Erection Work, Operating and Maintenance Instructions: Belt Press CPF2023 SL

Belt press CPF2023 SL
Diana Joint Stock Corporation, PF U1085/07
Erection Work, Operating and Maintenance Instructions

Machine: Belt press CPF2023 SL
Equipment No.: C-14-802813-011-1530
Year built: 2008
Order Code: Diana Joint Stock Corporation
Order no.: PF U1085/07
Issued: PF Wang Sufang, 2008-05
Checked: PF Jiang Lijie, 2008-05
Rev. 0, 2008.5.26 TITLE PAGE #434851 v1 - DECKBLATT

The operating manual is protected by copyright. All usual rights reserved. It must not
be wholly or partly reproduced without authorization by Andritz AG. Contraventions
shall entail damage claims and may have penal consequences. All rights shall also be
reserved for any patents granted, registration of trade marks and technical
modifications without prior notification.
© 2003 Andritz AG
Rev. 0, 2008.5.26 TITLE PAGE #434851 v1 - DECKBLATT

TABLE OF CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Standards and guidelines . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 How to use the manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Warranty and guarantee . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Manufacturer’s name and address . . . . . . . . . . . . . . . . . 4
1.6 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

2.2 Danger and warning signs . . . . . . . . . . . . . . . . . . . . . . . 1
2.3 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.4 General remarks on machine/plant safety . . . . . . . . . . 2
2.5 User’s obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 General obligations of personnel . . . . . . . . . . . . . . . . . . 5
2.7 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.8 Personal protective apparel . . . . . . . . . . . . . . . . . . . . . . 8
2.9 Safety at the machine installation site . . . . . . . . . . . . . 8
2.10 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.11 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.12 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.13 Hydraulics, pneumatics . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.14 Gases, steam or smoke . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.15 Oils and greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.16 Welding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . 1
3.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.2 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
4.1 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4.2 Main components of the machine . . . . . . . . . . . . . . . . . 2
4.3 Technological description. . . . . . . . . . . . . . . . . . . . . . . . 5
4.4 Machine monitoring equipment . . . . . . . . . . . . . . . . . . . 5
Rev. 0, 2008.5.26 Chapter , Page 1 of 4

#434851 v1 - DECKBLATT
5 ERECTION WORK and TRANSPORT. . . . . . . 1
5.1 General Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

5.2 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5.3 Haulage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
5.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.6 Cold test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6.3 Prerequisites for start-up . . . . . . . . . . . . . . . . . . . . . . . . . 2
6.4 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
6.5 Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7.3 Description of operating elements . . . . . . . . . . . . . . . . . 2
7.4 Control via DCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.5 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
7.6 Normal operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7.8 Re-start after emergency stop . . . . . . . . . . . . . . . . . . . . . 8
7.9 Operating malfunctions and troubleshooting . . . . . . . . 9
8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 1
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8.3 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8.4 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8.5 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.7 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8.8 Belt changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.9 Roll change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.10 Roll bearing change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.11 Changing the transverse sealing strip
behind the wedge zone . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.12 Changing the deckle strips . . . . . . . . . . . . . . . . . . . . . . 14

8.13 Installation and removal of the wedge plates. . . . . . . . 19

8.14 Belt stretcher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 SUPPLIER DOCUMENTATION . . . . . . . . . . . . 1
9.1 103 20 - Inductive belt guiding system . . . . . . . . . . . . . . 1

9.1.1 Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
9.2 105 01 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9.2.1 Planetary gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1


1 INTRODUCTION
This manual is part of the technical documentation of Andritz AG. It is
intended as a supplement to the training provided, to supply the basic
knowledge required for proper, safe and economical use of the equipment
delivered by Andritz AG. Observing these instructions helps avoid hazards
and reduce repair and downtime costs, as well as increasing the reliability
and useful life of machines.
1.1 Use
Target group This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator of the
mill and his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This refers
in particular to the following tasks:
• Handling, starting and stopping
• Troubleshooting
• Maintenance and upkeep
• Haulage
• Maintenance and disposal of process materials, cleaning of machine
and area around the machine.
The following sections are especially important:
• the Chapter on SAFETY,
• the safety instructions contained in various other chapters
Supplementary The mill operator shall complete this manual by adding national
instructions regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned to
the job shall also be added. This also includes instructions on supervising
and reporting obligations.
Safekeeping Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2 Standards and guidelines

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. The equipment conforms to
the equivalent appropriate standards.
Rev. 0, 2008.5.26 INTRODUCTION Chapter 1 , Page 1 of 4

#829700 v1 - INTRODUCTION
1.3 How to use the manual
Presentation • Chapter and paragraph headings are printed in capitals in the

continuous text.
SAFETY
• Designations of indicating and handling elements are written in
inverted commas in the continuous text.
Operate switch "xxx"
• Lists without numbering do not require operations to be carried out in a
certain order.
Pictograms The following pictograms are used in the manual:
Warning signs
Warning signs are shown with an explanation of the

type of the hazard.
The meaning of the different graduations of hazards

are described in the Chapter on SAFETY.
Marks an instruction on handling of the machine or

system.
Marks a useful piece of information
Marks a cross-reference to another Chapter with

absolute path indication.
e.g. /MACHINE/SAFETY

Work steps Work steps are presented in tables. Work steps are numbered and must
(operations) be carried out in the order specified.
Numbering of
pages, tables and
figures Pages Consecutive numbering of Chapters 2-1
Tables Tab.+ Consecutive numbering of Chapters Tab. 2-1
Figures Fig. + Consecutive numbering of Chapters Fig. 2-1
Abbreviations
Tab. Table
Fig. Figure
Illustrations and The illustrations and graphic charts show the basic design of the machine.
graphic charts This may not necessarily correspond exactly to the design supplied.
Detailed information on the equipment supplied
.../PARTS BOOK
.../SUPPLIER DOCUMENTATION
1.4 Warranty and guarantee

Andritz AG’s general terms of delivery and sale shall apply.
Guarantee and liability claims on Andritz AG shall become void if personal
injury or material damage is caused by one or several of the following:
• Use of the machine/system for any purpose other than its designated
use.
• Non-conformity of erection work, start-up and handling of the
machine/system.
• Non-observance of the safety instructions in the manual.
• Non-authorized structural changes to the machine/system.
• Non-observance of the maintenance and upkeep instructions.
In the event of a claim for repair under guarantee, ANDRITZ AG reserves
the right to assess the damage to the machine/system.

1.5 Manufacturer’s name and address

Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our Service Department will be pleased to help you and can be contacted
at:
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Pulp Technology Service Department
Tel.: +43/316-6902-2759
Fax: +43/316-6902-424
e-mail: Karl.Eickhoff@andritz.com
In case of emergency outside working hours

Tel.: +43 316 6902-0
1.6 Copyright
The operating manual is protected by copyright. All usual rights reserved.
It must not be wholly or partly reproduced without authorization by Andritz
AG. Contraventions shall entail damage claims and may have penal
consequences. All rights shall also be reserved for any patents granted,
registration of trade marks and technical modifications without prior
notification.
© 2003 Andritz AG

2 SAFETY
2.1 General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
In addition, the chapters in the operating manual contain further safety
regulations. These are marked by DANGER SIGNS.
Safety instructions on components not supplied by Andritz AG are
contained in the descriptions of the components provided by
sub-suppliers.
BELT PRESS CPF2023 SL/ SUPPLIER DOCUMENTATION
The safety instructions supplement ANDRITZ AG’s operating instructions.
All safety instructions must be observed. Disregarding the safety
instructions may cause a risk to life and limb, environmental pollution
hazards and damage to property.
2.2 Danger and warning signs

The entire SAFETY chapter is of extreme importance and relevant to
safety. The information in this chapter, therefore, is not marked with
special danger symbols.
In the Chapters on ERECTION WORK, START-UP, OPERATION, and
MAINTENANCE in this Manual, warnings are marked by a pictogram. The
following warning signs are used:
This symbol indicates there may be a risk to life and limb.

Non-compliance with the warning signs may lead to serious health
DANGER problems or even fatal injuries, and can cause extensive damage to
property.
This symbol points to an imminent health risk, as well as a risk of

environmental pollution and of damage to property.
WARNING Non-compliance with the warning signs may cause moderate health
problems and/or extensive environmental pollution and damage to
property.
This symbol points to a dangerous situation.

