HSM VK 5012 User manual

Keep in a safe place for future use! 6.417.999.120 - Issued 06/2005
GB
OPERATING MANUAL
CHANNEL BALING PRESS
VK 5012

6.417.999.120 - Issued 06/2005
Manufacturer:
HSM - Pressen GmbH + Co.KG
Bahnhofstraße 115
D-88682 Salem Germany
Tel. ++49 (0) 7553/822-0
Fax ++49 (0) 7553/822-160
e-mail: [email protected]

VK 5012
Contents
Contents - 1
6.417.999.120
Issued 06/2005
Contents
1Safety 1.1
1.1 Safety instructions............................................................................................1.1
1.1.1 The Safety symbol...........................................................................................................1.1
1.1.2 The Note symbol .............................................................................................................1.1
1.2 Classification of hazards ..................................................................................1.1
1.2.1 Danger.............................................................................................................................1.1
1.2.2 Warning ...........................................................................................................................1.1
1.2.3 Caution ............................................................................................................................1.1
1.3 Operating safety instructions............................................................................1.2
1.4 What to do in an emergency ............................................................................1.4
1.5 Inspecting the safety devices ...........................................................................1.5
1.5.1 Checklist for inspecting the safety devices......................................................................1.6
2General information 2.1
2.1 Nameplate........................................................................................................2.1
2.2 Technical features ............................................................................................2.1
2.3 Introduction ......................................................................................................2.2
2.4 Scope of application and proper use................................................................2.3
2.5 Warranty...........................................................................................................2.3
3Technical data 3.1
3.1 Dimensions ......................................................................................................3.1
3.2 Machine overview ............................................................................................3.2
3.2 Machine characteristics....................................................................................3.5
3.3 Press data ........................................................................................................3.5
3.4 Main drive.........................................................................................................3.5
3.4.1 Main drive unit motor .......................................................................................................3.5
3.4.2 Main drive unit pump .......................................................................................................3.5
3.4.3 Press cylinder ..................................................................................................................3.5
3.4.4 Wire insertion cylinder .....................................................................................................3.5
3.4.5 Precompactor cylinder.....................................................................................................3.5
3.4.6 Press ram locking cylinder...............................................................................................3.5
3.4.7 Cutting edge clearing device cylinder..............................................................................3.5
3.4.8 Twisting motor .................................................................................................................3.6
3.4.9 Wire shearing cylinder .....................................................................................................3.6
3.4.10Oil tank ............................................................................................................................3.6
3.5 Press channel adjustment................................................................................3.6
3.5.1 Motor ...............................................................................................................................3.6
3.5.2 Pump ...............................................................................................................................3.6
3.5.3 Adjustment cylinder .........................................................................................................3.6

Contents
VK 5012
6.417.999.120 Issued 06/2005Contents - 2
3.6 Oil-air cooling unit ............................................................................................3.6
3.7 Switchbox heating ............................................................................................3.7
3.8 Feeding conveyor.............................................................................................3.7
3.9 Total power requirement and fuse rate.............................................................3.7
3.10 Noise emission.................................................................................................3.7
4Installation 4.1
4.1 Transport..........................................................................................................4.1
4.2 Installation conditions.......................................................................................4.3
4.2.1 Space requirement / foundation ......................................................................................4.3
4.2.2 Installation personnel.......................................................................................................4.3
4.2.3 Operation outdoors..........................................................................................................4.3
4.3 Supply connections ..........................................................................................4.3
5 Start-up 5.1
5.1 Initial position of the baling press .....................................................................5.1
5.2 Controls and indicators ....................................................................................5.1
5.2.1 Main switch......................................................................................................................5.1
5.2.2 Emergency stop button....................................................................................................5.1
5.2.3 Ready ..............................................................................................................................5.3
5.2.4 Motor ...............................................................................................................................5.3
5.2.5 Service hours meter ........................................................................................................5.3
5.2.6 Set-up ..............................................................................................................................5.3
5.2.7 Automatic mode...............................................................................................................5.5
5.2.8 Bale ready / Strapping .....................................................................................................5.5
5.2.9 Bale length.......................................................................................................................5.5
5.2.10Lamp check .....................................................................................................................5.5
5.2.11Indicator light: Feeding conveyor.....................................................................................5.5
5.2.12Luminous push-buttons: Pause feeding conveyor ..........................................................5.6
5.2.13Additional operator panel.................................................................................................5.6
5.2.14Manual mode...................................................................................................................5.6
5.2.15Operating mode...............................................................................................................5.6
5.2.14OP 17 operating panel.....................................................................................................5.8
5.2.14.1Key functions .....................................................................................................................5.9
5.2.16Display...........................................................................................................................5.10
5.2.17Fault messages .............................................................................................................5.11
5.2.18Troubleshooting on the controls ....................................................................................5.12
5.3 Operating modes............................................................................................5.13
5.3.1 Set-up mode ..................................................................................................................5.13
5.3.2 Manual mode.................................................................................................................5.15
5.3.3 Automatic mode.............................................................................................................5.16

