bergmann ALPHA-PACK-BIN User manual

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ALPHA - PACK - BIN
I M P O R T A N T D O C U M E N T
Machine model
Serial - no.
Year
Operating instructions - No.
APB 616
17902
Translation of the original Operating Instructions
FO-09-39 Version 01

Table of contents
0. 01
1. Use for intended purpose............................................................................................................ 1.01
2. Introduction ................................................................................................................................... 2.01
2.1 View of the machine ........................................................................................................ 2.01
2.2 Background, benefits and features ............................................................................... 2.02
3. Principle safety considerations ................................................................................................ 3.01
3.1 List of symbols and notes.............................................................................................. 3.01
3.2 Principle safety rules ...................................................................................................... 3.02
3.2.1 Organizational measures ................................................................................ 3.02
3.2.2 Safety and protective devices ......................................................................... 3.03
3.2.3 Safety installations ............................................................................................ 3.04
3.2.4 Hazards through electrical energy ............................................................... 3.05
3.2.5 Hazards through hydraulic energy ............................................................. 3.05
3.2.6 Switching the machine pressure-free........................................................... 3.05
3.2.5 Maintenance and repair................................................................................... 3.06
3.2.6 Instructions in case of emergency ................................................................ 3.06
3.3 Emergency procedure "Person trapped in the compaction chamber" ............ 3.07
4. Commissioning ............................................................................................................................ 4.01
5. Operation ................................................................................................................................. 5.01
5.1 Filling and starting the machine ................................................................................ 5.01
5.2 The full signal ................................................................................................................... 5.03
5.3 Emptying the machine .................................................................................................. 5.04
5.4 Emptying the machine with a pendulum-type flap ................................................. 5.06
6. Electrical Circuit .......................................................................................................................... 6.01
6.1 General ................................................................................................................................ 6.01
6.2 The motor overload protection .................................................................................... 6.02
6.3 The electrical control ...................................................................................................... 6.03
6.4 The working hour counter ............................................................................................ 6.04
6.5 The isolator ........................................................................................................................ 6.04
6.6 The float switch ................................................................................................................ 6.04
6.7 Switch mechanism for container opening ................................................................ 6.05
7. The additional equipment ......................................................................................................... 7.01
7.1 The covering hood ........................................................................................................... 7.01
7.2 Switch mechanism for container lock ........................................................................ 7.01
7.3 The container full signal ................................................................................................ 7.02
7.4 The double pump............................................................................................................. 7.02
7.5 The HUB-TILTING DEVICE.................................................................................... 7.03
7.5.1 The operation of the HUB-TILTING DEVICE ...................................... 7.03
7.5.1.1 The automatic lid opener (optional)............................................ 7.05
7.5.1.2 The automatic swinging lid opener (optional) ........................ 7.06

Table of contents
7.6 The remote control .......................................................................................................... 7.08
7.7 The hydraulic lid opener ............................................................................................... 7.09
7.8 The electric lid opener .................................................................................................... 7.10
7.9 Preliminary setup for a GSM unit ............................................................................. 7.10
7.10 The GSM complete package ........................................................................................ 7.11
7.11 The ozone generator ....................................................................................................... 7.11
7.12 The RESET button ............................................................................................................. 7.12
8. The Hydraulic Power Pack ...................................................................................................... 8.01
8.1 General ................................................................................................................................ 8.01
8.2 The grade of hydraulic oil ............................................................................................. 8.01
8.3 Oil change on the hydraulic power pack ................................................................. 8.02
9. Technical Data.............................................................................................................................. 9.01
10. Dimensions..................................................................................................................................... 10.01
11. Maintenance and Care ................................................................................................................ 11.01
11.1 General ................................................................................................................................ 11.01
11.2 Maintenance and inspection list .................................................................................. 11.02
11.3 Lubrication of the bearings ............................................................................................ 11.03
11.4 Cleaning of electric motor ............................................................................................. 11.04
11.5 Working in the interior of the machine (pendulum-type flap) ............................. 11.04
12. Trouble-Shooting ........................................................................................................................ 12.01
13. Lubrication chart ......................................................................................................................... 13.01
14. Guarantee and liability ............................................................................................................. 14.01
14.1 Obligation of the user ..................................................................................................... 14.01
14.2 Guarantee and liability .................................................................................................. 14.01
14.3 Copyright ........................................................................................................................... 14.01
15. CE - Declaration of Conformity ........................................................................................... 15.01
16. Additional information .............................................................................................................. 16.01
0. 02

