.
On top of the head plate are pins located (8), on both sides and on the
bottom are loops (17) for fasten the head cloths. At the bottom on the
operator side the grey pin (11) identifies the head plate.
32
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.3.5
End plate
The end plate consists of a thick plate with a depression on the inside.
The outside of the filter plate is smooth.
Fig. 9:
4033, 4034, 4035
End plate
Pos.-No. Name
Function
3
Opening for compressed
air
Inlet of membrane air for the
membrane plates
4
Big opening top left
- filtrate out of membrane plates
- wash water
- compressed air for cake drying
5
Openings top, front and
back
- outlet of filtrate
- inlet of wash water
and drying air
6
Opening center top
Slurry inlet
7
Slot in frame
Slurry inlet into the filter chamber
8
Cloth locating pins
To hang filter cloths
Operating Instructions PKF 140 NG
33
3 Assembly and function of the PKF 140 NG
Pos.-No. Name
Function
9
Big opening top right
- filtrate out of end plate
- wash water
- compressed air for cake drying
10
Handle
To suspend the filter plate between the side rails
11
Pin, grey
Identification of end plate
12
Big opening lower right
- filtrate out of end plate
- wash filtrate out of end plate
14
Openings lower, front and - discharge of filtrate
- discharge of wash filtrate
back
15
Big opening lower left
- filtrate out of the membrane
plates
- wash filtrate out of
membrane plates
16
Connecting opening
Bolting the end plate to the end
piece
17
Loop
To fasten the end cloth
The slurry is channeled through opening (6) and the slot (7) which is
located below the opening into the filter chamber. The filtrate is discharged through the openings (5, 14) out of the filter chamber into the
conduit and is discharged through the openings (9, 12). The solids remain in the filter chamber and form the filter cake. The filtrate out of the
membrane plates is discharged through the openings on the left side of
the plate (4, 15).
Wash water and drying air for the filter cake are induced through the
openings left top (4) and right top (9) and are discharged through the
small openings (5) into the filter chamber. The wash filtrate flows
through the small openings (14) into the conduit and is discharged
through opening (12).
Prior to installing the end plate with the smooth side to the end piece,
seal rings have to be installed on the openings 4, 6, 9, 12 and 15.
The handles (10) are bolted onto the end plate to suspend the plate
between the side rails.
On top of the end plate are pins (8) and on both sides as well as the
bottom are loops (17) to hold the end cloth in place. On the operator
side at the bottom is the grey pin (11) to identify the end plate.
34
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.4
Filter cloths
The filter plates are fitted with different filter cloths.
•
Membrane plates and pressure plates: filter cloths and backing
cloths
•
Head plate: head cloth
•
End plate: end cloth
The filter cloths are held in place by the pins on top of the frame and of
the head- and end plates. For the head and end plates, 3 additional
loops on the side and on the bottom ensure proper fitting.
Fig. 10: Filter cloth
Pos. No.
Name
Function
3
Hole for compressed air
Inlet for air manifold of membrane
plates
4
Hole top left
- filtrate out of membrane plates
- wash water
- compressed air for cake drying
6
Hole center top
Slurry inlet
As big as opening in plate, burned
by soldering iron
4033, 4034, 4035
Operating Instructions PKF 140 NG
35
3 Assembly and function of the PKF 140 NG
Pos. No.
Name
Function
9
Hole top right
- filtrate out of pressure plates
- wash water
- compressed air for cake drying
18
Small holes top
For pin placement
19
Borders (only under
cloths and filter cloths)
For a good seal surface the cloth
must be coated with sealant on
the inside.
20
Cloths
- backing cloth
- filter cloth
- head cloth
- end cloth
21
Velcro tabs (only filter
cloths)
To secure filter cloths on membrane and pressure plates.
IMPORTANT
All openings of the cloths must be correctly aligned with the openings
on the pressure and membrane plates.
 After dressing of the plates, these openings have to be checked
for alignment.
To avoid mix up, all filter cloths are clearly marked on the sides.
Under cloths
Under cloths are a two piece design:
•
With Putsch Article Number.
Under cloths have been coated with sealant. The sealant coated side
must face the filter plate.
Under cloths are to be installed to the filter plate in this manner:
1. Under cloth to be hung onto the holding pins.
2. Smooth out the under cloth.
3. Under cloths to be tied to filter cloths with tie wraps.
Filter cloth
A filter cloth consists of two filter cloths which are connected in the area
of the slurry inlet with a cloth neck. The Filter cloths are identified by
Putsch Article Number.
The cloth is coated on the inside with a sealant.
Pressure and membrane plates are dressed by the following steps:
1. One side of the cloth must be folded and rolled.
2. The rolled side has to be inserted into the slurry inlet.
36
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3. Unrolled on the opposite side of the filter plate.
4. Lay the upper edge of the filter cloth on the pins.
5. Smooth the filter cloth.
6. The filter cloth to secure with Velcro tabs onto the membrane and
pressure plates
7. The backside and front side of the cloths and under cloths to be
connected with tie wraps.
8. To prevent the filter cloths from slipping the tie wraps should be
attached to the holding pins.
Head cloth
The head cloth is being installed on the head plate and is identified by
Putsch Article Number.
For the head cloth the top cloths and under cloths are sewed together.
Both cloths are sealed on both sides with sealant for improved sealing.
The inside faces the head plate.
The head cloth is to be installed as follows:
1. Install the cloth onto the holding pins.
2. Secure the three other sides of the head cloth with tie wraps onto
the loops.
3. The head cloth with a grommet at the location of the slurry inlet
must be secured.
4. Holes at the head cloth must be cut out to the appropriate size with
a soldering iron.
End cloth
4033, 4034, 4035
The end cloth is installed on the end plate and is identified by Putsch
Article Number. It will be installed like the head cloth. The difference
between both cloth types is the mirror image of the holes for slurry, filtrate and membrane air and all connecting points.
Operating Instructions PKF 140 NG
37
3 Assembly and function of the PKF 140 NG
3.5
Chute covers
In the base frame are two chute covers installed, utilizing a hydraulic
cylinder each. The doors are moved up for opening, and moved down
for closing on top of the dropping area.
During the washing cycle of the cloths, the closed doors protecting the
lower transport system from wash water. During the discharging cycle of
the filter press the doors provide a chute for the filter cake.
Fig. 11: Chute covers
3.6
1
base frame
2
hydraulic cylinder
3
chute covers
Safety doors
On each side of the filter press are safety doors installed which consist
of at least 2 frames with Polycarbonate sheets.
On each safety door are electro-mechanical switches, on top of the
stands. This allows safe press operation only at closed stage of the
safety doors.
If during a press operation a safety door is being opened, these switches turn the operation off. This guarantees no personnel can be harmed
through moving plates during operation.
38
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
3.7
Compressed air unit
The unit is installed at the head piece of the filter press. It includes
pressure regulator for the different pressure stages (pre-pressing, intermediate pressing, and after pressing) and also air filter.
Fig. 12: Air pressure unit
6
manifold
11 air filter
9
ventilation valve V13
12 pressure switch
10 connection for air pressure
13 pressure regulator
The shut off valve V 13 is used for venting the membrane plate pack.
IMPORTANT
In contrast to all other shut off valves, V 13 is normally open.
The valve is vented to the outside or through muffler.
4033, 4034, 4035
Operating Instructions PKF 140 NG
39
3 Assembly and function of the PKF 140 NG
3.8
Pneumatic installation
The automatic control valves are installed according to the drawings on
the distributor station of the head piece. For the actuation of the control
valves dried air or conditioned air with the pressure of minimum 6 bar
(85 psi) and maximum 8 bar (114 psi) is needed.
3.9
Cloth washing machine (AWM)
The cloth washing machine is designed to wash the filter cloths by
means of nozzles from the top down.
The automatic washing machine is located on the back side of the filter
press and moves on a rail along the filter plates. It can move over the
entire length of the filter press. On the top part, the wash machine is
secured by a guide rail.
AWM is delivered standard with filter press.
40
Operating Instructions PKF 140 NG
4033, 4034, 4035
3 Assembly and function of the PKF 140 NG
Fig. 13: Cloth washing machine
1
spray arm
7
Side rail
2
spray tube
8
roller support
3
slide
9
support for light barrier
4
lift cylinder
10 light barrier
5
guide wheels
11 safety hook
6
guide rail
12 main track
The spray arm (1) with the spray tube (2) is connected to the pneumatic
powered lift cylinder (4). The nozzles on the spray tube can spray both
sides of the filter chamber. The spray tube is being moved over the entire height of the filter plate with a lift cylinder.
The washing machine can also be semi-automatic, operated with remote control or from the HMI on the control panel.
4033, 4034, 4035
Operating Instructions PKF 140 NG
41
3 Assembly and function of the PKF 140 NG
3.10
Control cabinet
The control cabinet is mounted on the main frame of the filter press. All
functions of the press can be controlled by the control panel.
The door of the control panel is locked and the lock is protected by
moveable cover.
Fig. 14: Control cabinet
1
Control panel HMI
9
2
cover for controller and push
buttons
10 emergency switch
3
re-set button
11 main disconnect
4
indicator light – automatic on
position
12 indicator light press stopped at
end of cycle
5
indicator light – for acid application
13 indicator light Start
6
key switch for acid application
15 indicator light semi-automatic
on
7
key switch automatic/manual 16 indicator light control on
and semi-automatic opera17 indicator light manual operation
tion
on
selector switch chute covers 18 indicator light operation interopen or close
ruption
8
42
Operating Instructions PKF 140 NG
selector switch press plates
open and closed
14 push button control voltage on
4033, 4034, 4035
4 Scope of delivery and set up
4
4.1
Scope of delivery and set up
Scope of delivery
All parts of the PKF 140 NG, including control and hydraulic system, are
mounted on the main frame and are mostly enclosed.
For the transport the following components are delivered separately:
•
Cloth washing machine AWM
•
Safety doors
•
Ventilation V13
IMPORTANT
The separate delivered components should be installed by Putsch
personnel.
Fig. 15: 3D-view PKF 140 NG
1
Head piece
Switch cabinet including control and hydraulic aggregate
10 Side rail
2
Cloth washing machine
AWM
7
Panel view
12 Safety doors
3
Filter plates
8
Traverse
13 Main frame
4
End piece
9
Main cylinder
14 Air manifold
5
Transport cylinder
4033, 4034, 4035
6
Operating Instructions PKF 140 NG
11 Chute covers
43
4 Scope of delivery and set up
 The unit has to be immediately checked for damage after delivery.
 Possible damage has to be verified by transport agency.
 Verify the delivered components and construction of unit.
The unit has been tested at the manufacturer’s site but without filter
cloths in place
4.2
Installation
Main dimensions and weight of the unit see chapter 12, pg. 121.
DANGER
Death or bodily harm could occur from falling parts!
 Never stand below or near suspended load.
IMPORTANT
The installation of the press should be supervised by a Putsch specialists.
For the installation, an installation plan is included.
From the owner a frame has to be supplied to accommodate the main
frame of the PKF 140 NG. Drawings for the base frame are supplied.
44
Operating Instructions PKF 140 NG
4033, 4034, 4035
4 Scope of delivery and set up
Fig. 16: lifting points and transportation device
1
lifting eye (lifting point)
2
transportation device for truck
1. Prior to transport by truck machine has to be fastened securely with
help of the transportation device (2).
2. Before unloading remove the transportation device (2).
3. Lifting equipment is to be attached to lifting points (1) according to
regulations.
4. PKF is to be positioned on top of sub-frame.
5. Unit horizontally adjusted above cake discharge channel.
–
control is achieved by diagonal and parallel measuring on the
slide areas of the side rails with help of a level.
–
The variance should be 0 ± 1 mm.
6. Remove the lifting eye (1) after transport.
4033, 4034, 4035
Operating Instructions PKF 140 NG
45
5 Installation
5
5.1
Installation
Connection of the piping and control valves
For the connection of the piping a flow diagram is included which shows
the location and size of the piping and control valves.
5.1.1
Welding of the piping flanges
DANGER
Arc welding could cause bodily harm or death!
 Before work check equipment of working order.
 Protective equipment cannot be modified or removed
 Rod holder must be placed on insulated surface not your arm pit
 In tight or wet locations protective measures have to be taken for
stray electric current
 For extended welding periods, disconnect the power
 Damaged hand held rod holder need to be replaced by qualified
electrician
DANGER
Fire and explosion hazard due to electrical arc, sparks,
welding splatter or hot liquid!
 Do not wear any flammable or soiled cloths (i.g oil, grease , gas)
nor nylon fabric cloth.
 To prevent fire, after completion of welding observe the location.
DANGER
Danger of injury to eyes and skin due to UV-and heat radiation, sparks and welding splatter and hot liquid!
 Safety goggles, safety shield, safety gloves, safety shoes and
leather apron must be worn.
 Working only with completely enclosed clothing.
46
Operating Instructions PKF 140 NG
4033, 4034, 4035
5 Installation
ATTENTION
Destroying of the flex liner inside the control valve!
 The liner normally functions as a gasket. Therefore no additional
gaskets at these connections are needed.
Note:
There are different types of control valves which may need gaskets!
ATTENTION
Damaging of the flex liner within the control valve during
welding work!
 No complete welding, only spot welding of the flange with installed
control valve.
ATTENTION
Damaging of the plate package due to welding work!
 Install blank cover on entry flange.
4033, 4034, 4035
Operating Instructions PKF 140 NG
47
5 Installation
Fig. 17: welding of the piping flange
1
control valve
3
piping
2
pipe flange
4
flange connection
1. Insert control valve (1) with small clearance between flanges (2).
2. Insert control valve (1) and pipe flange (2) with 4 flange connections
(4) and tighten loosely.
3. Insure alignment of control valve and pipe flange (3) created under
2.
4. Spot weld the flanges (2) onto the piping (3).
5. Loosen flange connections (4) and remove control valve (1).
6. Weld piping flanges (2) to the pipe (3) in line.
7. Let the welding points cool down.
8. If necessary, clean up sealed surface of the flanges.
48
Operating Instructions PKF 140 NG
4033, 4034, 4035
5 Installation
5.1.2
Installation of the control valves

Piping flanges welded on according to rules.
The control valves are suitable for installation between flanges according to:
•
DIN EN 1092-1
IMPORTANT
Valve-discs and sleeve- liners of the control valves have to be made
out of wear resistant material.
IMPORTANT
In all slurry lines the control valves must be installed in horizontal position.
All other application control valves can be installed as desired.
1. Open valve disc by 10°.
2. Slide control valve between flanges. For slurry line position of the
control valve must be horizontal!
3. Adjust control valve.
4. Tighten bolt connection between control valves and pipe connections slightly.
5. Test the movement of the valve disc by opening and closing.
6. Cross tighten flange connections.
7. Test the movement of the valve disc by opening and closing.
4033, 4034, 4035
Operating Instructions PKF 140 NG
49
5 Installation
5.1.3
Connections on the head piece
Fig. 18: head piece of the PKF with pipe flanges
1
DN 150 for slurry inlet
6
Distributor for air manifold
2
DN 100 for filtrate from pressure plates, wash water inlet
and compressed air for cake
drying
7
DN 100 for filtrate from membrane plates and wash filtrate
8
DN 100 for filtrate from membrane plates, wash water inlet
and compressed air for cake
drying
Ventilation valve
3
Connecting points for side
rails
4
DN 100 for filtrate from pressure plates and wash filtrate
9
Air manifold
14 DN 20 for membrane air
5
10 connection for compressed air
The compressed air station has to be connected to the air supply of the
factory.
50
Operating Instructions PKF 140 NG
4033, 4034, 4035
5 Installation
5.1.4
Connections on the end piece
Fig. 19: end piece of the PKF
1
Check valve
2
Control valve V21
Through the control valve (2) the compressed air is directed to clean the
slurry channel.
5.1.5
Connections on the automatic washing machine
The AWM is connected with an energy chain:
4033, 4034, 4035
•
pressure water
•
compressed air
•
electrical controls
Operating Instructions PKF 140 NG
51
5 Installation
5.2
5.2.1
Assembly and Disassembly of filter plates
Disassembly of filter plates
DANGER
Death or bodily harm could occur from falling parts!
 Never stand below or near suspended load.
The complete disassembly of the filter plates doesn’t require change of
filter cloths.
1. Press stop after completed cycle.
The filter press discharges and closes again, then it opens the first
package and stays open.
2. Switch off main disconnect.
3. Place warning sign near filter.
4. Protect chute covers. Do not step. Cover with wood planks.
5. Remove bolts and washers from both sides of the connecting plates
in order to move the plates.
6. The loosened connecting plates need to swing upwards.
7. The disconnected filter plates push together to achieve a bigger gap
between the plates.
8. Install slings on the side arms.
9. Lift filter plates diagonal out of the frame.
The filter plates can also be removed by hand if desired.
With the exchange of multiple filters it is recommended that all nuts,
washers and connecting plates are removed of the package.
The second package can be opened as described in chapter 6.5,
pg. 65.
52
Operating Instructions PKF 140 NG
4033, 4034, 4035
5 Installation
5.2.2
Installation of filter plates

Main switch in off position.

