ENVIRO-PAK H Series Single Chamber Compactor Operation and Maintenance Manual Manufacturer of ENVIRO-PAK SAFESUB WINDCHILLER 800-737-5533 WWW.ENVIRO-PAK.NET SALES@ENVIRO-PAK.NET 4308 West Admiral Doyle Drive, New Iberia, LA 70560 800-844-8683 WWW.HOOVERSOLUTIONS.COM 1
Table of Contents H Series Compactors 3 Safety 4-8 Marpol 9 Installation 10-11 Electric Installation 12 Air Installation 13 Installation of Bags 14-15 Compactor Sequence of Operations 17-18 Removal of Full Compactor Bag 19-20 Maintenance Schedule 21 Troubleshooting Guide 22 Master Part List 23 General Arrangement and Layout Drawing 24 Electric Schematic 25 Wiring Diagram 26 Hydraulic Schematic 27 2
H-Series Single Chamber Compactors Benefits Features Rugged marine environment design needs little Compactor Features maintenance Improves MARPOL Compliance and waste handling practices Obtain lower disposal costs by reducing volumes Maximizes storage space and extend time between offloading Safe, user friendly design Compact unit with a small unit footprint Stainless steel construction Electric or Air configuration Explosion proof option available High compaction ratio On deck and Enclosed space installation Fail Safe controls and enclosed compactor ram unit Safety limit switch inside the compactor Compactor Specs Unit H2 H5 Height Width Depth Weight Capacity Deck space Compaction Force 2006 mm / 79 813 mm / 32 686 mm / 27 236 kg / 520 lbs 0.2 m³ / 6 ft³ 0.5 m² / 6 ft² 4536 kg / 10000 lbs 2261 mm / 89 1168 mm / 46 1219 mm / 48 733 kg / 1615 lbs 0.56 m³ / 20 ft³ 1.4 m² / 15 ft² 13608 kg / 30000 lbs H10 3048 mm / 120 1245 mm / 49 1397 mm / 55 876 kg / 1930 lbs 1.2 m³ / 45ft³ 1.7 m² / 19 ft² 27215 kg / 60000 lbs H15 3175 mm / 125 1320 mm / 52 1473 mm / 58 952 kg / 2100 lbs 1.6 m³ / 58 ft³ 1.9 m² / 21 ft² 27215 kg / 60000 lbs Marine Green and ENVIRO-PAK are registered trademarks of Tech Oil Products, Inc. 3
Safety ATTENTION: This unit uses high hydraulic pressures to acquire the compaction force needed. Caution should be at all times. THIS UNIT IS DESIGNED FOR COMPACTING TRASH: 1. Due to the close fit between the ram and the compaction chamber, always keep hands and loose clothing clear of the container during operation. 2. Under no circumstances should materials considered to be explosive be placed in the compactor. Serious injury may occur. 3. All adjustments on the unit are preset prior to delivery. Any attempt to alter or adjust the hydraulic, mechanical, or pneumatic systems may cause a dangerous situation. 4. Do not try to remove the bag from the container without first opening the doors on the container. Failure to open the doors may result in weakened or broken lifting straps. Always lift the bag using all four straps. 5. Notify Tech Oil Products, Inc. of any malfunctions. 337-367-6165. WARNING: ARC FLASH AND SHOCK HAZARD: Do not operate controls or open covers without appropriate personal protection equipment. Failure to comply may result in injury or death! EXPLOSION HAZARD: Do not disconnect equipment unless power has been switched off or area is known to be non-hazardous 4
Safety HYDRAULIC TANK: For shipping purposes, the hydraulic oil tank was sealed. This tank must be opened to ambient air in order for the compactor to operate. Remove the plug in the top of the tank and replace it with the tank breather that is provided. Hydraulic Tank and Breather Cap DO NOT OPERATE THIS EQUIPMENT UNTIL THE HYDRAULIC TANK BREATHER IS INSTALLED 5
Safety ATTENTION: This unit has access doors that must be closed during operation and that may have pinch points. Use proper PPE and observe these areas. 6
Safety ATTENTION: This unit has access doors must be closed during operation and that may have pinch points. Use proper PPE and observe these areas. 7
Safety ATTENTION: Process only proper wastes with approved bags. 8
Marpol 9
Installation 1. To ensure that the compactor operates properly, it must be placed on a level surface. Bolt down tabs have been provided for anchoring the unit to the floor. (Refer to pictures on the side for location of anchor bolt tabs.) There will be one on the inside of each leg. 2. The unit may have been shipped with the hydraulic cylinder and ram assembly lowered into the compaction chamber. This is done to accommodate height restriction of freight carriers. 3. After the unit is placed on a level surface, if the cylinder was lowered, the cylinder and ram assembly must be installed into the operating position. A crane or forklift and at least two people are required. 4. Open chamber door to reveal the cylinder and 4 cylinder mounting bolts. 