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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Index

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

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Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

INDEX

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Index

Table of Contents

1

About this manual

2

Description of equipment

3

Safety

4

Transportation and storage

5

Installation

6

Commissioning and start-up

7

Operation

8

Maintenance

9

Services and spare parts

10

Appendices

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual About this Manual Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

About this manual

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

ABOUT THIS MANUAL

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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ECFN-OUT-MC-P015-MAN-00001 About this manual

Contents Contents ............................................................................................................................. 3 1

Purpose and scope ................................................................................................. 5

2

Presentation conventions ...................................................................................... 6

3

Safety and warning symbols .................................................................................. 7 3.1

Safety symbols ........................................................................................... 7 3.1.1

Hazard symbols .................................................................................... 8

3.2

Danger ..................................................................................................... 12

3.3

Warning .................................................................................................... 12

3.4

Caution ..................................................................................................... 12

4

Reading and storing the IOMS manual ............................................................... 13

5

Warranty information ............................................................................................ 14 5.1

Warranty terms......................................................................................... 14

5.2

Warranty claim ......................................................................................... 15

3 (17)

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ECFN-OUT-MC-P015-MAN-00001 About this manual

All information and advice in this document have been written with our present experience and insights to the best of our knowledge. The original version of this document may have been written in another language. Details about original document version and translation are written in the front cover. All illustrations and drawings in these operating instructions only serve as a general illustration, as their details are not always decisive for construction. This document and its appendices must be kept throughout the lifespan of the product. Attach any further changes to the document and keep it clean and accessible for whenever it is needed. If the document is damaged, immediately order a new one. If the product is sold, the new owner must be provided with the document. Additional copies of these documents can be ordered from the manufacturer. Please note that further copies are not free of charge. This [•] (”Manual”) is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This Manual is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the Manual shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, license, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this Manual is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The Manual has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this Manual is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the Manual. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the Manual. Outotec's liability for any errors in the Manual is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this Manual may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

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1

ECFN-OUT-MC-P015-MAN-00001 About this manual

Purpose and scope The purpose of this manual is to make it easier to become acquainted with the machine and machine functions. Document contains important advice and instructions to operate the machine in a safe, proper and economical manner. Following these instructions will help to avoid risks, to reduce repair costs and downtimes and to improve the reliability and life of the machine.

NOTE: In addition to these Operating Instructions, the information and instructions in the supplier’s documentation must also be followed (see attachments).

This installation and operation manual includes the information for installing and operating the Outotec Larox pressure filter and related safety issues. The detailed technical data (e.g. drawings and spare parts list) and descriptions of the working methods, maintenance procedures etc. are contained in this operation and maintenance manual. An interleaf separates the groups of the main division from each other and the instructions in the main division are in numeric order. DANGER Do not operate or perform maintenance on the automatic pressure filter until you have read and understood this operation and maintenance manual.

We hope this manual will help you to make the best use of your filter.

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ECFN-OUT-MC-P015-MAN-00001 About this manual

Presentation conventions Tasks and procedures are presented as numbered step-by-step lists. For tasks where the sequence of actions is not important, bulleted lists may be used. Arial 10 bold font is used for words that represent graphical user interface (GUI) text. Notes are used to alert the reader to important information on the proper use of the product, user expectations, error situations, and actions related to these. Notes concern, for example, unauthorized modifications to the product that might affect liability, items that might be expected within a product delivery but are not included, and avoidance of errors during operation.

NOTE: Note text

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3

About this manual

Safety and warning symbols In Outotec documentation, dangers, warnings, and cautions are used when it is necessary to take special precautions to avoid a potential hazard. According to the ISO 3864 standards, warnings are divided into three groups according to the hazard severity and the level of risk or harm. DANGER

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.

Caution is also used to indicate a hazard that could cause damage to the product or system.

3.1

Safety symbols

The general shape and color of the safety symbols used with danger, warning, and caution is defined in ISO 3864-1.

Table 1.

Symbols

Hazard

Prohibition

Mandatory action

Hazard: The black symbol inside a yellow triangle with a black border describes the hazard. Prohibition: The black symbol inside a red ring with a diagonal red bar describes the action that should not be taken. Mandatory action: The white symbol inside a blue circle describes the action that must be taken to avoid a hazardous situation.

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3.1.1

About this manual

Hazard symbols

These symbols are used in warnings to indicate a hazardous situation or action. Hazard symbols are divided into five categories according to nature: 

Mechanical hazards



Electrical hazards



Radiation hazards



Material/substance hazards



Ergonomic hazards

Mechanical hazard symbols The hazard symbols related to each hazardous situation are presented in the following table.

Table 2.

Mechanical hazard symbols

Falling load hazard

Crushing hazard

Hand crushing risk

Sharp element

Entanglement hazard

Risk of falling

Floor-level obstacle

High pressure injection hazard

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About this manual

Electrical hazard symbols

Table 3.

Electrical hazard symbols

Electricity / Dangerous voltage

Radiation hazard symbols

Table 4.

Radiation hazard symbols

Radioactive material

Laser beam

Material / Substance hazard symbols

Table 5.

Material / Substance hazard symbols

Hot surface

Explosive hazard

Toxic material

Corrosive substance

Flammable material

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About this manual

Ergonomic hazard symbols

Table 6.

Ergonomic hazard symbols

Heavy object

Hazardous to the environment

Prohibited action symbols These symbols are used in warnings and notifications to indicate an action that should not be taken. The prohibited action symbols are presented below.

Table 7.

Prohibited action symbols

No open flame

Do not touch

Do not enter

Do not weld

Do not remove safety guard

General prohibition sign

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ECFN-OUT-MC-P015-MAN-00001 About this manual

Mandatory action symbols These symbols are used in warnings and notifications to indicate an action that must be taken. The mandatory action symbols are presented below.

Table 8.

Mandatory action symbols

Wear protective gloves

Wear eye protection

Wear head protection

Wear a safety harness

Wear ear protection

Wear safety footwear

Wear protective clothing

Wear high-visibility clothing

Wear respiratory protection

Disconnect main plugs

Disconnect before maintenance

Read the instruction manual

Use cardboard for locating leaks

General mandatory action sign

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3.2

ECFN-OUT-MC-P015-MAN-00001 About this manual

Danger

A danger is used to alert the user to an imminently hazardous situation that could result in death or serious injury. DANGER Warning text.

3.3

Warning

Warnings concern, for example, information about dangerous voltages or actions that could result in bodily harm or injury. WARNING Warning text.

3.4

Caution

A caution is used to alert the user to precautions needed to avoid hazard, which, if not avoided, could results in minor or moderate injury, or damage to the product or system. Cautions concern, for example, damage caused by electrostatic discharge. CAUTION Warning text.

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ECFN-OUT-MC-P015-MAN-00001 About this manual

Reading and storing the IOMS manual Before you use the equipment, carefully read the manual and make sure that you understand all safety precautions. After reading the manual, keep it in a convenient place for easy reference for all personnel who use the equipment. If one or more documents are damaged or lost, order a new copy from Outotec. Contact your nearest Outotec Service Center or our head office (www.outotec.com/services). Please note that the replacement copies may be liable to charge.

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5

About this manual

Warranty information 5.1

Warranty terms

Warranty terms of the delivered goods are in accordance with the "contract" or the "contractual purchase order" or if otherwise not specified, then in accordance with general terms NL 85 and NLM 84 with the exception of the below mentioned amendments and additions: The warranty does not cover: 

Wearing parts such as filter cloths, diaphragms, seals, slide pieces, valve balls and sleeves, V-belts, chains, scrapers, grids, closing device, hydraulic hoses and hydraulic seals.



Direct or consequential damages which have been caused by structural alterations or use of such parts, which are not of original manufacture.



Any filter or part of the filter resold by the original contractual purchaser unless agreed in writing with Outotec of the transfer of the remaining warranty period to the new owner.

The claims against the warranty must be made by the purchaser in writing, within a reasonable time after the damage has been discovered. The following information must be indicated on the claims: 

The serial number of the filter



Date when the damage was discovered



Operational data of the filter when the damage was discovered



Full details of the damage

The damaged part must be sent with the claim to Outotec, freight prepaid. If the mentioned terms are not followed properly, the purchaser may lose his right to the warranty. Unless otherwise stated, the warranty of the repair work and/or replacement parts shall expire simultaneously with the warranty of the filter.

Outotec (Finland) Oy

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5.2

About this manual

Warranty claim

WARRANTY CLAIM

CLAIM

Customer’s name/Contact

RETURNED GOODS DATE:

Affiliate or distributor Outotec (Finland) Oy

Address

P.O. Box 29 FIN-53101 Lappeenranta, Finland

Country

Phone

Email

Fax

Filter type

Model

Phone

+358 (0) 20 529 4236

E-mail

Fax

+358 (0) 20 529 4439

Internet

[email protected]

www.outotec.com

Filter No.

Date of failure

Principal part involved

Part No.

Operating cycles or time

For Outotec’s use only Business unit

Type of operation

Description of the case, place, circumstances and so on.

Goods to be returned Component delivered to customer with filter Qty.

other delivery date Code

Description

Signature

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About this manual

For Outotec´s use only

Warranty status

Actions

Warranty period

Yes

To be repaired

No

Date

By

Claim returned for completion To be scrapped Claim accepted To be delivered to supplier for inspection

Date

By

Rejected Date of credit

Credit invoice

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Description of Equipment Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Description of Equipment

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

DESCRIPTION OF EQUIPMENT

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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Description of Equipment

Contents Contents ................................................................................................................ 3 1

EC declaration by manufacturer ............................................................... 5

2

Product identification ................................................................................ 6

3

Intended use ............................................................................................... 7

4

Main components ....................................................................................... 8 4.1

Process operations ..........................................................................9 4.1.1

Plate pack ...................................................................................9

4.1.2

Process piping ......................................................................... 12

4.2

Auxiliary operations ........................................................................14 4.2.1

Closing device .......................................................................... 14

4.2.2

Filter cloth................................................................................. 15

4.2.3

Filter cloth tracking (hydraulic) ................................................. 18

4.2.4

Seam positioning ..................................................................... 19

4.2.5

Pressing water station .............................................................. 21

4.2.6

Pressing water pipe ................................................................. 22

4.3

Control operations ..........................................................................23 4.3.1

Control panel ............................................................................ 23

4.3.2

Description of controls and functions ....................................... 23

4.3.3

Hydraulic unit system ............................................................... 26

4.3.4

Lower pressing plate position sensor S171 ............................. 29

4.4

Hydraulic cake chute flaps .............................................................30

4.5

Load cell module (Optional) ...........................................................31 4.5.1

Hardware installation ............................................................... 32

4.5.2

Load cell replacement .............................................................. 33

4.5.3

Important installation notes ...................................................... 35

4.5.4

Operation instructions .............................................................. 36

4.5.5

Checking the load cell operation .............................................. 38

4.5.6

Alarms ...................................................................................... 39

4.6

5

Slurry feed control module (Optional) ............................................40 4.6.1

Operating modes ..................................................................... 42

4.6.2

Parameters and configuration bits ........................................... 43

Process description ................................................................................. 44 5.1

Filtration .........................................................................................45

5.2

Pressing I .......................................................................................45

5.3

Washing (optional) .........................................................................45

5.4

Pressing II (optional) ......................................................................45

5.5

Air drying ........................................................................................45

5.6

Cake discharge ..............................................................................45

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7

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Technical data........................................................................................... 47 6.1

Filter types ......................................................................................47

6.2

Technical description .....................................................................50

6.3

Vibration value ...............................................................................50

Product modifications ............................................................................. 51

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Description of Equipment

EC declaration by manufacturer The machine can be delivered in two alternative executions according to the definition by the EC Machinery Directive 2006/42/EC as follows: a.

as “complete machinery” (ref. Directive 2006/42/EC, Article 2 (a)) with the following declaration:

-

EC Declaration of Conformity of the Machinery (Directive 2006/42/EC, Article 5, Annex II, Sub A)

NOTE: CE-mark fixed on the machine by manufacturer.

b.

as “partly completed machinery” (ref. Directive 2006/42/EC, Article 2 (b)) with the following declaration:

-

Declaration of Incorporation of Partly Completed Machinery (Directive 2006/42/EC, Article 5, Annex II, Sub B)

NOTE: Machine delivered without a CE-mark.

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Description of Equipment

Product identification Table 1.

Product identification

Product name

Outotec® Larox PF Pressure Filter

Type designation

PF12 SERIES

Serial number

PF1226

Year of construction

2018

The product information is presented in the product plate on the machine.

Figure 1.

Name plate

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ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Intended use The Outotec® Larox PF Pressure Filter is intended for indoor professional automatic use in the mining and chemical process industries. It is an automatic operating pressure filter for efficient solid/liquid-separation. The machine can be operated remotely from a control room or locally from the control panel. DANGER It is strictly forbidden to use this machine in any other way or for any other purpose, other than those specified in this instruction manual and its appendices.

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4

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Main components

Figure 2.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Main components

Bed and vats Foundation plate Lower pressing plate Plate pack Columns Top pressing plate Top frame Cake chute Cloth tensioning device Cloth drive unit Hydraulic unit Process pipelines Covers Filter cloth Pressing water station

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Control panel Pinch valves Cake thickness device Open end cake chute Central lubrication Proc. Control unit Packing Hydraulic hoses Terminal box support Pneumatics Slurry feed pump unit Manifold flush pump Cloth wash pump Slurry pre-circulation valve V10

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4.1

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Process operations DANGER

Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never touch the plate pack during operation.

. WARNING High-pressure liquid injection hazard. Compressed liquid can cause death or serious injury. As a result of seal damage or foreign objects between the plate pack, liquid squirts are possible. When the pack is closed, always be careful.

4.1.1

Plate pack

The filter plate pack consists of horizontally laying filter plates which are connected to each other with suspension plates. When the filter plates are pressed together they form the chambers. The filter plate consists of two parts: the bottom plate (6) (filtrate chamber) and the frame (5) (filter chamber). The purpose of the bottom plate is to collect and take away the filtrate. Ensure all feed inlets are open all the time, so that both sides of the plate are under equal pressure during all the operation stages. Otherwise the plate bends and causes leakage and holes in the filter cloth.

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PF1226, PF16/19 M12 45

Figure 3.

1. 2. 3. 4. 5.

Description of Equipment

Plate pack

Grid Filter cloth Diaphragm Seal Frame

6. 7. 8. 9.

Bottom plate Feed pipe connection L-clamp Pressing media connection

Frame The frame serves as the fixing element for the diaphragm. The frame and diaphragm together allow the space required by the cake. Grid The grid supports the filter cloth and forms an outlet for the filtrate. Diaphragm The rubber diaphragm acts as a pressing element with which, by means of pressing media, the cake is pressed to remove the liquid from it. Pressure may rise above 16 bar, but as far as the durability of the diaphragm is concerned, it is much more recommendable to start with a pressure of 8 bar and then observe the effect of a pressure rise on the pressing time and the residual moisture. In this way the most suitable pressure of slurry for each process can be determined.

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Description of Equipment

In temperatures above +60 °C, a strong aging phenomenon affects rubber. If the slurry to be filtered is hotter than +60 °C, pay special attention to the temperature and follow the manufacturer's instructions. Check the condition of the diaphragms regularly. If the cakes from any of the chambers get wetter than the others or if the pressing water level in the tank starts rising or falling, replace the damaged diaphragm with a new one; check the condition of the pressing water. Clean the pressing water tank and change the pressing water if necessary. CAUTION With water pressing only clean water is recommended as the pressing medium. Using any other liquid may cause risk situations.

Seal The seal is located in the frame, above the filter cloth; its purpose is to prevent slurry leakage. There is no seal below the filter cloth – the filter cloth and the steel surface are face to face. If any counter-pressure forms space on the grid on its feed side, this will cause filtrate to leak from underneath the filter cloth.

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PF1226, PF16/19 M12 45

4.1.2

Description of Equipment

Process piping

The Outotec Larox PF filter includes two pipelines, which are directly in contact with the filtration process, namely the feed pipe and the filtrate pipe. Filtrate pipe The purpose of the filtrate pipe is to remove the filtrate or the wash liquid (filters with cake washing) which has penetrated through the cake. Some cases filtrate valves are located separately from filter to customer pipelines.

Figure 4.

Filtrate pipe with filtrate valves

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Description of Equipment

Slurry pipe The slurry as well as drying air is led through the feed pipe into the filter chambers. Also in filters with a cake washing option the same route is used for the washing liquid. Slurry is pumped through the lower end, drying air and the possible washing liquid through the upper end of the feed pipe.

Figure 5.

V02 V05 V06

Slurry pipe

Slurry feed inlet valve Cake wash liquid inlet valve Drying air inlet valve

V07 V16

Manifold drain outlet valve Butterfly valve

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4.2

Auxiliary operations

4.2.1

Closing device

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

WARNING The closing device is hydraulic. Any damage to the hydraulic pipeline is dangerous and may cause an injury.

The closing device is hydraulic. Any damage to the closing device comprises of hydraulic cylinders (14) and (16) and locking pins as shown in the drawing “Hydraulic PF filter closing and opening” on the next page. The closing of the plate pack is carried out in three stages: closing (=quick action), locking and sealing. The force of the quick action cylinder and the sealing cylinder can be adjusted by regulating the oil pressure. Quick action cylinders The filtration cycle starts with the closing of the plate pack (17), which is left open after the preceding cycle. The pack is lowered to a closed position by quick-action cylinders (14) which move down the upper pressing plate (3). Locking After the plate pack is closed, the locking pins (15) lock the top pressing plate (3) to the columns (6), which are fixed to the foundation plate (5). The filtration chambers have thus been formed. Now the plate pack is surrounded by the upper pressing plate, bottom plate and columns. Sealing The lower pressing plate (4) presses the plate pack against the upper pressing plate (3) closing the filtration chambers tightly. This is accomplished by short hydraulic cylinders (16) fixed to the foundation plate. After the cylinders (16) reach the force required to close the plate pack, automatic locking valves shut off the oil lines located in the cylinders. The purpose of these valves is to prevent the cylinder from yielding. When the filtration stage is finished, the plate pack opens to facilitate cake discharge. The sealing cylinders (16) return to their starting positions. Then the locking pins (15) are released. This frees the upper pressing plate (3) for quick opening. When the filter is stopped for maintenance, the plate pack is in the upper position, and the locking pins are used to lock the upper pressing plate to the columns.

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Figure 6.

4.2.2

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Hydraulic PF filter closing and opening

Filter cloth

The filter cloth operates both as a filtering element and a conveyor belt which transports cake out of the filter. Besides having a good filtering ability, the filter cloth must be able to withstand heavy pulling. Only special type of fabrics can be used. The most commonly used filter cloth is made of multifilament fabric that is stronger lengthwise (warp) than crosswise (weft). Should any holes appear in the filter cloth, these must be mended immediately. Solid material entering between the filter cloth and the rollers makes the rollers dirty and destroys the filter cloth.

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Figure 7.

1. 2. 3. 4. 5. 6. 7.

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Filter cloth

Centering roller Tensioning device roller Tensioning roller Impulse roller Guide roller Scraper Vat roller

8. 9. 10. 11. 12. 13.

Filter cloth wash nozzles Drive roller Pressing roller Cake Seam detector Encoder

Filter cloth drive mechanism To discharge the cakes and to wash the filter cloth, the filter cloth is moved with a drive roller between filtering cycles. The drive roller is actuated by a hydraulic motor. A spring loaded pressing roller presses the filter cloth against the drive roller to improve the maintaining of friction. Auxiliary drive motors (optional) Auxiliary drive rollers reduce the tension of the filter cloth during the filter cloth drive by dividing the tension into three points instead of one. Auxiliary drive motors are series-connected to the return port of the main drive motor. A pressure reducing valve PR91 is installed in the line after the main drive motor HM91. It determines the input pressure to the HM92 to approx. 50 bar.

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Description of Equipment

Adjustments The most important factor with the auxiliary drive rollers is to check they do not slip in the beginning of the filter cloth drive. Should this happen, reduce the pressure rate in PR91 by turning the adjusting screw counterclockwise.

Figure 8.

Adjustments of filter cloth

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4.2.3

Description of Equipment

Filter cloth tracking (hydraulic)

Normally the filter cloth moves in the plate pack without crossing the guide roller edges. However, if the filter cloth tends to be directed towards either of the edges, the automatic filter cloth tracking brings the filter cloth back into center position. The filter cloth tracking takes place by moving the left end of the centering roller in the filter cloth conveyor unit up or down or by moving it according to the signals of the filter cloth position sensor GT2HC4 on automatic control operation. The hydraulic cylinder of the tracking roller is equipped by filter cloth tracking cylinder position sensor GT1HC4.

2 6 1 5

3

4

Figure 9.

1. 2. 3.

Filter cloth tensioning and tracking unit

Filter cloth edge position transducer Seam position sensor Hydraulic cylinder of tracking roller

4. 5. 6.

Filter cloth tensioning roller Filter cloth tracking roller Guide roller

The sensors GS2HC4 and GS1HC4 are located in the filter cloth conveyor unit and have been adjusted at factory to give a signal before the filter cloth edge goes over the roller edge. If cloth tracking devices cannot control the cloth and it drifts too much to the side and activates either GS2HC4 or GS1HC4 limit switch, it will trigger an alarm.

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ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

FILTER CLOTH

GS1HC4 RIGHT

GS2HC4 LEFT

GT2HC4

GT1HC4

Figure 10.

4.2.4

Limit switches in filter cloth tracking unit

Seam positioning

After discharge, the clipper seam should stay outside the sealing surfaces of the filter plates. The seam can be positioned so, that it remains either on the same or other side of the plate back. A recommendable way is to choose the discharge plates (odd number) so, that the seam by turns remains on different sides of the pack, whereby also the cake in turns forms on both sides and thus gets washed by a counter flow principle. In case the desired result is as clear a filtrate as possible, the discharge distance (plates) should be chosen so, that the seam always gets positioned on the same side of the plate pack. The discharge distance (plates) should be such that the cloth moves at least four plate lengths during it. Thus in a normal case even all scraping remnants have had time to drop into the cake chute. In case the seam remains inside the sealing surfaces, it can be damaged by closing force and thus the change of cloth may become difficult. The slurry has also a direct route to the filtration chamber and affects the clarity of the filtrate, capacity and cake moisture. Following sensors are for control seam positioning: B331 (perambulator) and S332 (clipper seam sensor). B331 (1) is located on the impulse roller and is fixed to the upper frame. B331 send out impulses, the distances A-B and B-C (shown in the picture below) are measured by these impulses. S332 (2) zeros the seam positioning at point A. S332 is located another side than the B331, between the tensioning device frame and the cloth.

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Description of Equipment

1 A B

2

C

Figure 11.

1.

Seam positioning

Perambulator (B331)

2.

Clipper seam sensor (S332)

The automatic positioning of the clipper seam only functions when the filter is in automatic drive. The test drive of cloth does not include the positioning function, thus when returning to automatic drive (cake discharge subroutine), the cloth is driven so long that the seam is acceptable for closing plate pack. Note that if seam is not OK for closing plate pack (in SBR05) there will be S332D (Clipper seam displaced) alarm, due to security reasons it cannot be acknowledged until program is reset. When the cake discharge starts, the cloth is at first driven forward one plate length at cake discharge speed. When the first plate length is done, the rest of discharge is done by cloth wash speed. When the whole discharge is done the cloth stops to the next roller. Thus the seam always gets positioned at the end of the filter plate. In case the seam passes by the seam detector S332 (2) after the discharge has done, the seam stops under the upper roller of the plate pack, i.e. at point B. In case "end mode" has been chosen as the drive mode, the positioning of the cloth takes place only after the full length of the cloth has been washed. The number of revolutions can be changed from parameter screen. Normally one revolution is enough. The length of the cloth is given in meters through the operator's interface on the basis of which the number of pulses for the whole cloth length is calculated. In case S332 (2) does not receive an impulse from the seam after the said number of pulses, an alarm S332 "clipper seam alarm" is given. In case the cloth is changed and seam positioning has worked properly with the previous cloth, there is no need to change the parameters.

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Description of Equipment

In case the length of the cloth is changed (filter plate pairs have been added to the filter), the new length in meters should be given through the operator's interface and after that filter program should be reset, cloth is driven forward or reverse without tension (e.g. one second is enough) and started in automatic mode. Then PLC will measure cloth (and compare it to given cloth length) and position clipper seam. This initialization can take maximum 2 full cloth lengths, depending where clipper seam is when initialization starts. During this there is message “Searching clipper seam” at operator’s interface screen.

4.2.5

Pressing water station

Water for diaphragm pressing is pumped from the pressure water station with a multistage centrifugal pump. Variable speed drive (VSD) controls the output pressure of the pressure water station. The output pressure is limited with the spring-loaded safety valve normally set to 16 bar. Water station is equipped with a sieve located inside the water tank. Clean the sieve during normal maintenance; refer to maintenance manual. Circulation valve must be a bit open (10% of nominal output) at all times to ensure water is replaced inside the pump chamber. It is in most cases in a correct position when delivered; check the valve before adjusting it. The station is equipped with a level switch (LS1PWS) located inside the sieve to prevent the pump from running dry, among other components and switches introduced below. The terminal box for pneumatics is equipped with minimum pressure level switch PS1JB2PWS (6 bar), if the pressure reduces lower than limit it will cause an alarm and the filter will be stopped.

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PF1226, PF16/19 M12 45

Description of Equipment

PS1PWS GV104PWS GV113PWS

M1PWS QM1PWS

L37528

HZI1PWS

GSO113PWS GSC113PWS

JB2PWS

JB1PWS

LT1PWS GSO104PWS GSC104PWS LT1PWS

L40840 Figure 12.

Components of pressing water station

Symbol

Component

Symbol

Component

M1PWS

Pressing water motor

GSO104PWS /GSC104PWS

Process valve open / closed

QM1PWS

Motor safety switch

GSO113PWS /GSC113PWS

Process valve open / closed

JB1PWS

Terminal box, electrical

HZI1PWS

Emergency stop push button

JB2PWS

Terminal box, pneumatic

PS1PWS

Instrument air pressure, in pressing water station

GV104PWS /GV113PWS

Valve solenoid

LS1PWS

Pressing water level low (or sieve blocked)

LT1PWS

Pressing water level

L40840

Back pressure valve

L37528

Safety valve

4.2.6

Pressing water pipe

NOTE: Check the hose covers are always closed during filtering operations.

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Description of Equipment

The pressing water pipe distributes the pressing water to the filter plates and on top of the diaphragms. The pressing operation is carried out using the pressing water pump and is controlled by the safety valve and the pressing water return valve V04.

4.3

Control operations

The operator interface terminal consists of a touch screen unit, which is connected to the programmable logic with Ethernet connection via Ethernet switch. Information exchange between the PLC and the touch screen unit is automatically controlled by the touch screen unit.

4.3.1

Control panel

The control panel has a programmable logic controller (PLC) that automatically controls the filter. DANGER Explosion hazard. Explosions cause severe injury or death. Do not disconnect control equipment unless power is disconnected or the area is non-hazardous.

Explosion hazard. Explosions cause severe injury or death. When in hazardous locations, disconnect the power before replacing or wiring the control system modules.

A window provided with a lock protects the operator interface. Keep this window locked when the screen is used. Keep the control panel door always closed unless it is required to keep it open for some reason. CAUTION No changes to the PLC program are allowed without a written approval from Outotec.

Do not add or remove any components from the control panel without the manufacturer's permission. All components replaced during maintenance must fulfill the same technical requirements as the original parts.

. DANGER Electrocution hazard. Electrocution causes severe injuries or death. Do not use the control panel power supply to supply power for any other equipment.

4.3.2

Description of controls and functions

The control panel is used to facilitate the operation of the Outotec Larox pressure filter.

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Description of Equipment

The control panel incorporates switches, push buttons and an operator interface unit, which are required for filter operation. Each push button, switch and indicator lamp is provided with a label briefly describing the function of the device. The flow diagram is located in the display of the operator interface unit. The indicator lamps show the present state of the actuator or motor in question.