Warning sign placed by filter.

Protect chute covers. Do not step on it. Cover with wood planks.
IMPORTANT
Connecting plates to be installed inside and outside the plate packs.
 The re-assembly of the filter plates should be in reverse steps, as
described in steps 5 to 9 in chapter 5.2.1, pg. 52.
After completed assembly of the filter plates and installation of the connecting plates including washers and nuts the PKF press can be put
back into service.
5.2.3
Installation of the filter cloths

Main switch in off position

Warning sign placed by filter

Protect chute covers. Do not step on it. Cover with wood planks.
The filter cloths are being installed with the filter plates in the PKF.
1. The 1st package of the filter plates has to be opened manually.
2. Execute Steps 5 – 9 described in chapter 5.2.1, pg. 52.
3. Slide filter plates on side rails to create enough room to install
cloths.
4. Install cloths on pressure plates as described in chapter 3.4 “Filter
cloths“, pg. 35ff.
5.2.4
Removal of filter cloths

Disassemble filter plates as described in chapter 5.2.1, pg. 52.
1. Removed tie wraps.
2. Loosen Velcro straps.
3. Remove tie wraps from pins.
4. Fold one side of the cloth and roll up.
5. Pull rolled up cloth through the slurry channel.
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Operating Instructions PKF 140 NG
53
5 Installation
5.3
Installation of the Automatic Cloth Washing
Machine
ATTENTION
Property damage to the machine!
Clogging and damaging of the nozzles through loose deposits in the
pipes possible.
 The customer-side water pipe must be flushed before connecting
to the AWM and all loose deposits have to be removed.
The AWM for the cleaning of the cloth is being installed on the backside
of the PKF.
54

Rail for the AWM in mounted to the base frame of the PKF.

Support track is installed on the side rails.

Lifting device removed (for transport only).
Operating Instructions PKF 140 NG
4033, 4034, 4035
5 Installation
Fig. 20: Automatic Cloth Washing Machine
1
spray arm
7
side rail
2
spray tube
8
roller support
3
slide
9
support for light barrier
4
lift cylinder
10 light barrier
5
guide wheels
11 safety hook
6
guide rail
12 main track
1. Mount the cloth washing machine with both track wheels (5) on the
support track (12). Ensure that the roll connection (8) fits properly into the guide rail (6).
2. Safety hooks (11) have to be installed on the side and bottom to
guide the cloth washing machine on support track (12).
3. Install prepared energy chain.
4. Install high pressure water connection.
5. Install hose for compressed air.
6. Install guide trough
7. Install mounting (9) for light barrier (10), that the handle provides
position signal for the filter plates.
4033, 4034, 4035
Operating Instructions PKF 140 NG
55
5 Installation
8. Adjust pressure reducer for compressed to 7 bar (100 psi).
9. Move sliding unit (3) into upper position.
10. Mount spray arm (1) to the O-ring connection.
11. Mount spray arm (1) on the sliding unit.
Spray arm (1) with nozzles (2) hangs supported on top of the filter
plates.
12. Move AWM into park position near head piece of PKF.
Adjustment
after installation
is completed
Fig. 21: end limit positions
1. Limit switch (1) at head piece set on park position.
2. Safety switch (2) to be setup near end piece.
5.4
Installation of the safety doors
The safety doors are delivered separately of the PKF.
 Safety doors are to be set up according to included construction
drawings.
5.5
Connection to the air pressure station
1. The compressed air station ((5) see Fig. 3, pg. 21) needs to be connected to the small compressed air supply tank.
2. Compressed air line ((2, 8) see Fig. 3, pg. 21)) for the blow drying of
the filter cake has to be connected to the big compressed air supply
tank.
5.6
Connection of the pneumatic equipment
The control of all control valves are actuated by conditioned air which is
induced by the distribution station, positioned at the head piece end of
the PKF.
 All control valves have to be connected according to the supplied
pneumatic flow diagram.
56
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
6
Method of operation of the press filter
The PKF works as fully automatic membrane filter press and separates
solids from a slurry. The filter cake is pre-pressed, intermediate pressed
and washed in order to achieve a filter cake with the lowest possible
sugar content. After the washing the filter cake will be pressed again to
achieve de-watering. By means of compressed air the filter cake will be
dried.
ATTENTION
Damaging of the PKF!
If the temperature is too hot, the filter plates and the membranes can
be deformed. This can reduce the function of the PKF.
 The temperature of the slurry and the wash water shall not exceed
85 °C.
6.1
Filtration cycle – technological operation
The PKF works in cycles as a membrane filter press. A filtration cycle
consists of the following steps:
•
Filter filling
•
Pre-filtration (optional)
•
Filtration
•
Slurry channel rinsing
•
Pre-pressing
•
Pre-washing of the filter cake (optional)
•
Intermediate pressing
•
Displace filtrate with air (optional)
•
Washing of the filter cake
•
After-pressing
•
Drying of the filter cake
•
Draining and drying of the slurry channel
•
Venting and pressure relief
•
Discharging of the filter chambers
The optional steps can be activated or deactivated on the HMI. They
can be used to optimize the process.
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Operating Instructions PKF 140 NG
57
6 Method of operation of the press filter
6.2
Conditions for a proper operation
Solid contents
For optimal working conditions it is essential that the slurry has a constant solid content and also good filtration characteristics.
To determine the
amount of slurry per
filtration cycle
The minimum filing per cycle has to be 60 % of the total chamber volume to achieve a cake thickness of 20 mm with a chamber depth of
33 mm.
ATTENTION
Damaging of Membranes!
By inadequate fillings the membranes can be over-stretched. If the
press is over-filled the slurry channels can be plugged. In both cases
the membranes can be damaged beyond repair.
 The press must be filled around 60 % of the total chamber volume.
58
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
6.3
Automatic cycles
The PKF works in cycles as a membrane filter press. The automatic and
the semi-automatic cycle consist of the following steps:
6.3.1
Automatic cycle
•
Start
•
Close Filter Press with low pressure
•
Close chute covers
•
Close Filter Press with high pressure
•
Preparation filter filling
•
Fill filter out of slurry tank
•
Pre-filtration (optional)
•
Filtration
a) Filtration upper filtrate outlets, flow controlled
b) Filtration all filtrate outlets, flow controlled
c) Filtration, pressure controlled
4033, 4034, 4035
•
Slurry channel rinsing (optional)
•
Pre-pressing
•
Pre-washing 1 (optional)
•
Pre-washing 2 (optional)
•
Intermediate pressing
•
Displace filtrate with air 1 (optional)
•
Displace filtrate with air 2 (optional)
•
Washing of the filter cake 1
•
Washing of the filter cake 2 (optional)
•
Post pressing
•
Drying of the filter cake 1
•
Drying of the filter cake 2 (optional)
•
Discharging of the slurry channel
•
Drying of the slurry channel
•
Decompression membranes
Operating Instructions PKF 140 NG
59
6 Method of operation of the press filter
6.3.2
60
•
Decompression hydraulic
•
Open chute covers
•
Open filter press (open 1st package)
•
Plate transport (open 2nd package)
•
GOTO
•
Close Press with low pressure
•
Close chute covers
Semi-automatic cycle
•
AWM home position
•
Close Filter Press with low pressure
•
Close chute covers
•
Open filter press (open 1st package)
•
Package or AWM
•
Plate transport (open 2nd package)
•
Package or AWM
•
AWM left
•
Package or AWM 1 right
•
AWM washing
•
AWM package ready
•
AWM go to home position
•
Close Filter Press with low pressure
•
Close chute covers
•
Close Filter Press with high pressure
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
6.4
Basic description of the automatic cycle
The position of the valves in each step corresponds to the depicted
defaults in the table „Automatic Program PKF 140 NG“ (Appendix 1).
The values for the process variables are quoted in the description
„Operating parameters“ (Appendix 2).
ATTENTION
Attention: the values, indicated in the description „Operating parameters“ (Appendix 2), are guiding values which do not lead to satisfactory
filtration results under all operating conditions.
 It is recommended to document the operating parameters which
lead to good results during operation and attach them to the operating instructions.
Start
 The automatic cycle is in start status.
 There are no preconditions necessary to go to the next step.
Close Filter Press with
low pressure
Close chute covers
 The press closes till the low pressure, preset on the HMI, is reached
and the limit switch for closing the press is activated.

Low pressure is reached and press is closed.
 The chute covers are closed till the limit switches of the chute covers are activated.
Close Filter Press with
high pressure

Chute covers are closed.

Filter press is closed with low pressure.
 The Filter press now stays closed with high pressure.
Preparation filter filling

Filter press is closed with high pressure.
 Query whether all preconditions for the next step are fulfilled.
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Operating Instructions PKF 140 NG
61
6 Method of operation of the press filter
Fill filter out of
slurry tank

The filling level of the slurry tank is above the minimum start level.

Selection fill filter out of slurry tank is activated.
The temperature of the slurry should not exceed 85°C.
 The PKF will be filled with the desired filling volume preset in the
control panel.
Pre-filtration
(optional)

Filtration

The PKF is filled with the desired volume set-up in the control panel.

The slurry feed pump runs with the preset RPM.

The required flow rate is set.
Filter is filled.
 During Pre-filtration the filtrate flows back into the slurry tank till it is
solid free. This step is time controlled.
1. The flow control of the slurry flow starts. The RPM of the slurry feed
pump is controlled to reach the preset flow.
2. After reaching the preset filling volume, the valves of the lower filtrate outlets open.
3. When the preset filtration pressure is reached, the control switches
over to the pressure regulation and this pressure is maintained during the entire filtration cycle.
4. With increasing chamber filling the slurry flow will decrease. The
filtration cycle will finish when the preset minimum flow is reached.
For the positioning of the valves, please see drawing „pipe assembly
schematic“ (chapter 1.4, pg. 8).
ATTENTION
Damaging of membranes!
If during the filtration, the specified minimum amount of slurry is not
reached, the membranes will not be engaged during this cycle. The
operating cycle will be stopped and an alarm will be initiated.
 Requirement of the minimal volume of solids to be pumped into the
PKF, compare chapter 6.2.
62
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
Slurry channel rinsing
(optional)
Slurry which is after the filtration step in the slurry channel will be
flushed with water into the filter chambers. The water temperature
should not exceed 85 °C.

The filling level of the wash water tank is above the minimum level.
IMPORTANT
A check valve has to be installed in the connecting pipe between the
upper filtrate outlet and the slurry channel at the end piece.
The water enters into the slurry channel. The slurry is flushed into the
filter chamber. If the preset water volume is reached, the flushing cycle
is complete.
Pre-pressing

The pressure in the tank for the membrane air is above the minimum pressure.
The vent valve for membranes is being closed and the membranes are
being set-up to their pre-adjusted pressure with compressed air. This
pressure level is being kept for the preset time.
If pre-pressing was not successful, there is the possibility to repeat this
step (RESET) or to jump over this step (START).
Pre-Washing 1/2
(optional)
Intermediate pressing
Displace filtrate
with air 1/2
(optional)
4033, 4034, 4035
A Pre-washing cycle is executed.
The pre-washing cycle ends after the preset time or amount is reached.
After reaching the preset pre-pressing time, the membrane pressure will
be increased to the preset pressure for step intermediate pressing. The
intermediate pressure will be held for a preset time.
The filtrate is displaced with air. This step ends after the preset time.
Operating Instructions PKF 140 NG
63
6 Method of operation of the press filter
Washing of the filter cake 1
(Washing of the filter cake 2,
optional)

The filling level of the cake washing tank is above the minimum
level.
After completing the intermediate pressing cycle, the filter cake will be
washed with the preset water quantity.
The washing will be controlled by pressure and flow rate. The maximum
water flow rate and the maximum pressure inside the filtration chambers
are preset on the control panel.
The washing of the filter cake is time controlled. If the preset water volume does not penetrate the filter cake during the preset time, an alarm
will sound. The cycle continues. The wash water temperature should not
exceed 85 °C.
Post-pressing
Drying of the filter cake 1
(Drying of the filter cake 2,
optional)
The membrane pressure will be further increased and the final pressing
of the filter cake will be carried out for a preset time.

The pressure in the compressed air receiver is higher than the minimum pressure.
The drying air penetrates the filter cake during a preset time. The membrane pressure will be maintained during this step.
The compressed air pressure for drying will be adjusted mechanically
with a pressure reducer.
Discharging of the
slurry channel
The content of the „slurry channel“ is emptied into the slurry feed tank
by means of compressed air. This step is time controlled
Drying of the slurry
channel
The remaining liquid will be pushed into the chambers by means of
compressed air. This step is time controlled.
Decompression
membranes
All discharging valves are open to release the remaining pressure from
the filter press, especially from the membranes. This step is pressure
controlled.
Decompression
hydraulic
The hydraulic is decompressed. This step is time controlled.
Open chute covers
64
The chute covers are opened till the limit switches are activated.
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
Open filter press
(open 1st package)
Plate transport
(open 2nd package)
GOTO
The filter press opens the first package. This step is controlled by limit
switches.
The filter press is opened for the second package. This step is controlled by analog value.
If „Stop at the end of the cycle“ is selected by the operator, the filtration
cycle is stopped with step “close chute covers”. Otherwise the automatic
jumps back to step “Start” and the cycle restarts.
If the preset amount of filtration cycles is reached, the automatic jumps
to step “AWM check home position”.
Close Filter Press with
low pressure
Close chute covers
 The press closes till the low pressure, preset on the HMI, is reached
and the limit switch for closing the press is activated.
If „Stop at the end of the cycle“ is activated during step “GOTO”, the
filtration cycle ends by closing of the chute covers. The closing procedure is controlled by limit switches.
After a preset amount of filtration cycles (Process variables) the washing
of the filter cloths is automatically started.
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Operating Instructions PKF 140 NG
65
6 Method of operation of the press filter
6.5
AWM Check
home position
Close Filter Press
with low pressure
Close chute covers
Basic description of the semi-automatic cycle
The sensors at the AWM are checked. If there are no interruptions the
cycle continues with the next step “Close press with low pressure”.
 The press closes till the low pressure, preset on the HMI, is reached
and the limit switch for closing the press is activated.