Non-observance of these signs may cause environmental pollution and
CAUTION damage to property.
Further symbols and pictograms used are described under

/BELT PRESS CPF2023 SL/INTRODUCTION.
Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 1 of 12

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2.3 Designated use

The belt press should only be used according to the specifications forming
part of the purchase order.
Using the machine/plant for other purposes is considered contrary to its
designated use.
Any modifications to the scope of supply made without the agreement of
Andritz AG are considered contrary to the designated use.
The term designated use shall also include adherence to the operating
instructions, observance of the operating, inspection and maintenance
conditions and of the regulations on cleaning and upkeep.
2.4 General remarks on machine/plant safety

The machine/plant has been built in accordance with state-of-the-art
standards and the recognized safety rules. Nevertheless, its use may
constitute a risk to life and limb of the user or of third parties, or cause
damage to the machine/plant and to other material property.
The machine/plant may only be operated when in perfect condition and
with due consideration to safety and the risks involved. All protective
devices and the emergency cut-out devices must be in place and fully
functional.
Malfunctions and unforeseen changes to the machine/plant must be
remedied immediately.

#434794 v1 - SAFETY
2.5 User’s obligations
Designated use The user of the machine is responsible for its designated use.
Work instructions In addition to the operating instructions, applicable legal stipulations in the
user countries and other rules governing the safety at work, health and
environmental protection must be observed and personnel instructed in
them.
Qualification of The machine/plant may only be operated, maintained and serviced by

assigned authorized, skilled personnel with hands-on training.
personnel
Personnel must not be below the legal minimum age.
Any person undergoing training or in apprenticeship or under instruction
may only work on the machine/plant after receiving instruction on the
theory and only under the supervision of an experienced person.
Instructions The user’s operating and maintenance personnel will be instructed by

manufacturer personnel or his contractual distributor upon completion of
installation work.
The user undertakes to have new, additional operating and maintenance
personnel instructed in machine/plant operation and maintenance to the
same extent and applying the same care, and with due consideration to
the safety instructions.
Workers entrusted with the transportation, erection work, start-up,
operation, and maintenance of the machine/plant must have read and
understood the operating instructions, especially the chapter on SAFETY,
the safety instructions concerning a certain activity, as well as the safety
instructions issued by sub-suppliers.
Definition of areas The user shall be responsible for:

of responsibility
• definition of the machine operator's responsibility and his right to give
instructions
• definition of the contents and responsibility for keeping the records on
functioning and any failure of the monitoring equipment (log book)
• personnel areas of responsibility in terms of operating, tooling,
maintenance and upkeep.

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Inspections The operator undertakes

• to check at regular intervals whether the safety instructions and
regulations governing work on the machine are observed.
• to carry out regular training to confirm the level of knowledge of the
operating and maintenance personnel.
Attaching safety The user shall ensure that the following equipment, regulations, symbols
devices and instructions are mounted in the production area:
• Safety devices and regulations (see Chapter 2.7)
• Fire prevention regulations
• Markings on the floor for vehicle routes, protective fencing and danger
areas (yellow)
• Fencings and covers
• Railings (foot, centre and chest height)
• Emergency lighting
• Repair switch for drive motors
• Signs on fire-fighting equipment
• Signs for emergency calls
• Direction arrows to exits
• Direction arrows to escape routes
• Signs to first-aid post

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2.6 General obligations of personnel

To avoid personal and material damage all persons working on the
machine shall observe the following safety instructions:
• Observe the safety regulations in the operating instructions and on the
machine.
• Stop and secure the system if there is a safety-relevant functional
disorder. Report disorders and have them repaired immediately.
• Do not perform any work in a manner disregarding safety
considerations.
• Use only the machine accesses, paths and passages foreseen for this
purpose.
• Do not touch moving and rotating parts and/or reach out beyond them.
• Keep the machine and the work place clean. Do not place tools and
other objects on the machine/plant.
• Do not wear any garments/pieces of jewellery which might get stuck
on moving machine/plant parts, This includes ties, scarves, rings and
necklaces.
• Do not wear long hair hanging down.
• Familiarize yourself with the function and any failure of machine
monitoring equipment (log book) before starting work .
• No smoking in the vicinity of the machine/plant.
• Wear personal protective apparel when working on the machine/plant
(see Section 2.8).

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2.7 Safety devices

The machine/plant must not be operated without effective safety
equipment.
Safety equipment must not be circumvented, dismantled or made
unserviceable during operations. The safety equipment is there to protect
operating personnel.
Safety equipment and access thereto must be kept free.
Safety covers The machine/plant must not be operated without safety covers mounted.
The protective covers for the belt press are illustrated and described in
the following chapters:
/PLANT AND PERIPHERAL EQUIPMENT/PARTS BOOK/ (Gr.
11550)
Emergency-off The machine/plant has emergency-off buttons to stop it in case of an

switch, emergency emergency.
cut-out
The following emergency-off switches are provided on the machine:
• EMERGENCY-OFF switch at the belt press electric panel
The user shall provide the following emergency-off switches:

• EMERGENCY-OFF switch on the front side of the belt press
• EMERGENCY-OFF switch on the rear side of the belt press

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Indicative, warning Indicative, warning and prohibiting signs must be observed. They must be
and prohibiting checked regularly for legibility and completeness and they must not be
signs removed or obstructed.
The following indicative, warning and prohibiting signs are attached to the
machine.
Warning! Do not step on Caution: danger of Caution! Never insert hand Warning against hot
covers or protective crushing in machine when it is surface.
equipment. running.
Do not enter while Caution! Increased risk of Caution: body parts may Caution: body parts may
machine is running. accidents when changing be caught in the machine. be caught in the machine.
belts and clothing.
Caution! Put protective

equipment in place before
starting machine.

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2.8 Personal protective apparel
General
safety equipment
The following must always be worn when performing work on the

machine/plant:
• protective clothing to prevent the sludge from coming into contact with
the skin
• gloves to prevent hand injuries
• goggles to prevent eye injuries
• safety shoes as protection against foot injuries
• the required personal ear protection to avoid hearing defects
• standard hard hat as protection against head injuries
2.9 Safety at the machine installation site

Adequate lighting must be provided (industrial lighting).
The foundations must be sized to withstand the loads caused by the
machine. Customer will be provided with a load plan.
Area around machine and marked escapes to be kept free. Area around
machine must be marked as danger zone.
Make sure machine and surrounding area are kept clean. In particular, oil
and grease on the floor and on machine elements may cause slipping.
This is therefore a considerable source of injuries, as are tools.
The floor around the machine must be provided with a non-slip finish.
In order to prevent any falls from or damage to the machine, it is forbidden
to climb onto machine elements or on the machine (except for the
treading areas provided). Use ladders or similar equipment in accordance
with recognised standards.
Ramps, platforms and lifts must be used to avoid injury or excessive
physical effort.
2.10 Temperature
The belt press is designed for a sludge temperature of up to 65°C. If pulp
at higher temperatures is used, the operator must take the necessary
safety measures (e.g. protection for hands, training of operating staff,
etc.).

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2.11 Noise
The total noise emissions from all machines in the production room can
restrict spoken communication and impair hearing.
The machine is designed such that no operator is required in the
immediate vicinity of the machine during normal operation. Appropriate
hearing protection should be worn throughout maintenance and adjusting
work while the machine is running.
2.12 Electrical equipment

All work on the electrical equipment, without exception, must be carried
out by skilled electricians.
Any form of contact with electrical equipment may cause fatal injuries.
Before beginning any maintenance or repair work, the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Employees performing work on live parts should be accompanied by an
assistant who can operate the emergency switch if necessary.
Users of medical electronic equipment, such as pacemakers, must not
enter the electric danger zone.
Earthing Machine must be earthed to avoid electrostatic loading. Machine, gears

and motors must be connected to the earthing system.
/PLANT AND PERIPHERAL EQUIPMENT/ELECTRICAL
EQUIPMENT/....

