Technical Manual

Baling press type

VVH40C-DSK
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 Baling press VVH40C-DSK

G14-0048

Customer: Koopera Mediterraneo

C/ Fogainers parcela 45 A
Polígono sector 13
46190 Riba-roja de Túria (Valencia)
SPAIN

Manufacturer: Valvan Baling Systems NV

Krommebeekstraat 14
B-8930 Menen
België
Tel. +32 (0)56.52.13.80
Fax +32 (0)56.51.83.34

TECHNICAL MANUAL

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 This installation consists of:

• Baling press VVH40C-DSK

Attention

The manual is an essential part of the installation and

must always be present at the working area of the
installation for consultation.
Before starting up the installation read attentively the
manual, in particular section 1.2 “General safety
prescriptions“ and apply the instructions.

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 Content

1. GENERAL .................................................................................................................................... 5
1.1 Introduction ............................................................................................................................... 5
1.2 General safety prescriptions ..................................................................................................... 6
1.3 Technical specifications and marking on the baling press........................................................ 8
1.4 Declaration of conformity CE .................................................................................................... 8
1.5 Installation of the baling press .................................................................................................. 9
1.6 Electrical connection ............................................................................................................... 10
1.7 Oil filling ................................................................................................................................... 10

2. USE – OPERATION - ADJUSTMENT ....................................................................................... 11

2.1 Description of the baling press ................................................................................................ 11
2.2 Intended conditions of use ...................................................................................................... 12
2.3 Working area of VVH40R-DSK ............................................................................................... 13
2.4 Operation equipment............................................................................................................... 14
2.5 Start up and check before usage ............................................................................................ 16
2.6 Operation ................................................................................................................................ 17
2.7 Safety facilities ........................................................................................................................ 20
2.8 Adjustment .............................................................................................................................. 20
2.9 Emergency situation................................................................................................................ 20

3. MAINTENANCE ......................................................................................................................... 21
3.1 General.................................................................................................................................... 21
3.2 Hydraulic circuit ....................................................................................................................... 21
3.3 Maintenance of mechanical parts ........................................................................................... 22
3.4 Maintenance of electric circuit ................................................................................................. 22
3.5 Lubrication ............................................................................................................................... 23
3.6 Diagnostic ............................................................................................................................... 23
3.7 Spare parts .............................................................................................................................. 24
3.8 Out of use ................................................................................................................................ 24
3.9 Service .................................................................................................................................... 25

4. ANNEX ....................................................................................................................................... 26

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1. GENERAL

1.1 Introduction

This manual provides the user or those responsible for applying the press with all necessary
information to use, adjust and maintain safely and in the best way the baling press.

This manual is the result of years of experience in the workshop of Valvan Baling Systems
NV as well in the field by our customers. The information in this manual assures a safe and
perfect operation of the baling press. Particular attention must be paid to the instructions
and directions in order to avoid injuries and danger, to minimise repair costs and standstill
as well to increase the reliability and lifetime of the baling press.

We ask you to put the manual at the disposal of the persons who are responsible for the use
and maintenance of the baling press.

The Service at Valvan Baling Systems NV is always at your disposal for further information
or special requests.

ATTENTION

• Read very attentively the safety prescriptions before use, maintenance and
repair of the baling press.

• Valvan Baling Systems NV declines all responsibility when an accident occurs or

damage arises when the instructions and recommendation of the manual are not
followed.

• Always mention the serial number of the baling press in writing, request for
information or spare parts. The Serial number is given on the identification plate
of the baling press.

Reproduction of the content of this manual, in whole or in part, without prior and written permission of Valvan Baling
Systems NV is prohibited.

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1.2 General safety prescriptions

1. The baling press is designed in accordance with the ruling safety prescriptions. The
baling press and the various constituent parts are designed and constructed in such
way that they can, under the conditions foreseen by the manufacturer, fit the expected
working conditions as described in section 2.1 “Intended operation conditions”.

2. Modifications or rebuilt of the mechanical, electrical or hydraulic part by the user himself,
may only be executed after consultation and receipt of a written agreement of Valvan
Baling Systems NV. In no event will Valvan Baling Systems NV be responsible or liable
for indirect or consequential damages or injuries from the use or application of the
equipment.

