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BT_KNL100_V1.2 ENGLISCH_Display_mit Option Kippe_STAND Mai_2013 (1)
BT_KNL100_V1.2 ENGLISCH_Display_mit Option Kippe_STAND Mai_2013 (1)
KNL 100
WITH OPTIONAL
FEATURES
Tipping device
Tropical motor
BETRIEBSANLEITUNG
OPERATING INSTRUCTIONS
INSTRUCTION DE SERVICE
ERSATZTEILLISTE
SPARE PARTS LIST
LISTE DE PIECES DE RECHANGE
Edition: 01 / 2013
program version 1.2
CONTENT
KNL 100
1 Introduction ...................................................................................................................... 4
1.1 General ....................................................................................................................... 4
1.2 Vehicle identification plate......................................................................................... 4
1.3 Guarantee ................................................................................................................... 4
2 Safety ................................................................................................................................. 5
2.1 General ....................................................................................................................... 5
2.2 Use .............................................................................................................................. 5
2.3 Manual ....................................................................................................................... 5
2.4 Regulations and norms ............................................................................................... 6
2.5 Electric ....................................................................................................................... 6
2.6 Control and maintenance ........................................................................................... 6
3 Installation ........................................................................................................................ 7
3.1 Place of installation ................................................................................................... 7
3.2 Install .......................................................................................................................... 7
5 Start Up ............................................................................................................................. 9
5.1 Keys and buttons ........................................................................................................ 9
5.2 Test the emergency stop function ............................................................................. 10
8 Messages .......................................................................................................................... 14
9 Operation ........................................................................................................................ 16
9.1 Binding rope ............................................................................................................. 16
9.2 Filling and compressing ........................................................................................... 18
9.3 Binding bale with rope ............................................................................................. 19
9.4 Ejection..................................................................................................................... 19
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CONTENT
KNL 100
10 Maintenance .................................................................................................................... 20
10.1 After first 10 hours of operation ............................................................................... 20
10.2 Daily maintenance.................................................................................................... 20
10.3 Monthly maintenance ............................................................................................... 20
10.4 Annual maintenance ................................................................................................. 20
10.4.1 Lubricating nipples .......................................................................................... 21
10.4.2 Sliding surfaces ................................................................................................ 21
11 Hydraulic......................................................................................................................... 22
11.1 Hydraulic plan.......................................................................................................... 22
11.2 Hydraulic equipment ................................................................................................ 23
12 Cylinder ........................................................................................................................... 25
12.1 Main cylinder ........................................................................................................... 25
12.2 Tipping device .......................................................................................................... 26
13 Electric............................................................................................................................. 27
13.1 Circuit diagram ........................................................................................................ 27
13.2 Electric equipment.................................................................................................... 29
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INTRODUCTION
KNL 100
1 Introduction
1.1 General
With your purchase of a baling press KNL 100 (with tipping device) you have acquired a high quality
waste disposal machine.
This operating manual contains the latest product information. It must be read and observed by every
person who uses, maintains, services or checks the baling press.
Safety and warning comments are indicated separately. They must be taken
into account particularly before starting the machine, and during operation!
Keep the operating manual in easily obtainable place that is known to the operating,
maintenance and cleaning personnel.
Consequences arising from the regulations and instructions appearing in this operating manual being
disregarded releases the manufacturer from any liability. Subject to technical changes without notice. All
data is without obligation.
Guarantee claims and enquiries will not be processed without the machine number being provided.
1.3 Guarantee
Fill in the enclosed commissioning certificate and send it back (yellow form).
Guarantee can only be ensured if the quoted points have been checked in accordance with the obligations of
product liability and if the commissioning certificate has been filled in, signed and sent back to the
manufacturer.
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SAFETY
KNL 100
2 Safety
2.1 General
Attention: Danger of crushing and injuring
All guidelines and instructions for set-up, start-up and operation of the baling press must be complied with
according to the manual in order to guarantee the greatest possible safety.
Provide good lighting and keep the working area in order. Disorder gives rise to the danger of accidents.
Keep the baling press clean to ensure better and safer operation.
The baling press may be operated only in the presence, under the supervision and with the approval of two
trained operators authorized for operation.
Operating staff have to know the place of all available emergency-stop keys and make sure of their perfect
functioning.
Knowledge of operational procedures is a requirement for any operators working on the machine in order
to recognize any irregularity of operating performance and be able to rectify defects that endanger safety.