VK 5012
Contents
Contents - 3
6.417.999.120
Issued 06/2005
5.4 Reloading the baling press.............................................................................5.17
5.4.1 Adjusting the flow of the A10VSO axial piston pump.....................................................5.17
5.5 Inserting the strapping wires ..........................................................................5.20
5.5.1 Wires on the twisting unit...............................................................................................5.20
5.5.2 Wires on the insertion side ............................................................................................5.23
5.6 Automatic compression..................................................................................5.27
5.7 Strapping procedure.......................................................................................5.28
5.8 End of wire .....................................................................................................5.30
5.9 Clearing the press channel ............................................................................5.32
5.9.1 Relieving the press channel ..........................................................................................5.34
5.10 Shutdown .......................................................................................................5.35
6Inspection and maintenance work 6.1
6.1 Notes on maintenance .....................................................................................6.1
6.2 Maintenence overview .....................................................................................6.2
6.2.1 Maintenance intervals......................................................................................................6.3
6.2.2 Hydraulic fluid ..................................................................................................................6.3
6.2.3 Bearing grease ................................................................................................................6.3
6.3 Maintenance.....................................................................................................6.4
6.3.1 Changing the hydrauli oil .................................................................................................6.4
6.2.2 Changing the pressure filter ............................................................................................6.5
6.4 Press ram.........................................................................................................6.7
6.4.1 Inspecting the blade clearance........................................................................................6.7
6.4.2 Central lubrication, manually ...........................................................................................6.8
6.4.3 Press ram locking ............................................................................................................6.9
6.4.4 Checking the stripper rail...............................................................................................6.10
6.4.5 Checking the roller track stripper...................................................................................6.11
6.4.6 Cleaning the area behind the press ram .......................................................................6.11
6.5 Twisting unit ...................................................................................................6.12
6.5.1 Inspecting and cleaning the shearing blades ................................................................6.12
6.5.2 Inspecting the twisting disks ..........................................................................................6.13
6.5.3 Lubricating the twisting drive .........................................................................................6.14
6.5.4 Lubricating the wire guide rollers of the twising unit ......................................................6.15
6.6 Wire insertion unit ..........................................................................................6.16
6.6.1 Cleaning and lubricating the wire insertion unit .............................................................6.16
6.6.2 Lubricating the wire guide rollers of the wire insertion unit............................................6.17
6.7 Precompactor.................................................................................................6.18
6.7.1 Lubricating the journal bearings ....................................................................................6.18
6.7.2 Lubricating the cylinder bearings...................................................................................6.18
6.8 Wire brake......................................................................................................6.19

Contents
VK 5012
6.417.999.120 Issued 06/2005Contents - 4
6.9 Electric motors ...............................................................................................6.20
6.10 Oil/air cooling unit...........................................................................................6.21
6.11 Screw connections .........................................................................................6.22
6.12 Adjusting the safety rip cord...........................................................................6.23
6.13 Lubrication chart.............................................................................................6.24
6.14 Controls..........................................................................................................6.25
6.14.1Loading a new program.................................................................................................6.25
7Using and ordering spare parts 7.1
7.1 Customer service address ...............................................................................7.1
7.2 Accessories......................................................................................................7.1
8Wiring and hydraulic diagrams 8.1

1.1
6.417.999.120
Issued 06/2005
Safety informations VK 5012
1Safety
1.1 Safety instructions
1.1.1 The Safety symbol
You will see this symbol next to all operating safety instruction in
this operating manual where there is a risk of injury or death if
ignored. Please note these instructions and exercise particular
care in such cases. Pass on all safety instructions to other persons
using the machine.
In addition to the instructions in this manual the safety and
accident prevention regulations which generally apply must also
be observed.
1.1.2 The Note symbol
This symbol indicates particularly important instructions in this
manual which must be observed in order to ensure that guidelines
and regulations are correctly adhered to, that work is carried out in
the proper order, and that damage to the machine or other plant
components is prevented.
1.2 Classification of hazards
1.2.1 Danger
Indicates an immediate danger. Failure to take heed of this
warning will result in death or very serious injury.
1.2.2 Warning
Indicates a potentially dangerous situation. Failure to take heed of
this warning may result in death or very serious injury.
1.2.3 Caution
Indicates a potentially dangerous situation. Failure to take heed of
this warning may result in minor injury.
Also used to warn about material damage.