Additions (as platform, ………) by the user himself must always comply with the ruling
safety prescriptions. They may never affect the operation and safety of the existing
baling press.

3. A copy of the manual should always be at place of use of the baling press. In order to
assure the optimal operation and the safety of the baling press, the operating personnel
and bystanders, it is recommended to pay attention and to follow the recommendations
in the manual.

4. The erection, adjustment and maintenance must be done by qualified people with
sufficient knowledge of the baling press and who have read and understood the manual
before proceeding.

5. People who work for the first time with the baling press must receive a thorough training.
The training should include: explanation of the baling press and the operation from the
manual delivered with the baling press, as well on the risks to work with a baling press.

6. Emergency stop: When an emergency situation occurs always push the “Emergency
stop” button and disconnect the disconnecting switch. Put a warning sign on the
disconnecting switch: “DEFECT, OUT OF USE”, or "FORBIDDEN TO SWITCH ON”.

7. The operation of the emergency stop button has sometimes a reason. First eliminate the
eventual cause for the operation before unlocking (adjustment, dangerous or aberrant
situation, repair).

8. General instructions when working on:

The electrical box The connection must be done with regard to the ruling
prescriptions.
Open the electrical box only when the disconnecting
switch is switched off.

The hydraulic group: Follow carefully all maintenance prescriptions. For security
reasons never work on a hydraulic group under pressure.

The mechanical part: Valvan Baling Systems NV guaranties the mechanical

stability of the baling press and all constituent parts.

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 ATTENTION
It is forbidden to repair and maintain the baling press while in operation.

9. It is forbidden to operate manually, to short circuit or to put out of operation detection or

safety components of the baling press.

10. Signals attached to the baling press may never be removed and must always remain
visible

11. Follow correctly the instructions on the baling press.

12. The operator must always stop the machine when changes in the behaviour of the
press, which involves the safety and the good operation. He must report the malfunction
to the workshop foreman. He will take all necessary measures to let repair the press
safely.

13. It is recommended to wear safety gloves and shoes. Safety glasses are obliged when
strapping the bale.

14. Never exceed the maximum capacity of the baling press

15. The set value of the safety valve may never exceed the value given on the hydraulic
drawing.

16. When the baling press is not working, put the main switch off to avoid an unexpected
start.

17. During the operation of the installation the operating personnel shall always stay with
both feet on the floor. The operator shall take also care during the operation of the
installation that no other person is entering the operation area, in order to avoid risks.

18. Operating the press within the limits of its designated use also involves observing the
instructions set out in the manual and complying with the inspection and maintenance
instructions.

19. Adhere to prescribed intervals or those specified in the manual for routine checks and
inspections.

20. Take care that always the “Emergency Stop Buttons” may easily be reached.

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1.3 Technical specifications and marking on the baling press

1.3.1 Technical specifications

Capacity : 400 kN (40 T)

Maximum oil pressure : 200 bar
Total power : 22 kW
Voltage : 3 x 400 V + PE
Weight : 5000 kg

1.3.2 Marking on the baling press

Name and address of manufacturer : Valvan Baling Systems NV

Krommebeekstraat 14
B-8930 Menen
Belgium

Mark "CE"
Year of manufacturing : 2014
Type : VVH40C-DSK
Serial number : G14-0048

1.4 Declaration of conformity CE

The declaration of conformity CE for machines is sent together with the manual.

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1.5 Installation of the baling press

Check at delivery

The press has been charged in good condition on the truck. Damage during transport is
always possible.
We insist to check the installation on visible damage at arrival and to inform us: or on the
delivery note submitted by the transport service or by registered letter to Valvan Baling
Systems NV within 48 hours after delivery.

1.5.1 Handling

Always unload, erect, lift and install the installation with suited lifting equipment (p.e. with
forks of a lift truck under the frame. The lift truck shall have a capacity of minimum 5 Tons.

The weight of the baling press is important to the choice of the lifting equipment and is
noticed in section 1.4: “Technical specifications.”

