09 Bale Compactor

Deerberg-Systems GmbH – Moltkestraße 6a – 26122 Oldenburg – Germany

Phone: + 49 441 973 57 0 – Fax: + 49 441 777 33 7 – E-Mail: info@deerberg-systems.de
 OPERATING INSTRUCTIONS
VERTICAL BALER

DBP V 605
valid for
machine no.: 6112P02468

Keep this instructions for future use!

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V-PRESS 605

Contents

1 Notes on safety ............................................................................. 3

1.1 Safety symbols .......................................................................................... 4
1.1.1 "Work safety" symbol ............................................................................................................... 4
1.1.2 "Note" symbol ........................................................................................................................... 4
1.2 Classification of hazards ........................................................................... 4
1.2.1 Danger ..................................................................................................................................... 4
1.2.2 Warning .................................................................................................................................... 4
1.2.3 Caution ..................................................................................................................................... 4
1.3 Checking the safety devices ..................................................................... 5
1.4 Checklist .................................................................................................... 6

2 Use according to instructions ........................................................ 7

3 Technical data ............................................................................... 8

4 Operation of the baler ................................................................... 9

4.1 Machine overview ..................................................................................... 9
4.2 Operating elements / indicating elements ............................................... 10
4.2.1 Malfunctions ........................................................................................................................... 13
4.2.2 Reset of the control ................................................................................................................ 13
4.3 Transporting and setting up the baler ...................................................... 14
4.4 Inserting the strapping tapes ................................................................... 15
4.5 Starting and loading the baler ................................................................. 17
4.6 Strapping the bale ................................................................................... 21
4.7 Ejecting the bale ...................................................................................... 23
4.8 Shutting down the baler .......................................................................... 26
4.9 Operation outdoors ................................................................................. 26
4.10 Maintenance .......................................................................................... 27

5 Dimensional drawing ...................................................................29

6 Hydraulic diagram ....................................................................... 30

7 Wiring diagrams ....................................................................................... 31

7.1 DBP V 605 - 3 x 400V / 50 Hz ............................................................... 31
7.2 Transformer DAWN-G 6.0 (3 x 690V >> 3 x 400V) ................................. 32

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 V-PRESS 605

1 Notes on safety

– The baler DBP V 605 employs state-of-the-art technology . However, this

machine can become hazardous if used incorrectly by the instructed staff or for
purposes other than those for which it was designed.
– Always follow local safety and accident prevention regulations when operating the
baler.
– The employer has to observe and to keep the „Minimum safety and health
requirements for use of the work equipment by workers at work“. (89/655/CEE)
– The baler may not be operated by persons under 16 years of age.
– Each person given duties of the baler must have read and fully understood the
entire Operating Manual, in particular the "Safety" section.
– The baler may only be operated, serviced and repaired by authorized, trained and
instructed personnel. Such personnel must have received special instructions
about potential dangers.
– The drive and additional devices must be secured against unintentional switching-
on before performing work on the baler. Set the main switch to "0" and secure it.
Pull out mains plug.
– Do not perform any work which may impair your safety while operating the
machine.
– Immediately report any changes which impair your safety to the person responsible.
Shut the machine down until such damage has been resolved.
– Before putting the machine into operation, ensure that it is in perfect working
condition.
– Ensure that the workplace on the baler is always clean and safe.
– All connecting cables must be laid in such a way that they cannot be tripped over.
– The user must not make any conversions or changes on his own initiative which
impair the safety of the baler. Protective devices must not be removed or rendered
inoperative.
– Only persons with specialist knowledge and experience with hydraulics may work
on the hydraulic equipment.

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1.1 Safety symbols

1.1.1 "Work safety" symbol
This symbol marks all work safety notes in this Operating Manual which
endanger the health or life of people. Please pay attention to this
symbol and exercise particular care in such cases. Please also forward
all work safety notes to other users.

Apart from the instructions in this manual, you must also follow
generally applicable safety and accident prevention regulations.

1.1.2 "Note" symbol

This symbol marks information in this manual which requires particular
attention so that guidelines, regulations, instructions and correct working
procedures are followed and damage to or ruin of the machine and/or
other equipment prevented.