Figure 13.

Operator interface terminal with a flow diagram

The control panel is illustrated on the following page.

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Figure 14.

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Control panel

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4.3.3

Figure 15.

4.3.3.1

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Hydraulic unit system

Hydraulic unit system

Hydraulic pump

The pump used in the hydraulic system is an axial piston pump with a load sensing adjustment and a maximum pressure limitation. The pump regulators, i.e. compensators, keep to the system requirements and keep the delivery and pressure of the pump correct despite the load in the system. For a more detailed description see the information provided by the manufacturer.

4.3.3.2

Proportional valves and their plug amplifiers

The volume of flow and the pressure in the system is controlled by proportional valves. FCV1HU is for the volume flow and PCV1HU for the pressure. 

FCV1HU is a flow proportional valve. The output flow is proportional to the electrical current of the direction valve coil.

The operation of the flow proportional valve is controlled using the amplifying card located in the plug of the coil of the directional valve FCV1HU. 

The amplifying plug receives analog signals from the programmable logic and outputs current to the solenoid of the proportional valve.

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Description of Equipment

To direct the analog signal, the plug also contains a ramp which can be adjusted separately up or down, which slows down the change in the volume flow rate when shifting from one level to another. 

PCV1HU is a pressure proportional valve. The output flow is proportional to the electrical current of the direction valve coil.

The operation of the pressure proportional valve is controlled using the amplifying card located in the plug of the coil of the directional valve. 

The amplifying plug receives analog signals from the programmable logic and outputs current to the solenoid of the proportional valve.

4.3.3.3

Accumulator system

The bladder type accumulator is an energy reserve for the pinch valve line. Accumulator medium is nitrogen gas. The pre-charging pressure is 90 bar (0.9 times the minimum pressure of 100 bar of the pinch valve line). 

The accumulator recharges whenever the hydraulic pump is running and the pressure in the main line exceeds the accumulator pressure.



The accumulator pressure is monitored by the pressure transmitter PT2HU. If the accumulator pressure drops below set point in the program, the hydraulic pump is automatically started and accumulator recharged.

NOTE: Charging of the accumulator begins when the pressure is under 100 bar. Charging ends when the pressure has been over 160 bar for 5 seconds. 

The accumulator is equipped with accumulator safety block which consists of a system shut-off valve (lever), manual unloading valve (red rotary knob) and a pressure relief valve. The pressure relief valve is pre-set and sealed at 210 bar and shall not be re-adjusted.



The accumulator can be discharged for maintenance purposes by rotating the red unloading valve knob counter-clockwise. The hydraulic pump has to be stopped before. Connect a manual pressure gauge to a test point 46.5 to verify that the pressure has been totally discharged before removing any components from the system or opening any hydraulic connectors. Remember to close the unloading valve before starting the hydraulic pump again.

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4.3.3.4

Description of Equipment

Oil container equipment

Hydraulic system pressure transmitter PT1HU Location Hydraulic unit block, connection PG12 Functions The value of the pressure transmitter is shown on screen. The closing pressure can be modified within the range of 30 - 60 bar. The control pressure is 5 bar below the closing pressure. If the pressure during the closing stage is higher than the calculated control pressure for 3.5 seconds, the plate pack has been closed. If the closing pressure has been changed, the control pressure is set automatically. Hydraulic oil temperature transmitter TT1HU Location On the side of the hydraulic unit/oil container Functions The value of the temperature sensor is shown on screen. The general functions related to the oil temperature are, for example: 

If the oil temperature is below 0 °C, it stops the operation of the motor M1HU. The control panel issues an alarm and the oil heater turns on. The alarm can be reset as soon as the temperature of the oil rises above 10 °C.



When the temperature of the oil is below 20 °C, the closing time for the plate pack increases by 5 seconds, thus the pressure in the hydraulic unit is higher than the pressure of the closing control mechanism for 8.5 seconds.



When the oil temperature lies between 30 - 35 °C, the oil heater turns on.



When the oil temperature lies between 50 - 55 °C, the oil cooler starts up. (OPTIONAL)



When the temperature of the oil exceeds 60 °C, the control panel screen informs the user the oil temperature is too high and starts the ENDMODE program. Once the filtration cycle has completed, the filter stops and the control panel issues an alarm.



If the oil temperature exceeds 65 °C, the filter immediately stops and the control panel issues an alarm.

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4.3.4

Description of Equipment

Lower pressing plate position sensor S171

Location The S171 sensor is located underneath the bottom sealing plate, in the center of the plate, mounted to an arm sticking up from the filter foundation plate. The sensor is in a position where sensing surface is facing up towards the sealing plate. Sensor is detecting when the sealing plate is in lowest position (unsealed). Adjustment When the sealing plate is in its lowest position, the distance between the sensor and the sealing plate should be approximately 7 - 8 mm. Adjust the sensor position by moving the mounting bracket up or down. Function The sensor is used for the following purpose: 

Sealing plate in the low (unsealed or fully down) position. If the low position is not reached within 30 seconds during unsealing, the S171 LOWER PRESSING PLATE DOWN SENSOR alarm is triggered. CAUTION The hand held test unit must be used to set the sealing plate low position!

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4.4

Description of Equipment

Hydraulic cake chute flaps

When the air drying is completed, the plate pack opens and the filter cloth drive system starts. The filter cake on the filter cloth drops through the cake chutes: free end cake chute (4) and bifurcated cake chute (5), from the both sides of the filter. Before the filter cake discharge, the cylinder (1) automatically opens the swivel covers (2) of the cake chute flap (3). After the discharge the cylinder (1) automatically closes the swivel covers (2) of the cake chute flap (3). They prevent liquid or unwanted particles from going down the cake chute.

Figure 16.

1. 2. 3.

Hydraulic cake chute flaps

Cylinder Swivel flap Actuator arm

4. 5.

Free end cake chute Bifurcated cake chute

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4.5

Description of Equipment

Load cell module (Optional) The load cells must not be used for measuring any filtration capacities or for any other purposes which are not especially permitted herein. They are not certified scales according to EU directive 2014/31/EU and cannot be calibrated as such. The load cells are only meant to be used for guiding the filtration process by filter automation.

Load cell transducers are constructed of stainless steel. This figure illustrates a typical load cell configuration. The transducers are made to operate in industrial, wash down environments and require no periodic maintenance. Load cell wirings are very susceptible to electromagnetic interference, so any high voltage or high current cabling should not be installed in the vicinity of the load cell cabling. Load cell transducers are wired to signal processors, which convert the transducer’s millivolt signals to weight measurement.

Figure 17.

1. 2. 3.

Load cell module

Load cell transducer Terminal box (in filter) Control cabin

4. 5. 6.

Field bus cabling Filed bus cabling to other terminal boxes I/O modules (resistor bridge input terminals for weighing control)

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Description of Equipment

Load cells transducers will be installed between the filter and customers foundation with mounting kits. Some of filter may have separate weighing beam between the filter and the load cell mounting kit in order to stabilize load to load cells.

Figure 18.

4.5.1

Load cell transducer with mounting kit

Hardware installation

To achieve the most accurate weight measurement from the load cell transducers, there are factors to consider before installation: 

The surfaces where the base plates bolt down must be flat and horizontal with less than one degree of slope in any direction. The surface must be clean and smooth.



The foundation on which a filter rests must be of concrete or steel so it does not allow excessive movement when the weight of the filter changes.



Shock loads can damage load cells. If the load cell mounting kit can be struck by for example forklifts or trucks, install protective barriers or stops to prevent vehicles from hitting the mounting kit.

Figure 19.

Process control system without beams

Figure 20.

Process control system with beams

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4.5.2

Description of Equipment

Load cell replacement

To replace the load cells, do the following: 1. Disconnect the electric wiring from the terminal box. 2. Install a hydraulic jack to jacking point, see figure below. The hydraulic jack must be able to lift half of the mass of the filter. Use lifting ears if needed; they are included in the service tool kit.

Figure 21.

Jacking positions (1)

3. Install blocks of metal near to other load cells to bear the weight. It is possible to use the supporting rings delivered with the machine for this purpose. 4. Lift the machine five mm with the hydraulic jack. 5. Remove the bolts fastening the load cell. CAUTION Check the amount of shim plates when removing the bolts. Use the same amount when installing the new load cell.

6. Replace the load cell. 7. Fasten the load cell with the bolts.

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Description of Equipment

8. Lower the machine with the hydraulic jack. 9. Remove the hydraulic jack and the supports. 10. Connect the electric wiring to the terminal box.

Figure 22.

Load cell

6. Weighing sensor 9. Hexagonal screw M16 X 70 11. Hexagonal nut M16

12. Washer A16 18. Hexagonal screw M16 X 50

11. Check the load cell output from the user interface and adjust the load cell if necessary.

Figure 23.

Example of weight distribution of the load cells

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Figure 24.

4.5.3

Description of Equipment

Examples of hydraulic jacks

Important installation notes



During the filter installation do not put all filter loads on one transducer.



Position the load cell transducers so their cables won’t break and they can be easily routed to the terminal box.



In case you need to weld near a load cell, be sure the ground path is not through it. The ground cable should be close to the welding, in between the welding and the load cell, i.e. the welding current must not in any conditions run through the load cell. Also be careful with the heat. The load cell must always be so cool it can be touched. Further, it is recommendable to disconnect the wires from the sensor, to avoid a ground loop via the electronics.



Supporting structures of the pipelines connected to the filter should also carry the load of the filter’s pipelines. After the erection work, the filter’s pipelines are then released from the filter to stay on the supports of the pipelines connected to filter. Also, other vertical supports fixed to the filter, which may affect the process control system, have to be replaced by new supporting structures and disconnected from the filter.



Do not install the motor cables to the same cable routes or adjacent to the weighing cell cables.

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4.5.4

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Description of Equipment

Operation instructions



The process control system can be activated to control the FILTRATION stage. If the system is not activated, stages are controlled by preset time.



To activate the system to control the filtration stage, set parameter “MAX FILLING WEIGHT (kg)” in parameter screen No. 3. If the parameter value is Zero, control is not on.



When the process control is activated, filtration (filling the chambers) is controlled by time, weight or maximum pumping pressure. Whatever reaches the set value first, stops filling. The weight set point is set into parameter “MAX FILLING WEIGHT (kg)”.



To get access to capacity information select REPORT screen and press HISTORY report button in the operator interface panel.

Table 2.

Screen information

No.

Description

Unit

1.

Production per hour. Cumulative cake weights of the last hour.

kg

2.

Production per shift. Cumulative cake weights of the current 8 hour period.

t

3.

Production per day. Cumulative cake weights of the current day.

t

4.

Production per week. Cumulative cake weights of the current week.

t

5.

Production per month. Cumulative cake weights of the current month.

t

6.

Production per year. Cumulative cake weights of the current year.

t

7.

Total cake production from the start-up of the filter.

t

NOTE: Production per shift is reset according to the shift start time parameters (PARAMETER screen No. 3).

NOTE: Select “B91*” from process screen and from there “Param”.

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Figure 25.

Process screen

Figure 26.

Parameter screen

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

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4.5.5

Description of Equipment

Checking the load cell operation

In case malfunction is suspected each load cell can be checked with the OPTIONAL calibration equipment. 1. First check the piping supports. For reference see the important installation notes in chapter 4.5.3 Important installation notesError! Reference source not found.. 2. Drive the filter to full stop using END mode. 3. Turn OFF the filter main switch (HS1EB11FL) and hydraulic unit. 4. Install the calibration equipment to the filter. 5. Turn the main switch (HS1EB11FL) ON. 6. Use Hand pump (3) to put pressure to the hydraulic cylinder (2) on the calibration equipment. 7. Compare the readings between the scale (1) and the filter info screen for the load cell in question. If the readings differ significantly the load cell should be replaced.

Figure 27.

1. 2.

Calibration equipment

Scale Hydraulic cylinder

3.

Hydraulic hand pump

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Figure 28.

4.5.6 Table 3.

Description of Equipment

Calibration equipment installed to the filter.

Alarms

Minimum weight alarm

Cause

Reason

Corrective measures

Cake weight after pressing is less than minimum cake weight set in parameters.

Slurry pump has failed.

Skip over the air drying stage to avoid filtration plates bending.

Slurry feed time is too short. Slurry density is too low. Weight sensor or amplifier has failed.

Repair or replace the weight sensor/amplifier.

Cause

Reason

Corrective measures

Measured weight is greater than max tare weight after the plate pack closing stage.

Extra mass has been gathered onto the filter.

Remove the extra mass from the filter.

Weight sensor or amplifier has failed.

Repair or replace the weight sensor/amplifier.

Table 4.

Tare alarm

. NOTE: If the parameter “MAX TARE WEIGHT (kg) is set to zero, the alarm is not in use.

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4.6

Description of Equipment

Slurry feed control module (Optional)

Description Slurry flow is measured with magnetic flow meter. Density of slurry is calculated from slurry tank based on pressure and level measurements. With these measurements slurry feed can be optimized on several ways: pumping speed control for maximum recommended flow (l/s), pumping exact amount of slurry (kg) to filter, ramping slurry pump up/down.

M102

Figure 29.

Slurry feed control process

Hardware 

Slurry flow transmitter FT102



Slurry tank pressure transmitters LT102 (lower), B525 (upper)

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Description of Equipment

By touching slurry tank in process screen info window opens:

Figure 30.

Process screen

There you can enter to parameters:

Figure 31.

Parameter screen

You must log in on tools screen to change any parameter.

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Description of Equipment

Software Density ρ = (B525 - LT102) / (g*d)

Figure 32.

Density calculation

L max = 5000 mm d = 1000 mm

4.6.1

Operating modes

Slurry flow module has following operating modes: 

Flow control

(M102FLOW_ENABLE)



Filling control

(M102FILLING_ENABLE configuration bit)

Operating modes can be selected from Tools -> Configuration screen. Flow control While flow control mode is active (M102FLOW_ENABLE) configuration bit (from OIU tools -> configuration screen), slurry pump speed is controlled with parameter “slurry pump flow setpoint”. If flow control is not selected, slurry pump is ramped to max speed using parameters 1 4. Filling control While filling control mode is active, slurry amount is controlled by density and flow measurements. There is a parameter “Filling amount”, which means exact amount (kg) of solid to be pumped into the filter. Slurry density is calculated from pressure difference in slurry tank. To get filling amount of solid, you need to give parameters mother liquid and dry solid density.

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4.6.2 Table 5.

Description of Equipment

Parameters and configuration bits Parameters

Parameter

Unit

Description

Slurry flow

m³/h

Maximum slurry flow

Slurry pump ramp time

s

Slurry pump ramping time

Filling amount

kg

Filling amount

Slurry pump maximum speed

%

Slurry pump maximum speed

Table 6.

Configuration bits

Configuration bit

Description

M102FLOW_ENABLE

enable flow control mode

M102FILLING_ENABLE

enable filling amount control mode

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5

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Process description The main operating stages of the PF filter include filtration, diaphragm pressing, cake washing and compressed air drying. The filtration elements (i.e. plates) of the PF filter are placed horizontally between two pressure plates. During filtration the plate pack is pressed together, and the pack is opened for cake discharge. The plate pack is opened and closed with hydraulic cylinders. The endless filter cloth zigzags between the filter plates and results in the filtered cake being formed on either side of the filter cloth. While the filtrate squeezes through the filter cloth, it absorbs and removes solid matter particles remaining in the filter cloth from preceding filtration cycles. The filter cloth transports the cakes off the filter and, at the same time, the filter cloth is cleaned from both sides by high pressure water sprays. The filter cloth moving device is actuated by a hydraulic motor which actuates the filter cloth drive roller. When the filter plates are opening and closing, the tension of the filter cloth is maintained at a level by a simple filter cloth tensioning device. The filter cloth tensioning device operates during plate pack opening and closing. Slurry is fed into the filter chambers through a distributor pipe located on the feed side of the filter (the feed side is on the left looking from the direction of the drive unit). Wash liquid and drying air are fed through the same pipe. The distribution pipe is emptied through a drain valve. Pressing water is generated by a multistage centrifugal pump and is led above the diaphragm through a water distribution pipe. After the pressing stage the water returns to the pressing water station through the same pipe. The operation of the filter is controlled automatically by the operation unit containing the programmable logic, operator's interface, switches, push buttons and graphic display panel to enable easy adjustments and cycle observation. The automatically controlled actuators are hydraulically operated.

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5.1

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Filtration

When the filter plate pack has been closed, slurry is pumped into each filtration chamber through the slurry hoses. Filtrate flows through the filter cloth and into the filtrate chamber. The filtrate chamber is emptied through filtrate hoses into the filtrate pipe.

5.2

Pressing I

Pressing water is pumped above the diaphragm through the pressing water hoses. The diaphragm presses the cake against the filter cloth forcing the filtrate from the cake to flow through the filter cloth.

5.3

Washing (optional)

Wash liquid is pumped into the filter chambers in the same way as the slurry. As the wash liquid fills the filtration chamber, the diaphragm is lifted up and water is forced out from the upper side of the diaphragm. The wash liquid flows into the filtrate pipes after passing through the filter cake and the filter cloth.

5.4

Pressing II (optional)

The wash liquid remaining in the chamber after the washing stage is pressed out of the cake as in stage 2 above.

5.5

Air drying

The final drying of the cake is accomplished with compressed air. The air enters through the slurry pipe, fills the filter chamber, raises the diaphragm and forces the pressing water above the diaphragm out of the filter. The air flow through the cake reduces its moisture content to the optimum and, at the same time, empties the filtrate chamber.

5.6

Cake discharge

When the air drying is completed, the plate pack is opened and the filter cloth drive mechanism started. The filter cake on the filter cloth is discharged from both sides of the filter. The four-stage (short) program does not include washing and second pressing stages.

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Figure 33.

ECFN-OUT-MC-P015-MAN-00001

Description of Equipment

Filtration process

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6

Description of Equipment

Technical data 6.1

Filter types

The filtration area can vary depending on the model, as shown in the table below.

Table 7.

Typical product information

Model

9.5

12.5

16

Filtration area (m²)

9.45

12.6

15.75

Chamber volume 45mm (m3)

0.43

0.57

Chamber volume 60mm (m3)

0.57

6

Filter plates (pcs)

19

22

25

28

32

35

38

18.9

22.0 5

25.2

28.35

31.5

34.65

37.80

0.71

0.85

0.99

1.13

1.28

1.42

1.57

1.71

0.76

0.95

1.13

1.32

1.51

1.70

1.89

--

--

8

10

12

14

16

18

20

22

24

Filter plate size (mm)

900 x 1 750

Main dimensions, length (mm)

4 850

Main dimensions, width (mm)

3 800

Main dimensions, height (45 mm chambers) (mm)

2 600

3 100

3 600

4 100

4 100

4 600

Main dimensions, height (60 mm chambers) (mm)

2 600

Weight 45mm chamber (metric tons)

11.2

12.0

13.2

14.0

15.6

16.3

18.2

Weight 60mm chamber (metric tons)

10.9

12.0

13.5

14.2

16.1

16.8

17.4

3 100

3 600

Required floor area (m²)

39.5

Max. pressure (bar)

16

Filter cloths, width (m)

4 600

--

--

18.9

19.8

20.5

18.1

--

--

1.05

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Model

9.5

12.5

Filter cloths, length 45mm chamber (m)

21.5

26.0

Filter cloths, length 60mm chamber (m)

21.5

27.5

16

Description of Equipment

19

22

25

28

32

35

38

32.0

37.0

42.5

47.0

53.0

57.0

63.5

68.5

34

38.5

44.5

49.5

55

60.5

--

--

230…690 VAC, 50/60 Hz

Electric motors Hydraulic unit (kW-r/min)

18.5 - 1 500

Water pump motor (kWr/min)

11 - 3 000

18.5 - 3 000

Water station pump

CR 15 - 12 (50 Hz)

CR 32 - 9 - 2 (50 Hz)

CR 15 - 8 (60 Hz)

CR 32 - 6 (60 Hz)

1 500

3000

Pressing water tank (l) Oil tank (l)

300

General marking principle for the filters Company, Brand, Filter family, Size specification(s)/series, Material, Extra parameters, options

Table 8.

General marking principle for the filters

Outotec Larox PF 16/19 M12 1 45 C

16

/19

M12

1

45

C

Filtration area Frame size (max area) Filter series Construction material Chamber height Diaphragm type for 45 mm chamber

Construction material (material of parts in direct contact with slurry or filtrate) 

1 = AISI 304L used in processes in which pH = 4-14



2 = AISI316L used in processes in which pH = 2-4



3 = ASTM NO8904L used in strongly acid processes in which pH = 1-2



4 = PP polypropylene plates; steel parts & pipes AISI304



5 = EN 1.4462 (SAF 2205) for processes where high CL-content

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Description of Equipment



6 = EN 1.4162 (“Lean Duplex”) limited availability (Good chlorides resistance, high tensile strength, corrosion resistance slightly below material 2). Only base plate of filter plate made of 1.4162 other wetted parts acc material 1.



X = Other materials, specified in the technical description

Chamber height 

30 = 30 mm chamber (available only for 1.6 m 2 and 2.5 m2 plate size with certain limitations)



33 = 33 mm chamber (available for 6 m 2 plate size with certain limitations)



40 = 40 mm chamber (only option with PP plates, plate size 1.6 m 2, available for PF9.5 – PF32 in 12 series)



45 = 45 mm chamber



60 = 60 mm chamber



75 = 75 mm chamber (available only for PF 60-132 with certain limitations)

Diaphragm type for 1.6 m2 plate with 45 mm chamber 

No marking for flat diaphragm type



C = Cup-type diaphragm

Filter series M1.6 M12 M15 (M30) M48 M60

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6.2 Table 9.

Description of Equipment

Technical description

Technical description

Type Outotec Larox PF 12 Series Serial No. PF989

16/25

Filtration area

m2

15.75

Filter plates

pcs

10

Filter plate size

mm

900 x 1750

length

mm

4250

width

mm

3600

height

mm

3600

Weight without auxiliary equipment

t

14.1

Required floor area

m2

39.5

width

mm

1050

length

m

33.0

Hydraulic unit

kW-r/min

18.5-1500

Pressing water pump

kW-r/min

18.5-3000

Oil heater

kW

1.0

Main dimensions

Filter cloth

Electric motors 690 V 50 Hz

Water station/Pump type

60 Hz

Pressing water tank

TV 1.5/CRN16-120 l

1500

Slurry feed

bar

2.0 - 10.0

Pressing water

bar

2.0 - 16.0

Pressing air

bar

4.0 - 7.0

Filter cloth wash water

bar

min. 5.0

Cake wash water

bar

3.0 - 7.0

Hydraulic pump

bar

max. 180

Pressures

*Pump type is CRN when construction material is 2 or 3.

6.3

Vibration value

The highest root mean square value of weighted acceleration does not exceed 0.5 m/s 2.

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7

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Description of Equipment

Product modifications DANGER It is strictly forbidden to modify this machine or use it in any other way or for any other purpose, other than those specified in this instruction manual and its appendices. Unauthorized changes and modifications may affect operation and/or safety and may result in damage to property, personal injuries and even death.

Any modifications to the product may only be carried out by trained personnel with written consent from Outotec (Finland) Oy. If an unauthorized modification has been implemented, its effect on warranty liability will be considered and may result in the rejection of warranty applications. Outotec (Finland) Oy reserves the right to make alterations to the product, including documentation, at any time, in order to: 

Improve the product;



Update the product to comply with changed applicable standards;

if the need for modifications is recognized by Outotec Oy.

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Safety Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Safety

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

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Date

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Revision Text

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Status:

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Site No.:

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Replaces: Document Title:

SAFETY

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Language: EN

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ECFN-OUT-MC-P015-MAN-00001 Safety

Contents Contents ............................................................................................................................. 3 1

Essential safety principles ..................................................................................... 5

2

Limits of use ............................................................................................................ 6

3

2.1

Space limits ................................................................................................ 7

2.2

Time limits .................................................................................................. 7

2.3

Other limits ................................................................................................. 7

Personnel qualifications and training ................................................................... 8 3.1

Instruction form .......................................................................................... 8

4

Personal protective equipment .............................................................................. 9

5

Hazards and risks .................................................................................................. 10 5.1

Fire safety ................................................................................................ 12

5.2

Installation and maintenance of pneumatics ............................................ 12

5.3

Installation and maintenance of hydraulics .............................................. 13

5.4

Installation and maintenance of electrical system ................................... 14

5.5

Safety during welding and grinding .......................................................... 15

5.6

Noise levels and noise emission .............................................................. 15

5.7

In case of accident ................................................................................... 15

5.8

Original spare parts .................................................................................. 16

6

Danger zones ......................................................................................................... 17

7

Emergency stops and location of main switch .................................................. 18

8

7.1

Emergency stops ..................................................................................... 18

7.2

Location of main switch ............................................................................ 20

Safety devices and guards ................................................................................... 21 8.1

Protective door system ............................................................................ 21

8.2

Safety and monitoring devices ................................................................. 22

8.3

Devices for disconnecting from the electric supply .................................. 22

8.4

Devices for relieving pressure from pneumatic systems ......................... 23

8.5

Devices for relieving pressure from hydraulic systems ............................ 23

8.6

Devices for relieving pressure from process lines ................................... 23

8.7

Warning devices ....................................................................................... 23

9

Safety labels and signals ...................................................................................... 24

10

Chemical substances ............................................................................................ 25

11

Radiation ................................................................................................................ 26

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ECFN-OUT-MC-P015-MAN-00001 Safety

Environmental aspects ......................................................................................... 27 12.1

Disposal of the filter components ............................................................. 27

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1

ECFN-OUT-MC-P015-MAN-00001 Safety

Essential safety principles Only the personnel who have the required skills, experience, and specific training may install, operate, service or decommission the equipment. If you are unsure about the requirements, contact Outotec. WARNING Read the instruction manual. Failure to observe the limitations, requirements, cautions, and warnings in these instructions could result in death or severe injury.

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ECFN-OUT-MC-P015-MAN-00001 Safety

Limits of use DANGER It is strictly forbidden to use this machine in any other way or for any other purpose, other than those specified in this instruction manual and its appendices.

. WARNING Crushing hazard. Falling filter plates can cause death or serious injury. Do not place body parts between the filter plates without first securing the hanging plates.



Do not use the feed hoses or filter plates for climbing.



Do not take samples from the solids flow when the machine discharges.



Do not change the process operation parameters in the PLC. This can cause problems with material; the feed lines can become blocked or blinded. It can also cause a mechanical failure on the filter elements.



The slurry used in the machine must agree with the initial technical specification. Use of other slurry can cause corrosion, mechanical wear, dangerous chemicals, and so on.

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2.1

ECFN-OUT-MC-P015-MAN-00001 Safety

Space limits



The machinery is intended for industrial environment, indoors operation.



The machinery is to be connected as a part of plant process.



The machinery is to be connected to external electric and pneumatic power sources.



The space requirements for installation are defined in layout-drawings typical for each PF-filter. The filter has no such moving parts that would extend out of the defined installation space while in operation.



Physical human contact with the machinery is necessary only during maintenance tasks. Normal operation is fully automatic.



The machinery is typically divided in three individual units: main filter unit, hydraulic power unit and pressing water station.

2.2

Time limits



The machinery is intended for an operational life of 30 years with 90% availability which varies both ways depending of the application. In an extreme environment the operational life can be less than 30 years and favorable environment can extend it over 30 years.



The machinery needs regular maintenance from cleaning, lubricating and visual inspection to replacing several wearing parts, such as: filter cloth, pressing diaphragms, scrapers, plate slide pieces, feed hoses, hydraulic oil, hydraulic oil and air filter. Frequency of each task depends on site and process conditions, but visual inspection is a daily task.

2.3

Other limits



The machine is intended for use in ambient temperature between +0 °C…+50 °C. Temperatures over +50 °C need to be considered case by case.