The installation will be erected and putted carefully on the place. In order to avoid tumbling
down, tilting or damaging of parts, fasten the installation or parts during manipulation

Incorrect lifting and moving of the baling press may effect a distortion of the frame.

When the baling press VVH40C-DSK is moved later on, first switch off the voltage supply
and disconnect the supply cable. During handling take into consideration the above
information.

1.5.2 Erection and Installation

Before leaving our works, the machines are thoroughly inspected and tested. Next, the
installation is properly loaded onto the truck without causing damage to the machine.

The erection and commissioning is done by Valvan Baling Systems engineers, according to
the conditions fixed in the contract.
The user may execute the installation himself. In this case first take contact with Valvan
Baling Systems to obtain the written instructions for the installation, assembly and
connection.

The guarantee expires if the installation by the customer is not carried out regarding the
instructions from Valvan Baling Systems. In this case, Valvan Baling Systems cannot be
held responsible for damage, caused by a defective or incorrect installation.

The installation should be installed on a stable ground. When the installation is finished,
fasten the installation to the floor with anchoring bolts.

The installation may only be started up when all safety conditions are fulfilled. This condition
holds also after execution of modifications on whatever part of the installation. The
manufacturer is not liable when an accident occurs or damage arises. The risk lies entirely
with the user.

Start up, see section 2.6.

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1.6 Electrical connection

Always check if the supply voltage matches with the voltage indicated on the electrical box
and in the “Technical specifications”.

The electrical connection should be done according the ruling safety prescriptions by a
qualified person. This connection may not be changed after commissioning.

To avoid the possibility of malfunction of the installation, the nominal voltage may never
exceed the supply voltage with ± 5%.

The section of the supply cable is chosen in such way that the voltage drop never exceeds
the above-mentioned limit.

Requirements with regard to size of the supply cable (section, type, number of conductors)
see technical standard: “Electrical equipment of industrial machines EN 60204-1”

In the electrical box there is a copper screw for the obligatory earth connection.

1.7 Oil filling

The hydraulic oil for normal use should be pure and of a good quality.
The recommended viscosity is of 46 cSt at 40°C (104°F) (regardless of the branch name)

The oil tank must be clean and remain closed.

The oil filling is done by means of the inlet filter on top of the cover.

Check the oil level on the two level indicators (minimum and maximum). Normally the oil
tank is filled until the middle of the upper level indicator.

Motor and pump run clockwise, seen from the backside of the motor. When the rotation
sense does not correspond, inverse two wires on the motor relay,. In this case call for
qualified personnel, familiar with possible hazards involved.

Never mix oils of different qualities!

Note on oil temperature

The normal working temperature is 40 °C to 65 °C (1 04 and 149 °F).

The maximum temperature is 75 °C (167°F). If the te mperature exceeds 75 °C an oil-
cooling system is necessary.

Do not let run the installation at a temperature lower than 10 °C (50°F). If necessary let the
pumps run for a while without workload, to warm up the oil, or have an oil-heating system
fitted.

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2. USE – OPERATION - ADJUSTMENT

2.1 Description of the baling press

2.1.1 General

This hydraulic baling press is designed especially for baling small bales of used clothing,
with dimensions that fit perfectly in maritime containers.
It is a vertical hydraulic swivel press with two boxes, a filling and a pressing box, each
equipped with a filling door.
While 1 operator fills a new load in the filling box, a second operator finishes the previous
bale in the pressing box. This way, a capacity of up to 20 bales/ hour can be achieved,
depending on the model and the chosen options.

2.1.2 Description of the cycle:

Attaching wrapping material

After the previous bale is removed from the press, wrapping material is attached to the
pressing plates: the wrapping material is simply placed on the bottom plate and the top plate
is equipped with brushes on the 4 sides that hold the wrapping material in place.

The operator now operates the press to lift the top plate up and to lower the pressing box.
The press is now in starting position. By pushing a pedal, the frame with the pressing boxes
is separated from the frame of the press. The swivel can now manually be turned 180° in
order to switch the pressing box and the filling box.

