Manual - Pulper VCP 22

OPERATING AND MAINTENANCE MANUAL
PULPER VCP 22 - VOLCAN
OPERATING AND
MAINTENANCE MANUAL
PULPER VCP 22
VOLCAN
7331.0167
page 1
1 INTRODUCTION ................................................................................................... 5
1.1 Explanation of warnings and symbols ..................................................................................5
1.2 Dimensions ...............................................................................................................................5
2 SAFETY INSTRUCTIONS..................................................................................... 6
2.1 General safety instructions .....................................................................................................6
2.2 Designated use of the machine ..............................................................................................6
2.3 Organizational measures ........................................................................................................7
2.4 Safety devices ..........................................................................................................................8
2.5 Selection and qualification of personnel ...............................................................................9
2.6 Noise protection .......................................................................................................................9
2.7 Additional hazards .................................................................................................................10
2.8 Machine grounding ................................................................................................................10
3 TECHNICAL DATA ............................................................................................. 11

3.1 Machine data ..........................................................................................................................11
3.2 Weights ...................................................................................................................................11
3.3 Operating data ........................................................................................................................11
3.4 Drive data ................................................................................................................................12
4 TECHNICAL DESCRIPTION .............................................................................. 13

4.1 Use ...........................................................................................................................................13
4.2 Principle of operation ............................................................................................................13
4.3 Design .....................................................................................................................................14
5 INSTALLATION .................................................................................................. 15
5.1 Unpacking the machine .........................................................................................................15
5.2 Transporting the machine .....................................................................................................15
5.3 Disposing of the packing materials .....................................................................................15
5.4 Foundations ............................................................................................................................16
5.5 Setting up and aligning .........................................................................................................17
5.6 Connecting .............................................................................................................................20
5.7 Checking the direction of rotation .......................................................................................21
5.8 Mounting and dismounting the belt pulleys .......................................................................22
5.9 Mounting the belts .................................................................................................................24
5.10 Preparing for initial start-up..................................................................................................26
5.11 Disassembly ...........................................................................................................................27
page 2
6 OPERATION ....................................................................................................... 28
6.1 Safety instructions for operation .........................................................................................28
6.2 Starting the machine..............................................................................................................29
6.3 Checks during operation .......................................................................................................31
6.4 Shutdown ................................................................................................................................31
6.5 Prolonged shutdown .............................................................................................................31
7 TROUBLESHOOTING ........................................................................................ 32
8 MAINTENANCE .................................................................................................. 33
8.1 Safety instructions for maintenance work ..........................................................................33
8.2 Lubrication ..............................................................................................................................34
8.3 Checks ....................................................................................................................................36
8.4 Removing and fitting the slushing impeller ........................................................................37
8.5 Adjusting the screen clearance ............................................................................................38
8.6 Removing and fitting the shaft protection sleeve ..............................................................39
8.7 Removing and fitting the packings ......................................................................................40
8.8 Removing and fitting the screen plate .................................................................................41
8.9 Removing and fitting the bearing assembly .......................................................................42
9 PART LIST .......................................................................................................... 44
page 3
Copyright
The copyright on this Documentation remains with MFL Faserzementanlagen Ges.m.b.H.
The instructions and drawings contained therein must not be completely or partly
reproduced, distributed or used by unauthorized persons for competitive purposes or
disclosed to third parties.
MFL Faserzementanlagen Ges.m.b.H.

Julius Raab Promenade 27/1/12
A-3100 St.Pölten / Austria
Phone: ++43 3612 270 60

Fax: ++43 2742 76120
E-Mail: office@mfl-fc.at
page 4
1 Introduction
These operating instructions are meant to familiarize the user with the machine. They contain a
description of the machine‘s design and principle of its operation. Following these instructions
ensures safe and efficient start-up, operation and maintenance of the machine.
1.1 Explanation of warnings and symbols
This symbol indicates an imminent hazard. If this hazard is not avoided, it

will lead to serious injuries or death.
This symbol indicates a potentially hazardous situation. If it is not avoided, it

could result in serious injuries or death.
This symbol indicates a potentially hazardous situation. If it is not avoided, it

could result in minor or moderate injuries.
This symbol indicates a potentially damaging situation. If it is not avoided, it

could result in damage to the product or surrounding equipment.
This symbol indicates special hints for the user and other particularly useful
information. It is not a signal word for a hazardous or damaging situation.
1.2 Dimensions
Unless specified otherwise, all dimensions are in mm.
page 5
2 Safety Instructions
2.1 General safety instructions

During operation of the machine, the local safety and accident prevention rules and regulations
are binding and must be followed.
State of the art

This MFL-Fibercement stock preparation machine 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 and to other
material property, if:
– the machine is not used as designated,

– the machine is operated by untrained personnel,
– the machine is modified or converted improperly and/or
– the safety instructions are not observed.
Therefore, every person involved in erecting, operating, inspecting, maintaining, servicing and
repairing the machine must read, understand and observe the complete operating instructions,
particularly the Safety Instructions.
Preconditions for using the machine

The machine may only be used:
– in perfect technical condition,

– as designated,
– according to the instructions in the operating manual, and only by safety-conscious
persons who are fully aware of the risks involved in operating the machine,
– if all guards and emergency shut-off components are fitted and operative.
Any functional disorders, especially those affecting the safety of the machine, must therefore be
rectified immediately.
2.2 Designated use of the machine
Use
The VCP pulper is designed for the slushing of:
– semi-chemical pulps such as dry or wet pulp and groundwood,

– machine broke
– clean, sorted recovered paper at a stock consistency of up to 7%.
The material to be slushed can be fed into the pulper in bales or as loose material.
page 6
Liability for non-designated use

Using the machine for other purposes than those mentioned above is considered contrary to its
designated use. MFL-Fibercement cannot be held liable for any resulting damage. The risk of
such misuse lies entirely with the user.
2.3 Organizational measures
Availability of operating instructions

