operating and maintenance instructions channel-type baling … instruction.pdf · written consent...

PRESTO

GmbH & Co. KG

Bad Laer

04/2012

Operating and

maintenance instructions

CHANNEL-TYPE BALING PRESS

TYPE

CONTI COMPACT

CC-13 V

CC-20 V

CC-30 V

CC-40 V

PRESTO

GmbH & Co. KG

Bad Laer

04/2012

i

Table of contents

1. Introduction

1.1 Introduction

1.2 Structure of the operating

instructions

1.3 Duties and information for

the machine operator

1.4 All rights reserved

1-1

1-1

1-2

1-2

1-3

2. Intended use

2.1 Improper use

2.2 Amendments at the supplied

device by the operator

2.3 Residual risks at the channel

type baling press

2-1

2-1

2-1

2-1

3. Safety

3.1 General information

3.2 Safety instructions

3.3 Safety marking

3.4 Protective devices

3.5 Organisational measures

3.5.1 General information

3.5.2 Location

3.5.3 Selection and qualification

of staff

3.6 Operation

3.6.1 Normal operation

3.6.2 Danger areas

3.6.3 Reference to special

dangers

3.6.4 Transport and loading

3.7 Maintenance/Repair

3.8 Liability and warranty

3.9 Product liability

3.10 Warranty

3-1

3-1

3-3

3-3

3-4

3-5

3-5

3-6

3-6

3-7

3-7

3-9

3-9

3-10

3-11

3-12

3-12

3-12

4. Technical data

4.1 Sound emission

4-1

4-4

5. Constructive description


5.2 Basic construction

5.3 Press unit with channel

adjustment

5.4 Hydraulic unit

5.5 Electrical unit

5.6 Tie-off device

5.6.1 Fully automatic tie-off

device

5.7 Funnel with safety circuit

5-1

5-1

5-2

5-3

5-4

5-6

5-8

5-8

5-8

5-10

6. Operating elements and

operation


6.2 Operating elements

6.3 Works prior to initial

commissioning

6.4 Compacting process

6.4.1 Operation mode "Manual"

6.5 Control and program

description

6.6 Insert binding wire coils

6.7 Transport and loading

6-1

6-1

6-1

6-2

6-4

6-5

6-11

6-15

6-19

7. Maintenance


7.2 Cleaning

7.3 Maintenance

7.3.1 Maintenance schedule

7.3.2 Description of the

maintenance works

7.3.3 Fuels, fuel quantities

7-1

7-1

7-2

7-3

7-3

7-6

7-19

8. Repair

8-1

PRESTO

GmbH & Co. KG

Bad Laer

04/2012

ii

9. Behaviour in case of trouble

9.1 Error messages

9-1

9-2

10. List of spare parts

11. Appendix

11.1 List of machine operators

and personnel in charge

11.2 Maintenance and revision

list

11.3 Special equipment

11.3.1 Funnel

11.3.2 Special equipment

11.4 Wiring diagrams

11.4.1 General

11.4.2 Wiring diagrams for the

channel type baling press

11.5 Disposal

10-1

11-1

11-1

11-3

11-4

11-4

11-5

11-5

11-5

11-5

11-6

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 1-1

1 Introduction

1.1 Introduction

Dear customer,

to assure a safe and efficient use of the

unit we would ask you to read the present

operating instructions carefully prior to

the initial start-up.

The operating instructions contain all

relevant information for the operation and

maintenance of the channel-type baling

press.

Chapter 1 to 10 will inform you about the

standard equipment. If installed, the

special equipment will be dealt with in

chapter 11.

These operating instructions form a

constituent part of the complete

documentation for the channel-type

baling press of the types CC-13, CC-20, CC-

30 and CC 40.

Other essential parts are:

• Electrical and circuit diagrams,

• Assembly or layout diagram

• Declaration of Conformity or

alternatively Declaration of

Incorporation

In principle, every machine is supplied

with a Declaration of Conformity. This

states that the machine fulfils the basic

safety and health requirements of the EC

Directive on Machines.

In the event that no Declaration of

Conformity is issued, the attached EC

Declaration of Incorporation for

incomplete machines states with which

additional components the machine must

be assembled before it is put into

operation. Until the machine has been

completely assembled, commissioning of

individual components is forbidden.

As a rule all safety instructions have to be

fulfilled prior to the commissioning of the

channel-type baling press.

Only qualified and trained personnel of

PRESTO or persons authorised by them

may work with the channel-type baling

press.

If maintenance works are neglected or

carried out improperly we will not be able

to fulfil our guarantee obligations

according to our terms of delivery.

Only original-PRESTO- spare parts ensure

quality and interchangability.

How to identify your machine:

These operating instructions serve for the

operation and maintenance and apply for:

Project: Channel-type baling press

Type: ______________________

(see type plate)

Mach.- No.: ______________________

(see type plate)

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 1-2

The type plate is positioned at the

channel-type baling press as follows:

When contacting our service department

you should always have the information

ready which is given on the type plate.

Manufacturer: PRESTO GmbH & Co. KG

Customer:

______________________

Year of construction:

______________________

Conformity with EC-directive 2006/42/EG

To observe upon delivery

The channel-type baling press left our

plant in a technically perfect and ready to

use condition. Please check the condition

of the machine immediately upon receipt

and carry out a functional check. Possible

complaints have to be reported to the

forwarding agent immediately.

1.2 Structure of the operating

instructions

The operating instructions are laid down

in chapters according to the table of

contents.

The corresponding page number has been

assigned to each chapter.

The footnote contains the date of issue

and the page number.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 1-3

1.3 Duties and information for the

machine operator

As the operator of this unit you have to

inform and instruct the operating staff

about prevailing legal regulations and

accident prevention rules as well as safety

and operating devices at the machine.

Ensure that your operating staff has

understood the instruction and follows it.

How to achieve a safety and danger

conscious operation by your staff:

In the following we have prepared some

items for you with respect to the

instruction subjects

With respect to safety

• Accident prevention rules

• General legal regulations

• General safety instructions

• Measures in case of emergency

• Safety instructions for the

operation of the unit

• Dealing with the safety devices of

the machine

• Meaning of symbols and signs

With respect to the operation of the

machine

• Dealing with the operating

elements

• Explanation of the operating

instructions for the operating staff

• The use of aids and auxiliary

devices

• Experiences with regard to the use

of the machine

Maintenance and repair instructions

• Correct dealing with fuels

• Special experiences of the operator

for the cleaning and care,

maintenance and repair of the

machine

1.4 All rights reserved

All technical data, descriptions and photos

are valid on the day of the publication of

these instructions or its supplements. We

reserve all rights as well as amendments

by continuous further development.

The operating instructions serve for the

instruction of the customers. It may

neither in part nor fully be copied or

handed to third parties without the prior

written consent of PRESTO GmbH & Co.KG

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 2-1

2. Intended use

The channel-type baling press has been

constructed for the compaction of soft

materials as paper, cardboard, foils and

similar.

2.1. Improper use

Explosive materials or similar materials or

combustible materials may not be filled in.

It is also prohibited to charge rumble, wood,

form or bar racks from metal or other hard

materials, which can result in a jerky

jamming of the compressing die.

2.2. Amendments at the supplied device

by the operator

The declared conformity applies only to the

structural condition upon delivery of the

device in correspondence with the agreed

scope of delivery. Any installation or

equipment which is carried out by the

operator at a later time, however, has not

been developed or authorised by the

manufacturer of the machine, will result in

an expiry of the declared conformity.

This also includes unauthorised modifications

of the channel-type baling press with sheets,

wood, pasteboard or fabric of any kind by

the operator.

2.3. Residual risks at the channel-type

baling press

� Danger by nonobservance of the

operating instructions

� Danger by insufficient maintenance

and repair

� Risks arising during maintenance,

servicing, and repair work through

the use of sharp-edged or

inappropriately compacted materials

(see note in chap. 7, Maintenance

and Inspection).

The operator is responsible for these residual

risks.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 1

3. Safety

3.1. General

To safeguard the labour protection and the

on-the-job safety the following references

have to be adhered to:

Accident prevention regulations, in

particular:

BGV A1 General Regulations

BGV A2 Electrical systems and

operating resources

BGV A5 First Aid

BGV B3 Noise

BGV A8 Safety marking at the work

site

have to be adhered to.

The accident prevention rules of the country

where the unit will be used have to be

observed.

We wish to point out that the unit has to be

checked at least twice a year by a qualified

person with respect to the proper and safe

function in correspondence with the above

mentioned directives.

In addition to the above mentioned

regulations the following directives are

appropriate for the inspection as well:

Safety of machinery DIN EN 12100

Part 1 u. 2

Electrical equipment DIN EN 60204

EC- machinery

directive

2006/42 EG

During the operation of the machine the

laws and regulations applicable at the place

of use have to be observed. For the sake of a

safe work sequence the operator,

supervisory persons and machine operators

are responsible for observing the regulations.

The channel-type baling press may only be

used as directed. An improper use can result

in personal and property damages.

The PRESTO channel-type baling press has

been constructed for the compaction of soft

materials as paper, cardboard, foils and

similar.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 2

It is prohibited to load explosive or similar

materials or inflammable materials

(according to §1 SprengG).

Materials that are subject to special

conditions of disposal according to the waste

disposal law must not be loaded.

Furthermore it is prohibited to fill with

rumble, timber or other such materials out of

metal or other hard materials. Only such

material may be compacted which can be

deformed by the given pressure and which

can be compressed in the compression room.

Glowing or burning particles must not be

loaded.

Another use or a surpassing use does not

comply with the intended purpose. PRESTO

GmbH & Co.KG will not be liable for damages

resulting from this. The risk will be borne by

the user of the machine.

DANGER!

The electric machines

and/or equipment are

production equipment for

use in industrial high

voltage systems. During

operation this production

equipment has dangerous

live parts which may

cause very serious injury

to health or damage to

property for instance as a

result of unauthorised

removal of coverings,

improper use, incorrect

operation or lack of

maintenance.

The staff responsible for the safety of the

unit has to safeguard that only qualified

persons

are instructed with work on the machine-

that these persons always have the supplied

operating instructions available and that they

are obliged to strictly adhere to these

documents. Working at the unit or in the

proximity has to be prohibited for non-

qualified personnel.

During filling the compactor with

material that may cause skin

damage wear gloves!

Pay attention to flying solids!

Use eye protection!

At places where there are solid airborne

particles or where dusts, caustic substances

or the like are processed or produced.

Residual risks with regard to the channel-

type baling press:

• Endangering by failure to comply with

safety instructions

• Danger by insufficient maintenance and

repair

• Risks through hydraulic hoses

• Risks through sharp-edged casing corners

• Risks arising during maintenance,

servicing, and repair work through the

use of sharp-edged or inappropriately

compacted materials (see note in chap. 7,

Maintenance and Inspection).

The user will be responsible for these

residual risks.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 3

3.2. Safety instructions

The following symbols in these operating

instructions mean:

Danger!

Risk to life and limb!

Caution!

This maintenance work may

only be carried out by skilled

personnel.

Caution!

Risk of damage to or

destruction of the machine

or its parts.

Caution!

Risk of crushing!

Read and understand

the manual!

Caution!

Risk from electric current!

Note:

Additional important

information can be found here.

3.3. Safety marking

Safety instructions and the brief version of

the operating instructions are visible at the

machine

CAUTION!

NEVER CLIMB INTO THE

FEEDING OPENING!

DANGER!

Danger of crushing!

Do not reach into the

machine from the

bottom!

