Presto Conti Compact CC-20 V User manual

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
Originalversion
Revisionstatus04/15

Operatingmanualand
maintenanceinstructions

CHANNELBALINGPRESS


TYPES:
CONTICOMPACT

CC‐20V,
CC‐30V,
CC‐40V






GmbH&Co.KG
Gewerbepark4
D‐49196BadLaer
+49(0)542429270
[email protected]

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Project:ChannelBalingPress
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Type: ______________________

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Machine.‐no.:______________________
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
Yearof
construction:______________________
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Customer: ______________________

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 
 
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04/2015S.2
Summary
1.Preface...........................................................................................................................................4
1.1.Introduction.............................................................................................................................4
1.2.Toobserveupondelivery........................................................................................................5
1.3Dutiesandnotesfortheoperator..........................................................................................5
1.4Structureoftheoperatingmanual..........................................................................................6
1.5Safetyinstructionsoftheoperatingmanual...........................................................................6
1.6Allrightsreserved....................................................................................................................6
2.Legalinformation...........................................................................................................................7
2.1.Intendedandproperuse.........................................................................................................7
2.2.Improperuse...........................................................................................................................7
2.3Changesmadetotheshippedmachinebytheoperator.......................................................7
2.4Machinesafetytest.................................................................................................................8
2.5Warrantyandliability..............................................................................................................8
2.6Productliability........................................................................................................................8
2.7Guarantee................................................................................................................................8
2.8Residualrisksatthechannelbalingpress...............................................................................9
3.Safety............................................................................................................................................10
3.1.General..................................................................................................................................10
3.2.Staffselectionandtraining...................................................................................................11
3.3.Electricalwarningnotices......................................................................................................11
3.4.Generalregulations...............................................................................................................12
3.5Meaningofthesignsonthemachine...................................................................................12
3.6Siteofinstallation..................................................................................................................13
3.7Duringoperation...................................................................................................................14
3.8Specifichazards.....................................................................................................................15
3.9Storingthemachine..............................................................................................................17
3.10Operatingthemachine.........................................................................................................17
3.11Safetydevices........................................................................................................................18
3.12Transportationandloading..................................................................................................21
4.Technicaldata..............................................................................................................................22
4.1.Electricalandhydraulicdata.................................................................................................22
4.2.Technicaldata........................................................................................................................23
4.3.Dimension..............................................................................................................................24
4.4.Noiseemission.......................................................................................................................25
5.Constructivedescription..............................................................................................................26
5.1.General..................................................................................................................................26
5.2.FunktionalprincipleoftheCCV.............................................................................................30
5.3.Hydraulicsystem...................................................................................................................33
5.4.Electricalsystem....................................................................................................................36
6.Operatingcontrolsandoperation...............................................................................................40
6.1Workpriortofirststart‐up....................................................................................................40
6.2Initialstart‐up........................................................................................................................41
6.3Dailyinspectiontasks............................................................................................................41

 
 
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04/2015S.3
6.4Operatingtools.....................................................................................................................42
6.5Operatingthemachine.........................................................................................................43
6.6Replacingwirerolls...............................................................................................................44
6.7Settingthecounterpressure................................................................................................47
6.8Shutdown.............................................................................................................................49
6.9Predictablemisuse................................................................................................................49
6.10Disassemblyanddisposalofthemachine...........................................................................50
6.11Behaviourintheeventofanemergency.............................................................................50
7.Maintenance................................................................................................................................51
7.1.General..................................................................................................................................51
7.2.Cleaning.................................................................................................................................52
7.3.Maintenanceoverview..........................................................................................................53
7.4.Descriptionofmaintenancework.........................................................................................55
7.5.Operatingsupplies,specifications.........................................................................................67
8.Repair...........................................................................................................................................68
9.Whattodoincaseoffaults..........................................................................................................69
9.1Listoferrormessagesonthetouchpanel............................................................................70
9.2Generalerrormessages.........................................................................................................74
9.3Problemavoidance................................................................................................................74
10.Spareparts....................................................................................................................................75
11.Appendix.......................................................................................................................................84
11.1Optionalextras,others............................................................................................................84
11.2Wiringdiagrams......................................................................................................................86
11.3Records....................................................................................................................................87
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Preface 
 



04/2015S.4
1. Preface
1.1. Introduction

Dearcustomer

Pleasereadthisoperatingmanual
carefullybeforeputtingthemachineinto
operationinordertoensurethatitisused
safelyandefficiently.Theoperating
manualcontainsallthedetailsfor
operatingandservicingthechannelbaling
press.Itmustthereforealwaysbekeptin
thedesignatedplace.