Low pressure is reached and press is closed.
 The chute covers are closed till the limit switches of the chute covers are activated.
Open filter press
(open 1st package)
The filter press opens the first package. This step is controlled by limit
switches.
Package or AWM
In semi-automatic mode the plate package can be washed (Button on
HMI: AWM Start; jump to step “AWM left”) or the next package can be
opened (Button: Machine Start; jump to step “Plate transport”).
Plate transport
(open 2nd package)
Package or AWM
AWM left
Package or
AWM 1 right
66
The plate transport opens the second package and closes at the same
time the first package. This step is controlled by analog value.
In semi-automatic mode the plate package can be washed (Button on
HMI: AWM Start; jump to step “AWM left”) or the next package can be
opened (Button: Machine Start; jump to step “Plate transport”). Jump to
step “Close press with low pressure” if the last package is open and the
key selector switch is turned to “acid washing”.
The AWM moves to the washing position. That is the first plate of the
selected package. This step is controlled by a light barrier which is installed at the AWM.
After reaching the washing position in step “AWM left” the AWM moves
to the right to the next plate. This step is controlled by a light barrier
which is installed at the AWM.
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
AWM washing
The AWM washes the plate, which was reached during step “Package
or AWM 1 right”, by means of the spray arm, moving up and down. The
high pressure pump is started and the valves for water open.
The spray arm can repeat the procedure as often as selected in the
HMI.
AWM package ready
AWM go to
home position
Close Filter Press
with low pressure
Close chute covers
After washing each plate (step “AWM washing”) it is checked during this
step if the last plate of the package is reached. In this case there is the
possibility to move in semi-automatic mode to the next package by
pressing the start button (see steps “AWM left” till “AWM washing”) or to
stop the washing cycle.
In this step the AWM moves to its home position.
This step is controlled by limit switches.
 The press closes till the low pressure, preset on the HMI, is reached
and the limit switch for closing the press is activated.

Low pressure is reached and press is closed.
 The chute covers are closed till the limit switches of the chute covers are activated.
Close Filter Press
with high pressure

Chute covers are closed.

Filter press is closed with low pressure.
 The Filter press now stays closed with high pressure.
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Operating Instructions PKF 140 NG
67
6 Method of operation of the press filter
6.6
Filtration operation
Fig. 22: head piece of the PKF with pipe flanges
Filtration, Pressing,
Drying
1
DN 150 for slurry inlet
6
Distributor for air manifold
2
DN 100 for filtrate from pressure plates, wash water inlet
and compressed air for cake
drying
7
DN 100 for filtrate from membrane plates and wash filtrate
8
DN 100 for filtrate from membrane plates, wash water inlet
and compressed air for cake
drying
Ventilation valve
3
Connecting points for side
rails
4
DN 100 for filtrate from pressure plates and wash filtrate
9
5
Air manifold
14 DN 20 for membrane air
10 connection for compressed air
A filtration cycle includes the following steps:
1. Fill PKF through pipe (1) with slurry and filter the slurry. The Filtrate
is discharged with pipes (2, 4, 7 and 8).
2. The slurry channel is cleaned by sending water through pipe (1) into
the PKF.
68
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
3. Induce air pressure to the membrane for the pre-pressing of the
filter cake using pipe channel (14).
4. Increase air pressure for the intermediate pressing.
5. The washing process that follows reduces the residual sugar content in the filter cake. The wash water that is being send through the
membrane plates into the filter chambers (pipe 8), is being discharged as wash filtrate with pipe (4). During this process lines (2,
7) are closed.
6. For the post-pressing the air pressure is increased again.
7. For the drying of the filter cake air pressure is directed into the filter
chambers with line (8). During the dry-blowing cycle the membranes
stay induced with the post press pressure.
Slurry channel cleaning
and drying
Fig. 23: End piece of the PKF
1
Check valve
2
Control valve
8. To dry and clean the slurry channel, compressed air through the
control valve (2) is used to displace liquid in the slurry channel.
9. After cleaning and drying of the slurry channel, the membrane plate
pack is vented by V13 (see Fig. 22, Pos. 9) and the hydraulic pressure is released.
10. Open chute covers.
The filter chambers are emptied with the help of the automated plate
transport system (see chapter 6.7, pg. 70).
4033, 4034, 4035
Operating Instructions PKF 140 NG
69
6 Method of operation of the press filter
6.7
Filter chamber discharge
To discharge the mud out of the filter chamber all filter plates including
the end piece must be moved horizontally on the side rails. Depending
on the amount of plates and multiple plate packs, one or two steps are
needed. The first plate pack is on the end piece and the lower example
shows two plate packs
Fig. 24: Cake transport direction from left to right
3.1 Second plate pack
5
Transport cylinder
3.2 First plate pack
7
Hydraulic cylinder
4
21 End plate
End piece
IMPORTANT
The hydraulic cylinders are adjusted by the manufacturer and the adjustment should not be altered.
For the discharge of the first plate pack (3.2) the second plate pack (3.1)
are held in place by two main cylinders (5) which are located by the side
rails in neutral position.
After that the hydraulic actuated cylinder (7) moves the end piece (4)
and the bolted end plate (21) from the plate pack and opens filter chamber number one.
70
Operating Instructions PKF 140 NG
4033, 4034, 4035
6 Method of operation of the press filter
Interlinking plate
The filter plates on the plate pack are connected with interlinks (1). The
first interlink plate is also connected with the end piece of plate pack
number 1 to the handle of plate pack number 2.
To open the filter chamber, the end piece of the main cylinder and the
filter plate with a handle by the transport cylinder can be moved hydraulically. Through the interlinking plates each filter plates for cake discharge are separated.
Fig. 25: Interlinking plates for the discharge of filter chambers
1
Interlinking plates
If the first filter chamber is open the filter cake drops out to the transport
belt below the PKF 140 NG. The filter cake is transported to the storage
location.
IMPORTANT
For a particularly good crushing of the filter cake a twin screw can be
installed below the PKF 140 NG discharge.
For discharge of the consecutive chambers in the first plate pack all filter
plates are separated by the interlinking plates.
When the filter chambers of the first pack are empty the plates of the
second pack are opened one after the other by the transport cylinder.
During this procedure the plates of the first pack are moved together.
Hydraulic flow diagram is included in the documentation.
4033, 4034, 4035
Operating Instructions PKF 140 NG
71
7 Commissioning of the PKF
7
Commissioning of the PKF
IMPORTANT
Prior to first commissioning of the PKF follow instructions given in
chapter 7.5, pg. 88!
7.1
Control panel HMI
With the control panel the operation of the PKF is controlled and monitored.
On the display of the control panel are pictures and symbols of the process. Symbols are shown during operation interruptions.
•
Top area of display are interruptions
•
Bottom area of display are operation functions and information
Operation information includes information of momentarily program
steps and momentarily status of the PKF.
Fig. 26: Push buttons on the keyboard on the control panel
72
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
Button
Description
F1 – F8 &
F10 – F15
Process related selection button. Meaning each individual button is assigned a step in the process.
F9 &
Process non-related selection button with the following
meaning.
F16 - F24
F9
Actual operational information.
Visible in all display windows or
non-visible if selected.
F16
Fault history of the PKF.
Button ESC clears the picture.
4033, 4034, 4035
F17
Start picture with the possibility to
look at other possibilities.
F18
Activate the inter-lock for the safety
doors.
F19
The process information for adjustment of all operating parameter
and its sequence.
F20
Process information and process
data for example the charging time,
filtration time, etc...
F21
Process information for the operational status of the PKF.
F22
Trends of PKF operation.
Operating Instructions PKF 140 NG
73
7 Commissioning of the PKF
Button
Description
F23
Picture for controlling and display
of the status of the AWM.
F24
Process information of manual
control valves. (only possible for
manual operation).
Number
blocks
The number buttons are utilized to change the juice
amount, the pressure, or the timing.
Additional special buttons
Button
Cursor
control
Description
Cursor moves on display to top.
Cursor moves on display to bottom.
Cursor moves on display to right.
Cursor moves on display to left.
Process interruption confirmed.
Help text information (only if the LED is illuminated).
Enter: The changes of variable values confirmed.
74
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
Button
Description
Escape
No function
Operating and observing with the control panel
After energizing the control panel a start symbol is shown which displays the following function buttons:
Button
The push button under the symbol actuates the
following:
Test light indicators
The button to change language
Adjust information time of process cycle
Access to protected area (password)
(settings)
Access to protected area (password)
(settings)
Button F1 opens the license page.
F1: license
The license must be entered by Putsch employees.
The operation of the machine is not possible without
a valid license.
Alarm archive
F7: alarm log
4033, 4034, 4035
All errors are stored until the machine is switched off
with the main switch
Operating Instructions PKF 140 NG
75
7 Commissioning of the PKF
ATTENTION
Loss of warranty!
Unauthorized modification on displays in the protected area may void
warranty.
 Displays in the protected area should only be supplied by the supplier or authorized by supplier.
76
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
7.1.1
The timing, the pressure, and the amount of slurry into
the control system
1. Press button F19.
The first picture for adjusting the set points is displayed.
2. The variable to be changed has to be chosen by touching it.
3. With the numeric keypad enter the value.
The values shown are default values
4. For confirm push Enter button.
5. 2nd to 4th adjusting steps are to be repeated until all variables are
entered.
With the arrows to the left and to the right you can navigate to additional
pictures with variables.
The values for the listed variables correspond to the depicted specification in the description „Operating parameters“ (Appendix 2).
7.1.2
Operation of the AWM
The operation of the AWM at single machine unit can be controlled with
the HMI.
1. Press push button F23.
Image to control the AWM is displayed.
2. With the selection buttons F1 – F4 the operational commands can
be controlled.
Button F7 is used to preselect the operation steps.
Button F8 starts the automatic sequence cycle.
3. Button F10 moves the AWM to home position.
4. Button F15 activate washing after current cycle and sets the counter
to 0
4033, 4034, 4035
Operating Instructions PKF 140 NG
77
7 Commissioning of the PKF
7.1.3
Manual operation of the AWM
During the manual operation of the AWM through the HMI, especially for
testing, only the control valves can be opened or closed.
1. Press button F24.
The first picture for the manual operation of the adjusting butterfly
valves is displayed.
2. The valves can be opened or closed by pressing the selection buttons F1 – F8 once. The second activation of the button resets the
control valve.
With buttons << and >> (F10 & F15) can be navigated to additional options of manual modes.
7.1.4
Observation
For the observation of the process steps, two categories of displays are
available. It is not possible to make adjustments.
F20
At this function, only actual operating data will be
shown (e.g. filtration time, length of charge, etc.).
In another image data of the previous charges
can be displayed.
F21
At this function, control valve statuses are displayed,
light-green = valve open
dark-grey = valve closed
Furthermore, important operational steps of the
unit can be displayed.
F22
78
Images with trends of operation.
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
7.1.5
Operating messages
General operating messages
4033, 4034, 4035
Operating message
Explanation
Amount for pre-filtration is not
reached
The preset volume in step prefiltration could not be pumped into
the filter press.
Minimum volume not
reached, membrane pressing
deactivated
The minimal filtration flow rate was
reached before the minimum volume. In order not to damage the
membranes, membrane pressing is
deactivated during the running cycle.
Amount for channel rinsing is
not reached
The preset amount of water for rinsing the channel is not reached
Amount for pre-washing 1/2 is
not reached
The preset amount for pre-washing
1/2 is not reached
Amount for washing 1/2 is not
reached
The preset amount for washing 1/2
is not reached
Pre-pressing is not reached
The minimum pressure for prepressing is not reached
Pressure for intermediate
pressing is not reached
The minimum pressure for intermediate pressing is not reached
Pressure for post pressing is
not reached
The minimum pressure for post
pressing is not reached
No release by sequence control
Missing release by sequence control, possibly because another machine is in the same process
No release by customer
Missing release by customer, possibly because a customer’s machine is
not ready for the selected process
No release by slurry tank
The slurry tank has not reached the
required filling level.
No release for opening by
collecting conveyor
Collecting conveyor not ready
Possibly still in operation in connection with another PKF
No release for opening by
transport belt
Transport belt not ready
Possibly still in operation in connection with another PKF
Operating Instructions PKF 140 NG
79
7 Commissioning of the PKF
General operating messages
7.1.6
Operating message
Explanation
Air pressure drying too low
Air pressure in the compressed air
tank is too low for the process step
“cake drying” or “displace filtrate with
air”
AWM not in home position
AWM is not in home position
Alarm Messages
General alarm messages
No.
Alarm message
Reason
Troubleshooting
1, 16
Fault safety
doors washing
side right / left
The safety doors
on the washing
side are not closed
Close the safety
doors on the washing side
2, 3
Fault safety
doors operation
side right / left
The safety doors
on the operator
side are not closed
Close the safety
doors on the operator side
4
fault control voltage
Control voltage is
not active
Check the circuit
breaker
5
Fault Hydraulic
filter dirty
The Hydraulic filter
is dirty
Check and clean
the Hydraulic filter
Emergency stop
Emergency stop is
active
Unlock the respective emergency
stop and
acknowledge the
fault.
Fault extern voltage
The external voltage is missing
Check the circuit
breaker
The motor protecting switch tripped
14
Fault motor protection switch
Hydraulic
Check the motor
protecting switch
or for mechanical
problems at the
AWM
The motor protecting switch tripped
15
Fault motor protection switch
AWM
Check the motor
protecting switch
or for mechanical
problems at the
AWM
Breakdown of
sequence control
Breakdown of sequence control
Check bus
connection
8-12
13
97
80
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
General alarm messages
No.
Alarm message
Reason
Troubleshooting
98
Fault oil temperature to high
The temperature of
the hydraulic oil is
too high.
Check the Hydraulic system
99
Fault converter
water pump
A fault occurs on
the converter for
the water pump
Check the converter
Fault pressure in
the filter press to
high
The pressure in the
filter press is higher than 0,3 bar
Pressure inside
the press can be
decreased with
opening the outlet
valves of the machine
Fault pressure
sensor hydraulic
Hydraulic pressure
sensor sends
wrong values
Check the electrical connection and
the sensor itself.
Fault high pressure pump is not
running
High pressure
pump is not running
Check the high
pressure pump
Fault max. pressure hydraulic
The max. Hydraulic pressure was
exceeded
Check the hydraulic system and
decrease pressure
AWM LS packet
dirty
The higher light
sensor is
dirty/sending no
signal while in
home position
Clean the light
sensor.
AWM LS wash
position dirty
The lower light
sensor is
dirty/sending no
signal while in
home position
Clean the light
sensor.
107
AWM not in
home position
The AWM jets are
not in top position
Check position of
the AWM
108
AWM jets not in
upper position
The AWM jets are
not in top position
Check position and
air pressure of the
AWM
101
102
103
104
105
106
4033, 4034, 4035
Operating Instructions PKF 140 NG
81
7 Commissioning of the PKF
General alarm messages
No.
109
110
Alarm message
Reason
Troubleshooting
AWM monitoring
time drive to
home position
AWM needs to
much time to move
back to home position
Check the AWM
Fault converter
slurry pump
A fault occurs on
the converter for
the slurry pump
Check the converter
Fault slurry pressure to high
Slurry pressure is
higher than the set
point for pressure
control during filling the filter
Insure decreasing
of pressure
Pressure air system to low
the pressure air for
valves and membrane pressure is
too low
Increase the air
pressure
Fault temperature
sensor hydraulic
Hydraulic temperature sensor sends
wrong values
Check the electrical connection and
the sensor itself
Invalid license
No or invalid
Acquire valid
license
111
112
126
128
license
Alarm messages sequence control
No.
Alarm message
Reason
Troubleshooting
Pressure sensor
does not transmit
correct values
Check wiring
129
Fault pressure
sensor system
Air 1
Fault pressure
sensor drying
Air 1
Pressure sensor
does not transmit
correct values
Check wiring
130
Fault sensor for
filling level slurry
Sensor for filling
level does not
transmit correct
values
Check wiring
Fault pressure
sensor system
Air 2
Pressure sensor
does not transmit
correct values
Check wiring
143
145
82
Operating Instructions PKF 140 NG
Check sensor
Check sensor
Check sensor
Check sensor
4033, 4034, 4035
7 Commissioning of the PKF
Alarm messages sequence control
No.
Alarm message
Reason
Troubleshooting
Pressure sensor
does not transmit
correct values
Check wiring
146
Fault pressure
sensor drying
Air 2
Flow sensor does
not transmit correct values
Check wiring
147
Fault flow sensor
water 1
Flow sensor does
not transmit correct values
Check wiring
148
Fault flow sensor
water 2
Fault pressure
sensor water 1
pressure sensor
does not transmit
correct values
Check wiring
149
Fault pressure
sensor water 2
pressure sensor
does not transmit
correct values
Check wiring
150
Fault sealing
water slurry
pumps
pressure switch
does not transmit
correct values
Check sensor
153
Check sensor
Check sensor
Check sensor
Check sensor
Check sensor
Check water connections
Alarm messages Automatic-Mode
No.
66-78,
89-92
Alarm message
Reason
Troubleshooting
Monitoring time
XXX
Times for automated processes
are exceeded
Check the process
according to the
respective alarm
message
Alarm messages valves
4033, 4034, 4035
No.
Alarm message
Reason
Troubleshooting
17-64,
121124
Monitoring time
XXX open / close
Monitoring time
open / close
valve has tripped
Check respective
valves
Operating Instructions PKF 140 NG
83
7 Commissioning of the PKF
7.2
Pressure sensor for hydraulic and compressed
air
On the hydraulic and the compressed air station are each one pressure
sensor to control the operation of each unit. The pressure sensor for the
hydraulic has a range from 0 – 400bar. The pressure sensor for the
compressed air has a range of 0 – 10bar. Both sensors are adjusted
through a pressure control switch.
Fig. 27: pressure sensor for hydraulic and compressed air
1
7.3
7.3.1
LED-Display
Check points before each start-up
PKF
Before each start-up of the PKF the following steps must be checked
thoroughly:
84
•
Are the filter plates in the right sequence
(membrane plate – pressure plate – membrane plate)?
•
Are the filter plates correctly installed, are the contact points on the
right side?
•
Are the seal rings for the membrane air and the filtrate channel inserted correctly?
•
Are the filter cloth correct and fit tightly?
•
Are the openings for filtrate from the pressure plates, wash water
and drying air as well as the gaskets for membrane air clear?
•
Is the closing pressure adjusted correctly?
•
Are pressures for compressed air, timing for programming process
set-up correctly? See description „Operating parameters“
(Appendix 2).
•
Are the variables for the base amount of mud juice concentrate 1
and the flushing water amount adjusted correctly, see description
„Operating parameters“ (Appendix 2)?
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
7.3.2
Support equipment
Before the PKF is set-up for filtration after shutdowns, all support
equipment around the PKF has to be checked for proper working operation.
IMPORTANT
The readiness of the hydraulic system must be ensured before the
start-up of the PKF! See chapter 11.4, pg. 115.
7.4
7.4.1