1. Use for intended purpose
1. 01
The present unit is a stationary operated compaction container which can be taken up by a roller
tipper for transport and emptying purposes. The machine was only manufactured for a specific pick-
up system according to customer requirements and is therefore only suitable for use with this system.
The ALPHA-PACK-BIN has been designed only for the compaction of valuable substances and wastes
and may be used for this purpose only. Any other use or application beyond this must be considered
as improper use. BERGMANN will not accept any responsibility for any damages resulting from this.
Proper use also includes
• observing all operating instructions as set out in the Operating and Maintenance Manual,
• observing the service and maintenance instructions
• the prohibition of any extensions or reconstructions of the machine.
Awareness of the basic safety instructions and regulations is of utmost importance in order to handle
the machine safely and to guarantee trouble-free operation. These operating instructions contain the
most important information needed to operate the machine in compliance with the safety instructions.
Ensure that the operating manual is given
to the operator and kept in a safe location.
Read and observe the entire
operating manual, including all details.
There may be deviations in technical data, illustrations and dimensions due to continual further
development.
When ordering spare parts please quote the machine serial number, the spare parts list page and the
name of each item with its part number.
Label :

2. Introduction
2. 01
2.1 View of the machine APB 616
Pick-up hook Compaction
chamber
Hydraulic system
with control cabinet
Unloading door Shunting hook
Mains
connection
Isolator Rails Hinge Service shaft
Hydraulic system
Transportrollers
Door lock
Control panel
Switch cabinet
Control panel

2. Introduction
2. 02
BERGMANN - Waste Disposal Equipment - has as a result of many years experience, introduced the
BERGMANN ALPHA-PACK-BIN 616 with its patented throw-over blade.
The compact construction of the packer blade offers an outsized charging hole in the compaction
chamber. Thus there is enough space even for large objects and the time-consuming cutting of the
wastes becomes unnecessary.
The machine can be continuously fed due to the throw-over blade which brings the non-compacted
material back in front of the packer blade on the return stroke.
Cleaning behind or below the packer blade is absolutely unnecessary. On each forward stroke the
underside of the blade scrapes away any waste which may have got stuck between the charge box
and the container.
Positive driving of the packer blade is guaranteed even under extreme loads. This is helped by the
durable plastic guides on which the packer blade runs.
The power pack is situated in the upper part of the container and thus out of the dirty area. This
protects it from aggressive liquids, as well as the elements.
Below the power unit there is a pan for leaking oil in order to collect the hydraulic oil required for the
operation of the machine.
A sturdy and safe locking of the discharge opening prevents the material from escaping.
A clearly arranged operating keyboard and two EMERGENCY STOP buttons, as well as a time relay for
automatically switching off the machine are part of the serial scope of delivery
Optical and acoustic level indicators or a spring releasing cover beyond the charging hole can be
useful extra equipment.
The BERGMANN ALPHA-PACK-BIN APB 616 has been designed in order to be taken up by a roller
tipper. The take-up hooks can be matched to the corresponding vehicle type as required by the respective
customer.
The high economic benefit of the APB 616 results from the fast work cycles, the large charging hole in
connection with the high compaction ratios, the standard hinged roof (APB 606) and the easy emptying
as well as the resulting reduced costs for disposal, personnel and space.
BERGMANN - Machines are constantly adapted to technical and general safety provisions. This means
that minor deviations may occur in the operating instructions. All information is based on theoretical
calculations / values.
2.2 Background, benefits and features

3. Principle safety considerations
3. 01
3.1 List of symbols and notes
The following signs for hazards are used in the operating instructions and on the machine:
This symbol stands for a possible hazard for the life and health
of persons.
The non-observance of these instructions can result in serious effects to
health and even life-threatening injuries.
This symbol stands for a possible hazard.
The non-observance of these instructions can result in slight injuries or
damages to property.
This symbol points to important facts.
This symbol warns of dangerous electrical voltage.
This symbol indicates that it is prohibited to enter the compac-
tion chamber.
This symbol means that the operating staff is to have read and
understood the user manual.
This symbol means that the machine is to be disconnected from
the mains power supply and secured against reactivation during
repair and maintenance work.
This pictogram defines how to take up the PACK-BIN by means
of a hook.
Thereby the projecting end of the PACK-BIN on the collection vehicle
must not exceed half of the machine length.