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Safety informations
VK 5012
1.3 Operating safety instructions
The HSM baling press has been inspected for safety by the examination board of
the technical committee on printing and paper processing.
The baling press has been built with the most up-to-date technology. However, the
machine can be dangerous if improperly used, even by trained staff, or if used for
purposes other than those for which it was designed.
Anyone in the operating company charged with installation, assembly, reassembly,
start-up, operation, inspection, maintenance or repair of the baling press must have
first read and fully understood the entire operating manual, paying particular
attention to the “Safety” section.
The operating manual must be kept available for staff at all times.
The baling press may not be operated by anyone under 16 years of age.
The baling press may only be operated, serviced and repaired by authorised,
trained staff. These staff must have been given special instructions on any dangers
which may possibly arise.
Areas of personal responsibility for installation, assembly, re-assembly, set-up,
operation and maintenance must be clearly defined and strictly adhered to, in order
to avoid confusion which might compromise safety.
When carrying out installation, disassembly, re-assembly, maintenance, operation,
adjustment and repair work always observe the shut-down procedures described in
the operating manual.
Never use any working practices which may be detrimental to the safety of the
baling press.
The operator must ensure that only authorised staff work on the baling press.
The operator must immediately report any changes in the baling press which impair
safety and shut down the machine until the problem has been resolved.
The user must undertake never to use the baling press unless it is in perfect working
order.
The user must ensure that the workplace at the baling press is clean and tidy by
means of appropriate instructions and inspections.
Unauthorised modifications which may impair the safety of the baling press are not
permitted. Protective devices may not be removed or otherwise rendered
inoperative.
No work may be performed on the machine while it is running.

1.3
6.417.999.120
Issued 06/2005
Safety informations VK 5012
Before performing any work on the baling press it must be ensured that its drives
and additional devices cannot be switched on unintentionally (set the main switch on
the control cabinet to 0 and lock it).
Before starting the machine after repairs, make sure all protective devices are in
place.
Doors and flaps may only be opened after the baling press has stopped.
Test the protective devices after installing or repairing electrical components.
The operation of the baling press is always subject to local safety and accident
prevention regulations.
No platforms or other raised surfaces may be placed near the baling press if they
encroach on the specified safety clearances.
Riding on conveyors is strictly prohibited!
Connecting cables must be laid in such a way that they cannot be tripped over.
Check that mechanical wearing parts (such as the shear blade and rollers) are
working properly according to the maintenance instructions.
All electrical functional elements and components must be inspected every six
months by a qualified electrician.
Only persons with the appropriate skills and experience in hydraulics may carry out
work on the hydraulic equipment.
All lines, pipes and bolted joints must be regularly inspected for looseness, leaks
and visible damage. Any damage must be repaired immediately. Escaping oil can
cause fire and injury.
Any parts of the system and hydraulic pressure lines that need to be opened must
be depressurised according to the assembly instructions before commencing repair
work.
Hydraulic lines must be laid and installed correctly. Do not confuse connections. The
fittings, length and quality of the hose lines must meet the specified standards.
Replace pressure lines every 2 years !

6.417.999.120 Issued 06/20051.4
Safety informations
VK 5012
1.4 What to do in an emergency
In the event of an emergency press the red emergency stop button (1) on the
control cabinet of the baling press
or
turn the main switch (2) on the control cabinet to “0”
or
open any maintenance door or inspection door (3).
1
2
3
33

1.5
6.417.999.120
Issued 06/2005
Safety informations VK 5012
1.5 Inspecting the safety devices
Check the safety devices:
• At the start of each shift (if operation was interrupted)
• At least once a week if the machine is operated continuously
• After any maintenance or repair work
Check that the safety devices:
• Are in the correct condition
• Are in the correct position
• Are firmly secured
• Are working properly
Use the following checklist for your inspection. Correct any defects before starting
the machine.
If a defect arises while the machine is running, stop the press immediately and
correct it.
Do not modify or remove protective devices. Do not deactivate protective devices by
modifying the machine.
Changes to the machine are prohibited for reasons of safety.

6.417.999.120 Issued 06/20051.6
Safety informations
VK 5012
1.5.1 Checklist for inspecting the safety devices
Inspected
Date……………………………
Signed….......……………………
Photocopy this checklist for regular inspections.
Tick off the points if they are OK.
Do not start the machine until you have checked every point.
1. All protective covers (1) must be mounted and
firmly bolted on.
2. Check the safety switches
on the wire insertion unit maintenance door (2).
on the twisting unit maintenance door (3).
on the inspection door on the side of the hopper (4).
on the inspection door on the side of the precompactor (5).
on the maintenance doors for the press ram (6).
The safety switches shut down the machine immediately and prevent it
from being switched on again when the wire insertion unit or twisting unit
are swung open or any door is opened.
Test all switches to see if they work.
6
4
12
1
1
3
5
6
1

