KUHN GDSTP-24025-MAN-0002 P1 User manual

KWP Wash Press
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual
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Active 29/10/2013
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GDSTP-24025-MAN-0002_P1

Description and Technical Data
We reserve the right to make technical modifications Goodna STP KWP Washpress
Description and Technical Data
Goodnal STP ST041 Pre Treatment (KWP Wash Press) Vendor Manual
Q-Pulse Id VM364
Active 29/10/2013
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Description and Technical Data
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1 Product Description
1.1 Use as directed
The KWP wash press is intended exclusively for washing, compressing and
dewatering recycled materials already separated from waste disposal processes,
especially screenings from public sewage treatment plants.
The machine is not intended for other types of application.
Any type of use that deviates from the installation's intended purpose is
considered improper use!
Proper use also includes reading these operating instructions as well as
compliance with all the directions contained herein, especially safety indications.
In addition, this includes the performance of inspection and maintenance work in
the prescribed time intervals.
If the KWP wash press is used in violation of this condition, safe operation of the
machine is not guaranteed.
The machine operator and not the manufacturer shall be liable for all personal
injury and material damage resulting from improper use!
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Description and Technical Data
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1.2 Layout
1.2.1 Graphical representation
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Description and Technical Data
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1.3 Operational Description
1.3.1 Task
The KWP wash press was designed and built for washing, compressing and
dewatering solid matter (screenings).
Basically, the machine consists of a feed hopper; the combined conveyor,
washing and press screw; the press body with washing zone and press area; the
bearing housing; the geared motor; the press water tray and the wash water
distributor.
The entire machine is designed as a welded and stainless steel construction
treated in pickling bath.
1.3.2 Function
By direct ejection from the sluice, the screenings to be processed are fed into the
feed area of the wash press.
The rear part of the screw shaped as a conveyor spiral moves the screenings
from the feed area into the washing zone. Depending on the special type of spiral,
the material is milled and organic solids dissolved in the washing zone.
For this process the KWP wash press is designed for forward and backward
motion of the screw.
The hollow screw shaft injects wash water into the screenings in the center of the
washing zone. The water then takes the dissolved cargo and extracts it from the
screenings.
Additional rinsing from the top supports the extraction of dirty cargo through the
slotted screen bottom.
The washed screenings are then dewatered in the compaction zone and highly
compressed. The fully treated screenings are fed directly to a container or a
subsequent assembly through a discharge pipe.
A bagging mechanism is attached to the discharge pipe for hygiene and odor
containment.
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Description and Technical Data
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1.4 Technical Specifications
1.4.1 KWP Wash Press
Type: KWP 300/1000
Serial number:
1.4.2 Dimensions and technical specifications
Max. throughput
(raw screenings): xx m3/h
Degree of dewatering of the
screenings (depending on raw material and
design of the driving pipe): 40 - 45 % TS
Weight reduction of the
screenings: approx. 70%
Degree of washout: approx. 90%
Water requirement
at 3-4 bar: 1.2 l/s
Wash water connection
(internal screw thread): R 3/4 inch
Wash and press water discharge: xx mm
Screw diameter: xxx mm
Total
machine length: xxx mm
Total
machine width: xxx mm
Total
machine height: xxx mm
Machine weight: xxx kg
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Description and Technical Data
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1.4.3 Geared motor
Make: Siemens
Type: xxx
Number of phases: xx
Output P: xx kW
Current consumption I: xx Amp
Voltage U: 400 V
Frequency f: 50 Hz
Starter: Y DR (S100)
Method of protection: IP 56
Insulation class: F
1.4.4 Solenoid valves
Quantity: 4
Make: Buschjost
Connection: directly controlled,
zero-current enclosed
Voltage: V AC
Method of protection: IP 65
Terminal size: R 3/4 inch
1.4.5 Materials
Press body: AISI 316Ti
Conveyor, washing and press screw: HTMAS
Solenoid valve block: brass, bright nickel-plated
Ball valves: brass, nickel-plated
Standard geared motor with protective paint in color compliant with RAL 5015
(blue)
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Safety Notes
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Safety Notes
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Safety Notes
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1 General Safety Indications
1.1 Duty of due care of the operator
This machine was designed and built having due regard to an analysis of safety
hazards and after careful selection of mandatory harmonized standards, as well
as other technical specifications. It, therefore, meets the state of the art and
guarantees the highest degree of safety.