1.2 Classification of hazards

1.2.1 Danger
identifies an immediate danger. If not avoided, it will result in death or
severe injuries (crippling).

1.2.2 Warning
identifies a possibly dangerous situation. If not avoided, it could result
in death or severe injuries.

1.2.3 Caution
identifies a possibly dangerous situation. If not avoided, it could result
in light or minor injuries. Is also used for warnings concerning damage
to material.

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1.3 Checking the safety devices

Check the safety devices:

• at the start of every work shift (when operation was interrupted)

• at least once a week when the operation is interrupted
• after each maintenance or repair

Check the safety devices for:

• specified condition
• specified position
• safe attachment
• specified function

Perform a check using the following checklist. Eliminate the faults before putting
the machine into operation!

If faults occur during operation the machine must be stopped immediately and the
faults eliminated.

Do not change or remove protective devices. Do not hinder protective devices by

modifications of the machine.

The machine must not be modified, for safety reasons!

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 DBP V 605

1.4 Checklist
Copy this list for your regular checks.
Check off the individual points when they are in order.
Operate the baler only when all points have been check and are in order.

8 7 Both control cabinets (1) must be

closed and the warning sign with
flash must be attached at the
control cabinet.
1
Check the function of the safety
switch (2) for the loading door (3)
resp. the bale ejection door (4).
2 In normal operating mode it must be
impossible to start the baler if one of
the doors is open.
Check the function of the door
3 locking mechanism of the loading
1
door (3). If you close the loading
door the locking lever (5) must snap
in automatically.
The bale ejection mechanism (6)
4 should move smoothly.
5
The label (7) "Caution! One-man
operation" (6.116.999.090) and the
label (8)"Bale strapping "
(6.110.999.100) must be attached at
the indicated position.

checked

6 Date ……………………………

Signature ………………………

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 D B P V 605

2 Use according to instructions

The vertical baler DS V-PRESS 605 is intended only for compacting empty
cartons, paper (Condition: dry / solvent free) andsingle-ply plastic foil as well as
any other materials agreed upon in the contract.
Material which greatly expands, such as bubble wrap or foam, may only be
compacted after consulting D S .

No cardboard cores! (thickwalled cardboard

rolls)

No stacks!

No plastic bottles/tins!
P re miu m

PET

0,33 l

Paper Cardboard Foil

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DBP V 605

3 Technical data
Total machine weight ~ 644 kg

Strapping tape WG 30 / WG 40
WG 30 (8 mm) 6.205.993.010 (cardboard / foil)
WG 40 (11,5 mm) 6.212.993.010

Machine dimensions see dimensional drawings (chapter 5)

Press data
Pressing power 57 kN
Press cylinder ø 50/40 x 620 mm
Compression time with return stroke ~ 21 s
Bale size (WxDxH) 800 mm x 600 mm x max. 600 mm
Bale weight (cardbord) up to 70 kg
Motor data
Rated power 1.5 kW
Operating voltage 400 V/ 50 Hz
Rated current 3.6 A
Output RPM 1720 min-1
Protection mode IP55
Plug CEE 4x16A/5H (3P+PE)
Transformer
Power 6000 VA
Voltage Vpri = 3 x 690 V >> Vsec = 3 x 400V
Current sec Ipri = 3 x 5.5 A >> Isec = 3 x 8.67A
Frequency 50 / 60 Hz
Protection mode IP55
Isolation class T40 / F
Total fuse protection 3 x 16 A (K, C-characteristics)
Pump
Discharge Q1 4.9 l/min
Oil tank
Oil volume 5 l (3,5 l)
Oil type Multigrade oil to DIN 51524-T3
ISO viscosity class HVI 22
Noise emission values
The sound pressure level according to DIN 45635 Part 27, does not exceed the value
of 80 dB (A).

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4 Operation of the baler

4.1 Machine overview
16

3 10
12

11

2
13

17
5

9
8

15 7
14

1 Press chamber 10 Hydraulic unit

2 Control cabinet 11 Tape station
3 Press cylinder 12 Press ram
4 Locking lever for loading door 13 Lever for bale ejector
5 Loading door 14 Bale ejector
6 Safety switch 15 Guide profiles for tape/wire
7 Retaining claw 16 Tape insertion needle
8 Bale ejection door 17 Transformer 690V > 400V
9 Handwheel door lock device

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4.2 Operating elements / indicating elements

ELECTRONIC

10

2
8
4 3

9 7

1 Main switch when bale ejection door is open:

2 Selector switch cardboard / foil
3 Light symbol Foil 7 + 10 Two-handed operation: Raise press ram
4 Standby (Ready for operation) 5 + 10 Two-handed operation: Lower press ram
5 Lower press ram
6 Press ram stop
7 Raise press ram
8 Bale finished
9 Malfunction
10 Second key for two-handed operation

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Main switch
When turned 90° clockwise, the main switch is on.
The main switch can be locked in the "Off" position with a padlock.