Agitator on the slurry tank must be switched ON.

Hydraulic system must be turned ON.

Slurry tank level minimum is reached.

Filling pump switched ON.

Pump for flushing water switched ON.

Compressor for compressed air switched ON.

Transport direction of the filter cake is verified.

Conditioned air for control valves is available.

Conditioned air for the AWM is available.

Compressed air for the blow drying is available.

Safety doors are closed.
Mechanical test runs
PKF
General requirements
4033, 4034, 4035

Conditioned air for control valves is available.

Conditioned air for AWM is available.

Compressed air for membrane air is available.

Slurry feed pump operation able.

Compressor for compressed air is operation able.

Transport belt is operation able.

Flushing water pump operation able.

Minimum level in Slurry tank exists.

Compressed air is available.
Operating Instructions PKF 140 NG
85
7 Commissioning of the PKF
Electro/mechanical requirements

Safety doors closed.

AWM is in park position.

Filter press package is open.

All control valves are closed (V13 – membrane vent is open)

No interruptions
Fig. 28: View of switch cabinet
1. Set Main switch (11) to ON.
2. Emergency switch (10) disengage if needed.
3. Push Button (14) control voltage ON.
4. Push Button (3) reset interruption.
5. Set key switch (7) Automatic/Manual/Semi-Automatic to
Semi-Automatic mode.
On the switch panel (1) appears step no.1.
Light button (13) Start flashes.
6. Start filter press by pressing button light button (13) START.
Light button lights continuous.
7. After completing a semi-automatic process the button (13) START
begins flashing again.
Push button (13) again to complete the semi-automatic process.
86
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
7.4.2
Cloth washing machine

Mechanical test run of filter press has been completed.

High pressure pump for wash water is operation able.

Shut off valve for wash water is open.

Air pressure 7 bar for the cylinders has been established.

Safety doors are closed.

Cloths washing machine is in park position.

1st plate pack is open.
Initially the first plate pack (at end piece) and the second plate pack (at
head piece) are washed.
1. Cloth washing machine starting.
2. Visual inspection of the following steps:
–
If the spray arm is in the vertical position at the upper edge of
the filter plate the spraying action has to start.
–
When the spray arm reaches the bottom of the filter plate it
should move up again or retract.
–
If the spray arm reaches the top edge of the filter pack the water
flow should stop.
–
The spray arm continues to move to the upper end position.
–
In this position the spray bar moves to the next filter plate pack.
After the 1st plate package is cleaned the cloth washing machine moves
back to the park position.
4033, 4034, 4035
Operating Instructions PKF 140 NG
87
7 Commissioning of the PKF
Fig. 29: Positioning sensors
3. Positioning sensors (1) must be adjusted if the operational steps are
not fulfilled in operational description number 2.
4. Close the filter press in the operation phase semi-automatic.
5. 2nd plate package opening
The cloth washing machine moves to the middle of the press and cleans
the 2nd plate package.
After the 2nd plate package is cleaned the automatic washing machine
moves back into park position.
7.5
88
First time commissioning

All in chapter 7.3 pg. 84 mentioned requirements are fulfilled.

All operating parameter are adjusted (see description „Operating
parameters“ (Appendix 2)).

The filtration end pressure is set to 2 bar.

The variable for the base mud flow 70 m3 is adjusted.

The display of the control panel indicates process PKF ”automatic”

The button Start blinks
Operating Instructions PKF 140 NG
4033, 4034, 4035
7 Commissioning of the PKF
The first cycles are to warm up the filter plates and control the filling of
the filter chambers. In this phase no membrane air should be introduced.
In the first cycle the press is operated without pre-pressing, intermediate
pressing, and post-pressing. Therefore to achieve dry filter cake for
discharging purpose the time of cake drying must be extended.
1. Membrane pressure is shut off at the HMI
For security rotate the three way valve (1) located in pipe for membrane air to vent the membrane plates.
2. Adjust the value for cake drying to 180 seconds.
Fig. 30: Three way valve (1) for membrane air
ATTENTION
Destroying of the membranes by compressed air in case of thin
filter cake in the chambers!
Run the first 2 – 5 cycles always without membrane pressing.
 Shut-off membrane pressure at the HMI.
 The three-way valve (1) located in the head piece turned to membrane plates venting
The atmospheric pressure behind the membranes can escape during
the fill cycle of the filter, but the air pressures for the 3 pressing stages
are simulated only for the automatic phases.
3. Push Start button.
4. If the slurry has a solid content of 15 g/l, charging volume of 110 m3
of the medium that is filtered is needed.
4033, 4034, 4035
Operating Instructions PKF 140 NG
89
7 Commissioning of the PKF
The filtration ends automatically, once the value of the through-put flow
from the prior selected value 25 – 30 m3/h is reached.
The 3-way valve in the membrane air line (see Fig. 30, pg. 90) stays in
the open position.
Fig. 31: Button Stop press at end of cycle
5. During the automatic operation push button Stop press at end of
cycle (12)
6. After reaching the last step Cycle finished, all conditions to be reset.
7. For the cycles 2 up to max. 5, the steps 3 to 7 are to be repeated.
8. The value for cake drying, after completing the charges 2 - 5, to be
re-adjusted to 90 sec.
9. Start membrane air pressure at the HMI.
The 3-way valve (1) in the pipeline for membrane air turned to normal position.
10. Adjustment of the filtration pressure to achieve a filter cake thickness of 20 mm by increasing or decreasing the first setting.
The desired washing result in the filter cake will partly be reached
after approx. 200 cycles.
90
Operating Instructions PKF 140 NG
4033, 4034, 4035
8 Operation
8
8.1
Operation
Modes of operation
The PKF has 3 modes of operation, which can be set with key switch (7)
on the switch cabinet.
•
automatic operation
•
semi-automatic operation
•
manual operation
Above the key switch an indicator light for each mode of operation is
located.
Fig. 32: Key switch for modes of operation
4033, 4034, 4035
Operating Instructions PKF 140 NG
91
8 Operation
8.2
Automatic operation
All operational steps are controlled by the PLC. The PKF operates in
continuous operation.
IMPORTANT
The filtration of carbonated remelt syrup can only be carried out in
automatic mode (key selector switch).
The automatic operation can be started under these requirements:

All requirements in chapter 7.3 are met.

All values are adjusted.

Minimum slurry level is reached.

Necessary release signals from the customer are active.
Additional electro-mechanical requirements

Main switch on.

Emergency stop disengaged.

Safety doors closed.

Cloth washing machine AWM in park position.

All control valves closed.

Membrane vent valve (V13) open.

No error messages from the hydraulic pumps.
1. Push button control voltage on.
2. Push re-set button.
3. Turn key selector switch to automatic.
Once all requirements are fulfilled the display shows process PKF:
Automatic.
The illuminated button Start flashes and the PKF can be started.
4. Push Start button.
The steps which are triggered in automatic operation mode are explained in detail in chapter 6.4:
More information of the program sequence are displayed on the control
panel.
92
Operating Instructions PKF 140 NG
4033, 4034, 4035
8 Operation
8.3
Semi-automatic operation
In semi-automatic operation the following steps are achievable:
•
The hydraulic opening and closing of the chute covers and the filter
press
•
the cleaning of the filter cloths with the washing machine (see chapter 9, pg. 97)
To switch into the semi-automatic operation mode
1. Press button stop at the end of the cycle (see Fig. 31, pg. 90).
This button will discontinue automatic operation mode.
2. For the semi-automatic operation mode, the key selector switch has
to be turned to semi-automatic position (see Fig. 32, pg. 91, Pos. 1).
The steps which are triggered in semi-automatic operation mode are
explained in detail in chapter 6.5:
8.3.1
Program steps for washing of the filter cloths