Chapters1to10containinformationon
thestandardfeatures.Optionalextras,as
farastheyareinstalled,aredealtwithin
chapter11.

Otheressentialpartsare:

•Electricalandcircuitdiagrams,
•Assemblyorlayoutdiagram
•DeclarationofConformityor
alternativelyDeclarationof
Incorporation

Inprinciple,everymachineissupplied
withaDeclarationofConformity.This
statesthatthemachinefulfilsthebasic
safetyandhealthrequirementsoftheEC
DirectiveonMachines.
ConformityinaccordancewithEC
directive2006/42/EEC

IntheeventthatnoDeclarationof
Conformityisissued,theattachedEC
DeclarationofIncorporationfor
incompletemachinesstateswithwhich
additionalcomponentsthemachinemust
beassembledbeforeitisputinto
operation.Untilthemachinehasbeen
completelyassembled,commissioningof
individualcomponentsisforbidden.

Ifmaintenancetaskshavebeenneglected
orperformedincorrectly,wecanno
longerfulfilourguaranteeobligations
accordingtoourconditionsofsale.All
safetyrequirementsmustalwaysbemet
beforestartingtooperatethechannel
balingpress.

Everymachinehasanameplateanda
briefmanualinstructionattheswitchgear
box.Besidesthebriefmanualinstruction,
thenameplatealsocontainsimportant
informationonthemachine,forexample
themachinetypeandthemachine
number.Pleasebeawarethatthesebrief
instructionsarenotareplacementforthe
operatingmanual.


Fig1:briefmanualinstruction

Pleasehavetheinformationonthe
nameplatetohandwhentalkingtoour
customerservicedepartment.


Preface 
 
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04/2015S.5
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Fig.2:nameplate&sealofapprovalforaccident
prevention

1.2. Toobserveupondelivery

Themachineleftthefactoryina
technicallyandoperationallysafe
conditionandisreadyforoperationifit
hasbeeninstalledaccordingtothe
technicaldocuments.Pleasecheckthe
conditionandcompletenessofthe
machineaccordingtothescopeof
deliveryandeffectafunctionalcontrol.
Anycomplaintsshouldbetakentothe
manufacturerPRESTOGmbH&Co.KGand
leaveanoteonthepackingslip.


1.3Dutiesandnotesfortheoperator

Astheoperatorofthismachineyoumust
informabout,instructand/ortrain
operatingstaffintheexistinglegal
provisionsandsafetyregulationsaswell
asexistingsafetyfeaturesanddevicesand
usercontrolsandfacilitiesonthe
machine.

Youroperatingstaffmusthave
understoodtheinstructionsanditmustbe
guaranteedthattheyarefollowed.
Theinstructionhastobedocumentedon
thepreparedform(seeannex).

Inthiswayyouensurethatyour
employeesworksafelyandareawareof
therisks.
Wehavepreparedsomeexamplesof
instructiontopicsbelow.

Onsafety
Safetyregulations
Generallegalprovisions
Generalsafetyinstructions
Emergencymeasures
Safetyinstructionsforoperatingthe
machine
Usingthesafetydevicesofthe
machine
Meaningofsymbolsandsigns

Onoperatingthemachine
Usingtheoperatingcontrols
Explainingtheoperatingmanualtothe
machineoperators
Usingaidsandaccessories
Experiencesinusingthemachine

Serviceandmaintenanceinstructions
Theproperuseofinputmaterials
Operator'sspecialexperiencefor
cleaning,andcare,servicingand
maintenanceofthemachine

Preface 
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

04/2015S.6
1.4 Structureoftheoperating
manual

Theoperatingmanualisdividedinto
chaptersinlinewiththetableofcontents.
Eachchaptershowstheappropriatepage
number.

Dateofissueandpagenumberareshown
inthefooter.

1.5 Safetyinstructionsofthe
operatingmanual

Thefollowingsymbolsareusedinthis
operatingmanual:





Caution!
Riskofdamagetoor
destructionofthemachine
oritsparts!