Selector key "Cardboard / Foil"

Pressing this key you can switch over from compacting "Foil" to "Cardboard".

Light symbol "Foil"

This yellow symbol lights up, when the compacting material "foil" has been selected.

Light symbol "Standby"

This green symbol lights up, when the main switch is switched on and under power.
This green symbol is flashing when the loading door is open and goes off if there is
any malfunction.

"Lower press ram" key

Pressing this soft-key while the door is closed starts the compression. The press ram
moves down, compresses the material and returns automatically into its starting
position. The motor stops automatically.

"Press ram stop" key

With this soft-key the press ram can be stopped in any position.
The movement can be continued by pressing the "Raise/lower press ram" soft-key.

"Raise press ram" key

When this soft-key is pressed, the press ram returns into its starting position with the
door closed.

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Light symbol "Bale finished"

This message is displayed when a bale has reached a certain size. The press ram
stops automatically in extended position on the pressed material.
This symbol is flashing, if the press ramis not in bale ejection position. The ejection
postion is reached, when the blue symbol is displayed continuously.

Light symbol "Malfunction"

This red symbol lights up, when there is any malfunction on the baler. The baler is
switched off immediately . (-> see section "Malfunctions")

Key for two-handed operation for the functions:

• Raise press ram >> door is open (press 7 + 10 key simultaneously)
• Lower press ram >> door is open (press 5 + 10 key simultaneously)

Note
Works only in manual operation mode or at bale ejection.

Two-handed operation: Raise press ram (keys 7 + 10)

By simultaneous pressing of both soft-keys (within 0,5 seconds) the press ram can
be moved upwards. If one of the both soft-keys is released the press ram stops.

Two-handed operation: Lower press ram (keys 5 + 10)

By simultaneous pressing of both soft-keys (within 0,5 seconds) the press ram can
be moved downwards. If one of the both soft-keys is released the press ram stops.

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 DBP V 605

4.2.1 Malfunctions

Indicators Malfunction Remedy

LED 1 to 4 are blinking Wrong direct. of rotation, phase is missing Contact DESYS

LED 1 is blinking Inductive switch press ram in starting Contact DESYS

position resp. function inductive switch,
time monitoring of the press ram

LED 1 is shining Motor temperature, oil temperature, Let baler cool down
temperature sensor defective

LED 1 and 2 blinking Machine protective switch defective Contact DESYS

LED 1 and 4 blinking System error on the board, Contact DESYS

short circuit at an output of the board

LED 1, 2, 3, 4 are Machine in setup mode Reset control

blinking successively

ELECTRONIC

LED 3

LED 2 LED 4

LED 1

4.2.2 Reset of the control

– Switch the red main switch off

– Press simultaneously: and hold them pressed

– Switch main switch on while the 3 keys are pressed
– Release the 3 keys
– Switch the red main switch off and on again

• Now the baler is in normal working mode again

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DBP V 605

4.3 Transporting and setting up the baler

Warning!
The baler may be transported only with the press ram lowered and
the door locked. If this is not observed, the baler kan tip over.

– For transporting on a lorry the baler must be fastened with tightening straps on
both sides.

Here tightening straps

for transport or straps
for unloading by crane
Here tightening straps
for transport or straps
for unloading by crane

– The pick-up points for unloading from a lorry by means of a forklift truck must be
observed.
– A hand forklift truck can also be used for transport to the installation site.(Carrying
capacity 500 kg!!!)
– Position the baler on a flat floor at the installation site (level out possible
unevenness of the floor with pieces of metal)
– Screw the baler with 8 screws onto the prepared floor
– Remove the packaging foil and dispose of it in an environmentally friendly manner
– Open the doors and take out the remaining accessories
– Insert the plug in the on-site socket and switch the main switch on
• If there are blinking one or more indicators -> consult an electrician! (see
section"Malfunctions")

– Observe that the baler is only operated under dry and clean operating conditions.