The operating instructions must be available wherever and whenever the machine is in
operation or being installed or maintained.
Additional regulations
In addition to the operating instructions, observe all other generally applicable legal and other
mandatory regulations relevant to accident prevention and environmental protection and instruct
the personnel to comply with them.
Additional instructions
Provide the personnel with supplemental information covering duties involved in supervising
and notifying special organizational features, such as job organization, working procedure or the
personnel entrusted with the work.
Checks
Periodically check that the personnel carry out the work in compliance with the operating
instructions and that they pay attention to risks and safety factors.
Protective equipment
Use protective equipment wherever and whenever required.
Safety instructions and warning signs

Observe all safety instructions and warning signs attached to the machine. Make sure these
signs are legible and replace damaged or illegible signs immediately.
Modifications or changes in operating conditions

In the event of safety-related machine modifications or changes in operating conditions, stop the
machine immediately and report the modification or malfunction to the person responsible for
the machine.
page 7
Rebuilds or modifications
Never make any unauthorized rebuilds and modifications which could impair safety. Any verbal
agreements with the manufacturer or the design engineer require written confirmation.
Replacing damaged parts

Machine parts that are not in perfect working order must be replaced immediately with original
spare parts.
Use only original spare and wearing parts from MFL-Fibercement! Unauthorized parts provide
no guarantee that they have been designed and manufactured according to the application.
Danger of accidents!
Checks and maintenance

Comply with the intervals specified in the operating instructions for routine checks and
maintenance work.
Working with hazardous substances

Observe the data safety sheets and the safety instructions by the manufacturer or the supplier!
Make sure that dangers to the environment caused by hazardous substances are precluded
when working on lubricating systems and devices and when cleaning the machine with solvent-
containing detergents.
Lifting equipment
Make sure that the lifting equipment is properly installed and its capacity is at least equal to the
weight of the machine or of the parts to be lifted.
Do not stay or work in areas where parts are being moved!
Ladders
When installing the machine beyond body height, use the suitable ladders or working platforms.
Do not climb on machine parts for installation! Wear fall protection equipment guards when
installing the machine at greater heights!
2.4 Safety devices

Guards must be removed only after the machine has been shut down and locked out to prevent
unintentional start-up.
Ensure that all guards have been replaced before starting or restarting the machine.
Make sure that after installation of the guards, every gap between the plates is smaller than
specified in Standard EN 294. The person responsible for installation work must procure
additional guard plates if the loose guards supplied with the machine are not sufficient.
page 8
2.5 Selection and qualification of personnel
Qualification of personnel
Any work done on the machine must be performed by trained and instructed personnel
authorized by the owner.
Responsibilities
Clearly establish and observe the responsibilities involved with the operation of the machine.
Any unclear responsibilities could impair safety.
Instructions contrary to safety

Give the operator the authority to refuse instructions by third parties that are contrary to safety.
Maintenance and repair

Maintenance and repair require special knowledge and may only be carried out by trained
technical specialists.
2.6 Noise protection

Depending on the operating conditions, place of installation, pipe runs, and other unit parts, the
machine may produce a noise level which exceeds 80dB (A).
Therefore, wear appropriate ear protection when working in the immediate vicinity of the
machine in operation.
In general, the machine is operated/controlled from a sound-proof operating room.
page 9
2.7 Additional hazards
Entanglement, crushing and cut/sever hazards due to:

– moving machine parts left exposed by removing covers for inspection, sampling, etc.,
– running and exposed shafts, cylinders, drums, or belts,
– automatically operated discharge valve traps.
Burning or scalding hazards due to:

– Opening or leaving open function-check and/or sampling openings on equipment
operating at high temperatures (above 40°C).
– operating temperatures ≥ 70°C: Short contacts (approx. 1 s) of the skin with the
surface of the machine may cause burns (pr EN 563).
– operating temperatures = 65°C: Longer contacts (approx. 3 s) of the skin with the
surface of the machine may cause burns (pr EN 563).
– operating temperatures 55°C…65°C: Longer contacts (approx. 10 s…3 s) of the skin
with the surface of the machine may cause burns (pr EN 563).
Gases and vapors

Open covers may allow harmful gases or vapors to escape into the atmosphere.
Chemicals or decomposing stock residues in the pulper may produce harmful gases or harmful
gases may settle at the bottom. These gases may cause poisoning or suffocation because they
are heavier than air so that they displace the air at the tank bottom.
Therefore, make sure that the tank is supplied with enough air before entering the pulper.
2.8 Machine grounding

The machine must be grounded according to VDE/0100 using the enclosed grounding plate.
Follow the specifications required by the type of grounding (TN or IT systems). Machine parts
which can be touched at the same time must be connected to the same grounding system.
page 10
3 Technical Data
3.1 Machine data

Order number 7331.0167
Year of construction 2019
3.2 Weights
Tank 3.847 kg
Cover hood 706 kg
Slushing unit 1.037 kg
Bearing assembly 1.009 kg
Drive parts 367 kg
Base plate and motor bracket 966 kg
Protect cover 152 kg
Motor 1.455 kg
3.3 Operating data

Power requirements 170 kW
Machine speed 314 rpm
Stock consistency 3-7 %
Seal water pressure, min. 3 bar
Seal water consumption appr. 3 l/min
Seal water quality Freshwater
page 11
3.4 Drive data
Motor
Motor rating 200 kW
Motor speed 1000 rpm
Design V5
Protection IP 55
Belt data
Belt type (power belt) 4-SPC-7500

Number of power belt 2
Belt length 7.500 mm
Center distance 2.417 mm
Motor pulley diameter 400 mm
Machine pulley diameter 1.250 mm
page 12
4 Technical Description
4.1 Use
The VCP pulper is designed for the slushing of:
– semi-chemical pulps such as dry or wet pulp and ground wood,

– machine broke
– clean, sorted recovered paper
at a stock consistency of up to 7%.
The material to be slushed can be fed into the pulper in bales or as loose material.
4.2 Principle of operation