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2.13 Hydraulics, pneumatics

Hydraulic and pneumatic systems operate at high pressure. Malfunctions
of the hydraulic system may cause hazards to operating personnel,
damage to property and environmental pollution.
The specified operating data and the prescribed revision and
maintenance intervals must be observed at all times.
Systems must be depressurized before carrying out maintenance work.
Work on hydraulic and pneumatic equipment must not be carried out
other than by skilled erection personnel with special training and
experience in handling hydraulic and pneumatic equipment.
All pressurized flexible hoses and pipes must
be tied or held together according to EN 983 / EN 892 - item 5.3.4.3.2 in
order to avoid injuries, e.g. from whiplash.
2.14 Gases, steam or smoke

Unintentional chemical reactions may take place in the sludge during a
prolonged standstill and hazardous fumes may be produced.
The machine must be thoroughly cleaned if shut down for longer than 2
hours.
The area must be adequately ventilated.
Before beginning work on the machine, ensure that no gas, vapour or
smoke can enter the working area from feed pipes, discharge pipes or
shafts.
If it is not possible to reliably exclude the risk of gas, steam or smoke
flowing in, all persons working in the danger zone must be equipped with
a safety harness and a safety rope. Each worker must be monitored by a
second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
2.15 Oils and greases

The safety instructions for the products concerned must be observed
when handling oil, grease and other chemical substances.
Suitable skin protection is required when handling aggressive media. See
manufacturers' information for the type of skin protection required.
Also observe relevant requirements for disposal.

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2.16 Welding work

In general, welding work is only permitted after consulting Andritz AG. Any
welding work that is described in detail in the maintenance instructions is
excluded from this ruling.
When performing welding work, always observe the relevant safety
regulations and the appropriate safety regulations for work performed in
enclosed and confined spaces.
Danger of fire or explosion!

There is a considerable risk of fire or explosion during welding work.
HOT WORK PERMIT Always take the appropriate fire precautions before beginning work,
REQUIRED! e.g. keep fire extinguishers at the ready.
All motors should be disconnected before carrying out electric welding

work.

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3 TECHNICAL DATA
3.1 Data
Type CPF2023 SL
General data Working width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 mm

Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6200 mm
Inlet consistency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5%
Outlet consistency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30%
Filtrate load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000mg/l
Wire cleaning Number of shower pipes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

shower Operating pressure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1500kPa
Wire STANDARD: . . . . . . . . . . . . . . . . . . . . . . LE 015(Huyck Austria)
Wire Seam:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .endless
Line pressure Line pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 N/mm
Drive See motor list for details

2 drives with frequency converter. . . . . . . . . . . . . . . . . . . . 2 x 5.5 kW
Machine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5-7 m/min
Weight Shipping weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15t
Rev. 0, 2008.5.26 TECHNICAL DATA Chapter 3 , Page 1 of 2

#434800 v1 - TECHNICAL DATA
3.2 Diagrams
Belt tension
diagrams
Fig. 3-1 Top belt Fig. 3-2 Bottom belt
Rev. 0, 2008.5.26 TECHNICAL DATA Chapter 3 , Page 2 of 2

#434800 v1 - TECHNICAL DATA
4 DESCRIPTION
4.1 Field of application
The belt press is used to dewater mixed sludge.
Fig. 4-1 Belt press
Rev. 0, 2008.5.26 DESCRIPTION Chapter 4 , Page 1 of 6

#434802 v1 - DESCRIPTION
Rev. 0, 2008.5.26

4.2
11 5 1 2 9
Main components of the machine

DESCRIPTION
4 6 8 7
Fig. 4-2 Belt press CPF2023 SL
Chapter 4 , Page 2 of 6
Item Designation Item Designation Item Designation

1 Gravity zone 5 Belt stretcher 9 Machine drive
2 Wedge zone 6 Belt guiding, belt regulating 10 Filtrate collecting tray, filtrate outlet
3 Press zone 7 Doctor 11 Tower mixer - headbox
4 Machine frame 8 Belt cleaning
Sludge feed Comprising sludge feed, slide plate and distribution baffle.
(Gravity zone, Item
1) In the gravity zone, solid/liquid separation is effected by gravity alone, i.e.
most of the liquid contained between the solids agglomerates drains off.
The first part of the gravity zone is used for sludge feed and spreading the
suspension evenly over the entire working width of the belt.
In order to form the flocs required, the sludge must be treated with organic
or inorganic conditioning agent, particularly suspensions containing finest
grain solids
Wedge zone (Item The wedge zone is the first pressure stage, which is generated by the top
2) and bottom belts converging over suitable plastic slide plates to form a
wedge. The resulting reduction in volume causes the pressure to rise
continuously in the running direction of the belt, thus causing the solids to
separate from the liquid.
The wedge zone is closed off at each side by a stainless steel mounting
and an elastic sealing lip made of plastic on either side.
Press zone (Item In the press zone the filter cake formed in the wedge zone is subjected to
3) the greatest possible pressure in order to obtain the highest possible final
dry content. The filter cake formed in the wedge zone is subjected to
surface pressure only.
For this purpose, the two filter belts under a pre-set tensile strength value
"S", and with the filter cake between the two, run over several S-rolls, the
diameters of which decrease gradually in the running direction of the belt.
By adjusting the belt stretcher, the belt tension can be varied infinitely to
achieve the most effective area pressure for the specific press cake.
Machine frame The machine frame consists mainly of the top and bottom frame sections,
(Item 4) the cross beams, as well as various brackets, fixtures and mountings to
hold the other structural components (S-rolls belt stretcher, etc.).
The frame is sandblasted, galvanized and provided with 1 prime and one
finishing coat as corrosion protection.
Belt stretcher The two filter belts are each tensioned by a belt tensioning roll which is
(Item 5) supported on two solid slide rods made of stainless steel. The slide rods
are supported in spherical plain bearings and are moved horizontally by
pneumatic cylinders.
The slide rods have toothed wheel work with two rigidly connected
toothed wheels gearing in, thus forcing the tensioning roll used in each
case to run parallel.
This guarantees constant belt tension over the entire width of the filter
belts, as well as preventing the belts from running off centre and suffering
premature wear.
Belt tracking and A slewing regulating roll is provided for each filter belt to prevent it form
regulating (Item 6) running off centre. The regulating rolls are slewed automatically by a
control device.

Take-off doctor The doctors are used to remove the press cake and clean the belts.
(Item 7)
The press cake is removed from the filter belts by low-wear doctor blades.
The doctor blades with variable nip loading are mounted on sturdy beams
and can be lifted off the filter belt with levers for cleaning purposes.
Belt cleaning (Item The top and bottom filter belts each run through a separate wash box after
8) the press cake has been removed.
The belt is washed by showers which have non-clogging flat jet nozzles.
Metal brushes are mounted inside the showers in order to clean these
jets. The metal brushes can be operated by a hand wheel while the
machine is in operation. Thus, it is possible to use water with a moderate
solids load to clean the filter belts.
Machine drive The belt press is driven by two drive rolls.

(Item 9)
These rolls are each driven by one planetary gear motor secured directly
to the drive roll journal.
Filtrate collecting The filtrate draining off in the individual solids/liquid separating zones is
tray, filtrate outlet collected in the corresponding filtrate trays mounted inside the machine
(Item 10) frame.
There are three collecting trays: one for the gravity zone, one for the
wedge zone, and one for the press zone, as well as two filtrate trays, one
for the top and one for the bottom belt cleaning device. If necessary, the
filtrate streams can be drained off separately from one another if they are
to undergo separate post-treatment. The filtrate trays are rustproof.
Tower mixer - The sludge is mixed with the flocculent before entering the tower mixer. In
headbox (Item 11) the tower mixer itself the mixture of sludge and polymer is homogenised
carefully using an agitator until proper flocs have formed. The flocculated
sludge is then fed to the gravity zone of the belt press, where it is spread
over the entire working width of the belt by a distribution device.

4.3 Technological description

The flocculent is added to the mixed sludge and the two are then mixed
intimately in a tower mixer before being fed down a chute into the gravity
zone of the belt press.
The belt press largely comprises a torsion-proof frame, which allows the
use of pin seam belts and also houses the individual dewatering zones:
Gravity zone Gravity dewatering zone, where the interstitial water still free drains off
through the top belt under the force of gravity.
Wedge zone Wedge zone, where the initial pressing forces are applied to the
pre-dewatered sludge.
S-rolls S-zone, where the press cake is dewatered by area pressure to the
highest possible dryness.
4.4 Machine monitoring equipment

The CPF is fitted with various monitoring elements which guarantee
maximum possible operating reliability.
Emergency-off An emergency-off switch is fitted on both the front and the rear side of the
switch at the machine. These are designed as cable switches and can be triggered by
machine a pull cord (cable) on either side of the belt press. Before re-starting the
machine, the interlock bypass switch at the cable switch must be
activated. An emergency-off switch is provided in the control panel.
Belt tracking If the belt runs well off track, the limit switches are actuated and the
switch machine is stopped.
Belt regulating This prevents the belts from running off track. A tracking device positions
device the regulating rolls on a slant such that the belt always runs towards the
centre of the machine. Setting instructions are provided in the section of
this manual headed Operation.
Electic switch When set to "Group start", all drives are shut down in the event of a defect
cabinet or if any one unit fails.


