10 hp Owner's Manual - Automation R & D

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Automation Recycling Systems, LLC.

4600 Hanger Access Rd.

Darlington, SC 29540

(843) 395
-
6655 Phone

(843) 393
-
0605




Owners Manual



The following is a user’s guide and maintenance manual for the
ARS DS
-
10
(Dual)
and SS
-
10
(Single)
vertical down stroke

balers.


The SS
-
10 is a
S
ingle
S
tation 10 hp baler designed primarily for
Cardboard and/or Paper. Bales are usually in the 700


900 pound
range.


The DS
-
10 is a
D
ouble
S
tation 10 hp baler with two chambers, the
larger chamber is designed primarily fo
r Cardboard and/or Paper.
The smaller baler is designed for baling plastic
material
. Cardboard
b
ales are usually in the 700


1000

pound range and plastic bales
in the 60 to
120

pound range.

Actual bale
weight

is determined by

moisture content and the
adj
ustable

vertical size.



Features:




10 hp 3 phase motor (230 or 460 vac / 2
8

or 1
4

amps current)

{575 motors on Special Order}
.



2000 psi hydraulic pressure.



6” Hydraulic Cylinder

(8” Cylinder


Option)



Interlocking door(s)



Push button controls

o

Up

o

Down

o

Push

button
E
-
Stop

with key release.



Indicator lights

o

Doors
Open

(Amber)

o

Bale Made (Green)

o

Power /
Error (
White
)

Over
view of components

(Note: the SS
-
10 may not have certain features)


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SAFETY




Do Not attempt to operate this baler without proper training.
If there is any question, check with your supervisor first!



Obey and enforce all warnings including OSHA requirements and ANSI standards.



Stand Clear when the baler is in operation.



Always wear hand and eye protection when working with tie wire.



Follow OSH
A lock
-
out procedures when working in or on the baler.



Never place any part of the body, head or limbs into a potential pinch or shear point.



Be sure all guards, gates and doors are secure when the baler is in operation.



Be aware of people in the work area

who may be at risk during operation or when ejecting the bale.



Know where to get help in the event of an emergency.



Do Not operate the baler if work ability is impaired for any reason.



Always wear the safety equipment as called for by employer.



Do Not ste
p up or climb on the baler at any point.



No one under 18 years of age is allowed to operate or unload the baler.



No one under 16 years of age is allowed to load material into the baler.



Do not operate the baler if any concern arises as to safe operation


T
he baler(s)
are

built to ANSI Z245.5

standards.

Operations SS
-
10 (and large baler on the DS
-
10)


Never raise the platen with the extractor hook engaged
and

the door closed.


1.

Verify that the ejector device is “Unhooked”.

2.

The operator will
release the

gate
(if it is not already open)

3.

Card
board and / or paper can be stacked inside the chamber through the opening above the door and
below the gate.

4.

CARE should be given to evenly stack the cardboard and paper in the chamber to create an even
bale. Never load th
e chamber un
-
eve
n
ly.

5.

When the chamber is full of material, close the gate. Lift up and pull out the handle on the gate.
Then lower the gate until it is fully closed. The light on the control panel that shows that a door is
open should go out.

6.

Verify that n
o one is in harms way.

7.

Press the down button on the control pendant.

8.

The system will extend the compressing cylinder fo
r a pre
-
deter
mined amount of time or until
pressure is reached.

9.

If on the extension stroke, the
computer will determine if a “bale” has b
een made; if not, the platen
will
pause and then
automatically rise

back to the top
. The operator can then add more material and
repeat steps 2


9
.

10.

If the
computer determines that a
bale
has been made, the

system will turn off the hydraulic power at
the
end of the down timer and illuminate the “Bale Made” light on the pendant.

11.

Press in the E
-
Stop button.

12.

The gate can be

opened and the main door’s latch undone. Care should be given on loosening the
main door’s latch as material under pressure may be pushin
g on the door.

13.

Swing the main door open to gain access for threading the baling wire.

14.

Thread the baling wires through the spaces provided in the floor and the bottom of the platen.

TAKE CARE THAT THE BALING WIRE DOES NOT HIT SOMEONE IN THE EYE OR
BODY.

15.

B
ring the ends of the baling wire together, remove slack and tie them off.

16.

On the back side of the baler, hook the extraction chain to the lip on the back side of the platen.

17.

Make sure that the floor is clear in front of the baler.