The pulper may be operated batch-wise or in some special cases in continuous mode.
The furnish fed into the pulper is disintegrated in a fiber-preserving manner by the slushing
impeller and the strong turbulence of the tank contents. Large baffles quickly move the furnish
to the center of the turbulence.
The pumpable slushed stock leaves the pulper through the screen plate held open by the
slushing impeller. The clearance between the slushing impeller and the screen plate is
adjustable by moving the bearing assembly.
page 13
4.3 Design
1…Tank 25…Impeller 79…Motor pulley 93 … Motor bracket

7…Cover hood 41…Bearing housing 80…V-belts 96 .... Protective cover
15…Screenbox 78…Machine pulley 84…Motor tensioning unit 103 …Motor
page 14
5 Installation
5.1 Unpacking the machine
– Loosen the machine fixing.
– Check consignment against delivery note for completeness.
– Check consignment for transport damage.
– Report any transport damage immediately to MFL-Fibercement.
5.2 Transporting the machine

Ensure that the ropes and the lifting equipment are suitable for the transport weight of the
machine components.
Only use undamaged ropes and lifting equipment. Only attach the ropes to the intended and
marked positions.
5.3 Disposing of the packing materials

– Dispose of the packing materials in an environmentally sound manner.
– Recycle packing materials.
– Observe the applicable regulations.
page 15
5.4 Foundations
General
The foundations are the sole responsibility of the customer.
The foundation plan contains all dimensions necessary to prepare the foundations.
Preconditions
– Location known and accessible.
– Load capacity of the substructure is sufficient.
– The reinforcement plan is available.
Preparations
– Set up forms as shown in the foundation plan.
– Make and lay reinforcements.
– Fill foundation recesses with filling materials.
Concreting
– Mix and pour concrete, allow to set.
Finishing work
– Remove forms.
– Remove filling materials.
– Clean recesses.
Do not use thinners when cleaning the recesses, other wise the grout will not harden.
– Determine and mark the main centerlines of the tank and drive.
page 16
5.5 Setting up and aligning
Preconditions
– Foundations for machine and drive are ready.
– Suitable lifting equipment is available.
Tank
1…Stone bolt 4…Grout

2…Hex. nut 5…Setscrew
3…Tank foot 6…Flat steel bars
– Hook tank on a crane.

– Fasten stone bolts with hex. nuts (2) to the tank feet.
– Screw greased setscrews (5) into the tank feet (3).
– Position flat steel bars (6).
– Lower tank onto flat steel.
– Position tank according to foundation plan.
– Place grout (4) and allow to set.
– Loosen hex. nuts (2).
– Align tank horizontally using the setscrews (5).
– Slightly tighten hex. nuts (2).
– Remove bracing from tank.
page 17
Mounting the filling
See picture section slushing unit and bearing in chapter 9
– Paste flange seal (part list pos. 16) to screenbox-flange

– Pay attention to the position of stock outlet (see enclosed foundation plan).
– Insert filling from below and fasten with hex. screws (part list pos. 17, 18) to tank
Drive
1…Stone bolt 4…Grout

2…Hex. nut 5…Setscrews
3…Base plate 6…Shims
– Fasten stone bolts (1) with hex. nuts (2) to base plate (3).
– Screw greased setscrews (5) into base plate (3)
– Position shims (6).
– Lower slide base plate (3) onto shims and position according to the foundation plan.
– Place grout (4) and allow to set.
– Loosen hex. nuts (2).
– Align base plate (3) horizontally.
– Slightly tighten hex. nuts (2).
page 18
Grouting the tank feet and drive base plate
1…Grout
2…Hex. nut
3…Hex. screw
– Align tank and base plate so that axes are in parallel.

– Set up forms for grout.
– Place grout and allow to set.
– Remove forms.
– Tighten hex. nuts (2).
Setting up the motor

The motor is not included in the MFL scope of supply. Observe the
manufacturer’s specification when setting the motor up.
page 19
5.6 Connecting
Preconditions
– Pulper is set up, aligned and grouted in.
– Plant is off circuit.
Machine
Pipework
The inlet and outlet piping can be positioned more or less as required. To avoid disturbing
deposits, for example in dead corners, the flange connections between the single pieces of the
pipework must be exactly concentric. Sampling valves must be fitted in all stock-conducting
pipes by the customer on site.
All pipework must be connected completely free of tension.

Do not join with force using the fastening screws.
Support and suspend pipework so that it does not swivel or affect the machine during operation,
for example through pipework expansion caused by heat.
Control and monitoring equipment of stuffing box

Control and monitoring equipment shown below must be procured by the customer.
to sealing, connecting G ½“
from sealing,
connecting G ½“
1…Ball valve - hand operated 4…Non return flap

2…Ball valve - pneum. operated 5…Regulating valve - hand operated
3…Flow indicator with regulation
Grounding
The machine must be grounded according to VDE/0100 using the enclosed grounding plate.
Follow the specifications required by the type of grounding (TN or IT systems). Machine parts
which can be touched at the same time must be connected to the same grounding system.
page 20
Motor
Preconditions
– Motor is mounted.
Connecting the motor

Connect motor according to the VDE rules VDE/0100 and 0113 or the locally applicable rules
and regulations.
For safety reasons, we recommend to install a lockable 3-pole safety main switch with padlock.
The power supply circuits are to be routed in such a way that the entire adjusting range of the
motor can be covered without disconnecting the lines.
– Connect motor electrically.

– Check connections (Ö terminal diagram from motor supplier).
Emergency stop switch
– Install emergency stop switch in the vicinity of the machine.
5.7 Checking the direction of rotation
Preconditions
– Motor is connected.
Checking the direction of rotation
Possible danger of injury due to the dismounted belt guard.

If the machine is not disconnected, the shaft seal could run dry and thus be damaged.
Only check the direction of rotation after the power bands have been removed.
– Switch on motor for a short time.