5 ERECTION WORK and TRANSPORT

5.1 General Remarks
This chapter describes certain steps for transport, storage and installation
of the belt press which may be the responsibility of the user.
Activities which are carried out by ANDRITZ AG, including works
assembly, are not the subject of this description.
5.2 Safety regulations
Disregarding the safety regulations may cause a risk to life and limb.
Disregarding the safety regulations may cause a risk to life and limb
and damage to the machine or its components.
DANGER
All safety instructions in this Chapter must be strictly observed.
General safety Start-up will be carried out under the supervision of ANDRITZ AG’s
instructions start-up manager.
All applicable accident prevention rules must be observed.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus forbidden.
Jerking must be avoided. This applies especially to pre-assembled
machines and rolls.
Qualification of Transport and unloading is to be carried out by personnel specially

assigned familiar with such work.
personnel
Workers entrusted with lifting and conveying equipment must have the
required national qualification.
Start-up may only be carried out by trained, skilled workers.
Personal The following protective equipment must be worn when carrying out
protective apparel start-up and transport work:
• Hard hat
• Protective gloves
• Protective shoes
• Goggles
Rev. 0, 2008.5.26 ERECTION WORK and TRANSPORT Chapter 5 , Page 1 of 10

#434803 v1 – ERECTION WORK
Belt press
5.3 Haulage
… during transport of machine or loading/unloading (machine may

fall).
Do not lift machine and transport crates except at the points marked
DANGER
for lifting by crane or forklift.
Do not step or walk below suspended loads.
Supply The belt press is supplied pre-assemblied. Machine components and

auxiliary materials are packed in crates.
Transport sizes and weights are stated in the shipping documents.
Largest supply weights:
/Belt press/TECHNICAL DATA
Acceptance • Check whether supply is complete (against shipping documents and

packing lists) and in perfect condition.
• In the event of transport damage or short supply, do not accept goods
but notify forwarder and ANDRITZ AG’s shipping department.
• If there is a hidden defect or damage, notify forwarder and ANDRITZ
AG's shipping department within two weeks.

Transporting Rubber-covered rolls should only be transported in cases made of stable

rubberized rolls boards.
Specification of crating
• Built-in bearing sections are required for the roll journals. (Fig. 5-1)
• Rubber-covered rolls should have enough clearance at the side and
underneath.
• Roll body must not rest on the base of the case.
• The bearing sections must be firmly attached to the front sides and
should be as close as possible to the roll core.
Fig. 5-1 Crates with built-in bearing sections.
Roll transport Rubberized rolls without special heat insulation may only be transported
during the cold at outside temperatures above freezing point.
season
At sub-zero temperatures as far as -10°C, rubberized rolls should only be
transported in closed vehicles. In this case, the covering must be
protected with suitable heat insulation or the case properly lined.
At temperatures below -10°C, rubber-covered rolls should only be
transported in closed vehicles with an inside temperature above freezing.
Also observe the maintenance instructions of the rubberizing

company.
/ATTACHMENT
… during transport of rolls or loading/unloading (roll may fall) !

DANGER

Belt press
Lifting of rolls Rolls should be lifted at the journals (Fig. 5-2).

When lifting rolls in the rubberized area, use broad, padded slings (Fig.
5-3).
Fig. 5-2 Roll suspended at the journals Fig. 5-3 Roll suspended at rubberized
roll body.
Rubber coating may be damaged when lifting the roll out of the
crate.
Open crate carefully and remove wood splinters and nails.
CAUTION
Do not remove cover paper.
When lifting the roll out, rope lashing must not touch roll front sides.
Protect roll ends with squared timber.
Transport at Before beginning transport, prepare the hauling paths and define the
installation site degree to which the machine has to be dismantled together with Andritz
AG's erector in charge.

5.4 Storage
The following instructions must be observed if the system is not to be
installed immediately.
• Please inform ANDRITZ AG's shipping department.
• Provide weather protection for stored machine components. Wide
variations in temperature must be avoided and the machine should not
be dirtied.
• Incidentals should be protected against damage and unauthorized
withdrawal by storing in a lockable room.
• Packing should not be removed until erection work begins.
Rubberized rolls Rubberized rolls should always be stored indoors, in their shipping crates.
Rolls must be stored at temperatures above freezing point.
A roll which has become too chilled should not be placed in service right
away. It should be allowed to adjust slowly to the temperature at the
installation site for one or two days.
If rolls are to be stored for a lengthy period, the roll and the bearing should
be turned once a month to prevent the roll body from sagging and
moisture from penetrating the bearings.
Also observe the maintenance instructions of the rubberizing

company.
/ATTACHMENT

Belt press
5.5 Installation
General Installation takes place in accordance with the sequence plan defined by
ANDRITZ AG.
Disregarding the sequence plan and the installation instructions

may result in hazardous situations causing a danger to life and limb
and in machine damage.
WARNING
The sequence of erection work is important and must be strictly
observed.
Implementation of the various steps must be documented in the certificate

of completion of erection work.
The sequence of erection work is shown in step-by-step tables. Individual

activities are numbered in their order of precedence.
Required The following supplementary documentation must be available at the

documentation at beginning of erection work:
installation site
• foundation and arrangement drawing
• assembly drawings for the different sub-assemblies
• pipe connection diagram
• documentation on electrical, measuring and control equipment
• list of components for sub-assemblies
• packing lists for each individual delivery
Space requirement for erection work, operation and maintenance will be
defined together with the ANDRITZ AG representative in charge before
the beginning of erection work.
Ambient temperature during erection work should not be less than
10-15°C.
Preparations Foundation
Foundation prepared according to ANDRITZ AG's foundation plan.
The following preparations have to be made prior to placing the belt press
on the foundation:
• Mark axes and levels on the foundation.
• Check the finish of the foundation before beginning erection work.
Preservation
Corrodible machine parts are protected with "Cortec VCI 369"
preservative grease.
The preservative grease need not be removed.

… due to falling machines or machine components during transport

on installation site.
DANGER
... due to parts of the body being jammed or crushed during

installation work.
DANGER Wear your personal protective apparel.
Machine Machine installation is to be carried out according to the following

installation step-by-step plan.
Machine placement
Step Activity
1 Place the foundation slabs on the supports supplied and align
(height, axes) using the adjustment screws also supplied.
2 Place belt cleaning device and regulating roll beneath the belt
press.
3 Erecting the belt press
Machine erection according to Andritz AG’s installation
sequence plan.
Tab. 5-1 Machine placement
The extent of work required is dependent on the degree of disassembly

of the machines; work is to be carried out according to ANDRITZ AG’s
erection work sequence plan.
The degree of disassembly is defined together with Andritz AG’s erector
in charge.
Transport devices that are forgotten may result in risks to life and
limb and in damage to the machine.
WARNING Remove all transport devices.

Belt press
Alignment and foundation work
4 Align the belt press according to axes and height.

max. deviation (+/- 1 mm).
Align the belt press at the rolls, using a water level.
Check max. deviation (on front and rear side 0.1 mm/m
max.).
5 Grout foundation slabs with shrink-free grouting compound
(Fig. 5-4).
6 Re-check after curing of the grouting compound.
Foundation slab
Grouting compound
Fig. 5-4 Foundation slabs
Installation of Installation of peripheral equipment

peripheral
equipment • Staircases and walkways
• Operating panel
• Pneumatic pipework.
• Water pipes (shower water, etc.)
• Process pipes (sludge and white water pipes)
• Complete installation of electrical equipment, including installation of
limit and emergency switches according to electrical, measuring and
control diagrams provided by ANDRITZ AG
• Instrumentation, positioners, control equipment
Errors in performing the installation of pipework and hoses may

result in risks to life and limb and in damage to the machine.
Mount all pipes stress-free.
CAUTION
Make sure hose connections are attached correctly.
Other work • Clean machine.

• Mount protective covers and warning signs.