Construction materials for parts in contact with process media are selected case by case and define maximum chemical limitations like pH, feed temperature, Clcontent.



Maximum pressure for process feed connections is 1,6 MPa (16 bars).



Operating the machine in altitudes over 3000 m above sea level need to be considered case by case.

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3

Safety

Personnel qualifications and training 

Only reliable personnel may carry out installation, operation, maintenance or decommissioning work on the machine.



Personnel must be trained or instructed to carry out their duties. Ensure that only authorized personnel are working with the machine.



Clearly define the responsibilities and accountabilities of each member of personnel.



Only an experienced person may train and instruct personnel or supervise apprenticeships.



Electrical work may only be carried out by a qualified electrician or by an instructed person who is under the supervision of a qualified electrician.



Only qualified personnel with experience may carry out work on the hydraulic/pneumatic system.

3.1

Instruction form

Use the instruction confirmation form that follows to make sure personnel have important information applicable to the filter.

Table 1.

Instruction confirmation

Name of the instructed person

Function of the instructed person

___________________________________

____________________________________

No.

Instruction item

Date

1.

To read the Operating Instructions and to clarify all possible questions.

2.

The operation method of the filter

3.

Pictographs and information signs

4.

Safety equipment of the filter

5.

Personal protective equipment

6.

Changing the filter cloth

7.

Work regulations

8.

Additional operating instructions

9.

Cleaning instructions

Signature of instructed person

Signature of instructor

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ECFN-OUT-MC-P015-MAN-00001 Safety

Personal protective equipment Make protective equipment available for all personnel involved in the installation, operation and maintenance of the machine. CAUTION Wear protective gloves.

Wear protective shoes/boots.

Wear a helmet.

Wear protective clothing.

Wear eye protection when handling possibly hazardous substances and applied media.

Wear ear protection in the area of the hydraulic unit.

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5

ECFN-OUT-MC-P015-MAN-00001 Safety

Hazards and risks CAUTION Make sure there are no unauthorized persons in the danger zones during use.

Always use personal protective equipment, such as a safety helmet, goggles, protective overalls, protective footwear and safety gloves when working with the machine. Other protective equipment, such as ear protection, a respirator etc. must also be used whenever needed.

When carrying out maintenance or repair work, make sure the machine cannot accidentally be turned on. Use the appropriate lockout-tagout procedure.

Observe local laws, rules and regulations whenever applicable.

To avoid potential damage or injury, carefully plan your work beforehand.

Keep all warning labels on the machine clean and visible at all times.

All discovered defects or faults must immediately be brought to the attention of the operator or an authorized person.

. DANGER It is strictly forbidden to remove or disable any safety feature before starting the machine. When the machine is in use, all safety features must be in place and operational.

Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Stop the machine completely before maintenance, repairs or disassembly. Do not touch the machine unnecessarily when it is use.

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ECFN-OUT-MC-P015-MAN-00001 Safety

Electrocution hazard. Electrocution will cause serious injury or death. • Connect the grounding points on the frame of the machine to an earth before connecting the machine to a power supply. • Cut the power supply to the machine before maintenance, repairs or disassembly and use the appropriate lockout-tagout procedure.

Falling load hazard. Falling loads will cause severe injury or death. Never stand under a lifted load.

. WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Ensure the pneumatic system is not pressurized before maintenance, repairs or disassembly.

High-pressure oil injection hazard. Compressed hydraulic oil can cause death or serious injury. Ensure the hydraulic system is not pressurized before maintenance, repairs or disassembly.

Slipping/tripping hazard. An untidy work area can cause severe injury or death. Keep the machine and the area around the machine accessible and clean. Clean up spilled liquids and oils immediately.

Cutting hazard. Sharp edges or corners on the machine can cause severe injury or death. Wear the appropriate protective equipment when working near the machine.

Burning hazard. May cause severe injury or death. Some surfaces of the machine or substances used in the process may be hot. Wear protective overalls and gloves and do not unnecessarily touch the machine.

Fire hazard. Fire can cause death or serious injury. Keep heat sources, ignition sources and all forms of open fire away from the machine.

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5.1

ECFN-OUT-MC-P015-MAN-00001 Safety

Fire safety WARNING

In the event of a fire, immediately evacuate the area to reduce the risk of injury from flames, heat, hazardous vapors, explosion, or any other hazard that may arise.

. CAUTION Follow your local rules and regulations in the event of a fire.

5.2

Installation and maintenance of pneumatics DANGER

Only qualified personnel are allowed to carry out installation, maintenance and repair work on the pneumatic system.

.. CAUTION Wear safety goggles when maintaining, repairing or disassembling the pneumatic system.

The customer must provide a device with which the machine can be disconnected from the pneumatic supply. The device must be clearly marked and lockable to prevent accidental switch on.

WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Make sure the pneumatic system is not pressurized before maintenance, repairs or disassembly.

Perform a visual check of all pipes, hoses and screw fittings for leaks and visible damage daily and regularly check the condition more thoroughly. Repair any damage immediately. To locate leaks in the pneumatic system, use a piece of cardboard. Lay and install all lines and connections correctly. Fittings, lengths and hose pipe qualities must correspond to requirements.

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5.3

Safety

Installation and maintenance of hydraulics DANGER

Only qualified personnel are allowed to carry out installation, maintenance and repair work on the hydraulic system.

.. CAUTION Wear safety goggles when maintaining, repairing or disassembling the hydraulic system.

The customer must provide a device with which the machine can be disconnected from the hydraulic supply. The device must be clearly marked and lockable to prevent accidental switch on.

. DANGER Hydraulic fluid injection hazard. High-pressure hydraulic fluid spray can penetrate the skin and will cause death or serious injury. Make sure the hydraulic system is not pressurized before maintenance, repairs or disassembly.

Perform a visual check of all pipes, hoses and screw fittings for leaks and visible damage daily and regularly check the condition more thoroughly. Repair any damage immediately. Put down and install the hydraulic lines and connections correctly. Fittings, lengths and hose pipe qualities must agree with the requirements. Prevent a skin contact with the hydraulic fluid.

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5.4

ECFN-OUT-MC-P015-MAN-00001 Safety

Installation and maintenance of electrical system DANGER

Only qualified personnel are allowed to carry out the installation, maintenance and repair work of the electrical system.

. CAUTION The customer must provide a device with which the machine can be disconnected from the electrical supply. The device must be clearly marked and lockable to prevent accidental switch on.

. DANGER Electrocution hazard. Electrocution will cause severe injury or death. Disconnect the supply voltage before performing work on the electrical system.

. CAUTION Stop the machine immediately if electrical failure occurs.

Only use original Outotec fuses with the correct intensity of current.

If it is absolutely necessary to work on live parts, ensure there is a second person present to actuate the main switch or emergency stop. Appropriately close off and clearly mark the working area. Only use appropriate, insulated tools and devices.

Do a visual check of the condition of the electrical equipment once a day. Regularly do a check of the electrical equipment more fully. Repair the damage immediately. Examples of typical damage: loose connections or damaged electrical cables.

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5.5

Safety

Safety during welding and grinding

Before the welding, determine the material to be welded, the appropriate method of welding and the consumables. CAUTION Carry out welding, firing or grinding on the machine only if it is permitted.

. DANGER Explosion hazard. Explosions will cause severe injury or death. Clean all dust and flammable substances from the machine and its surroundings and ensure sufficient ventilation.

Poisonous gas hazard. Poisonous gases will cause severe injury or death. Maintain and check the working order of the ventilation installations regularly.

5.6

Noise levels and noise emission WARNING

Sound insulation devices on the machine must be in operation when the machine is running. Wear ear protection.

5.7

In case of accident

Stop the filter immediately to prevent further damage. Refer to 7 Emergency stops and location of main switch on how to do this. Follow the factory safety rules and regulations.

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5.8

ECFN-OUT-MC-P015-MAN-00001 Safety

Original spare parts

Only original spare parts or parts approved by Outotec (Finland) Oy can be used for replacement. CAUTION Any damage that occurs by using other than original or Outotec approved spare parts or accessories rules out all liability and warranty on the suppliers’ behalf.

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6

Safety

Danger zones DANGER Do not unnecessarily touch the machine when it is in use.

A danger zone is any space within and/or around the machine in which a person can be exposed to hazards. The danger zones have been recognized during the design phase of the machine (risk assessment process) and the risks have been minimized by design and by the use of safety guards and/or safety devices. When the safety instructions in the manuals are observed and all safety features are in place and operational, moving inside the “Danger zones” is safe and allowable. The danger zones are presented in the following illustration.

Figure 1.

1. 2.

Danger zones

Danger zone A (both sides) Danger zone B (both ends)

3.

Danger zone C

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ECFN-OUT-MC-P015-MAN-00001 Safety

Emergency stops and location of main switch 7.1

Emergency stops WARNING

Make sure the emergency stops are accessible at all times.

. CAUTION Check the operation of the emergency stops and protective doors weekly.

Close the hydraulic hand valves always after pressing an emergency stop button. Open the hydraulic hand valves before restarting the filter.

The filter is equipped with several emergency stop buttons. In case of danger, the filter can be stopped immediately by pressing the emergency stop button. When the button is pushed, the filter stops and all of its functions cease. An emergency stop message is displayed on the screens in the control room. After all emergency stop buttons are released, the emergency stop circuit can be reset by pressing the alarm acknowledgement push button. CAUTION When the filter is equipped with protective door system, all filter protective doors must be closed in order to operate the filter automatically. If any door is opened during automatic operation, the filter stops immediately.

Only test mode functions are possible with doors opened.

Reset the emergency stop push button by pressing the emergency stop acknowledgement push button (6) on the control panel (4). Do not release an emergency stop button until it is safe.

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Figure 2.

1. 2. 3. 4.

Safety

Emergency stop push-button positions

Emergency stop S702, on hand held unit Emergency stop S735, on the right side of cloth drive unit and S745 on the left side of filter (near free end) Emergency stop HZ1HU, in hydraulic unit

5. 6. 7. 8. 9.

Hydraulic unit Control panel Emergency stop S701, on control panel Alarm acknowledgement push button S733 Emergency stop button S703 in pressing water station

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7.2

Safety

Location of main switch

The main switch (1) is located on the cover of the control panel (2).

2

1

Figure 3.

Main switch

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8

Safety

Safety devices and guards The following safety equipment is used. 

Emergency stop push buttons



Protective door system (if applicable)



Safety rails



Safety covers and plates



Warning labels



Working platforms

8.1

Protective door system WARNING

All protective doors must be closed to operate the filter automatically.

The filter is equipped with protective doors which are monitored with safety switches. All the safety switches are connected to the safety controller. The machine will be brought to a safe state (stop category 0) following actuation of any of the safety switches (i.e. opening a protective door). As a result, all electrical power is disconnected from actuators. If any of the doors are opened during automatic operation, the filter will stop immediately. If any of the protective doors are open, only test mode functions are possible. If a protective door is opened during filtration, it must be acknowledged before filtration can be restarted. The acknowledgement buttons on the filter (2 pcs) are situated on the left and right sides of the filter. The acknowledgement must be done in two parts. Firstly, by pressing the acknowledgement button on that side of the filter at which the protective door was opened. And secondly, after acknowledging the protective door alarm at the filter, the alarm must also be acknowledged from the filter’s main control cabin.

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Figure 4.

8.2

ECFN-OUT-MC-P015-MAN-00001 Safety

Protective door system

Safety and monitoring devices CAUTION

Keep all safety and protective devices in perfect condition.

Safety and monitoring devices may only be deactivated by persons entitled to do so. Do not remove safety or monitoring devices unless necessary to perform repair or maintenance work. Safety devices must be installed, activated and checked before starting the machine.

8.3

Devices for disconnecting from the electric supply CAUTION

Disconnect any electric supplies prior to maintenance operations. Note that in some cases electric devices may have an electric charge even if disconnected from the power supply.

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See maintenance chapter for detailed instructions.

8.4

Devices for relieving pressure from pneumatic systems CAUTION

Relieve any residual energy or stored energy in the pneumatic system without danger of personal injuries prior to maintenance operations.

See maintenance chapter for detailed instructions.

8.5

Devices for relieving pressure from hydraulic systems CAUTION

Relieve any residual energy or stored energy in the hydraulic system without danger of personal injuries prior to maintenance operations.

See maintenance chapter for detailed instructions.

8.6

Devices for relieving pressure from process lines CAUTION

Relieve any residual energy or stored energy in the process system without danger of personal injuries prior to maintenance operations.

See maintenance chapter for detailed instructions.

8.7

Warning devices CAUTION

Find a description of the optical and/or acoustic warning from OEM documents, electrical drawings and spare part book attached to these instructions.

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ECFN-OUT-MC-P015-MAN-00001 Safety

Safety labels and signals WARNING The safety symbols found in this manual may also be posted on the machine. All personnel involved in the operation, installation, maintenance or repairing of the machine must observe and be familiar with all safety symbols, labels and instructions.

. CAUTION Keep safety instructions and safety labels clean and visible at all times.

Replace any illegible or missing safety instructions and safety labels before operating the machine.

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ECFN-OUT-MC-P015-MAN-00001 Safety

Chemical substances CAUTION Materials and supplies are to be used and disposed in accordance with the manufacturer’s instructions.

Use appropriate personal protective equipment when handling chemical substances.

. WARNING Hot materials hazard. Hot materials and supplies can cause severe injury or death. Observe extreme caution and wear appropriate personal protective equipment when handling hot materials or supplies.

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Radiation The filter does not contain any radiation sources. Regarding the used process media please refer to application and site specific documentation provided by the filter operator.

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ECFN-OUT-MC-P015-MAN-00001 Safety

Environmental aspects 12.1 Disposal of the filter components CAUTION Dispose the filter parts according to local regulations. Separate the plastic and metal parts of the filter and recycle them correctly.

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Transportation and Storage Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001 Transportation and

PF1226, PF16/19 M12 45

Storage

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

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Replaced by:

Replaces: Document Title:

TRANSPORTATION AND STORAGE

PF1226, PF16/19 M12 45 Equipment No:

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IOMS MANUAL

PF1226

Language: EN

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Contents Contents ............................................................................................................................. 3 1

Dimensions and mass ............................................................................................ 4

2

Transportation ......................................................................................................... 6

3

2.1

Filter protection for sea shipments ............................................................. 6

2.2

Protected parts ........................................................................................... 6

2.3

Removing protection .................................................................................. 6

Storage ..................................................................................................................... 7 3.1

Storage of the machine .............................................................................. 7

3.2

Storing filter plates ..................................................................................... 7

3.3

Storing soft rubber diaphragms.................................................................. 8

3.4

Storing hydraulic unit.................................................................................. 8

3.5

Storing spare parts ..................................................................................... 9

3.6

3.5.1

Hydraulic equipment ............................................................................. 9

3.5.2

Rubber parts ....................................................................................... 10

3.5.3

Hose assemblies ................................................................................. 11

3.5.4

Hydraulic hoses .................................................................................. 12

3.5.5

Conveyor belts .................................................................................... 12

3.5.6

Electronic parts ................................................................................... 12 Machine restart after long term storage ................................................... 13

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1 Table 1.

Storage

Dimensions and mass Main package dimensions and weights

Item

Length (m)

Width (m)

Height (m)

Gross weight (kg)

Net weight (kg)

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Figure 1.

ECFN-OUT-MC-P015-MAN-00001 Transportation and Storage

Main package dimensions and weights

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2

Storage

Transportation DANGER Only qualified personnel are allowed to attach loads and do transporting duties.

2.1

Filter protection for sea shipments

Individually identified parts in each Outotec filter are specially protected for the transportation.

2.2

Protected parts

Delivery as a whole filter: 

Piston rods of hydraulic cylinders



Hydraulic blocks/valves/connectors



Column holes



Locking pins

Delivery as dismantled filter and spare parts: 

in addition to the above, all machined, uncovered (not painted) surfaces

2.3

Removing protection

A tin of thinner is delivered with each filter for removing the protection. The person who starts up the filter removes the protection from the piston rods of hydraulic cylinders, locking pins and column holes.

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3

Storage

Storage These instructions give a basis to prepare your fast opening filter press for storage. CAUTION .

Site specific details can vary and must be taken into consideration by the client. These instructions do not overrule local operating instructions or regulations.

3.1

Storage of the machine CAUTION

.

When preparing the machine for storage, all liquid must be removed from the machine parts to prevent freezing, corrosion and other damage. Use appropriate means, such as greasing and waxing, to protect all bright or uncoated parts.



Minimum temperature: -15 °C



Maximum temperature: +65 °C

The storeroom must be dry, shady and kept at a constant temperature. Solvents, oils or paints cannot be stored in the same room. Protect filter plates from frost, direct sunlight or heat. Make sure they do not come into contact with oil or solvents. 

Depressurize all pipelines.



Close the plate pack but do not seal it.



Position the pinch valves to be in open position to avoid formation of pinch valve hose.



Turn the main switch in off position and lock it.



Check the purity of the filter and the surrounding equipment. If needed, wash all equipment well to prevent corrosion. Note the IP rating of equipment when cleaning the filter and use only proper methods for cleaning.



Cover the filter with tarpaulin.

3.2

Storing filter plates

The filter plates are delivered lying flat on pallets if they are not installed onto the machine. 

Remove the packing and undo the wrapping tape (be careful when using sharp or hard tools).



Check every filter plate for transport damage.

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

Store the plates horizontally on a smooth surface. Handle the filter plates with care.



Protect synthetic material filter plates from solvents, frost, direct sunlight or heat. Store them in a dry and shady place at a constant temperature.



Install only undamaged and flawless filter plates on the machine.

3.3

Storing soft rubber diaphragms



Soft rubber diaphragms must be packed on pallets or in crates stacked in a flat plane. When packing the diaphragms on pallets, use several layers of corrugated board and wood ledges to protect the edges, and then band the diaphragms with packing hoop steel. Put cardboard layers between the individual diaphragms.



Transport and store pallets or crates with diaphragms only with the diaphragms lying flat and do not pile up the loaded pallets. Avoid compression, friction and shock stresses.



Unpack the rubber diaphragms carefully one by one.



Store them in darkened rooms which are kept at a moderate temperature. The best storage temperature is 12…25 °C. The air moisture has no influence on the physical properties.



Put the diaphragms flat one upon the other with layers of strong cardboard in between them (if possible, on a flagged floor), but do not stack more than five diaphragms.



As for the rest, we refer you to the guidelines of the DIN 7716 standard "Caoutchouc and rubber products -requirements for storage, cleaning and maintenance" and, in particular, to par. 3 and 4 of the DIN 7716 standard if the storage will last longer than six months. If these prescriptions and requirements are complied with, the usability of the diaphragms will not undergo any substantial change within a two years' storage time.



In case of a longer storage time, also protect the diaphragms against damage with strong tarpaulins.

3.4

Storing hydraulic unit



Disconnect the hydraulic power pack from the electric power supply.



Make sure the hydraulic power pack is unpressurized.



Fill up the oil reservoir almost full (two centimeters from the top level). The purpose of this is to reduce air volume in the reservoir and avoid condensation.



Remove the air breather and plug the connection of the reservoir.

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3.5

Storage

Storing spare parts

Keep the spare parts always in clean and dry conditions. Think about using moisture protective products such as Zerust bags, capsules or spray. If there is a contradiction between this instruction and that of the part manufacturer, always obey the latter.

3.5.1

Hydraulic equipment WARNING

Hydraulic pressure warning! Storing a hydraulic cylinder filled with oil is very dangerous because a temperature raise can develop extremely high hydraulic pressure inside the cylinder. This may lead to death or serious injury when opening the ports.

For short time storing, store the hydraulic equipment as delivered. If you are storing for longer periods and/or using repairable assemblies, obey these guidelines: Store hydraulic pumps and motors: 

Indoors in dry and clean conditions.



Inside a Zerust bag or similar.



Ports are plugged.



Rotate the shaft 10 revolutions every 3 months.



Is drained of oil.

Store hydraulic cylinders: 

Indoors in dry and clean conditions.



Inside a Zerust bag or similar.



Make sure the ports are plugged.



Make sure the cylinder is fully retracted.



Protect the chrome left visible on the piston from corrosion for example with a Zerust spray or Denso tape.



Extend and retract the piston 10 centimeters every 6 months.



Rotate the cylinder 90° every month if stored horizontally.



Drain the cylinder of oil.

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3.5.2

ECFN-OUT-MC-P015-MAN-00001 Transportation and Storage

Rubber parts

The properties of rubber parts deteriorate during storage. Careful keeping helps to keep the damages minimal. Temperature The storage temperature maximum is +25 °C. If the storage temperature is below +15 °C, handle the rubber parts carefully as they can stiffen and be twisted. Humidity The surrounding air should be dry. Prevent water from condensing on the products. Light Protect the products against direct sunlight and ultraviolet light. Oxygen and ozone Remove equipment developing ozone from the store room. Minimize the store room ventilation. Deformation Store the rubber and polyurethane parts (diaphragms, plate seals, rollers, scrapers, hoses) free of tension; straight, not rolled. If you must roll these parts, make the coils as large as possible. Solutions and solvent vapors Protect the rubber parts from chemical solutions and solvent vapors. Stock circulation Keep the storing times of the rubber parts as short as possible. Use the first in, first out principle. Rodents and insects Protect from pests and vermin. Metals Prevent contact with metals (such as copper, iron, manganese), as these may cause rubber to deteriorate when in contact.

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Storage

Different rubber qualities Prevent different rubber qualities from touching. Refer to Table 2 below for storage period recommendations of different rubber types. For example natural rubber parts can be stored for 5 years after which they must be inspected. If no defects are found, the part qualifies for additional 2 years of storage time.

Table 2.

Storage periods of unassembled rubber components in ISO 2230:2002

Rubber types

Storage period

Group A Natural rubber, polyisoprene, polyurethane, polybutadiene, SBR

5 years + 2 years extension

Group B Nitrile, butyl, neoprene

7 years + 3 years extension

Group C EPDM, silicone, chlorosulphonated polyethylene, fluorocarbon

10 years + 5 years extension

For more information, refer to standards ISO 2230 and DIN 7716.

3.5.3

Hose assemblies

In addition to general rubber storing instructions, pay attention to the following: Plugs When storing hydraulic hoses, do not remove protection such as plugs or wrap from the hose heads. Please refer to hose specifications for more specific instructions.

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3.5.4

Storage

Hydraulic hoses

Please familiarize yourself with standards such as BS 5244, ISO/TR 17165-2 or DIN 20066 to secure the safe storage and utilization of spare part hydraulic hoses. Keep in mind that a hydraulic hose as any rubber product has a maximum shelf life. See Table 3 and Table 4 below for more details.

Table 3.

Shelf life according to BS 5244

Age

Recommended Action

< 3 years

No testing required

3 – 5 years

Proof pressure test

5 – 8 years

Proof, impulse and burst pressure tests, cold bend test, electrical test

> 8 years

Scrap

Table 4.

Service life according to DIN 20066

Age

Recommended Action

< 2 years

Maximum storage period

< 6 years

Maximum service life

> 6 years

Scrap

DIN 20066 limits the shelf life of hose assembly to 2 years. Total service life (including the storing) cannot exceed 6 years.

3.5.5

Conveyor belts

Please refer to standard ISO 5285 for the storage of conveyor belts.

3.5.6

Electronic parts

Electronic parts must be stored stocked indoors and in their original packages to avoid damage, for example because of static electricity. Obey the following instructions: Temperature The storage temperature is +5 °C…+40 °C. Humidity Avoid high moisture contents in the surrounding air. Prevent water from condensing on the products.

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Storage

Light Protect the products against direct sunlight.

3.6

Machine restart after long term storage



Do an inspection of wearing parts and replace worn out wearing parts.



Clean the waxed surfaces and remove the motor hoods (inhibitor plastic).



Drain an additional amount of hydraulic oil to get to the correct oil level. Make sure that the oil is in correct condition. Replace the oil if necessary.



Reinstall the air breather into the oil reservoir.



Follow the commissioning instructions in this manual.

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation Operation Maintenance and Service Manual Installation Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Installation

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

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Date

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Date

Checked

Name

Date

Revision Text

Released

Status:

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Preliminary

A4

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Project Phase:

Site No.:

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Replaces: Document Title:

INSTALLATION

PF1226, PF16/19 M12 45 Equipment No:

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IOMS MANUAL

PF1226

Language: EN

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Contents Contents ................................................................................................................ 3 1

Safety ........................................................................................................... 5

2

Unpacking ................................................................................................... 6 2.1

3

4

Checking delivery .............................................................................6

Lifting ........................................................................................................... 7 3.1

Bed and vat lifting.............................................................................9

3.2

Foundation plate lifting ...................................................................10

3.3

Lower pressing plate lifting ............................................................11

3.4

Quick action cylinder lifting ............................................................12

3.5

Column lifting .................................................................................13

3.6

Filter plate lifting .............................................................................14

3.7

Top pressing plate lifting ................................................................15

3.8

Front vat lifting ................................................................................16

3.9

Small cake chute lifting ..................................................................17

3.10

Cloth tensioning unit lifting .............................................................18

3.11

Upper body lifting ...........................................................................19

3.12

Cloth drive unit lifting ......................................................................20

3.13

Pipe lifting .......................................................................................21

3.14

Cake chute lower part lifting ...........................................................22

3.15

Cake chute upper part lifting ..........................................................23

3.16

Cake chute lifting............................................................................24

3.17

Shield lifting ....................................................................................25

3.18

Water station lifting.........................................................................26

3.19

Hydraulic unit lifting ........................................................................27

Installing .................................................................................................... 28 4.1

Installation readiness check list .....................................................28

4.2

Bed and vat installation ..................................................................29 4.2.1

4.3

Load cell installation (optional) ................................................ 29 Foundation plate installation ..........................................................30

4.3.1

Filter leveling ............................................................................ 30

4.4

Lower pressing plate installation ....................................................33

4.5

Column installation .........................................................................34

4.6

Filter plate installation ....................................................................35

4.7

Top pressing plate installation .......................................................36

4.8

Front vat installation .......................................................................37

4.9

Filter plate guides installation .........................................................38 4.9.1

Suspension plate installation ................................................... 39

4.9.2

Slide piece installation ............................................................. 41

4.10

Small cake chute installation ..........................................................43

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4.11

Cloth tensioning device installation ................................................44

4.12

Upper body installation ..................................................................45

4.13

Cloth drive installation ....................................................................46

4.14

Piping installation ...........................................................................47

4.15

Cake chute installation ...................................................................49

4.15.1

Cake chute assembly............................................................... 50

4.16

Shield installation ...........................................................................51

4.17

Pressing water station ....................................................................52

4.18

Control panel ..................................................................................52

4.19

Torque for screws and nuts ...........................................................52

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1

ECFN-OUT-MC-P015-MAN-00001 Installation

Safety DANGER .

Read the Safety manual before starting to work with the tasks described in this manual. Safety manual has information of the safe installation of the machine.

CAUTION Before starting installation, use the packing list to check all the items for the filter and all the accessories have been supplied completely and are undamaged. Immediately contact Outotec (Finland) Oy if there are any missing or damaged parts.

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2

ECFN-OUT-MC-P015-MAN-00001 Installation

Unpacking 2.1

Checking delivery

Inspect the machine and accessories after delivery for transport damage. Report any damage immediately to the carrier, insurance company and the supplier. Check the entire delivery against the attached delivery note to make sure it is complete. Please refer to Outotec terms of sale and delivery. The assembly and connection material for the interfaces of the dismounted components is included in the delivery. All the other accessories are appropriately packed and included with the delivery. CAUTION Dispose the packing and insulating material properly and in an environmentally compatible manner. Observe national regulations.