– The direction of rotation of the motor shaft must be anticlockwise when viewed
towards the shaft end face.
– Shut off motor.
page 21
5.8 Mounting and dismounting the belt pulleys
Preconditions
– Main switch is turned off and locked out to prevent unintentional start.
– Belt not installed.
– Belt pulley is supported
1…Supporting elements
Parts required
Machine belt pulley 1 pcs. part list pos. 78

Tension disc (machine) 1 pcs. part list pos. 81
Motor belt pulley 1 pcs. part list pos. 79
Taper-Lock bushing (motor) 1 pcs. part list pos. 79
Machine
Mounting
– Fasten belt pulley to the shaft end.

– Mount tension disc with hex. screw.
Dismounting
– Remove tension disc.

– Remove belt pulley.
page 22
Motor
1…Taper-Lock bushing 3…Socket head cap screw

2…Hub bore 4…Jackscrew hole
Mounting
– Clean shaft, hub bore (2) and bushing (1), remove varnish or oil.
– Insert bushing in tapered bore so that screw holes line up and place screws (3)
loosely into holes.
– Fit hub and bushing to shaft as one unit, locate in position and tighten screws
alternately with uniform force.
– Remember that bushing will nip the shaft first and then hub will be slightly drawn onto
the bushing.
– Align motor and machine belt sheaves.
Dismounting
– Loosen screws by several turns.
– Screw one of the screws into one of the provided jackscrew holes (4).
–
Do not mount belt sheaves without positioning the supporting elements.

The belt sheaves might be damaged when slipping from the journal.
– Turn screw until bushing is removed from hub.

– Remove assembly from shaft.
page 23
5.9 Mounting the belts
Preconditions
– The belt sheaves are mounted to motor and machine and secured with retainers.
Installing the belts
– Adjust minimum center distance between motor journal and rotor shaft.
– Install belts.
Tensioning the belts on initial mounting
The belts are not included in the MFL scope of supply. Observe the
manufacturer’s specification when tensioning the belts.
Retensioning the belts
Belts must be retensioned after 24 hours of operation.
Observe the manufacturer’s specification when retensioning the belts.
Loose belts result in lower power input and higher wear (smell of burning rubber) or even
screen plugging.
Tensioning the belts
See part list pictures in chapter 9.
– Loosen hex. nuts (part list pos. 87) of motor bracket (part list pos. 93).
– Loosen locknuts (part list pos. 95) on both tensioning screws (94).
– Use the two tensioning screws (part list pos. 89) to tension belts.
– Fasten hex. nuts (part list pos. 87) of motor bracket (part list pos. 93).
– Retighten locknuts on both tensioning screws (part list pos. 89).
page 24
Fitting the guards
Fall protection equipment

The edge of the vat must be protected against the risk of falling in accordance with the
applicable safety rules and regulations. When the upper vat section projects less than 1.20
meters over the operating floor, a suitable fall protection equipment must be fitted around the
tank on site. This fall protection equipment must be designed as a complete shell with a smooth
outer surface. A railing or a protective grating is not sufficient.
Belt guard
– Mount belt guard (part list pos. 96).
Parts list for electric guards

Emergency switches and other electric guards as well as the conveyor belt interrupting
equipment must be fitted in accordance to the applicable safety rules and regulations. The
pulper must be locked out to prevent unintentional restart during maintenance and repair work.
page 25
5.10 Preparing for initial start-up
Preconditions
– Main switch is turned off and secured to prevent unintentional start.
Rotating slushing impeller!
Persons in the tank can be caught and killed by the slushing impeller.
Always cut off the current to the drive motor whenever you want to control the smooth running
of the slushing impeller or when you want to perform any other work in the tank.
Flushing
– Thoroughly flush inlet piping.
Lubrication
– Lubricate bearing points of pulper in such a way that escaping grease can be seen.
Checklist
Component Nominal status Checked

Connections Mounting correct
screws tight
Slushing impeller Can be rotated manually
Guard Installed
Emergency stop switch Location known
The machine is ready for operation when all items on the check list have been checked.
page 26
Test run

Check that nobody is in the tank before starting the test run.
– Open valves for stuffing-box seal water.

– Fill approx. 30% of the amount of water needed for slushing.
– Switch motor on and fill with remaining water with the slushing impeller running.
– Check the rotation direction of the slushing impeller.
– The slushing impeller must rotate clockwise when viewed from above.
– Monitor ammeter.
– The current consumption should be approx. 10 - 20% below the rated current of the
motor.
– Tighten nuts of stuffing box gland until seal water drips out.
– Turn off the motor after approx. 15 minutes.
– Open outlet valve.
– Water drains off.
Checks after the test run

Always cut off the current to the drive motor whenever you want to control the smooth running
of the slushing impeller or when you want to perform any other work in the tank. Then wait until
the slushing impeller has come to a halt.
– Check the slushing impeller for smooth movement.

– Check the function and lubrication of all additional equipment (conveyor belt, drain
pump, valve for contaminants discharge, drive, etc.) and clear faults as required.
5.11 Disassembly
– Shut machine down.
– Prepare machine for long-term shutdown.
– Disconnect all pipework.
– Disconnect supply piping flanges.
– Remove belt guard and belts.
– Remove belt sheaves.
– Remove slushing impeller.
– Remove screen plate.
– Remove bearing.
– Loosen union between foundation and tank.
– Lift tank from foundation.
page 27
6 Operation
6.1 Safety instructions for operation
Guards
Rotating parts, such as V-belts, couplings, shafts, slushing impellers, etc. may catch loose
clothes, long hair, jewelry or limbs.
You could get seriously injured or killed.
The machine must never be used without the required guards.
Protection of persons
Unplanned incidents may result in personal injury.
To ensure rapid reaction, always check where the emergency stop switch is installed and
whether it works properly before putting the machine into operation.
are heavier than air so that they displace the air at the tank bottom. Therefore, make sure that
the tank is supplied with enough air before entering the pulper.
page 28
6.2 Starting the machine
Preconditions
– The preparations for start-up are completed.
– The pulper is drained and flushed.
Starting the machine

Lubrication
– Lubricate the bearing assembly.
Filling
There is a risk of being dragged along when the belt is running.