Caution!
Thismaintenancework
mayonlybecarriedoutby
skilledpersonnel



Caution!
Riskofcrushing!



Danger!
Risktolifeandlimb!



Caution!
Riskfromelectriccurrent!



Note:
Additionalimportant
informationcanbefound
here.


1.6 Allrightsreserved

Alltechnicalspecifications,descriptions
andillustrationsarevalidonthedayof
printingofthisdocumentationand/orits
amendments.Wereserveallrightsand
therighttomakechangesasaresultof
technologicaldevelopments.

Theoperatingmanualisintendedto
informcustomers.Withoutexpress
writtenpermissionitmayneitherbe
copiednorpassedontothirdparties
whetherinwholeorinpart.




Readandunderstandthe
manual!

Legalinformation 
 



04/2015S.7
2. Legalinformation
2.1. Intendedandproperuse

Thechannelbalingpressisdesignedfor
compactingsoftmaterialssuchaspaper,
cartonboard,foilsandsimilarmaterials.

Onlythosematerialscanbecompacted
whichcanbedeformedbytheforceof
pressurespecifiedandwhichcanbe
compactedintothepresschamber.Any
otheruseoranyusebeyondthisuseis
deemedtoconstituteimproperuse.
PRESTOGmbH&Co.KGwillnotbeliable
foranydamagewhatsoeverasaresultof
this.Anyriskisbornesolelybythe
operatorofthemachine.

2.2. Improperuse

Explosiveandequivalentsubstancesor
thosewhicharehighlyflammable
(accordingto§1SprengG)mustnotbeput
intothemachine.
Substanceswhicharesubjecttospecial
conditionsunderthewastedisposalact
whendisposedmustnotbeputintothe
press.

Neithermaythefollowingsubstancesbe
putintothemachineastheymaycause
thepressureramtobecomeblocked
suddenly:buildingrubble,woodorform
orrodframesmadefrommetalorother
hardmaterials.Incandescentorburning
particlesmustnotbeputintothe
machine.

2.3 Changesmadetothe
shippedmachinebytheoperator

Thestatedconformityonlyappliestothe
structuralconditioninaccordancewith
theagreedscopeofsupplyatthetimeof
shippingofthemachine.Installations
madeand/orequipmentaddedbythe
operatoratalaterdatewhichhasnot
beendevelopedand/orapprovedbythe
manufacturerofthemachinevoidthe
statedconformityandareinadmissibleas
thesecurityofmachinemightbeaffected.

Theseincludechangestothechannel
balingpressbymeansofsheetmetal,
wood,cartonorfabricsofanykind,which
theoperatormaynotcarryoutwithout
properauthority.




Donotmakeanychanges,
additionsormodifications
tothemachinewithout
obtainingconsentfrom
PRESTOGmbH&Co.KG.


Legalinformation 
 



04/2015S.8
2.4 Machinesafetytest

Theoperationalsafetyofthemachine
mustbeinspectedbyanauthorized
specialistatleast1xperyear.
(Operationalsafetyinspectionaccording
totheaccidentpreventionguidelines)
Thesealofapprovalnexttothe
nameplateshowswhenthelast
operationalsafetyinspectionwas
performed.

YoucanalsogetintouchwithPRESTO,we
wouldbehappytonegotiatea
maintenanceandinspectioncontractwith
you.

2.5 Warrantyandliability

Themachinesuppliedwasmanufactured
accordingtostate‐of‐the‐arttechnology
andrecognisedsafetystandards.
However,dangertolifeandlimband/or
impairmentofthemachineorother
propertymayneverthelessresultifitis
usedimproperlyorcontrarytoits
intendeduse.PRESTOGmbH&Co.KGwill
notbeheldliableforanydamageresulting
fromsuchimproperuse.Theriskisborne
solelybytheoperatorofthemachine.

Onlyoperatemachinewhenitis
technicallyinorderandaccordingtothe
intendeduse.Thisrequirescompliance
withthecompulsorysafetyrulesand
regulationsapplicableatthesiteof
installationandwithrecognisedtechnical
rulesforsafeandproperworkingaswell
astheoperatingmanual,inspectionand
maintenanceinstructions.