18.

Reset the E
-
stop button (
turn the key and let the button pop back out).

19.

Press the up switch on the pendant. The system will raise the platen only as long as the button is
pressed.

20.

As the platen is raised,
the extractor will lift the bale out of the chamber.

21.

Pay attention to the ba
le as it falls from the baler. DO NOT ATTEMPT TO STOP OR GUIDE THE
BALE AS IT COMES OUT OF THE BALER.

22.

Use appropriate material handling devices to move the bale away from the baler.

23.

Close the main door
, latch it closed

and pull down the gate.
Do not over
tighten the main door latch.
It is just brought to the fully closed position.

24.

Cycle the system for one compression cycle to allow the ejector mechanism to “U
nhook
”.

25.

Before putting material in the chamber, verify that the ejector mechanism has

Unhooked”.



Bale Size:

There is no exact size for a bale. The computer determines the size based upon the time that pressure is
reached after starting a down stroke. The operator is ultimately responsible to determine if it is time to tie
off and remove a bale. If b
ales are made to large, then the gate see more than normal force and it may be
difficult to eject a bale.


Maintenance

1.

Check for hydraulic leaks.

2.

Check for adequate fluid levels in the main tank.

a.

The fluid should only be checked if the cylinder(s) is/are
retracted.

b.

The fluid level needs to visible on the sight gauge.

3.

Check the ejector mechanism for signs of wear. Replace components as needed.

4.

Supervisors should:

a.

Verify that the cylinders will not extend if the doors are opened.

b.

Verify that the system will

not automatically raise the

platen if the gate
or door is opened

c.

Observe the visible structural welds and members for signs of stress.

d.

Tag the machine out of service if deficiencies are found.



Adjustments

Adjustments should only be attempted by people f
amiliar with the operation of the components or when
instructed to do so by ARS personnel.


Force Sensor: This is either a pressure switch or a current sensor. In either case, this device tells the
computer when the system has achieved pressure. If the sen
sor is set to high, the computer may not get the
signal that pressure has been achieved and not cycle properly. If the sensor is set to low, then the computer
may think that it has achieved an acceptable force prematurely. The baler can start the up stroke

to soon or
in extreme conditions, the system will think that it has reached the top before it has fully retracted.


Modes of Operation

Normal Mode: Load the chamber. Close the gate. Press the down switch. The system will extend and then
return to the loa
d position.


Bale Made: On the down stroke, the system will stop at the tie off position. If the up button is pressed
without opening the doors, the system will flash the bale made and door open lights. If you need to raise the
platen


press and release t
he E
-
Stop to clear the error.


Stay Down: If the down button is held for 5 seconds when starting a down stroke, the system will “stay
down”. When the force sensor sees that pressure has been reached, the system will shut off in the down
position but not di
splay that a “Bale made” light. To retract the platen, press the up switch. If the door and
gate are closed, the platen will automatically raise and shut off at the top. Use this mode to help remove the
“memory” effect of materials. Especially if there is
a long time between loadings.


Lights

There are three major lights and several on the face of the computer.


White Light:

The white light is used to show power and errors. If the light is solidly on, then the system has
power and the E
-
Stop is out.


Amber
Light:

This light is used to show that a door is open. If both the main door and gate are in the closed
position, then the light should be out.


Green Light:

This light is used to show that a bale is “made”. It solidly illuminates when the computer
thinks
that a bale is ready for tie off.


PLC Lights
:


X0 = Estop Input


On when the Estop is out in the run position.

X1 = Up button


On when the Estop is out and the up button is pressed.

X2 = Down Button


On when the Estop is out and the down button is pres
sed.

X3 = Force Sensor


On when the Estop is out and the force sensor sees force.

X4 = Not used on most models

X5 = Not used on most models

X6 = Door Sensor


On when the Estop is out and the door is closed.

X4 = Gate Sensor


On when the Estop is out and

the gate is closed.


Error conditions:


Too long to go down


White light flash 1/10 second rate.

Too long to go up


White light flash at 1 second rate.

No power or E
-
Stop pushed


White light out.


Bale Made and press UP


The computer thinks that a bal
e has been made and someone is pressing up with
the doors closed. The Amber light will flash and the Green light will flash. To clear the fault, press the E
-
Stop, open the doors, tie off the bale, reset the E=Stop and follow above procedures in ejecting a
bale.






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