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3

ECFN-OUT-MC-P015-MAN-00001 Installation

Lifting The pressure filter must be lifted slowly because it will not rise quite horizontally. When it is lifted off the platform it tends to move towards its longitudinal axis. During the lifting and the lowering there must be enough room around the filter. Moving on top of the pressure filter (when fixing and loosing lift chains) requires special attention and carefulness. Water or ice on painted surfaces makes them extremely slippery. Leads, cables and other components must not be damaged. . DANGER Falling load hazard. Falling loads cause severe injury or death. Do not stand under a lifted load. Make sure no personnel are under a lifted load.

Squashing hazard. A moving hoisted loads cause severe injury or death. Make sure no unauthorized personnel are in the vicinity of a lifted load.

. WARNING Falling hazard. Falling causes severe injury or death. Moving on the pressure filter, for example when fixing and loosening lift chains, requires special attention and caution. Water or ice can make the painted surfaces slippery.

. CAUTION Incorrect hoisting may also cause damage to the machinery. Do not damage leads, cables and other components when fixing and loosening the lifting equipment

The shafts of the quick action cylinders (4 pieces) are covered with plastic pipes in the factory. Check they are in place. Prevent the shafts from being damaged.

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ECFN-OUT-MC-P015-MAN-00001 Installation

Use appropriate and certified lifting equipment, such as cranes, hoisting slings and hoisting chains. Make sure the condition and lifting class of the lifting equipment is sufficient. Carefully plan your work beforehand. Keep the transport accessories (plywood frame, steel supports and tarpaulin) on the machine during the lift. Lift very slowly and leave enough room around the filter. The filter does not rise quite horizontally. When it is lifted off the platform it usually moves towards its longitudinal axis.

Before lifting the filter check the installation site is as level as possible and that the positions of the fixing holes, pipe inlets and cake chutes of the filter frame are according to drawing “General arrangement” (appendix). Follow the specific lifting instructions for this machine.

NOTE: The lifting pictures below are not definitive. They give the recommended lifting principles and the lifting points with the mass of the component. Components may be different in appearance and configuration, but this does not affect lifting.

Needed lifting tools: 

Crane with correct capacity.



Lifting beam with correct capacity.



Shackles with correct capacity.



Hoisting cloths or chains with correct capacity.



Lifting eyes (the supply can include some, see the packing list) with correct capacity.



Tools for tightening.

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3.1

ECFN-OUT-MC-P015-MAN-00001 Installation

Bed and vat lifting

Bed and vat mass 600 kg.

Figure 1.

Bed and vat lifting

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3.2

Installation

Foundation plate lifting

Foundation plate mass 2300 kg.

Figure 2.

Foundation plate lifting

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3.3

Installation

Lower pressing plate lifting

Lower pressing plate mass 1500 kg.

Figure 3.

Lower pressing plate lifting

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3.4

ECFN-OUT-MC-P015-MAN-00001 Installation

Quick action cylinder lifting

Cylinder mass 200 kg.

Figure 4.

Cylinder lifting

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3.5

ECFN-OUT-MC-P015-MAN-00001 Installation

Column lifting

Column mass 500 kg.

Figure 5.

Column lifting

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3.6

ECFN-OUT-MC-P015-MAN-00001 Installation

Filter plate lifting

Filter plate mass 600 kg. DANGER .

Maximum number of filter plates that can be lifted at the same time is two filter plates. Tie the filter plates together to make sure the top one does not fall during the lift.

Figure 6.

Filter plate lifting

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3.7

Installation

Top pressing plate lifting

Top pressing plate mass 1600 kg.

Figure 7.

Top pressing plate lifting

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3.8

ECFN-OUT-MC-P015-MAN-00001 Installation

Front vat lifting

Front vat mass 110 kg

Figure 8.

Front vat lifting

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3.9

Installation

Small cake chute lifting

Small cake chute mass 200 kg.

Figure 9.

Cake chute lifting

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3.10

Installation

Cloth tensioning unit lifting

Cloth tensioning device mass 700 kg.

Figure 10.

Cloth tensioning unit lifting

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3.11

ECFN-OUT-MC-P015-MAN-00001 Installation

Upper body lifting

Upper body mass 500 kg.

Figure 11.

Top frame lifting

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3.12

ECFN-OUT-MC-P015-MAN-00001 Installation

Cloth drive unit lifting

Cloth drive unit mass 650 kg

Figure 12.

Cloth drive unit lifting

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3.13

ECFN-OUT-MC-P015-MAN-00001 Installation

Pipe lifting

Pipe maximum mass 100 kg.

Figure 13.

Pipe lifting

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3.14

Installation

Cake chute lower part lifting

Cake chute lower part mass 60 kg.

Figure 14.

Cake chute lower part lifting

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3.15

Installation

Cake chute upper part lifting

Cake chute upper part mass 160 kg.

Figure 15.

Cake chute upper part lifting

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ECFN-OUT-MC-P015-MAN-00001 Installation

Cake chute lifting

Cake chute mass 220 kg.

Figure 16.

Cake chute lifting

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3.17

ECFN-OUT-MC-P015-MAN-00001 Installation

Shield lifting

Side shield door mass 50 kg.

Figure 17.

Shield lifting

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3.18

ECFN-OUT-MC-P015-MAN-00001 Installation

Water station lifting

Water station mass 900 kg.

Figure 18.

Water station lifting

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3.19

ECFN-OUT-MC-P015-MAN-00001 Installation

Hydraulic unit lifting

Hydraulic unit mass (without oil) 1000 kg.

Figure 19.

Hydraulic unit lifting

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4

Installation

Installing Refer to the Foundation drawing (appendix) and inspect the foundation before starting the installation. The recommended model for an assembly plate is a so called horseshoe sheet (See appendices, drawing “Instructions for installation” parts 2 and 3), which will be placed around the fixing bolt. 1. Tighten the fixing bolts and check the horizontal position again after adjusting the position of the filter. 2. If the piping work is not done immediately after installing the pressure filter on the platform, cover the pressure filter with the tarpaulin used during the transport.

4.1

Installation readiness check list

In order to facilitate the installation, all answers should be yes.

Table 1.

Installation readiness check list Description

YES

1.

The filter shipment arrived at the site.

2.

Shipment inspected and counted. Possible damages reported to Outotec. NOTE: Do not open the boxes.

3.

The Installation manual and electrical drawings available.

4.

Foundation ready according to Outotec foundation drawing(s). Including floor openings.

5.

Required manpower available according to separate schedule

6.

On site transportation of filter components and auxiliaries available.

7.

Lifting equipment available according to Outotec filter manual (e.g. overhead crane).

8.

Tools available according to Outotec tools list.

9.

Scaffolds or manlift available.

NO

10. Electric power for tools and lifting equipment available. 11. Compressed air for pneumatic tools available. 12. Office including, heating/cooling, lighting, internet, printer, furniture’s, and toilet

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4.2

Installation

Bed and vat installation

Install the bed and vat on the load cells (optional) or on the foundation.

Figure 20.

Bed and vat installation

1. Hex screw M16x70 & M16x50, hex nut M16, washer A16 2. Load cell (installed with hex screw M16x50) / support 3. Hex screw M16, hex nut M16, washer A16 4. Support

4.2.1

Load cell installation (optional)

Reserve maintenance space for the load cells to enable replacement if needed. Refer to Description of equipment 4.4.1 Hardware installation.

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4.3

Figure 21.

Installation

Foundation plate installation

Foundation plate installation

1. Hex screw M20x60, washer M20, spring washer B20

4.3.1

Filter leveling WARNING

.

Make sure you have enough adjusting plates before starting the leveling.

Aligning starts from the lower pressing plate. All the other parts will be aligned in reference to it so it is important to do it correctly. 1. The required leveling tolerance is ± 1 mm and it can be achieved using a theodolite. Use the factory wall to transfer the level to the other side of the filter. Here are few alternative ways to measure the filter level: -

Measure the horizontal level using a measuring stick set vertically on the column pin. This is possible before the columns have been installed.

-

Measure the level from the column pin fixing holes. See Figure 1. Column pin covers must be removed.

-

Measure the level from any machined surfaces on the upper edge of the lower pressing plate.

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Figure 22.

Installation

Column pin fixing holes (1)

2. To correct alignment, lift the lower pressing plate with a hydraulic jack from the lifting points shown in Figures 2 and 3. 3. Install required stainless steel adjusting plates under the feet. Adjusting plates are normally excluded from Outotec delivery.

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Figure 23.

ECFN-OUT-MC-P015-MAN-00001 Installation

Jacking points

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4.4

Figure 24.

Installation

Lower pressing plate installation

Lower pressing plate installation

1. Guide pin 4 pcs, adjusting plate 32 + 24 pcs (extra plates for later adjustments)

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4.5

Figure 25.

Installation

Column installation

Column installation

1. Hex screw M24x100, spring washer B24

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4.6

Figure 26.

Installation

Filter plate installation

Filter plate installation

1. Top suspension plates, suspension plates, retaining rings

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4.7

Figure 27.

Installation

Top pressing plate installation

Top pressing plate installation

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4.8

Figure 28.

ECFN-OUT-MC-P015-MAN-00001 Installation

Front vat installation

Front vat installation

1. The gap between front vat and the foundation is sealed with sealing tape. 2. Washer M16, hex screw M16x40, spring washer B16

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4.9

ECFN-OUT-MC-P015-MAN-00001 Installation

Filter plate guides installation

Correct guide rail (1) alignment is essential for the plate pack sealing. Guide rails are located on both sides of the plate pack. They act as support surfaces for slide pieces attached to the filter plates. Dimensional tolerance for guide rail alignment is 1 mm/m along X-axis and 1 mm/m along Y-axis in reference to plumb line.

Figure 29.

Guide rails

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Figure 30.

Installation

Filter plate guides installation

1. Hex screw M16x70, Washer A16, spring washer B16, hex nut M16 2. Hex screw M16x80, washer A16, Hex nut M16, spring washer B16, adjusting plates if necessary, spring cotters after the alignment of the guides.

4.9.1

Suspension plate installation

1. Assemble suspension plates in their places from top to bottom. Remember to install retaining rings in their places.

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Figure 31.

Installation

Assembly order of the suspension plates

A) Assemble the inner suspension plates (1, 2, 3.). B) Assemble the top suspension plate (1) and the midmost suspension plates (2, 3, 4…)

Figure 32.

C) Assemble the outer suspension plates and retaining rings.

Correct order for suspension plates

2. Make sure that the suspension plates move correctly.

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4.9.2

Installation

Slide piece installation

spanner, size 24 mm

Tape measure

String and tape

Pliers with adjustable jaw

1. Unscrew the fixing nuts and eccentric sleeves and remove the slide pieces. 2. Insert and adjust new slide pieces. Press the filter plates sidewards parallel. Adjust the plates lengthwise with the slide pieces, e.g. dim. A should be biggest possible and the same at both ends of the roller according to the drawing. 3. Tighten as shown by the arrow (counterclockwise). This secures the pressing force on the slide piece does not open the locking nut. 4. Check that the adjusting nut of the eccentric sleeve does not bump into the guide bar support when the plate pack moves.

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Figure 33.

ECFN-OUT-MC-P015-MAN-00001 Installation

Slide piece replacement and adjustment

1. slide piece 2. guide 3. eccentric sleeve 4. nut 5. filter plate

NOTE: Ensure that the slide bar is vertical and flat. If not the slide pieces will wear more rapidly.

Adjust the top two filter plates so that the A dimension is exactly the same. Repeat this for the bottom two filter plates. Then tape a string on the center of the top and bottom roller shaft. Then each side of the filter can be visually checked without needing to use a tape measure.

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4.10

Figure 34.

Installation

Small cake chute installation

Small cake chute installation

1. Hex screw M16x40, spring washer B16, Hex nut M16

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4.11

Figure 35.

ECFN-OUT-MC-P015-MAN-00001 Installation

Cloth tensioning device installation

Cloth tensioning device installation

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4.12

Figure 36.

Installation

Upper body installation

Upper body installation

1. Hex screw M30x70, washer A30, fastening sleeve, hex screw M10x45, M12 hex screw.

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4.13

Figure 37.

Installation

Cloth drive installation

Cloth drive unit installation

1. Hex screw M16x60, spring washer B16, hex nut M16

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4.14

Figure 38.

ECFN-OUT-MC-P015-MAN-00001 Installation

Piping installation

Piping installation

1. Hex screw M16x35, washer A16, hex nut M16 2. Hex screw M16x55, washer A16, hex nut M16

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PF1226, PF16/19 M12 45

Installation

3. Bracket fastener, nyloc nut M8, washer M8 4. Bracket fastener, hex screw M16x65, hex nut M16, washer A16 5. L-coupling clamp DN3, seal, hex screw M10x30, washer M10

Figure 39.

Piping installation, 2

1. Hex screw M16x35, washer A16, hex nut A16 2. Hex screw M16x55, washer A16, hex nut A16

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4.15

Figure 40.

Installation

Cake chute installation

Cake chute installation

1. Hex screw M20

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4.15.1

Figure 41.

ECFN-OUT-MC-P015-MAN-00001 Installation

Cake chute assembly

Cake chute assembly

1. Hex screw M8x30, Hex nut M8 2. Hex screw M8x20, hex nut M8

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4.16

Figure 42.

ECFN-OUT-MC-P015-MAN-00001 Installation

Shield installation

Shield installation

1. Hex screw M12x35, washer A14, hex nut M12, hex screw M16x30, washer A16, hex nut M16 2. Hex screw M16x40, washer A16, hex screw M16

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4.17

Installation

Pressing water station

The fixing and lifting points of the pressure water station can be seen on the drawing “Water station” (appendix). The horizontal tolerance for the pressure water station is 2 mm/m. Measure from the frame bar of the pressure water station.

4.18

Control panel

The control panel is delivered in a plywood box. The control unit weighs about 200 kg. The lifting loops are located on top of the control panel. The fixing holes of the control panel are inside the control panel. Leave the bag containing moisture aspirating material inside the control panel until the start-up. Keep the protective window closed when filter is running normally. If the piping etc. installation work is carried out near the control panel, it must be covered against dust and dirt.

4.19

Torque for screws and nuts

Pre-stress approx. 80% of minimum yield limit.

Table 2.

Torque for screws and nuts

Thread

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

M36

Strength class

Tensioning torque Nm(Nm ≈ 0.1 kp m ≈ 0.1 kgm)

A4-80

7.8

19

36

65

103

160

230

320

445

570

840

1170

1980

8.8

11

25

48

80

125

190

265

350

480

590

960

1290

2270

The values in the table require a friction coefficient of µ1 = 0.12, µ2 = 0.12, which correspond to a lightly oily surface – seizing deterrent must be used in all screw joints unless otherwise instructed. µ1 = friction coefficient of the thread µ2 = friction coefficient between the base and the screw (nut) head

NOTE: The screws for the filter plate/frame have their own torque value.

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ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Commissioning and Start-up Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001 Commissioning and

PF1226, PF16/19 M12 45

Start-up

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

COMMISSIONING AND START-UP

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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PF1226, PF16/19 M12 45

ECFN-OUT-MC-P015-MAN-00001 Commissioning and Start-up

Contents Contents ................................................................................................................ 3 1

Start-up inspection ..................................................................................... 4

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ECFN-OUT-MC-P015-MAN-00001 Commissioning and

PF1226, PF16/19 M12 45

1

Start-up

Start-up inspection CAUTION Make sure the safety systems are installed to the filter and auxiliary equipment before start-up.

In order to carry out the filter start up, following issues have to be ready and completed. 1. Filter is installed and no pending actions found in mechanical assembly inspection list. 2. Filter electrification is installed and tested, no pending actions in safety- or automation check lists. 3. Hydraulic unit reservoir filled with oil meeting Outotec’s recommendation. Refer to the Maintenance chapter for more information. 4. Mechanical test run has been completed without pending actions. 5. Hydraulic oil cleanliness is checked after mechanical test run and inside required limits. 6. Return filters of the hydraulic unit have been replaced after mechanical test run. 7. Hydraulic system is ready for operation. 8. Process pipelines are connected and system meets Outotec’s recommendation. 9. Process isolation valves are installed. 10. Cake handling system is ready and meets Outotec’s recommendation. 11. Filter cloth wash liquid is available. 12. Hose / cake wash liquid is available. 13. Compressed air is available and quality and capacity meets the Outotec’s recommendation. 14. Start-up spare part kit available.

The filter is now ready for first filtration runs and parameter adjustments. Filter automatic mode production test run will be done after adjustments. When the steps above have been completed, the filter is ready for operation and can be started according to the “Operation instructions” chapter in this manual.

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ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Operation Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Operation

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

OPERATION

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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PF1226, PF16/19 M12 45

ECFN-OUT-MC-P015-MAN-00001 Operation

Contents Contents ............................................................................................................................. 3 1

Intended use ............................................................................................................ 5

2

Recommended operating conditions .................................................................... 6

3

Starting and stopping ............................................................................................. 7 3.1

Starting the filter ......................................................................................... 7 3.1.1

Start-up from complete shutdown ......................................................... 7

3.1.2

Start-up from standby shutdown ........................................................... 8

3.1.3

Start-up from power failure ................................................................... 8

3.1.4

Start-up from emergency shut down ..................................................... 8

3.2

4

Stopping the filter ....................................................................................... 9 3.2.1

Complete shutdown .............................................................................. 9

3.2.2

Standby shutdown ................................................................................ 9

3.2.3

Emergency shutdown ........................................................................... 9

Normal operation ................................................................................................... 10 4.1

Checks after start-up ................................................................................ 11

4.2

Control panel ............................................................................................ 13

4.3

Operator interface .................................................................................... 15 4.3.1

Screen selection ................................................................................. 15

4.3.2

Operator interface structure ................................................................ 16

4.3.3

Cleaning the touch screen .................................................................. 16

4.3.4

Drive mode .......................................................................................... 17

4.3.5

Process ............................................................................................... 18

4.3.6

Filter .................................................................................................... 19

4.3.7

Recipe ................................................................................................. 20

4.3.8

Changing the recipe ............................................................................ 22

4.3.9

Parameters screens ............................................................................ 22

4.3.10

Messages ............................................................................................ 24

4.4

Switching on the voltage .......................................................................... 25 4.4.1

4.5

Description of the indicator light functions .......................................... 26 Test mode ................................................................................................ 27

4.5.1

Safety system description ................................................................... 27

4.5.2

Safety functions .................................................................................. 28

4.5.3

Test selector S714 .............................................................................. 35

4.5.4

Push buttons S725 and S723 ............................................................. 36

4.5.5

Restrictions in testing the actuators .................................................... 37

4.5.6

List of symbols in handheld test unit ................................................... 37

4.6

Manual mode ........................................................................................... 38

4.7

Automatic mode ....................................................................................... 41 4.7.1

Stopping the filter ................................................................................ 43

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PF1226, PF16/19 M12 45

4.7.2

5

ECFN-OUT-MC-P015-MAN-00001 Operation

Restarting the filter with automatic mode............................................ 43

4.8

End mode ................................................................................................. 44

4.9

Reset mode .............................................................................................. 45

4.10

Cloth tracking ........................................................................................... 46

4.11

Operation stages of Outotec Larox pressure filter ................................... 49

Alarms and troubleshooting ................................................................................ 52 5.1

Indications and alarms in safety relay KA100 .......................................... 52

5.2

Malfunctions and alarms .......................................................................... 53 5.2.1

General ............................................................................................... 53

5.2.2

Alarm acknowledgement..................................................................... 53

5.3

Alarm functions ........................................................................................ 55

5.4

Troubleshooting ....................................................................................... 61

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PF1226, PF16/19 M12 45

1

ECFN-OUT-MC-P015-MAN-00001 Operation

Intended use 

The machinery is intended for automatic use.



Purpose of the machinery is to separate solids from liquids in the process media.



The machinery is solely intended for professional use.



The machinery is operated by trained professionals.



The machinery can be operated remotely from a control room or locally from the control panel. All machine functions are controlled by integrated PLC.



Maintenance is to be done by trained professionals. Maintenance tasks require skills to operate the machinery with a manual hand-held unit.

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ECFN-OUT-MC-P015-MAN-00001 Operation

Recommended operating conditions Ambient temperature: 0 °C … 50 °C

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

3

Operation

Starting and stopping 3.1

Starting the filter

Do the following checks before starting the filter. 

Make sure the condition of the filter cloth seam is good.



Make sure the duration of all the operational stages agree with the optimal times achieved in test filtration or test runs.



Make sure no ladders or other objects touch the filter.



The filter’s first lubrication is performed by Outotec before the first test run, though it is recommended to lubricate items with an interval of week or less before starting the production run. Otherwise follow the lubrication intervals found in Lubricant recommendations chapter. CAUTION Pieces of filter cake left in between the sealing surfaces might damage the filter cloth. Make sure the spaces between the plates are clean before the plate pack is closed.

3.1.1

Start-up from complete shutdown

Filter has been shut down and power is switched off from main switch HS1EB11FL on the control panel. 1. From the control panel turn the main switch HS1EB11FL to “ON”. 2. Check and close the filter doors and acknowledge the alarms with push buttons HSI2FL141 and HSI2FL121. 3. From the control panel push ACKNL / ALARM button HSI4CB11FL to acknowledge the alarms. 4. From the control panel turn the MODE SELECTION switch HS6CB11FL to “A”. 5. From the control panel turn the HYDRAULIC UNIT switch HS7CD11FL to “1”. 6. From the OIU screen select AUTO mode. 7. On the control panel wait until the START button HSI2CB11FL begins flashing slowly and push it to start the filter.

NOTE: If any of the alarm lights are on or the emergency stop push-button is pushed down, the "ready for operation" indicator lamp does not illuminate.

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

3.1.2

Operation

Start-up from standby shutdown

Filter has been stopped for brief period of time. No alarms are triggered and on the control panel START push button HSI2CB11FL is flashing slowly. 1. From the control panel push FILTER START button HSI2CB11FL to start the filter.

3.1.3

Start-up from power failure

Filter status is STOP. The filter PLC will remember the stage before power failure and will continue from it. 1. Close the filter doors and push buttons HSI2FL141 and HSI2FL121 to acknowledge the alarms. 2. From the control panel push ACKNL / ALARM button HSI4CB11FL to acknowledge the alarms. 3. From the control panel turn the HYDRAULIC UNIT switch HS7CD11FL to “0” and back to “1”. 4. From the control panel turn the MODE SELECTION switch HS6CB11FL to “A”. 5. From the OIU screen select AUTO mode. 6. On the control panel push START button HSI2CB11FL to start the filter.

3.1.4

Start-up from emergency shut down

Filter has been stopped with an emergency stop switch. 1. Verify the reason for shut down is resolved. 2. Release the emergency stop switch used to stop the filter 3. From the control panel push ACKNL / ALARM button HSI4CB11FL to acknowledge the alarms. 4. From the control panel push the FILTER START button HSI2CB11FL to start the filter.

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

3.2

Operation

Stopping the filter CAUTION

Secure the inlet process valves on the filter and the main switch HS1EB11FL on the control panel against accidental switch-on before maintenance work. Use the appropriate lockout-tagout procedures.

3.2.1

Complete shutdown

Follow the steps below to shutdown the filter for maintenance or for longer period of time. 1. From the OIU screen select END mode. 2. Wait until the status shown on the screen is STOP.

NOTE: Make sure the filter completes the END mode. In case of an alarm resolve the issue and acknowledge the alarm. Select AUTO mode and press START and select the END mode again. 3. From the control panel turn the HYDRAULIC UNIT switch HS7CD11FL to “0”. 4. From the control panel turn the MODE SELECTION switch HS6CB11FL to “0”. 5. From the control panel turn the main switch HS1EB11FL to “OFF”.

3.2.2

Standby shutdown

This is intended for only short stopping of the filter. In case longer stop is needed it is highly recommended to follow the complete shutdown process. 1. From the control panel push the FILTER STOP button HSI3CB11FL. The push button will illuminate to indicate the filter has stopped.

3.2.3

Emergency shutdown

Using the emergency shutdown will put the filter in safe state. 1. From the control panel push EMERGENCY STOP button HZ(I)1CB11FL or use any other emergency stops installed on the filter.

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4

ECFN-OUT-MC-P015-MAN-00001 Operation

Normal operation Monitor the variables below and adjust the filter and the process to get the best results in all steps of the process. Filtration: 

The filterability of the slurry.



The condition of the filter cloth.



How open the filtrate channels are.

Quantity of the filter cake: 

The solid contents of the slurry.



The feed line pressure.



The filtration time.

Dryness of the filter cake: 

The particle size of the slurry.



The pressing pressure.



The drying air pressure.



The air drying time.

Cake washing: 

The wash liquid pressure.



The filter cake washing time.



The wash liquid properties.



The filter cake permeability.

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

4.1

Operation

Checks after start-up

In order to reach the best possible results pay attention to the following: 1. When the slurry valve opens, monitor the pressure. If the pressure does not increase, check the following equipment. 

There are closed valves on the slurry pipeline.



A pipe is blocked.



Slurry pump does not operate correctly.

2. A leakage between the filter plates during the filtration stage is a sign of following faults. 

A seal is damaged.



The filtrate piping is clogged.

3. Monitor the pressure of the water station. 4. When the “cake washing” starts, monitor the wash liquid pressure. If the pressure does not increase, check the following equipment: 

There are closed valves on the feed pipeline.



A pipe is blocked.



The wash liquid pump malfunctions.

5. A sufficient quantity of compressed air is necessary to dry the filter cake. Make sure that at the start of the “cake drying” the pressure of the distribution pipe is 0.3 MPa (3 bar) or more. 6. During cake discharge, make sure there is a filter cake on each filter plate. An empty space is a sign of a problem: 

Blockage in the feed hose or in the feed joint of the filter plate. CAUTION Blockages can cause the empty filter plates to bend under the pressure. Clear all blockages before carrying on with filter operation.

7. Monitor the condition of the filter cloth. An acid washing is sometimes necessary. 8. Monitor the filter cloth to make sure it is not damaged. A damaged filter cloth must be repaired immediately to prevent the particles from going through a broken filter cloth out of the filtrate flow channels. 9. Monitor the diaphragms: do not let them become damaged. 10. Always use the lowest possible pressure to get the necessary results. If you use too high pressure, the life of the diaphragm and other wearing parts becomes shorter.

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PF1226, PF16/19 M12 45

Operation

11. Do not put too much material into the filter. The maximum filter cake thickness is 40 mm for 45 mm high filtration chambers, and 55 mm for 60 mm filtration chambers. The risks of too much load are: 

Feed lines get clogged.



The filter cake discharge becomes hard.



If the material is heavy, the filter cloth can break. DANGER Do not feed too much slurry into the filter to avoid damage.

12. Do not let the feed lines to get clogged up. An empty filtration chamber during pressuring stage bends the filter plate. It can cause leaks in the filter plate, holes in the filter cloth and make the filter cake discharge hard. DANGER Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never push anything in between the plates while the filter is in operation.

13. Rubber starts the aging process in temperature above +60 °C. If the temperature of the slurry is more than +60 °C, monitor the temperature and obey the instructions of the manufacturer. DANGER Do not direct the pressure-water spray directly at the electrical devices when washing the filter.

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PF1226, PF16/19 M12 45

4.2

ECFN-OUT-MC-P015-MAN-00001 Operation

Control panel

The control panel is used to facilitate the operation of the Outotec Larox pressure filter. The control panel incorporates switches, push buttons and an operator interface terminal, which are required for the operation. Each push-button, switch and indicator lamp is provided with a label briefly describing the function of the device. The flow diagram is located in the display of the operator interface terminal. The indicator lamps show the present state of the actuator or motor in question.

Figure 1.

Operator interface terminal with a flow diagram

The control panel is illustrated on the following page.

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R S D C 5 V F R C E R U N S O T P

DC2

DC3

L N PE

Running No: 2

3

DI

4

DI

5

DI

6

DI

7

DI

8

DI

9

DI

10

DI

D U MM Y 1 1

2

3

4

5

Revision:

0

7

8

9

1

2

AO AO

X9

KA101

X207

D U MM Y 2 END

F11

2

PE/FE

KA121

3

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Outotec Document ID: OU750009576 FOR APPROVAL

REV. F REV. G REV. H

REV. C

REV. D

X

DRN

DATE

APPR

CHD

Customer name

S700 PÄÄ KYTKIN

S710 STAR T / KÄYNNISSÄ

J Ä NN I T E S YÖ T Ö T E NN E N H U O L T O T Ö I T Ä .