5.6 Cold test
Prerequisites The following utilities must be available:

• Electric power
• Compressed air
• Water
Lubrication
• Initial filling of lubricant according to lubricating schedule (gearing,
bearings, etc.).
Machine may be damaged if inappropriate oil grades are used.

Only use oil with the properties listed in the lubrication schedules.
CAUTION
Cold test Cold test is to be carried out together with the customer's authorized
representative.
The steps listed in the table shall be carried out for the cold test, and
documented.
Components Activity
Connections Visual check
Sludge feed Visual check
Wedge zone Check the gap set by the manufacturer
/BELT PRESS CPF2023 SL/ MAINTENANCE
Press zone Visual check / Function / Setting the movable end of
the wedge / Limit stop of S-nip
Drive Function test and direction of rotation check
Process pipes Flush with water
Tanks and chests Open, clean, inspect and flush with water.
Belts Thread in the belts
/BELT PRESS CPF2023 SL/ MAINTENANCE
Doctor Setting /BELT PRESS CPF2023 SL/
MAINTENANCE
Belt regulating • Place feeler rod on belt
device • Adjust the belt run-off switch
Belt stretcher Pressure setting
Final inspection The customer and the erection work supervisor shall conduct a final
inspection of the installation on completion of the cold tests.

Belt press
Ensure in particular that there is no foreign matter between the belts.
Certificates The following certificates are issued after completion of the ISO cold test
• Cold test certificate
• Certificate of completion of erection work
Certificates: /ATTACHMENT/CERTIFICATES AND BLOCK
DIAGRAMS

6 START-UP
6.1 General
Initial start-up of the belt press shall be prepared and carried out by
ANDRITZ AG personnel. Start-up takes place in accordance with the
start-up sequence plan and ANDRITZ AG’s start-up records.
DANGER
General safety Start-up shall be carried out under the control of ANDRITZ AG’s start-up
instructions supervisor.
All applicable accident prevention rules must be observed.
Qualification of Start-up may only be carried out by trained, skilled workers.

assigned
personnel
protective apparel start-up and erection work:
• Hard hat
• Goggles
• Gloves must be worn when handling aggressive media (oil, cleaning
agent, chemicals, lubricants, white water, etc.).
Rev. 0, 2008.5.26 START-UP Chapter 6 , Page 1 of 2

#437394 v1 – START-UP
6.3 Prerequisites for start-up

The following must be checked before start-up:
• completion of erection and cold tests
• installation site has been cleared and is clean
• electricity, water, compressed air are available
• initial filling of lubricant according to lubricating schedule (gears,
bearings, etc.).
• all electric interlocks must be functional and checked.
• all control circuits have been installed and tested.
• process control system (DCS) installed and tested
6.4 Start-up
Before start-up the procedure is to be defined together with Andritz AG’s
start-up engineer..
Machine may be damaged by inappropriate starting.

All electric interlocks must be functional and checked.
CAUTION
Machine start-up according to the following documents:

• Block diagram for start-up
/ATTACHMENT/CERTIFICATES AND BLOCK DIAGRAMS
• Start-up certificate:
During start-up practical machine training will also take place on the
machine. Participants must have undergone theoretical training.
After start-up, machine is handed over to the mill operator in a complete,

reliable condition and ready for operation.
6.5 Certificates
The following certificates must be completed and signed after start-up:
• Start-up certificate:
• Provisional acceptance certificate:
Rev. 0, 2008.5.26 START-UP Chapter 6 , Page 2 of 2

#437394 v1 – START-UP
7 OPERATION
7.1 General
This chapter describes the activities required for starting, operating and
stopping the belt press. Possible malfunctions and troubleshooting
methods are also presented.
The belt press is part of the plant. It must be borne in mind that there are
interactions with other machines in the plant.
DANGER
General safety All applicable accident prevention rules must be observed.

instructions
Operating the belt press is not permitted without all the required safety
devices.
Qualification of The equipment may only be operated by qualified personnel.

assigned
personnel Operating personnel must know where the emergency-off switches and
the escape routes are located.
Operating personnel must have been instructed in the function and
possible failure of machine monitoring equipment, and in carrying out
maintenance and inspection work (shift log book, maintenance inspection
records).
Personal The following personal protective equipment/apparel shall be used when

protective apparel performing work on the machine (e.g. troubleshooting):
• Hard hat
• Goggles
Rev. 0, 2008.5.26 OPERATION Chapter 7 , Page 1 of 10

#434838 v1 – OPERATION
7.3 Description of operating elements
Pneumatic panel
Top belt stretcher
Bottom belt stretcher
Fig. 7-1 Pneumatik panel for belt press

Electric panel Abb. 7-2 shows the electric panel

Drawings of the panel: /PLANT AND PERIPHERAL
EQUIPMENT/ELECTRICAL EQUIPMENT
Fig. 7-2 Electric panel

7.4 Control via DCS

The belt press can be started up entirely from the DCS. Group start and
Group stop functions start and stop the press and all auxiliary equipment,
feed sludge to the machine and control all belt tension and press nip
loading functions.
7.5 Start-up
Prerequisites Before starting the following preparations must be made:
If there is sludge between the belts, proceed as described under

"Start-up after an emergency shut-down".
• Check whether there are any sludge deposits in the area around the
headbox seal, deckle strip and wedge zone, rolls, take-off doctor and
belts.
• Check belt tensioning setting.
• Check function of belt tracking system and smooth running of
servo-valve.
• Check belts for evidence of folding. Belts begin to shrink because they
dry up when there is a prolonged standstill, and folding may occur.
If there is folding in the belts, they should be moistened before starting
up the machine.
Automatic starting When using the group start, all necessary steps are carried out
automatically with the DCS.

Manual start Carry out the following steps for manual start.
Step Activity Operating device

1 Set compressed air supply ready for local
operation.
2 Switch to local operation Switches at electric panel
3 Tension the belts Buttons (Fig. 7-2 ) on electric panel.
4 Check the belt tension according to belt Pressure readings in pneumatic panel
tension diagram. (Fig. 7-2)
5 Set the belt tensioning pressures if Pressure regulator in pneumatic panel
required. (Fig. 7-2 )
6 Switch on subsequent machines. DCS
7 Switch on belt press motor. DCS
8 Turn on water supply to showers. OPEN/CLOSE valve via DCS.
Switch on oscillator. Manual valve at belt press

9 Switch on shower water pump. at the belt press
10 Check belt cleaning for proper function DCS
and clogging of nozzles.
11 Check belt running and belt regulator. Belt press
12 Check belt for evidence of folding. Belt press
13 Activate water circulating system. (Fan DCS
pump, dilution water pump)
Tab. 7-1 Manual start
If there is evidence of folding,

wet the belts and run the belt press with press nips disengaged and
CAUTION belt cleaning on until folding disappears.
14 Switch on sludge feed. DCS

Tab. 7-1 Manual start

7.6 Normal operation
Do not operate without all safety devices ON.

DANGER
During operation, operating personnel must make sure that data are
recorded in the shift log book and data recording sheets, and also carry
out the following work.
once per shift The following work has to be performed per shift in normal operation.
Component Activity
Belt cleaning, nozzles Operate cleaning device
Rubberized rolls Check for soiling and clean if
required.
daily The following work has to be performed daily in normal operation:
Component Activity
Pneumatic service unit Check filter tank and oil level.
Empty if necessary and top up.

Deckle strip Visual function check.
Feeler rod at belt regulating device Visual function check.
Belt guiding system Visual function check.
Doctor Visual function check and check for
wear.
Clothing (belts) Visual check for holes and wear.
Belt press and tray Cleaning off sludge deposits
Tab. 7-2
In case of a malfunction, proceed as outlined under operating faults and

troubleshooting, item 7.9
7.7 Stopping
Automatic stop When using the group stop, all necessary steps are carried out
automatically by the DCS.

Manual stop Carry out the following steps for manual stop.

1 Shut off sludge feed. DCS
2 Operate machine for approx. 10 minutes
with the belt cleaning unit on.
3 Shut down water circuits. (Fan pump, DCS
dilution water pump)
4 Switch off belt press motor. DCS
5 Close water supply to showers. OPEN/CLOSE valve via DCS.
Manual valve at belt press

6 Shut off subsequent machines. DCS
Tab. 7-3 Manual stop
After shutting down the belt press, always remove any residual
sludge.
Watch out especially for indivudal sludge clots in the pipework,
headbox, in the wedge zone area, and on rolls, doctors and belts.
Tension on belts should only be relieved at longer shutdowns.