Filling cycle
The material is fed manually through a filling door. When the filling box is full, the door is
closed and the swivel is manually turned again. The load can now be pressed in the
pressing box.

Pressing cycle
The press is operated from a console, which is connected with the frame, at a safe distance
from the press. So that the operator cannot reach the press, while pushing the buttons.
Through a selector switch, the operator can choose to press with 25 or 40 tons.
To make a bale, the operator pushes “pressing plate down”. As soon as the pressing plate
has come down into the pressing box, the button can be released. When the maximum
pressure is reached, the plate remains in its position and the pressing box is lifted up by a
hydraulic cylinder.

Wrapping and strapping

The operator can now wrap and strap the bale. Next, the bale is manually removed from
the press and a new cycle can start.

2.1.3 Selector switch 40/20T

Through the selector switch 20/40T, you can choose with what pressing force, the bales will
be pressed. The choice is depending on the type of material and the weight that needed to
be load in a container.

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2.2 Intended conditions of use

The baling press VVH40C-DSK is designed and built to press second hand clothing
and rags. Other materials are not allowed.

It is forbidden:

• to use the press without the foreseen guards.

• to press scrap, spry cans, dangerous products.

• to enter in or to mount on a part of the installation with whichever part of the body when
the main switch is not disconnected and locked.

• to operate manually, short circuit or to put out of operation detection or safety devices
(proximity switches, limit switches, light guards ...).

• to use moving parts and to displace or lift materials or other applications which do no fit
with the intended use.

• to withdraw from view or remove warning pictograms or other signalisations.

• to use the baling press or other parts of the installation as a point of support for
whatever fixation which is not inherent to the baling press.

• to open or to let open the filling door when pressing

• to operate the locking pedal during the pressing operation

• to put hands in the openings of the retainer dogs

• to put the operation standard within the turning circle of the turning box group

• that unauthorised persons enter the working area when then the installation is in
operation

ATTENTON
Always fill the box equally with material in order to avoid an excessive and
unnecessary charge of the pressing plate. Unequally filling of the box may cause
severe damage to the hydraulic cylinder of pressing plate. In the most worse case,
the piston rod can break.

The manufacturer is not responsible for damage, which occurs by injudicious or

not allowed usage of the VVH40C-DSK baling press. The user carries entirely risk.

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2.3 Working area of VVH40C-DSK

Only two persons may use the baling press and they are allowed to stay in the
working area, during the operation of the press:
- one person fills the material into the empty pressing box
- one person (the operator) is responsible for the operation of the baling press: the
turning of the carrousel, pressing the bale, strapping of the bale and evacuation
of the bale outside the operation area.

The baling press may only be operated by one operator, who is allowed to stay in the
operation area.
The operator must warn the person who fills the press before the rotation of the
carrousel.

The operator as well as the person, who is filling the press box, must always - during each
operation (filling, pressing, strapping and evacuation of the bale) - stay with both feet on the
floor.
The operation standard is fixed on the frame of the baling press, on a safe distance outside
the turning circle of the box group. See figure below.

Turning circle
of carrousel
(turning table)

Operation
standard

Schematic upper view of VVH40C-DSK

Operation zone of operator

Working zone

We insist to:
• mark the working area on the floor with wear resistant proper marks (yellow-black
stripes under 45°). Only the filler and operator ar e allowed in this area.
• to mark the operation area on the floor with wear resistant proper marks (Red
stripes under 45°). Only the operator is allowed in this area.

Any other person who stays in the working area of the VVH40C-DSK must be
informed that this is a hazardous zone (carrousel). The operator must warn the
person, who is filling the empty press box, before the turning of the carrousel.

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2.4 Operation equipment

Below the operation equipment of the baling press is listed.

2.4.1 Control relays

See annex C: electric drawing

2.4.2 Solenoid of hydraulic valves

See annex C: electric drawing

2.4.3 Push buttons

See annex C: electric drawing

2.4.4 Main switch

See annex C: electric drawing

2.4.5 Control lamps

See annex C: electric drawing

2.4.6 Photo electric cell

See annex C: electric drawing

2.4.7 Pressure switch

See annex C: electric drawing

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2.4.8 Control panel
Reset Stop motor Start motor

Press plate
up 40 / 20 Ton

Press plate
down Press box
down

Emergency stop

Two hands control

(on left and right side of the
panel is a push button for
the two hands control

This control panel is fixed on the frame of the baling press, on a safe distance from the
turning circle of the carrousel.