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 4

3.4. Protective devices

It is prohibited to put control, switching or

safety devices out of operation or to make

modifications. Non-compliance may result in

criminal prosecution.

Safety covers held in place by bolts which fit

through keyhole-shaped slots are removed

from the machine by loosening the bolts 3 or

4 turns. The bolts should remain in the drill

holes. The cover can now be slid along the

keyhole and removed by lifting over the bolt

heads which fit through the round, upper

keyhole aperture. The covers are replaced by

reversing the sequence.

Seals may not be destroyed and pre-set

pressures may not be changed because this

would result in an expiration of the warranty

and criminal prosecution.

Equipment for the protection of the staff:

Emergency-off switch, switch box

Safety switch, charging funnel

Safety switch with rope release (1)

Emergency-off, key bar

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 5

Safety switch (Type CC-30 only)

Cover, manual tie-off device

Safety switch needle flap

3.5. Organisational measures

3.5.1. General

The operating instructions always have to be

kept at the intended place.

In case of multiple shift operation it has to be

determined who will be responsible to carry

out the maintenance works.

Check machine with regard to external

recognisable and/or audible damage and

defects, at least once per shift. Stop and

secure machine immediately if necessary.

Before starting the work the operational

tests at the emergency-off switch and the

safety switch and light barriers if necessary.

ATTENTION!

Any work such as taking into operation,

maintenance and repairs may be performed

by qualified staff only and have to be

checked by responsible experts. The user has

to notify any trouble or irregularities to his

person in charge immediately. This applies

for the mechanical and electrical devices.

The machine has to be stopped and secured

immediately in case of malfunctions or

safety-relevant changes of the behaviour of

the machine. Malfunctions have to be

corrected immediately.

It has to be seen to it that the operating

instructions, the maintenance and special

tools and devices, the oil cans and grease

guns as well as cleaning agents and

lubricants belonging to the channel-type

baling press container are always kept in the

intended receptacles.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 6

3.5.2. Location

The location has to be chosen that way that

the channel-type baling press stands on a

plain surface. The location must have a

concrete plain surface that corresponds to

the weight of the machine.

The unit may be operated in an electrical

network with the corresponding conditions

(see chapter "electrical system").

As a protective measure against indirect

touching the fault-current circuit breaker

according to VDE 0100 has to be used when

erecting the machine in the open. Only fault-

current circuit breakers may be used with a

nominal fault current as specified in the

wiring diagrams of the manufacturer.

The provisions of the water household and

environmental protection law have to be

adhered to when setting up the unit and

taking it into operation.

Sufficient space has to be provided in front

of the channel-type baling press for the bale

which is pushed out. The access must be

possible for industrial trucks without

endangering persons.

The loading and starting area for industrial

trucks has to be marked.

3.5.3. Selection and qualification of

staff

Only such persons selected according to BGV

A1 § 13, BGV A2 are authorised to operate

and maintain the channel-type baling press.

The user will be responsible for the

occupation of the channel-type baling press

with machinists who have been instructed

about the use of the machine according to

BGV A1 § 13. The above mentioned is only

valid for the Federal Republic of Germany.

The corresponding regulations and guidelines

of the country where the machine is used are

applicable.

Only qualified and reliable staff may work at

and with the machine.

Persons instructed with work at/with the

machine must have thoroughly read and

understood the operating instructions and

here especially the safety instructions and

they must be in a corresponding mental and

physical state.

Non-compliance with these instructions may

result in danger for life and limb and/or

danger for the machine or other physical

assets.

3.6. Operation

3.6.1. Normal operation

The use in explosive areas and in an

explosive atmosphere is strictly prohibited.

The channel-type baling press is appropriate

for manual loading from ground level to the

loading space of the machine. If the loading

takes place from a ramp, PRESTO offers a

corresponding ramp funnel that guarantees

the necessary minimum height with regard

to safety.

This means, that the location of the loading

level has to be designed in such a way that a

minimum height to the load opening and to

the laterally fixed loading door (if any) does

not fall below 1100 mm. If the loading level

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 7

varies PRESTO will supply the corresponding

funnel.

When using a lifting/tipping device to empty

the containers according to the dimensions

shown in the appendix, care has to be taken

that no person stays in the swivel area of the

device. Loading from other containers is

regarded as improper use. Using externally

manufactured loading or suction devices is

subject to the agreement of PRESTO.

The user must be aware of the

power supply of the channel-

type baling press as well as

their interrupting possibilities.

Beyond this the user has to be

familiar with the instructions

according to BGV A2.

According to the chapter "Operation" of the

operating instructions the dangerous zones

have to be paid attention to.

Attention!

To avoid malfunctions it is indispensable to

have the maintenance and inspection work

performed at regular intervals. Changes in

comparison with the normal operation

(increased power consumption,

temperatures or vibrations, extraordinary

noise or odours, response of control

instruments, etc.) show that the function is

impaired.

To avoid malfunctions that may either

directly or indirectly result in serious

personnel or property damages, the

responsible maintenance personnel have to

be informed immediately..

Before taking the unit into operation all

protective devices have to be in protective

position and the locking devices and other

protective measures involved in the control

of the machine have to be in function. The

function of the operating elements has to be

checked.

The channel-type baling press must not be

used if the mains lead is not satisfactory.

Using electrical coupling devices and

adapters for the operation of the channel-

type baling press is not allowed. Only

plugging devices according to VDE 0113 acc.

to DIN EN 60204 may be used.

The mains plug may be replaced by a

qualified electrician only. In case of a

replacement of the mains lead or equipment

connecting line it is not allowed to deviate

from the type stated by the manufacturer.

The mains plug may not be plugged before

the channel-type baling press has been

properly installed at the location.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 8

Entering the shaft of the

channel-type baling press is

strictly prohibited.

Before taking the unit into operation make

sure that nobody will be endangered.

Watch turn-on transient and turn-off

transient as well as control lamps according

to operating instructions.

User - decide responsibility.

Enable the user the refusal of instructions

from third parties that impair safety!

Ensure that only authorised persons are

working at the machine. Please keep persons

who are not involved in the work process in a

distance.

The staff may not wear long loose hair, loose

clothes or jewellery including rings. There is a

considerable danger to be injured, for

example by getting caught or being trapped.

Switch off machine when having finished the

work and secure against unauthorised

reclosure (lock main switch).

Comply with adjustment and maintenance

work instructions for the replacement of

parts / part equipment.

This work may be performed by skilled

personnel with sufficient knowledge and

corresponding tools, only.

As far as necessary or if required by legal

provisions use personnel protective

equipment!

Observe protection against accidental risks

(Guideline of the council 2001/45/EC).

Wear protective gloves!

Use eye protection!

at places where there are solid airborne

particles or where dusts, caustic substances

or the like are processed or produced.

It is prohibited to erect platforms, ladders or

other aids.

If there is no possibility of supervision, the

operation has to be locked by the actuation

of the main switch that can be locked by a

key.

The cover to the cylinder room may be

opened for the purpose of cleaning,

maintenance or repair only. For this purpose

the channel-type baling press has to be

disconnected from the power supply.

Additionally the main switch has to be put

into "0" position and be secured against

unauthorised interference by means of a

padlock. After having finished the work care

has to be taken that the flap is mounted

again correctly.

When using oils, grease and other

substances, adhere to the safety regulations

and legal provisions valid for the product!

An immediate interruption by the user is

absolutely necessary if defects occur, which

impair the safety.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 9

These are:

• Failure of light barriers,

• Emergency-off switches and protective

devices

• • Damaging of electrical equipment and

lines as well as insulators.

In case of doubt immediately stop the

unit!

3.6.2. Danger areas

The danger area of the machine is limited to

the horizontal distance measurement of 1 m

to the external dimensions of the channel-

type baling press.

3.6.3. Reference to special dangers

Electrical energy

The machine will be supplied ready for

operation.

The power connection has to be provided at

the side, doing this the electrical safety

instructions, the regulations and the

electrical information in the chapter

"Electrical unit"

Attention!

The rotational direction of the electric

motor of the hydraulic pump has to be

strictly observed. A short time wrong

running destroys the hydraulic pump.

The motor is running correctly when the

ventilator wheel at the electric motor rotates

in the direction of the arrow at the housing

indicating the rotational direction and the

compressing die makes a movement

within 5 seconds.

If the compressing die does not make any

movement within this time turn off motor

immediately and change two phases of the

feed line by an electrical expert.

As the pump runs without oil flow in case of

a wrong rotational direction, the motor may

be turned on for a very short time only (5

seconds as a maximum).

Before working on electrical units or systems

these have to be switched dead.

The five safety rules before starting work:

• Switch off

• Secure against reclosure (switch off main

switch and lock)

• Ensure dead circuit

• Grounding

• Cover or screen of adjacent live parts

Funnel

Schematic view

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 10

3.6.4. Transport and loading

Use corresponding hoisting equipment and

proper securing measures:

Lift machine at intended loading point only

or use forks of forklift truck only at bearing

parts! See schematic view!

The forks only in places marked by the

Following sign set.

CC 13, Points of notice forks



Secure load against unintended changes of

the position.

Parts that are removed during transit have to

be mounted and fixed again before taking

the machine into operation again!

Transport safety devices and transport aids

have to be removed.

The machine has to be separated from every

external energy supply also in case of a slight

change of the location of the machine!

Before taking the machine into operation

again, the machine has to be connected to

the mains again properly!

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 11

3.7. Maintenance / Repair

Danger!

Staying in the dangerous zone

is allowed only during the

specially described work by

authorized personnel and/or

experts adhering to the

corresponding safety

instructions.

The maintenance of electrical equipment

may be performed by experts or instructed

persons only.

Before the inspection and cleaning of the

electrical equipment the unit must be dead

for the duration of the work.

The machine has to be turned off completely

during maintenance and repair work and be

secured against unauthorized reclosing (see

chapter "maintenance").

Before starting to work on electrical plants or

resources, de-energize them.

Do not switch. Work in progress Place: Date: This sign may only be removed by:

Attach a telltale sign prior and during work!

Danger!

Before taking the unit into

operation all safety

elements have to be

checked regarding their

function. All protective

covers and doors must be

closed and locked.

Inform operating staff about this point

before starting special and repair work!

Nominate a supervisory person!

Secure dangerous zone!

Tighten loosened connections properly again

during maintenance and repair work!

Dismantled protection- and safety devices

have to be properly mounted again and

checked regarding a tight seat before taking

the unit into operation again!

Use fuses in accordance with regulations and

current intensity only.

It is strictly forbidden to repair fuses!

Welding work on all supporting members are

prohibited.

Maintenance, cleaning and inspection work

may be performed during standstill and

turned-off machine and by authorized

personnel only. The padlock has to be

provided and locked at the main switch in

order to avoid unintended turning on. The

key has to be kept in a safe place by the

supervisory staff or the nominated qualified

personnel.

Keys and tools by which the channel-type

baling press can be put into operation and/or

protective devices can be dismantled, must

be in possession of the instructed authorized

person or be kept in a safe place.

Electrical components or control elements

must not be directly splashed with water.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 3 - 12

The use of flammable materials (e.g. petrol is

forbidden – BGV A1 § 43 and 44! During

cleaning work, repairs, etc. the main switch

(1) always has to be locked in 0-position with

a padlock.

Operating fuels (e.g. gear lubricant oil) during

maintenance, repair work and oil changes

have to be collected in appropriate vessels

and disposed of according to the regulations

(EC guideline 75/439/EEC and decrees, 5a, 5b

AbfG and AltölV).

3.8. Liability and warranty

The completeness of the scope of delivery

according to the delivery note has to be

checked upon receipt of the machine.