PÄÄKYTKIN EI KATKAISE APUJÄNNITTEITÄ (ORANSSIT JOHTIMET)

S708 SEIS/PYSÄ HTYNYT

S733 KUITT AUS / HÄLYTYS

OIU

H1

S710 S708 S733

J Ä N N I T T E E L L I S IÄ P II R E J Ä . K Y T K E P O IS

VAROITUS:

S700

S701

S701 HÄTÄSE IS

4

0

S780

T ES T

AUTO / TESTI

S780

A

1

S755

0

HYDRAULI IKK A YKSIKKÖ

S755

5

V *

S702

4 5 6 7 8

S725 ACKNL V0* UP/FWD

A V M X1 X2 X3

M

40 M03& M03 M04 M07 M02 M05

S723 START V1* DN/REV

AC T SE LECTO R

S714

1 2 3 X

A

EMERGENCY STO P

HANDHELD-UNIT HH

7

8

Location

Serial no

Filter type

+

=

PF 12

Drawing number

Project number

OIU = OPERATOR INTERFACE UNIT CPU = LOGIC CPU ETH = ETHERNET CARD PRO = PROFIBUS CARD SW1 = ETHERNET SWITCH H1 = ALARM BEACON H2 = CABIN LIGHT / SOCKET C1 = COUNTER KA1** = EMERGENCY STOP RELAYS T1= POWER SUPPLY 24 VDC AC.X1= VOLTAGE SUPPLY 230VAC AC.X2 = VOLTAGE DISTRIBUTION 230VAC FOR X2 X8.*,X207 = TERMINALS FOR EMERGENCY STOP CIRCUITS FAC* = VOLTAGE DISTRIBUTION 230VAC (AUTOMATIC FUSES) N1.1 = NEUTRAL FOR 230VAC FDC*/ F** = VOLTAGE DISTRIBUTION 24VDC (AUTOMATIC FUSES) DC* = VOLTAGE SUPPLY 24VDC 0VDC = TERMINALS FOR 0VDC I/O MODULES = BUS UNIT AND REMOTE I/O MODULES PE = POTENTIAL EARTH TERMINALS FE = FUNCTIONAL EARTH TERMINALS X9 = TERMINALS FOR I/O S700= MAIN SWITCH S701 = EMERGENCY STOP PUSH-BUTTON S708 = STOP PUSH-BUTTON S710 = START PUSH-BUTTON S733 = ALARM RESET PUSH-BUTTON S755 = HYDRAULIC UNIT MODE SWITCH S780 = MODE SELECTION (AUTOM. - TEST MODE)

Control cabin layout, LOG_SI

Page description

6

9

Page

X1

Location

1

Copyright (c) 2010 Outotec Oyj. All rights reserved

CERTIFIED

PRELIMINARY

REV. E

REV. B

PANEL MEASURES : (1800x800x400) mm + socle (100x800x400) mm MATERIAL : MILD STEEL, RAL9022 IP66, NEMA4

X8.8

6

DO DO DO DO DO DO DO DO DO

I/O MODULES

DI

1

C1

SW1

KA120

F1-9

KA100

0VDC

T1

X8.7

X8.2 X8.4 X8.6

DI

H1 H2

KA130

L N PE

X8.1 X8.3 X8.5

AC.X1

S700 AC.X1 AC.X2

FD C* DC1

D C

FAC* N1.1

ETH

S I M A TI C S 7-30 0

R U N S T O P M R E S

CPU PRO

1

AC.X2

Document Type: KA110

1 0B Y5

KA111

Plant Unit Code: M0 1

Plant Code: 3

9

Project ID: 2

0

Figure 2. 1

REV. A

0

PF1226, PF16/19 M12 45

ECFN-OUT-MC-P015-MAN-00001 Operation

Control panel

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

4.3

Operation

Operator interface

Controlling and observing the operation of the filter, choosing the required filtering recipe, changing parameters and testing actuators are operated through the operator interface. In addition, the operator interface gives clear text information about alarms.

4.3.1

Screen selection

Touch buttons are used to select screens. Never use objects like a screwdriver, pencil etc. to activate a touch button. The screen needs to be touched lightly and for an instant only. Some screens may seem to have a slight delay before performing the function requested, so it is a good idea to have a pause before touching again.

Figure 3.

Screen selection

The HELP touch button [?] is always located in the top right hand corner of the display. When this area is touched, a screen containing the requested information is displayed. To quit any HELP screen, the Previous screen touch button is used. This touch button is always located in the top left hand corner of the display. The available screens of the operator interface are illustrated in a form of a diagram on the following page.

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PF1226, PF16/19 M12 45

4.3.2 PROCESS HELP

FILTER HELP

PROCESS

FILTER

Operation

Operator interface structure

MODE POP-UP

RECIPE HELP

PARAMETER HELP

REPORT HELP

TOOLS HELP

RECIPE

PARAMETER1

REPORT

TOOLS

ALARM & ALARM HISTORY HELP

ALARM 1 HELP ALARM 1 HELP ALARM 1 HELP ALARM 1 HELP

ALARM HELP

PARAMETER2 DIRECT ACCESS SCREENS*

HELP

PRESSURE GRAPHS

INPUT STATUS

SCREEN CLEAN

ALARM HISTORY

LAST ALARM HELP

OUTPUT STATUS

HISTORY

PASSWORD

SYSTEM CONFICURATIO N

Figure 4.

Operator interface structure

*) Direct access screens (inside the grey frame) can be accessed directly from any screen inside the frame or linked to it.

4.3.3

Cleaning the touch screen

It is an essential part of the unit maintenance to keep the screen clean. Even if great care is taken to touch the display with clean hands only, dirt will still collect on the display surface. For cleaning of the display (since all screens have at least some part of the display active), a screen has been programmed into the display unit. This screen is accessed from the TOOLS screen and it is called the Screen cleaning [CLS]. After the selected time the display will automatically return to the FILTER screen.

Figure 5.

Cleaning the screen

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ECFN-OUT-MC-P015-MAN-00001 Operation

To clean the display, use a soft cloth or paper towel and any ordinary window cleaner. To help prevent damaging the plastic sheet on the surface of the display, carefully clean off any abrasive particles on the display surface, and then clean as advised above.

4.3.4

Drive mode

Figure 6.

Filter mode

Use the [MODE] touch button to select a filter mode. Following ones are available:

Table 1.

Filter modes

AUTO

The filter operates using the preset recipe stage times.

MANUAL

The filter can be operated one stage at a time. This mode is used e.g. for optimizing the stage times.

END

When this mode is selected, the filter stops at the end of the cycle. This is used whenever the operator wishes to stop a filter running in auto mode.

RESET

Is used to reset filtering cycle. In this case the filter starts filtering in a controlled manner from the very first stage.

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

4.3.5

Operation

Process

Figure 7.

Process screen

The PROCESS screen displays the main devices of the filtering process as well as the process diagram. In addition to the filter and the pressing water station, the slurry tank with level information, feed slurry pump, and cake conveyor are displayed. The rest of the basic screens can be accessed by means of the touch buttons in the lower part of the display. The filter mode can also be selected directly from this screen. List of symbols on the PROCESS screen:

Table 2.

Symbols on process screen

M02

Pressing water pump motor

V13

Pressing water tank filling valve

M06

Cloth wash liquid pump motor

V16

Drying air control valve

M08

Cake conveyor motor

B415

Feed manifold pressure

M09

Slurry feed pump motor

B419

Pressing manifold pressure

M15

Cake wash liquid pump motor

S516

Pressing water level

V02

Slurry inlet valve

B516

Pressing water tank level

V04

Pressing water outlet valve

B491

Cloth wash water pressure

V05

Cake wash liquid inlet valve

B921

Cloth wash water flow

V06

Drying air inlet valve

SLOK

Slurry tank level OK

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

V07

Manifold drain outlet valve

V09

Cloth wash liquid inlet valve

4.3.6

Operation

SLLOW

Slurry tank level, min.

Filter

Figure 8.

Filter screen

List of symbols on the FILTER screen:

Table 3.

Symbols on filter screen

B415

Feed manifold pressure

Y51X

Plate pack balancing

B419

Pressing manifold pressure

Y61

Locking pins unlocked

PT1HU

Hydraulic pressure

Y62

Locking pins locked

TT1HU

Hydraulic oil temperature

Y71

Unsealing

PT2HU

Line 2 pressure

Y72

Sealing

LT1HU

Hydraulic oil surface

Y81

Cloth slackening

B505M

Plate pack open

Y82

Cloth tensioning

B505C

Plate pack closed

Y91

Cloth drive forward

S16*

Locking pins unlocked

Y92

Cloth drive reverse

S26*

Locking pins locked

M1HU

Hydraulic unit motor

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PF1226, PF16/19 M12 45

ECFN-OUT-MC-P015-MAN-00001 Operation

S171

Seal plate position

R1HU

Hydraulic oil heater

S332

Cloth seam detector

M3HU

Hydraulic oil cooler

Y41

Tracking cylinder up

Y51

Plate pack opening

Y42

Tracking cylinder down

Y52

Plate pack closing

4.3.7

Recipe

Figure 9.

Recipe screen

The RECIPE screen displays the filtering recipes the filter is provided with. The preset recipes (max. 10) can be scrolled, modified and activated. The [PREV] and [NEXT] touch buttons are used to scroll the recipes. The title of the recipe is displayed in the RECIPE field above the [ACTIVATE] button (the first 18 letters). To modify the control data, log in on TOOLS screen and enter username and password. After log in you are able to select the value to change it. A new value is set accordingly. Use the arrow keys in the numerical keyboard in order to move to the previous/next stage or simple just touch the value you want to change. [CLR] is used to delete the field indicated by the cursor.

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Figure 10.

ECFN-OUT-MC-P015-MAN-00001 Operation

LOG IN on tools screen

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

4.3.8

Operation

Changing the recipe

Figure 11.

Changing the recipe screen

The displayed recipe is activated by the [ACTIVATE] button. Confirmation screen is now displayed. Push [YES] to accept and [NO] to disregard. The text field RECIPE (SELECTED FOR USE) in the upper part of the RECIPE screen displays the selected recipe. The selected recipe will be selected for use at the end of the ‘plate pack closing’ stage. The rest of the basic screens can be accessed directly using the touch buttons in the lower part of the display.

4.3.9

Parameters screens

The PARAMETER screens display the filter control parameters that are valid for any recipe. The parameters are distributed between two screens, which can be scrolled by means of the [PAGE 1] and [PAGE 2] touch buttons.

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Figure 12.

Parameter 1

Figure 13.

Parameter 2

ECFN-OUT-MC-P015-MAN-00001 Operation

To modify the values, log in on TOOLS screen and enter username and password. After log in you are able to select the value to change .A new value is set accordingly.

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ECFN-OUT-MC-P015-MAN-00001 Operation

Use the arrow key in the numerical keyboard in order to move to the previous/next parameter or simple just touch the value you want to change. [CLR] is used to delete the field indicated by the cursor. The RECIPE field of the PARAMETER screen displays the title of the active recipe. The rest of the basic screens can be accessed directly by means of the touch buttons in the lower part of the display. Filter mode can also be selected directly from this screen.

4.3.10 Messages

Figure 14.

Messages screen

The Outotec Larox pressure filter control system informs the operator about a number of operating situations by means of a message runner at the bottom of the screen, the color of which is green. These kinds of situations are, for example, such in which the filter seems to have stopped without any visible reason, like when waiting for discharge permission or some level information. The message text tells the reason for the message. The messages automatically disappear as soon as the cause for a message is eliminated.

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

4.4

Operation

Switching on the voltage HSI2CB11FL START / RUN

HZ(I)1CB11FL EMERGENCY S TOP

HSI3CB11FL STOP / STOPPED

HS6CB11FL HYDR AULIC UNIT

HS5CB11FL MODE SELECTION

HSI4CB11FL ACKNL / A LARM

0

0

1

TEST

A

HZI1CB11FL

HSI3CB11FL HSI2CB11FL

HS5CB11FL

HS6CB11FL

HSI4CB11FL

HS1EB11FL MAIN SWI TCH

HSIEB101 WARNING: LIVE CIRCUI TS INSIDE. DISCONNECT POWER SUPPLIES BEFORE SERVICING.

MAIN SWI T CH DOES N O T SWI TCH OFF EXTERNAL A UXILIA R Y VO LTAGES (YEL LOW WIRES)

Figure 15.

Switching on the voltage

1. Turn the MAIN SWITCH to the ON (1) position. 2. The HSI4CB11FL button should be flashing and HSI3CB11FL button should be illuminating now. In case they fail to do so, check the main switch and the fuse(s) inside the panel. 3. Make sure there are no unwanted objects between the filter plates. 4. Switch off the emergency stop buttons. The status of indicator lamps should be following: -

HSI2CB11FL = OFF

-

HSI3CB11FL = ON

-

HSI4CB11FL = FLASHING

5. Turn the HYDRAULIC UNIT switch HS7CD11FL to position 1. The hydraulic unit is automatically started and stopped according the filter mode. In Test Mode, if no actuator or function is activated within five minutes, the hydraulic unit will stop. It will restart as soon as any actuator or function is being activated.

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4.4.1

ECFN-OUT-MC-P015-MAN-00001 Operation

Description of the indicator light functions

Table 4.

Description of the indicator light functions

HZ(I)1CB11FL EMERGENCY STOP Emergency stop push buttons are not illuminated. HZI1CB11FL

EMERGENCY STOP

HSI2CB11FL READY/RUN When flashing slowly, it indicates that the filter is ready for operation. When steadily illuminated, the filter is in operation (RUN). HSI2CB11FL STA RT / RUN

HSI3CB11FL STOP/STOPPED When illuminated, it indicates that the filter is stopped.

HSI3CB11FL

STO P / STOPPED

In case of alarm, the alarm light on top of the panel as well as the HSI4CB11FL button start flashing and an alarm message will appear on the display.

When HSI4CB11FL is pushed once the alarm light will stop flashing. The second push will acknowledge the alarm provided that the cause has been eliminated.

HSI4CB11FL ACKNL / ALA RM

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4.5

ECFN-OUT-MC-P015-MAN-00001 Operation

Test mode

The test mode is used during troubleshooting and routine maintenance of the filter. All valves and motors present on the pressure filter can be individually actuated (with some restrictions) when in the TEST MODE. The test mode can be activated with KEY SWITCH (S780). DANGER Before operating the machine, ensure no one is near the danger zones of the filter.

DANGER Filter is equipped with several emergency stop buttons. If there is any danger, filter can be stopped immediately by pressing an emergency stop button. Never release the emergency stop buttons until it is safe to do so. After all emergency stop buttons are released, emergency stop circuit can be acknowledged by pressing the alarm acknowledge push button (S733).

If the filter is equipped with protective door system, all filter protective doors must be closed in order to operate filter automatically. If any door is opened during automatic operation, the filter will stop immediately. Only test mode functions are possible with open doors.

Emergency stop buttons and protective door limit switches and related safety functions must be tested regularly.

4.5.1

Safety system description

Safety system consists mainly of: -

Programmable safety controller KA100

-

Expansion relay unit KA110 for hydraulic motors

-

Expansion relay unit KA111 for process motors

-

Expansion relay unit KA103 for pressing water pump

-

Safety link bus module KA2, KA35 and KA45 in control cabinet

-

Safety link input modules KA2.1 in terminal box X2

-

Safety link input module KA12.1 in terminal box X12

-

Safety link input module KA35.1, KA35.2, KA35.3 and KA35.4 in terminal box X35

-

Safety link input module KA45.1, KA45.2, KA45.3 and KA45.4 in terminal box X45

-

Communication module KA130 for communication with PLC

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ECFN-OUT-MC-P015-MAN-00001 Operation

KA100 Programmable safety controller, base unit, includes 20 digital inputs, 4digital semiconductor outputs and 2 relay outputs (potential free contacts). Expansion unit KA110 includes 8 relay contacts. KA110 is used for hydraulic unit. Expansion unit KA111 includes 8 safety relay contacts. KA111 is used for equipment (pumps and motors) outside of filter. Link Module KA2 is bus module for IO modules KA2.1 and KA12.1 Link Module KA35 is bus module for IO modules KA35.1, KA35.2, KA35.3 and KA34.4 Link Module KA45 is bus module for IO modules KA45.1, KA45.2, KA45.3 and KA45.4 Safety system includes also: -

Emergency Stop Push Buttons

-

Door Switches

-

Acknowledge Pushbuttons with signal lights for door alarms S/H741 and S/H742

-

DM Enable Switch S790 (DM = Dead Man)

Safety controller KA100 includes the safety program. The safety signals from safety devices and safety control devices are connected to the safety inputs of the controller as well as the safety inputs of the expansion IO-modules. The outputs are used for controlling the expansion safety relays (KA110, KA111 and KA102) and via these relays the other devices.

4.5.2

Safety functions

Auto mode In Auto mode (Key Switch S780 in Auto position), the Hand Held unit must be connected on Right or on Left side, in terminal box X35 or X45. DM Enable Switch S790 can be connected to opposite corner of the filter, but the DM Enable Switch S790 must be released. The doors must be closed and the door alarms must be acknowledged. When these conditions are true and all the safety relays are ON (KA110, KA111 and KA102), the Auto Ready signal is sent to PLC. In Auto mode the PLC together with Safety System controls the functions of the filter and auxiliary equipment. Test HH mode In Test Mode (Key Switch S780 in Test HH position) it is possible to make the maintenance and test functions for the single devices of the filter. In Test HH mode the Hand Held can be connected on Right side or on Left side. Test Functions can be activated with Hand Held test activation push buttons. When Hand Held is connected to Right side, the doors can be open on Right side and similarly when connected to Left side the doors can be open on Left side. If the doors are opened on the other side, it must be used the DM Enable switch. If the doors are open on the other side and the DM Enable switch is not pressed, there will become a

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ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Operation

message to display “CLOSE DOOR RIGHT OR USE DM ENABLE SWITCH” or “CLOSE DOOR LEFT OR USE DM ENABLE SWITCH”. Using the remote test functions (HH-unit) Outotec pressure filter is provided with a handheld test unit. The device can be connected to left side or right side of the filter. This allows the handheld unit to be brought to the actuator to be tested facilitating thus maintenance and adjustments of the actuator. The handheld test unit has an Emergency Stop push button S702, test selector switch S714, and two test push buttons S723 and S725. Test mode can be selected only with key switch S780. After activated Test HH mode the handheld test unit can be used. When the test operation is over, turn the selector switch to position “A” in the handheld unit and put the handheld unit back to its suspension hook. The filter is ready for normal process use. Select Auto-mode on the control panel key switch. (Turn key switch to AUTO-mode) After using test mode, remove key to prevent unauthorized test mode use.

S702

EMERGENCY STOP

A

HC 5 HC 6

3

2

4

1

V* 5 6 7

.H

0

X

HU R1

1 2 3

L BA

9

L BA

8

H

7 9 HC 8& HM HM9 HM8 HC 4 M3 HU

C5

S714

ACT SELECTOR

S725

S723

ACKNL V0*

Figure 16.

A V H X1 X2 X3

START

V1*

Handheld test unit

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ECFN-OUT-MC-P015-MAN-00001 Operation

Manual operation of the process pumps and conveyor. When filter is in auto mode and stopped and all doors are closed, valves and pumps can be manually operated by selecting device from process screen. If there is any interlock preventing operation, it is shown in device popup. When filter is started, all devices turns to auto.

Figure 17.

Popup window

Observation mode Observation mode is selected with the key switch S782 in terminal box X35. The Key switch S780 in control cabinet must be in Auto position. When the Observation mode is ON, the yellow alarm beacon H35 on the top of box X35 and H45 on the top of box X45 is flashing showing that some abnormal situation is going on at the filter. Slow flash in the indicator light H782 in the terminal box X35 will show that Observation mode in ON at the filter. In Observation mode one corner door can be open on the end where the Hand Held unit is connected. The Observation can be started without pause in production by turning the key switch in Observation position. If the Observation is needed on the opposite end, the Hand Held must be connected on that side. That is why the filter must be stopped for the time when Hand Held is changed from one side to the other. Loosing of Hand Held cable will cause the Emergency stop. When turned the key switch S782 to Observation mode, the filter will continue the automatic run normally. If the filter is stopped during or in the beginning of mechanical movements for safety reasons, it is needed acceptance by operator for continuing the

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ECFN-OUT-MC-P015-MAN-00001 Operation

run of the filter. The PLC will send “Observation Run Request” signal to safety program, when it is ready to run the filter. The green light in Hand Held will start blinking. The Safety Controller will set the signal “Observation acceptance needed” and sends it to PLC. At Display Screen it will appear message “Observation Acceptance needed”. If the operator will not press the green button in 3 seconds after “Observation Run Request” or if the filter is stopped for some other reason, the Safety system will set the safety controller in safe state. The safety expansion relay KA102 will go into OFF state and takes the power off from all solenoid valves. When pressed again the green button during “Observation Run Request is ON”, the filter will continue its cycle. Functions during mechanical steps: -

When plate pack opening SBR starts, PLC will send the request signal to safety program. PLC will prevent the plate pack opening before the operator will give the acceptance. When pushed the green button in HH, the program will continue

-

When Cake discharge SBR starts, filter PLC will send the request signal to safety program. Filter PLC will prevent the cake discharge before the operator will give the acceptance. When pushed the green button in HH, the program will continue.

-

When plate pack closing SBR starts, filter PLC will send the request signal to safety program. Filter PLC will prevent the plate pack closing before the operator will give the acceptance. When pushed the green button in HH, the program will continue.

-

If the filter is stopped for waiting (cake discharge, slurry level, etc.) during mechanical stage (plate pack opening, cake discharge or plate pack closing), the filter PLC will give stop command to filter. When filter PLC allows to start the filter again, filter PLC will send the request signal to safety controller. Filter PLC will prevent the filter run before the operator will give the acceptance. When pushed the green button in HH, the program will continue.

-

If in Observation mode the filter is stopped by operator or by some other reason, the filter can be started when the filter PLC will send the request signal to safety program. The filter can be started by operator acceptance. When pushed the green button in HH, the program will continue.

In Observation mode the filter can be started only from Hand Held unit by green button. The control cabin start button function is prevented during Observation mode in the filter PLC program. When opened doors on the other end where the Hand Held is connected or opened two doors at same time or any middle door, there will become door alarm. Before starting the filter again, the door alarm must be acknowledged. In observation mode it is not allowed to do any other maintenance or cleaning works and it is not allowed to go near to the filter. In Observation mode the operator must carry the Hand Held unit. If there will be some safety needs, the operator must stop the filter immediately. Hand Held is provided with E-Stop button.

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ECFN-OUT-MC-P015-MAN-00001 Operation

Expansion safety relay KA110 Emergency Stop Push Buttons are located in different units. S701 in Control cabinet X1, S703 in pressing water station, HZ1HU in hydraulic unit, S735 in X35, S745 in X45 and S702 in Hand Held unit. There can be also some other Emergency stop Push Buttons. KA110 is controlled only by the emergency stop push buttons. Expansion safety relay KA111 Expansion safety relay KA111 is reserved for motors and equipment outside of filter. All motors and equipment that supply water, slurry or some other material to the filter and equipment that can cause damage to the machine or injuries to the people, must have contact from KA111 for stopping those devises. Expansion safety relay KA111 is not active in test mode. In auto mode it is on every time when auto ready conditions are on. Expansion safety relay KA102: In terminal box X2 near to the filter there is Safety Expansion Relay KA102. Via this relay the power supply is activated to solenoid valves and other devices in the filter. In Test HH mode KA102 will be ON only when the Test Activate push Button S723 or S725 is pushed in HH unit. If during test the doors are open on both sides, in the other side another operator must use DM Enable switch S790. When the doors are open on both sides, the DM Enable switch must be kept in middle position, before KA102 can be activated and any device or function can be activated. If not pressed the DM Enable switch, there will be message in HMI, “CLOSE DOOR LEFT OR USE DM ENABLE” or “CLOSE DOOR RIGHT OR USE DM ENABLE”. Expansion safety relay KA103: KA103 is located in control cabinet X1. KA103 is for pressing water pump. In Auto Mode KA103 is ON when KA102 is ON and Locking pins are locked and Plate pack is closed. In Test mode KA103 is ON only when the Test Activate push Button S731 in Pressing Water Station is pushed. If pressed at same time HH Test button, Pressing Water Pump test is deactivated. Feedback signal from MCC Feedback signal from MCC must be on before emergency safety relay system can be acknowledged. This loop ensures all the motors and equipment are stopped before the safety system can be activated. There are 3 Feedback loops:

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PF1226, PF16/19 M12 45

Operation

-

Feedback from Hydraulic unit motors, relay KA110, needed in TEST mode and AUTO mode. If the signal is missing, it is given “KA100 OUTPUT FAULT”, when control signal for the safety relays are true.

-

Feedback from Process motors, relay KA111, needed in AUTO mode. If the signal is missing, it is given “KA100 OUTPUT FAULT”, when control signal for the safety relays are true.

-

Feedback from pressing water pump, relay KA103. If the signal is missing, it is given “KA103 FAULT”, when control signal for the safety relays are true.

Safety in testing Hand Held unit can be connected to both sides of the filter, normally the connectors are in opposite corners. When operator is testing alone, the doors can be open on the side where the HH is connected. For safety reasons the doors on the other side must be closed. If it is necessary to open the doors on both sides, the other operator must use DM Enable switch S790. DM Enable switch must be pressed into middle position. First it must be pressed the Enable switch in middle position by one operator and after that the other operator can push the test activate push button in HH unit. The operator can stop the test function by releasing the DM Enable Switch Alarms and messages in safety system -

Alarm: “EMERGENCY STOP” There are separate alarms from every E-Stop push button

-

Alarm: „S80x SIDE PROTECTIVE DOOR x SENSOR“. Every door has separate alarm to filter PLC. This alarm must be acknowledged by Alarm Acknowledge push button in Control Cabinet.

-

Alarm: “KA103 PWS FAULT”. The alarm is given if Feedback signal from pressing water pump is missing when trying to activate safety relay KA103.

-

Message: “OBSERVATION SELECTED“. This message is seen all the time when Observation mode is selected.

-

Message: “OBSERVATION ACCEPTANCE NEEDED”. The message will come in the beginning of plate pack opening, plate pack closing, cake discharge or if the filter after stopping or after waiting time is ready for starting.

-

Message: “ACKN RIGHT SIDE DOOR”. This information will come if door alarm on right has come. After closing the door the alarm must be first acknowledged from JBX35 by S741.

-

Message: “ACKN LEFT SIDE DOOR”. This information will come if door alarm on left has come. After closing the door the alarm must be first acknowledged from X45 by S724.

-

Message: “CLOSE DOOR RIGHT OR USE DM ENABLE SWITCH”. This message will come, if HH is connected to left side, Test Activate button in HH unit is pressed, door is open on right side and DM Enable is not pressed.

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-

Operation

Message: ”CLOSE DOOR LEFT OR USE DM ENABLE SWITCH”. This message will come, if HH is connected to right side, Test Activate button in HH unit is pressed, door is open on left side and DM Enable is not pressed.

Indications and alarms in safety relay KA100 The RUN light must be on in relay. This means that the program is running. If there is some FAULTs in the system, the program will be stopped leading to safe condition. FAULT LED ON: External error on the base unit, leading to a safe condition, e.g. terminator not connected. The alarm can be seen in HMI. FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. I_FAULT LED ON, INPUT Ix FLASHING: External error, leading to a safe condition, e.g. short across the contacts or error on safety mat input. The alarm can be seen in HMI. I_FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. I_FAULT LED FLASHING, RUN LED ON: External error on the inputs of the base unit, which does not lead to a safe condition, e.g. partially operated. O_FAULT LED ON: External error on the outputs of the base unit, e.g. short across the contacts, leading to a safe condition. The alarm can be seen in HMI. O_FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. O_FAULT LED FLASHING, RUN LED ON: External error in the outputs of the base unit, which does not lead to a safe condition, e.g. feedback input defective. The alarm can be seen in HMI.