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2.5 Start up and check before usage

2.5.1 Commissioning

Service engineers of Valvan Baling Systems NV do the start up of the installation. This
includes the erection, electrical connection, oil filling, inspection of the operation and
training.

Note: We ask to provide the material, which is mostly processed to test the installation
during the start up.

ATTENTION: The customer is responsible for any use of the installation before
start up. This involves a revocation of the guaranty. The guaranty resumes after
inspection of the press with conveyor and possible repair at customer’s cost.

2.5.2 Inspection

Before the start up, the service engineer checks on the installation a number of points,
which are important to the safety and proper operation of the installation.

The operator must check as well before stating the job or once pro shift, the next points:

• Operation and accessibility of the operation standard and emergency stops.

• Operation and state of detection components.
• These components should be free from materials, which may affect the normal
operation.
• Visual inspection on presence of oil leaks.
• Leaks result in:
- oil on the bales = loss of quality
- oil on the floor = danger to slip
• Presence of foreseen protection.
• Safety relevant changes in the behaviour which prevent normal operation

Only when all the above-mentioned points are right, the installation may be putted
in operation.

The above-cited warning holds also after modifications to the press, if not each
responsibility lapses for Valvan Baling Systems NV. If there is some doubt about the
operation or when abnormal situations occur, first consult the manual or contact Valvan
Baling Systems NV. (see section 3.9).

2.5.3 Start up

When all conditions are fulfilled, the installation is ready for operation. Start the
installation by switching the disconnecting switch. The operation of the installation is
explained in section 2.6.

2.5.4 Training

The service engineer explains the operating instructions to the personnel entrusted with the
operation of the installation. Attention is given to the safety devices, instructions for safe
operation, use, maintenance and adjustment.

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2.6 Operation

2.6.1 Introduction

In this chapter are consecutively described:

• Put in operation: see paragraph 2.6.2
• Emergency stop module 2.6.3
• General operation 2.6.4

2.6.2 Put in operation

• Switch on electrically Switch on disconnecting switch: position 1. The

disconnecting switch is on the electrical cabinet

• Switch off electrically Switch off disconnecting switch: position 0. The

disconnecting switch is on the electrical cabinet

• Start hydraulic motor Push on the button “Start motor” (on the control
panel)

• Stop hydraulic motor Push on the button “Stop moto” (on the control
panel)

• Check emergency stop Check if emergency button is unlocked.

ATTENTION: the emergency stop button may

only be activated in an emergency situation and
never as a normal stop.

2.6.3 Emergency stop module

The baling press VVH40C-DSK is equipped with following security measures:

- Safety contact on the filling doors of the press boxes.
- Safety contact for the turning table, to detect if the turning table is in position and
locked.
- Emergency stop (on the operation standard)

All these contacts are connected with an emergency stop module, which prevent the
movement of the pressing plate, if the security measures are not activated.
If all contacts and the emergency stop are active, the pilot light inside the push button
‘RESET” illuminates continuously. All conditions are fulfilled to make a bale (pressplate
moving downwards).

When the pilot light inside the push button “RESET” blinks, this means that the button must
be pushed to activate the security measures. Thereafter the pilot light illuminates
continuously, so all conditions are fulfilled to make a bale (pressplate moving downwards).

When the pilot light inside the push button “RESET” doesn’t illuminate, this means there will
be a problem with one of the security measures, for example:
- A filling door of the press box is still open.
- The turning table is not is the correct position or not locked.
- The emergency stop button has been pushed.
In this case, you must solve the problem, and then the pilot light inside the RESET button
will blink, in order to indicate that the all conditions are fulfilled to push the RESET button.