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4.4 Inserting the strapping tapes

– Put the three rolls of strapping tape onto the tape holder
– Open the hand wheel door lock device and the bale ejection door
– Swivel the tape brake to the left (tape brake is open)
– Push the tape end from top down into the corresponding hole in the brake shaft

– Push the strapping tape through the opening in the press frame and following pull
it through the eyelet at the rear of the press ram

– Pull the strapping tape in front of the fixing hook and wind it around it several times
– Position the strapping tape into the guide profiles on the floor and in the
channels of the rear panel.

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– Perform these steps for the 3 strapping tapes

– Swivel the bale ejection door against the baler and latch the locking bolt.
– Swivel the tape brake to the right (tape brake is closed)

– Close the bale ejection door by turning the handwheel

Note
Only tighten the handwheel slightly so that you can easily open it
after compression. Pressure is applied to the bale ejection door and
its locking mechanism by the compressed material.

The baler is now ready for operation.

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 DBP V 605

4.5 Starting and loading the baler

– Connect the switch cabinet of the transformer (1) to the main power supply 690V.
– Insert the red CEE-plug of the baler (2) into the socket of the transformer (3)

– Switch the black main switch of the transformer (4) on

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DBP V 605

To load the baler, the bale ejection door must be closed and the press ram must
be in its starting position.

– Switch the red main switch of the baler (5) on

• symbol lights up

Note
The baler is ready for operation when the press ram is in its starting position.
If the press ram is not in its starting position, press the button until the
press ram stops.

Depending on material which should be compacted, you can switch over from "Foil"
to "Cardboard" by repeated pressing of the selection key.

Cardboard >> light symbol "Foil" is off.

Foil >> light symbol "Foil" lights.

ELECTRONIC

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 D B P V 605

– Open the loading door

– Fill the press chamber evenly with pressing material until it is completely full.

Caution!
If the baler is loaded unevenly e.g. with stacks at one side, the press ram
will incline while compacting the material.
This will damage press ram and press cylinder.

Note
We recommend to feed large pieces of cardboard for the first and
last compression. This prevents small pieces of material from
separating from the top and bottom of the bale and you will obtain a
better bale.

– Close the loading door

Load press
chamber
evenly!

P re miu m

PET

0,33 l

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DBP V 605

As soon as the loading door is closed, the compression cycle starts automatically.
The first compression cycle after bale ejection however must be started by pressing

the "Lower press ram" soft-key.

Note
The press ram moves downwards and compresses the material. After
having reached the bottom limit position, the press ram automatically
moves back into starting position. The motor is switched off automatically.

– Repeat the loading and compression procedure several times until the
"Bale finished" light symbol comes up

The baler then switches off automatically and the press ram remains standing on the
compacted material.

Note
When the "Bale finished" symbol appears, it is possible to move the
press ram upwards forseveral times to proceed a further compression
cycle. (e.g. to put a cardboard as a cover on the top of the bale).

– You can start strapping now.

Note
The bale can be strapped even before the light symbol "Bale finsihed"
appears, e.g. if the compression material shall be changed.

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 DBP V 605

4.6 Strapping the bale

You can start strapping when the "Bale finished" symbol lights up.

– Turn the handwheel towards yourself as long as you can unlatch the locking bolt.

– Open the bale ejection door completely.

(Opening angle more than 90°)

> 90°

– Loosen the tape brake by swivelling it towards the left

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DBP V 605

– Push the tape insertion needle (14) through the respective channel in the press
ram up to the rear panel

Note
The hook of the tape insertion needle must show upwards.

– Turn tape insertion needle (14) counter-clockwise until the tape hooks in

14

– Pull out strapping tape with the tape insertion needle

– Cut the tape loop
Note
Do not change the tape ends (12) and (13) of the cut tape loop,
otherwise strapping is not possible.

– Loosen tape end from fixing hook and tightly knot tape end (11) with strapping tape
(12) (on top of bale)
– Perform these steps for all 3 strapping tapes

✂ 13

12 11

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 DBP V 605

4.7 Ejecting the bale

Warning!
Make sure that no further persons are standing at the baler when the
bale is ejected.
Observe safety area!

Achtung ! Einmannbedienung
Caution ! One-man operation
Attention ! Commande à un seul opérateur
Atención ! Manejo unipersonal
Attentie ! Eenman-bediening

Gefahr ! • Danger !
Danger ! • ¡ Peligro !
Gevaar !