OnlyoriginalPRESTOsparepartsassure
quality,changeabilityandthesecureund
conditionofthemachine.Safety‐relevant
componentsmaynotberepairedor
manipulated.Otherwisetheremightbean
increasedaccidentrisk.PRESTOwillnotbe
boundbythetermsoftheguaranteein
casesofuseofnotoriginalspareparts.

2.6 Productliability

Wherenon‐compliancewithand/ornon‐
observanceoftherulesandinstructions
containedinthisoperatingmanualresults
inaccidentsinvolvinginjurytopersons
and/ordamagetoproperty,PRESTO
GmbH&Co.KGshallbereleasedfromany
liabilityfordamagesandany
indemnificationofconsequentialdamage
suchasinjurytopersons,fordamageto
propertywhichisnotsubjectofthe
contract,forlossofprofitandlossof
production,whicharemadeagainst
PRESTOGmbH&Co.KGunderthetitle
"PRODUCTLIABILITY".

2.7 Guarantee

PRESTOonlygivesaguaranteeforthe
systemiftheoperatingmanualand
maintenanceinstructionsarecomplied
with.
Unauthorisedrepairworkbytheoperator
isnotallowed.Incaseofwrongful
modificationstothemachine,the
warrantyandliabilityclaimsagainstthe
manufacturerarenullified.


Legalinformation 
 



04/2015S.9
2.8Residualrisksatthe
channelbalingpress

•Risksthroughnon‐compliancewiththe
operatinginstructions
•Risksduetounintendeduse
•Risksthroughlackofserviceand
maintenance
•Risksthroughnon‐observanceof
securityhints
•Risksthroughhydraulicpipes
•Risksfromlossofoil
•Risksthroughdust
•Riskfromsharphousingedges
•Dangertobeexpectedfromsharp
edgedmaterialsormaterialsnot
compressedasspecified(seechapter
7,ServicingandInspection)when
servicingandmaintenanceworkis
carriedout.
•Riskofinjuryfrompartspossiblyflying
around.
•Dangeroffireduetofrictionalheat
ÎAvoidunnecessaryoperation
(emptystrokes)


Theresidualrisksaretheresponsibilityof
theoperator.


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

Safety 
 



04/2015S.10
3. Safety
3.1. General

Thefollowingnotesandguidelineswhich
ensuresafetyatworkmustbeobserved.

Theretobelongspeciallytheseoperating
andmaintenanceinstructionsaswellas
therelevantindustrialsafetydirectives
concerning:

‐qualification,instructionand
commissioningofoperationaland
maintenancepersonnel
‐theuseoffuel‐drivenmachineryand
electronicequipment
‐handlingwithcontainersandchangeable
roll‐offcontainers
‐noiseattheworkplace
‐firstaid

Thesafetyregulationsofthecountryin
whichtheequipmentisusedmustbe
observed.

Allrecurringinspectionsandmaintenance
tasks,definedinthechapteron
maintenance,mustbeperformedatthe
specifiedintervalsanddocumentedinthe
recordsprovidedforthispurpose.

Themachinesuppliedwasmanufactured
accordingtostate‐of‐the‐arttechnology
andrecognisedsafetystandards.(DINEN
ISO16252:2012).






Attention!
Toavoidmalfunctionsit
isnecessarytohavethe
specifiedmaintenance,
inspectionandauditing
actionsperformed
regularly.

Inadditiontotheregulationsabovethe
followingguidelinesarealsodeemedto
besuitableforchecking:

Safetyofmachines
DINEN12100:2010

Electricalequipment
DINEN60204‐1

EUmachinestandard
2006/42EG

Whileoperatingthedevice,thelawsand
regulationsoftheplaceofinstallation
mustbeobserved.Intheinterestofsafe
operationtheauthorizedoperator,
supervisorypersonnelandthemachine
operatorareresponsibleforkeeping
withintheregulations.

Thelawsandregulationsapplicableatthe
siteofusemustbeobservedwhen
operatingthesystem.Intheinterestof
safeworkprocesses,operators,
supervisorsandmachineoperatorsare
responsibleforobservingtheregulations.

Observethevalidity(sealofapproval)of
theoperationalsafetyinspectionforyour
machine.(Seesub‐chapteroperational
safetyinspection).




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