2.2 Use
For compression of any type of cardboard and papers, fruit crates, foil, etc.
Any other materials must not be compressed with this baling press!
Be sure that there are no metallic parts or residues inside the press because these parts as well as hard
objects can cause damage (deformation) to the press, inexpert working and safety faults.
2.3 Manual
The operating manual must be read and observed by all persons authorized to use, maintain, service or
check the machine so that danger can be averted.
Understanding and knowledge of the manual as well as knowledge of any possible dangers, especially in
connection with operational procedures, is a requirement for any work carried out in connection with the
machine.
Operating staff and any staff who carry out work in connection with the baling press, have to undergo a
training with main emphasis on safety engineering within this manual and confirm their participation,
understanding and knowledge by their signature.
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SAFETY
KNL 100
2.4 Regulations and norms
The baling press KNL 100 (with tipping device) is constructed in accordance with accident prevention
about protection regulations, as well as the generally recognized rules concerning safety regulations and
industrial medicine.
Norms: Appendix I of EC Machinery Directive 2006/42/EC in its current version. And, therefore,
Appendix I of the Machine Safety Regulation (MSV); BGBI II 2008-282 in its current version.
EN ISO 12100-1, EN ISO 12100-2, EN ISO 13849-1, EN ISO 13850, EN ISO 13857, EN ISO 4413,
EN 349, EN 953, EN 1088, EN 60204-1/07 (Pkt. 5,6,7,10)
2.5 Electric
Attention: Check voltage!
The switch box must be locked during normal operation. Keep the switch box key in a safe place.
Handle electric cable carefully. Protect it against heat, oil and sharp edges.
Never carry out any adjustments, checks, repairs, maintenance and cleaning work while the motor is
switched on.
Defects, irregularities, etc. must be discovered immediately and corrected once the machine has been
switched off (before work continues) and all safety guidelines and instructions must be complied with
(notify the manufacturer!).
Before changing the position, repairing and working on the machine which is not in connection with the
operation, switch off the machine and unplug.
The press must undergo an annual safety inspection in accordance with the national law, which is to be
carried out by Austropressen or proficient personnel.
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INSTALLATION
KNL 100
3 Installation
3.1 Place of installation
Loading throat
Without dismantling Width mm 1200
Height mm 2000
Space required
Width mm 2200
Height mm 2150
Length mm 3800 + bale outlet
Power connection
Voltage V 400V
Frequency Hz 50
Fuse protection A 16
Socket connecting poles Stk 3x400V + N + PE
Ambient temperature
-5°C to +30°C, protection against atmospheric influence
Composition of ground
Flat, level industrial ground.
3.2 Install
Transport
Transport with lifting truck or appropriate lifting device.
ATTENTION: Machine top heavy!!
Packaging
Remove and carry out disposal of packaging material!
Connection
Connect the feeder (CEE). Engine rotates clockwise, if not change rotating field!
Attention: Changes must only be carried out by an electrician!!
Working place
Machine face and back!!
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TECHNICAL DATA
KNL 100
4 Technical data
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START UP
KNL 100
5 Start Up
5.1 Keys and buttons
Main switch HS
• To switch off and on the voltage of the press.
ON
• To switch on the machine after f.ex. using the emergency-stop or after opening of the filling door
START
• Starts the automatic pressing cycle.
• To start manual functions (see below)
STOP
• Stops the automatic pressing cycle.
• To show the status display (press button for 5 seconds)
BALE (BALLEN)
• To scroll in the text display in the configuration menu and in the status menu
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START UP
KNL 100
KEYS FOR MANUAL OPERATION:
The buttons for a manual operation of the machine must be pressed simultaneously with the START button.
(Beidhandfunktion, 2-hand-mechanism)
FORWARD
• For manually moving the press plate forwards when counter door is closed and locked (pressing
bales)
• For manually moving the press plate forwards when counter door is open (ejecting bales)
REVERSE
• For manually moving the press plate backwards when filling door is closed
• For manually moving the press plate backwards for 2 seconds when filling door is open (for
emergency retract of the machine)
Note: When the filling door is open, the press plate will only move backwards for 2 seconds and will stop
automatically. To repeat the process release and press the ‘reverse’-key again.
OPTION: For models with tipping device, there are following additional buttons:
UP (tipping device)
• For manually moving up the tipping device.
Note: Only possible if filling door is open, the press plate is at the rear and the safety bar of the tipping
device is closed.