Key selector switch in position semi-automatic

Automatic washing machine in park position

One plate pack is opened in semi-automatic mode

Water pressure pump operational
The automatic washing machine can operate in semi-automatic mode
by means of a remote control, a hand held pendant or from the control
panel on the switch cabinet.
The steps in the washing process are indicated at the control panel. The
personal observation position is on the side of the AWM.
The steps which are triggered in semi-automatic operation mode are
explained in detail in chapter 6.5:
 The washing sequence is described in chapter 9, pg. 97.
4033, 4034, 4035
Operating Instructions PKF 140 NG
93
8 Operation
8.3.2
Status displays of the automatic washing machine
AWM
At the machine four display lamps are signaling the operating steps:
Fig. 33: Status display on the automatic washing machine
Pos.-No.
8.4
Operating Status
Definition
1
Status machine
Status machine (same behavior as
illuminated start button under the
HMI)
2
Fault
Fault; observe indication on the HMI
3
Wash position has
been reached
Wash position has been reached
4
High pressure pump High pressure pump has been
is running
started with confirmation
Manual operation
During manual operation maintenance and repair work are performed.
The filter press can only be opened and closed hydraulically.
1. Press push button stop at the end of the cycle (see Fig. 31,
pg. 90) to disengage the filter press out of automatic operational
mode.
2. Key selector switch to manual position (see Fig. 32, pg. 91,
Pos. 1).
94
Operating Instructions PKF 140 NG
4033, 4034, 4035
8 Operation
8.5
Operation of the PKF under extreme conditions
Breakdowns can cause extreme bad filtration conditions. In such a case
a normal filtration is not possible and the thickness of filter cake in the
press sometimes reaches less than 10 mm.
The Filter Press is to be emptied according to the following emergency
measures, in order to prevent a shutdown of operation.
ATTENTION
Destruction of the membranes!
The membranes could be destroyed if pressed air is introduced during
fill volume and if the solid volume in the chambers is too low.
 Insure that the membrane air is shut off.
1. Membrane air is to be shut off at the HMI.
2. With the control panel the volume of the wash water “cake washing
1: flow rate” has to be reduced to 0,01 m³ (see description
„Operating parameters“ (Appendix 2).
This way only a small amount of wash water enters the filter chamber and does not dilute the slurry.
IMPORTANT
Do not discharge PKF press in automatic mode to prevent difficulties
to operate transport conveyors underneath the unit.
 The PKF press should be discharged in small steps in the manual
mode.
4033, 4034, 4035
Operating Instructions PKF 140 NG
95
8 Operation
Fig. 34: Control Panel emergency operation
3. While the 1st package is opened, turn key selector switch (7) (see
chapter 8.2, pg. 92, step “Open filter press”), to manual operation.
4. Open or close the PKF press with the selector switch (9).
IMPORTANT
 Because in the filtered chamber may only be sludge it’s important
to observe the discharge and remove the remaining sludge in the
chambers.
5. Filter chambers to be emptied step by step.
6. Close the safety doors to close PKF plate pack. In case of failure:
–
correct the cause of the problem
–
acknowledge the problem and push button (3)
–
start PKF press again.
7. Close filter press.
IMPORTANT
As soon as bad mud juice concentrate condition improves:
 Clean filter cloths with AWM.
96
Operating Instructions PKF 140 NG
4033, 4034, 4035
9 Washing of the filter cloths (option)
9
9.1
Washing of the filter cloths (option)
Washing procedure
For the washing of the filter cloths, the PKF press has been taken out of
the automatic mode, switched to semi-automatic mode and started. The
washing machine moves to the end of the opened plate package. The
automatic washing machine is controlled with a light barrier which senses a position at the handle of the filter plate.
For the washing, the spray arm moves vertical down. As soon as it detects the edge of the filter plate the spray nozzles are at an angle spray
with high pressure the remaining filter cake particulars off the filter cloths
on both sides of the chambers.
When the lower edge of the filter plates is reached the pneumatic automated cylinder moves the spray arm to the top again. When the spray
arm reaches the top of the filter plate the control valve for wash water
will be closed and the spray bar continues to move to the top end position.
The wash procedures/steps continue until all filter plates of the opened
pack are cleaned. The amount of wash steps per chamber is preprogrammed and can be adjusted to the requirements.
When the last filter plate in the opened pack is washed the machine
moves back to the home position at the head piece and the next pack
will be opened with the semi-automatic operation mode. The washing
machine will start again and washes all filter cloths on the opened pack,
according to the same procedure as described above.
9.2
Actuator steps
During the washing operation of the filter cloths certain actions on the
PLC of the control cabinet have to be carried out.
IMPORTANT
To prevent plugging of the spray nozzles due to contamination the
wash water should be filtered through a Putsch cartridge filter
(200 micron).
4033, 4034, 4035
Operating Instructions PKF 140 NG
97
9 Washing of the filter cloths (option)
If the PKF works normal:
1. Push button Stop at end of cycle.
The button lights up.
The filter press stops at the end of the current cycle.
2. Key selector switch turn to semi-automatic position.
The button Start starts flashing, once following conditions are
reached:
–
Safety doors closed
–
cloth washing machine in home position
3. Select menu position AWM on the PLC
4. Push Start button at the press. The first package is opened.
The automatic washing cycle of the opened block starts after pressing
the Start button for the AWM on the HMI.
The cloth washing machine AWM moves to the left end of the opened
pack, turns around and starts to clean the cloths of the opened plate
pack in sequence. Once the whole plate pack is washed, the washing
machine moves to its home position.
The next pack is opened after pressing the Start button.
The automatic washing step starts if the pack is opened and the Start
button for the AWM on the HMI is pressed.
After the washing of the last pack the cloth washing machine moves to
the home position.
5. Quit menu position AWM on the HMI.
Return to the automatic
mode of operation
IMPORTANT
Due to high pressure water the o-ring seals maybe flushed out of the
seal area.
 After the completion of the wash cycle and prior to the start up in
automatic mode it is important to check all o-rings for the proper fit.
6. Key selector switch is to be positioned to automatic.
As soon as illuminated start button flashes, the PKF press is ready
for automatic operational mode.
98
Operating Instructions PKF 140 NG
4033, 4034, 4035
9 Washing of the filter cloths (option)
IMPORTANT
The washing program can be interrupted and manually continued anytime by switching between Automatic and Manual at the PLC in
menu position AWM.
 Automatic washing machine can be moved to the desired position,
through pushing the button left or right.
 The automatic washing machine can be moved to the next chamber in manual mode with the button „Start“.
 Cloths to be washed by pushing the button spray arm upwards
or downwards. Make sure that the movement of the spray arm
reaches the center of the plates.
4033, 4034, 4035
Operating Instructions PKF 140 NG
99
10 Actions during interruption
10
Actions during interruption
The automatic control system monitors continuously the entire PKF
press operation system, including control valves, slurry feed pump,
compressed air station, and the transport of the filter cake.
All interruptions are graphically shown at the display of the control panel. If an interruption occurs, an instant view of the problem and the function is displayed on the screen.
The interruption function display can be acknowledged with the button
ACK at the HMI.
IMPORTANT
 The indicated interruption has to be corrected.
 After correction of the interruption the re-set button has to be
pushed.
The image which is shown at the interruption is shown again on the
monitor.
10.1
Minimal volume of slurry
not reached
Control time
exceeded
Indication for interruption
If during the filtration the minimal volume of slurry is not been reached,
the message on the display indicates „Minimum volume not reached,
membrane pressing deactivated“. The filtration cycle is terminated. In
the next step the membrane air pressure for the membrane plate pressure is shut-off. The drying time for the filter cake will be automatically
increased to 180 seconds. At the end of cycle the machine stops and
can be cleaned. You have to change the mode to manual before you
can restart the automatic cycle.
If the control time of the washing of the filter cake is exceeded:
 Check if the pump for the wash water works properly
 Check if cartridge for wash water is plugged.
At extremely poor slurry filterability, the time of the wash cycle can increase. If the monitoring time for cake washing is reached a message
will be displayed on the HMI and the automatic cycle continues.
100
Operating Instructions PKF 140 NG
4033, 4034, 4035
10 Actions during interruption
Correct
adjustment
A control of the filtration conditions and the solid content concentration
can give you information of changes needed for the operating parameters of the PKF. For adjusting the parameters see Appendix 2
“Operating parameters”.
How to adjust the parameters under extreme conditions see chapter 8.5,
pg. 95.
See chapter 7.1.6, pg. 80 for more alarm messages.
10.2
Restarting after actuating the emergency stop
or after power failure
After interruption of the filter program due to activating of the emergency button or a power failure, a dangerous situation might have occurred. The reason for actuating the emergency button must thoroughly questioned and investigated.
The operating personnel must be instructed that the emergency stop
can only be activated in dangerous situations.
If the emergency stop button is activated the control system is deactivated. The position of control valves, doors, etc. is shut-off. In automatic mode the control system will remember the last step of the program.
Fig. 35: Restarting
4033, 4034, 4035
Operating Instructions PKF 140 NG
101
10 Actions during interruption
1. Correct dangerous situation.
2. Disengage emergency stop button (10).
3. Push reset button (3)
4. Push button control voltage on (14) to restart control system.
5. If the emergency stop button was activated during filtration cycle,
and uncertainty regarding the filtration condition exists, close membrane air through the 3-way valve, see Fig. 30, pg. 89.
For other operating modes:
102
•
The semi-automatic mode allows restarting where operation was
stopped.
•
The wash cycle can be continued where it stopped.
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
11
Control and maintenance
Precise and controlled maintenance has to be exercised to extend the
functional integrity and the life cycle of the PKF press.
Prior to each campaign:
•
Membrane plates are to be dressed with new filter cloths.
•
Change oil in the hydraulic system.
IMPORTANT
During the warranty time frame all maintenance and repair work has to
be performed by the manufacturer or a manufacturer authorized company.
11.1
11.1.1
Control and maintenance during the campaign
Control of the filtration system
At the presses and needed support equipment daily inspections have to
be performed:
 Check proper fit of all filter cloths.
 Check cleanliness of filter cloths including sealed surfaces.
 Inspect filter cloths especially in the neck area for damage.
 Check all 0-rings on the filter plates for proper fit.
 Open drain valve on the pipe for membrane air short term.
If larger amounts of water are present the membrane plates are defective.
 Bolts on the handles and the connecting plates and all other moving
parts are to be checked.
 All pipelines including the hydraulic unit and all pressure transmitter
indicators are checked for leakage.
 Oil level for the oil mist units for the solenoid valve to be check and
may be refilled. Set consumption to minimum.
 Air filter at the compressed air station is to be checked and possibly
cleaned.
 Check pressure on the pressure reducing valve for air and water
possible correct and secure the security nut.
4033, 4034, 4035
Operating Instructions PKF 140 NG
103
11 Control and maintenance
 Check compressed air connection on the automatic control valve for
leaks.
 Check automatic dewatering device on air tanks.
 Check leaks and pressure on the pump and filter cartridge for wash
water.
 Check cleanliness of the transport systems for filter cake particular
on transfer points to prevent plugging of units.
11.1.2
Service and lubrication of equipment components
The following components are to be serviced according to lubrication
instruction:
Fig. 36: Lubrication surface
104
•
Side bars (1) to be cleaned daily and lubricated with thin silicon oil.
•
Guide trough and energy chain (2) to be kept clean.
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
Fig. 37: Lubrication points at the cloth washing machine
 Guide rods (1) for the slide of the automatic washing machine AWM
are to be oiled weekly.
 Bushings (Grease Zerk) (2) at the guide rod are to be greased
weekly.
 Drive chains (3) at the automatic cloth washing machine are to be
oiled or re-greased weekly.
4033, 4034, 4035
Operating Instructions PKF 140 NG
105
11 Control and maintenance
11.2
11.2.1
Control and maintenance of the hydraulic unit
Overview of the hydraulic unit
The hydraulic unit is completely mounted and filled with oil prior to delivery. All needed adjustments are tested at the test run at the manufacturer.
The important segments are shown in the following image:
Fig. 38: Hydraulic unit front view
106
1
Motor
8
Control block
2
Valve block – decompression
9
Return filter with flow indicator
3
Valve block – closing cylinder
10 Pressure gauge
4
5
Valve block – pressure switch 11 Hydraulic unit
(high to low pressure)
12 Service cover
Valve blocks – chute covers
13 Level indicator
6
Valve block – plate transport
14 Connection for pump priming
7
Measure point 6.2
15 Fill and ventilation filter
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
Fig. 39: Hydraulic unit top view
11.2.2
1
Motor
9
return filter with flow indicator
2
Valve block – decompression
14 connection for pump priming
3
Valve block – closing cylinder
15 Fill and ventilation filter
4
Valve block - pressure switch
(high to low pressure)
16 Drain valve
5
Valve blocks – chute covers
6
Valve block – plate transport
17 control valve
Hints to work on the hydraulic system
The customer performs after installation visual controls for possible
damage during installation of the PKF press.
ATTENTION
Damage due to change of system pressures!
If pre-adjusted pressure values have been changed it may result in
equipment damage.
 Pre-adjusted pressure values should not be changed.
4033, 4034, 4035
Operating Instructions PKF 140 NG
107
11 Control and maintenance
DANGER
The hydraulic system operates under high pressure!
Severe injury or death may occur.
 Work on hydraulic units is only performed by trained personnel.
 Prior to work on hydraulic units the unit must be de-pressurized.
 Never disconnect pipe fittings or connections as long as the unit is
under pressure.
IMPORTANT
The following directions for work on the hydraulic system must be considered:
 Do not work with greasy hands.
 Practice extreme cleanliness.
 Close all openings with protective covers to prevent contamination.
 Do not use steel wool to clean oil reservoir.
 Use only 25 micron filters or finer ones to fill the unit with oil.
 To paint cover all gaskets and bearings and surfaces of moving
parts.
 Control valves and solenoid valves are to be mounted stress free
to prevent seizing.
 For sealing only Teflon tap or copper seal rings are to be used.
 After 200 operating hours the customer must check all connections
and re-tighten if necessary.
108
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
11.2.3
Preparation and Start-up by the manufacturer
All control valves are outfitted with emergency hand activation (see
Fig. 41 pg. 111, Pos. 4 and 5). This allows a manual activating without
control voltage. The valves have a recessed pin in the center of the
magnet area.
 Pin can be pushed in if necessary. Do not use any sharp or pointy
objects; this could cause damage to the valve.
All emergency actuations are spring-loaded. By non-activation the normal position is shown in the flow diagram.
IMPORTANT
If the maximum oil level is exceeded at extended main cylinder position the oil reservoir can overflow when the cylinder retracts.
 The maximum oil-level is to be adjusted at extracted main cylinder
position only.
 Oil level is to be checked periodically (see chapter 11.2.1, pg. 106).
Fig. 40: Pressure reducing valve
4033, 4034, 4035
1
Pressure reducing valve
4
Safety block
2
Pressure gauge
5
3
Pressure sensor
Adjustment screw for pressure
reducing valve
Operating Instructions PKF 140 NG
109
11 Control and maintenance
On the bottom of the main cylinder is a safety block (4) installed, which
even in case of a hose failure (or emergency stop) keeps the PKF
closed.
Next to it is a pressure sensor (3) to control the main cylinder as well as
a pressure gauge (2).
The pressure sensor (3) controls or builds the building pressure of the
press. If the closing pressure is lowered during the operation the hydraulic pump starts up again. The pump operates with a time delayed
shut-down.
Transport cylinder
To ensure a synchronized movement of both transport cylinders (see
Fig. 2, pg. 20, Pos. 5) a distance measurement system is installed. The
transport cylinders are controlled separately. Therefore the control can
determine the exact position of the transport cylinder and compensate a
stroke difference. A synchronization of ± 1 mm will be achieved by this
control. The two hydraulic flow streams are secured with a pressure
limiting valve, which is pre-adjusted to a level of 80 bar. This pressure
value should not be changed.
Chute covers
In contrast to the main cylinder the plate transport cylinder and the chute
cover cylinder operate with lower operating pressure. The adjusted
pressure of 70 bar from the manufacturer shall not be changed.
The cylinder of the chute covers (see Fig. 11, pg. 38, Pos. 2) are controlled by two way valves (see Fig. 38, pg. 106, Pos. 5) with integrated
flow delay. The best speed for opening and closing the chute covers is
adjusted by the manufacturer. If wanted, adjustments to open the doors
faster can be done easily.
110
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
Fig. 41: Control valves chute covers
Control block
high pressure
6
flow control check valve
7
flow control check valve
2
Control valves chute covers
8
pressure reducing valve
3
Control valves chute covers
9
4
emergency hand control
adjusting screw on pressure
reducing valve
5
emergency hand control
1
On each of the control valves (2, 3) is a flow control check valve (6, 7)
installed. Depending on the lay-out the valves can be adjusted with
wrench.
IMPORTANT
If the adjusting screw is completely inserted, the oil supply is cut-off
and the chute covers cannot be moved.
 Do not insert the screw all the way.
1. The extruded screw increases the speed of the doors movement.
– or –
The insertion of the screw decreases the speed of the doors movement.
2. After adjustment of the desired speed secure the bolt with a lock
nut.
4033, 4034, 4035
Operating Instructions PKF 140 NG
111
11 Control and maintenance
Oil filter in the
return line
The oil filter on top to the oil reservoir (see Fig. 39, pg. 107, Pos. 9) has
a visual (see Fig. 38, pg. 106, Pos. 9) and an electronic debris indicator.
 Display during the operation has to be checked periodically to insure
timely exchange of the filter elements.
11.3
Changing of the hydraulic oil
The pressure fluid has the following purposes:
•
power transmission
•
wear reduction/ wear protection
•
heat transfer
ATTENTION
System damage!
Failure of hydraulic components due to inadequate hydraulic fluid
 only use hydraulic oil type recommended by the manufacturer
 check the quality of the hydraulic oil regularly
The standard hydraulic oil is Tellus TD 46 and filled into the hydraulic
unit by the manufacturer. Other suggested hydraulic oil types see chapter 12.3, pg. 123.
IMPORTANT
The ambient temperature of the PKF 140 NG stays between 10 ⁰C
and 30 ⁰C. At higher or lower temperatures other oils must be used.
Required hydraulic oils can be requested at the manufacturer.
112
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
11.3.1
Draining of hydraulic oil
DANGER
Penetration of skin is possible due to pressurized oil!
Severe injuries and infections!
 Hydraulic hose connections to be checked regularly
 Exchange damaged or altered hydraulic hose connections immediately.
 In case of incident see immediate medical attention.
WARNING
Hot Hydraulic oil!
Severe bodily injury!
 Before draining the hydraulic oil wait to cool.
1. Use appropriate container under drain valve.
2. Drain valve at lower part to be opened.
3. Drain oil completely.
4. Close drain valve.
5. Dispose used oil according to local rules and regulations (see chapter 13.3, pg. 126).
4033, 4034, 4035
Operating Instructions PKF 140 NG
113
11 Control and maintenance
11.3.2
Filling of hydraulic oil
ATTENTION
System damage
Interruption of hydraulic components due to inadequate hydraulic fluid.
 Only use manufacturer specified hydraulic oil
 Quality of the hydraulic oil to be check regularly
 Fill hydraulic oil with a filtration pump
 Alternative to fill the oil through a 25 µm filter
1. Remove lid of fill and vent filter
IMPORTANT
Check the oil level during the filling process.
2. Main cylinder has to be filled completely on both sides of the piston
by moving the cylinder back and forth.
3. Use approximately 300 l hydraulic oil.
4. Fill to the optimum oil level with a retracted cylinder.
5. Once the level is reached, replace the lid of fill and vent filter.
Oil change intervals
Oil change frequency depends on the following conditions:
•
working pressure
•
operating temperature
•
operating cycle
•
fluid type
Due to these variables a general statement about the useable duration
of the intervals cannot be made. The following intervals are recommended:
114
•
Oil change will be done immediately after commissioning of the PKF
by the manufacturer.
•
Additional oil changes are necessary after 2000 - 3000 operating
hours.
•
Prior to each campaign change hydraulic oil and filter elements of
the return filter.
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
Operating temperature
ATTENTION
System damage due to high temperature!
If the oil exceeds a temperature of 60 °C the lubricity of the oil is reduced. This can cause damage to the hydraulic pump.
 Maintain correct oil temperature!
 Oil temperature to be controlled, keep below 60 °C.
11.4
Adjustment of the hydraulic unit
Because the hydraulic unit is completely installed and pre-adjusted before delivery usually no other adjustments are needed. In case of possible repair or changing of components has been done, some adjustments and venting of cylinders may be required.
IMPORTANT
Adjustments and vent work are to be performed by qualified and
trained personnel.
The work has to be performed in sequence as described by the manufacturer and done at the initial commissioning of the filter press.
Pre-requisite for all work is that the hydraulic tank is filled with the recommended hydraulic oil.
11.4.1
Commissioning of the pump