In practice, however, this safety can only be achieved if all the necessary
measures are taken. The operator's duty of due care for the machine requires it to
plan these measures and monitor their performance.
In particular, the operator must ensure that
■the machine is used only as directed (cf. Chapter Product Description)
■the machine is operated only in perfect working condition and the safety devices
especially are checked regularly for their operability
■the required personal safety gear for operating, maintenance and repair
personnel is available and is used
■the operating instructions are always available in legible condition and in
complete form at the installation site of the machine
■only adequately qualified and authorized personnel operate, maintain and repair
the machine
■this personnel is regularly instructed in all the pertinent issues involving
occupational safety and environmental protection, and is familiar with these
operating instructions and especially the safety indications in them
■all the safety and warning signs attached to the machine are not removed and
remain legible.
In particular, the operator must ensure that
■a hazard assessment (in the context of Working Conditions Act § 5) determines
the hazards that arise owing to the special working conditions at the installation
site of the machine
■a user manual (in the context of Work Equipment Use Regulation § 6)
summarizes all other directives and safety indications that ensue from the
hazard assessment of the workstations at the machine.
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Safety Notes
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1.2 Explanation of the Safety Symbols Used
1.2.1 Safety symbols on the machine
These symbol must refer to the hazards ensuing from the machine.
Biohazardous materials
The medium processed by the machine falls under the
category of “Biohazardous materials“.
Switching notice
Switch on the machine only if aware of the attached safety
symbols and with the knowledge of these operating
instructions.
Automatic startup
The machine starts automatically. This could cause specific
hazards.
Ventilation / Aeration
Biogases may develop due to the nature of the material being
conveyed.
See to it that there is adequate ventilation or aeration at the
mounting site.
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Safety Notes
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1.2.2 Safety Symbols in these Operating Instructions
These symbol must, above all, draw the attention of the reader to the text of the
adjacent safety indications.
Caution
Places with this label point to possible risk of accident and
injury.
Danger
This sign warns against danger posed by electrical equipment.
Note
Places with this sign provide technical information about the
fact that damage to the machine must be avoided.
Prohibited
It is prohibited to remain under suspended loads
Note
Places with this sign provide information about possible
hazards to the environment
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Safety Notes
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1.3 Basic Safety Measures
1.3.1 Keep information available
Keep these operating instructions by the machine. Ensure that everyone who has
to work on the machine can view the operating instructions at all times. In addition
to the operating instructions, the operator must also provide user manuals as
defined in the Work Conditions Act and the Work Equipment Use Regulation.
Always keep all safety signs and instruction plates on the machine in legible
condition. Immediately replace signs that have become damaged or unreadable.
1.3.2 Biohazardous materials
When operating the machine, especially when performing maintenance and
upkeep, it is imperative that you comply with applicable instructions and
guidelines on safety, occupational medicine and hygiene since the medium
processed by the installation falls under the category of
biologically hazardous material
Apart from these operating and maintenance instructions, the occupational safety
and accident prevention specifications (UVV), as amended, are applicable and
absolutely binding for the entire plant and the operator. This includes, in particular,
the individual accident prevention specifications of the industrial professional
guilds (VBG specifications), some of which are specified below:
VBG 1 : General specifications
VBG 4 : Electrical machinery and operating
equipment
VBG 5 : Powered operating equipment
VBG 7 to 5.3 : Spindle – Presses
VBG 10 : Continuous transporters
VBG 54 : Effluent water systems
1.3.3 Before switching on the machine
Sufficiently familiarize yourself with
■the operating and control elements of the machine
■machine equipment
■the mode of operation of the machine
■the immediate surroundings of the machine
■the safety gear of the machine
■the measures to be taken in the event of an emergency.
Every time before the machine is switched on, do the following:
■Check and ensure that all safety devices are attached and functioning.
■Check the machine for visible damage. Immediately rectify defects or report
them to supervising personnel.