If parts are missing or transport damages are

found, please inform PRESTO GmbH & Co. KG

immediately.

The supplied unit has been constructed

according to the latest state of the art and

the accepted safety standards (DIN 12100

part 1 and 2 and DIN EN 60204 T1 and

DIN ISO 13849).

In case of improper use and non-compliance

with the regulations, dangers to life and limb

and trouble of the machine or other tangible

assets might occur.

The PRESTO channel-type baling press

primarily serves for the compaction of soft

materials as paper, cardboard, foil, etc.

Another or surpassing use may be regarded

as improper use. PRESTO GmbH & Co.KG will

not be liable for damages resulting from this.

The risk will solely be borne by the user of

the machine.

Operate unit in a technically good order and

according to the regulations.

This requires the adherence to the applicable

regulations of the accident prevention and

the accepted

technical regulations for safety and proper

working and the operating instructions,

inspection and maintenance regulations valid

in the country of the user and at the location.

Modifications, extensions and

changes of the design of the

machine must not be made

without the approval of

PRESTO GmbH & Co.KG.

3.9. Product liability

If non-compliance/non-adherence to the

regulations and instructions of this operating

manual leads to accidents with personal

injury or property damage, PRESTO GmbH &

Co.KG will not be liable for any

damage and the compensation of indirect

damage as injuries of persons, damage to

goods, which do not form the subject of the

contract, loss of profits and production

failure which will be directed to PRESTO

GmbH & Co.KG under the title

"PRODUCT LIABILITY".

3.10. Warranty

PRESTO will accept the warranty for the unit,

provided that the operating and

maintenance manual is adhered to.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 4 - 1

4. Technical data

Type CC-13 fully automatic

Pressing power kN 130

Spec. pressing power N/cm2 24,8

Channel cross section mm 700 x 750

Charging opening mm 750 x 750

Filling volume max. m3 0,39

Power kW 5,5

Volume in idle running m3/h 59

Volume under operating conditions m3/h 50

Weight related to the apparent density t/h

- 35 kg/m3 (department store) t/h 1,7

- 60 kg/m3 (mixed products) t/h 2,5

- 100 kg/m3 (collected products) t/h 3,8

Bale weight Depends on and bale length

Machine weight approx. t 1,9

Tie off – threefold vertically wire ∅ 2,8

Electric connection – standard plug CEE form, 5

pole, fuse protection

A 16

Lifting time s 24





Charging opening m3 1000 x 750


Power kW 7,5







Bale weight Depends on and bale length



Electric connection – standard plug CEE form,

5 pole, fuse protection

A 32

Lifting time s 24

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 4 - 2







Power kW 11,0







Bale weight Depends on material and bale length





A 35

Lifting time s 34







Power kW 15





- 60 kg/m3 (mixed products) t/h 4


Bale weight Depends on material and bale length


Tie off – threefold vertically Wire 2,8-3,1



A 35

Lifting time s 34

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 4 - 3

Dimensions (mm)

Typ A B C D E F G H L M

CC-13 V 1225 1475 1830 380 1050 600 1560 1400 2800 750

CC-20 V 1225 1475 2030 380 1135 700 1900 1650 3300 750

CC-30 V 1225 1475 2130 380 1350 700 2540 1800 3700 950

CC-40 V 1275 1575 2200 380 1640 750 2540 1800 4200 1100

M = Semiautomatic V = Fully automatic

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 4 - 4

4.1. Sound emission

The sound intensity level was measured according to EN 23744.

The sound intensity level is stated according to MRL Appendix I, point 1.7.5. f in a free sound

field in a distance of 1 m from the machine and a height of 1.6 m with the highest measured

value.

The sound intensity level measured at the channel-type baling press of the types

• CC-13,

• CC-20,

• CC-30 and

• CC-40 V

is < 75 dB(A).

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 5 - 1

5. Constructive description

5.1. General

For a better representation of the components

we have dispensed with protective covers in

some cases.

Danger!

Before taking the unit into

operation it has to be

ensured that all protective

covers, flaps or sheets have

been duly mounted. They

serve for the protection of

the staff, however, also for

the proper function of the

machine.

The PRESTO channel-type baling press has

been constructed for the compaction of soft

materials as paper, cardboard, foil, etc.

It is prohibited to load explosive or

assimilated materials or inflammable

materials (according to §1 SprengG).

When erecting the unit and taking it into

operation the guidelines of the water

household and environment protection law

have to be adhered to.

Materials that are subject to special conditions

for the disposal according to the waste disposal

law must not be loaded.

Furthermore it is prohibited to fill in rumble,

timber or other bar racks from metal or other

hard materials.

Glowing or burning particles must not be

loaded.

The channel-type baling press is controlled

by a stored program control (SPC). The

compaction of the material is effected by a

compressing die which is moved in the

pressing channel by means of a hydraulic

cylinder. According to the design the pressed

material is tied up to a bale automatically (V).

These operating instructions generally apply

for all machine types of the channel-type

baling press Conti-Compact CC-13, CC-20, CC-

30 and CC-40 V.

The above illustration only shows machine

type CC-20V.

In case of constructive deviations this is

stated extra. In order to simplify matters the

operating instructions refer to the channel-

type baling press.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 5 - 2

5.2. Basic construction

The basic construction is a steel construction

and, on the whole, it is the housing (A) for the

following components:

• the compressing unit (see section 5.3),

• the channel adjustment (C),

• tie-off device (D) with cover,

• the electrical unit (E), with

• the stored program control - SPC - (F),

• the hydraulic unit (G),

• the funnel with (H) safety circuit.

The components cannot be shown completely

in the following illustration. However these will

be dealt with more thoroughly in the individual

sub-chapters 5.3 to 5.7.

5.3. Compressing unit with channel

adjustment

This assembly is responsible for the compaction

of the material filled in the charging opening.

The assembly mainly consists of the following

components:

Baling channel with press body (1),

Telescope sheets (2),

Polyamide guide rails (3) for the press body,

Polyamide guide rails (4) for the telescope

sheets,

Hydraulic cylinder (5), see hydraulic unit,

Channel adjustment sheets (6) with

tightening elements (7), and plate for bale

rest.

The press body is moved in the baling

channel by means of two hydraulic cylinders.

The movement of the press body is guided

by polyamide rails. Telescope sheets, which

protect the space behind the press body

against material falling into it, are pulled out

during the pressing movement.

Knives (9) are provided at the upper side of

the press body or the underside of the

channel entrance. At their cut edge the

knives cut the material filled in. They prevent

the pressure build-up on the upper side of

the press body and thus avoid excessive wear

at the polyamide guide rails.

PRESTO

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04/2012 5 - 3

The material to be compacted is pushed into a

narrowing channel. The narrowing avoids that

a back pressure is building up. A retaining

device avoids the compacted material from

getting back into the pressing channel.

Retaining device – on both sides

As extra equipment the installation of a

hydraulic channel adjustment is possible. You

will find the corresponding description in

chapter 5.3.1.

Retaining device – from the inside.

While the compressing process starts, tie-up

material is fed by several rollers on the one

side of the forming bale. While the bale grows

both in volume and length tie-up material is

pulled over and under the bale. This tie-up

material later on, after the requested bale

length has been achieved, serves to tie up

the bale.

5.3.1. Hydraulic channel adjustment

Four hydraulic cylinders are mounted at the

channel outlet.

The material to be compacted is pushed into

a narrowing channel. Channel narrowing

causes counter-pressure to build up. A

retaining device (10) is used to keep the

compacted material in the press chamber

(see page 5-4).

Cylinder for hydraulic adjustment

PRESTO

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04/2012 5 - 4

5.4. Hydraulic unit

The hydraulic unit of the channel-type

baling press generates heat that has to be

dissipated by the customer by corresponding

ventilation and/or waste air openings.

If the machine is erected in rooms with a

permanent temperature of more than 30° C

the installation of an oil cooler might be

necessary. Our sales or service department will

be glad to advise you correspondingly.

The assembly "Hydraulic unit" is responsible to

provide the hydraulic pressure which is

required for the compaction of the filled in

material.

The electrically driven hydraulic pump, gear

pump design, provides the hydraulic unit with

the required operating pressure. A valve has

been installed as an overload protection which

protects the hydraulic unit against excessive

pressure.

The assembly "Hydraulic unit" mainly

consists of the following components:

(1) aggregate (hydraulic part)consisting of

the hydraulic pump in the hydraulic tank (2)

and filter unit (3 ), valve block (4) ,

exhauster (5), pressure gauge (6).

PRESTO

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04/2012 5 - 5

• Two hydraulic cylinders (7),

• Hydraulic lines (10),

• Temperature display (8) – optional

• Switch - lack of oil/temperature (9).

The hydraulic pump of the aggregate cannot

be illustrated because it is positioned in the

hydraulic tank.

8

Switch-lack of oil

PRESTO

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04/2012 5 - 6

5.5. Electrical unit

The electrical works may be

carried out by an authorised

qualified electrician only!

Bauseitige Voraussetzung zur Installation der

Kanalballenpresse ist 400V und 50 Hz.

Type CC-13

Anschluss 3L, PE, 400 V, 50 Hz,

5,5 kW, Drehstrom

Netzanschlussleitun

g

4 x 2,5 mm2

Gummischlauchleitun

g

FI-Schutzschalter: 30 mA

Vorsicherung: 16 A, träge Sicherung

nach DIN 49462/63

Type CC-20


7,5 kW, Drehstrom

Netzanschlussleitun

g

4 x 6 mm2



nach DIN 49462/63

Type CC-30


11 kW, Drehstrom

Netzanschlussleitun

g

4 x 10 mm2



nach DIN 49462/63

Type CC-40


15 kW, Drehstrom

Netzanschlussleitun

g

4 x 10 mm2



nach DIN 49462/63

The a.m. fuse protection and FI-switches

must be observed even if larger plugs with

adapters are used.

Attention!

It is absolutely necessary to

ensure the correct rotation

of the electric motor. A

short time reverse run will

destroy the hydraulic pump.

The motor is running correctly when the

ventilator wheel at the electric motor rotates

in the direction of the arrow on the housing.

As the pump runs without oil flow in case of

wrong rotation, the motor may only be

turned on for a very short time (5 seconds as

a maximum).

The assembly "Electrical unit" controls the

machine and supplies it with electrical

energy.

PRESTO

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04/2012 5 - 7

• Switch box (1) with relay (2) motor

protection switch (3), fuses (4) and

operating elements, stored program

control (5) and wiring,

• Limit switch, press in front (B33)

• Limit switch, press backwards (B31)

See fig. “Overview limit switches”, page 5-8

B33

B31

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04/2012 5 - 8

Overview limit switches

B30 Puls generator bale length

B31 Stop position press backwards

B33 Stop position press in front

B34 Stop position needle down

(left side)

B35 Stop position needle down

(right side)

B36 Stop position needle up

B37 Puls generator drill

View from the right sight of the machine

View from the left sight of the machine

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04/2012 5 - 9

• Pulse generator (B37), drill

• Pulse generator (B30), bale length

• measuring wheel bale length (16)

See fig. “Overview limit switches” page 5-8

You will find information with regard to

maintenance and care in chapter 7.

5.6. Tie-off device

5.6.1. Fully automaticl tie-off device

The assembly of the manual tie-off device

consists of the following components:

Drill and cutting device (15),

Limit switch for needle down, operation

(B35),

limit switch for needle up (B36)

See fig. “Overview limit switches” page 5-8

PRESTO

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04/2012 5 - 10

If the desired bale length has been achieved

the compressing die will stop in the front final

position. The drilling discs make a half way

rotation and transport the upper wire in one

opening. The lower wire is led from the needle

as a loop upward and laid into the free opening

of the drilling disc (⇒). After a number of

rotations of the drilling disc the drilling process

is finished with a return rotation and the

subsequent cutting.