This can lead to serious injuries.
Ensure safe footing at the stock inlet!
Only run the conveyor belt with a cutoff grip or rope in front of the feed opening.
Wires can spring off when bales of raw material are being handled.
These wires could cause eye and/or hand injuries.
Always wear goggles and safety gloves when handling bales of raw material!
– Load raw materials on the conveyor belt.

– The individual bales should break down into layers when fed into the pulper.
– Start the pulper using the distributed control system with the installed hardware and
software.
– Fill pulper with 1/3 of the dilution-water quantity with stock shut-off valve closed.
– Check the pulper for leakages.
Leakages are sealed with stock after a short time.
– Switch motor on.

– The seal water for the stuffing box starts to flow.
– Feed in dilution water and furnish until the fill level has been reached.
Furnish and dilution water feeding should be stopped simultaneously.

The standard filling time is 5 min.
The slushing consistency depends on the furnish and the dilution-water supply. The optimum
slushing consistency is obtained when sufficient turbulence but no air core is produced.
page 29
Filling quantity calculation
Stock [t]:
Water [m3 or t]:
V: Capacity [m3]
G: Weight of furnish [t OD]
D: Stock consistency (%)
Slushing
Discharge
– Switch drain pump on.

– Fully open stock shut-off valve.
The max. screen speed limits the minimum possible discharge time.
To keep the screen plate open, always discharge with slushing impeller running.
– Re-dilute with water towards the end of the discharge process.
page 30
6.3 Checks during operation

– Check the current consumption (ammeter on control panel) of the drive motor.
– The average current consumption must be 10 to 20% below the rated current of the
motor!
– Check the amount of seal water:
– Water must drip out of the stuffing box gland.
Drying stock in the stuffing-box gland leads to premature wear of the hub protective sleeve.
Seal water must flow continuously because overheating can damage the coating of the hub
protection sleeve.
No stock may drip out!
6.4 Shutdown
– Switch drain pump on.
– Fully open stock shut-off valve.
To keep the screen plate open, always discharge with slushing impeller running.
– Re-dilute with water towards the end of the discharge process.

– Turn drive motor off.
– Seal water valve for stuffing box closes.
– Remove dirt retained at the screen.
6.5 Prolonged shutdown

– Pulper is shut down.
– Clean pulper thoroughly.
page 31
7 Troubleshooting
Problem Possible cause Solution Remarks
Drive problems Lose or wet belt Clean, dry belt and
adjust correct belt
tension.
Wrong belt tension Adjust correct belt
tension.
Reduced power Worn slushing Check slushing
consumption impeller impeller and replace
increased flake or repair if
contents necessary.
Reduced specific
power
Noises, vibrations Foreign matter in the Clean impeller and
area of impeller rotor rotation area.
Bearing damage Replace bearings.
Slushing impeller Remove and
unbalanced balance slushing
impeller.
Excessive current Excessive stock Reduce stock
consumption consistency consistency.
Coarse particles or Empty the pulper as
dirt stuck between quickly as possible.
slushing impeller Remove
and screen plate contaminants.
Motor does not start Thickening raw stock Close the valves of
after stop or stuck the downstream
contaminants equipment.
Use gripper to
remove
contaminants.
Empty the pulper
when necessary.
Insufficient furnish Stock portion too Refill water.
high
Worn slushing Repair slushing
impeller impeller.
Stuffing box too No seal water Open seal water
warm supply.
Stuffing box gland Loosen stuffing box
too tight gland.
Stock dripping from Stuffing box packing Renew stuffing box
stuffing box worn packing
Too much water Stuffing box gland Tighten stuffing box
dripping from stuffing too loose gland
box
page 32
8 Maintenance
8.1 Safety instructions for maintenance work
Guards
Ensure that all required guards have been replaced after completion of all maintenance work.
Protection of persons
Ensure that the main switches of the machine and of all upstream or downstream equipment
are turned off and locked out to prevent unintentional restart prior to any maintenance work.
Make sure that the machine and all stock pipes to the machine have been emptied and
depressurized.
are heavier than air so that they displace the air at the tank bottom.
Therefore, make sure that the tank is supplied with enough air before entering the pulper.
Safe operation
To ensure safe operation after completion of maintenance and repair work, use only new and
undamaged fasteners (screws, bolts, washers, locking elements, nuts, etc.) and new seals for
reassembly.
Handling heavy machine parts or components

There is the risk of crushing when handling heavy machine parts or components!
Use protective equipment!
page 33
8.2 Lubrication
every 200 operating hours
page 34
During workshop assembly, the bearings are filled with

grease for adequate corrosion protection during transport
and storage. Prior to start-up, the individual bearings must
be lubricated such that grease is seen to egress.
No. Lubrication interval Lubrication Component Lubrication Lubricant Quantity per

type point point
1 Every 200 Grease Bearing Grease Grease 110 g
operating hours lubrication assembly nipple
2 Every 200 Grease Bearing Grease Grease 220 g
operating hours lubrication assembly nipple
The use of inappropriate lubricants considerably reduces

bearing life.
Use a lubricant appropriate for the ranges specified in the
following table.
Process water properties Lubricant properties DIN designation

Non-aggressive process water General purpose grease or roller Lubricating grease K2K DIN
bearing grease on a lithium 51825/1
grease base, water resistant,
corrosion inhibiting, temperature
range to +130°C
Aggressive process water Pressure gun grease with Lubricating grease KP2K DIN
extreme pressure additives on a 51825/3
lithium grease base, water
resistant, corrosion inhibiting,
vibration stable, temperature
range up to +130°C
page 35
8.3 Checks
General
The pulper only requires very little maintenance.
The checks and maintenance work described in the following must be
carried out at the specified intervals. Keep record of all checks and
maintenance work in a maintenance manual.
Preconditions
– Tank is drained and flushed.
– For work in the tank:
Equipment suitable for safely climbing into the tank is available.
Written inspection permission has been obtained.
Part list Component Check interval Check Action

