Edition 1, From serial no. 10901- Publ. no A922-90619 OM B 900, 2010-01 Orwak Brickman 900 Operating instructions (in the original)
CONTENTS Safety... 2-3 Safety features... 3 Range of application... 3 Technical specifi cations... 4 Installation... 4 Diagram of terminal functions. 5, 9 Machine parts... 6 Prior to operation... 7 Operation... 7 Troubleshooting... 7 Setting the operating time... 8 Weekly inspection and maintenance... 10 Safety checks... 10 Transport... 10 Service... 10 CE... 11 SAFETY Please read the operating instructions BEFORE operating the machine. Our warranty/product responsibility requires that instructions are followed, and that original spare parts and recommended hydraulic oil and lubricants are used, and that no conversion or modification is carried out. The user of the machine is responsible for the safety checks, and for ensuring that daily maintenance of the machine is carried out. The user is responsible for ensuring that any faults are rectifi ed, and that neither the user nor other individuals are exposed to danger. The owner is responsible for ensuring that national and local laws are complied with when using the machine. This symbol means WARNING or DANGER personal safety instruction! The machine must not be used if the safety features (e.g. switches and protections) have been deactivated, damaged or removed. Lost or damaged parts must be replaced with original spare parts. Installation, repair and service work must only be performed by qualified and competent personnel, and in accordance with the installation and service instructions. The machine must not be used by minors. Never climb on the machine. Operators and other persons must not enter the feed hopper (A) under any circumstances. Material to be compacted should be added into the feed hopper. No tools or other means of assistance should be used when adding material into the hopper. Material should only be fed into the hopper whilst standing on the floor, i.e. no steps, pallets, stools or other means of assistance should be used to facilitate the feeding of material. The distance between where the operator is standing and the upper edge of the feed hopper should never be less than 1500 mm. The machine must never be operated without the briquette collection bin having been placed under the briquette chute (B). The machine should always be turned off when changing the collection bin. Errors and omissions excepted. 2
The machine must only be used if all the cover plates and caps/protective covers are in place and correctly fi tted. The electrical box (C) must be closed when the machine is connected to the mains. No work (service, repairs, disassembly, maintenance, etc.) should be carried out on the machine unless the main power switch (D) is padlocked in the off position. Always turn the main power switch off before disconnecting the mains cable for any reason. The machine and the area surrounding it should be kept clean and free of foreign objects. The machine is not intended to be placed in areas where there is a high risk of explosion. SAFETY FEATURES The machine is equipped with the following safety features: Caps/protective covers restrict access to dangerous moving parts. The machine is also equipped with two emergency stops (E), as well as a main switch (D) that can be padlocked to prevent unauthorised use, e.g. during service, cleaning and maintenance, or when removing any material that has become trapped. RANGE OF APPLICATION The machine is essentially designed to compact corrugated cardboard. However, other types of material can be compacted in the briquetting press, subject to the approval of the manufacturer. The machine must only be used in areas that have a roof, protection against wind, and normal lighting. Materials that are flammable or of an explosive nature (e.g. pressurised containers or the like) which, when exposed to pressure or sparks, could cause damage, fi re or an explosion, must not be compacted in the machine. The same also applies to compact paper material (e.g. newspapers, brochures, data lists, books, etc), metal materials, glass, wood materials, liquids, foodstuffs, plastics, rubber, minerals, chemicals and rubber, none of which should be compacted in the machine. 3