Drilling disc

You will find the detailed description with

regard to the operation and the sequence of

the tie-off process in chapter 6 "Operation".

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 5 - 11

5.7. Attachable funnel with safety

circuit

Attention, danger of

crushing!

Do not climb or reach into

loading opening!

Danger!

This assembly is responsible to observe the

minimum safety height of the loading opening

of 1100 mm above the loading level. The

attachable funnel becomes necessary, if the

channel-type baling press is loaded by means

of a ramp.

(A standard funnel with revision door (25) and

safety switch (S2) is shown.

The assembly mainly consists of the following

components

• Charging funnel with installation

material,

• Light barrier (see chapter 11 "Appendix,

special equipment")

• Safety switch.

PRESTO will adapt the attachable funnel to

the local conditions. As a rule the channel-

type baling press and the attachable funnel

have to be installed at the customer's

according to the enclosed project plans.

Attention!

The installation of the funnel

may be carried out be

specialists only!

You will find further information in chapter

11, "Appendix / special equipment"

25

S2

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 6 - 1

6. Operating elements and operation

6.1. General

The channel-type baling press has left our

plant ready for operation. Please check

stationary compression unit for damages by

visual inspection and function test and

inform your forwarding agent immediately

about possible complaints.

Works at/with the unit may

only be carried out by

instructed, reliable staff

and/or by experts.

In general the function and operation of all

types of channel-type baling presses is

similar. There are, however, differences with

regard to the pressing power. This results in

considerable differences in the control and

work sequence.

Prior to the commissioning make sure what

kind of channel-type baling press you use

(see type plate and chapter 4 "Technical

data").

Any accessories, which form part of the

special equipment, are described in the

following point. You will find a more detailed

description with regard to this extra

equipment in chapter 11 "Appendix, special

equipment."

6.2. Operating elements

This section describes the operating

elements of the channel-type baling press

CC-13, CC-20, CC-30 and CC-40 with fully

automatic tie-off device.

With respect to all types of channel-type

baling presses the essential operating

elements necessary for the operation are

located centrally in the switch box. If

applicable there might be a Button bar in the

rear area of the unit.

Switch box for channel-type baling press

Type CC-13V, CC-20V, CC-30V and

CC-40V

>> fully automatic tie-off device <<

1. Main switch

2. "Start" Button

3. Illuminated switch "Operation"

4. "Emergency-off" switch

5. Button "Press forward"

6. Button "Press backward"

7. Button "Needle up"

8. Button "Needle down"

9. Selector switch "Twisting"

10. Selector switch "Cutting"

PRESTO

GmbH & Co. KG

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04/2012 6 - 2

For detailed description of adjustment

possibilities of the touch panel see page

6-11.

6.3. Works prior to initial commissioning

You will find information with regard to

transport and loading in section 6.6

"Transport and loading".

First check the unit for completeness of

supplied parts. Use the enclosed shipping

documents for this purpose.

The unit may be erected by

qualified staff with the

corresponding specialized

knowledge only (Explanation

see chapter 7, page 1).

Project documentation and wiring diagrams

of the manufacturer are enclosed to the unit.

The unit has to be installed and connected

according to these plans.

Place unit on a plain base. The base must be

capable of bearing the unit permanently. It

must be possible to screw the legs of the unit

with the base. In order to fix the unit you

should use heavy-duty dowels and

corresponding screws (see enclosed project

documentation).

Leave sufficient space around the machine as

shunting area for industrial trucks.

Screw the sheet, i.e. the "bale slide" (50)

contained in the scope of supply with the

bottom side of the channel

(see fig. page 6-3).

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 6 - 3

A qualified electrician has to

provide and to check the

correct electrical connection.

Doing this the relevant VDE

regulations and/or the

regulations of the country

where the unit will be used

have to be observed.

Furthermore the wiring

diagrams of PRESTO have to be

observed.

When erecting and taking the unit into

operation the guidelines of the

environmental protection law and the water

household law have to be adhered to.

Carry out the following checks now:

• See to it that it is not possible to damage

the mains connection by running over,

crushing or dragging.

• check all hydraulic lines and screwing for

tight fit and obvious damages..

• Check whether all screwed connections

were properly tightened.

• Check the electric installation.

• Check function of all protective devices

(see chapter 7). Never bring into

commission without all security devices

working perfectly.

In case of fire in the switch box

only use fire extinguishers

permitted for this purpose. NO

WATER!

Prior to the initial

commissioning the

operator of the unit must

have read and understood

the operating

instructions.

It is possible to stop the

unit immediately in case

of danger by pressing the

emergency-off switches.

Carry out the following works every day

before taking the unit into operation:

• Visual inspection for obvious damages at

mechanical or electrical components. It is

prohibited to take the unit into operation

if one protective device does not work

properly.

• Check the protective devices in chapter 7

for correct function.

• In case of strong pollution the unit has to

be cleaned. Prior to cleaning put main

switch into "0" position and secure with a

padlock against unauthorised

intervention. Close and lock all protective

covers or doors or inspection flaps after

the cleaning.

• Check whether there is sufficient binding

wire on the coils.

• All further regular works have to be

carried out according to the maintenance

plan.

PRESTO

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04/2012 6 - 4

6.4. Compacting process

Attention! Danger of

crushing!

Never climb into charging

opening while the channel-

type baling press is in

operation.

Operation mode "Manual"

This operation mode is normally intended for

maintenance and repair works.

The unit is ready to use, i.e. the safety switch

is unlocked, the covers are closed.

Ensure that no persons are endangered.

• Switch on main switch, press button

operation, light “operation” is lighting.

• Put operation mode selector switch into

"Manual" position

• Press "Start" Button, the hydraulic pump

starts up.

• Move selector switch "Press

forward/back" into desired direction and

keep as long as the press is to be moved.

When running forward care has to be taken

that in the front final position there is not

cut-off by the limit switch. Observe the

pressure gauge. If the press is drawn back

manually the rear limit switch cuts off the

valve automatically when having reached the

limit switch.

Operation mode "Auto"

See to it that no persons are

endangered by the operation

of the unit!

For the fully automatic tie-off device you

should use coiled binding wire. In order to

safeguard a proper function you should use

binding wire which you can acquire through

our service department.

Properties:

• Binding wire for CC-13V and CC-20V on a

20 kg-coil, patent coiling, 2.8 mm

diameter, close annealed and oiled.

• Binding wire for CC-30V and CC-40 on 40

kg-coil patent coiling, 3.1 mm diameter,

close annealed and unoiled.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 6 - 5

Note:

Always use binding wire with the a.m.

properties. Binding wire that does not

correspond to the specification may lead to

trouble in the work sequence. You will find

the part numbers in chapter 10, spare parts.

• Throw the material into the charging

funnel. Fill the shaft up to slightly above

the counter knife.

Make sure that no pressing strokes are

effected if the filled in material is not slightly

above the counter knife.

• Check whether there is sufficient binding

wire on the coils.

• Put operation mode selector in "Auto"

position.

• Switch on main switch, press "Operation"

key. The flashing of the control lamp

indicates the readiness for operation of

the unit.

• Press "Start" key (4). The unit starts up

and starts compressing.

• If the funnel has been filled up with

sufficient material and the compressing

die is in its end position, the machine

starts automatically via the installed light

barrier.

The unit will check after the start

whether the compressing die is in the

rear position. The compressing die returns to

the back limit position and the pump is

switched off.

• The length of the bale permanently

increases. It is continuously collected by

the pulse generator and indicated.

6.4.1 Operation mode "Manual"

General

The manual operation modes

described in the following

assume that the operation

mode selector switch is put in

"Manual" position. The

operation mode "Manual"

has to be used for the

threading of a new binding

wire and for maintenance,

repair and adjustment works.

• Switch on main switch, press button

operation, light “operation” is lighting.

• Put operation mode selector switch into

"Manual" position

• Press "Start" Button, the hydraulic pump

starts up.

• Move selector switch "Press

forward/back" into desired direction and

keep as long as the press is to be moved.

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04/2012 6 - 6

Needle upward / downwards

Condition: The final limit switch (B33)

"Press in front" is actuated. This is the case

when the compressing die is in the front final

position.

• Press key "Needle up" and hold. The

valve for” Needle up” is switched on as

long as the key is pressed.

The needle runs through the

compressing die upward until the limit switch

"needle up" (B36) switches. If the hydraulic

cylinder for the needle has fully extended and

if the switch is further kept in "needle

upward" position the pressure at the

hydraulic cylinder will increase to the

maximum pressure of 130bar.

Needle down

• Press key "Needle up" (7a) and hold.

The needle moves downward until the

limit switches "needle at the bottom" switch.

Needle from the "operating position" to

"threading position"

Conditions: The needles are in the basic

position, i.e. the limit switches "needle at the

bottom" (B34/B35) are actuated. The

compressing die is in the rear limit position,

i.e. the limit switch (B31) "Press at the rear"

is actuated.

• Press key (7b) "Needle down". This

process takes about two seconds.

The needle moves into the lowest

position, i.e. up to the limit stop. The

threading position has been reached. The

compressing die cannot be moved now. A

new lower wire can be threaded in now.

B33

B31

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04/2012 6 - 7

Needle from " Threading position" to

"operating position"

Conditions: The needles are in threading

position, i.e. the limit switches "needle at

the bottom" (B35) are not actuated. The limit

switch “Needle in threading position” (B34) is

actuated. The compressing die is in the rear

limit position, i.e. the limit switch (B31)

“press at the rear" is actuated.

• Press key (7b) "Needle up".

The needle drives forward up to the

limit switch "needle at the bottom"

(B34/B35). The needle is in basic position.

The compressing die can be moved again.

Twisting

• Press key "Twisting" (8a) and hold.

The drilling disc carries out a half

rotation. The pulse generator simultaneously

switches "Drill" (B37). Thereby the wires are

not cut.

Cutting

• Press key "Cutting" (8b) and hold.

The drilling disc carries out a half

rotation anticlockwise when drilling. The

cutting-off will not yet be made. The cutting-

off is possible when the cutting-off device is

held by the stop. The wires are cut off after a

new actuation of the key "Cutting" and a half

rotation of the drilling discs.

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04/2012 6 - 8

Visible only right side of the machine

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04/2012 6 - 9

Adjustment of pressing power

As a standard design the unit of CC13V and

CC20V are supplied with manual channel

adjustment. Optionally a hydraulic channel

adjustment with control can be supplied. You

will find the description of the hydraulic

channel adjustment in chapter 11.

The pressing power depends on the

backpressure of the material in the channel.

In order to achieve this back pressure the

cross section in the direction of the channel

outlet becomes smaller.

The back pressure of the material depends

on the following factors:

• Coefficient of friction of the channel walls

which slightly reduces after the running-

in period of the unit,

• Coefficient of friction of the material to

be compacted. This can vary very strongly

(e.g. relatively high with respect to

cardboard and relatively low in case of

foils),

• The fill height in the fill in funnels by the

start of the press procedure. The fill in

funnels must be filled up to the upper

edge of the press body with material at

least, so that the channel discharge is

filled evenly.

• Adjustment of the tensioning elements

(10) on both sides of channel outlet

which must be changed especially during

the running-in period and in case of

material change.

The adjustment is correct if during the

forward stroke phase approx. 140 - 160 bar

are indicated at the pressure gauge. For this

reason the pressure gauge has to be

observed as a rule after material changes.