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2.6.4 Two hands control

For the safety of the operator, some movements can only be operated by means of the two
hands control :
- Press plate down
- Press plate up
- Press box down
The buttons for the two-hands control are the 2 yellow push buttons on each side of the
control panel.

Two-hands control
(on left and right side of the
panel is a push button for
the two hands control

To start the movement “Press pate down”, follow this procedure:

- Push on the button “Press pate down” on the control panel
- Then push simultaneously on both yellow buttons of the two-hands control.
- Keep on pushing until the press plate is lowered into the press box.

To start the movement “Press pate up”, follow this procedure:

- Push on the button “Press pate up” on the control panel
- Then push simultaneously on both yellow buttons of the two-hands control.
- Keep on pushing until the press plate is gone up, into the press box.

To start the movement “Press box down”, follow this procedure:

- Push on the button “Press box down” on the control panel
- Then push simultaneously on both yellow buttons of the two-hands control.
- Keep on pushing until the press box is complete down.

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2.6.5 General operation

2.6.5.1 Start position:

• The carrousel is in working position and locked (Limit switch “FDC Safety Position carrousel”
is activated)
• The doors of the boxes are closed (Proximitiy switches are activated)
• The press plate is up and the press box is down.

2.6.5.2 The operation cycle consists of following steps:

Open the filling doors by means of the handle on the door.

Fill the box equally with material.
When the box is full, close and lock the door of the filling box. Then push on the RESET
button to activate the safety module.
Push the pedal of the carrousel, the locking device opens.
The turning table is now free to be turned by means of the handle on the free box.
Turn the carrousel until the full box is positioned under the pressing plate and the
locking device is closed. Push on the RESET button to activate the safety module.
Push the button “Press plate down” on the control panel. Then push simultaneously
on both buttons of the two-hands control, to start the movement “Press plate down”.
Push both buttons until the press plate is completely in the pressing box.
The press plate lowers and presses the material to obtain a bale. The press plate will
stop when the limit switch “Press plate down” is activated or when the set pressure is
reached.
Then the press box will rise automatically. The bale is now free for wrapping and
strapping.
Wrap and strap the bale.

Note: For a safe use of the strapping tool, we refer to the manual of the tool.
Be careful and never put fingers between the bale and the strap.

After strapping the bale, push the button “Press plate up“ on the control panel. Then
push simultaneously on both buttons of the two-hands control, to start the movement
“Press plate up”. Push both buttons until the press plate is mounted enough, so that the
bale can be taken out of the press. Release both push buttons and the press plate will
stop.
When the press plate has stopped, take the strapped bale out of the press and stack it
outside the working area.
Then put new wrapping material on the pressing plates.
Push the button "Press plate up" on the control panel. Then push simultaneously on
both buttons of the two-hands control, to start the movement “Press plate up”. Push
both buttons until the pressing plate has reached the limit switch “Press plate up”.
Push the button "Press box down" on the control panel. Then push simultaneously on
both buttons of the two-hands control, to start the movement “Press box down”. Push
both buttons until the pressing box has reached the limit switch “Press box down”.

Attention: The press box must be completely down on the limit switch "Press box
down" in order to turn the turning table freely.

The press is now ready for next cycle.

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2.7 Safety facilities

2.7.1 Safety facilities foreseen by Valvan Baling Systems

Emergency stop button on the control panel

Safety contacts on the filling doors of the press boxes
Safety contacts on the turning table, in order to detect the position and locking of the
turning table.
Two-hands control to operate the movements, press plate up, press plate down, press
box down.
Pictogram on the electrical box: “Danger under voltage“

2.7.2 Safety facilities to foresee by the customer

Mark the turning circle area and the operation area on the floor.

2.8 Adjustment

The baling press has been adjusted during the assembly and the commissioning by Valvan
Baling Systems NV, further adjustment is normally not necessary.

Valvan Baling Systems NV offers you qualified technical support for your press, if you wish
some help. See section 3.9

ATTENTION

The pressure limit valves of the pumps are important for the proper
operation of the baling press. These valves have been adjusted before
leaving the workshop at Valvan Baling Systems NV. at a value determined
:
by the function of the press.
Some timers in the electrical cabinet has been adjusted and set on the
correct time for a proper operation of the baling pres.