7.8 Re-start after emergency stop
The machine may only be switched off in emergencies when there is

sludge between the belts.
Prerequisites for In the event of power failures or emergency shutdown the machine should
starting not be started up again until the following requirements are met:
• The sludge between the belts should not have hardened to the extent
that it could damage belts, rolls, drive or any other machine
components.
Please also see item 7.9 (Malfunctions)
• The belts must be thoroughly soaked with water in order to make them
as soft as possible before starting up again.
Starting Follow this table when re-starting after emergency stopping.

1 Reason for emergency shut-down, reset DCS
emergency-off switch and acknowledge.
2 Switch on the drives of subsequent DCS
machines.
3 Start acc. to item 7.5 (Starting)
Tab. 7-4 Re-start after emergency stop
If it is impossible to start the belt press because of impermissible power

absorption by the motors or because of the belts slipping on the drive
rolls, proceed as follows:
• Dismantle deckle strip
• Remove sludge from between the belts
Damage to the machine caused by non-observance of this item shall void
our warranty/guaranteed availability.

7.9 Operating malfunctions and troubleshooting
Malfunction Cause Remedy

Belts slip on drive rolls Production or basis weight too Reduce sludge feed flow rate
high or increase machine speed.
Reduce basis weight
Belts not sufficiently tensioned Readjust tension
Motor protection becomes Motor is overloaded (blocks) Reduce sludge feed
responsive
Cake does not separate Belts in poor condition Check belts
satisfactorily from the belts Feed consistency too low Increase consistency
Basis weight too low Reduce machine speed
Sludge escaping at the side of Wedge seals damaged or Replace seal
the wedge zone worn
Wedge seal no longer Remove deckles and repair or
centered between the belts replace seal
Sludge inlet consistency too Increase inlet consistency
low
Belts not cleaned sufficiently Spray nozzles clogged Clean showers, possibly
replace nozzle.
Water pressure too low Check operating pressure
Belts worn Replace belts
Belt runs off track Fibre deposits on rolls Clean sludge off rolls
Tracking system fails Actuate feeler rod, check belt
tracking device
Roll stoppage Bearing damaged Change bearing
(non-driven rolls)
Gears too hot Not enough oil in gear box Top up oil
Overloading Reduce production
Too much oil in gear Drain off oil
Wrong oil in gear Check oil
Roll bearings: Not enough lubrication Re-lubricate or check supply
Overheating or noise coming of lubricant
from bearing Bearing worn or broken Change bearing
Tab. 7-5 Operating malfunctions and troubleshooting


8 MAINTENANCE
8.1 General
This chapter describes the maintenance and upkeep of the belt press,
which is the responsibility of the machine/mill operator.
All activities mentioned in this chapter must be performed at the correct
time.
The ANDRITZ AG service department is at your disposal for
troubleshooting, as well as for extensive maintenance and repair work.
( .../INTRODUCTION)
Repair work on the plant components must be carried out at the
manufacturer's works.
Workers trained and authorized by Andritz AG may carry out repairs on
site after obtaining consent from AAG.
DANGER
General safety All applicable accident prevention rules must be observed.

instructions
Sufficient space for maintenance work must be included right away in the
arrangement drawing.
Maintenance and upkeep must not be performed when the machine is in
operation.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus forbidden.
Machine must be thoroughly cleaned before carrying out any
maintenance work.
Use only original spare parts.
Rev. 0, 2008.5.26 MAINTENANCE Chapter 8 , Page 1 of 20

#434840 v1 - MAINTENANCE
Safety guards After completion of maintenance work, all required safety guards must be
mounted again.
Energy supply Before beginning any maintenance or repair work the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Lighting The operator shall ensure that adequate lighting is provided (with
extra-low voltage bulbs) during service and repair work.
Qualification of Maintenance and upkeep must be carried out by trained and skilled
assigned personnel only.
personnel
Work on the electrical equipment must be carried out without exception by
skilled electricians.
protective apparel cleaning and maintenance:
• Hard hat
• Goggles
• Protective clothing

Welding work In general, welding work is only permitted after consulting Andritz AG.
When performing welding work, always observe the relevant safety
regulations and the appropriate safety regulations for work performed in
enclosed and confined spaces.
HOT WORK PERMIT REQUIRED!

Danger of fire or explosion!
There is a considerable risk of fire or explosion during welding work.
DANGER
Always take the appropriate fire precautions before beginning work,
e.g. keep fire extinguishers at the ready.
All motors should be disconnected before carrying out arc welding work.
During arc welding work the earthing should never be allowed to run over
the rolling bearings. An earthing cable is to be clamped in the immediate
vicinity of the welding area.
Before beginning any welding work, always ensure that the atmosphere
inside the machine is not explosive.
Gases, steam or Before beginning any service work, ensure that no gas, vapour or smoke
smoke can enter the working area from feed pipes, discharge pipes or shafts.
If it is not possible to reliably exclude the risk of gas, steam or smoke
flowing in, all persons working in the danger zone must be equipped with
a safety harness and a safety rope. Each worker must be supervised by a
second person outside the danger zone.
It must always be possible to evacuate a worker from the danger zone
without delay.
Before beginning any maintenance or repair work with devices, that are a
potential source of ignition, always ensure that the atmosphere inside the
machine is not explosive.
8.3 Regular maintenance

For machines operating continuously (24 hours/day, 7 days/week), a
prescheduled maintenance period every two weeks is recommended.
During these periods the machine should be shut down, thoroughly
cleaned and checked for wear.
Machines operating less than 24 hours per day should be subjected to
these routine checks and cleaned at each stoppage.

General machine The following checks should be made when the machine is at a standstill:
checks
Component Checks
Belts Cracks, holes, evidence of folding
Minor repairs can be made by sewing the belt

or gluing together with a contact adhesive.
Doctor blade Cracks and uneven wear.
Distance between the belt and the doctor

blade.
Pneumatic system Wear and leakage
Instruments Correct read-out and glasses intact
Rolls Wear and cleanliness
Belt running function Smooth running of control valve
Tab. 8-1 General machine checks
In the course of general machine checks all additional units should also
be checked to guarantee that the entire plant functions satisfactorily. For
these checks, the attached manufacturer's maintenance and upkeep
instructions must be observed.
/BELT PRESS CPF2023 SL/SUPPLIER DOCUMENTATION
Malfunctions and inadmissable changes found during these checks must
be eliminated immediately.
Cleaning Clean machine by hosing down or brushing when it is at a standstill.
Contact with the sludge may cause skin damage and burning.
Persons handling the sludge should not suffer from an allergic
condition to such substances.
WARNING
Personal protective apparel must be worn.
The following cleaning work has to be performed in particular:

• Clean sludge residue from rolls and doctors.
• Clean showers and nozzles.
• Run the machine without sludge and with cleaning showers switched
on.
Do not use caustic agents for cleaning.

Make sure no water, steam or other cleaning medium enters
CAUTION electrical plant components.

8.4 Maintenance schedule

In addition to the work outlined below, maintenance has to be carried out
in accordance with Chapter 8.3 and for normal operation work
( /BELT PRESS CPF2023 SL/ OPERATION).
Monthly The following maintenance work is to be carried out at monthly intervals.
Component Activity
Bearings • Check temperature
• Measure vibrations
Gears • Check oil level
• Check temperature
• Check for leaks
• Check for unusual noises
Pneumatic tubes • Check for damage and wear.
Semi-annually The following maintenance work is to be carried out at 6-monthly

intervals.
Component Activity
Rubberized rolls • Check surface for wear and damage.
Screws • Check that screws are firm and tighten if
necessary
Flexible connections • Check for damage and wear.
Seals at sludge • Check for wear
headbox
Deckle strip • Check for wear and deformation
Belt run-off limit switch • Check function
Emergency-OFF button • Check function
Annually The following maintenance work is to be carried out at annual intervals.
Component Activity
Stainless steel rolls • Check surface for soiling and damage.
Bearings • Analyse grease

8.5 Fasteners
Screw material Bolts and screws are manufactured in several classes of material. The
heads of these screws and bolts are marked to identify the strength class
of the screw or bolt. Damaged or lost fasteners should only be replaced
with fasteners of the same material.
Check Unless they are suitably tightened, screws can work loose or fail under
operating conditions. In the course of maintenance work, all fastening
screws must be checked.
• during the first six months: every 2 to 2½ months
• after the first six months: semi-annually
Tighten During checks and maintenance work it is imperative to tighten all

fastening screws to the torque specified for each screw in the drawings or
in the table below.
Prestressing forces and tightening torques in the table apply to normal
screw connections. Please contact Andritz AG in the event of special
requirements.
The thread and screw head should be lubricated with an appropriate
lubricant (for example Molyslide Plus from Loctite).
Tab. 8-2 Tightening Torques and Pre-stressing Forces for Rigid Screws (Normal thread)
Wrong torque tightening may cause machine damage and hazards

leading to personal injury.
The pre-stressing forces and tightening torques on the drawings
CAUTION
and/or the above table must be observed.

