Vulcan-Hart EWP 250-1200 User manual

Table of Contents
Cover –Title Sheet
Instructor Resume
Coarse Objectives
Training Outline
Operation and Maintenance Training for Vulcan Industries EWP Washing Press
Section 1 - Safety
Section 2 –Operations
Section 3 –Electrical Sequence of Operation
Section 4 –Maintenance
All training will consist of both Classroom and hands-on training.
Twelve (12) sets of this outline will be provided for training purposes
No additional audio/visual training aids are required for this training.

Training Manual
Vulcan Industries, Inc. www.vulcanindustries.com [email protected]
Project: Beaver Channel Pump Station and Related
Modifications and Contract C- New WWTP
Project Location: Clinton, IA
Equipment:
1 –Screening Washing Press Model EWP 250-1200
Equipment Tag No.: 10SCS-WSP01
Contract Specification Section: 11092
Related Equipment:
1 - Mensch Crawler Screen Model No. FT48 CI “Severe Duty”
(2) Shaftless Screw Conveyor Model KSF- 240
Contractor:
Gridor Construction, Inc.
4025 S. 30th St.
Clinton, IA 52732
Engineer:
HDR Engineering Inc.
1860 Boyson Road
Hiawatha, IA 52233
Manufacturer:
Vulcan Industries, Inc.
212 S. Kirlin St.
Missouri Valley, IA 51555
712-642-2755, FAX [phone]
Manufacturer’s Representative:
Doonan Environmental
809 W. Spring St.
Eldridge, IA 52748
Vulcan Job No. 10100
Prepared by: Mark Hoffman
[e-mail]

VULCAN INDUSTRIES, INC.
Submittal Documents for: Clinton WWTP
Clinton, IA
Vulcan Ind. Job No.: 10010
Contractor: Gridor Construction
Specification Section References: 11092
SERVICETECHNICIANRESUMES
Vulcan Industries, Inc.
212 S. Kirlin St., Missouri Valley, IA. 51555
Email: www.Vulcanindustries.com
Phone [phone] • Fax [phone]

2
VULCAN INDUSTRIES, INC.
WATER / WASTEWATER TREATMENT EQUIPMENT
212 S. KIRLIN ST. MISSOURI VALLEY, IA. 51555
[phone] or fax [phone]
Email www.vulcanindustries.com
SERVICE REPRESENTATIVE QUALIFICATIONS
Carlton Griffin
Mr. Griffin has been employed full time by Vulcan Industries for fifteen years as a service
representative. He has been trained in the proper equipment start-up and operating
procedures as required by the field service employee manual as approved and signed by
the President of Vulcan Industries, as well as other Service Personnel.
Carl assisted other service representatives on several service and training operations before
becoming a full time serviceman. Prior to being employed by Vulcan, Carl worked as a
service technician in the food packing equipment industry.
He has performed start-up services and operator training on approximately 300 bar screens
and other wastewater plant equipment across the United States and abroad. Mr. Griffin has
a vast background in the operation and maintenance of plant equipment, as well as
electrical control and hydraulic equipment.
Mike Sharp
Mr. Sharp likewise has been employed full time by Vulcan Industries for approximately six
years as a service representative. He too, has been trained in the proper equipment start-
up and operating procedures as required by the field service employee manual as approved
and signed by the President of Vulcan Industries, as well as other Service Personnel.
Mike also assisted other service representatives on several service and training operations
before becoming a full time serviceman. Prior to being employed by Vulcan, Mike was a
service technician and manager for several companies involved in the manufacturing field.
Mike has an extensive mechanical background as well as vast experience in electrical
control, pneumatics, hydraulics and customer service.
While not performing field services, the technicians assist in the manufacturing of equipment
and electrical controls related to the Wastewater Treatment Industry.
Mike has performed start-up services and operator training on approximately 150 stair
screens, washing presses and related equipment, and is particularly specialized in the start-
up and optimization of rotary drum thickeners.
Kenny Athay
Mr. Athay has been employed full time by Vulcan Industries for approximately three years as
a service representative. He was trained in the proper equipment start-up and operating
procedures by the other Service Personnel.

3
Kenny assisted other service representatives on several service and training operations
before becoming a full time serviceman. Prior to being employed by Vulcan, Kenny worked
for many years as a technician in the HVAC and electrical industry. He has extensive
knowledge in the areas of electrical, electronics, mechanical and pneumatic equipment.
While not performing start-up services, Kenny assists in the manufacturing of equipment
and electrical controls related to the Wastewater Treatment Industry.
He has performed start-up services and operator training on approximately 100 wastewater
screens, presses and related plant equipment across the United States.
Jay Kirk
Mr. Kirk has been employed full time by Vulcan Industries for approximately sixteen years,
with 8 serving in the capacity of service technician. He is currently employed in our
electrical controls design department. He too, has been trained in the proper equipment
start-up and operating procedures as required by the field service employee manual as
approved and signed by the President of Vulcan Industries, as well as other Service
Personnel.
Jay assists other service representatives in troubleshooting, adjustments and optimizing the
operation of equipment . Prior to being employed by Vulcan, Jay was a service shop
foreman for a major agriculture distributor. Jay has an extensive mechanical background
and while working with John Deere, Jay received specialized, extensive training in electrical
control, pneumatics, hydraulics and customer service.
Jay has performed start-up services and operator training on approximately 140 bar screens
and other wastewater plant equipment across the United States and abroad.
Mr. Kirk has a vast background in the operation, maintenance and electrical control of the
supplied equipment