Pos.
36 Shaft seal Every 2 weeks Check the seal water outlet. Remove and
replace
component.
31 Sealing disk At each idle time Check part for damage and/or Remove and
wear. replace
component.
25 Slushing impeller At each idle time Check hard surfacing for Renew hard
wear. surfacing.
20 Screen plate At each idle time Check weld beading for wear. Renew weld
beads.
Screen clearance At each idle time Check the screen clearance Adjust the
between the hard surfacing clearance when it
on the slushing impeller and is too small.
the weld beading of the
screen.
80 Belts Every 2 weeks Belt tension Retensioning the
belts
80 Belts Every 6 months Check for cracks and/or wear. Remove and
replace
component.
78 Belt pulleys Every 6 months Check for damage and/or Remove and
79 wear. replace
component.
page 36
8.4 Removing and fitting the slushing impeller
Preconditions

– Equipment suitable for safely climbing into the tank is available.
– Suitable impeller lifting equipment is available.
Removal
– Slacken and remove socket head cap screws (part list pos. 30)
– Lift hood (part list pos. 29)
– Loosen and remove hexagon screws (part list pos. 27)
– Remove tension washer (part list pos. 26)
Shock loads may damage the coating on the shaft protection bush (part list pos. 33).
Avoid shock loads.
– Mount pull-off device (not included in MFL scope of supply)

– Use pull-off device to remove slushing impeller (part list pos. 25) from the shaft cone.
If the slushing impeller seating on the shaft cone is very tight, withdrawal is facilitated
by simultaneously heating the hub and the upper side of the impeller to approx.
150°C.
Fitting
– Check O-ring (part list pos. 28) on the hood, replace when necessary.
– Check the wear on the hard surfacing, have it renewed when necessary.
– Clean cone surfaces on impeller and shaft cone with rug soaked in oil.
Do not apply lubricants.
– Mount slushing impeller (part list pos. 25) onto the shaft.
– Fasten tension washer (part list pos. 26) with hex. screws (part list pos. 27)
Tightening torque M = 98 Nm; hex. screws M20, screw material 8.8-A3C.
– Fit hood (part list pos. 29) with O-ring (part list pos. 28)
– Adjusting the screen clearance
page 37
8.5 Adjusting the screen clearance
Clearance a between slushing impeller and screen plate weld beads is called screen
clearance. It should be reduced to a minimum (0.5…1 mm).
Reducing the screen clearance
– Slightly loosen hex. nut (part list pos. 45)

– Remove distance piece (part list pos. 42)
– Tighten hex. screws alternately until the desired screen clearance is obtained.
– Measure clearance between extraction chamber and bearing housing flange and fit
suitable distance pieces.
– Remove hex. screw.
– Firmly tighten hex. nut
Tightening torque M = 400 Nm; hex. nut M20, screw material 8-A3C
Enlarging the screen clearance
– Slightly loosen hex. nut (part list pos. 45)

– Remove distance piece (part list pos. 42)
– Retighten hex. nuts (part list pos. 45) until the desired screen clearance is obtained.
– Measure clearance between extraction chamber and bearing housing flange and fit
suitable distance pieces.
– Tighten hex. Nut
Tightening torque M = 400 Nm; hex. nut M20, screw material 8-A3C
page 38
8.6 Removing and fitting the shaft protection sleeve
Preconditions

Removal
Sensitive coating on the shaft protection sleeve.

Shock loads may damage the coating on the shaft protection bush (part list pos. 33).
Avoid shock loads.
– Loosen and remove hexagon screws (part list pos. 34)

– Use forcing screws to remove shaft protection sleeve (part list pos. 33) from impeller.
– Check shaft protection sleeve for damage and replace as necessary.
Check and, if required, replace sealing disk (part list pos. 31) each time when the hub
protection sleeve is fitted or removed.
Fitting
– Fit shaft protection sleeve together with parallel pins (part list pos. 32) and sealing
disk on slushing impeller.
– Screw in and tighten hex. screws
– Install slushing impeller
– Insert new packings (part list pos. 36)
page 39
8.7 Removing and fitting the packings
Preconditions
– Packing extractor and eyelet bolts are available
– Sealing water channel is removed.
Removal
– Loosen and remove hexagonal nuts (part list pos. 40)
– Pull down and remove the split rod packing gland (part list pos. 37) over the
stud bolts (part list pos. 38)
Sensitive coating on the shaft protection sleeve.

Sharp-edged tools may damage the coating. Do not use sharp-edged equipment
when replacing the packings.
Avoid shock loads.
– Remove both halves of the rod packing gland.

– Remove the packing rings (part list pos. 36) with the packing extractor
– Use the eyelet bolts to pull the seal water ring (part list pos. 35) out of the packing
area.
Fitting
– Clean shaft protection sleeve and packing area.
– Check hub protection sleeve and sealing disk for wear and replace as necessary.
– Insert 1 packing ring.
– Slide the seal water ring on the shaft up to the packing ring.
– Insert the remaining packing rings, each twisted by 120°.
– Push the split rod packing gland over the stud bolts.
The rod packing gland may only be retightened up to the thread end of the stud bolts.
Having reached the thread end the packing must be completely renewed to avoid
destruction of the seal water ring and the sealing disk.
–
– Tighten the hex. nuts evenly so that the packing rings in the stuffing-box area are
pressed into shape.
– Loosen hex. nuts again until the packings are almost slack.
The stuffing box gland is set exactly when the machine is running.
Start-up after renewing the packing