Note: Only possible if filling door is open and the safety bar of the tipping device is closed.
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MENUES AND DISPLAYS
KNL 100
6 Configuration menu
6.1 General
Start
• Switch off main switch, switch on main switch.
• Press the buttons “START”, “STOP” and “BALE” simultaneously during the start message
(Austropressen KNL 100 V1.2 or KNL 100-dump V1.2) is indicated.
To come to the next menu point you have to press the button “BALE”.
After the fourth digit you have to press the button “STOP” again and the password is checked. Either
the message “password wrong” or “password correct” is indicated. Press the button “START” to change
the first digit of the password if it is necessary. With the bale button you can skip to the next menu item.
If a correct password was entered, all configuration parameters can be viewed or changed, otherwise
only the disassembly mode menu is displayed.
Language
It is necessary to enter the password to come into this menu.
This menu point is to change the language of the messages of the PLC.
• Press button “START” or “STOP” - another language is selected.
Press time
It is necessary to enter the password to come into this menu.
The time in seconds how long the press plate is moving forwards.
• Press button “START” - Value is raised by 1.
• Press button “STOP” - Value is reduced by 1.
Ejection time
It is necessary to enter the password to come into this menu.
The time in seconds how long the press plate is moving forwards.
• Press button “START” - Value is raised by 1.
• Press button “STOP” - Value is reduced by 1.
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MENUES AND DISPLAYS
KNL 100
Contrast
It is necessary to enter the password to come into this menu.
To value the contrast of the PLC.
• Press button “START” - Value is raised by 1.
• Press button “STOP” - Value is reduced by 1.
Parameter
It is necessary to enter the password to come into this menu.
Parameter can be reset to their standard values.
• Press button “START” and “STOP” together - Parameter are reset.
Attention: The bale counter, the press cycle counter and the working hour counter are
reset as well.
Exit
To exit configuration menu
• Press button “STOP” You exit configuration menu and all values are
stored.
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MENUES AND DISPLAYS
KNL 100
7 Status display
7.1 General
Start
• Press button “STOP” for 5 seconds.
To come to the next status display you have to press the button “BALE”.
7.2 Displays
Bale
Display: STATUS DISPLAY
Bales : 108
Working hours
Display: Working hours
78:52:08
Indicates the achieved working hours of the motor (78 hours; 52 minutes; 8 seconds).
Press cycles
Display: Press cycles
405
Shows whether the inputs (01 – 11), or the outputs are free or not. On the left hand side is input or
output no. 01
Exit
Display: STATUS DISPLAY
End with Stop
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MENUES AND DISPLAYS
KNL 100
8 Messages
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MENUES AND DISPLAYS
KNL 100
ERROR MESSAGES
Error message: (Timeout Press) 30 fault cycle too long
The Press was stopped because the Press cycle took too long.
Cause:
• end switch „press rear“ – is not reached
• end switch is adjusted wrong – broken switch or cable
30
• hydraulic motor does not work (Motor protection switch
dropped down);
• hydraulic motor gives no pressure
• hydraulic valves don´t work
• press sticks
Error message: (Press forward) 31 fault press forw.
Press does not move forward Rotation motor?
Cause:
• direction of rotation is false (no pressure is built up);
• hydraulic motor does not work (Motor protection switch
dropped down);
31
• hydraulic motor gives no pressure
• hydraulic valves don´t work
• end switch „press rear“ is not left
• end switch plugged in wrong – broken, foreign actuated
or broken cable
• press sticks
Error message: (closing) 32 fault closing both
Both end switches of locking mechanism actuated switches active
Cause:
32
• locking is not open or closed totally (open or close
closing manual)
• end switch plugged in wrong – broken, foreign actuated
Notice for operator mistake: 33 counter gate not
Will be fade in if 2 hand „press forward“ is pressed and counter open!
33 gate not opened.
Adjustment: Open the counter gate so that you can complete the 2-
hand-function
Notice for operator mistake: 34 press not at rear
Will be fade in if Up/Down of the tipping device is pressed, and
the press plate is not at the rear.
or
34
Will be fade in if Open/Close of the counter door is pressed, and
the press plate is not at the rear.
Adjustment: The press has to move to the rear position, so that you
can complete the 2-hand-function.
Notice for operator mistake: 35 counter gate open!
Will be fade in if buttons to close locking of counter door are
35 pressed and the counter door is not closed. .
Adjustment: Close the counter gate, so that you can complete 2
hand mechanism.