PRESTO

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04/2012 6 - 10

Attention!

Never fall short of the measurement of 65

mm (the spring package is almost completely

pressed together).

PRESTO

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04/2012 6 - 11

Adjusting the compaction pressure

hydraulically

The compaction pressure depends on the

counter-pressure of the material in the

channel. To achieve this counter-pressure,

the channel is narrowed by means of 4

hydraulic cylinders.

The counter-pressure of the material

depends on the following factors:

• Coefficient of friction of the channel

walls, which decreases slightly during the

plant running-in period;

• Coefficient of friction of the material to

be compacted, which varies highly (e.g. it

may be relatively high for cardboard

packaging and relatively low for plastic

films).

• The fill height in the fill in funnels by the

start of the press procedure. The fill in

funnels must be filled up to the upper

edge of the press body with material at

least, so that the channel discharge is

filled evenly.

6.4.2.1 Adjust bale length, twist

The unit must be switched on

during these adjustment

works. Therefore ensure that

no persons are endangered

during your activities. Visibly

fix a sign in order to point to

the adjustment works. Any

other procedure will be

pointed out extra.

Adjusting bale length (8)

Factory adjustment: 20

Potential range of adjustment:

13 counting pulses = about 0.65m

50 counting pulses = about 2.5m

(One counting pulse corresponds to about

0.05m)

If you want an adjustment that differs from

the factory value, proceed as follows:

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6.5 Control- and programdiscription

Main menu

Fig. 1: Main menu

Navigation and adjustments with Touch

Panel

With the button „Menu“ in the starting

picture you get to the window „main menu“.

In the main menu of the press different

menu entries can be chosen, e.g. show

„machine-data“. Adjustments can be edited

after entering a password in the menu entry

„settings“ (see “Settings”).

Options

Fig. 2: Options

Pressing the button „Options“ the window

will open. Additional control and display for

the control of the conveyor (if existent) can

be found here.

A pre-selector for the limit position

disconnection of the compactor decides

whether the ram stops in front or rear

position after pressing.

Machine Data

Fig. 3: Machine data

Following menu entries can be found in

„machine-data“: bale counter, daily bale

counter and the graphics of the pressure at

the moment (shown in “bar”). The bale

counter indicates the total sum of wired

bales. The daily bale counter counts the

bales and can be reset to “0” after entering

the password.

Key assignment in main menu:

F1-> display help

F2-> user login

F3-> language choice

F4-> show message buffer

F5-> lamp test

F6-> standard picture press

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Pre-selection pressure level

Fig. 4: Preselection pressure level

With menu entry „pre-selection pressure

level“ the desired pressure level for the

material can be chosen. The values for the

different pressure levels are edited

separately in the menu „settings“.

Language choice

Fig. 5: Language choice

The menu entry „Language choice“ can be

activated out of the main menu or settings

menu.

Menu Settings

Fig. 6: Settings

Via „main menu“ you get into the menu

entry „settings“ after entering the „User“

password (see entering password).

With the suitable function key you reach

further settings such as „time setting“ and

„system settings“. „System settings “ are

protected with a „PRESTO“ password (*see

entering of password).

Key assignment

„Settings“:

F1-> display help

F2-> login user

F3-> language choice

F4-> time settings

F5-> system settings

F6-> main menu

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Entering the password

Fig.: Entering the password

Some of the menus and functions are

secured with a password. Whenever a

password is needed, a window opens to

enter the password. Authorization is effected

by login of the user and the password.

Basically there are two levels of passwords.

First the „USER“ password level which is for

the operator and secures operation of the

press as well as settings of modification by

unauthorized persons. The second password

level „PRESTO“ secures system settings of

modifications by unauthorized persons and is

intended for the service technicians.

To login user and password the entry field of

the login screen has to be actuated (see fig.

password inquiry). The password or the user

name can now be entered with the touch

screen and has to be confirmed with enter

(fig.: entering password). The USER password

is „100“.

Next the user name and the password have

to be confirmed with the button „OK“ (see

fig.: Password inquiry). If the password is

correct the user has access to all

corresponding menu entries and functions.

Unless an error message appears.

Setting of material pressure levels

Fig.: Pressure level „High“

Fig.: Pressure level „Middle“

Fig.: Pressure level „Low“

The values have to be set separately with the

corresponding buttons in the menu “settings.

Following pressure stages according to the

material:

Pressure level „High“ = Material: corrugated

board, paper, cardboard or similar.

Pressure level „Middle“ = Material: PET, PET-

bottles or similar.

Pressure level „Low“ = Material: Foil or

similar.

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Following values can be set:

Bale length 13 – 50 (1 = ca. 5-

6 cm.)

Half twist turnings 11 – 18 (1 = ½

twists)

Half backstroke in sec. 4 – 20 sec.

Relief pressure „nominal“ in

bar

10 – 260 bar

Channelpressure „nominal“

in bar

10 – 250 bar

Time setting

Whenever the time set does not correspond

to the actual time, time and date can be

changed via menu entry „time setting“..

System settings

System settings include internal settings of

the touch panel and can only be modified

from our service technicians (fig.: system

settings).

System time

Input fields

Button „Entering Input“ (press

longer than 1 sec.)

Contrast

regulation

Button „funnel door

yes/no“ (press to

choose)

Button „View right/left“

(press to choose)

Shut down

Touch Panel

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6.6 Insert binding wire coils

Inserting the lower wire

Loading the wire containers or the large roller stations with wire.

Master switch ON (13)

Selector switch to „Manual“ (8)

Press Operation button (9). System is ready for operation.

Press Start button (1). Electrical motor and hydraulic pump (20) are running.

Pressing ram backwards (button 3b). Press and hold button “ram backwards”. Ram

moves backwards until end position (B31) is reached and valve is closed.

Needle in threading position: Pressing ram must be completely retracted; press the

Needle down button (4b). Needle moves down and stops in Threading position

(only B34).

Pulling in the wire Straight align the wire and pull in.

Threading position Operating position

Threading example for the lower wire for CCV

1 through the spring winding at the end of the press 2 through the drill bushes at the rear support legs 3 through the needle profile above the needle head 4 pull wire through to the end of the channel

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Retract needle to operating position. Pressing ram is retracted (rear). Press and hold the

Needle up button (4a). Needle moves up and stops in the Operating position (B34 + B35).

Inserting the upper wire

a) Pull the wire through the wire deflection pulley as shown below. Push the wire as far

as possible through the opening in the press shaft

b) Close all doors/covers

c) Select Automatic operating mode (8)

d) Press Operation button (9).

e) Perform approximately 2 – 3 press operations with the material until the upper wire

is tight.

f) During the subsequent extension of the pressing ram, rotate the bale length wheel

(B30) until Binding is indicated on the Touch panel (or if existent the light signal

Binding flashes).

2 3 4 1

Bale length

wheel

Binding signal

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Once the binding process is completed, check the quality of the connection of the upper

and lower wire above the knotting device; make some improvements, if necessary (the

pre-tensioning of the wire, which occurs during normal operation, has not been applied

yet)

The processes 12 and 13 have to be carried out together at least twice with the

operating personnel.

Good knot Knot too loose

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6.7 Transport and loading

Before the transport and loading work take

place the following accident prevention rules

have to be adhered to:

BGV D8 Gear, lift- and draft devices

BGV D6 Load bearing facilities

BGV D27 Ground conveyors

BGV D29 Motor vehicles

BGV A8 Safety labelling at the

workplace

Use corresponding lifting devices and proper

securing measures (for information

concerning the maximum permissible weight

see type plate or chapter 4 "Technical data"

in these operating instructions).

Lift device at the intended

lifting points only. Secure

load against unintended

changes of the position.

Separate unit from every external energy

supply also in cases of a slight change of the

position!

Parts that are removed for transport

purposes have to be mounted and fixed

before taking the unit into operation again!

Remove transport safety devices and

handling systems

See to it that no persons

stay under the suspended

load.

Connect unit to the mains before taking the

unit into operation again.

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Using a forklift truck

Adhere to accident prevention rules BGV D27

and D29. Empty the unit completely.

• Separate unit from mains and place

supply cable on the unit bound together.

• Disassemble all projecting parts or lead

the tie-up material over such parts.

• Only drive under bearing frame parts

with forks (directly under machine

housing), never drive under needle

guide and/or hydraulic cylinder.

• Tie-up unit on a transport vehicle by

diagonal attachment or make use of the

existing eyes.

• Disassemble all projecting parts at first

and/or do not lead tie-up material over

such parts.

Lift machine at intended loading point only

or use forks of forklift truck only at bearing

parts! See schematic view!

The forks only in places marked by the

Following sign set.

Example: CC 30, Points of notice forks

Example: CC 40, Points of notice forks

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7. Maintenance

As a rule it is recommended to conclude a

maintenance agreement with PRESTO. The

maintenance will be carried out twice a year

by our service department. Because of the

special knowledge of our service mechanics

sources of trouble are found in time and can

be corrected.

Attention!

Safety equipment for the

prevention or elimination of

hazards must be maintained

at regular intervals

according to § 39(3), BGV A1

- General regulations and

must be checked with

respect to their proper

function at least once per

month by a qualified person.

A qualified person is

someone who on the basis

of his special training has

sufficient knowledge in the

field of the used machine.

Furthermore the qualified

person must be familiar with

the relevant on-the-job-

safety provisions, accident

prevention rules, guidelines

and generally accepted

technical rules to such an

extent that he/she can judge

the safe condition of the

used machine.

For channel-type baling presses which are

operated outside of the application area, the

existing regulations and guidelines of the

user country will be valid.

7.1. General

Safety covers held in place by bolts which fit

through keyhole-shaped slots are removed

from the machine by loosening the bolts 3 or

4 turns. The bolts should remain in the drill

holes. The cover can now be slid along the

keyhole and removed by lifting over the bolt

heads which fit through the round, upper

keyhole aperture. The covers are replaced by

reversing the sequence.

For a better presentation

we have left away the

protective covers in some

illustrations. The channel-

type baling press may be

taken into operation with

properly fixed or closed

protective covers only.

In case of maintenance and repair works the

machine has to be cut off completely and be

secured against unauthorised reclosing.

Danger!

Staying in the danger zone is only permitted

during specially described works for

correspondingly instructed personnel

and/or qualified experts whereby the safety

instructions have to be adhered to.

ATTENTION!

All works, such as commissioning,

maintenance and repairs may be carried out

by qualified personnel only and/or have to

be controlled by responsible experts.

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The operator of the unit has to notify his

superior as soon as possible about any

occurring trouble or irregularity. The same

applies for mechanical and electrical

equipment.

See to it, that the operating instructions

belonging to the channel-type baling press,

the maintenance and special tools and

devices, the oil cans and grease guns

required for lubrication is always kept in the

provided receptacles.

When dealing with oils, greases and other

substances the specific safety regulations

and legal provisions which are valid for the

product have to be observed!

Observe adjustment and maintenance works

described in the operating instructions

including information for the replacement of

parts/partial equipment!

These works may be carried out by qualified

persons with sufficient knowledge and

corresponding tools.

Danger of injury! Before

carrying out any cleaning

and maintenance work,

always check the area for

foreign matter such as

sharp-edged material, one-

way injection needles etc.

Also check whether

contaminated materials

have been compacted.

Contact the operators before if required.

Non-compliance may cause severe health

problems.

7.2. Cleaning

Properly clean the unit weekly or in case of

excessive pollution.

Cut off electrical current

prior to starting the

cleaning.