Coarse Objectives
Vulcan Model EWP Washing Press
Identify, describe and/or perform the following:
1. Safety Hazards
2. Functional Description of Equipment
3. Technical Description and Component Identification
4. Equipment Operation
5. Troubleshooting
6. Maintenance and Lubrication
7. Maintenance Demonstration
The intent of this training is to provide all plant personnel (Operations, Maintenance and
Electrical) with the general knowledge to operate and maintain the equipment. Personnel will
understand the functional and technical operation of the equipment, be able to troubleshoot,
maintain and repair the equipment and adhere to recommended safety procedures. Following is
a basic outline of the content of this training session:
Operation and Maintenance Training Outline
1. Safety
a. Biohazard warning
b. Electrical Hazards
Mechanical Hazards
2. Operations
a. Functional description
b. Owners responsibilities
c. Operational sequence of equipment
d. Operational procedures of equipment
3. Electrical Sequence of Operation
a. Normal start-up sequence
b. Electrical sequence of operation

c. Electrical equipment device functions
4. Maintenance
a. Lubrication schedule
b. Daily maintenance schedule
c. Weekly maintenance schedule
d. Monthly maintenance schedule
e. Half-yearly maintenance schedule
f. Maintenance and repair of individual components

Section 1
General Safety
Instructions
1General Safety Instructions
1.1 Operator’s Responsibilities
This machine was designed and built to operate within all applicable safety guidelines.
In practice, however, this safety can only be achieved if all the necessary measures are
taken. It is the responsibility of the owner and/or operator to ensure that these measures are
taken and to monitor their performance.
The operator must ensure that:
The machine is used only as directed in this manual.
The machine is in good working condition and the safety devices are checked regularly
for their operability.
The required personal safety gear for operating, maintenance and repair is available and
is used.
The operating instructions are available in legible condition and in complete form.
Only adequately qualified and authorized personnel operate, maintain and repair the
machine.
All the safety and warning signs attached to the machine are in place and remain legible.
All doors, panels, covers, and guards are closed or secured in place.
1.2 Safety Measures
A. Keep Information Available
Keep these operating instructions in an easily accessible location. Ensure that everyone
working on the machine can access the operating instructions at all times.
Keep all safety signs and instruction plates on the machine in legible condition. Immediately
replace signs that have become damaged or unreadable.
B. 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. The medium processed by the machine falls under the category of;
“Biologically Hazardous Material”!

Section 1
General Safety
Instructions
C. Before Turning the Machine on
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 devices on the machine.
Emergency measures.
Before the machine is turned on, perform 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 good working condition.
Ensure that only authorized personnel remain the in the area of the machine and no one
might be injured when the machine is activated.
Caution: Automatic Equipment! When the machine is
activated, it can run in automatic mode. It can start automatically
at any time.
D. During Normal Operation
Do not remove or deactivate any safety device while the machine is running.
Do not operate the machine with guards, doors, panels or covers removed.
E. During Maintenance
Perform the maintenance work prescribed in the operating instructions –adjustment,
cleaning, lubrication, upkeep and inspection –within the suggested maintenance schedule.
Take note of special requirements for individual components in these operating instructions.
Before performing maintenance work:
Disconnect the power supply. Follow all Lock-Out Tag-Out procedures in place for the
worksite. Note that control panels may have more than one source of power.
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.
Replace machine parts that are not in good working condition
Use only genuine replacement parts from the manufacturer.
Ensure that suitable collection containers are available for all substances that are
hazardous to groundwater (oils, coolants, etc.).
After maintenance work is completed and before switching on the machine:
Check that all bolted joints previously loosened are securely fastened.
Check whether all safeguards and covers previously removed are properly installed.

Section 1
General Safety
Instructions
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.
Ensure that all safety devices of the machine are functioning properly.
F. Working on Electrical Equipment
Only trained electricians should perform work on electrical equipment of the machine.
Regularly check electrical equipment:
Reattach loose connections.
Immediately replace damaged wires or cables.
Always keep the control panel and all electrical supply units closed. Access is allowed only
by authorized personnel.
Never clean electrical equipment with water or similar liquids.
G. Environmental Protection
When performing work on the machine follow the protocol for waste prevention and proper
recycling or waste disposal.
Ensure that hazardous substances such as grease, oils, coolants, solvent-containing
cleaning fluids, etc. are collected and disposed of in a safe manor and as prescribed by
environmental laws.
H. Equipment Modifications
For safety reasons, do not perform any unauthorized modifications to the machine. This also
applies to welding work on load-bearing parts.
Vulcan Industries, Inc. must approve all modifications in writing.
Use only genuine replacement parts from the manufacturer. Parts manufactured from a third-
party do not conform to the manufacturers design standards.
The use of third-party parts and special equipment on the machine could result in
catastrophic failures and void the warranty.
1.3 Requirements for Operating Personnel
Warning: All operating and maintenance personnel
must read and understand these operating instructions before
operating and/or performing maintenance to this machine.
A. Operating Personnel
Only personnel who are trained, instructed and authorized to operate the machine may do so.