Error message: (Software crashed) 36 Software crashed
36 An unknown software error has occurred. Switch off machine and start machine again
switch it on again.
Notice for operator mistake: 37 filling door not
Will be fade in if Up/Down of the tipping device is pressed and the open!
37
filling door is not open.
Adjustment: Open the door.
Notice for operator mistake: 38 safety bar
Will be fade in if Up/Down of the tipping device is pressed and the not closed
38
safety bar is not closed.
Adjustment: Close the safety bar.
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OPERATION
KNL 100
9 Operation
9.1 Binding rope
9.1.1 Article
Binding rope WG 40, 13mm (Art.-No.: 05-0004) for carton
Binding rope WG 45, 13mm (Art.-No.: 05-0005) for foil
a) Insert the rolls (1) on the back side of the machine (2).
b) Acknowledge “EMERGENCY STOP” (push “ON” button).
c) Open the locking from the counter gate.
d) Raise the counter gate.
e) Move press plate approx. 20 cm forward (push „START“ and open the filling door after 3-5
seconds).
f) Open brake of ropes (put lever outside the closure).
g) Put end of ropes (1) through the brake (3).
h) Put end of ropes through the pipes into the press chamber.
B
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B
i) Pull binding tape forward along the guides inside the machine.
j) Pull the rope hooks out of the press plate.
k) Put rope through the hole of the hook (5) – and turn it back into the press plate.
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OPERATION
KNL 100
l) Bind a loop at the end of the rope and fix the knot at the pin (8).
m) Pull rope to the front of the counter gate and turn it at the upper pin (7).
n) Pull rope to the bottom of the machine and turn in at the lower pin (6).
77
66
B
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B
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OPERATION
KNL 100
rope hook
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OPERATION
KNL 100
9.3 Binding bale with rope
• Repeat filling and compressing until required bale size is reached. (approx. 600 mm)
• Stop machine at the highest pressing point in front (push „STOP“ button)
• Open lever of brake of ropes.
• Open filling door
• Put the rope hooks out of the press plate
• Cut the rope
• Tie the two ends of the rope
• Close filling door
9.4 Ejection
• Acknowledge “Emergency stop” (push “ON” button)
• Press plate moves back (push ON button)
• Open locking of counter gate
• Raise counter gate
• Automatic bale eject (push “START” button for more than 3 seconds)
• Remove the bale of the press.
• Put press plate in the middle of the filling door (push „START“ button and “Reverse” within 0,2
seconds together)
• Open filling door
• Start with position of ropes i)
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MAINTENANCE
KNL 100
10 Maintenance
ATTENTION DANGER TO LIFE!
Always switch off the main switch and protect it by means of a padlock during any maintenance and repair
work.
All removed safety devices must be attached immediately after carrying out these works. It is forbidden to
operate the machine with removed safety devices. It is strictly forbidden to walk on the conveyor and the
pressing installation when the main switch or the control unit are not switched off.
Attention: If the filter contains impurities and excessive dirt, immediately inform the
manufacturer of the press!
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MAINTENANCE
KNL 100
• Check and tighten screws in general
• Check, clean and re-grease guide plates and wearing bars.
• Check if electric supplies and cables fit well and tighten them if necessary.
We would be very pleased to service and maintain your machine in order to guarantee a long life of your
baling press.
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HYDRAULIC
KNL 100
11 Hydraulic
11.1 Hydraulic plan
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HYDRAULIC
KNL 100
11.2 Hydraulic equipment
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HYDRAULIC
KNL 100
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CYLINDER
KNL 100
12 Cylinder
12.1 Main cylinder
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CYLINDER
KNL 100
12.2 Tipping device
Cylinder Ø63/40x268mm
22-30-6-0006
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ELECTRIC
KNL 100
13 Electric
13.1 Circuit diagram
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ELECTRIC
KNL 100
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ELECTRIC
KNL 100
13.2 Electric equipment
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SPARE PARTS
KNL 100
14 Spare Parts
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PLEASE CONSIDER
KNL 100
15 Please consider
Only use original AUSTROPRESSEN – spare parts!
Quote your exact address, and zip code and railroad station.
Please write legibly!
The client is responsible for any wrong deliveries due to incomplete details.
Please prepare your order carefully.
Phone (+43)7662/8218
Telefax (+43)7662/8218-21
E-mail office@austropressen.com
sale@austropressen.com
Website www.austropressen.com
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