Put main switch (1) in "0" position, pull out

yellow safety bow and secure with a padlock.

Do not direct water nozzle directly to

electrical components, bearing- and

lubrication points.

Inspect and clean the area (1) behind the

press body.

Inspect and clean the hollow spaces on both

sides in which the lateral beams of the press

body are immersing.

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Be sure to check the guide grooves of the

telescopic plates once a month for blockage

or

material accumulation and eliminate if

necessary.

7.3. Maintenance

7.3.1. Maintenance schedule

On the following pages you will find a list of

the maintenance works with information

with respect to the maintenance interval and

reference to the description of the work.

The maintenance of electrical equipment

may be carried out by experts or instructed

persons only.

Meaning of the abbreviations:

A = works, that can be carried out by

the operator of the machine

F = works that have to be carried out

by an expert (e.g. PRESTO service

mechanic)

Abbreviation for the intervals:

T daily

W weekly

M monthly

H every six months

J annually

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Electrical system Interval Page Resp.

person

Controls on the switch cabinet and control bar: function check T A

Main switch and Emergency OFF switch: function check T 7-17 A

Motor protection relay: function check J 7-14 F

Wiring in the switch cabinet and on machine housing: visual check J 7-10 F

Power cable: visual check W 7-10 A

Safety switch on side service doors, needle hatches: function check T 7-9 A

Safety switch on twister hood: function check T 7-9 A

Safety switch on service door in the hopper: function check T 7-8 A

Terminal position switch for emergency pull line (optional): function check W A

Ventilation hood on electrical motor: check for cleanliness T A

Automatic start system (optional): check function and cleanliness W A

Hydraulic system

Hydraulic aggregate and fittings: check condition and tightness H A

Hydraulic oil: check condition and oil level and refill if necessary M 7-11 A

Filter insert and ventilation filter: replace J F

Hydraulic hoses and fittings: check condition and tightness H A

Hydraulic lines and fittings: check condition and tightness H 7-15 A

Hydraulic valves: check tightness H A

Hydraulic cylinder (main, needle, twister, channel): check tightness and condition H 7-16 A

Compaction pressure: check setting acc. to specification J F

Other hydraulic accessories: check function and tightness H A

Oil change J 7-17 F

Mechanical system

Plunger: check condition and wear J F

Plunger setting in channel: check and adjust if necessary M A

Polyamide guides on plunger: check for wear M 7-14 A

Telescoping sheets: check the condition J F

Polyamide telescoping sheet guides: check condition and wear M 7-14 A

Cutting gap on the plunger: check and adjust if necessary W 7-12 A

Counter-blade and blade on the plunger: check condition and wear W 7-18 A

Compaction channel floor: check condition and wear J F

Needle guide rollers: check cleanliness and wear W A

Needle head: check condition and wear M A

Binding system: check function and cleanliness T A

Twister disks: check the setting T 7-13 A

Twister chain: check the condition, lubricate, adjust and re-tension if necessary M 7-13 A

Twister blade: check wear and movability W A

Polyamides in the twister: check for wear J F

Retainer: check function W 7-19 A

Locking pins on hydraulic cylinder: check wear and lubricate J F

Press bar on channel outlet: check the securing pin W A

Guides for binding wire and binding strap: check free run W A

PVC cover on channel outlet: check the condition H A

Service doors, twister hood, service and cleaning hatches: lubricate J F

Moving parts on compactor: check movability and lubricate J F

Ground anchors of the compactor: check firm seat J F

Service doors, protection hoods and cover panels: check the condition M A

Hopper: check the condition J F

Overall condition of the compactor's welded construction: check the condition J F

Bolted connections in general: check for firmness T 7-7 A

Labels: check condition and legibility H A

Overall condition of the machine's welded construction: visual check W A

Other accessories (optional): check condition and function W 7-10 A

Note:

Maintenance works, as far as they concern special equipment, are described in chapter 11 "Appendix, special equipment".

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This page shows a table where all work of the previous page is listed again. Copy this list as often as

required and keep records about the work carried out.

Result of maintenance carried out on: _____________________ by:__________________

Electrical system

Controls on the switch cabinet and control bar: function check

Main switch and Emergency OFF switch: function check

Motor protection relay: function check

Wiring in the switch cabinet and on machine housing: visual check

Power cable: visual check

Safety switch on side service doors, needle hatches: function check

Safety switch on twister hood: function check

Safety switch on service door in the hopper: function check

Terminal position switch for emergency pull line (optional): function check

Ventilation hood on electrical motor: check for cleanliness

Automatic start system (optional): check function and cleanliness

Hydraulic system

Hydraulic aggregate and fittings: check condition and tightness

Hydraulic oil: check condition and oil level and refill if necessary

Filter insert and ventilation filter: replace

Hydraulic hoses and fittings: check condition and tightness

Hydraulic lines and fittings: check condition and tightness

Hydraulic valves: check tightness

Hydraulic cylinder (main, needle, twister, channel): check tightness and condition

Compaction pressure: check setting acc. to specification

Other hydraulic accessories: check function and tightness

Oil change

Mechanical system

Plunger: check condition and wear

Plunger setting in channel: check and adjust if necessary

Polyamide guides on plunger: check for wear

Telescoping sheets: check the condition

Polyamide telescoping sheet guides: check condition and wear

Cutting gap on the plunger: check and adjust if necessary

Counter-blade and blade on the plunger: check condition and wear

Compaction channel floor: check condition and wear

Needle guide rollers: check cleanliness and wear

Needle head: check condition and wear

Binding system: check function and cleanliness

Twister disks: check the setting

Twister chain: check the condition, lubricate, adjust and re-tension if necessary

Twister blade: check wear and movability

Polyamides in the twister: check for wear

Retainer: check function

Locking pins on hydraulic cylinder: check wear and lubricate

Press bar on channel outlet: check the securing pin

Guides for binding wire and binding strap: check free run

PVC cover on channel outlet: check the condition

Service doors, twister hood, service and cleaning hatches: lubricate

Moving parts on compactor: check movability and lubricate

Ground anchors of the compactor: check firm seat

Service doors, protection hoods and cover panels: check the condition

Hopper: check the condition

Overall condition of the compactor's welded construction: check the condition

Bolted connections in general: check for firmness

Labels: check condition and legibility

Overall condition of the machine's welded construction: visual check

Other accessories (optional): check condition and function

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7.3.2. Description of the

maintenance works

The stated maintenance intervals have to be

understood as standard values which apply

under normal operating conditions. In case

of extreme conditions as e.g. high humidity,

aggressive atmosphere, temperature

fluctuations etc. the maintenance intervals

have to be shortened if required. Please

contact the PRESTO service department in

this regard.

The unit has to be

switched off completely in

case of maintenance and

repair works and be

secured against

unauthorised reclosure. In

case of other procedures

this will be especially

pointed out.

Main switch damaged and lockable

• Check whether main switch (1) can be

switched into "0" or "I" positions.

• Put main switch into "0" position and

check whether the yellow safety bow can

be pulled out and clicked into place.

Emergency-off switch, check function

• Press emergency-off switch (2). The key

must click into place in this position.

• Put main switch (1) in "I" position.

• Put operation mode switch (3) in "Auto"

position

• Press key "Operation" (4)

• Press "Start" (5) key in order to check the

proper function of the emergency-off

switch

• The function test is ok if the unit does not

start operation.

• After having finished the function test,

put main switch (1) into position "0"

• Pull emergency-off switch and lock into

place noticeably.

If no further maintenance works have to be

carried out in this field, replace removed

protective covers and retighten properly

again.

Safety signs (6), undamaged and legible

• Check whether the safety signs (signs

with yellow background) are undamaged

and legible.

• Replace the safety sign (6) if it is

damaged or illegible.

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Type plate undamaged and legible

• Check whether type plate (7) is

undamaged and legible.

• Replace the sign if it is damaged or

illegible.

Check safety switch at

charging funnel with respect

to function

• The unit is out of operation at the

beginning of the inspection.

• Open inspection cover (20) of the

charging funnel.

• Put main switch into position "I"

emergency-off pulled and unlocked.

• Put operation mode switch in "Auto"

position.

• Press "operation“ button.

• Press "Start" button in order to test the

proper function of the safety switch (21).

• The function test is ok. if the machine

does not start up.

• Close inspection cover properly after the

function test has been finished.

20

21

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Safety switch, bottom area


beginning of the inspection. For this

inspection you will need a person who

has been instructed in the operation of

this machine and the test sequence prior

to the inspection.

• The second person opens the flap in the

rear area at the bottom side of the unit.

The flap has to be kept open with a metal

pin, e.g. a screwdriver.

Attention! Never use the

hands! Danger of crushing!

• Put main switch into position "I",

Emergency- off pulled and unlocked.


position.

• Press "Operation" key.

• Press start key in order to test the proper

function of safety switch (22)..

• The function test is ok if the machine

does not start up.

• Close the flap after the function test.

22

Pull cord switch, check function


beginning of the inspection.

• Press the reset button of the pull cord

switch until it clicks into place.

• Now pull the pull cord (23) until you can

hear how the switch clicks into place.

• Put main switch in "I" position,



position.


• Press "Start" key in order to test the

proper function of the pull cord switch

(24).

• The function test is successful if the

machine does not start up.

Re-establish the condition of the unit in the

same way as prior to this function test.

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Inspect area behind press ram and clean as

required

Put main switch in "0"

position and secure with a

padlock prior to this work.

• Take off coils with tie-up material.

• The area can be inspected from the back

(see arrow). Clean this area with a metal

bar if required.

Check function of safety switch of tie-off

device

The unit is out of operation

prior to the inspection! During

the inspection no persons

may stay in the area of the

tie-off device.

• Open the cover (26) of the tie-off device.

• Put main switch in "I" position,



position.


• Press the "Start" key in order to test the

proper function of safety switch (27).

• The function test is successful if the

machine does not start up.

Close the cover to the tie-off device after

having finished the function test.

Current, connection cable, check condition

Check the connection

cable for obvious

damages as e.g.

squeezing, porosity etc.

If damages are found the connection cable

has to be replaced immediately by a qualified

electrician.

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The channel type baling

press must not be taken into

operation if the condition of

the connection cable is not

proper.

Current, plugged connections, check condition


position before opening the

switch box.

• Inspect plugged connections for obvious

damages as e.g. corrosion etc.

• The damaged plugged connections have

to be replaced immediately by a qualified

electrician.

Check hydraulic oil level

• First drive press ram into open limit stop

Prior to the start of this

work put main switch into

"0" position and secure

with a padlock.

• Check the hydraulic part of the aggregate

for tightness (visual inspection).

• Screw out tank ventilator.

• Check run-in hydraulic cylinders if the

distance between liquid level and upper

edge of the screwed socket is not more

than 4 - 5 cm.

• Refill hydraulic oil as required. You will

find information with regard to the used

hydraulic oil in the section "Operating

fuels, specifications".

• See to cleanness in the area of the tank

ventilator. Retighten tank ventilator.

If no further maintenance works have to be

carried out in this area, replace removed

protective covers again and retighten

properly.

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Carry out cutting clearance check

Ex works the cutting clearance is adjusted

less than 1mm. Make sure this value is not

exceeded. A too big cutting clearance or

blunt knives could block the pressing ram in

the worst case. Furthermore it could lead to

damages at the machine casing.

• Run press ram into the direction of the

channel that far that the outer knives of

the pressing die are covered by half of

the counter knife each.


crushing!


position prior to the

start of the following

works and secure with

a padlock.

• Measure the distance (max. 1.0 mm)

between knives (40) and counter knives

(41) with a feeler gauge.