Operate the machine only when it is in perfect condition.
■Check and ensure that only authorized people remain the in the work area of
the machine and no other people might be injured when the machine is
activated.
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Safety Notes
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After the machine is switched on, it works via the control unit in
automatic mode.
It can lead to an automatic run at any time.
1.3.4 In normal mode
Do not remove or deactivate any safety device while the machine is running.
Operating personnel must remain only on their specified workstations while the
machine is running.
Operating personnel must ensure that no unauthorized people remain in the work
area of the machine.
1.3.5 During maintenance
Perform the maintenance work prescribed in the operating instructions –
adjustment, cleaning, lubrication, upkeep, inspection – within the stipulated
period.
Take note as well of the special indications for individual components in these
operating instructions.
Pay attention to the following issues before performing maintenance work:
■switch off the central power supply on the main switch, lock the main switch and
attach a warning sign against reclosing
■ensure that all parts of the drive have cooled down to room temperature
■ensure that appropriate hoisting gear and load suspension devices are available
when large machine parts have to be replaced
■bar access to the work area of the machine and ensure that no unauthorized
people remain in it
■immediately replace machine parts that are not in perfect condition
■use only original spare parts
■ensure that suitable collection containers are available for all substances that
are hazardous to groundwater (oils, coolants, etc.)
Take note of the following issues after maintenance work is completed and
before switching on the machine:
■once again check that all bolted joints previously loosened are securely
fastened
■check whether all safeguards and covers previously removed are properly
installed
■ensure that all tools, materials and other equipment used have been removed
from the work area
■clean the work area and remove liquids that might have spilled and remove
similar substances
■ensure that all safety devices of the machine are once again functioning
perfectly
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Safety Notes
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1.3.6 When working on electrical equipment
Basically, only trained electricians may perform work on electrical equipment of
the machine.
Regularly check electrical equipment:
■Reattach loose connections
■Immediately replace damaged wires or cables.
Always keep the switch cabinet and all electrical supply units closed. Access is
allowed only to authorized personnel.
Never clean electrical equipment with water or similar liquids.
1.3.7 For environmental protection
When performing work on and with the machine follow the rules for waste
prevention and for proper recycling or waste disposal.
See to it that substances that are hazardous to groundwater such as grease, oils,
coolants, solvent-containing cleaning fluids, etc. do not overload the soil or reach
the sewage system especially when performing installation and maintenance
work. Collect, store, transport and dispose of these substances in suitable
containers.
1.3.8 Modifications to the machine
For safety reasons, do not undertake any unauthorized modifications on the
machine. This also applies to welding work on load-bearing parts.
All planned modifications must be approved by Kuhn GmbH in writing.
Use only original spare parts. If third-party parts are used, there is no guarantee
that they were designed and manufactured according to load and safety
specifications.
We also do not approve third-party parts and special equipment being used on the
machine.
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Safety Notes
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1.4 Requirements for operating personnel
All people who work on the machine must read the operating
instructions and confirm with their signature that they have
understood them.
1.4.1 Operating personnel
Only people who are trained, instructed and authorized to operate the machine
may do so. These people must be familiar with the operating instructions and only
then act. The operator is to issue the respective authorization for operating
personnel in the form of a user manual.
In addition, the following qualifications are needed for the following activities:
■Only technicians may perform installation and assembly.
■Only electricians may perform work on electrical equipment.
■Only trained personnel may perform maintenance, upkeep and repair work.
1.4.2 Operating personnel to undergo training
Operating personnel who have to undergo training may work on the machine only
under the supervision of an experienced person. Successfully completed training
must be confirmed in writing.
1.5 Special types of danger
1.5.1 Risk of crushing
If you intervene in the operating sequence of the wash press, you run the risk of
being crushed in the hopper.
Do not reach into the hopper without first shutting down the
machine!
1.5.2 Build-up of biogas
Because of the nature of the material being conveyed, biogas may form and lead
to an explosive atmosphere.
There is risk of explosion or detonation.
Biogas can be identified by its smell which is akin to rotting eggs.
If it is discovered that biogas has built up on the machine, evacuate all people
from the surroundings of the machine.