– First run the pulper with water for 30 minutes. -> The packings swell up.
The packing leaks heavily during the first few minutes. After a short while, the
packings expand due to the absorption of water. This increases the sealing pressure
on the shaft and the initial high loss of seal water decreases during the 30 minute run-
in time. If this does not happen: Tighten the stuffing box gland evenly until water just
drips out. The outside temperature of the stuffing box housing can be between 40°C
and 50°C during the run-in time. The temperature generally sinks to a lower value
after two to four hours.
page 40
8.8 Removing and fitting the screen plate
Preconditions

– Slushing impeller is removed.
Removal
Removing the screen
The screen consists of a support frame (part list pos. 21) to which a screen plate (part
list pos. 20) is screwed.
To prevent the screws from working loose, the thread ends of the socket head cap
screws (part list pos. 22) must be welded to the screen plate.
– Loosen and remove socket head cap screws (part list pos. 23 and 24).
– Use lifting equipment to lift screen out of the steel vat.
Removing the screen plate
– Grind off weld points.

– Loosen socket head cap screws (part list pos. 22) and separate the screen plate from
the support frame.
Fitting
Fitting the screen plate
– Put screen plate on the support frame.

– Insert and tighten socket head cap screws (part list pos. 22).
Tightening torque M = 140 Nm; socket head cap screw M16, screw material A4-70.
– Weld thread end of socket head cap screws (part list pos. 22) to the screen plate.
Fitting the screen
– Check weld beading for wear and renew as necessary.

– Clean contact surfaces.
– Insert screen.
– Insert and tighten socket head cap screws (part list pos. 23 and 24).
Tightening torque M = 140 Nm; socket head cap screw M16, screw material A4-70.
– Install slushing impeller.
– Check screen clearance and adjust when necessary.
page 41
8.9 Removing and fitting the bearing assembly
Preconditions

– Protective belt cover is removed
– Screen box pipings are disassembled.
– V-Belts not installed.
– Suitable lifting equipment (hand pallet truck with 200 mm stroke) is available.
Removal
– Place lifting equipement (with wooden bars) under belt pulley (part list pos. 78).
– Lift until pulley.
– Remove hex. screws (part list pos. 17).
– Lowering pallet truck slowly and carefully.
– Carry out complete bearing assembly to workshop.
– Remove belt pulley

– Remove slushing impeller
– Remove screen plate and support frame.
– Remove packing
– Remove screenbox
– Remove sealing ring (part list pos. 60), centrifugal disk top (part list pos. 58), bearing
covers (part list pos. 56 and 70), and centrifugal disk down (part list pos. 68).
– Remove shaft with spherical roller bearing (part list pos. 66) and inner ring of
cylindrical roller bearing (part list pos. 53) from bearing housing by pulling it
downward.
– Remove locknut with locking plate (part list pos. 66).
– Remove spherical roller bearing (part list pos. 66).
– Remove locknut with locking plate (part list pos. 54 and 55).
– Remove inner ring of cylindrical roller bearing (part list pos. 53) from the shaft.
– Use pull-off device to remove outer ring and rolling elements of cylindrical roller
bearing.
Fitting
Reverse removal sequence when fitting the assembly and observe the following instructions.
– Always replace both bearings.

– Heat inner ring of cylindrical roller bearing (part list pos. 53) in an oil bath to mount it
on the shaft
– Use mounting ring (part list pos. 67) when installing the spherical roller bearing (part
list pos. 66).
– Observe reference dimension k = 81 mm.
page 42
Adjusting the internal bearing clearance
The inner ring of the spherical roller bearing is mounted with an interference fit. The
bearing is fitted by pressing the bearing onto the tapered seating of the adapter
sleeve. The reduction in the initial radial internal clearance is used as a measure of
the degree of interference. Measure the clearance before, during and after mounting.
Turn the bearing several times prior to each measurement, so that the rollers can roll
into position. During the measurement, the roller at the measuring point is pressed
against the guide ring between the two roller rows. The measured radial internal
clearance must be the same for both rows of rollers.
Bearing type with Radial internal Reduction in radial Min. adm. final
“normal“ internal clearance before fitting internal clearance clearance after fitting
clearance (mm) (mm) 1) (mm)
min. max. min. max.
22334 K 0.14 0.20 0.08 0.11 0.06
1) The specified minimum values for the reduction in internal clearance should generally be used for bearings with
normal internal clearance which before mounting have an initial radial internal clearance close to the lower limit. This
ensures that the specified minimum values for the admissible final clearance are met.
Lubrication
Fill the free space in bearings with grease before final assembly.
page 43
9 Part list
page 44
page 45
section slushing unit and bearing
Pos Qty Designation Dimension DrawNo/Stand S/W

1 1 tank to pulper VCP 22 Ø4010x3200 8812-002660
2 1 dirt hopper 927x652x360 8812-002240
3 8 hexagonal screw M20x100 ISO 4017
4 16 stone bolt A M24x320 DIN 529
5 16 hexagon nut M24 ISO 4032
6 16 washer 24 ISO 7089
7 1 cover hood to pulper VCP 22 4012x4012x1777 8812-002414
10 24 washer 16 ISO 7089
11 1 rubber plate (curtain) 1600x1500x2 8812-001808
12 1 locking bar 1706x65x9 8812-001807
page 46