Hydraulic tank filled with recommended oil.
ATTENTION
Wrong rotation of the motor!
The motor must turn right (clock wise direction)
 Check rotation of the motor and change if necessary.
1. During the initial commissioning of the system fill the pump through
the prime connection (see Fig. 38, pg. 106, Pos. 14).
Short start-and-stop cycles will allow quick ventilation and filling of
the pump cavities.
2. After ventilation is completed, close lid of the prime connection.
4033, 4034, 4035
Operating Instructions PKF 140 NG
115
11 Control and maintenance
3. Start pump in no-pressure circulation mode during this run, no control valves are actuated or manually activated.
4. Slowly build pressure.
11.4.2
Adjustment of the operating pressures

wrench SW13

screw driver

pressure gauge (400 bar) with appropriate hose connection (length
about 1 m)
Adjusting operating
pressure to 70bar
Fig. 42: Control valve
1
Solenoid Y30
3
Control valve
2
Adjusting bolt
pressure limiting valve
4
Solenoid Y34
5
Adjusting bolt pressure reducing
valve
1. Retract adjusting bolt on pressure reducing valve (see Fig. 41,
pg. 111, Pos. 8).
2. Retract adjusting bolt on pressure limiting valve by about 50 %.
3. Solenoid Y31 of control valve (3) to be energized.
4. Solenoid Y30 (1) of control valve (3) to be energized.
116
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
5. Adjusting bolt on pressure limiting valve has to be adjusted until
pressure reaches 70 bar at measuring point 6.2 (see Fig. 38,
pg. 106, Pos. 7).
If the pressure of 70 bar has not been reached, additional adjusting
is necessary.
6. After reaching the 70 bar value secure the adjusting bolt with lock
nut.
7. Check adjustments:
–
Shortly disconnect the power of the control valve (3).
–
Re-establish the power.
The pressure at the measuring point must be 70 bar again.
Adjusting operating
pressure to 290 bar
1. Adjusting bolt of pressure limiting valve (see Fig. 42, pg. 116,
Pos. 2) to be turned on block.
2. Solenoid Y31 of control valve (3) to be energized.
3. Adjusting bolt on pressure limiting valve has to be adjusted out until
pressure reaches 320 bar at measuring point 6.2 (see Fig. 38,
pg. 106, Pos. 7).
4. Secure the adjusting bolt with a lock nut.
5. Turn adjusting bolt 2 revolutions out and disconnect electric power
for a short period of time.
6. Re-establish electric power.
7. Re-check pressure.
8. Adjusting bolt on pressure limiting valve has to be adjusted in, until
pressure reaches 290 bar at the measuring point 6.2.
9. Secure with lock nut.
Adjusting of the pressure reducing valve
1. Energize solenoid Y38 and Y34 of the control valve.
2. Adjusting bolt on the pressure reducing valve has to be turned in
until the pressure reaches 70 bar at the measuring point 6.4 (see
Fig. 44, pg. 120).
The pressure must be adjusted slightly higher as at the pressure limiting
valve (see Fig. 42, pg. 116, Pos. 2), to prevent unnecessary temperature increase of the oil.
3. After the adjustment of the pressure stages all functions should be
checked with low pressure stage of 70 bar.
4033, 4034, 4035
Operating Instructions PKF 140 NG
117
11 Control and maintenance
11.4.3
Adjusting of the pressure limiting valve
1. Adjusting bolt of pressure limiting valve (see Fig. 40, pg. 109,
Pos. 5) to be turned in on block.
2. Close PKF filter pack up to 70 bar.
3. Energize solenoid Y32 (see Fig. 45, pg. 120) and Y34 (see Fig. 42,
pg. 116, Pos. 4).
4. Close PKF filter pack up to 290 bar.
5. Energize solenoid Y33 (see Fig. 45, pg. 120) and Y34 until 290 bar
are reached.
All control valves stay energized.
6. Adjusting bolt (see Fig. 40, pg. 109, Pos. 5) on pressure limiting
valve to be turned out again until oil splatters.
7. Adjusting bolt to be turned by one revolution and secure by lock nut.
8. Check the function and adjustments of the valves:
–
release pressure of the cylinder and build up pressure again
At 290 bar no oil should be flowing out off the pressure limiting valve
(see Fig. 40, pg. 109).
118
Operating Instructions PKF 140 NG
4033, 4034, 4035
11 Control and maintenance
11.4.4
Adjusting the speed of the chute covers
Fig. 43: Adjusting speed of chute covers
Y39
Close chute covers, AWM
side
Y41 Open chute covers, operating
side
Y40
Close chute covers, operat- Y42 Open chute covers, AWM side
ing side
1. Close flow control check valves (see Fig. 41, pg. 111, Pos. 6 and 7).
Use the adjusting bolts on front and back and tighten fully.
2. Open chute covers on operating side of the filter press:
–
Pressurize solenoid valve Y41 (LED illuminates) and adjust the
flow control check valve which is below the solenoid valve Y41,
until the required speed of the chute covers is reached.
3. Close chute covers on operating side of the filter press:
–
Pressurize solenoid valve Y40 (LED illuminates) and adjust the
flow control check valve which is below the solenoid valve Y40,
until required speed of the chute covers is reached.
4. Open chute covers on AWM side of the filter press:
–
4033, 4034, 4035
Pressurize solenoid valve Y42 (LED illuminates) and adjust the
flow control check valve which is below the solenoid valve Y42,
until the required speed of the chute covers is reached.
Operating Instructions PKF 140 NG
119
11 Control and maintenance
5. Close chute covers on AWM side of the filter press:
–
Pressurize solenoid valve Y39 (LED illuminates) and adjust the
flow control check valve which is below the solenoid valve Y39,
until the required speed is reached.
After completing the adjusting secure each adjusting bolt with lock nut.
11.4.5
Control block with valve- and solenoid descriptions
Fig. 44: Valves
Fig. 45: Solenoids
120
Operating Instructions PKF 140 NG
4033, 4034, 4035
12 Technical data
12
12.1
Technical data
General technical data
Type PKF 140 NG
Filter area (m²)
139
Plate size (mm)
1300x1300
Chamber volume (l)
2135
Plate material
PP
Amount of chamber
50
Chamber depths (mm)
33
Max. Operational pressure allowed (bar)
7,5
Max. operational temperature allowed (°C)
85
Measurements
Overall lengths ca. (mm)
8920
Overall widths with safety doors ca. (mm)
3150
Overall height with base and washing machine ca. (mm)
3800
Weight
Empty with AWM ca. (kg)
15700
Operating weight ca. (kg)
20100
Filter plates with handles ca. (kg)
90
Connections data
Hydraulic pump (kW)
15
Washing machine (kVA)
0,37
Total electrical ca. (kVA / Hz / V)
12 / 50 / 400
(USA: 12 / 60 / 480)
4033, 4034, 4035
Control voltage DC (V)
24
Max. post press pressure (bar)
7,5
AWM (bar)
40
Operating Instructions PKF 140 NG
121
12 Technical data
12.2
Operational and functional requirements for
electrical and control systems
IMPORTANT
To insure functionality of the installed electrical and control systems
the following requirements need to be met, especially also during the
maintenance period or inter-campaign.
Components
Environmental requirement
Switch cabinet
Protection class IP55, NEMA 12
Code – UL, CSA, VDE
PLC control
•
During idle period the cabinet heater should
be on!
•
Mechanical stress should be avoided. Vibrations and shocks cannot be tolerated
Protection class IP65
Isolation class C to DE 0110
Ambient temperature 0 °C ... +55 °C
(on the air inlet)
Storage temperature –20 °C ... +70 °C
Humidity according to class F DIN 40040
(15 % to 95 % without dehumidifier)
Operator panel
Protection class out IP65, NEMA 4
Protection class in IP20
Ambient temperature 0 °C ... +50 °C
Storage temperature –20 °C ... +60 °C
Relative humidity 85 %
Surrounding electrical panels
Initiators IP66, NEMA 4
Pressure gauge IP54, NEMA 3R
Pressure sensor IP65, NEMA 12
Valves IP65, NEMA 12
Distributor box IP65, NEMA 12
Safety switch IP65, NEMA 12
Flow meter
Protection class IP65
Hard rubber liner:
Temperature maximum 90 °C
PTFE-liner:
Maximum temperature 130 °C
Maximum material pressure 16 bar (227 psi)
Maximum vacuum pressure 400 mbar abs.
122
Operating Instructions PKF 140 NG
4033, 4034, 4035
12 Technical data
12.3
4033, 4034, 4035
Components
Environmental requirement
Cable and connections
All electrical systems to be protected against
mechanical damage according to operational
guidelines.
Approved oil types
Supplier
Oil type
Shell
Shell Tellus TD 46 (Standard from the manufacturer)
Aral
Aral-Vitem DE 46
Chevron
Chevron EL Hydrauliköl 46
ESSO
ESSTIC 46
Mobil
Mobil DTE Oil
BP
BP Energol HL 46
FINA
FINA Cirkan 46
TEXACO
Rando Oil 46
VA
Valvoline ETC-10
Operating Instructions PKF 140 NG
123
13 Operation interruption and disposal
13
13.1
Operation interruption and disposal
Short term operation interruption
If the PKF press discontinues to operate for several hours or longer
period:
1. Push stop button at the end of the cycle (see Fig. 31, pg. 90,
Pos. 1) to disconnect the PKF press on completion of the running
cycle out of the automatic operational mode.
2. Wash all filter cloths with the automatic washing machine.
3. For safety reasons close all hand operating valves in the pipes for
slurry, for the wash water and for compressed air.
IMPORTANT
The control air for the pneumatic system must not be shut off!
13.2
13.2.1
Control and maintenance prior to long operation interruptions
Cleaning and control
1. Immediately after campaign ends clean all filter cloths with washing
machine.
2. Clean the PKF press with a cleaning solution to remove deposit at
the openings of the filter plates.
ATTENTION
Destruction of membrane plates!
If the membrane plates are introduced to high pressure during the test
run they can be destroyed.
 Membrane plates during the test run to be exposed to max. 0,2 bar
(3 psi).
124
Operating Instructions PKF 140 NG
4033, 4034, 4035
13 Operation interruption and disposal
3. Check the condition of all filter plates.
Test unit for the membrane plates can be supplied by Putsch.
–
Membrane plates can be tested with a device with pressure to
0,2 bar (3 psi).
If no pressure reduction is visible within 3 to 4 minutes the membrane plate is in good condition.
4. Possible leakage can be detected with a soap solution.
5. Check slide plates on the handles for wear.
6. Remove and clean all control valves and pressure reducers.
7. Clean filters at the compressed air station (see Fig. 12, pg. 39).
8. Clean the outside of the PKF press completely.
9. Lubricate and protect all parts according to the lubrication requirements with oil or grease.
10. Dress filter plates with filter cloths and close the PKF press.
11. The filter press remains in the closed position until the next operation.
12. The energy chain and trough of the AWM clean two times with low
pressure steam cleaning.
13.2.2
Action to the storage period
 After operation period turn on the heating in the switch cabinet to
prevent extreme moisture and temperature swings.
 After operation period do not expose the filter plates to minus 10
degrees C. In countries with extreme low temperature the filter
plates must be heated.
 Filter plates which are spare parts to be stored in the upright standing position and protected with black cover to prevent ultraviolet
(UV) exposure.
 Filter cloths which are spare parts to be stored in closed packaging
to be protected from ultraviolet (UV) light.
4033, 4034, 4035
Operating Instructions PKF 140 NG
125
13 Operation interruption and disposal
13.3
Disposal
•
Packaging material to be disposed to local regulations.
•
Oil, grease or machine parts with grease and oily to be disposed
according to local regulations.
•
Mechanical or electrical components are to be disposed according
to local regulations.
•
For the disposal of electrical or electronic waste at the regular disposal possible hazardous material could endanger the environment
or human health.
Therefore the unit cannot be disposed in the regular landfill. It must
be separated at a special approved disposal site or disposal company.
As a note, in regards to this unit the following symbols
according to the European guide lines 2002/96/EG is
marked. In addition to this are other special national
specific requirements have to be followed and or considered.
126
Operating Instructions PKF 140 NG
4033, 4034, 4035
Putsch GmbH & Co. KG
Automatic Program PKF 140 NG
Filtration
Schritt
Function
1
Start
Appendix 1
Quang Ngai Sugar
slurry p
2
3
4
5
9
10
Closing of Filter Press with low pressure
Closing of chute covers
Closing of Filter Press with high pressure
Preparing Filter filling
Filter filling from slurry feed tank (regulated)
Pre-Filtration (regulated)
X
X
11
a) Filtration, upper filtrate outlets (regulated)
b) Filtration, all filtrate outlets (regulated)
c) Filtration (regulated)
X
X
X
DA3
DA 4
V6
V7
X
X
X
X
X
X
X
X
X
V8
V9
V10
V12
V24
V28
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
V13
X
12
Rinsing slurry channel
X
X
X
13
14
15
16
17
18
Pre-Pressing (time-controlled)
Pre-Washing 1 (regulated)
Pre-Washing 2 (regulated)
Intermediate pressing (controlled)
Replacing Filtrate with air 1
Replacing Filtrate with air 2
X
X
X
X
X
X
X
X
X
X
X
X
X
19
20
21
22
23
Filter cake washing 1 (regulated)
Filter cake washing 2 (regulated)
Post-Pressing (controlled)
Cake drying 1
Cake drying 2
X
X
X
X
X
X
24
25
Discharging slurry channel
Drying slurry channel
X
X
26
Pressure drop membranes
X
X
27
Pressure drop hydraulic
X
28
29
30
31
32
33
34
35
Open Chute covers
Open Filter press (open 1st package)
Plate transport 1 (open 2nd package)
Plate transport 2 (open 3rd package - if existing)
Plate transport 3 (open 4th package - if existing)
GOTO Closing of press with low pressure or stop after loop
Closing of Filter Press with low pressure
Closing of chute covers
X
X
X
X
X
X
X
X
V17
V18
V21
X
X
optional
optional
optional
optional
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
optional
X
X
X
X
optional
X
X
X
optional
optional
X
X
V19
X
X
X
X
X = Valve open /Pump running
gedruckt, am 04.12.2018
Appendix 2
Appendix 2
Parameters
Parameters
IMPORTANT
The parameters described in this chapter should be seen as guiding
values and must be adapted to the individual operation conditions and
the process requirements.
The filtration process can be optimized by adjusting the parameters.
This can be done at the HMI of the PKF.
Filtration
Refinery
Parameter
Common range
value / unit
Minimal Volume for activation
membranes
90 m³
80 - 100 m³
Filter filling: volume
2.1 m³
2.1 m³
Filter filling: pump speed
35 %