3. Principle safety considerations
3. 02
3.2 Principle safety rules
The safety and availability of the machine depends on the observance of these
regulations.
You will also find the most important requirements as a sticker on your machine.
3.2.1 Organisational measures
* The machine is transported and emptied using a roller tipper. Each of the machines was only
manufactured for a specific pick-up system according to customer requirements and is therefore
only suitable for use with this system.
* Before placing the machine by the disposal vehicle, it must be assured that at the assembly site all
operating elements can be easily reached.
* Only trained and instructed personnel may operate the machine. The operating staff must have
read and understood the operating instructions.
* The operating instructions must always be at the PRESS-BOX or at the place of use.
* The operating staff has to wear the necessary protective equipment, i.e. safety shoes and gloves.
This equipment must be provided by the operator.
* Safe operation of the machine is only possible if sufficient illumination is provided. This is the
responsibility of the operator.
* In addition to the operating instructions the general and local regulations for the prevention of
accidents and the protection of the environment must be observed.
Machines with a cover above the feed opening :
This symbol warns that reaching into the pivoting area of the covers is prohibited.
This symbol points out the danger of injury in case of improper use of the covers.
Machines with a BIN-LIFT-TIP DEVICE :
This symbol warns that staying in the pivoting area as well as underneath the
raised lift-and-tilt device is prohibited.
Machines with automatic start-up :
This symbol means that the machine starts automatically.
The following pictograms have validity for machines and special equipment :

3. Principle safety considerations
3. 03
* It is not allowed to make any modifications, extensions or reconstructions on the machine without the
prior written consent of BERGMANN. This is also valid for welding works at load bearing parts.
* If the machine is combined with other machines (e.g. conveyor belts, etc.), a separate risk
assessment has to be created by the operator.
* The pressure in the hydraulic system may only be changed by an authorised expert of BERGMANN.
* It is not allowed to make changes on sealed components. This applies especially for hydraulic
valves.
* During the operation, all noise protection devices (aggregate doors, aggregate hoods, etc.) must be
closed.
* The type of material compacted can result in different noises. The decibel value indicated was
measured on an empty machine.
* To minimise noise emission, we recommend a cover hood.
* The substances and materials used must be used and disposed of properly.
* Toxic, explosive and chemical materials may not be compacted and must be disposed according to
the local regulations.
* It is the owner/user's responsibility to provide the operating personnel with special protective
equipment (e.g. protective clothing, goggles, gloves, etc.) for medical waste. For this use, we
recommend equipping the machine with a hood and covers, which must be closed prior to
compaction.
* Fill in compactable material only. Otherwise steel girders, timber planks etc. might damage the door.
* Smaller hard material (screws, glass etc.) and hardening materials as well as materials which are
subject to special regulations according to the law concerning waste disposal must not be compacted.
* It is not allowed to press materials that may incur the risk of hauling out (hard plastic, splintering
wooden parts). If hauling off of smaller parts cannot be fully excluded, the filling opening must be
closed with a special covering hood during the pressing process. The hood must be approved by
the manufacturer for this use.
* On the plastic versions small metal parts may accumulate and cause noise.
They must be immediately repaired by an authorised expert.
* Use a rubber sheathed cable type H07 RN-F with a minimum cross section of 2.5 mm² for the
power supply.
* An earth leakage circuit breaker with 30 mA should be provided by the customer.
* Pressure receptacles, like hair spray cans, spray cans, etc. may not be compacted. Risk of explosion.
* The container must not be overfilled.
3.2.2 Safety and protective devices
* It is prohibited to enter and to reach into the compaction chamber.
* Prior to switching on make sure that there is nobody in the compaction chamber resp. in the
container.
* It is not allowed to remove or change any safety devices. The safety devices must be fully-
functioning.
* In case of malfunctions, the machine must immediately be shut off and the fault must be eliminated
by an expert with the corresponding knowledge.
* Machine parts which are not in a perfect condition must be replaced immediately.
* In consideration of the safety distances (see point 3.3 “Safety distances”) the use of ramps and
platforms is allowed.
* If the machine is filled via ramps, platforms, etc., the owner/user must create a separate risk
assessment.