8.6 Lubrication
Lubrication of the belt press is carried out according to
the plant lubrication schedule.
/PLANT and PERIPHERAL EQUIPMENT/LUBRICATION
Details on lubrication are also included in specifications from component

suppliers.
/BELT PRESS CPF2023 SL/ SUPPLIER DOCUMENTATION
Please also observe maintenance instructions on the maintenance signs
and nameplates attached to machine/components.
8.7 Spare parts

A list of the spare parts required for the belt press can be found in the
parts book.
.../PARTS BOOK
Details on spare parts from sub-suppliers are also included in
specifications from component suppliers.
/BELT PRESS CPF2023 SL/SUPPLIER DOCUMENTATION

8.8 Belt changing
Preparation The machine must be thoroughly cleaned before carrying out any
maintenance work.
Sharp cutting edges on doctor blade.

Wear your personal protective apparel.
DANGER
Limbs can be crushed or pinched during belt changing work.

DANGER
Starting position The following procedures must be completed before changing a belt:
Step Procedure
1 Cut drive at all poles and lock to prevent switching on again.
2 Remove safety gratings and covers (front and rear sides).
Tab. 8-3 Starting position
1 2 3 1
4 5 2 2 5 4
Fig. 8-1 Belt changing

Belt changing When changing the belt, proceed according to the following table:
Step Procedure
1 Run stretcher roll (Item 1) in to its minimum limit position.
2 Remove take-off doctor (Item 2).
4 Remove belt cleaning device (Item 3).
5 Cut old belt right through and remove.
6 Lay out new belt in correct running direction.
7 Secure one rope each to the left-hand and right-hand sides
from the eyelets on the belt. Pull both ropes through the
plant together with the belt from the drive roll up to the
stretcher roll. Then pull from the stretcher roll further up to
the drive roll.
Caution: Belt must be pulled into the centre of the machine.

The distance to the side deckles must be the same on both
sides.
8 For instructions on splicing the belt, see /BELT PRESS
CPF2023 SL/ SUPPLIER DOCUMENTATION.
Tab. 8-4 Belt changing
When opening the belt cleaning box!

The belt cleaning box may be full of water or sludge and can fall
CAUTION under the weight it holds.
Be careful not to damage belt by inserting it carelessly and

do not use inappropriate tools.
CAUTION Only use the tools foreseen for the purpose.
After changing the belt, return the belt press to operating status.
Checks after belt • Check that screws fit tightly.

change
• Check the setting of the take-off doctor and scraper.
• Check that the new belt is running properly.
• Check functioning of the belt tracking limit switch (Item 5).
• Check setting of belt guiding system (Item 6).

The tightening torques in the drawings and/or table (Tab. 8-6) must
CAUTION
be observed.

8.9 Roll change
Preparation The following parts must be prepared before starting to change the rolls:
• Tools
• Lifting gear
• Sling belts
• Rolls
The machine must be thoroughly cleaned before carrying out any
maintenance work.
Requirements • Crane, if possible with two trolleys

• Tranined personnel for roll and belt changingl
Limbs can be crushed or pinched during belt changing work.

DANGER Do not touch underside of roll after suspending it from crane.
There is a greater risk of accidents when changing the rolls because

some gratings, walkway railings, protective devices, etc. have to be
removed or moved out of position.
DANGER
Use stable ladders and platforms!
Risk to life and limb during transport of rolls or loading/unloading

(roll may fall) and risk of roll damage !
Use the required lifting tools.
DANGER
When tightening the screws after roll changing, make sure that the
bearing casings of the press roll rest against their stops.
When installing the roll, check that the fixed bearing is always on the
CAUTION
rear side of the machine.
Fig. 8-2 Lifting of rolls

Starting position Initial position at each roll change.
Procedure
1 Cut drives on all poles and lock to prevent switching on again.
2 Move stretcher roll to minimum limit position by actuating the
RELEASE button on the electric operating panel.
Roll change The following table describes the roll change:
Step Procedure
1 Remove belt as described in Section 8.8 (Tab. 8-4).
2 Detach lubricating pipes.
3 Attach roll to a suitable lifting device (Fig. 8-2) and raise
carefully until the sling belts are taut.
4 If the roll cannot be attached to lifting gear,
under lay it with suitable means.
5 Dismantle the pedestal bearing by loosening the fastening
screws at the bracket.
6 Slightly lift rolls and move sideways towards the front side as
far as possible.
7 Prop roll on front side.
8 Detach front side belt.
9 Support roll outside the machine frame with the front side
sling belt.
10 Move roll out further out to the side, prop again and support
outside the frame with the rear side sling belt.
11 Place roll on a suitable support.
Roll installation in reverse order.

The drive must be removed when changing the drive rolls.
Checks after the • Ensure that the bearing mounting screws are tight
roll change
• Alignment of the roll

8.10 Roll bearing change

It is essential to observe the lubrication intervals indicated in the
lubrication schedule, as well as to use the recommended (or equivalent)
lubrication greases.
/PLANT and PERIPHERAL EQUIPMENT/LUBRICATION
When changing the roll and bearing, check that the fixed bearing is
on the rear side of the machine.
The bearing is changed with the roll removed from the machine.
Changing the Change the bearings according to the following table:

bearings
Step Procedure
1 Remove housing (Item 1) and bearing cover (Item 2).
2 Remove shaft nut (Item 3) and locking plate (Item 4).
3 Remove the sleeve (Item 5) with the shaft nut.
4 Remove the bearing (Item 6).
5 Remove conical nipples (Items 7 and 8).
Tab. 8-5 Changing the bearings
1 Fixed bearing
2
3 7
5
4
6 Loose bearing
Fig. 8-3 Changing the bearings
Bearing damage may be caused by incorrect installation.

Roll journal must be cleaned and greased before assembling.
CAUTION Bearing play to be adjusted with the shaft nut.
Bearing play: C3

8.11 Changing the transverse sealing strip behind the wedge

zone
Change the sealing strip according to the following table:
Step Procedure
1 Remove clamping strip at side deckles.
2 Pull sealing strip out of the machine to the side.
3 Push in new sealing strip carefully from the side.
Tab. 8-6 Changing the sealing strip
Clamping strip
Sealing strip
Fig. 8-4 Changing the sealing strip

8.12 Changing the deckle strips
Extracting the Change the strips according to the following table:

strips
Step Procedure
1 Detach screws (Item 1) on all deckle strip supports.
2 Detach the screws (Item 2) for deckle strip support height
adjustment.
3 Lower the deckle strip support (Item 3).
4 Pull the deckle strips out of the belt press at the side.
Tab. 8-7 Extracting the strips
Fig. 8-5 Extracting the strips
Limbs can be jammed or crushed during installation work.