15 1 screenbox 1552x1390x643 8812-001593
16 1 flange sealing Ø1390/1185x3 8812-001500 S
18 24 washer 20 ISO 7089
19 1 base bush Ø360/250x65 8812-001357
20 2 screen plate Ø1175/270x18 8812-001501 W
21 1 supporting frame to screen plate Ø1175/270x38 8812-001502
22 22 socket head cap screw M16x30 ISO 4762
25 1 impeller Ø1000x252 8813-002408 W
26 1 tension washer Ø150x25 8812-001361
28 1 o-ring D6 Ø167/155x6 S
29 1 hood to impeller Ø250x65 8812-001362
31 1 sealing washer Ø248/190x20 8812-001363 W
32 2 parallel pin 5M6x20 ISO 2338
33 1 shaft protection bush Ø210/142x168 8812-001364 W
35 1 sealing water ring Ø250/212x55 8812-001365
36 1 packing 20x20x9500 W
37 1 rod packing gland 2-parts Ø330/212x75 8812-001366
38 4 stud M20x90 DIN 938
39 4 washer 20 ISO 7089
41 1 bearing housing Ø570/290x820 8812-001367
42 12 distance piece 40x11x90 8812-001368
43 12 stud M20x90 DIN 938
44 12 washer 20 ISO 7089
46 1 shaft Ø180x1550 8812-001369
47 1 key form D D-32x18x78 DIN 6885
49 1 key form B B-36x20x109 DIN 6885
50 1 distance washer top Ø320/195x40 8812-001370
51 1 feltring Ø225/193x12 DIN 5419
52 1 counter ring top Ø193/150x46 8812-001371
cylindrical roller bearing
53 1 Ø320/150x65 DIN 5412 S
typ: NU 330 ECM /C3
54 1 locknut KM30 DIN 981 S
55 1 safety plate MB30 DIN 5406 S
56 1 bearing cover top Ø410/240x27,5 8812-001372
58 1 centrifugal disc top Ø455/135x85 8812-001373
59 3 hexagon socket set screw M16x35 DIN 916
60 1 sealing ring Ø200/136x6 8812-001374 S
61 1 o-ring D6 Ø147/135x6 S
63 1 distance washer down Ø360/222x45 8812-001375
page 47

64 1 feltring Ø252/220x12 DIN 5419 S
65 1 counter ring down Ø220/150x60 8812-001376
spherical roller bearing with adapter
sleeve DIN 635
66 1 Ø360/150x120 S
incl. locknut and safety plate DIN 5415
typ: 22334 CCK/W33 + H 2334
67 1 mounting ring for fixed bearing Ø460/320x50 8812-001377
68 1 centrifugal disc down Ø295/150x95 8812-001378
69 3 hexagon socket set screw M16x25 DIN 916
70 1 bearing cover down Ø460/192x97 8812-001379
71 1 feltring Ø222/190x12 DIN 5419 S
72 12 stud M20x60 DIN 938
74 1 pipe 3/4" x3,25 Ø3/4"x85 8812-001380
75 1 grease trap plate 200x110x108 8812-001381
77 2 flat lubrication nipple G 1/2"
V-belt pulley
78 1 Ø1250 DIN 2211
type: 1250 SPC 8
V-belt pulley
79 1 Ø435 DIN 2211
type: 400 SPC 8
Power belt effective lenght:
80 2 W
Type: 4-SPC x 7500 7500 mm
81 1 tension disc Ø225x20 8812-001382
82 3 washer with external tap 21 DIN 432
84 1 base plate to pulper VCP 22 1220x1075x30 8812-002409
85 4 stud screw M24x65 DIN 939
86 4 washer 24 ISO 7089
89 2 threaded rod M24x710 DIN 976
90 4 stone bolt A M24x320 DIN 529
92 12 washer 24 ISO 7089
93 1 motor bracket 1522x1050x900 8812-002410
96 2 protective cover (4-parts) 3376x1330x300 8812-002657
97 4 support for protective cover 630x150x70 8812-002658
98 3 support for protective cover 630x150x70 8812-002659
100 7 hexagonal nut M12 ISO 4032
101 7 disk 12 ISO 4089
102 14 HILTI-HSA Segment anchor HSA M12x100/5/25
103 1 three-phase motor size: 355, 200 KW S
106 4 washer 30 ISO 7089
S…sparepart, W…wearpart
page 48
NOTES

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OPERATING AND MAINTENANCE MANUAL

PULPER VCP 22 - VOLCAN

3 TECHNICAL DATA ............................................................................................. 11

4 TECHNICAL DESCRIPTION .............................................................................. 13

9 PART LIST .......................................................................................................... 44

MFL Faserzementanlagen Ges.m.b.H.

Phone: ++43 3612 270 60

1.1 Explanation of warnings and symbols

This symbol indicates an imminent hazard. If this hazard is not avoided, it

This symbol indicates a potentially hazardous situation. If it is not avoided, it

This symbol indicates a potentially hazardous situation. If it is not avoided, it

This symbol indicates a potentially damaging situation. If it is not avoided, it

2.1 General safety instructions

State of the art

– the machine is not used as designated,

Preconditions for using the machine

– in perfect technical condition,

2.2 Designated use of the machine

– semi-chemical pulps such as dry or wet pulp and groundwood,

Liability for non-designated use

2.3 Organizational measures

Availability of operating instructions

Safety instructions and warning signs

Modifications or changes in operating conditions

Replacing damaged parts

Checks and maintenance

Working with hazardous substances

2.4 Safety devices

2.5 Selection and qualification of personnel

Instructions contrary to safety

Maintenance and repair

2.6 Noise protection

In general, the machine is operated/controlled from a sound-proof operating room.

2.7 Additional hazards

Entanglement, crushing and cut/sever hazards due to:

Burning or scalding hazards due to:

Gases and vapors

2.8 Machine grounding

3.1 Machine data

3.3 Operating data

3.4 Drive data

Belt type (power belt) 4-SPC-7500

– semi-chemical pulps such as dry or wet pulp and ground wood,

at a stock consistency of up to 7%.

4.2 Principle of operation

1…Tank 25…Impeller 79…Motor pulley 93 … Motor bracket

5.2 Transporting the machine

5.3 Disposing of the packing materials

5.5 Setting up and aligning

1…Stone bolt 4…Grout

– Hook tank on a crane.

Mounting the filling

See picture section slushing unit and bearing in chapter 9

– Paste flange seal (part list pos. 16) to screenbox-flange

1…Stone bolt 4…Grout

Grouting the tank feet and drive base plate

– Align tank and base plate so that axes are in parallel.

Setting up the motor

All pipework must be connected completely free of tension.