TECHNICAL SPECIFICATIONS (Brickman 900) INSTALLATION There should be at least 1 metre of open space around the machine. The clearance height where the machine is to be placed should be at least 30 centimetres (see Technical specifi cations). (Illustrations referred to in the text appear on the next two pages.) GENERAL DATA A 2470 mm B 2010 mm C 585 mm D 1350 mm E 1500 mm F 1870 mm G 5710 mm H 1355 mm I 695 mm J 1350 mm K 950 mm L 1180 mm M 1570 mm N 265 mm O 1035 mm P 230 mm Q 930 mm R 535 mm S 840 mm T 1960 mm U 1300 mm V 1155 mm Machine weight: Dimensions: 3200 kg Height: 2470 mm Width: 5710 mm Depth: 1960 mm Feed hopper: Depth: 930 mm Width: 1300 mm Volume: 1.5 m³ Colour: RAL 2001 (orange) Noise level: 68 db (A) ELECTRICAL DATA Operating voltage: 3x400V Control voltage 24V (DC) Mains connection: 5-pin Euro plug (32A) Fuse: 25A (delay action) Electric motor: 7.5 kw Protection class: IP 55 HYDRAULIC DATA: Working pressure: max 200 bar Press force: 250 kn Compaction pressure/cm² 62 kg Cycle time, total: 29 s Volume of oil: 160 litres Recommended oil: +5 C to +60 C: Statoil HVXA 32, or equivalent Below +5 C A special oil or a heater may be necessary at lower temperatures. Fit the briquette chute (B) (it is normally placed in the feed hopper (A) during transport) by fi rst removing the protective cover/cap (F) or cover plates on the machine. Secure the briquette chute using the four bolts and the springs (G). Replace the cover plate(s)/cap(s). Remove any transport protections between the hydraulic pump (X) and the tank. If fi tted, activate the guillotine's (4) optional lubrication cans (J). Electrical installation (should be carried out by a qualified electrician) Check the motor s (H) direction of rotation, as follows: Activating manual mode (on the terminal): - Turn the main power switch (D) on Terminal text BRICKMAN - Press F4, twice READY TO START Main menu Manual mode F1 FEED PLATE FOR- WARD F2: FEED PLATE BACK - Press the down arrow until the cursor is on Manual mode - Press Enter - Move the cursor to Feed plate - Press Enter - Press and hold F1 for 4 seconds 1. Make sure that the feed plate (I) has moved towards the cutting blades (R). 2. If no movement has occurred: turn the main power switch off and disconnect the mains cable. 3. Change the incoming phases. - Press F4 several times until "BRICKMAN READY TO START" is displayed. 4
DIAGRAM OF TERMINAL FUNCTIONS Use the arrow keys and confi rm with Enter. MAIN MENU: OP info Settings Manual mode Language Service Log in MANUAL MODE Press briquette out Feed plate Knife Press Brake Motor Pressure Air fan Press and hold button to operate manually. F1:BRIQUETTE OUT F1:FEEDPLATE FORW. F2:FEED PLATE BACKW F1:KNIFE UP F2:KNIFE DOWN F1:PRESS OUT F2:PRESS BACKW. F1:BRAKE UP F1:MOTOR F1:HIGH P.+MOTOR F2:HP+LP+MOTOR LANGUAGE: SERVICE: For authorised service personnel only F1:COOLING FAN For authorised service personnel only LOG IN: F1:L.in F2:L.out F3: Change password 5
MACHINE PARTS These illustrations are referred to by the italic text in the operating instructions. Springs (G) Feed hopper (A) Upper sensor (T) Briquette chute(b) Guillotine (Y) Cover plate (F) Emergency stop (E) Lubrication can(j) Cover plate (O) Press chamber(s) Lower sensor (Q) Cover plate (P) Guillotine (Y) (knife) Press loop/brake Cutting blade (R) Feed plate (I) Emergency stop (E) Lubrication can(j) Front sensor (Z) Cover plate (V) Electrical box (C) Rear sensor (U) Protective cover (N) Motor (H) Hydraulic pump (X) CONTROL PANEL / DISPLAY Rear sensor (Å) Start (L) Stop (M) Main power switch (D) Emergency stop (E) Reset button (K) NUM - ust be pressed and held when entering numbers. The arrow keys are used to move the cursor to the item to be selected. To see the whole the whole menu, scroll using the arrow keys. F4 - to go back through the menus. Enter confi rms the selection. 6
PRIOR TO OPERATION Ensure that the main power switch (D) is turned off. Make sure that there are no foreign objects in the feed hopper (A) or on or around the machine. Ensure that the collection bin has been placed under the briquette chute (B). Turn the main power switch on. Press the Reset button (K) The machine is now ready for use. OPERATION Press the start button (L). Place material into the feed hopper (A). The machine operates for a pre-set period of time and then stops. When delivered, the machine is normally set for an operating time of 2 minutes. (The operating time can be changed see the section Setting the operating time.) The machine can also be stopped by pressing the stop button (M). The machine will stop once an operation cycle has been completed, i.e. once it is in the home position, ready for new material to be fed in. If necessary, the machine can be stopped by using either of the two emergency stops (E). Rectify the