Never change the settings.

If an engineer of Valvan Baling Systems NV notices that one of these valves is tuned up to a
higher pressure then allowed, the manufacturer does not assume responsibility for
subsequent damage and wear. The manufacturer is also not responsible for premature use
of the baling press.

2.9 Emergency situation

:
Always push the “Emergency stop” button in case of personal risk or
when the press does not operate properly.

Never grab in the press when in operation.

Next disconnect the disconnect switch and put a warning sign: “DEFECT, OUT OF USE“.

Inform immediately the workshop supervisor, who cares for the repair of the baling press.

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Edit date: January 2015
3. MAINTENANCE

3.1 General

Before starting maintain and repair first read section 1.2 “General prescriptions for
safety” and follow the guidelines of the manual.

Qualified people who know the baling press very well should do repair and maintain.

Replacement of parts for reasons of wear of damage should be done safely and with
adequate handling equipment.

Disconnect power supply and lock the disconnecting switch of the baling press
before any repair or maintenance.

A maintenance schedule is to be set up of the installation. On the schedule will be noted the
preventive actions already taken and during the check-ups, the anomalies to be dealt with,
as well as the maintenance work to be done.

Clean regularly the whole press with a vacuum cleaner to take away dust and rubbish.

3.2 Hydraulic circuit

Trouble free operation of any hydraulic group requires strict adherence to the maintenance
instructions.

For reasons of safety, no pipe connectors, flexible hoses or components are loosened
while the system is under pressure, switch off the pump, support or put the plate down. Do
not forget to take the support away.

Extreme cleanness is essential when working on the hydraulic system. Dust and impurities
are the greatest enemy of every hydraulic group.
Clean before disassembling the surroundings of the hydraulic group. Cover all openings so
that no dirt can enter the circuit.

3.2.1 Hydraulic oil

A trouble free operation of the hydraulic group is obtained when the most suitable type of
fluid is used.
The technical specification of the oil is: Viscosity 46 cSt at 40° C (104 ° F). (ISO Class VG
46)

Next:
Check regularly (every month) the oil level and add oil if necessary. The maximum level
corresponds to the middle of the uppermost oil glass.
When the oil level sinks, it means that there is somewhere a leak, locate the leak and
take action to repair.
Check every 6 to 8 weeks the oil purity (colour, condition).
Let check the quality of the hydraulic oil for the first time after 2000 hours, next once a
year. Regarding the results the oil supplier will decide either to add some additives to
the oil or to change the oil.
Rinse the oil tank to remove oil rests.

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3.2.2 Filter

By far the largest numbers of breakdowns in a hydraulic group are due to contaminated
fluid. The task of the fluid filter is to keep the contamination within limits and to protect the
equipment from excessive wear.

Check and clean the return filter:

• after 500 workings hours
• at each oil change
• minimum once per year
Replace the contaminated filter at least every 2000 working hours or earlier if necessary.

Check and clean the oil inlet-filter on top of the tank when changing oil. When changing oil
in tank, check and clean the tank.

3.2.3 Pump

The choice of the pump has been done with regard to the characteristics of the baling press.
The pump type is given on the hydraulic drawing.
Normal use and regular oil change have on influence on the lifetime of the hydraulic
components.

ATTENTION
• Never let the pump run without oil in the tank.
• Never let the pump run in the wrong direction.
• Never let the pump run with a dirty filter.

3.3 Maintenance of mechanical parts

Check periodically mechanical parts of the press as: locking pedal, box doors, the box
group, the connection between piston and press plate: fasten screws, bolts, nuts. Replace
or repair worn or damaged parts.

3.4 Maintenance of electric circuit

ATTENTION

Always disconnect the disconnecting switch

Check regularly: (every 3 months) • the wire connection on terminals

• relays
• the connection of wires to the valves
• cable connection
• the operation panel
• detection components

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3.5 Lubrication

The numbers of lubrication points are limited on the VVH40C-DSK baling press.