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4.5.3

Operation

Test selector S714

The test selector S714 has several functions. 1. When in AUTO position, the alarms during testing can be acknowledged directly from the handheld test unit.

1

2 0

9

1 2 3

X

H 7 9 HC 8& HM 9 M H HM8

HU R1 L C5 BA L.H BA

4 5 6 7 8

3

HC5 HC 6

A

V*

S714

ACT SELECTOR

Figure 18.

Auto position on test selector S714

2. VALVE side positions permit the testing of the process valves as shown on switch S714. The left hand side push button S725 activates the valve V0*. The eventual parallel valve V1* can be activated by the right hand side push button S723.

1

2 0

9

1 2 3

X

H 7 HC

9 8& HM HM9 HM8

HU R1 L C5 BA L.H BA

4 5 6 7 8

3

HC5 HC 6

A

V*

S714

AC T SELECTOR

Figure 19.

Valve position on test selector S714

3. HYDRAULIC side positions permit testing of the hydraulics and motors as shown on switch S714. Note that there may be two devices or two directions for each position of S714. In case of two devices, the left hand side push button S725 operates the device listed on the left and the right hand side push button S723 operates the device listed on the right. If there are two directions in which the device may operate, the left hand side push button S725 runs the device either upwards or forward and the right hand side push button S723 runs the device either downwards or reverse.

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PF1226, PF16/19 M12 45

1

3

2

H 7 9 HC 8& HM HM9

HM8

0

9

1 2 3

X

HU R1 L C5 BA L.H BA

4 5 6 7 8

HC5 HC 6

A

V*

Operation

S714

AC T SELECTOR

Figure 20.

Hydraulic position on test selector S714

Three positions between V and H are reserved for customer equipment test functions and are indicated by X1, X2 and X3.

4.5.4

Push buttons S725 and S723

S725 White illuminated push button (leftmost button).This push button activates the hydraulic cylinder or motor Selected up or forward when S714 is positioned on the HYDR side, and the valve V0* when S714 is positioned on the VALVE side. This push button also operates as the ALARM ACKNOWLEDGE push button when S714 is in AUTO.

S725

ACKNL V0*

Y101

S723

A V H X1 X2 X3

Figure 21.

START V1*

Y102

Push buttons S725 and S723

S723 Green illuminated push button (rightmost button) This push button activates the hydraulic cylinder or motor selected down or reverse when S714 is positioned on the HYDR side, and the valve V1* (parallel to V0*) when S714 is positioned on the VALVE side. Testing continues as long as the push button is switched on. Note that cloth drive is provided with positions both with and without cloth tensioning.

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4.5.5

Operation

Restrictions in testing the actuators



The quick action cylinders (up or down) will operate only when the locking pins are fully locked or unlocked.



The filter cloth drive will operate only when the plate pack is fully open and sealing plate is down.



Unsealing the plate pack does not work (lower pressing plate down) if there is pressure (pressure transmitter B419) in the pressing manifold.



Sealing the plate pack will operate only when seam is parked outside the chamber area.

4.5.6

List of symbols in handheld test unit

Table 5.

Symbols in handheld test unit

V01

Filtrate outlet valve

V02

Slurry inlet valve

V04

Pressing water outlet valve

V05

Cake wash liquid inlet valve

V06

Drying air inlet valve

V07

Manifold drain outlet valve

V08

Pre-/ wash filtrate outlet valve

V09

Cloth wash liquid inlet valve

V10

Slurry recycle valve (optional)

HC5

Quick action cylinders

HC6

Locking pins

HC7

Sealing cylinders

HM8

Cloth tensioning motor

HM9

Cloth drive motor

HC4

Cloth track cylinder

BAL

Quick action cylinder balancing

HC5&BAL

Quick action cylinders and balancing

M3HU

Oil cooler.

R1HU

Oil heater.

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4.6

Operation

Manual mode

The manual mode can be used when the operator is searching for the optimal values of the process variables as well as when the sequence must be continued from a different point than from where it was stopped, or if the operator wants to run any stage longer than normal.

Figure 22.

Manual mode

1. Select MANUAL MODE from the touch screen and turn the HYDRAULIC UNIT switch S755 to position 1. The hydraulic unit is automatically started and stopped by the control system according to the filter mode.

S755 HYDRAULIC UNIT Figure 23.

Hydraulic unit switch S755

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Operation

The MANUAL MODE field is now displayed. The field has the following elements.

Table 6.

Elements in MANUAL filter mode

[?]

Touch button to activate HELP-screen

RECIPE

Displays the current program

STAGE

Displays the number of the current stage.

MODE

Displays the current mode. MAN MODE.

ELAPSED

Displays the time elapsed in MAN MODE.

STATUS

Displays the current status, e.g. RUN, READY, ALARM, STOP

[]

Touch button to forward.

2. For PRESSURE RELEASE proceed to step 4. For any other stage, use the [< |] or [| > |] touch buttons for scrolling through the stages. Note that the [< |] touch button does not forward the sequence from the beginning to the end, where as the [| >] touch button rewinds the sequence from the end to the beginning. Note also that this kind of selection process is possible only when the filter is stopped. 3. To start the filter, push the START button once. Note that prior to starting the filter, the START button should be flashing indicating that the filter is ready to begin operations. In case it fails to do so, make sure there are no active alarms. Once the filter is running, the START button is illuminated.

S710 / H710 START / RUN Figure 24.

Start button S710

The time elapsed during filter operations will be displayed in the TIME ELAPSED area. Note that while in MAN MODE, this time will COUNT UP from zero to show actual time elapsed in the stage currently running. 4. To proceed to the next stage, push the START button once. 5. To stop the filter push STOP button. When you push the STOP button once, it is illuminated indicating that the filter has stopped.

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S708 / H708 STOP / STOPPED Figure 25.

Stop button S708

6. To restart the filter from the stage it was stopped in, push the START button. The START button should be flashing indicating the filter is ready to run. Restrictions 1. The filtration stage cannot be selected twice during one operation cycle. If filtration has been going on for 10 seconds or more and is stopped and restarted, the sequence will automatically skip over slurry feeding and continue from pipe and hose washing. 2. The process stages cannot be selected unless the plate pack is fully closed and sealed. 3. The discharge stage cannot be selected unless the plate pack is fully open. CAUTION .

Overfilling can cause serious damage to the filter plates. When in manual mode, supervise the prefiltration and filtration stages.

. WARNING Hazardous moving parts. The plate pack consists of several moving parts, which can cause serious injury or death. Never leave the filter running by itself in MAN mode.

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4.7

Operation

Automatic mode

Automatic mode is the normal operating mode of the filter. All necessary operations to run the filter are automatically executed by the control system.

Figure 26.

Automatic mode

1. Select AUTO MODE from the touch screen and turn the HYDRAULIC UNIT switch HS7CD11FL to position 1. The hydraulic unit is automatically started and stopped by the control system according to the filter mode.

S755 HYDRAULIC UNIT Figure 27.

Hydraulic unit switch S755

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Operation

The AUTO MODE screen will be displayed. The screen has the following elements: [?]

Touch button to activate HELP-screen

RECIPE

Displays the current program

STAGE

Displays the number of the current stage.

MODE

Displays the current mode. AUTO MODE.

REMAINING

Displays the time remaining in AUTO MODE.

STATUS

Displays the current status, e.g. RUN, READY, ALARM, STOP

2. To start the filter from the present stage, push the START button once. Note that prior to starting the filter, the START button should be flashing indicating that the filter is ready to begin operations. In case it fails to do so, make sure that there are no active alarms. Once the filter is running, the START button is illuminated.

S710 / H710 START / RUN Figure 28.

Start button S710

The time remaining during filter operations will be displayed in the REMAINING area. Note that while in AUTO MODE, this time will count down from the preset to show the time remaining in each stage. 3. If you want to start from another stage, see instructions for program RESET in section RESET MODE and MANUAL START in section MANUAL MODE.

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4.7.1

ECFN-OUT-MC-P015-MAN-00001 Operation

Stopping the filter

1. To stop the filter, push the stop button. When you push the stop button once, it is illuminated indicating the filter has stopped.

S708 / H708 STOP / STOPPED Figure 29.

Stop button S708

NOTE: The filter may be stopped due to an alarm or a voltage break.

If the filter has been stopped and been sitting idle for a long period of time, it is recommended that the filter to be driven in the discharge stage in MANUAL MODE until the full length of the filter cloth has been washed. Once the full length has been washed, the AUTO MODE can be switched on, operating the filter normally.

4.7.2

Restarting the filter with automatic mode

If the filter has been stopped due to an alarm or if the STOP button has been pushed, proceed as follows: 

Locate and eliminate the alarm or malfunction prior to restarting the filter (see chapter 5.2 Malfunctions and alarms).



When the START button is flashing indicating the filter is ready to run push the START button once. The filter restarts from the stage it was stopped in and continues the automatic operation.

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4.8

Operation

End mode

The end mode is used to stop the filter automatically after completing the cycle (after cake discharge), freeing the operator from having to wait for the end of the present cycle. In this mode the filter will perform an orderly stop after the end of cake discharge. All functions in end mode are similar to those in auto mode.

Figure 30.

End mode

1. Select end mode from the touch screen. 2. The filter will continue its operation through the cycle as if in auto mode and stop after the end of cloth washing. At this time the filter will perform an orderly shutdown either by locking the moving press plate in the upper position or by closing the plate pack (according to the selection). The filter can be restarted at any time in either man mode or auto mode by pushing the start button (see man mode or auto mode). The filter will restart from cake discharge after end mode stop.

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4.9

ECFN-OUT-MC-P015-MAN-00001 Operation

Reset mode

The reset mode is used to reset the program sequence back to the pressure release stage and load into the operational area of the program any new recipe data that has been entered.

NOTE: Before starting the filter from another point than where it was stopped, the program sequence must be reset.

Figure 31.

Reset mode

1. Select reset mode from the touch screen. The program then asks for a confirmation and requests you to stop the filter. 2. Push stop button HSI3CB11FL to reset the filter program sequence.

S708 / H708 STOP / STOPPED Figure 32.

Stop button S708

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3. The default starting stage after resetting the filter program sequence is pressure release. To start the filter from another stage, see man mode.

4.10 Cloth tracking CLOTH TRACKING screen displays information about the device status and settings. You must log in on TOOLS screen to adjust the settings like TRACK INIT or CLOTH POSITION OFFSET.

Figure 33.

TOOLS screen

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Figure 34.

ECFN-OUT-MC-P015-MAN-00001 Operation

TRACK INIT screen

[TRACK INIT] button is used to fine tune cloth middle position. Cloth middle position must be adjusted with GT2HC4 to 0° before initializing cloth edge measurement!

Figure 35.

INITIALIZING CLOTH EDGE MEASUREMENT

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Operation

CLOTH POSITION OFFSET can be adjusted by touching parameter value and entering new offset value in mm. +1 mm = cloth is driven 1mm to right -1 mm = cloth is driven 1mm to left

Figure 36.

CLOTH POSITION OFFSET

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4.11 Operation stages of Outotec Larox pressure filter SBR01 Pressure release For security reasons, pressure release is always the first stage when starting an Outotec Larox Pressure Filter. During this stage, the remaining pressure in the filter chambers is released for a safer plate pack opening. This stage is divided into two periods of time: in the first and main period pressure is released through cake. During the second period, the manifold drain valve V07 is opened. SBR02 Plate pack opening On completion of the PRESSURE RELEASE the plate pack is unsealed by driving the sealing cylinders downwards. The quick action cylinders are then driven to release the locking pins from the column holes. The locking pins are unlocked (pins move into the upper pressure plate). After the locking pins have been unlocked, the plate pack is opened by driving the quick action cylinders upwards until the plate pack is fully open. The cloth strain starts at the same time as the plate pack opening. SBR03 Cake discharge When the plate pack is fully open, the cloth drive motor HM09 is started and the cloth wash inlet valve V09 is opened. The cake formed on the cloth is then discharged into the cake chutes at both ends of the filter. After the first plate length of discharge, the speed of the cloth is increased reducing the cloth washing time. On completion of the discharge the clipper seam is placed outside the plate pack at a lower speed and the cloth drive motor HM09 stops. SBRO4 Restart operation The position of HC5, HC6 and HC7 is checked and if necessary, corrected so that next stage (PACK CLOSING) can be properly executed. SBR05 Plate Pack closing On completion of the restart operations delay the filter begins to close the plate pack. First the quick action cylinders are moved downwards after which the locking pins are locked. Finally, the plate pack is sealed by driving the sealing cylinders upwards until the required sealing pressure is reached. The pressing water outlet valve V04 is open. SBR06 Pre-Filtration (Filling) When the filter plates are closed and sealed, the slurry is fed to the distribution pipe through V02 and further to each chamber through the feed collectors. The pressing water outlet valve V04 is held open thus ensuring a free discharge of the pressing water still present in the diaphragms from the previous cycle. The filtrate passes through the cloth into the filtrate pan and exits the filter chamber via filtrate collectors into the filtrate side pipe and out through the valve V08. Cake begins to form on the cloth. When the pre-filtration time runs out, the filtration stage starts.

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SBR07 Filtration (Slurry feed) When the filter plates are closed and sealed, the slurry is fed through the distribution pipe to each chamber through the feed collectors. The pressing water outlet valve V04 is open. Filtrate passes through the cloth into the filtrate pan and exits the filter chamber via filtrate collectors into the filtrate side pipe and out through the valve V01 (optional). Cake begins to form on the cloth. SBR08 Pipe washing After the filtration stage, the distribution pipe is cleaned by opening the manifold drain valve V07 and feeding water through the pipe from cake wash inlet valve V05. SBR09 Hose washing After the pipe washing stage, the slurry feed hoses are cleaned by opening the cake wash inlet valve V05 and closing drain valve V07 which forces water through the slurry feed hoses and into the filter chambers. SBR10 Pressing 1 In the pressing stage, the pressing water is pumped through the pressing water pipe and the hoses into the space above the rubber diaphragms. All the remaining liquid is forced through the cake and it exits the filter. SBR11 Cake washing The washing liquid is fed to the filter chamber through the wash liquid inlet valve V05. If pressing end delay is used, V04 is kept closed until pressing end delay time has elapsed. After the pressing end delay time, in order to ensure a free discharge of the pressing water, the V04 is opened while the washing liquid enters the filter chamber. The washing liquid washes the cake and passes then through the cloth and into the filtrate side pipe. SBR12 Pressing 2 After the washing stage the washing liquid remaining in the filter chamber is pressed out by pumping the pressing water into the diaphragms, like in the Pressing 1 stage. SBR13 Drainage of distribution Pipe After the last pressing stage and before the cake air drying the distribution pipe is drained of water/slurry by opening V07. SBR14 Cake air drying Drying of the cake is accomplished with compressed air. The air enters the distribution pipe through V06. If pressing end delay is in use, V04 is kept closed until pressing end delay has elapsed. After pressing end delay, V04 is opened for a free discharge of the

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pressing water. The air flowing through the cake reduces its moisture content to the optimum value simultaneously emptying the filter chamber from the pressing water.

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5

Operation

Alarms and troubleshooting 5.1

Indications and alarms in safety relay KA100

The RUN light must be on in relay. This means that the program is running. If there is some FAULTs in the system, the program will be stopped leading to safe condition. FAULT LED ON: External error on the base unit, leading to a safe condition, e.g. terminator not connected. The alarm can be seen in HMI. FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. I_FAULT LED ON, INPUT Ix FLASHING: External error, leading to a safe condition, e.g. short across the contacts or error on safety mat input. The alarm can be seen in HMI. I_FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. I_FAULT LED FLASHING, RUN LED ON: External error on the inputs of the base unit, which does not lead to a safe condition, e.g. partially operated. O_FAULT LED ON: External error on the outputs of the base unit, e.g. short across the contacts, leading to a safe condition. The alarm can be seen in HMI. O_FAULT LED FLASHING, DIAGNOSTIC LED FLASHING: Internal error on the base unit. The alarm can be seen in HMI. O_FAULT LED FLASHING, RUN LED ON: External error in the outputs of the base unit, which does not lead to a safe condition, e.g. feedback input defective. The alarm can be seen in HMI.

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Operation

5.2

Malfunctions and alarms

5.2.1

General

Outotec filter control system has extensive diagnostic functions. Alarms stopping the filter immediately 

Emergency stop



Voltage break

Alarms stopping the filter after a preset delay 

Valve or sensor failure



Motor failure



Process pressures



Cloth drive



Plate pack movements



CPU battery low



Failure in hydraulics



Level of process fluid tanks

5.2.2

Alarm acknowledgement

When in state of alarm, the filter will stop immediately. The alarm beacon on top of the control panel and the alarm reset button S733 will flash indicating alarm or malfunction existing in the filter.

S733 / H733 ACKNL / ALARM Figure 37.

Alarm reset button S733

Push the ACKNL / ALARM button once to stop the alarm beacon and the alarm reset button from flashing. The ACKNL / ALARM button remains illuminated.

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Once the cause of the alarm has been located and eliminated, push the ACKNL / ALARM button again to acknowledge the alarm. Then the filter can be restarted by pushing the START button S710.

S710 / H710 START / RUN Figure 38.

Start button S710

CAUTION Find the cause of alarm before starting the filter again.

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5.3 Table 7.

Operation

Alarm functions

Alarms, causes and functions

Name (Group)

Cause

Reason

Solution

S70* EMERGENCY STOP (D)

One or more of the several emergency stop buttons is engaged.

Emergency stop by the operator.

Find out the reason for the Emergency stop. Make sure that it is SAFE to restart the filter. Release the engaged button(s). Emergency-stop buttons are located in the control panel, filter, hand held unit and on the pressing water station. If possible do not leave the emergency stop button activated for a longer time because the pinch valves may open, otherwise close the process line manual valves.

S801...S809 PROTECTIVE DOOR SENSOR (D)

Protective door sensor indicates that door is open.

Protective door is open. Sensor adjusted wrongly. Sensor fault.

Close protective door. Adjust/replace sensor. Check electrical system.

POWER LOSS OR PLC RESTART (H)

PLC stopped and restarted.

Main voltage break. PLC has been in PROGRAM mode.

Check the reason for PLC stop.

B331 CLOTH INCREMENTAL ENCODER (B)

No impulses from incremental encoder when cloth drive activated.

Pressing roller is loose. Cloth is cut or too long. Tensioning mechanism inoperative. Cakes are too thick. Cloth cannot move forward. Water remains in the pressing diaphragms. Encoder has failed.

Adjust the pressing roller. Check the cloth, repair. Check the cloth tension. Check the cloth can move freely. Replace encoder.

S332 CLIPPER SEAM SENSOR (B)

Seam not detected within one cloth revolution or detected in improper place.

Sensor not adjusted properly or has failed. Clipper seam not existing.

Adjust/replace sensor.

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Operation

Name (Group)

Cause

Reason

Solution

S838A OR S839A CLOTH DISPLASED TO LEFT OR RIGHT SENSOR (B)

The automatic cloth tracking system has failed to keep the cloth centered.

Cloth not adjusted properly. Tensioning roller displaced. Cloth seam in not straight. Material has accumulated on the rollers. Scrapers are not adjusted properly. Jammed roller(s) Press roller not evenly adjusted. Switch not adjusted properly or have failed

Center the cloth using the tracking roller (If the cloth is badly displaced, loosen the cloth in TEST mode and manually center the cloth). Check tensioning roller. Check rollers and scrapers. Adjust press roller for evenly pressure against drive roller. Adjust/replace switch.

B505M PLATE PACK POSITION SENSOR´S VALUE TOO SMALL (F)

The B505 sensor is located in the center of the upper pressing plate, attached to the top frame. The linear measurement wire is attached to the moving pressing plate and moves up and down with the plate. Abnormal signal from sensor B505. The signal value is equal or less than value that indicates B505M minus 6 mm.

Sensor wire disconnected. Wiring has failed. Sensor has failed.

Check the position of upper pressing plate. Adjust/replace sensor and/or wiring. Acknowledge the alarm and restart the filter.

B505C PLATE PACK POSITION SENSOR´S VALUE TOO HIGH (F)

Abnormal signal from sensor B505. The signal value is equal or greater than value that indicates B505C plus 6 mm.

Sensor wire disconnected. Sensor has failed. Wiring has failed.

Check the position of upper pressing plate. Adjust/replace sensor and/or wiring. Acknowledge the alarm and restart the filter.

B505S ABNORMAL MOVE OF PLATE PACK (F)

Abnormal signal from sensor B505. The signal is continuously monitored and compared to respective functions.

Upper Pressing plate not moving properly. Hydraulic solenoid is jammed. Hydraulic pressure too low. Sensor wire disconnected. Sensor has failed.

Check movement and position of the upper pressing plate. Check hydraulic solenoids. Check hydraulic pressures. Adjust/replace sensors.

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Operation

Name (Group)

Cause

Reason

Solution

B505D PLATE PACK NOT IN DISCHARGE POS. (F)

Plate pack is not in cake discharge position when cake discharge stage is active.

The plate pack has flown too down when filter has been stopped. Sensor has failed. Wiring has failed.

Check the position of pressing plate. Drive the plate pack to up with hand held. Adjust/replace sensor and/or wiring.

B505O PLATE PACK OPENING (F)

Abnormal state of the transmitter B505 when operating the quick action opening of the plate pack.

- Upper pressing plate not moving properly - Hydraulic oil too cold - Hydraulic pressure too low - Hydraulic valve HV5 malfunction

- Check movement of moving press plate - Check hydraulic oil temperature and pressures - Acknowledge the alarm and restart the filter

B505CL PLATE PACK CLOSING (F)

Abnormal state of the transmitter B505 when operating the quick action closing of the plate pack.

- Upper pressing plate not moving properly - Hydraulic oil too cold - Hydraulic pressure too low - Hydraulic valve HV5 malfunction

- Check the parameter value - Check movement of moving press plate - Check hydraulic oil temperature and pressures

S161…S164 LOCKING PINS UNLOCKED SENSORS (F) S261…S264 LOCKING PINS LOCKED SENSORS (F)

Abnormal state of the displayed sensor when operating the locking pins (locking or unlocking).

Locking pin jammed in the mid position. Hydraulic pressure too low. Mechanical failure. Sensor not adjusted properly or has failed.

Inspect locking pin assembly. Test locking pin movement. Check hydraulic pressures. Adjust/replace sensor.

PT2HU ACCUMULATOR RECHARGE PRESSURE (G)

The recharging of the pressure accumulator takes too long, or the recharging occurs too often.

Leak in the pipelines or hoses. Unsuitable oil type. Accumulator charge pressure is too low. Flow control block (FC1) assembly is leaking internally. PT2HU has failed.

Check the pipes and hoses. Check the oil type. Check accumulator charge pressure. Check that FC1 adjustment screws are completely set in and the lock nuts are tightened. Check the pressure from PG4 when recharging the accumulator. Replace PT2HU.

PS1HU RETURN LINE OIL FILTER PRESSURE SWITCH (G)

Pressure switch PS1HU signals a high differential pressure in the RETURN.

Return line oil filter is clogged. Oil temp is too low or oil is too thick (improper viscosity). Cable is disconnected. Pressure switch.

Run the hydraulic unit to warm up the oil. If alarm is active when the oil is warm, replace the oil filter. Reconnect the cable. Replace PS1HU.

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Operation

Name (Group)

Cause

Reason

Solution

PS2HU OIL FILTER PRESSURE SWITCH (G)

The differential pressure switch PS2HU signals a high differential pressure.

Oil filter is clogged. Oil temp is too low or viscosity improper. Cable is disconnected. Pressure switch PS2HU has failed.

Run the hydraulic unit to warm up the oil. If alarm is active when the oil is warm, replace the oil filter. Reconnect the cable. Replace PS2HU.

LT1HU OIL LEVEL LOW (G)

Oil level switch LT1HU in hydraulic oil reservoir is indicating low oil level.

Leak in the hydraulic system. Level switch LT1HU has failed.

Check the oil level and add oil if necessary. Check system for oil leaks. Never run the hydraulic pump if the reservoir is empty. Replace LT1HU.

TT1HUL OIL TEMPERATURE LOW (G)

Oil temperature transmitter TT1HU in hydraulic oil reservoir is indicating low oil temperature (below 10 °C).

Oil heater is not on. Ambient temperature is low. Transmitter TT1HU has failed.

Check that the oil heater is on. Check oil temperature from the thermometer TM. Allow heater to warm up the oil for 30 minutes. Replace TT1HU.

TT1HUH OIL TEMPERATURE HIGH (G) TS1HU OIL TEMPERATURE HIGH HIGH THERMOSTAT (G)

Oil temp transmitter TT1HU in hydraulic oil reservoir or thermostat TS1HU is indicating high oil temperature (TT1HU above 65 C / TS1HU above 70 C).

Oil cooler is not on. Oil heater has failed on. Transmitter TT1HU has failed. Thermostat TS1HU not adjusted properly or has failed.

Check that the oil cooler is on. Check that the oil heater R1HU is off. Check oil temperature from the thermometer TM. Allow cooler to cool down the oil for 30 minutes. Check adjustment of TS1HU. Replace TT1HU/TS1HU.

M1HU HYDRAULIC PUMP MOTOR (C)

No feedback signal after K1M** output turns on, or the feedback signal still on after K1M** output turns off. Alarm delay 2 sec.

Safety switches open. Fuse tripped.

Reset switches. Replace fuses. Test the motor in question with TEST mode.

M02 PRESSING WATER PUMP M06 CLOTH WASH PUMP MOTOR (C) (OPTIONAL) M08 CAKE CONVEYOR (C) M09 SLURRY PUMP MOTOR (C) M15 CAKE WASH PUMP MOTOR (C) (OPTIONAL)

No feedback signal after output turns on, or the feedback signal still on after output turns off. Alarm delay 5 sec.

Safety switches open. Fuse tripped.

Reset switches. Replace fuses.

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Operation

Name (Group)

Cause

Reason

Solution

R1HU OIL HEATER (C)

No feedback signal after output turns on, or the feedback signal still on after output turns off. Alarm delay 2 sec.

Fuse tripped.

Replace fuses.

CONTROL VOLTAGE OVERLOAD (C)

Thermal overload protector for control voltage has tripped.

Overload. Short circuit. Lose wire connection.

Reset the tripped protector. Measure the current of the protector and find out the reason for the overload.

***F MOTOR FAILED (C)

Thermal overload relay or motor protector has tripped or inverter failed.

Overload. Short circuit. Lose wire connection.

Reset the tripped device. Measure the current of the device and find out the reason for the overload. Clean the motor.

VALVE SENSORS S1** is open sensor. S2** is closed sensor.

Abnormal state of sensor in valve V**.

Instrument air / hydraulic oil pressure low. Break in pneumatics/ hydraulics. Sensor not adjusted properly or has failed. Break in electrical wiring. Blown fuse in terminal box.

Actuate the valve in question in TEST mode. Follow the indicator LED's in the valve circuit for easy troubleshooting. Check instrument air/lines. Adjust/replace sensors. Check electrical system.

B415M FEED MANIFOLD PRESSURE HIGH (E)

Feed manifold pressure transmitter B415 is indicating too high pressure (above max. operating pressure setpoint in auxiliary parameters, typically 16.0 bar).

Slurry feed, wash water or drying air system produces excessive pressure. Transmitter B415 has failed.

Check feed manifold pressure from the pressure gauge. Correct the reason for over pressure. Replace B415.

B415F SLURRY FEED PRESSURE LOW (E)

Feed manifold pressure transmitter B415 is indicating low slurry feed pressure while slurry pump is running and slurry inlet valve V02 is open.