6.417.999.120
Issued 06/2005
Generalinformation VK 5012
2.1
The machine number is stated on the nameplate on the baling press (above).
Warranty claims and queries cannot be dealt with unless you quote the machine
number.
2.2 Technical features
-Can be continuously loaded
-Electro-hydraulic channel baling press
-Hydraulic precompactor
-Hydraulic cutting edge clearing device
-Automatic press channel adjustment
-Fully automatic bale strapping system (four-wire)
- Press ram with central lubrication (fully automatic or manual)
- Oil cooler / tank heater (option)
- Welded frame construction with reinforcements
-Variable bale length setting
-Hydraulic drive and complete electronic protection, switching and control system
- Loading via conveyor belt
HSM-PressenGmbH+CoKG
HSM-Pressen
GmbH+CoKG
Postfach1163
Postfach
1163
D-88678Salem
D-88
678
Salem
WestGermany
West
Germany
MODELL
MASCH.-NR.:
PRESSKRAFT: kN
SPANNUNG: V Hz
BAUJAHR:
LEISTUNG: kW
NENNSTROM: A
2General information
2.1 Nameplate

6.417.999.120 Issued 06/2005
Generalinformation
VK 5012
2.2
2.3 Introduction
This information is intended to be read, understood and observed in all points by all
those responsible for the baling press.
The complete technical documentation should kept near the baling press at all
times.
Particularly important information for the use of the baling press is pointed out in this
operating manual.
Only by reading this operating manual can mistakes at the baling machine be
avoided and trouble-free operation guaranteed. It is therefore essential to make sure
that those in charge of the machine are familiar with this operating manual.
We recommend that you read this operating manual carefully before starting up the
machine, since we do not accept any liability for damage and malfunctions resulting
from failure to observe these instructions.
If you should encounter any problems, please contact our after-sales service, our
spare parts department or one of our authorised agents, and they will be glad to
assist you.
The illustrations in the operating manual are of a simplified nature.
The illustrations also depend on the side on which the controls are mounted and
may therefore be mirror images of the actual configuration.

6.417.999.120
Issued 06/2005
Generalinformation VK 5012
2.3
2.4 Scope of application and proper use
The HSM VK 5012 is a hydraulic baling press capable of continuous loading.
The material to be pressed is transported to the machine on an inclined feeder
conveyor.
The pressing cycle is initiated with the aid of light barriers in the hopper.
The pre-compactor pushes the material into the press chamber, the press ram
moves forward and compacts the material. The baling press has a cutting edge
clearing device to prevent material from jamming in the shearing area.
The baling press can be refilled even during the pressing cycle.
The HSM VK 5012 is specially designed for compacting paper, cardboard,
plastic foil and any other materials listed in the contract.
Any other use is considered improper.
The manufacturer accepts no liability for damage resulting from improper use
the operator carries sole responsibility for such use.
Proper use also includes carrying out installation, assembly, reassembly, start-up,
operation and maintenance work as prescribed by the manufacturer.
The relevant accident prevention regulations and any other generally recognised
health and safety standards must also be observed.
2.5 Warranty
The warranty conditions for the HSM VK 5012 are outlined in our general terms and
conditions or in a special contract concluded with you.
In order to prevent damage resulting from ignorance we recommend a general
maintenance and inspection contract .

6.417.999.120 Issued 06/2005
Generalinformation
VK 5012
2.4

6.417.999.120
Issued 06/2005
VK 5012
Technical data
3.1
3Technical data
3.1 Dimensions

6.417.999.120 Issued 06/2005
Technical dataVK 5012
3.2
1. Press channel
2. Press channel adjustment
3. Hopper
4. Inspection door
5. Precompactor
6. Wire insertion cylinders
7. Wire insertion unit maintenance door
8. Twisting unit
9. Twisting unit maintenance door
10. Press ram maintenance flap
11. Control cabinet
12. Oil tank
13. Wire station
14. Wire brake
3
14
91
2
4
6
13
11
12
10
7
8
3.2 Machine overview
5

6.417.999.120
Issued 06/2005
VK 5012
Technical data
3.3
16 18
19 20 21
17
15
15. Press ram lock
16. Oil cooler
17. Main drive motor and pump
18. Oil level gauge
19. Motor and pump for press channel adjustment
20. Valve block
21. Venting filter
22. Wire insertion unit
23. Wire insertion cylinder
24. Needle head
24 25 22

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Technical dataVK 5012
3.4
32
31
28
27 26
25. Guide roller
26. Twisting unit
27. Twisting motor
28. Wire shear cylinder
29. Twisting disc
30. Twisting rod
31. Press cylinder
32. Press ram with manual central lubrication
33. Counting wheel
34. Cutting edge clearing device
29
30
26
33
34