situation that caused the emergency stop to be used. Reset the emergency stop by pulling it out, then press the reset button (K). FAULT FINDING (messages on the terminal screen) Check the terminal located on the machine s electrical box (C) for any error messages. If the screen is empty/there is no text: Turn the main power switch (D) off, disconnect the mains cable and open the electrical box. Check the automatic fuses in the electrical box. Check the fuses for the machine s power supply in the building s distribution box. Close the electrical box. Check that the mains cable is not damaged. Reconnect the mains cable and turn the main power switch back on. If the reset button (K) is fl ashing: Check the terminal screen for any messages. In the event of an alarm or loss of power, the machine must be reset by pressing the reset button. Terminal messages Ready to start The machine is reset and ready to start. Emergency Stop active An emergency stop button (E) is pressed in. Emergency Stop An emergency stop button (E) has been pressed but the machine has not been reset. Preheating oil The oil is being heated. The machine will not run until the correct temperature has been reached. Oiltemp OK The oil has reached the correct temperature. Reset is not required. "Oil overheated" The temperature of the hydraulic oil is too high. The machine will not reset or start until the oil has cooled down and the message Has been overheated is displayed. Has been overheated The temperature of the hydraulic oil has been too hot but is now back down to an acceptable level, and the machine can be started without being reset. Low The oil level in the hydraulic tank is too low. Check for any oil leak. Repair the leak and refi ll with oil. The message Oil level is displayed. Reset by pressing the reset button (K). Oil level The oil level in the hydraulic tank has been too low or is close to the too-low level. Reset by pressing the Reset button (K). Motor protection The electrical motor s overload protection has been activated (the motor is overloaded). Wait for a few minutes so that the overload protection can reset itself. Reset by pressing the reset button (K). 7
0 OFF When cleaning, all power to the machine should be turned off and the main power switch (D) should be secured with a padlock. A notice informing people that servicing is in progress should be hung on the control panel. Always use protective gloves and appropriate tools when cleaning the space in and around the guillotine. Knife down The guillotine (Y) has not reached the lower sensor (Q). Press the reset button (K). Start the machine using the start button (L). Run the machine until the guillotine reaches its upper position. Stop the machine in this position using emergency stop (E). Turn the main power switch (D) off and disconnect the plug from the mains. Clear the press chamber (S) of material. Knife up The guillotine (Y) has not reached the upper sensor (T). Remove the cover plate (P) on the rear of the machine in order to access the guillotine (Y). Check that no material has accumulated on the guillotine. Check the function and position of the upper sensor. Feed plate The feed plate (I) has not reached the rear sensor (U). Remove the cover plate (V) on the feed plate. Check that no material has accumulated at the rear of the feed plate. Check the function and position of the rear sensor. Press The press cylinder has not reached its forward position. Press the reset button (K). Start the machine using the start button (L). Run the machine until the press cylinder reaches its rear position. Stop the machine in this position using emergency stop (E). Turn the main power switch (D) off and disconnect the machine s power cable. Secure the main power switch using a padlock. Clear the press chamber (S) of material. Also clean around the front (Z) and rear (Å) sensors. Fault on B317 Pressure sensor fault. Contact authorised service personnel. Important. Change PLC battery! - The battery in the PLC must be changed. Contact authorised service personnel immediately. Book service The machine requires servicing. Contact authorised service personnel. SETTING THE OPERATING TIME (on the terminal): Terminal text BRICKMAN - Press F4, twice READY TO START Main menu - Press the down arrow until the cursor is on Settings - Press Enter Settings - Scroll down until the cursor is on Operating time at start - Press Enter Operating time Time control - Move the cursor to YES (to set the number of minutes) - To change to NO (continuous operation), press Enter - Scroll the cursor to XX in Operating time xx minutes - Press and hold the NUM key and enter the desired operating time in minutes - Press Enter to confirm the selection - Press F4 several times until "BRICKMAN 300, READY TO START" is displayed. 8