• If the value of 1.0 mm is achieved or

exceeded the cutting clearance has to be

adjusted as follows:

• Loosen the counter nuts (42) of the

adjusting screws (43) on both sides of the

unit.

• First screw in cautiously only one

adjusting screw on each side. This should

preferably be the adjusting screw in the

middle of the screw field.

• Measure cutting clearance again. Repeat

this procedure until the measured cutting

clearance is 0,3 mm +/- 0,1 mm.

• Tighten all other adjusting screws

manually without using any tools. The

adjusting screws have to sit close then.

Use a screwdriver now and screw in all

adjusting screws by approx. 1/6 rotation.

• Retighten counter nuts again.

• Repeat measurement of the cutting

clearance (0,3 mm +/- 0,1 mm).

• Remove possible foreign bodies (e.g.

tools or similar) from the pressing room.

• Check by the aid of a person who has

been instructed in advance the proper

function of the unit. Agree upon a clear

sign for the immediate stop of the unit.

41 41

40

40 40 40

Adjusting screw with counter nuts (only right hand shown)

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• Let the press ram run forward or

backward several times in the operation

mode "Manual". See to it that neither

pressure fluctuations can be seen at the

pressure gauge (44) nor seizing marks are

visible at the upper side of the press ram.

• Stop the unit, if the above described

signs occur.

• Repeat adjustment works if necessary.

Prior to starting with the maintenance

works first see to safe working

conditions, see first section of this

maintenance point.

When compressing plastic foil the

cutting clearance has to be as small as

possible. Initial pressures of approx. 150 bar

during the return stroke indicate a jamming

by pulled along foil resulting from an

excessive cutting clearance. A too big cutting

clearance (>2mm) in connection with blunt

cutting edges (edge radius >0,5mm) and

appropriate material behaviour (e.g. foils,

PET o.s.) results in vertical force introductions

into the housing structure which could add a

multiple of the thrust of the pressing ram.

Thus severe damages (cracks, permanent

deformations) can be caused.

Drilling/cutting device, check chain tension

and lubricate chain (in case of fully automatic

only)

Prior to starting with this

work put main switch into

"0" position and secure with

a padlock.

• Open cover in order to make the chain

drive accessible.

• Measure the totally remaining range of

spring of the disk spring package at the

chain tensioner (60). The value may be 5

mm as a maximum. The chain tension has

to be adjusted as required.

• Turn the nut clockwise or anti-clockwise

until the measured value is less than 5

mm.

• Provide chain with a commercial quality

chain spray type lubricant on this

occasion.

• Properly close cover again.

60

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Motor protection relay (50)

Type Setting (A)

CC-13 (4 kW) 9,0 A

CC-20 (7,5 kW) 15,5 A

CC-30 (11 kW) 22 A

CC-40 (15kW) 30A

Check the adjustment according to the

enclosed PRESTO wiring diagrams.

You will find the wiring diagrams and the

adjustment values in chapter 11.4. "Wiring

diagrams".

Check fuses and replace if required

Put main switch into "0" position

before you open the switch box.

Remove the defect fuse and replace it by a

new one (F) of the same specification (see

chapter 10, spare parts or chapter 11

Appendix, wiring diagrams).

Check condition of polyamide rails

The machine has to be cut off

completely during maintenance

and repair works and has to be

secured against unauthorised

reclosing. If to proceed in another

matter, this will be clearly stated.

• Drive press body to rear final position.

• Put main switch into "0" position and

secure with a padlock.

• Apply a thin grease layer if the polyamide

rails develop loud noise.

• Check the polyamide rails (55) of the

telescope sheets and the press body for

obvious damages as e.g. broken out

pieces, cracks etc. Damaged rails have to

be changed!

After having finished the work mount cover

sheets again and tighten correctly.

55

55

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Check condition and tight fit of hydraulic lines

and screwing

Put main switch into "0" position

and secure with a padlock before

you start with this work.

• Check all pipe and hose connections for

tight fit. Retighten if required. This check

has to be carried out for the first time

approximately 4 weeks after the

commissioning of the unit. All further

controls have to be carried out according

to the interval stated in the maintenance

schedule.

• Carry out a visual inspection for obvious

damages on this occasion. Keep an eye

on fabric damages at hoses, damages at

pipes etc.

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Check hydraulic cylinder with regard to

condition and leakage

The machine has to be cut off

completely during

maintenance and repair works

and be secured against

unauthorised reclosing. If to

proceed in another matter,

this will be clearly stated.

Check all hydraulic lines in the area of the

hydraulic cylinder (see arrows) for possible

leakage.

Check all other screwed connections for tight

fit and/or missing parts (without illustration).

Put main switch into "0" position and secure

with a padlock before you start with this

work.

Aggregate, oil change

First drive press body into open final

position.

• Put main switch into "I" position,


• Push "Operation" button.

• Put selector switch in "Manual" position.

• Push the button "Press backwards"; now

the press ram drives to the open limit

position. When having achieved the final

position the press ram is stopped.

Put main switch into "0"


padlock before you start

with this work.

Prior to draining the oil it must have reached

the operating temperature.

!!! Attention, hot oil.

Danger of scalding!!!

Collect operating fuels (e.g. hydraulic oil) in

appropriate vessels during maintenance

works and discharge according to the (acc. to

EC directive 75/439/EWG and orders acc. to

§§ 5a, 5b AbfG and AltölV).

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• Irrespective of the achieved number of

operating hours an oil change has to be

carried out at least once a year.

• Combine the oil change with a proper

cleaning of the installation area around

the aggregate.

• Screw out tank ventilator (60).

• Screw out the sealing cap (61) of

the oil filter and remove the filter

element.

• Pump the waste oil out of the oil

filter opening into an appropriate

vessel.

• Fill new hydraulic oil into the

control opening. The oil level is

correct if the distance between the

liquid level and the upper edge of

the screw in opening does not

amount to more than 4-5 cm.

• You will find information with regard to

the hydraulic oil in the section "Operating

fuels, specifications".

• Reinstall the new filter element and the

new ventilation filter.

• Continue with the maintenance point

"Replace filter insert".

Oil sight glass

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Any movable parts not mentioned in the

above list as e.g. hinges, spindles etc. have to

be lubricated at regular intervals. With this

easy care you will preserve the function of

these components.

Check anchorage (70) of channel-type baling

press

Check whether the screws of the channel-

type baling press to the concrete plate have

been properly tightened. These screws have

to be retightened if required.

Replace knives/counter knives

• Knives (40) and counter knives (41)

always have to be replaced completely.

Knives and counter knives have to be

replaced if the cutting edges are

damaged and/or show a curve radius of

=0,5 mm.

• First drive press ram into the direction of

the open final position until knives and

counter knives are accessible without any

problems.




with this work.

• Push back telescope sheet with a metal

bar if necessary.

• Completely replace the knives (40)

(tightening torque = 100 Nm).

• Completely replace the counter knives

(41) (tightening torque = 100 Nm).

• Adjust cutting clearance.

• Drive press ram forward at first. The

knives of the press ram must not reach

the counter knives.

• Loosen counter nuts and (see page 7-12)

first turn all adjusting screws one rotation

counter clockwise.

• Drive press ram into the direction of the

channel until the outer knives of the

press ram are covered by half of the

counter knives each.


crushing!




with this work.

41 41

40 40 40 40

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• Continue in the same way as described

under "check cutting clearance" starting

with the measuring by means of a feeler

gauge.

Hydraulic cylinders (four pcs.), check channel

adjustment unit for state and leaks

In case of maintenance and

repair work, the machine

needs to be completely

turned off and secured

against unauthorized

reconnection. If a different

procedure is used, this will

be clearly indicated.

- Check all hydraulic pipes for potential leaks

in the hydraulic cylinder area.

� Check retaining device (on both sides) for

functionality

Paper or plastic remainders in the

retaining device can settle. Accomplish

therefore weekly, or when excessive

contamination a thorough cleaning of the

retaining device, in order to ensure a perfect

function.

Attention, keep a sufficient

distance from the machine.

• Observe during operation whether the

retaining device keeps pressed material

from returning to the pressing chamber.

In case of malfunction,

springs may have to be

replaced. This work may be

done only by an expert.

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7.3.3. Operating fuels, specifications

Aggregate

Filled up at the manufacturer's

Esso HLP 32

Brand of other manufacturer:

NUTO H 46, Esso

Spay type grease for other lubrication points

Use commercial quality chain spray grease.

Quantities

Aggregate, oil filling

CC-13: 20 l

CC-20: 100 l

CC-30: 140 l

CC-40: 140 l

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8. Repair

Repair works may be

carried out by

� authorised

specialists or

service personnel of

the manufacturer

or

� Personnel trained

by the

manufacturer only.

Disconnect the machine

from the mains before

performing any

maintenance and repair

work.

• Place main switch in pos. “0“.

Secure the main switch with a padlock

against unauthorized switching-on.

Unauthorised repair works by the

operator are not permitted. In case of an

unauthorised interference into the

machine there will no longer be a

warranty and liability claim against the

manufacturer.

Repair works at electrical

devices may be carried out

by qualified staff only.

The regulations according to VDE and BGV

A2 have to be adhered to and the

regulations and guidelines of the

application country

Fuses of the intended type and amperage

have to be used.

It is strictly prohibited to repair fuses.

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9-1

9 Behaviour in case of trouble

The following check list will assist the user to narrow down error sources. Should problems occur which are not

described in the list, please contact the after-sales service of PRESTO. During any such contact, have available the type

designation and the machine number stated on the type plate.

In the very right column you will find an abbreviation that will provide you with information about the person

authorised to carry out the remedial measures.

Explanation: F = skilled workers

A = person operating the unit

Never carry out any works at the machine you are not entitled to

carry out!

Repair work on electrical installations may be carried out by our after-sales

service staff or by qualified electricians only. Before starting electrical work,

ensure that the machine has been cut off from the mains.

For a better differentiation the check lists for channel-type baling presses with manual and/or fully

automatic tie-off device are shown separately.

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9-2

Error messages:

The messages appear automatically and are

self-explaining. The messages can be

different regarding the Equipment of the

machines. A summary of all messages is

attached as a table.

(1) Operating messages

Operating messages are information

regarding what the machine does at the

moment and what the position of the

different moving parts is. They are

displayed in the mid part of the panel (Pic

2: Auto mode).

(2) Error messages:

If a fault arises a separate "Alarms page"

window and an alarm indicator are

displayed on the panel (Pic 7: Failure

signals). For every failure message you can

call a help text activating the - button.

The "Alarms page" window can be closed

with the - button. When the failure is

repaired, and the message is reset by the

"Reset" button, the "Alarms page" the

indicator disappears and the "standard

page" is displayed. The messages will get a

time stamp and will be stored in a

"reporting buffer". When the main switch is

switched off, all the messages in the

"reporting buffer" will be deleted.

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Possible error messages:

No.: Message: Reason:

8000 fail of proxy, ram, rear position

(B31)

This error message appears if:

The proximity switches „ ram in rear position “ (B31) and „ ram in front “ (B33)

are activated and the proximity switch „ ram in front “ (B32) is not activated.

8001 fail of proxy, ram, front position

(B32)


The valves „ram forward “ and "bypass" are activated, and the limit switch

„ram in front position“ (B32) turns on.

8002 fail of proxy, ram, front position

(B33)


The valves „ ram forward “ and "bypass" are activated, the proximity switch „

ram in front “ (B32) is activated, and the proximity switch „ ram in front “ (B33)

is switched on.