;
;;;
; Sicherheitsbereich

;;;
; ;
einhalten !

o.k. Observe
safety area !

No ! Respecter la
zone de sécurité

¡ Observar el
área de seguridad !

Veiligheidsafstand
bewaren!
6.116.999.090 - 03/2001

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DBP V 605

Note
The opening angle of the door must be more than °90
, otherwise the bale
ejector does not work.

– Place a sufficiently large pallet in front of the baler to facilitate transport. (e.g.
EURO-pallet 1,20 x 0,80 m)
– Pull the bale ejector lever towards you

– Press both "Raise press ram" soft-keys (within 0,5 seconds) and keep
them pressed as long as the bale is ejected and the motor has switched off.

• The press ram moves upwards and pulls up the bale ejection device. The bale
ejection device tilts the bale forwards out of the press and then automatically
falls back to its initial position

ELECTRONIC

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 DBP V 605

– Carry away the ejected bale.

– Re-insert the strapping tapes
– Lock the tape brake by swivelling it to the right (tape brake is closed)

– Swivel the bale ejection door against the baler and latch the locking bolt.
– Close the bale ejection door by turning the handwheel

Note
Only tighten the handwheel slightly so that you can easily open it
after compression. Pressure is applied to the bale ejection door and
its locking mechanism by the compressed material.

– Close the loading door

Note
As soon as the loading door is closed again, the bale ejector falls
back into its initial position.

The baler is now ready for operation.

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DBP V 605

4.8 Shutting down the baler

The baler can be put out of operation for longer interruptions of work, end of work or
for maintenance and installation work and can be secured against unauthorized use.

– Move press ram into starting position.

– Close the loading door and the bale ejection door
– Switch off the main switch and secure it.
– Unplug the baler

4.9 Operation outdoors

Warning!
Put into operation only under supervision.

The operator must ensure that unauthorized persons do not have

access to the baler.

When the baler is not operated it must be shut down and secured against
unauthorized use.

– The baler must not be directly exposed to rain.

– The maintenance intervals must be reduced.
– If the temperature drops below 0°C, use hydraulic oil with a suitable viscosity,
if required.

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 DBP V 605

4.10 Maintenance
Note
When using detergents and solvents, observe applicable accident
prevention regulations of the vocational cooperative society.
Observe environmental legislation when disposing of used oil.
Never mix mixtures of hydraulic oil and detergents with used oil.
Always collect these substances in separate containers and dispose
of them correctly!

Change the hydraulic oil every two years:

– Move the press ram into its starting position

– Unplug the baler
– Remove the cover(s)
– Unscrew the venting filter (with dipstick)
– Suck off oil with an oil suction aggregate
– Clean the hydraulic oil tank if it is severely soiled
– Fill the tank with the specified oil volume and check the oil level by means of
the dipstick
• The filling volume of the oil tank is 3.5 l
Oil type: Multigrade oil DIN 51524-T3 / ISO viscosity grade HVLP 22
ISO-
Viskositäts- ESSO DEA SHELL ARAL BP FINA
klasse

Mineralöle ISO VG 22 UNIVIS Astron Tellus Öl Aral Vitam Bartran HYDRAN

Mineral oils HVLP N 22 ZHLP 22 T 22 HF 22 HV 22 HV 22

– Screw in a new venting filter (35)

– Insert the plug in the on-site socket and switch the main switch on
– Move the press ram up and down several times and check the oil level again with
the press ram in the upper position.
– Top up oil as necessary.
– Screw on the cover(s)

V-Press 605
35

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DBP V 605

Note
Lubricate all moving parts and hinges on demand, in particular the door
hinges as well as the bearings of the door lock with multi-purpose grease
/ multi-purpose oil.

every month every three months

JY
ÖL JA
OL IE
OL EO
ÓL ITE
E
AC LIO
O ILE
HU IL
O
ÖL

every three months

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 DBP V 605

5 Dimensional drawing

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DBP V 605

6 Hydraulic diagram

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 DBP V 605

7 Wiring diagrams

7.1 DBP V 605 - 3 x 400V / 50 Hz

Wiring diagram 100000069888
see appendix

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DBP V 605

7.2 Transformer DAWN-G 6.0 (3 x 690V >> 3 x 400V)

Construction drawing

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