3. Principle safety considerations
3. 04
* All handles, steps, railings, pedestals, platforms and ladders must be kept free of soiling, snow
and ice.
* The safety and danger instructions on the machine have to be kept in a legible condition and
must be replaced if necessary.
* Operation of the PACK-BIN in publicly accessible areas such as market places etc. is only allowed
under supervision of the operator. If the machine is not under supervision, it is necessary to
secure the main switch by means of a padlock. If the machine is equipped with a cover hood over
the filling opening, this hood must be closed and also secured with a lock. The keys to these locks
must be kept in a safe place.
* PACK-BINs which are equipped with four transport rollers must be secured in such a way that
inadvertent rolling is prevented.
* The pick-up hook at the discharge opening is used as a shunting and maneuvering aid only.
* If the machine is pulled onto the transport vehicle by means of the pick-up hook the projecting
end of the PACK-BIN on the collection vehicle must not exceed half of the machine length.
* The locking of the PACK-BIN on the tipper vehicle must be carried out according to the
instructions of the vehicle manufacturer. The driver is to ensure that the machine was correctly
locked.
* When releasing the discharge opening and emptying the PACK-BIN it is prohibited to stand
behind the discharge opening.
* After emptying the box the discharge opening must be locked safely again.
* If the machine is operated with an integrated LIFT-TILT DEVICE, the movement range of
the machine incl. container should be marked on the floor.
3.2.3 Safety installations
Faultless function of the safety installations must be checked each time before beginning work.
Main switch Main switch in OFF position switches the machine off and all
poles are disconnected. Switching on the machine is not possible.
(See chapter 6.6)
EMERGENCY STOPEMERGENCY STOP
EMERGENCY STOPEMERGENCY STOP
EMERGENCY STOP buttons If one of the EMERGENCY STOP buttons is pressed, the machine
is switched off. (see chap. 5.1)
3.2.4 Hazards through electrical energy
* During works at the machines, the 5 safety rules must be adhered to:
- Activating,
- securing against accidentally being switched back on,
- checking for no current,
- earthing and short-circuiting,
- Cover or fence off adjacent parts which are live.
* Repairs or maintenance on the electrical supply system may be carried out by qualified electrician
only.

3. Principle safety considerations
3. 05
* The electrical equipment of the machine must be inspected at regular intervals. Any faults such
as loose connections and/or scorched cables must be cleared immediately.
* In the event of a defect on the electrical equipment, further operation of them machine is prohibited.
That is valid until authorised expert staff confirms that all faults have been successfully eliminated.
* Extinguish fire in the electric control with a CO2 extinguisher.
* Location and operation of fire extinguishers must be made public. The possible measures of fire
detection and fire fighting must be observed.
* The switch cabinet must always be kept closed. Access is only allowed for authorised staff.
* Plugged connections have to be loosened and/or plugged in when the current has been switched
off.
* When connecting equipment to the mains, the local EVU-regulations must be observed.
* The adjustment of the motor protection switch must not be changed.
* Dust deposits may lead to dangerous explosions in connection with electric components. Therefore
deposits must be removed at regular intervals.
* Due to extreme temperature differences (especially in winter), condensation can never completely
be ruled out in the console enclosures and switch boxes. In the event of a fault, the mains plug
must be pulled and the console housing and control cabinet must be inspected by a qualified
professional and, if present, the condensation must be removed.
3.2.5 Hazards through hydraulic energy
* Only staff with specialised know-how and experience may work on the hydraulic equipment.
* The hydraulic equipment must be inspected at regular intervals. Any faults such as chafe marks
on the hoses or leakages at the screwed connections must be corrected immediately.
* System sections and pressure pipes that can be opened must be depressurised prior to the start of
repair (see chapter 3.2.6). Liquids that escape under high pressure can penetrate the skin and may
cause severe injuries.
3.2.6 Switching the machine pressure-free
* The machine must be set up on a firm, level surface.
* Disconnect the PACK-BIN from the power supply and secure against switching on.
* For machines with BIN-LIFT-TIP DEVICE (BLT), both hydraulic cylinders of the BLT must be
fully moved in. This means, the BLT must be in home position. In home position, the container can
be slid in.
3.2.7 Maintenance and repair
* The operating instructions are no instructions in order to carry out extensive servicing. These
works must be carried out by recognised specialised staff.
* The above mentioned maintenance and service must be carried out within the prescribed time
limit (see chapter 11 “Maintenance and care”).
* Maintenance and repair may be carried out only be qualified staff with the corresponding know
how. On this occasion the machine must be disconnected from the mains and be secured against
being switched on by mistake.