5. Attach a lifting cable to the lifting eye on top of the hydraulic cylinder. 6. Slowly lift the hydraulic cylinder **CAUTION: Be careful not to jam the hydraulic hoses or fittings during lifting. 7. When the mount plate on the cylinder aligns with the mounting holes on the compactor frame, install the four bolts provided with the unit. 8. Disconnect the lifting cable. Remove the lifting eye and circular stabilizing plate. 9. Connect the hydraulic hoses; SEE WARNING BELOW!! Connecting Hydraulic Hoses **CAUTION: At any time during installation there is danger of the ram free falling. Introducing air into the cylinder by removing a hose, cap, or any hydraulic fitting would be a dangerous situation. Take appropriate precautions such as a support system being placed under the ram to prevent it from free falling. 10
Installation WARNING: HYDRAULIC OIL TANK. For shipping purposes, the hydraulic oil tank was sealed. This tank must be opened to ambient air in order for the compactor to operate. Remove the plug in the top of the tank and replace it with the tank breather that is provided. DO NOT OPERATE THIS EQUIPMENT UNTIL THE HYDRAULIC TANK BREATHER IS INSTALLED. Remove the hydraulic tank plug before connecting the electrical system. Your unit s motor and pump configuration may differ, but the tank plug is the same on all units. 11
Electric Installation 1. To ensure proper operation and highest performance, the unit should be placed on a level surface. 2. If installation location guidelines require the unit to be electrically grounded in addition to the grounding that occurs when the unit is bolted down, locate and connect a grounding wire to the grounding lug provided on the compactor. 3. Voltage required for unit is shown on the electrical schematic and wiring diagram. The unit will be tagged on the electrical enclosure to identify the correct voltage. 4. Connect the three wires into the starter box and onto the magnetic starter. Rotation on the motor is checked by viewing the fan end of the motor. Turn the power to the motor on momentarily and then turn the power off. Determine which way the fan is rotating (clockwise or counter clockwise). Proper rotation is indicated on the motor. If the fan is rotating clockwise, the unit is wired properly. Step 2 Step 3 Step 4 12
Air Installation 1. To assure proper operation and rolling of the carriage, the unit should be placed on a level surface. 2. To put unit into service, simply connect a 1" air line to the crowfoot connection. Make sure the ON/OFF valve is off before applying pressure. Air supply should have a minimum of 90 psi and 60 cfm. 13
Installation of Compactor Bags H 2 Open both of the doors of the unit. Pass the two (2) metal lifting bag holders provided through the side loops on the compactor bag. Insert the two metal lifting bag holders through the corner slots in the rear of the unit. Attach the metal lifting bag holders to the pins located on the compactor door. Close the chamber and load doors.(refer to Picture 1) Bag Removal Open the load door. Slide the lifting bag holders out from the compactor. Open the main door. Remove compactor bag. 14
Installation of Compactor Bags 1. Open the main door of the compactor. H 5 / 10 / 15 2. Fully open the compactor bag and pull the lifting straps through the slots provided in the top of the bag at each corner so that the duffel material lays flat on the outside of the compactor bag. This prevents the duffel material being compacted into the bag during the compaction process. PUT THE BACK STRAPS ON THE HOOKS PROVIDED FIRST, THEN THE FRONT STRAPS. 3. Pull the straps through the slots provided in each corner of the compaction chamber. 4. Pull the bag straps very tight so that the bag sides are fully against the inside compaction chamber walls. 5. Attach the straps to the strap hooks provided around the outside of container, starting with the rear straps. (SEE PHOTO # 1A BELOW) 6. Press down on the handle to tighten the bag into place. Repeat on all other bag straps. 7. Close the compactor door and lock. 1a COMPACTOR IS NOW READY FOR OPERATION Slot to Pass Strap Through Strap Hooks for Securing Bag Straps LOADING THE CHAMBER The top door of the unit is used for introducing waste into the compactor bag. 1. Open the load door. 2. Load the compactor with waste. 3. When finished loading, close and secure the load door. 15
Sequence of Operations Electric Powered Compactors This section, along with diagrams, is designed to assist in understanding the operations of the compactor. An electric motor is used to turn the hydraulic pump. The motor will start when the following conditions are met: a: The electrical supply must be connected to the unit. b: The door of the compactor is securely closed. Electric Motor 16