Slurry feed pump inoperative or cavitating. Slurry tank is empty. Manual valve closed. Pressure setpoint “MINIMUM FEED PRESSURE” incorrectly set. Transmitter B415 has failed.

Start the slurry feed pump. Maintain correct slurry level. Open the manual valve. Enter correct value into “MINIMUM FEED PRESSURE” setpoint. Adjust/replace pressure transmitter B415.

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Operation

Name (Group)

Cause

Reason

Solution

B415H HOSE WASH PRESSURE (E) LOW B415C CAKE WASH PRESSURE LOW (E)

Feed manifold pressure transmitter B415 is indicating low wash water pressure during HOSE WASH or CAKE WASH stage.

Wash water pump inoperative or cavitating. Wash water tank is empty. Manual valve closed. Pressure setpoint in Data 2 for HOSE WASH or CAKE WASH stage incorrectly set. Transmitter B415 has failed.

Start the wash water pump. Maintain correct wash liquid level. Open the manual valve. Enter correct value into Data 2 setpoint. Adjust/replace pressure transmitter B415.

B415A DRYING AIR PRESSURE LOW (E)

Feed manifold pressure transmitter B415 is indicating low drying air pressure immediately after opening the valve V06 during DRYING stage.

Compressor not running. Manual valve closed. Low air pressure/volume. Pressure setpoint in Data 2 for DRYING stage incorrectly set. Transmitter B415 has failed.

Start up the compressor. Open the manual valve. Check operation of compressor. Enter correct value into Data 2 setpoint. Adjust/replace pressure transmitter B415.

B415N FEED MANIFOLD PRESSURE NOT RELEASED (E)

Feed manifold pressure transmitter B415 is indicating too high pressure after opening the drain valve V07.

Drain pipe is clogged. Slurry strainer is clogged. V07 valve failed. Transmitter B415 has failed.

Ensure that pressure in feed manifold is released. Clean the pipeline. Check operation of valve V07. Adjust/replace pressure transmitter B415.

B419M PRESSING MANIFOLD PRESSURE HIGH (E)

Pressing manifold pressure transmitter B419 is indicating too high pressure (above max. operating pressure setpoint in auxiliary parameters, typically 16.0 BAR).

Pressing system produces excessive pressure. Transmitter B419 has failed.

Check pressing manifold pressure from the pressure gauge. Correct the reason for overpressure. Replace B419.

B419P PRESSING MANIFOLD PRESSURE NOT REACHED (E)

Transmitter B419 is indicating low pressing manifold pressure after closing the valve V04 and starting the pressing water pump M02.

Pump M02 not running or is cavitating. Manual valve closed. Valve V04 not closed. Pressure setpoint in “MIN. PRESSING PRESSURE” incorrectly set. Transmitter B419 has failed.

Ensure pump M02 is operating normally. Open the manual valve. Enter correct value into “MIN. PRESSING PRESSURE” setpoint. Adjust/replace pressure transmitter B419.

B419N PRESSING MANIFOLD PRESSURE NOT RELEASED (E)

Pressing manifold pressure transmitter B419 is indicating too high pressure after opening the pressing water outlet valve V04.

Outlet pipe is clogged. V04 valve failed. Transmitter B419 has failed.

Ensure that pressure in manifold is released. Clean the pipeline. Check operation of valve V04. Adjust/replace pressure transmitter B419.

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Operation

Name (Group)

Cause

Reason

Solution

B415D FEED MANIFOLD PRESSURE TRANSMITTER DRIFT (E) B419D PRESSING MANIFOLD PRESSURE TRANSMITTER DRIFT (E)

Signal from transmitter that pressure does not fall below 0.5 bar when it should.

Feed manifold drain valve V07 inoperative. Drain pipeline blocked. Pressing water return valve V04 inoperative. Transmitter not adjusted properly or has failed.

Measure mA-signal (4 - 20 mA) when pipeline pressure is zero. Check feed manifold drain pipeline. Adjust/replace pressure transmitter.

S516 PRESSING WATER LEVEL LOW (E)

The pressing water level switch S516 in the pressing water tank does not give signal.

Tank water level is low. Discharge valve is open. Leak in diaphragms. Evaporation. Leak in pressing water hoses or pipelines. S516 not adjusted properly or has failed. Wiring problem.

Fill the tank (the water level should be at the level off the overflow). Follow the operation of the filter during pressing, try to find leak. Replace the damaged diaphragm(s) Replace the damaged hose. Adjust/replace sensor.

SLLO SLURRY LEVEL LOW (E)

The signal from SLURRY TANK LOW LEVEL switch is missing and causes the filter to stop at the end of cycle.

Slurry tank is empty. Level switch is faulty adjusted or failed.

Check the slurry level and level switch. Check the signal coming to the control panel.

S418 INSTRUMENT AIR PRESSURE LOW (E)

The signal from pressure switch S418 is missing for more than 30 seconds.

Instrument air pressure low. Pressure switch faulty adjusted or failed.

Check instrument air pressure. Check pressure switch. Open manual valve. Start up compressor.

BxxxW TRANSMITTER WIRE BREAK

Analog signal of transmitter below 4 mA.

Wire break. Transmitter failed. Analog card failed.

Check wires. Check/replace transmitter. Check/replace analog card.

5.4

Troubleshooting

If the cause of the alarm is not known, the display screen helps the operator to find it and remove it.

Table 8.

Troubleshooting

Malfunction

Possible cause

Solution

1.

Hardened or crystallized cake on sealing surfaces under the filter cloth or foreign material between plates.

Open the plate pack, clean plates and wash the filter cloth.

Defective seal.

Replace the seal.

Leak between plates during filtering.

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Malfunction

2.

3.

4.

5.

6.

7.

Operation

Possible cause

Solution

Bent plate.

Replace or straighten the plate.

Local deflection which does not compensate.

Examine and straighten the sealing surface if necessary.

Counter pressure in the filtrate side.

Check the pipelines.

Slurry feed is greater than the filter's hydraulic capacity.

Decrease the slurry feed rate.

Slurry properties have changed.

Install control equipment for the slurry.

Damaged diaphragm.

Replace the diaphragm.

Pressing water station low level alarms and stops the filter.

Leak in pressure water piping.

Locate and stop the leak.

Damaged diaphragm.

Filtering must not continue by adding water; replace the diaphragm.

Filter cloth slips sideways off the rollers (displaced).

Filter cloth seam is not perpendicular to the edges.

Repair the filter cloth.

Rollers are not correctly positioned.

Adjust the rollers.

Cake sticks to the rollers.

Adjust the roller scrapers closer to the rollers.

Bad seam in the filter cloth.

Repair the clipper seam.

Filter cloth seam gets caught on scrapers.

Check the scrapers and adjust them if necessary. Check the clipper seam and replace the filter cloth if the seam is damaged.

Filter cloth scrapers make the filter cloth go slower.

Adjust the filter cloth scrapers.

Water is left in the pressing diaphragms and it presses the filter cloth.

Remove the water from the diaphragms.

The filter cloth slips on the drive roller due to insufficient filter cloth tensioning.

Adjust the tensioning pressure.

Too much water remains in the pressing diaphragms pressing the filter cloth thus preventing the filter cloth from moving.

Close the pack carefully in TEST mode. Adjust a longer drying time.

Cakes are too thick.

Remove the filter cake manually. Do a check of the plate feed inlets. Do a check of the slurry feed time.

Cake is wetter than normal.

Folding in the filter cloth.

Filter cloth moves jerkily but without slipping on the drive roller.

The filter cloth does not move and stops the filter.

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Operation

Malfunction

Possible cause

Solution

8.

Cake gathers on the rollers.

The filter cloth is not cleaned correctly.

Adjust the filter cloth scrapers to get closer to the filter cloth. Adjust the roller scrapers. Do a check of the filter cloth wash system.

9.

Too high solid content in the filtrate.

Hole in the filter cloth.

Repair the hole immediately.

Filter cloth wash does not operate properly.

Do a check of the filter cloth wash nozzles and their direction. Do a check of the direction of the nozzle pipes. Clean or replace the clogged nozzles.

10.

Blocked grids.

Hole in the filter cloth.

Repair the hole immediately!

11.

Filtrate outlets and pipes wear out fast.

Filter cloth wash does not operate properly.

Do a check of the filter cloth wash nozzles and their direction. Do a check of the direction of the nozzle pipes. Clean or replace the clogged nozzles.

12.

A very thin filter cake or no filter cake.

Blocked slurry feed inlet.

Clean the slurry feed inlet and do a check of the slurry sieve.

13.

Filter cloth guiding is difficult, filter cloth edges get frayed, and filter cloth limits give an alarm.

Slide pieces are worn or not correctly adjusted.

Adjust the slide pieces or replace them if necessary.

14.

A roller does not rotate or rotates jerkily.

Bearing fail because of a damaged seal.

Replace the bearing.

15.

The chains of the tensioning device do not stay on the sprockets.

The chains have stretched.

Tighten the chains.

16.

The pinch valve leaks.

A broken pinch valve sleeve.

Replace the sleeve and adjust the actuator.

17.

Problems with the pressure water pump; wearing out, dropped pressure, increased cake moisture.

Broken diaphragm.

Replace the diaphragm and clean the water station.

18.

Filter cloth drive and centering is difficult and filter cloth life gets shorter.

Aging of the rubber (drive, press and centering rollers).

Replace the roller(s).

Too high pressing force (between the drive roller and pressing roller).

Adjust the coil springs of the press roller to the length of 55 mm and replace the damaged roller(s).

19.

Faults in sub-supplied parts.

See the manufacturer's instructions.

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Outotec P.O. Box 1000, FI-02231 Espoo Tel +358 (0) 20 529 211 www.outotec.com E-mail [email protected] © 2017 Outotec Oyj. All rights reserved.

ECFN-OUT-MC-P015-MAN-00001

Outotec® Larox PF Pressure Filter PF1226 PF16/19 M12 45 Installation, Operation, Maintenance and Service Manual Maintenance Doc. No. OU750009576, English 2017

ECFN-OUT-MC-P015-MAN-00001

PF1226, PF16/19 M12 45

Maintenance

This document is proprietary to Outotec Oyj and its affiliated companies (“Outotec”). This document is intended for the use of Outotec's customers only for the purposes of the agreement under which the document is submitted and no ownership rights are hereby transferred. No part of the document shall be used, reproduced, translated, converted, adapted, stored in a retrieval system, communicated or transmitted by any means, for any commercial purpose, including without limitation, sale, resale, licence, rental or lease, without the prior express written consent of Outotec. Customer understands and accepts that the information in this document is subject to any change without notice. It is the customer's responsibility to determine whether there have been any such updates or amendments. The document has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Despite the fact that every effort has been made to ensure that the information in this document is accurate Outotec does not make any representations, warranties or guarantees, express or implied, as to the accuracy or completeness of the document. In case of any discrepancies between different language versions English version shall prevail. Outotec shall not be liable in contract, tort or in any other manner whatsoever to any person for any loss, damage, injury, liability, cost or expense of any nature, including without limitation incidental, special, direct or consequential damages arising out of or in connection with the use of the document. Outotec's liability for any errors in the document is limited to the documentary correction of errors. Outotec logo is a registered trademark of Outotec Oyj. Other product names mentioned in this document may be trademarks of their respective companies, and they are mentioned for identification purposes only. Copyright © Outotec Oyj 2017. All rights reserved.

Outotec Oyj Address:

Rauhalanpuisto 9, PO Box 1000 FI-02231 Espoo, Finland

Telephone:

+358 (0) 20 529 211

Fax:

+358 20 529 2200

Internet:

www.outotec.com

04 03 02 01 00

annvla

7.11.2017

Rev

Name

Date

Preliminary Name

Prepared

Date

Checked

Name

Date

Revision Text

Released

Status:

Original Size:

Preliminary

A4

Customer:

Project Phase:

Site No.:

Fruta del Norte Project Name:

Customer Document ID:

Replaced by:

Replaces: Document Title:

MAINTENANCE

PF1226, PF16/19 M12 45 Equipment No:

Item No:

IOMS MANUAL

PF1226

Language: EN

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PF1226, PF16/19 M12 45

ECFN-OUT-MC-P015-MAN-00001 Maintenance

Contents Contents ............................................................................................................................. 3 1

2

Planned maintenance ............................................................................................. 6 1.1

Maintenance Schedule .............................................................................. 6

1.2

Lubrication recommendations .................................................................... 8

Maintenance procedures ...................................................................................... 10 2.1

Safety during maintenance work .............................................................. 10

2.2

Using safety devices prior to maintenance .............................................. 11 2.2.1

Preparing the machine for maintenance ............................................. 12

2.2.2

Isolation from process lines ................................................................ 12

2.2.3

Isolation from hydraulic power supply ................................................. 12

2.2.4

Isolation from electric power supply .................................................... 12

2.2.5

Isolation from pneumatic system ........................................................ 13

2.3

Space arrangement between filter plates ................................................ 13 2.3.1

Reversing plate pack space arrangement .......................................... 17

2.3.2

Suspending and locking the plate pack .............................................. 17

2.3.3 2.4

Checklist for safe plate pack maintenance ......................................... 19 Plate pack maintenance ........................................................................... 20

2.4.1

Filter plate replacement ...................................................................... 20

2.4.2

Finding leaking diaphragms ................................................................ 25

2.4.3

Diaphragm replacing by removing filter plate ..................................... 26

2.4.4

Diaphragm replacing in plate pack ..................................................... 27

2.4.5

Seal replacing by removing filter plate ................................................ 29

2.4.6

Seal replacing without removing the filter plate .................................. 30

2.4.7

Slide piece replacement and adjustment ............................................ 31

2.4.8

Grid replacement without removing the filter plate ............................. 32

2.4.9

Rollers ................................................................................................. 32

2.4.10

Scraper adjustment (Flat plate) .......................................................... 43

2.4.11

Plate pack cleaning ............................................................................. 44

2.4.12

Suspension plate inspection and replacement for flat plate pack ...... 44

2.4.13

Slurry sieve ......................................................................................... 47

2.4.14

Hose replacement ............................................................................... 47

2.4.15

Pressing transmitters .......................................................................... 49

2.4.16

Valve position sensors adjustment ..................................................... 52

2.5

Pressing water station maintenance ........................................................ 53 2.5.1

Pressure adjusting .............................................................................. 53

2.5.2

Pressing water station inspections ..................................................... 53

2.5.3

Pressure water tank sieve cleaning .................................................... 54

2.5.4

Pressing water hose maintenance ...................................................... 54

2.6

Control panel maintenance ...................................................................... 55

2.7

Hydraulic system maintenance ................................................................ 56

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2.7.1

Filling the hydraulic oil reservoir ......................................................... 56

2.7.2

Hydraulic system start-up ................................................................... 57

2.7.3

Adjustments ........................................................................................ 57

2.7.4

Calibration of Bosch proportional plug ................................................ 57

2.7.5

Controlling the filter cloth driving speed .............................................. 57

2.7.6

Filter cloth washing speed control ...................................................... 57

2.7.7

Sealing force adjustment .................................................................... 58

2.7.8

Pump adjustments .............................................................................. 58

2.7.9

Hydraulic unit service .......................................................................... 58

2.7.10

Quick action cylinder bleeding ............................................................ 60

2.7.11

Sealing cylinder bleeding .................................................................... 61

2.7.12

Closing device limit switch adjustment ............................................... 62

2.8

Closing device maintenance .................................................................... 64 2.8.1

Closing device inspections.................................................................. 64

2.8.2

Guide rails ........................................................................................... 64

2.8.3

Quick action cylinder replacement ...................................................... 65

2.8.4

QAC seal replacement ........................................................................ 80

2.9

Filter cloth maintenance ........................................................................... 82 2.9.1

Filter cloth tensioning .......................................................................... 82

2.9.2

Filter cloth seam positioning ............................................................... 83

2.9.3

Filter cloth patching ............................................................................. 86

2.9.4

Filter cloth replacement....................................................................... 87

2.9.5

Adjusting of filter cloth limits (hydraulic) .............................................. 88

2.9.6

Filter cloth wash water spray adjustment............................................ 90

2.9.7

Filter cloth tracking .............................................................................. 90

2.9.8

Filter cloth tensioning device maintenance ......................................... 90

2.10

Washing the filter ..................................................................................... 91

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ECFN-OUT-MC-P015-MAN-00001 Maintenance

CAUTION Use appropriate protective equipment, such as a safety helmet, goggles, protective overalls, protective footwear, safety gloves, safety harness, ear protection and respirator whenever needed.

Before maintenance or repair work, make sure the machine cannot accidentally be turned on: follow the correct lockout-tagout procedures.

. DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Stop the machine completely before maintenance, repairs or disassembly.

Electrocution hazard. Electrocution will cause serious injury or death. Cut the power supply to the machine before maintenance, repairs or disassembly.

Hydraulic fluid injection hazard. High-pressure hydraulic fluid spray can penetrate the skin and will cause death or serious injury.

Crushing hazard. Falling filter plates can cause death or serious injury. Do not work between filter plates unless the plate pack is secured open with suspension plates and locking pins.

. WARNING High-pressure air injection hazard. High pressure air spray can cause death or serious injury. Make sure that the pneumatic system is not pressurized before maintenance, repairs or disassembly.

General maintenance Flush the filter from outside when necessary and only when the filter is not in operation. Keep the filter and its surroundings clean and free from any unnecessary objects. Maintenance of OEM parts According to the instructions given by the sub-suppliers attached to OEM documents.

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1

Maintenance

Planned maintenance 1.1

Table 1.

Maintenance Schedule

Maintenance schedule

Maintenance period x filtering cycling or lifetime A = daily B = weekly C = monthly D = semi-annually 15000 x E = yearly 30000 x Object

A

B

C

Adjusting valve of pressing water pressure

D

E

1

Control panel

Clean if necessary. Refer to chapter 2.6. 1

Emergency stop switches

Operation Adjust if necessary. Refer to chapter 2.5.1.

1

Diaphragm

2

1

Visual inspection for wear and tear. For replacement refer to chapters 2.4.2, 2.4.3 and 2.4.4. Verify operation by testing.

Fastening of rollers Filter cloth

1 =check / filling / adjust 2 = change

1 1

Check torque of mounting screws / nuts. Check filter cloth condition / centering. Refer to chapter 0.

Seam of filter cloth

1

Check condition of seam wire Refer. To chapter 2.9.2.

Filter plates

1

Check grids + plates straightness. Refer to chapter 2.4.

Grease nipples

1

Refer to chapter 1.2 for lubrication recommendations.

Hoses

1

Check fixing points and condition for wear and tear. For replacement refer to chapter 2.4.13.

Hydraulic unit

1

Visual inspection for leaks and reservoir oil level. Refer to chapter 2.7.

Hydraulic piping and hoses

1

Check connections change hoses in every 3 years.

Hydraulic cylinders

1

Check piston for corrosion, scratches, leaks and mounting hardware torque.

Hydraulic motors

1

Check for overheating, leaks and abnormal sound.

Hydraulic motor couplings

1

Check flexible element and change if necessary.

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PF1226, PF16/19 M12 45

Maintenance

Maintenance period x filtering cycling or lifetime A = daily B = weekly C = monthly D = semi-annually 15000 x E = yearly 30000 x Object

A

B

C

D

1 =check / filling / adjust 2 = change

E

Operation

Hydraulic oil

1

Change or finefilter the oil. Refer to chapter 2.7.9. For recommended hydraulic oil.

Pressure water station and hydraulic unit level controllers

1

Visually check level and compare to oui values. In case of deviations verify controller functions.

Limit switches

1

Rollers

Check mounting, cleanliness and mechanical condition. Refer to filter layout in electrical drawings for list of targets. 1

Plate seal

Check for abnormal sounds, corrosion and coating for wear and tear. For lubrication refer to chapter 1.2. 1

Pressing water pump

2

Visual inspection for wear and tear. For replacement refer to chapters 2.4.5 and 2.4.6.

1

Check cleanliness, mounting torque and for leaks. Refer to chapter 2.5.

Pressing water tank

1

Clean if necessary. Refer to chapter 2.5.

Pressure switches

1

Check mounting, cleanliness and mechanical condition. Refer to filter layout in electrical drawings for list of targets

Scrapers

1

Adjust if needed. Refer to chapter Error! Reference source not ound..

Sealing pressure

1

Check and adjust if necessary. Refer to chapter 2.7.7.

Slide pieces

1

Adjust and change if necessary. Refer to chapter 2.4.7.

Slurry sieve

1

Check and clean if necessary. Refer to chapter 2.4.13.

Tensioning device

1

Valve actuators

1

Valves

1

Wash nozzles + filter

1

Check + adjust. Tightness of chains. Visual inspection for leaks. Visual inspection for corrosion and leaks. Clean and replace if needed. Refer to chapter 2.9.6.

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PF1226, PF16/19 M12 45

1.2

Maintenance

Lubrication recommendations

These lubrication instructions are for general use, and should not be used as a reference in special conditions. Lubricate the following items with a grease gun or brush regularly: 

Locking pins



Chain and sprocket of the cloth tensioning device



Cloth tensioning device cylinder and cake chute flap’s cylinders



Roller grease nipples

Figure 1.

Lubrication points

Table 2.

Lubrication chart

Position

Description and number of lubrication points

Lube

Amount

Interval

1.1

Roller bearing/2 points

NLG-2

25 g

1 x MONTH

1.2

Roller bearing/2 points

NLG-2

25 g

1 x MONTH

4

Roller bearing/20 points

NLG-2

10 g

1 x MONTH

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PF1226, PF16/19 M12 45

Maintenance

Position

Description and number of lubrication points

Lube

Amount

Interval

6

Locking pin/4 points

NLG-2

Lube with brush

1 x MONTH

9.1

Roller bearing/2 points

NLG-2

10 g

1 x MONTH

9.2

2 Sprockets and 2 Chains

NLG-2

Lube with brush

1 x MONTH

9.3

Cylinder/2 points

NLG-2

20 g

1 x MONTH

10

Roller bearing/2 points

NLG-2

10 g

1 x MONTH

22.1

Cylinder/2 points

NLG-2

20 g

1 x MONTH

22.2

Cylinder/2 points

NLG-2

20 g

1 x MONTH

Note that amounts and intervals are indicative.

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2

Maintenance

Maintenance procedures 2.1

Safety during maintenance work

Before starting any maintenance work: 

Make sure you know the structure of the filter.



Get familiar with all different operation stages of the filter.



Learn how to use the control panel push buttons.



Study all safety regulations.

The filter operates automatically; never start any maintenance or repair work when the filter is energized. CAUTION Do not fix maintenance tools on the filter.

Inspect the condition of the distribution pipelines and hoses for wear and tear, as well as their joints.

For possible emergency situations during maintenance, there are several emergency stop switches on the machine. They are situated on the control panel, on the side of the filter cloth conveyor unit casing, on the pressure water station and on the HH unit. The emergency stop switches stop the filter immediately. Ensure the emergency switches are released before a restart. The filter uses hydraulic pressures so in case of possible failure the pressure is released immediately. The filter is always open on its filtrate side. Check the hose guards are in place, because they receive the force of the pressure blow in case of possible hose damage. When changing the filter cloth, beware of the pinch points formed by the rollers. If the filter is located in a place with a danger of explosion, make sure the filter cloth does not move before it is wetted all around with conductive liquid, for example, water. CAUTION If the filter cloth is moved while dry, ensure there are no hazardous gases, dust or any other explosively sensitive materials in the same space with the filter.

If there are explosively sensitive materials in the space where the filter cloth has to be moved, follow the mill practice when carrying out maintenance work (for example welding at the same area).

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Maintenance

The reason for these safety precautions is a possibility of electrical charging of the filter cloth. The filter cloth charges with static electricity under some conditions. If the particles attaching to the filter cloth are electrically non-conductive, they can create a spark associated with rapid electrostatic discharge (ESD).

2.2

Using safety devices prior to maintenance

There are four different energy sources related to PF Filter: 1. Hydraulic pressures from hydraulic power unit and accumulator circuit. 2. Electric power from power supplies. 3. Process pressures from process pipe lines. 4. Compressed air pressures from compressors and reservoirs. Isolate these energy sources before the maintenance to prevent accidents. Some of the energy sources are necessary during the maintenance of the filter (for example, hydraulic and electric power is necessary to operate the plate pack). The person that does the maintenance decides which energy sources to isolate and which are necessary to do the maintenance work safely. This person takes responsibility for isolating these energy sources. CAUTION Keep the emergency stop button pushed down if the activation of the filter functions is not necessary.

Do not use the emergency stop function as the only isolation method.

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2.2.1

Maintenance

Preparing the machine for maintenance

1. Stop the filter: select the END mode from the touch screen. 2. The filter continues its operation through the cycle and stops after the end of cloth washing. The filter performs an orderly shutdown by closing or opening the plate pack depending on the mode selected from the configuration page. 3. Switch the filter to the TEST mode: turn the mode selector switch S780 to the TEST position.

2.2.2

Isolation from process lines

1. Switch off all feed pumps of the filter process. Lock the pump switches with a safety lock and tag and close the isolation valves. 2. Isolate the filter from the process: close the isolation valves from all process lines connected to the filter.

NOTE: Pinch valves start to open after a small delay after the hydraulic / pneumatic pressure to their actuators is disconnected.

2.2.3

Isolation from hydraulic power supply

1. Stop the hydraulic unit by using the control panel switch (S755 Hydraulic unit). 2. Switch off the hydraulic unit motor safety switches and lock them with padlock and warning tag. 3. Drain all the hydraulic pressure from the accumulator circuit with help of manual valve SV01. For the location of the switch (1), see the drawing below and respective hydraulic diagram for the location of SV01 manual valve.

2.2.4

Isolation from electric power supply

Figure 2.

Control panel

1. Turn the filter main switch (S700) to 0-position on the control panel. 2. Lock the main switch with safety lock and tag. For the location of the switch (2), see

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Maintenance

drawing above.

2.2.5

Isolation from pneumatic system

1. Ensure the instrument and process air supplies (for example air reservoirs) are isolated properly with a safety lock and tag. 2. Drain all the pneumatic pressures from the circuits with respective valves. Close 3way valve in pneumatic cabinet.

2.3

Space arrangement between filter plates DANGER

Crushing hazard. Falling filter plates can cause death or serious injury. Do not work between filter plates unless the plate pack is suspended and locked according to instructions in this manual.

Wear overalls, gloves, helmet, eye protection, ear protection, safety harness and safety boots when doing maintenance in between the filter plates.

Space arrangement between the filter plates is needed for following maintenance tasks. See the separate service work books for these tasks. 

Diaphragm replacement

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

Seal replacement



Filter plate replacement



Grid replacement

ECFN-OUT-MC-P015-MAN-00001 Maintenance

1. Drive the plate pack to its close position. Close the plate pack by using the handheld unit; see figure below. Select HC5 and push the button S723 (QA-cylinder closing). When the QA-cylinders are down, lock the locking pins: Select HC6 and push the button S725 (Locking pins lock). 2. Stop the hydraulic unit by using the control panel switch (S755 Hydraulic unit). For the location of the switch, see Figure 4 Control panel.

Figure 3.

Hand held unit

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Maintenance

2

1

Figure 4.

1.

Control panel

Main switch

2.

Hydraulic unit switch

3. Activate the emergency stop circuit by pushing the emergency stop push button S702 from the hand-held unit, see Figure 3 Hand held unit. 4. Turn the filter main switch (S700) to 0-position on the control panel. Lock the main switch with safety lock and tag. For the location of the switch, see Figure 4 Control panel. 5. Open the safety guards. 6. Cut the plate pack by removing four pairs (8 pcs) of suspension plates from the filter plate, below the place where space is needed. 7. To have enough working space between the plates (approx. 250 mm), turn the suspension plates as shown in figure below.

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Maintenance

8. Install other suspension plates back and fix all the retaining rings.

Figure 5.

1.

Suspension plates positions

Pack closed. Suspension plates in normal position.