DANGER

Changing the Change the deckle seal according to the following table:
deckle seal
Step Procedure
1 Mark end of seal strip on support (Fig. 8-6)
2 Remove welding spot. (Fig. 8-8)
3 Detach clamping strip fixing screws (Fig. 8-6) and shift strip
until bayonet closure
(Fig. 8-7) opens.
4 Remove clamping strip and seal.
Tab. 8-8 Changing the deckle seal
Fig. 8-6 Deckle strip and seal with Fig. 8-7 Bayonet closure
clamping strip
New seal installation

5 Grooved side must face support.
Centre seal on support and align ingoing end of seal with
mark previously made.
6 Place clamping strip on support and shift until locking screw
can be put in place. Tighten screw.
7 Position welding spot at the end of the deckle strip between
clamping strip and support.
Welding spot
Fig. 8-8 Welding spot

Installation of the Install the strips according to the following table:

deckle strip
Step Procedure
1 Check wedge inlet height.
2 Check whether sludge headbox side seal is correctly
installed. (When checking, the belt should be stretched).
3 Fasten rope to last fastening clip on strip (Fig. 8-9).
4 Press sealing strip together and push in deckle strip from the
sludge headbox towards the wedge end at an angle of
approximately 30° (measured towards the end of the wedge
plate) (Fig. 8-10).
Push in manually only, do not force. Should this prove

impossible, check wedge adjustment.
5 Extract deckle strip with rope until it is parallel with belt edge
or leaning slightly outwards (0-10 mm).
Tab. 8-9 Installation of the deckle strip
Fig. 8-9 Fig. 8-10
6 Push strip inside over the length of the belt press until it can
be screwed to the sludge headbox.
Check that the deckle strip fits against the lateral headbox
seal without a gap (Fig. 8-11).
If there is a gap, the seal must be shifted in the strip support
in the direction of the headbox.
If the two seals overlap, either the lateral headbox seal must
be shortened somewhat or the strip must be pushed towards
the wedge end inside the support.
7 Fasten the deckle strip at the headbox (Fig. 8-11) and at the
retainers along the length of the wedge (Fig. 8-12).
Check whether the deckle strip is parallel to belt end or leans
slightly outwards toward the end of the wedge. Tighten the
fastening screws for lateral adjustment of the deckle strips.

8 Adjust deckle strip support in vertical direction so strip is

positioned in the centre between the upper and lower wedge
plates.
Tighten the fastening screws (Fig. 8-12).
Fig. 8-11 Fig. 8-12
9 With new sealing strips a small gap forms at the end of the
headbox. ((Fig. 8-13 ). In this case a nick must be made in the
Robadur strip here. The position of the cut should be
measured or marked directly on the Robadur strip.
10 Pull deckle strip out again and make a notch with a sharp
knife approximately 6 - 10 mm deep at the appropriate point
in the Robadur strip (Fig. 8-14).
Deckle strip
Fig. 8-13 Fig. 8-14

11 Widen the ends a little towards both sides of the notch (Fig.
8-15). Install deckle strip again.(Fig. 8-16)
Secure the deckle strip to the headbox and to the supports

over the length of the wedge.
Check whether the deckle strip is parallel to belt end or leans
slightly outwards toward the end of the wedge. Tighten the
fastening screws for lateral adjustment of the deckle strips.
12 Adjust deckle strip support in vertical direction so strip is
positioned in the centre between the upper and lower wedge
plates.
Tighten the fastening screws.
Fig. 8-15 Fig. 8-16
Pressing too hard may damage the belts.

Push in deckle strip by hand only and do not force in.
CAUTION
Sludge leaking through the gap may damage the belts.

Check that there is no gap between the headbox seal and the roll,
CAUTION nor at the transition from the lateral headbox seal to the deckle strip.

8.13 Installation and removal of the wedge plates.
Installation and Installation and removal of the wedge plates according to the following
removal of the table:
wedge plates
Step Procedure
1 Remove the deckle strips on the front and rear sides.
2 Relieve the belt tension.
3 Remove the fixing plates on the front side of the belt press.
4 Remove spacer in frame.
5 Extract the wedge plates on the front side. If necessary, the
wedge plate can be eased out from the rear side using a
hammer and wooden wedges.
6 Align the wedge plates with T-rails and push in from the front
side until they are at the machine centre.
7 Secure wedge plates by screwing on with the fixing plate.
8 Install the deckle strips.
Tab. 8-10 Installation and removal of the wedge plates.
Fig. 8-17 Fig. 8-18 Bottom wedge plates
Limbs can be trapped or crushed during installation work.

DANGER

8.14 Belt stretcher

If the belt can no longer be tensioned with the tensioning device, proceed
according to the following table:
Step Procedure
1 Relieve belt (Item 1) tension and spring bellow (Item 2)
pneumatically
2 Detach screws (Item 3)
3 Push the entire stretcher device forwards at both sides
towards the tensioning roll (Item 4).
4 Cover bracket (Item 5) with pre-drilled threaded holes in
frame (Item 6) and screw down
5 Tension belt (Item 1) and spring bellow (Item 2)
pneumatically
Tab. 8-11 Re-tensioning the belt
1 4 6 2 3
1 5
Fig. 8-19 Tensioning device

The pre-stressing forces and tightening torques on the drawing
CAUTION
and/or table (Tab. 8-6) must be observed.
If the belt is badly or wrongly tensioned, this may cause machine

damage and hazards leading to personal injury.
DANGER

9 SUPPLIER DOCUMENTATION
9.1 103 20 - Inductive belt guiding system
9.1.1 Proximity switch
Name of company IFM
Technical data Type . . . . . . . . . . . . . EFECTOR IG 2008-ABOA AC/DC,ALLSTROM
9.2 105 01 Drive
9.2.1 Planetary gear
Name of company SEW
Technical data Type . . . . . . . . . . . . . . . . . . . . . . . . . . . PHF001RF87 DM132 S4 / TF

Motor power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 kW
Transmission rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 V / 50 Hz
Rev. 0, 2008.5.26 SUPPLIER DOCUMENTATION Chapter 9 , Page 1 of 1

#434846 v1 – LIST OF SUB-SUPPLIES

Erection Work, Operating and Maintenance Instructions: Belt Press CPF2023 SL

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Erection Work, Operating and Maintenance Instructions: Belt Press CPF2023 SL

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Belt press CPF2023 SL

Diana Joint Stock Corporation, PF U1085/07

Erection Work, Operating and Maintenance Instructions

Rev. 0, 2008.5.26 TITLE PAGE #434851 v1 - DECKBLATT

Rev. 0, 2008.5.26 TITLE PAGE #434851 v1 - DECKBLATT

2.1 General safety regulations . . . . . . . . . . . . . . . . . . . . . . . 1

4.1 Field of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rev. 0, 2008.5.26 Chapter , Page 1 of 4

5 ERECTION WORK and TRANSPORT. . . . . . . 1

5.1 General Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Rev. 0, 2008.5.26 Chapter , Page 2 of 4

8.13 Installation and removal of the wedge plates. . . . . . . . 19

9.1 103 20 - Inductive belt guiding system . . . . . . . . . . . . . . 1

Rev. 0, 2008.5.26 Chapter , Page 3 of 4

Rev. 0, 2008.5.26 Chapter , Page 4 of 4

1.2 Standards and guidelines

Rev. 0, 2008.5.26 INTRODUCTION Chapter 1 , Page 1 of 4

1.3 How to use the manual

Presentation • Chapter and paragraph headings are printed in capitals in the

Pictograms The following pictograms are used in the manual:

Warning signs are shown with an explanation of the

The meaning of the different graduations of hazards

Marks an instruction on handling of the machine or

Marks a useful piece of information

Marks a cross-reference to another Chapter with

Rev. 0, 2008.5.26 INTRODUCTION Chapter 1 , Page 2 of 4

1.4 Warranty and guarantee

Rev. 0, 2008.5.26 INTRODUCTION Chapter 1 , Page 3 of 4

1.5 Manufacturer’s name and address

In case of emergency outside working hours

Rev. 0, 2008.5.26 INTRODUCTION Chapter 1 , Page 4 of 4

2.2 Danger and warning signs

This symbol indicates there may be a risk to life and limb.

This symbol points to an imminent health risk, as well as a risk of

This symbol points to a dangerous situation.

Further symbols and pictograms used are described under

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 1 of 12

2.3 Designated use

2.4 General remarks on machine/plant safety

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 2 of 12

2.5 User’s obligations

Qualification of The machine/plant may only be operated, maintained and serviced by

Instructions The user’s operating and maintenance personnel will be instructed by

Definition of areas The user shall be responsible for:

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 3 of 12

Inspections The operator undertakes

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 4 of 12

2.6 General obligations of personnel

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 5 of 12

2.7 Safety devices

Emergency-off The machine/plant has emergency-off buttons to stop it in case of an

The user shall provide the following emergency-off switches:

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 6 of 12

Caution! Put protective

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 7 of 12

2.8 Personal protective apparel

The following must always be worn when performing work on the

2.9 Safety at the machine installation site

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 8 of 12

2.12 Electrical equipment

Earthing Machine must be earthed to avoid electrostatic loading. Machine, gears

Rev. 0, 2008.5.26 SAFETY Chapter 2 , Page 9 of 12

2.13 Hydraulics, pneumatics