Lubricate regular following parts:

• Oil monthly the guide rod
• Lubricate monthly the locking pedal

3.6 Diagnostic

The fault diagnostic gives some indications for a logical approach of a fault in order to
quickly locate and correctly solve a breakdown.

Fault Probable cause Action

Pump does not run, when Check:

pushing the button "Plate No voltage • if the disconnecting switch is in position
up (⇑⇑)" or "Plate down “1”
⇓)"
(⇓ • the output voltage of main supply
• the input voltage of the electric box
No command • the motor fuses
• the fuses of the pilot circuit
• if the emergency stop is unlocked
• if the limit switch of the box is engaged.
See electric drawing.

Plate does not lower after Check:

pushing the button: No command • if motor is running (see above)
⇓")
“Press plate down“ ("⇓ • if plate is down
• hydraulic circuit is still under pressure
(pressure switch)
• if limit switch “Plate down“ on guide rod
is still engaged.
• the push button “⇓ ⇓”

Plate does not rise after Check:

pushing the button: No command • if motor is running ( see above )
“Press plate up“ ("⇑⇑") • if plate is up
• if limit switch “Plate up“ on guide rod
still is engaged.
• the push button “⇑ ⇑”

FDC = Limit switch

In case of an electric fault, check the electric circuit systematically:

• check all supply voltages
• check the pilot voltage
• check which movement does not take place and locate this on the electric drawing
• check systematically on the electric drawing in the line of the concerned
component or if the different elements work properly (i.e. fuse, relay-contacts,
operation buttons, ….)

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Edit date: January 2015
 In case of a mechanical break down:
• when a mechanical part has broken down, first locate the part and search for the
reason before starting the replacement and adjustments in safe conditions

Above suggestions may help to solve a break down.

If you think to need our help, call the Service of Valvan Baling Systems NV (see section
3.9).

3.7 Spare parts

We recommend using always replacement parts of origin, which match as well the safety as
the operation requirements.

If replacement parts are ordered to Valvan Baling Systems NV, always mention the serial
number of the press.

3.7.1 Hydraulic spare parts

See part list on the hydraulic drawing: Annex B

3.7.2 Electric spare parts

See electric drawing: Annex C

3.8 Out of use

Only authorised persons, with experience and knowledge, are allowed to dismantle
and to put the installation out of use.

Proceed as follows:

1. Disconnect all energy sources in advance:

• Disconnect the supply cable in the electrical box (electric connection). Check
before if the supply cable is disconnected from electric supply.
• At the latest disconnect the earth cable.
• Release the pressure from the pneumatic and hydraulic circuit.

2. Next empty the oil from oil tank in a convenient barrel. Take care that no part of the
circuit is still under pressure. Disconnect the hydraulic pipes and collect the oil from the
pipes, valves and cylinders.

3. Parts, which are soiled with oil, must be cleaned thoroughly. Take care that no hydraulic
oil ends up on the ground or in the environment.

4. Take also care machine parts do not lower uncontrolled by gravity (these parts must be
fixed or supported).

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Edit date: January 2015
 5. Foresee all necessary devices (e.g. lifting equipment) to fix, disconnect and dismantle
all parts of the installation (baling press and auxiliary equipment). Take contact with
Valvan Baling Systems for complementary information about the procedure.

6. All parts of the installation, de materials and the hydraulic oil must be removed
regarding the ruling legislation in the country where the installation has been
dismantled.

3.9 Service

Do not hesitate to call our Service, if you want our help to solve a problem.

Krommebeekstraat 14
B - 8930 Menen
Tel: (0032)(0)56/52.13.87
Fax: (0032)(0)56/51.83.34
E-mail: service@valvan.com

Sometimes a problem or breakdown can be solved by phone or fax. In this case we ask you
to give all necessary information and a clear description of the breakdown in order to avoid
misunderstanding.

So doing the stand still of the press can be reduced to a minimum.

Hold always the press documentation at hand in case of an intervention by phone.

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Edit date: January 2015
4. ANNEX

ANNEX A

General view of the baling press

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 ANNEX B

Hydraulic drawing

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 ANNEX C

Electric drawing

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Edit date: January 2015