20 - 40 %
25 m³/h
20 - 40 m³/h
0 m³
0 - 4 m³
Filtration: minimal flow rate
20 m³/h
15 - 20 m³/h
Filtration pressure: maximum
4.5 bar
3 - 6.5 bar
1 bar
1 - 5 bar
(Pre-) Filtration: set point flow
rate
Pre-filtration, volume
Filtration pressure: open V6/ V7
Minimal Volume for activation membranes
The Minimal Volume for activation membranes is the minimal filling volume for active membrane pressing, compare to chapter 6.2.
Filter filling: volume
The PKF will be filled with a specific volume of slurry before the filtration
starts. There is no need for adjustments at normal operation.
Filter filling: pump speed
This is the speed of the pump during the filter filling step. There is no
need for adjustments at normal operation. The flow rate should be between 150 and 200 m³/h.
Pre-filtration: volume
At the beginning of the filtration the filtrate can be send back to the slurry tank. This reduces the solid content of the slurry and enhances the
filtrate quality. A high volume extends the cycle time.
Filtration:
set point flow rate
The beginning of the filtration is flow controlled. A higher flow rate will
reduce the cycle time, but the filling of the chambers can be negatively
affected. A low flow rate will unnecessarily extend the cycle time.
Parameters PKF 250 NG
1
Appendix 2
Filtration pressure:
maximum
The filtration gets switched from flow control to pressure control when
the maximal filtration pressure is reached. The pressure influences the
amount of slurry filtrated in each cycle. A high value can lead to a
plugged slurry channel. A low value will decrease the amount of solids
in the chamber, so that the chambers get insufficiently filled.
Filtration pressure:
open V6/ V7
The valves V6 and V7 open after the filter filling step when a sufficient
filter cake has been built up. This ensures a uniform distribution of the
filter cake in the chambers.
Filtration: minimal flow rate
The filtration will be stopped when the flow rate drops under the minimal
flow rate. A lower value will lead to higher filtration volumes and higher
solid contents in the chambers. This can lead to a blocked slurry channel. High values reduce the amount of solids in the chambers.
Process Times
Refinery
Parameter
Pre-pressing
Intermediate pressing
Post pressing
Displace filtrate
with air 1/ 2
2
Parameters
Common range
value / unit
Pre-pressing
40 s
30 - 60 s
Intermediate pressing
60 s
40 - 90 s
Final pressing
90 s
80 - 150 s
Displace filtrate with air 1
0s
0 - 40 s
Displace filtrate with air 2
0s
0 - 40 s
Cake drying 1
0s
0 - 120 s
Cake drying 2
90 s
60 - 180 s
Feed channel emptying
20 s
10 - 40 s
Feed channel drying
20 s
10 - 40 s
Pressure release membranes
20 s
10 - 50 s
Delay open plate packs
1s
process-dependent
Shut off delay conveyor
600 s
process-dependent
Longer pressing steps reduce the sugar content in the filter cake. Very
long periods do not have many advantages, because no more liquid can
be removed from the cakes and the cycle time gets unnecessarily extended.
A longer step reduces the sugar content in the filter cake. Very long
periods do not have many advantages, because no more liquid can be
removed from the cakes, but the cycle time gets unnecessarily extended
and the air consumption rises.
Parameters PKF 250 NG
Appendix 2
Parameters
Cake drying 1/ 2
Longer drying steps reduce the sugar and the liquid content in the filter
cake. Very long periods do not have many advantages, because no
more liquid can be removed from the cakes, but the cycle time gets
unnecessarily extended and the air consumption rises.
Feed channel emptying
The time should be long enough to remove all the liquid out of the slurry
channel. Very long periods do not have many advantages, because no
more liquid can be removed out of the slurry channel, but the cycle time
gets unnecessarily extended and the air consumption rises.
Feed channel drying
The time should be long enough to push the liquid out of the slurry
channel into the filter cakes. Very long periods do not have many advantages, because no more liquid can be removed out of the slurry
channel, but the cycle time gets unnecessarily extended and the air
consumption rises.
Pressure release
membranes
The air pressure in the membranes will be relieved during this step. The
time should be long enough to ensure a complete relieve of the pressure. Very short periods will lead to insufficient pressure relieves and
hence to errors during the opening step. Very long periods unnecessarily extend the cycle time. There is no need for adjustments at normal
operation.
Delay open plate packs
This time can be used to adjust the cake discharge on the local conveyor to ensure undisturbed cake transportation. There is no need for adjustments at normal operation.
Shut off delay conveyor
The screw conveyor has to run longer than the actual cake discharge
out of the PKF. This ensures an entire discharge of the cake out of the
PKF cake hopper. There is no need for adjustments at normal operation.
Parameters PKF 250 NG
3
Appendix 2
Membrane Pressure
Refinery
Parameter
Pre-pressing
Parameters
Common range
value / unit
2.5 bar
2.5 - 3.5 bar
4 bar
3.5 - 4.5 bar
Final-pressing
5.5 bar
4.5 - 5.5 bar
Accepted pressure difference
0.3 bar
0.3 bar
PKF open at
0.3 bar
0.3 bar
Intermediate-pressing
Membrane pressure
Membrane pressing is not used during the start of commissioning. The
membrane pressing can be manually switched off during bad filtration
conditions at the HMI to reduce the mechanical stress of the membranes. If the “Minimal Volume for activation membranes” is not reached
the membrane pressing gets automatically deactivated, compare with
chapter 6.2.
Pre-pressing
Depending on the compressibility of the filter cake the dewatering of the
filter cake can be controlled by pressing. The pressure during the prepressing step should be approximately 60 % of the intermediate pressing pressure.
Intermediate-pressing
High pressure reduces the sugar and the liquid content in the filter cake.
The porosity of the cake can be lowered if the pressure is too high. This
will degrade the water flow during the cake washing step. The intermediate pressing pressure should be approximately 0.3 bar higher than the
wash water pressure at the inlet of the PKF.
Final-pressing
High pressure reduces the sugar and the liquid content in the filter cake.
The porosity of the cake can be lowered if the pressure is too high. This
will degrade the air flow and hence the effectiveness of the cake drying
step.
Accepted pressure difference
Maximal permitted pressure difference between the membrane pressure
and the ambient pressure at the PKF opening step. There is no need for
adjustments at normal operation.
PKF open at
The PKF will be opened when the internal pressure measured at the
pressure transmitter at the inlet membrane pressure is lower than the
set point. This parameter is not changeable.
4
Parameters PKF 250 NG
Appendix 2
Water
Refinery
Parameter
Parameters
Common range
value / unit
Feed channel rinsing: volume
0.8 m³
0.5 - 1.5 m³
Feed channel rinsing: flow rate
40 m³/h
20 - 80 m³/h
Cake pre-washing 1: volume
0 m³
0 - 5 m³
Cake pre-washing 1: flow rate
40 m³/h
20 - 80 m³/h
Cake pre-washing 2: volume
0 m³
0 - 5 m³
Cake pre-washing 2: flow rate
40 m³/h
20 - 80 m³/h
Cake washing 1: volume
0 m³
0 - 5 m³
Cake washing 1: flow rate
40 m³/h
20 - 80 m³/h
Cake washing 2: volume
8 m³
6 - 10 m³
Cake washing 2: flow rate
40 m³/h
20 - 80 m³/h
Water pressure: maximum
3 bar
2 - 4.5 bar
Slurry channel rinsing:
volume
The slurry gets pushed into the chambers after the filtration with water
for cleaning the feed channel. Some parts of the slurry will stay in the
channel if the amount is small. High water amounts will clean the channel properly, but it unnecessarily extends the cycle time and the water
consumption. Very high amounts can also lead to cleaned chamber
inlets, which may cause damages at the membranes.
Feed channel rinsing:
flow rate
The slurry channel will be flushed faster or slower depending on the flow
rate. A low flow rate unnecessarily extends the cycle time. A high flow
rate can cause a non uniform cleaning of the slurry channel.
Cake pre-washing 1/ 2:
volume
A high amount reduces the sugar content in the filter cake. This leads to
a higher consumption of wash water and the amount of incurring wash
filtrate rises.
Cake pre-washing 1/ 2:
flow rate
A high wash water flow rate can reduce the cycle time. But it can also
lead to channelling within the filter cake which reduces the efficiency of
the washing process. This leads to non uniform desweetening of the
filter cake.
Cake washing 1/ 2:
volume
A high amount reduces the sugar content in the filter cake. This leads to
a higher consumption of wash water and the amount of incurring wash
filtrate rises.
Cake washing 1/ 2:
flow rate
A high wash water flow rate can reduce the cycle time. But it can also
lead to channelling within the filter cake which reduces the efficiency of
the washing process. This leads to non uniform desweetening of the
filter cake.
Parameters PKF 250 NG
5
Appendix 2
Water pressure:
maximum
The maximal water pressure during the cake washing step should be
approximately 0.3 bar lower than the intermediate pressing pressure.
There is no need for adjustments at normal operation.
AWM
Refinery
Common range
Parameter
No.
No.
Washing after X cycles
10
1 - 40
No. of wash cycles per chamber
1
1
Washing after X cycles
The cloth washing machine (AWM) will start after a certain amount of
cycles automatically.
No. of wash cycles per
chamber
If one washing cycle is not sufficient the number of washing cycles can
be raised.
Slurry Pump
Refinery
Basic speed slurry pump
Basic speed slurry pump
30 %
Refinery
Parameter
Common range
value / unit
Set point low pressure
70 bar
60 - 90 bar
Set point high pressure
270 bar
260 - 280 bar
Set point pressure hysteresis
20 bar
20 bar
Set point pressure release
300 bar
290 - 310 bar
5 bar
5 bar
Maximum pressure
Set point high pressure
process-dependent
This is the speed of the pump when the PKF is not filtrating. There is no
need for adjustments at normal operation.
Hydraulic System
Set point low pressure
Common range
value / unit
Parameter
6
Parameters
Set point of maximal hydraulic pressure during the opening and closing
of the filter press.
Set point of the maximal hydraulic pressure of the closed PKF.
Set point pressure
hysteresis
This is the allowed pressure difference from the high pressure set point.
The hydraulic pump will start when this difference is reached.
Set point pressure
release
During the pressure release step the pressure of the hydraulic has to
decrease below this set point before the press can be opened.
Parameters PKF 250 NG
Appendix 2
Maximum pressure
Parameters
The hydraulic system will be switched off for safety reasons if the maximal hydraulic pressure exceeds this value.
Air Pressure Settings
Refinery
Parameter
Common range
value / unit
Air pressure system minimum
7.0 bar
6.5 - 7.5 bar
Air pressure drying air min. value
7.0 bar
6.5 - 7.5 bar
Air pressure system
minimum
Set point of the minimum pressure for instrument air and the membrane
pressure system. If the actual value is below the set point, the filter will
go in alarm mode.
Air pressure drying air
min. value
Set point of the minimum pressure for the cake drying. If the actual value is below the set point, the filter will switch to alarm mode.
Level Slurry Tank
Refinery
Parameter
Common range
value / unit
Level slurry tank minimum
10 %
5 - 15 %
Level slurry tank ok
60 %
40 - 80 %
Level slurry tank
minimum
The feed pump will be stopped when the actual level in the slurry tank is
below the set value. This is the dry run protection for the pump.
Slurry tank level ok
The filtration can be started if the slurry tank level is higher than the set
point.
Times
Refinery
Parameter
Runtime collecting belt
Runtime collecting belt
Common range
value / unit
tbd s
tbd s
The collecting conveyor belt is in operation for the set time after the
discharge to ensure a complete transport of the cake out. The time will
be adjusted during the commissioning.
Parameters PKF 250 NG
7
Appendix 2
Monitoring Times
Refinery
Parameter
Monitoring times
8
Parameters
Common range
value / unit
Open/ close valves
15 s
10 - 20 s
Open/ close 1st package
90 s
80 - 100 s
Plate transport 2, 3, 4
90 s
80 - 100 s
Pressurize hydraulic
50 s
40 - 60 s
Depressurize hydraulic
25 s
15 - 35 s
Pressurize membranes
60 s
40 - 80 s
Depressurize membranes
25 s
10 - 60 s
Open/ close covers
90 s
80 - 100 s
Filter filling
600 s
500 - 700 s
Precoating
600 s
500 - 700 s
Feed channel rinsing
600 s
500 - 700 s
Cake pre-washing 1
900 s
600 - 1000 s
Cake pre-washing 2
900 s
600 - 1000 s
Cake washing 1
900 s
600 - 1000 s
Cake washing 2
900 s
600 - 1000 s
AWM: positioning
5s
5 - 10 s
AWM: washing
20 s
15 - 25 s
Each step und movement gets controlled by time. If the monitoring time
runs off before the step is done a fault occurs. There is no need for adjustments at normal operation.
Parameters PKF 250 NG
Appendix 3
Filter Press PKF
Maintenance plan
5-15923.95-01.2
Version 02/2014
© 2014
Putsch GmbH & Co. KG
Frankfurter Straße 5 – 21
58095 Hagen
Phone:
+49 (0) 2331 399-0
Fax:
+49 (0) 2331 399-3600
E-Mail:
info@putsch.com
Internet
www.putsch.com
All copyrights are protected. Copies can only be made with owner’s written
permission by Putsch GmbH & Co. electronically or otherwise.
2
Maintenance plan PKF
5-15923.95-01.2
Table of contents
1
2
Service and maintenance of the filter press ..................................................................................4
1.1
Daily maintenance ..............................................................................................................4
1.2
Weekly maintenance ...........................................................................................................5
1.3
Twice a year maintenance ..................................................................................................6
1.4
Once a year maintenance ...................................................................................................6
Drawing Maintenance plan ..............................................................................................................7