3. Principle safety considerations
3. 06
* Maintenance work must be carried out on the stations intended for this purpose.
* As far as necessary the repair area must be secured.
* If maintenance personnel have to access the machine through the unloading door, this door
must be secured by means of an arresting cable. For this purpose, a snap hook is mounted on
the bottom of the container (see also chapter 5.3).
* During maintenance work, the filling hole must be closed by the cover hood or scaffold boards.
If necessary, use a certified ladder or work platform sufficient for the respective purpose. It is
the owner/user's responsibility to provide this equipment.
* If required a certified ladder or platform appropriate for the respective purpose must be used.
These auxiliaries must be supplied by the operator.
* Larger assemblies must be fixed and secured carefully with lifting devices when being replaced.
* Hydraulic hoses must be replaced every 6 years as a minimum, even if no safety relevant faults are
visible.
* When handling oils, greases and other chemical substances, follow the safety instructions applicable
to the product.
* Only use original spare parts in case of replacement.
* After finishing service work check functioning of all safety devices (see chapter 3.2.3) and mount
again all lids, cleaning flaps, etc. and check them for tightness.
3.2.8 Instructions in case of emergency
* Always press the EMERGENCY STOP button in emergency situations and pull the
mains plug. For the exact emergency procedure, refer to chapter 3.3.
* Extinguish fire in the electric control with a CO2 extinguisher.
* Burning oil must be extinguished using a Co2 extinguisher or dry powder extinguisher.
* Location and operation of fire extinguishers must be made public. The possible measures of
fire detection and fire fighting must be observed.

3. Principle safety considerations
3. 07
3.3 Emergency procedure "Person trapped in the compaction chamber"
If a person is trapped in the compaction chamber, proceed as follows:
1) Actuate the EMERGENCY STOP button
2) Pull the mains plug.
3) Call emergency services.
4) Clear the filling area of waste and refuse as much as possible and secure the filling
area prior to any further filling.
To release the press ram, proceed as follows:
These steps may only be carried out when supervised by emergency
services!
5) Secure the press ram against any further movement in the direction of the trapped
person using suitable lifting means (e.g. a crane, forklift truck, etc.).
6) Open the cylinder cut covers on the LH and
RH side of the machine.
7) Disconnect the hydraulic hoses (A and B
line) from the cylinder.
Note the emerging hydraulic oil.
If necessary, seal the line (using a rag, etc.).
8) Use the lifting equipment to carefully pull or push the press ram back.
9) Rescue the person from the filling area of the machine.

4. Commissioning
4. 01
Prior to lifting the machine,
ensure that the COMPACTION
BOX is disconnected from the
mains.
Pull the remote control plug prior
to lifting (optional).
For machines with a LIFT-TILT-
DEVICE or a cover hood, move
these to their transport position
first (optional).
1) Transport the PACK-BIN to a site with
solid, level ground.
You will find special hooks at the front side
and at the discharge opening of the unit.
2) Check to see if the mains voltage is the same
as the machine voltage.
You will find this information on a sticker
at the front side of the unit.
( e.g. in case of 380V, 50 Hz )
Commissioning must only be carried out by a BERGMANN
authorized dealer.
The following instructions have to be observed for the commissioning and in case of a later change in
location:
Electricitysupply O 220-240V3~
O 380-415V3~ O 480V3~
Frequency O 50 Hz O 60Hz
Mainfuse(byuser) 3x25A
Powerrating O 5,5kW O 7,5kW
Protection IP 44

4. Commissioning
4. 02
3) If the voltage is the same connect the
PACK-BIN to the mains.
4) Switch on the isolator.
5) Release the two EMERGENCY SHUTOFF
button by turning the buttons to the
right.
In case of danger imme-
diately press the
EMERGENCY SHUTOFFEMERGENCY SHUTOFF
EMERGENCY SHUTOFFEMERGENCY SHUTOFF
EMERGENCY SHUTOFF
button.

4. Commissioning
6) Actuate the RESET button.
7) After the connection to the electrical mains the
rotational direction of the motor must be
tested.
For this purpose press the ON switch.
If the rotational direction is correct the com-
pacting piston will move backward.
If this is not the case, the ma-
chine must be disconnected from
the mains immediately and the
rotational direction of the motor
must be changed.
This can have two causes :
* Two of the three phases in the supply line
were switched.
This work is only to be carried
out by a qualified electrician.
or
* The implement hitch on your machine is
equipped with a phase inverter.
The phases are hereby switched by the
insulating part being rotated by 180° by
applying light pressure to a lock.
4. 03
L1 L2
L3