DIAGRAM OF TERMINAL FUNCTIONS Svenska Use the arrow keys and confi rm with Enter MAIN MENU: OP. info Settings Manual mode Language Service Log in OPERATING INFO: Total running time Oil temperature Monitor view I/O Status TOTAL RUNNING TIME: 00000 hours OIL TEMPERATURE: 20 degrees Celsius MONITOR VIEW: READY TO START I/O STATUS Inputs: X0 OFF X1 ON etc. Outputs: Y0 ON Y1 OFF etc. Blocks in this colour are only accessible after logging in using the password. Original password: "0000" Blocks in this colour are only accessible to authorised service personnel. SETTINGS: OP time Auto start Air fan 50/60Hz Press loop Default reset OPERATING TIME: Time control (YES) OP. time 2 minutes NOTE! Password required: AUTO START: Auto start (Off) FC/UL time 10 s AIR FAN: Start temp. 50 degrees C 50/60Hz: Select frequency 50 Hz Press loop: 110 bar Reset to default (F1) WARNING! 9
WEEKLY INSPECTION AND MAINTENANCE NOTE! Always padlock the main power switch (D) during inspection and maintenance, service work and the removal of trapped waste, etc. 0 OFF Clean the machine and the area around it. Ensure that there are no foreign objects on the machine. Ensure that there are no signs of damage on the machine. Remove the cap (N). Vacuum the hydraulic assembly. Make sure that there are no oil leaks. If a fan is fi tted: Before lifting off the cap, disconnect the connector in the electrical box (C) that connects the fan in the cap above the hydraulic assembly. Remove the cover plate (O) and clean out any material that may have got onto the wrong side of the feed plate (I). Remove the cover plate (P) and clean out any material that may have got onto the guillotine (Y). Check that the machine has no oil leaks and that all bolts and nuts are tightened. Check that no parts are loose or damaged. SAFETY CHECKS Regularly check that the cover plates are intact and in place. Also, be sure to regularly check the function of the two emergency stops (E). Contact authorised service personnel immediately if the emergency stops do not work. If any fault is found in the functions listed above, the machine must not be used until it has been repaired by authorised service personnel. Service and repairs must only be carried out by qualifi ed and competent personnel, and in accordance with the machine manufacturer s instructions. SERVICE The fi rst service should be carried out within 500 hours of operation. Subsequent service should be carried out at 500-1000 hour intervals or once a year. These intervals may vary depending on the surrounding environment and the material to be compacted by the machine, and should therefore be discussed with the manufacturer s authorised service personnel. Oil change: Contact the local authorities for advice regarding how to reduce environmental impact when dealing with residual oil. 10
EC DECLARATION OF CONFORMITY We AB ORWAK Box 58 SE-576 22 Sävsjö, Sweden Tel: 46-382-15700 Fax: 46-382-10607 declares under its sole responsibility that the product model:... Brickman 900 with serial number:... to which this declaration relates is in EC conformity with the following Standards or other normative documents following the provisions of Directive 2006/42/EEC (Machinery Directive) 2004/108/EEC (EMC Directive) 73/23/EEC, 93/68/EEC, 2006/96/EC (Low Voltage Directive) SS-EN 60204-1 SS-EN ISO13850 SS-EN ISO12100-1 SS-EN ISO12100-2 SS-EN ISO13857 SS-EN 982 EN 954-1 Ljungby 2010-01-01 Product Manager and compiler of technical documentation 11
Leader in compaction and baling solutions Orwak is a world leader in compaction and baling solutions for solid waste material at source. We develop, manufacture and market a comprehensive range of waste compactors, baling systems and Brickman briquette presses for recyclable materials that make waste management more profi table. We also o er fully automatic balers for recyclable materials through our subsidiary Presona. This is where Orwak s unequalled technology, expertise and service support make all the di erence. When you partner with Orwak, you also gain access to the vast experience we have built up over the last 35 years. Orwak is wholly owned by the Norwegian company Tomra, a leading global player in providing integrated solutions for recovering and recycling used packaging.