2.

Turn upper suspension plates as shown in the drawing (e.g. grid needs replacement is in the plate no. 4)

9. Close the safety guards. 10. Release the emergency stop push button from the hand-held unit 11. Open the main switch safety lock and tag. Turn the filter main switch (S700) to 1position on the control panel. 12. Start the hydraulic unit by using the control panel switch (S755 Hydraulic unit). 13. Acknowledge alarms on the control panel button S733/H733. The alarm signal will stop flashing when S733/H733 is pushed once; the second push will acknowledge it provided that the cause of the alarm has been eliminated. 14. Drive the plate pack into its open position. Open the plate pack by using the handheld unit: Select HC6 and push the button S723 (Locking pins open). When the locking pins are open: Select HC5 and push the button S725 (QA-cylinders opening) until the plate pack is open. When the QA-cylinders are up, lock the locking pins: Select HC6 and push the button S725 (Locking pins lock). 15. Stop the hydraulic unit by using the control panel switch (S755 Hydraulic unit). 16. Activate the emergency stop circuit by pushing the emergency stop push button S702 from the hand-held unit. 17. Turn the filter main switch (S700) to 0-position on the control panel. Lock the main switch with safety lock and tag. 18. Open the safety guards. 19. Prior commencing any maintenance or repair work within the plate pack, check visually that: -

Isolation of the energy sources is done properly (with lock and tag)

-

Plate pack position is secured by locking all 4 locking pins (from the OIU panel)

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-

Plate pack position is secured by locking all 4 locking pins (from the locking pins itself)

-

All the suspension plates and retaining rings are installed correctly

-

Emergency stop push button is pressed down from the hand-held unit CAUTION

Checklist for safe plate pack maintenance at the end of this book should be copied and signed before proceeding any further with the maintenance work every time when plate pack is cut.

2.3.1

Reversing plate pack space arrangement

For hand held and control panel switches, refer to chapter 2.3 Space arrangement between filter plates. 1. Close the safety guards 2. Drive the plate pack to its close position. Close the plate pack by using the handheld unit: Select HC5 and push the button S723 (QA-cylinder closing). 3. Stop the hydraulic unit by using the control panel switch (S755 Hydraulic unit). For the location of the switch (1). 4. Activate the emergency stop circuit by pushing the emergency stop push button S702 (3) from the hand-held unit. 5. Turn the filter main switch (S700) to 0-position on the control panel. Lock the main switch with safety lock and tag. 6. Open the safety guards. 7. Assemble the suspension plates in original order and reverse the previous steps to get the filter operational. See chapter 2.3.2 Suspending and locking the plate pack. 8. Drive the plate pack up and down to ensure suspension plates are correctly assembled.

2.3.2

Suspending and locking the plate pack CAUTION

Follow the instructions in this chapter every time before starting any maintenance work between the filter plates. Fill in a copy of the 2.3.3 Checklist for safe plate pack maintenance when suspending and locking the plate pack.

Always use 12 pieces of suspension plates (2 pieces in every support pin) when the filter plate is lifted and suspended by the suspension plates.

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Maintenance

Lock the suspension plates with the retaining rings and ensure the correct assembly of suspension plates. (See figures below).

.

Figure 6.

1.

Suspension plate order

Pack closed. Suspension plates in normal position

2.

Turn upper suspension plates as shown in the drawing

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2.3.3

ECFN-OUT-MC-P015-MAN-00001 Maintenance

Checklist for safe plate pack maintenance CAUTION

Filling template Checklist for safe plate pack maintenance is obligatory before any maintenance work between the filter plates.

The template can be found Appendices 10 chapter 6.

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2.4

Maintenance

Plate pack maintenance DANGER

Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Always when maintaining the plate pack, make sure that the filter is stopped, the manual valves of the pipes are closed and the emergency stop switch of the hand held unit is pressed down.

Crushing hazard. Falling filter plates can cause death or serious injury. When working between the plates, secure the open position of the plate pack by using suspension plates and by locking the plate pack.

Falling hazard. Do not climb on the machine or the filter plates and use a safety harness when necessary.

2.4.1

Filter plate replacement CAUTION

Incorrect hoisting may cause damage to the machinery. When choosing the steel tubes keep in mind the weight of one filter plate is about xx kg.

Position yourself so the filter is in front of you and the filter cloth tensioning device is located on the left side of the filter, see the picture below. There are two kinds of filter plates in the plate pack. The ones with the roller on left side from your point of view are called left handed filter plates. The ones with the roller on right side are called right handed filter plates.

Figure 7.

Filter cloth tensioning device

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1.

Filter cloth tensioning device

Maintenance

A) B)

Left handed side Right handed side

1. If you’re taking a right handed filter plate out of the plate pack, the filter cloth needs to be cut from the seam. First drive the filter cloth so the seam is positioned on the roller of filter plate to be removed. 2. Loosen the filter cloth by driving the tensioning roller to its uppermost position. Lock the tensioning roller in place by using the throttle check valve. See the picture in next page.

View A

Figure 8.

Throttle check valve (1)

3. Split the filter cloth from the seam in case of removing the right handed filter plate. 4. Drive the plate pack to closed position and remove four pairs of suspension plates so the plate to be removed is the lowest one still attached to plate pack. 5. Remove slurry, filtrate and pressing water hoses from the plate to be removed. 6. Drive the plate pack to open position and lock it in place. 7. Insert four pcs of steel tubes with a minimum diameter of 60 mm under the filter plate to be removed as shown in the picture below.

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Figure 9.

ECFN-OUT-MC-P015-MAN-00001 Maintenance

Steel tubes in filter plate replacement

NOTE: The minimum wall thickness of the steel tubes is 4-5 mm for supporting the filter plate(s).

8. Lower the plate to be removed carefully on top of the steel tubes. Depending on the plate to be removed you will need to lower 2 or 3 of the lowest plates on top of the tubes to be able to remove the suspension plates from the plate to be removed. 9. Remove the suspension plates from the plate to be removed. Drive the plate pack to open position and lock it in place. 10. Release the guide bars of the plate pack from the brackets in columns and loosen the fixing screws on the upper end of the guide bars. 11. Draw the guide bars sideways to their extreme position and secure them in place. 12. Install a chain tackle and two lifting ropes to the suspension pins on the plate to be removed. 13. Pull the filter plate carefully out of the plate pack. Make sure not to pull it all the way out yet. See the figures A and B below.

NOTE: If the filter plate is left handed and has an auxiliary drive motor attached, remove the motor before proceeding to take the filter plate out of the plate pack.

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.

A

Figure 10.

Filter plate removal, A

Figure 11.

Filter plate removal, B

14. Install two more lifting ropes of equal length to the support pins on the plate to be removed. In case of right handed plate use the slide pieces pins. For the left handed filter plate use the pins located on the back corners of the filter plate. See figure C below.

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Figure 12.

Maintenance

Filter plate removal, C

15. Adjust the chain tackle so the filter plate is in balance. Hoist the filter plate out of the plate back. See figure D below.

Figure 13.

Filter plate removal, D

NOTE: It is recommended to have one person operating the crane, a second using the chain tackle and a third one observing the filter plate moves steadily and is in balance.

16. Install a new filter plate in a reversed order. 17. Adjust slide pieces and make sure the suspension plates move properly. The slide bars and pieces have been originally adjusted and pinned by Outotec and should be reassembled identically.

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2.4.2

Maintenance

Finding leaking diaphragms CAUTION

Wear safety goggles when searching for a leaking diaphragm. Do not open the feed pipe when the plate pack is closed.

A defective diaphragm is localized as follows: when the plate pack is open, the filtrate pipe is opened at its upper end. Then the plate pack is closed and sealed. After this, the pressing water motor M1PWS is started. By looking into the pipe it can be checked from which connecting piece the water comes out. The defective diaphragm is located above this connecting piece.

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2.4.3

Maintenance

Diaphragm replacing by removing filter plate

Filter plate has to be removed from the plate pack in order to change a diaphragm. 1. Remove the filter plate containing defective diaphragm according to chapter 2.4.1 Filter plate replacement. 2. Place the filter plate down on wooden planks or similar flat plane. Be careful not to damage the seal on the bottom of the plate. 3. You may now remove the plate fixing screws using a pneumatic wrench delivered with the filter. Bolt size is 24 mm. See figure below.

Figure 14.

Removing plate fixing screws

4. After all the screws are loosened and removed, hoist the upper part of the filter plate away from the suspension pins. 5. Replace the defective diaphragm. Put the nubbly side up. See figure below.

Figure 15.

Removing diaphragm

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NOTE: As the diaphragm is not symmetric the nubbly side must be facing up and the reinforced area facing down.

6. Hoist the upper part of the filter plate back on top of the plate frame and fix it in place with the screws. Apply anti-seizing compound on the screws to prevent seizing of the threads. 7. Tighten the screws with a torque wrench. Tightening torque is 250 Nm. 8. Install the serviced filter plate back to the plate pack according to chapter 2.4.1 Filter plate replacement. 9. After cleaning and filling the pressure water tank start the filter. If the diaphragm still leaks from the edges of the diaphragm, add an O-ring strip in the groove of the frame before installing the diaphragm. A suitable O-ring strip diameter is 6 mm.

2.4.4

Diaphragm replacing in plate pack

1. Locate the leaking diaphragm according to chapter 2.4.2 Finding leaking diaphragms and mark the respective filter plate. 2. Arrange working space above the marked filter plate by cutting the plate pack above the filter plate where the broken diaphragm is. See chapter 2.3 Space arrangement between filter plates. 3. Remove the plate fixing screws with the pneumatic wrench (with a wrench opening of 24 mm) delivered with the filter. See figure below.

Figure 16.

Removing the plate fixing screws

4. Reverse the space arrangement according to chapter 2.3.1 Reversing plate pack space arrangement. 5. Cut the plate pack again, see the instructions in chapter 2.3 Space arrangement

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Maintenance

between filter plates, with the following exception: -

Fix the filter plate that requires maintenance on the filter plate above it. Use eight suspension rings for fixing. After this it is possible to lift the upper half of the filter plate off.

6. Replace the defective diaphragm with a new one. The nubbly side of the diaphragm must face up. See figures below.

Figure 17.

Installing diaphragm

Figure 18.

Correctly assembled diaphragm

7. After replacing the diaphragm ensure it is properly in its groove. 8. Reverse the plate pack space arrangement according to chapter 2.3.1 Reversing plate pack space arrangement. 9. Cut the plate pack again, see the instructions in chapter 2.3 Space arrangement between filter plates, with the following exception:

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-

Maintenance

The suspension links are attached to their original place to allow the upper half of the filter plate to stay on top of the lower half.

10. Fix the filter plate frame screws with the pneumatic wrench. Apply anti-seize compound on the screws to prevent the seizing of threads. Leave no gaps in the frame plate. Tightening torque is 250 Nm. 11. Reverse the plate pack space arrangement according to chapter 2.3.1 Reversing plate pack space arrangement.

2.4.5

Seal replacing by removing filter plate

To change a seal (4), remove the filter plate from the plate pack the same way as when changing a diaphragm. 1. Place the filter plate upside down on a wooden planks or similar flat plane. Do not damage the sealing surface of the filter plate. 2. Remove defective seal from its groove. 3. Clean the groove carefully from any leftover parts. 4. Press a length of 100 mm of seal in the groove at the corners (points A in the picture). 5. Press a length of 100 mm of seal into the groove at the mid points of the frame (points B in the picture). 6. Press a length of 100 mm of seal into the groove at the mid points of the frame (points C in the picture). 7. Press the rest of the seal into the groove. 8. Install the filter plate back to the plate pack by reversing the instructions in chapter 2.4.1 Filter plate replacement.

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Figure 19.

2.4.6

Maintenance

Filter plate seal installation order

Seal replacing without removing the filter plate

1. Mark the filter plate with the broken seal. 2. Arrange working space between the filter plates by cutting the plate pack above the marked filter plate. Refer to chapter 2.3 Space arrangement between filter plates. 3. Remove defective seal from its groove with a screwdriver. See figure below.

Figure 20.

Removing seal with screwdriver

4. Clean the groove carefully from any leftover parts. 5. Refer to previous chapter 2.4.5 Seal replacing by removing filter plate for

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instructions on installing a new seal. 6. Reverse the plate pack space arrangement; refer to chapter 2.3.1 Reversing plate pack space arrangement.

2.4.7

Slide piece replacement and adjustment

Wearing of guide pieces makes the plates move in direction of their longitudinal axes and thus the roller arms run into the back of the upper plate during the sealing stage. Seals can no longer press freely together and this may cause leakages in the plate pack. Observe the slide pieces for possible wear, and adjust whenever necessary. Instructions for adjustment are given below. When there is no adjustment allowance left, replace the slide pieces by new ones, following these instructions: 1. Unscrew the fixing nuts and eccentric sleeves and remove the slide pieces. 2. Insert and adjust new slide pieces. Adjust the plates lengthwise with the slide pieces (dim. A). A should be as big as possible and the same at both ends of the roller according to the drawing. 3. Tighten as shown by the arrow (counterclockwise). This secures the pressing force on the slide piece does not open the locking nut. 4. Check the adjusting nut of the eccentric sleeve does not bump into the guide bar support when the plate pack moves. SLIDE PIECE A-A A

FILTER PLATE ECCENTRIC SLEEVE

GUIDE

FILTER PLATE

A

NUT

Figure 21.

Slide piece replacement and adjustment

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2.4.8

Maintenance

Grid replacement without removing the filter plate

1. Mark the filter plate with the broken grid. 2. Cut the plate pack above the marked filter plate; refer to chapter 2.3 Space arrangement between filter plates. 3. Remove the either end grid plate first and work your way through the plate. Use a screwdriver if needed. 4. Clean the filter plate bottom plate / filtrate vat before installing new grids. 5. Install a new grid plate and fasten it by pressing it into the next grid plates. Push the removed grid plate at the end of the plate into its place and check the grid fixings. 6. Reverse the plate pack space arrangement; refer to chapter 2.3.1 Reversing plate pack space arrangement.

2.4.9

Rollers

Plate roller replacement DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Make sure there are no persons or foreign objects in between the moving parts.

Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Always keep the emergency stop button pushed down (for preventing the manual and remote starts), when the activation functions of the filter are not necessary.

. CAUTION Ensure the working conditions are safe. Inform the operating personnel when maintaining the unit, and close the manual valves in the process piping.

Wear proper protective clothing.

. NOTE: The filter plate roller weighs about 40 kg, so a crane is highly recommended for the work.

NOTE: Because the uppermost rollers of the plate pack are located quite high, extreme caution is needed when replacing them. Use a lifting platform to guarantee safe working conditions.

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Necessary maintenance tools for replacement of the plate roller

Figure 22.

Lifting belt (2 pcs)

1. The roller is located at the end of the filter plate in a "loop" formed by the filter cloth. There are two possible ways to get the roller out. 2. The first one is to drive the cloth so the clipper seam stops at the roller to be changed. The seam is opened and the roller can be changed. 3. Another and more recommendable possibility is to gather so much loose cloth at the roller, which is to be changed by using the "extra" cloth in the tensioning device. The cloth can be drawn over the end of the roller to either side of the filter plate. Proceed as follows: 4. Stop the filter, and drive the plate pack completely open with the HH unit. Drive the locking pins into their holes. Refer to Operation instructions section if needed. 5. If the roller is at the free end of the filter, remove the upper part of the cake chute according to paragraph Removing the upper part of the cake chute. 6. Slacken the filter cloth according to paragraph Slackening the filter cloth. Draw the loosened cloth over the roller’s end sidewards from the filter plate. 7. Remove scrapers from the plate pack frame. -

Roller scraper (1): Loosen the adjusting screws (2). Remove the locking nuts (5) and adjusting pieces (6) at end of the axle. Pull the holder of scraper out from the roller fixing lugs and remove the scraper.

-

Cloth scraper (3): Loosen the fixing screws of the cloth scraper (4) and remove the cloth scraper. Refer to picture on next page.

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Figure 23.

1. 2. 3.

Maintenance

Cloth scraper

Roller scraper Adjusting screw (Hex socket M8) Cloth scraper

4. 5. 6.

Fixing screw of cloth scraper (M10) Locking nut (M12) Adjusting piece

8. Remove scrapers from the plate pack 45 & 60 mm (flat diaphragm). -

Roller scraper (2): Loosen the rubber cushion (1) and the adjusting screw (3). Remove the adjusting levers (4). Turn the scraper so that the knife of scraper is outside the roller fixing lug. Move the scraper laterally and release it from the roller fixing lugs.

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Figure 24.

1. 2.

Maintenance

Roller scraper

Rubber cushion Roller scraper

3. 4.

Adjusting screw (M10) Adjusting lever

9. Use lifting belts for lifting. The roller must be lifted up as straight as possible to avoid bending of the lug. If the roller tends to get stuck during the lift, hit the roller lightly with a rubber hammer. Lower the roller down on the platform on the cake chute. 

Side of the filter cloth drive unit: -

Insert the lifting belt around the top pressing plate and install two lifting belts to it. Lower the roller down on the platform on the cake chute.

10. Install a new roller in a reversed order. See pictures of lifting below and on the next page.

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Figure 25.

1. 2.

Maintenance

Plate roller lifting at the free end of the filter

Lifting belts Cloth loop drawn sideward from the filter plate

A)

Lifting the guide roller

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PF1226, PF16/19 M12 45

Figure 26.

1. 2.

Maintenance

Plate roller lifting at the side of the cloth drive unit

Lifting belts Cloth loop drawn sideward from the filter plate

3. 4. A)

Lifting belt around the top pressing plate Cover the cake chute with platform Lifting the guide roller

Pressing roller replacement DANGER Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Make sure there are no persons or foreign objects in between the moving parts

Hazardous moving parts. Moving parts of the machine will cause serious injury or death. Always keep the emergency stop button pushed down (for preventing the manual and remote starts), when the activation functions of the filter are not necessary.

CAUTION Make sure the working conditions are safe. Inform the operating personnel when maintaining the unit, and close the manual valves in the process piping.

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Wear proper protective clothing.

. NOTE: The filter plate roller weighs about 50 kg, so a crane is highly recommended for the work.

NOTE: Because the uppermost rollers of the plate pack are located quite high, extreme caution is needed when replacing them. Use a lifting platform to guarantee safe working conditions.

Necessary maintenance tools for the pressing roller replacement

Figure 27.

Lifting belts (2 pcs)

1. The pressing roller is located under the drive roller in the cloth conveyor unit. There are two possible ways to get the roller out. -

The first one is to drive the cloth so the clipper seam stops at the roller to be changed. The seam is opened and the roller can be changed.

-

Another and more recommendable possibility is to gather so much loose cloth at the roller, which is to be changed by using the "extra" cloth in the tensioning

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device. The cloth can be drawn over the end of the roller to either side of the filter plate. Proceed as follows: 2. Stop the filter when the filter cloth is in a suitable position. Refer to Operation manual if needed. 3. Draw the loosened filter cloth over the roller’s end sideward or open the clipper seam; see step one. 4. Loosen the pressing roller fastening/pressing screws. 5. Use lifting belts for lifting. The roller must be lifted up as straight as possible to avoid bending the lug. If the roller tends to get stuck during the lift, hit the roller lightly with a rubber hammer. 6. Install a new roller in a reversed order. 7. See picture of the lifting below.

Figure 28.

1. 2.

Lifting the pressing roller

Lifting belt Pressing roller

A)

Lifting the pressing roller

Plate roller bearing replacement 1. Remove the plate roller requiring maintenance according to section Plate roller replacement. 2. Remove retaining ring (10) (figure A). 3. It is recommended to use a pull-out tool (11) to remove the seal housing (3). The

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other way is to hit the other end of the roller with a rubber hammer, in order to release the seal housing and bearing (7) (figure B). 4. Remove the seal housing (3), seals (5, 6 & 8) and bearing (7) (figure C). 5. If the seal sleeve (4) is damaged replace it. Lock it with LOCTITE 641, WEICON AN 306-41 or equivalent. 6. Clean all parts and install a new bearing in a reversed order. Replace the seals and the O-ring (Look at the spare part list). Lubricate bearing with SKF LGFP2.

NOTE: It is recommended to replace both roller bearings at the same time.

See picture below.

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Figure 29.

1. 2. 3. 4. 5. 6.

Maintenance

Replacing roller bearings

Shaft Roller housing Seal housing Seal sleeve (bushing) Roller seal kit Seal, shaft

7. 8. 9. 10. 11.

Bearing O-ring Grease nipple Retaining ring Pull-out tool

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Plate roller positioning The following drawings present four different roller shaft positions in which they can be installed. Different positions change the height of the roller in relation to the filter plate top surface.

Position 1 The upper edge of the roller is above the filter plate top surface whereby filter cloth conveyance tends to lift the filter cloth from above the filter plate thus decreasing friction between the filter cloth and the grid. This position is used when filtering heavy materials.

Positions 2 and 3 The upper edge of the roller is below the filter plate top surface whereby the filter cloth shuffles on the top surface of the filter plate thus cleaning the sealing plate surfaces. These positions are generally used when filtering light materials which tend to get stuck on the sealing surfaces.

Position 4 “Normal” position. The roller does not lift or press the filter cloth in relation to the filter plate.

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Maintenance

2.4.10 Scraper adjustment (Flat plate) Adjust the cloth scraper to touch the cloth so that the cloth is as clean as possible after being scraped and that the amount of material transported by the cloth to the grids and rollers is as small as possible.

Figure 30.

Cloth scraper adjustment

To adjust the cloth scraper, loosen the fixing nuts (2) and adjust the scraper by turning the adjusting screws (3) so that the scraper lifts the cloth up about 2 mm. Tighten the fixing nuts. Cloth scraper has two running surfaces, the other surface can be taken in to use by turning the scraper upside down. Adjust the roller scrapers according to the drawing below so that the scraper lightly touches the roller.

Figure 31.

Roller scraper adjustment

Start the adjustment by loosening the rubber stoppers (part 3) and locking screws (part 5). Then turn the scraper (part 1) to touch the roller and the adjusting lever (part 2) to touch the rubber stopper. Now tighten the locking screws (part 5). Carry out the actual adjustment by tightening the rubber stopper. When the adjustment is correct, lock the rubber stoppers by means of a locking nut (part 4).

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Maintenance

2.4.11 Plate pack cleaning The plate pack must be washed daily with water. It is important to wash the rollers and scrapers as well. This ensures the filter cloth tracking functions properly and that the plate pack stays tight.

2.4.12 Suspension plate inspection and replacement for flat plate pack CHOOSE ONE OF THE FOLLOWING CHAPTERS AND DELETE OTHERS AND THIS TEXT Check all suspension plates annually for possible cracks and replace damaged ones. The designed maximum service life of suspension plate is 5 years. (Variations to both directions are possible depending of several reasons; number of working cycles, cake weight, number of filter plates, environmental factors etc…). CAUTION Omitting the inspection and possible replacement of the suspension plates may lead to personal injury or damaged property which Outotec cannot be held responsible.

Checking/replacing of the suspension plates: 1. Close the plate pack. 2. Remove the retaining rings and washers of the topmost suspension plates.

Figure 32.

1. 2. 3.

Removing retaining rings and washers

Upper pressing plate Filter plate Retaining ring

4. 5.

Washer Top suspension plate

3. Remove all suspension plates from the plate pack. 4. Clean all suspension plates in a meticulous manner. 5. Check suspension plates visually and replace the damaged ones.

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CAUTION Pay attention to the possible cracks in the suspension plates. Slight battering and polishing of the pinholes is acceptable. Areas A and B (see picture below) where the biggest stresses affect are most likely to break first.

6. After inspection, mark the inspected suspension plate with a nail punch. When there are five marks made by nail punch, replace the suspension plate. CAUTION Check the condition of each suspension pin and its joint to the filter plate. Cracks in the welding area and excessive bending of the pin needs to be fixed before reassembly. Slight battering and polishing of the pins is acceptable.

.

Figure 33.

A)

Suspension plate

Possible failure area at the circular hole

B)

Possible failure area at the end of the elongate hole

7. Assemble suspension plates in their places from top to bottom. Remember to install retaining rings in their places.

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Figure 34.

A) B)

Maintenance

Assembly order of the suspension plates

Assemble the inner suspension plates (1, 2, 3.). Assemble the top suspension plate (1) and the midmost suspension plates (2, 3, 4…)

Figure 35.

C)

Assemble the outer suspension plates and retaining rings.

The correct order of suspension plates

8. After reassembly check the movement of suspension plates.

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Maintenance

2.4.13 Slurry sieve Check and rotate the sieve of the slurry pipe once a month. Periodical rotating extends the sieve’s operating life, because the sieve wears most from near the feedholes. To check and rotate the sieve, do the following: 1. Open one feed hose at the lower part of the slurry pipe. 2. Ensure the sieve is undamaged and the holes are open. 3. Rotate the sieve with a screwdriver. If the sieve is stuck and rotating with screwdriver is not possible, remove the sieve from the slurry pipe. 1. Remove the top coupling bail and the branch pipe. 2. Lift the slurry sieve from the slurry pipe. 3. Clean the slurry sieve. 4. Lower the slurry sieve onto its place and rotate it to a new position.

Figure 36.

Removing of the slurry sieve

2.4.14 Hose replacement Pay attention to the following when changing feed, filtrate and pressing water hoses: 

The right type and length of the hose (see figure below).



Mount the hoses when the pack is open. Close the pack and tighten the hose clips.

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

No sharp bends in the hoses are allowed.



Pressure rating of the slurry feed hoses must be 25 bar (or more).



Use the original spare parts as reserve hoses.

Figure 37.

Hoses

2.4.14.1

L-coupling band circle installation CAUTION

.

Do not over tighten the L-coupling bands.

Max torque for M8 nut is 10 Nm. Leave about 2 mm gap between the bands.

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ECFN-OUT-MC-P015-MAN-00001 Maintenance

Gap between bands

2.4.15 Pressing transmitters B415 FEED MANIFOLD PRESSURE TRANSMITTER Location The B415 pressure transmitter is located on the top section of the feed manifold, in the left side of the filter. The transmitter is measuring feed manifold pressure.

Figure 39.

Feed manifold pressure transmitter B415

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Setpoints The transmitter signal is used for multiple purposes and the following set points are used to trigger respective functions. 1. B415>MAXOPPR; Feed manifold pressure has exceeded maximum operating pressure setpoint “MAXOPPRE” in auxiliary parameters. This pressure is typically 16.0 bar but can be adjusted lower if necessary. This setpoint will trigger an alarm B415MALM, which stops the filter. 2. B415>MINFEED (FILTRATION); the feed manifold pressure is monitored during filtration (slurry feed) where a minimum pressure setpoint “MINFEED” in auxiliary parameters must be reached. If the pressure does not raise above the setpoint an alarm B415FALM will be triggered. 3. B415>D2SP (HOSE WASH); the feed manifold pressure is monitored during hose wash where a minimum pressure setpoint in Data 2 must be reached. If pressure does not raise above the setpoint an alarm B415HALM will be triggered. 4. B415>D2SP (CAKE WASH); the feed manifold pressure is monitored during the cake wash where a minimum pressure setpoint in Data 2 must be reached. If pressure does not raise above the setpoint an alarm B415CALM will be triggered. 5. B415>MINDRY; Minimum drying air pressure setpoint in Data 2 has been reached. This is monitored in the beginning of drying stage immediately after V06 is opened. If the drying air minimum pressure is not reached within 3 seconds, an alarm B415AALM is triggered. 6. B415MAXOPPR; pressing manifold pressure has exceeded maximum operating pressure. This pressure is typically 16.0 Bar but can be adjusted lower if necessary. This setpoint will trigger an alarm B419MALM, which stops the filter. 2. B419>MINPRPRE; Minimum pressing pressure has been reached. This is monitored during pressing stage once pressing water pump M02 is started. If the minimum pressing pressure is not reached within 180 seconds, an alarm B419PALM is triggered. 3. B419