5-15923.95-01.2
Maintenance plan PKF
3
1
Service and maintenance of the filter press
1.1 Daily maintenance
1
Open the drain cock of the membrane air pipe for a short period. Larger water
quantities coming out indicate defective membrane plates.
2
Check lubricator for solenoid valves and fill up with oil if necessary. Adjust
lubricator to minimum dosing.
3
Check the strainer of the compressed air station and clean it if necessary.
4
Keep clean the energy chain and guide trough of AWM.
Check all pipes inclusive hydraulic unit and valves for tightness.
5
6
Check slide surface of the cross beams. Clean them if necessary. Lubricate
them with silicone spray or thin oil (use low viscosity oil only, e.g. silicone oil or
multi-function oil like WD40!!!)
7
Check all screws of the filter plate handles, the transport plates as well as all
other moving parts.
8
Check that filter clothes are clean and correctly positioned incl. sealing edges.
9
Check the filter clothes for damage - especially in the neck area.
10
a
4
Check air filter and return flow filter for soiling (watch clogging indicator during
operation). Check oil level.
Check all gaskets of filter plates to make sure they are in good condition and
seated properly.
Clean the filter press if necessary.
b
Visual inspection of the safety equipment: emergency pull cords, emergency
stop switch, protection switches of the safety doors. Any damage identified has
to be repaired immediately.
c
Compressed air connections of all automatic butterfly valves should be checked
regularly for leak tightness.
Maintenance plan PKF
5-15923.95-01.2
1.1 Daily maintenance
d
Pay attention to cleanliness of any transport devices for carbonation lime, especially on the exchange points.
e
Check pumps for leak tightness and pressure. Check for differential pressure of
cartridge filters for cake washing water and cloth washing water. Replace filter
cartridge if necessary.
f
Check dewatering on the air receivers of the compressed air station.
1.2 Weekly maintenance
11
Lubricate transmission chain of the automatic cloth washing machine (use low
viscosity oil only, e.g. silicone oil or multi-function oil like WD40!!!)
12
Lubricate guide bars of the slide of the cloth washing machine (AWM). Clean
them before lubricating if necessary (use low viscosity oil only, e.g. silicone oil
or multi-function oil like WD40!!!)
a
Clean filter press inclusive hydraulic unit (simplifies recognition of malfunction
and leakage)
b
Clean slide surface of the cross beams and lubricate them with silicone spray or
thin oil: use low viscosity oil only, e.g. silicone oil or multi-function oil (WD40,
Brunox, Caramba, Kontakt 40!!!). These lubricants infiltrate moisture and
dissolve contaminations. Standard oil or grease must not be used because with
the carbonation lime they will generate a compound that will restrain movement
of the filter plates. See also item 6, daily
Function inspection of the safety equipment: emergency pull cords, emergency
stop switch, protection switches of the safety doors.
c
d
5-15923.95-01.2
Check the tension of the emergency pull cords under the crossbeams. There is
a small sag necessary to avoid automatic switch-off of the filter press during
final pressing.
Check adjustments of the pressure reducers. Correct them if necessary and
secure the screws.
Maintenance plan PKF
5
1.3 Twice a year maintenance
Inspection of the seat rings of the following critical valves (e.g. DA2, DA3, DA4,
V19, V21, V23)
1.4 Once a year maintenance
Hydraulic oil change; as an alternative the hydraulic oil can be analysed in a
laboratory to check for further use.
Change filter cloths.
Inspection of membrane plates and pressure plates for mechanical damage.
Inspection of seat rings of all butterfly valves.
6
Maintenance plan PKF
5-15923.95-01.2
1
2
3
4
5
6
7
8
7
A
A
8
9
10
B
C
B
C
12
5
6
D
4
D
11
E
E
Schematic illustration! Modifications in
details are without any influence on function.
Schematische Darstellung! Abweichungen im
Detail haben keinen Einfluss auf die Funktion.
F
1
3
2
Diese Zeichnung und ihre Beilagen sind unser
geistiges Eigentum. Sie dürfen ohne unsere vorherige
schriftliche Zustimmung nicht kopiert, vervielfältigt
oder anderen Personen zugänglich gemacht werden.
Bearb.
Gepr.
Norm
This drawing and its enclosures are our intellectual
property. They must not be copied, duplicated or
made accessible to other persons without our
previous written permission.
Datum
Name
15.01.2013
Schneider
Wartungsplan PKF
F
maintenance plan
5-15923.95-01.2
0022327
1
2
3
4
5
6
7
8
Appendix 4
Changing of
Overhang-Membranes 1300
Installation Instructions
5-15162.95-25
Version 01/2014
© 2014
Putsch GmbH & Co. KG
Frankfurter Straße 5 – 21
58095 Hagen
Phone:
+49 (0) 2331 399-0
Fax:
+49 (0) 2331 399-3600
E-Mail:
info@putsch.com
Internet
www.putsch.com
Translation of the original installation instructions.
All copyrights are protected. Copies can only be made with owner’s
written permission by Putsch GmbH & Co. Electronically or otherwise.
2
Installation Instructions Changing Membranes
5-15162.95-25
Table of contents
Table of contents
1
Description of the Membrane-plate ................................................................................................4
1.1
2
3
Membrane L (left) and R (right) ..........................................................................................6
Exchange of the Membranes...........................................................................................................7
2.1
Removal of the Membranes ................................................................................................7
2.2
Installation of the Membranes .............................................................................................7
Exchange of the Gaskets .................................................................................................................8
3.1
Gasket for the Membrane air and Compensation gasket ...................................................8
3.2
Gasket for the Filtrate-discharge ........................................................................................8
3.3
String gaskets on the membrane-carrier ............................................................................8
5-15162.95-25
Installation Instructions Changing Membranes
3
1 Description of the Membrane-plate
1
Description of the Membrane-plate
The Exchangeable membrane-plate consists of the following parts:
•
Membrane L (left) Format 1300,
(01)
•
Membrane R (right) Format 1300,
(02)
•
Membrane carrier,
(03)
•
Seal Membrane air,
(04)
•
Compensation gasket,
(05)
•
Ring Gasket Filtrate discharge,
(06)
•
String-Gasket post pressing,
(07)
•
String-Gasket lower Filtrate discharge,
(08)
•
String gasket upper Filtrate discharge,
(09)
•
String gasket mud inlet,
(10)
•
Steel bolts mounted through the carrier
and both Membranes,
(11)
tie wraps in the lower and lateral
seal-rim, run through the carrier
and both Membranes,
(12)
One pair of steel rails, mounted together
with steel bolts through bore holes in the
membranes and the carrier.
(13)
•
cloth securing pins
(14)
•
Retainer bar for membrane
(16)
•
•
4
Installation Instructions Changing Membranes
5-15162.95-25
1 Description of the Membrane-plate
5-15162.95-25
Installation Instructions Changing Membranes
5
1 Description of the Membrane-plate
1.1
Membrane L (left) and R (right)
To distinguish the membranes, locate the filtrate-discharge openings
(15) in the membrane in question.
(view from the front).
Membrane L:
The Filtrate-discharge openings are located on the left
side (upper side and lower side).
Membrane R:
The Filtrate-discharge openings are located on the right
side (upper side and lower side).
Picture. 5:
Filtrate-discharge openings lateral upper left
(picture. Membrane L)
Note:
The filtrate flows away on one side of the membrane plate
only.
Therefore the membrane has to be mounted in a way that
the lower filtrate-discharge openings are located on the
same side as the corresponding opening in the carrier
plate.
6
Installation Instructions Changing Membranes
5-15162.95-25
2 Exchange of the Membranes
2
Exchange of the Membranes
Necessary tools:
•
Wire cutter,
•
Hex-head screwdriver SW 8,
•
Box end wrench or nut driver SW17 (2x).
The exchange of the membranes can be done individually or as a pair
as well as outside or inside the PKF.
The plate should be in an upright position.
2.1
2.2
Removal of the Membranes
•
Remove 11 tie wraps.
•
Remove 4 bolts M8 that fasten the steel plate in the mud inlet area
and remove steel plate.
•
Remove nuts from the 6 bolts M10 and remove one membrane.
•
After removing the 6 bolts completely, the second membrane can be
removed.
Installation of the Membranes
ATTENTION
When installing the new membranes, attention should be given to the
correct selection R (right) and L (left).
ATTENTION
Before installing the new membrane it is recommended to change the
gasket for the membrane air (04), the Compensation gasket (05) as
well as the string gaskets (07, 08, 09, 10) on the membrane-carrier
(03) (see section 3).
Fit one membrane (including the gasket for the membrane air (04) and
compensation gasket (05)) onto the retainer bar of the membranecarrier and insert 6 steel bolts M10 (11) through the membrane and the
membrane- carrier.
The second membrane (including the gasket for the membrane air (04)
and compensation gasket (05)) is fitted from the other side onto the
retainer bar of the membrane carrier and fastened loosely with the nuts
M10.
The steel plate (13) is fastened at the mud inlet area with 4 bolts M8
(exact alignment of the membrane is necessary).
Tighten down the 6 steel bolts M10 (11) completely.
Secure membranes with 11 tie wraps.
5-15162.95-25
Installation Instructions Changing Membranes
7
3 Exchange of the Gaskets
3
Exchange of the Gaskets
It is recommended while exchanging the membrane to exchange the
gaskets located beneath (Pos. 07, 08, 09, 10).
3.1
Gasket for the Membrane air and Compensation
gasket
The gaskets for the membrane air (04) and the compensation gasket
(05) are identical. Before the installation of the membrane on the carrier,
insert gaskets have to be pushed from behind into the corresponding
openings in the membrane.
3.2
Gasket for the Filtrate-discharge
The ring gaskets for the filtrate-discharge (06) are fastened with flanges.
3.3
String gaskets on the membrane-carrier
•
1 piece of string gasket in the post press area (07) (length 4490mm
(176.78 inches)),
•
1 piece of string gasket lower filtrate discharge (08) (length 479mm
(18.86 inches)),
•
2 pieces of string gasket upper filtrate discharge (09) (approx. length
4445mm (175 inches)),
•
1 piece of string gasket mud inlet area (10) (length 580mm (22.84
inches)).
The string gaskets must be cut to the proper length with the ends cut at
an angle to achieve a complete overlap.
We recommend to upset gaskets during assembly by 3%. This has already been considered for the dimensions given above.
8
Installation Instructions Changing Membranes
5-15162.95-25
3 Exchange of the Gaskets
Picture 6
5-15162.95-25
Position of the gaskets and retainer bars (16) on the membrane carrier
(View :from the front, suitable for membrane L)
Installation Instructions Changing Membranes
9
Nettogewicht : 14900 kg
net weight : 32849 lb
3
3
3.1
3.1
3
2
1
1
2
5.1
4
5
ca.500
ca.850
ca.850
8.2
8.4
7
8
8
8.3
7
8
8
6
292
8.3
800
8.1
8
8.2
8.3
9.1
9
9
step 1
4x
bracket
32x spring washer 8
32x cheese head screw M8x16
32x grooved block M8
step 5
4x
gusset plate
32x cheese head screw M8x14
32x spring washer 8
32x grooved block M8
step 8
8x
connecting bracket
16x cheese head screw M8x16
16x washer A 8,4
16x grooved block M8
step 2
2x
base plate
8x
counter sunk screw M8x25
step 5.1
4x
gusset plate
32x cheese head screw M8x14
32x spring washer 8
32x gusset plate M8
step 8.1
4x
cam follower
4x
cheese head screw M8x30
4x
spring washer 8
4x
plate
8x
cheese head screw M8x12
8x
washer A 8,4
8x
grooved block M8
4x
guide plate (angle)
8x
cheese head screw M6x12
8x
grooved block M6
step 3
16x cheese head screw M12x100
16x spring washer 12
4x
end cap 80x80
9.1
9
step 3.1
8x
cheese head screw M12x100
8x
spring washer 12
step 4
28x clip
56x counter sunk screw M6x25
56x grooved block M6
step 6
28x wall fastening
56x cheese head screw M5x8
step 7
16x carriage
16x stud bolt M8x30
16x nut M8
16x washer A 8,4
16x grooved block M8
8x
adjustable locking
step 8.2
4x
trestle 3
8x
cheese head screw M6x16
8x
washer A 6,4
4x
fastening trestle 3
8x
counter sunk screw M6x16
8x
grooved block M6
step 8.3
4x
trestle 4
8x
cheese head screw M6x60
8x
feeding angle
4x
fastening trestle 4
8x
cheese head screw M6x20
16x washer A 6,4
8x
grooved block M6
step 8.4
4x
plate for switch
4x
switch
16x cheese head screw M5x45
8x
cheese head screw M8x20
8x
washer A 8,4
8x
grooved block M8
4x
fastening
8x
cheese head screw M5x10
8x
cheese head screw M6x16
8x
washer A 6,4
8x
grooved block M6
step 9
4x
handle
8x
cheese head screw M8x20
8x
grooved block M8
step 9.1
2x
connecting bracket
4x
cheese head screw M8x16
4x
washer A 8,4
4x
grooved block M8
6x
4x
8x
8x
1x
aluminium profile 80x80 - 2262mm
aluminium profile 80x80 - 3378mm
launching tube 40x34 - 2975mm
mounted door-fields 1690x2140mm
side-field 1700x 600mm
E
E-E
1440
1150
V9
PI
TI
PT
V18
TI
PT
V28
PI
1175
V12
F
2355
V10
V19
1060
V8
V24
PI
V7
V6
PI
V17
DA4
B3
B2
DA3
B1
182
FT
676
840
P6
P7
1277
1158
1581
1415
B6
E
V17
1498
DA4
G
G
C
D
D
B
B
A
A
C
C-C
A-A
PI
B-B
TI
V18
PT
TI
PI
V10
D-D
V19
V9
V12
V28
V8
S19
V24
PI
G-G ( 1 : 5 )
B1
PI
B3
V7
B2
min. 240
V6
FT
S7
P6/P7/P8
P7
DA3
min. 360
S6
P6
B6
V17
DA4
Ersetzt durch:
Ersatz für:
Maßstab:
Zust.
Änderung
Diese Zeichnung und ihre Beilagen sind unser
geistiges Eigentum. Sie dürfen ohne unsere vorherige
schriftliche Zustimmung nicht kopiert, vervielfältigt
oder anderen Personen zugänglich gemacht werden.
This drawing and its enclosures are our intellectual
property. They must not be copied, duplicated or
made accessible to other persons without our
previous written permission.
Bearb.
Gepr.
Norm
Datum
Datum
Name
Name
06.07.2018
GROSSE
Gewicht:
Werkstoff:
1 : 15
Allgemeintoleranz
ISO 2768 - mK
Rohrleitungsplan PKF 140 NG
pipe arrangement plan
M 5-18149
2022107 01
1
A0