Sequence of Operations Electric Powered Compactors Once the compactor bag has been installed, begin loading trash through the load door. Once the compactor bag has been installed, begin loading trash through the load door. When you have finished loading the compactor, close the load door and latch securely. Pull the red Stop button out. The green Start button will illuminate. Press the green START button to engage the motor. WHILE PRESSING THE START BUTTON push down on the Manual Control Valve Arm to the RAM DOWN position. After compacting, move the Manual Control Valve Arm to the RAM UP position while pressing the green START button until the ram returns to the top position. Turn the unit off by releasing the green START button and the Manual Valve Arm. AS A SAFETY PRECAUTION, if the motor continues to run even after the START button is released, press Latch must be closed causing the door to depress the safety switch / valve for the unit to operate. Illuminated START button STOP button Ram UP / DOWN Manual Valve control lever 17
Sequence of Operations Air Powered Compactors This section, along with diagrams, is designed to assist in understanding the operations of the compactor. An air motor is used to turn the hydraulic pump. The motor will start when the following conditions are met: a. The air supply must be connected to the unit. b: The door of the compactor must be securely closed. AIR VALVE RAM UP/ RAM DOWN CONTROL VALVE 1. After compactor bag is loaded into the cart, secure the cart into the unit. 2. The front access door is used for introducing waste into the compactor bag. Load the compactor with waste. When finished loading, close and secure the load door. 3. Turn the air valve to turn on the air supply. 4 Press the air valve down and hold to turn the air motor on. 5. Pull DOWN the control valve lever and the ram cylinder rod will move downward. The ram extends fully into the chamber. 6. Push the control valve lever UP and the cylinder rod and ram will retract. 7. When the ram fully retracts, release the air valve handle and turn off the air supply. 18
H2 Compactor Bag Removal 1. Fully retract compactor ram and turn unit off. 2. Open front access door 3. Remove the metal lifting bag holder. 4. Remove the bag 19
H5/10/15 Compactor Bag Removal 1. Fully retract compactor ram and turn unit off. 2. Open front access door 3. Release the bag straps from the locking arms. 4. Press and hold the green START button or push down on the air valve to engage the motor. 5. Push down on the Eject Control Valve Arm to the Out position until the eject system is in the full eject position. 6. Release the Start button or the air valve to stop the motor. 7. Remove the bag. 8. Press and hold the green START button or push down on the air valve to engage the motor. 9. Push up on the Eject Control Valve Arm to the In position until the eject system is in the full retract position. 10.Turn the unit off by releasing the green START button or the air valve. 20
Maintenance Schedule Task Frequency Procedure Hydraulic Fluid in Tank Hydraulic Cylinder Bolts Motor and Pump Bolts As Needed Three (3) Months Ninety (90) Days The hydraulic system contains 2 to 3 gallons of hydraulic fluid. To check this fluid level the hydraulic cylinder must be in the UP position. Unscrew the cap on the hydraulic reservoir. Maximum level in the reservoir is 2 to 3 inches from the top of the tank. Should fluid need to be added, a check for leaks is advised. Hydraulic fluid used is Rando 68 or equivalent. Check for tightness. Adjust as needed Hydraulic Filter As Needed Remove the suction line from the bottom of the tank. Unscrew the filter from the line fitting. Installation is in reverse. Hydraulic Hose Sixty (60) Days Check hydraulic hose for weather degradation and/or rub spot wear. If signs are evident of either condition, remove the existing hose and replace with a new hose. 21
Troubleshooting Guide Problem Probable Cause Solution Motor will not start No electrical power Check that unit has power Blown fuse or overload circuit breaker tripped Replace fuse or reset circuit breaker Unit will not retract Load door and chamber door not closed Close the doors Motor running backwards Proper rotation of electrical motor Low hydraulic fluid Check hydraulic fluid, add as necessary Hydraulic hose leak Check all hydraulic hose for leakage, replace as necessary 22
Master Parts List 23
General Arrangement 24
Electric Schematic 25
Wiring Diagram 26
Hydraulic Schematic 27
Rev. 1-03/2016