Switch off the machine from the switch cabinet.
Ventilate the installation site until the gas has disappeared.
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Maintenance Instructions
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Maintenance Instructions
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Maintenance Instructions
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1 Maintenance
1.1 Safety Indications for Maintenance
When maintaining the wash press make sure to comply with following safety
indications to prevent mortal injuries to people, machine damage and other
property damage.
■Only operating personnel who adhere to the letter of the user manual may
perform cleaning, lubrication and maintenance work.
■Only authorized specialists who follow accident prevention regulations may
perform repair work.
■Basically, only trained electricians may perform work on electrical equipment of
the machine.
■Safeguard a wide area around the work area before beginning maintenance
work.
■Disconnect all voltage sources and secure against unintentional reclosing.
■Use only the indicated fuels.
■Used only spare parts that are included in our spare parts list.
■Always replace self-locking nuts.
■Always maintain the indicated bolt tightening torques.
■Dispose all non-recyclable fuels, lubricants and additives in an ecologically
acceptable way.
■Comply with the chapter "General Safety Indications”.
Document all work performed and keep the records safe!
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Maintenance Instructions
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1.2 Inspections and Preventive Maintenance
1.2.1 Daily
1.2.1.1 Checking operability
During operation observe whether:
■unusual running noises can be heard
■oil is leaking from the gearbox
■the hinge is tight.
Immediately initiate repairs if damage is discovered.
1.2.2 Monthly or every 100 operating hours
1.2.2.1 Checking the safety devices
■Switch the wash press forward in manual mode.
■Activate the emergency button.
The machine must shut down and the red indicator lamp on the
switch cabinet must light up.
■Unlock the activated emergency button.
■Activate the "CONTROL VOLTAGE ON” button.
■Switch on main switch and restart the machine using the control elements in the
desired operating mode.
Do not operate the machine without operational emergency stop
devices. Immediately rectify any defect discovered.
1.2.2.2 Checking the screw, bearing unit and slotted screen bottom
■Switch on the main switch.
■Switch the wash press forward in manual mode.
The machine is now working in continuous operation. Do not reach
into the motion outlet of the machine. You run the risk of injury.
■Check the screw for smooth running and concentricity.
Immediately initiate repairs if damage is discovered.
■After the inspection switch off the main switch and secure against unintentional
reclosing.
■Check the slotted screen bottom visually for deformations.
■Switch on main switch and restart the machine using the control elements in the
desired operating mode.
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Maintenance Instructions
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1.2.2.3 Assessing the press output and throughput
■If the press output and throughput diminish, assume that the screw is worn. In
this case, disassemble the screw and check for dimensional accuracy. Consult
Kuhn GmbH when doing so.
1.2.3 Semi-annually or every 600 operating hours
1.2.3.1 Checking fastenings and screw connections
■Switch off the machine using the main switch and secure against unintentional
reclosing.
■Check all screw connection and fastenings for secure fit. Tighten loose screw
connections and fastenings.
■Switch on main switch and restart the machine using the control elements in the
desired operating mode.
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Maintenance Instructions
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1.3 Cleaning, lubrication, maintenance
1.3.1 Weekly or after 30 operating hours
1.3.1.1 Cleaning
■Switch off the machine using the main switch and secure against unintentional
reclosing.
■Clean the outside of the machine using a suitable cleaning device.
Caution! It is imperative that the solenoid valves and other electrical
equipment are not directly cleaned with the water jet but with a
brush, etc.
■Switch on main switch and restart the machine using the control elements in the
desired operating mode.
1.3.2 Monthly or every 100 operating hours
1.3.2.1 Check the cleaning brushes
■Switch off the machine using the main switch and secure against unintentional
reclosing.
■Check the cleaning brushes for wear and tear.
Replace the cleaning brushes if the bristles no longer protrude over
the side of the screw or if there is build-up of material to be pressed
in the feed hopper.
■Switch on main switch and restart the machine using the control elements in the
desired operating mode.
1.3.2.2 Checking the solenoid valves
Observe the wash press during a wash procedure (with the fewest screenings)
and check whether the solenoid valves switch according to specifications and
open and close correctly.
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