8003 fail of proxy, needle down (B34) If the proxy switch „ needle down in operating position “ (B35) and the proxy

switch „needle up“ (B36) are activated at the same time and the proxy switch „

needle down in threading position“ (B34) is not activated, this message

appears.

8004 fail of proxy, needle down (B35) If the proxy switch „ needle down in operating position “ (B35) is activated and

the proxy switch „ needle down in threading position “ (B34) is not activated,

this message appears.

8005 fail of proxy, needle on top (B36) This error message appears if:

The proximity switches „ needle down in operating position “ (B35), „ needle

down in threading position “ (B34) and „ needle on top “ (B36) are activated at

the same time.

8006 fail at valve channel relief This error message appears if:

The maximum pressure at the channel is reached, and the valve „channel

pressure relief " does not relief.

8011 fail at oil level or oil temperature

(B1)


The switch "oil level or oil temperature monitoring" is activated.

Oil loss in the system or is too hot (>90°C)!

8012 fail at valve channel pressure If the valve "canal pressure built-up" is activated for more than 5 seconds in

automatic mode without interruption, this message appears.

8013 needle is not in operating

position

If the plant is activated in Auto mode and no "binding signal" lines up and

either the proximity switch „needle down in operating position “(B35) or the

proximity switch „needle down in threading position“(B34) is not activated,

this message appears.

8014 twister not in operating position This error message appears if:

The proximity switch 'twister' (B37) does not switch in Auto mode without

'binding' signal.

8015 fail at motor protection (Q2) This error message appears if:

Motor protection relays of the pump or if available conveyor belt,

Fluffer etc. is tripped.

! Reset motor protection relays. Push the button "reset" to acknowledge!

8016 fail at sensor ram pressure (B2) This error message appears if:

The pressure sensor "ram pressure" (B2) is defective.

Check the plug at pressure sensor!

8017 fail at sensor channel pressure

(B3)


The pressure sensor "canal pressure" (B3) is defective.

Check the plug at pressure sensor!

8024 error, wire left-hand This error message appears if:

The binding wire on the left is ripped or missing or the proximity switch

"binding wire on the left" is defective.

8025 error, wire middle-left This error message appears if:

The binding wire on the middle left is ripped or missing or the proximity switch

"binding wire on the middle left" is defective.

8026 error, wire middle-right This error message appears if:

The binding wire on the middle right is ripped or missing or the proximity

switch "binding wire on the middle right" is defective.

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No.: Message: Reason:

8027 error, wire right-hand This error message appears if:

The binding wire on the right is ripped or missing or the proximity switch

"binding wire on the right" is defective.

8031 fail at function: ram forward If the valve "ram forward" is activated for more than 40 seconds in automatic

mode, without break, this message appears.

8032 fail at function: ram reverse If the valve "ram backwards" is activated for more than 40 seconds in

automatic mode, without break, this message appears.

8033 fail at function: needle up If the valve „needle down“ is activated for more than 8 seconds in Auto mode,

without break,, the machine tries to eliminate the blockage by automatic short

moving back and again move forward of the needle. Even if this does not

succeed in the 4th attempt, this message appears.

8034 fail at function: needle down If the valve „needle up“ is activated for more than 8 seconds in Auto mode,

without break,, the machine tries to eliminate the blockage by automatic short

moving back and again move forward of the needle. Even if this does not

succeed in the 4th attempt, this message appears.

8035 fail at function: wire threading If the threading position is not reached in 10 seconds while the binding process

is activated, this message appears.

8036 fail at function: tying the wires If the tying of the wires is not finished after 30 seconds, this message appears.

8037 fail at function: cutting the wires If the cutting of the wires is not finished after 15 seconds, this message

appears.

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10. List of spare parts

Spare parts for channel-type baling press type Conti-Compact

Type CC-13, CC-20, CC-30 and CC-40V

V = Fully automatic tie-off device

Pos. Designation / Type Illustration Item no. 1 Knives for compressing die

CC13 and CC20:

short (143mm), outer r.h. 1x

short (143mm), outer l.h. 1x

short (200mm), inside 2x

Special:

long (151mm), outer r.h. 1x

long (151mm), outer l.h 1x

long (215mm), inside 2x

counter knives 13/20 2x

CC30


short (134mm), outer l.h 1x


Special:

long (142mm), outer r.h. 1x

long (142mm), outer l.h 1x

long (215mm), inside 3x

counter knives CC30 2x

CC40


short (134mm), outer l.h 1x


counter knives CC40 2x

100118400

100118500

100118600

100049502

100049503

100049601

100050300

100153301

100153302

100118600

100153304

100153303

100049601

100022600

100153311

100153312

100118610

100079000

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Pos. Designation / Type Illustration Item no. 2 Screws for knives:

CC13/20:

Pressing die

8 x M10x20

Casing:

6 x M10x150

CC30:

Pressing die:

10 x M10x20

Casing:

8 x M12 x35

CC40:

Pressing die:

10 x M10x20

Casing:

10 x M12x35

without fig.

250510013

250510010

250510013

250512067

250510013

250512067

3a

3b

Slide rail, guide of the compressing

die

CC-13 (6x)

CC-20, CC-30, CC-40 (6x)

Inside rail CC-30 / CC-40

Screws each 2xM 12 x 35

Chain guidance CC13/20: (4x)

Chain guidance CC30: (5x)

screws:

je 2 x M 10 x 80

je 2 x M 10 x 70

je 1 x M12 x 100

+ each 2 x clamping sleeve 10 x 50

3a 171201091

3b

100048500

171201091

100174800

250512019

100088300

100088300

250510001

250510050

250512034

250710005

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Pos. Designation / Type Illustration Item no. Chain guidance CC40:

(2x)

(3x)

100088300

100088300

100120600

4 Telescope guide

CC-13

Screws:

each 2 x M 12 x 40

CC-20, CC-30 and CC-40

Screws:

each 2 x M 12 x 40

100050001

250510026

171201090

250510026

7 Spring for back owners Without Illustration 100088201

8 Knotting device

CC-13 and CC-20

CC-30

CC-40

050008700

050008800

050027500

9 Oil motor, knotting device

401500002

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Pos. Designation / Type Illustration Item no. 11 Counting vane, knotting device

100100300

12 Chain with chain joint, knotting

device

CC-13 and CC-20

CC-30

CC-40

101041200

101040900

101082500

13.1

13.1

13.2

13.3

13.4

Drilling disc with knife and

mounting material

Drilling disc

Drilling disc bolt

knife

Nut M12 (2x)

50027800

100224100

100056701

251012003

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Pos. Designation / Type Illustration Item no. 14.1

14.2

Pawl

CC 13, CC 20, CC 30 (2x)

CC 40 (2x)

Leaf spring (2x)

100056802

100120702

100088101

15.1

15.2

15.3

Deflection wheel z16

Bearing

“Seeger” circlip ring

100039800

253001008

601300004

16.1

16.2

16.3

Deflection pinion z = 11

Bearing

“Seeger” circlip ring

100039700

253001008

601300004

14.2

14.1

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Pos. Designation / Type Illustration Item no. 17

17.1

17.2

17.3

17.4

Chain adjuster

Junction piece

Tension lever

Straining screw M12 x 290 with

accessories

Screw M12 x 95

---

100110700

100111400

---

250512006

18 Needle trace complete

CC13 / CC20

CC30 / CC40

051020900

400513001

19 Needle cylinder

CC13 / CC20

CC30 / CC40

400512002

400513001

20 Needle roller (Polyamid roller)

Bolt

Needle element

Extension for needle element

100011300

100013600

100013900

50507200

21 Needle head

050101800

23 Pressing cylinder

CC-13

CC-20

CC-30 + CC-40

400510013

400512012

50040301

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Pos. Designation / Type Illustration Item no. 24 Telescope sheets

CC-13 (3x)

CC-20 (4x)

CC-30 (2x)

CC-40 (2x)

50011200

50040401

50519610

50011200

25 Telescope- covering sheet CC-30

Telescope- covering sheet CC-40

100174600

100563530

26 Rear wall, bottom

CC-13 and CC-20

Rear wall, top

CC-13 and CC-20

CC-30

CC-40

050043400

101200044

050047300

50519609

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Pos. Designation / Type Illustration Item no. 27 Limit switch for pull cord

300500393

28 Oil temperature indicator

CC-20, CC-30 and CC-40

406000010

29 Light switch

300500202

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Pos. Designation / Type Illustration Item no. 30 Cable with plug

302100059

31 Cable with plug

302200107

32 Roller limit switch

300500149

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Pos. Designation / Type Illustration Item no. 33 Limit switch, inspection flap

300500182

34 Inductive switch 30mm

Inductive switch 18mm

300500009

300500027

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Pos. Designation / Type Illustration Item no. 35 Float switch

300500299

36 CC-13, CC-20, CC-30 and CC-40:

Magnetic coil NG6

Magnetic coil NG10

402510015

402510017

37 Pressure gauge

405000002

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Pos. Designation / Type Illustration Item no. 38 Hydraulic pump with seal

CC-13

CC-20

CC-30

CC-40

(CC-40)

401005002

401005005

401005014

401001002

39 Vent cap CC-30 / CC-40

403002002

40 Vent cap with dipstick

CC-13 and CC-20

403002001

41 Coupling

CC-13

CC-20

CC-30

CC-40

051000600

051000500

051000330

051000100

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Pos. Designation / Type Illustration Item no. 42 Return filter

CC-20 up to CC-40

403001006

43 Filter insert for return filter

CC-20, up to CC-40

403050002

44 Return filter CC-13

403001004

45 Filter insert for return filter

CC-13.

403050003

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Pos. Designation / Type Illustration Item no. 46 Valve block

CC-13

402510028

47 Valve block

CC-20 and CC-30

CC-40

402510041

402510042

48 Electro valves on plate

CC-13 up to CC-40

402516042

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Pos. Designation / Type Illustration Item no. 49 Electric motor

CC-13

CC-20

CC-30

CC-40

300105046

300107030

300111004

300115001

50 Hydraulic hoses

CC-13

1 St. NW13 x 550 (reservoir)

2 St. NW13 x 550 (Jetschutz)

CC-20

1 St. NW13 x 1000

2 St. NW16 x 600 (Jet protect.)

CC-30

1 St. NW16 x 1000

4 St. NW16 x 800 (Jet protect.))

CC- 40

1 St. NW10 x 200 + Jet

4 St. NW10 x 600 (Jet protect.))

402013003

402013012

402013005

402016014

402016001

402016021

402010011

402010006

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Pos. Designation / Type Illustration Item no. 53 Fuses

2 A

3,15 A

4 A

Without illustration

301100052

301100023

301100056

55 Binding wire Ø 2,8 mm (20 kg

/Rolle) for CC 13 and

CC 20

Without illustration 600700010

56 Binding wire Ø 3,1 mm (40 kg

/Rolle) for CC 30 and CC 40

Without illustration 600700001

Hydraulic channel adjustment

57 Hydraulic cylinder

CC 13, CC 20

400500004

58 Hydraulic cylinder

CC 30

CC 40

400500003

400500005

59 Hydraulic hoses

NW 10x1000 lg

402010009

60 Hydraulic hoses

NW 10x600 lg

402010006

61 Pressure relief valve ¼“ Without illustration 402506104

62 Pressure switch ¼“ Without illustration 402525019

63 Pressure sensor

+ Cable

402800257

302200116

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11. Appendix

11.1. List of the machine operators and personnel in charge

Every operator of the unit will confirm by his signature that he has received, read and understood

the operating instructions. He undertakes to observe all points described therein.

In case of nonobservance there will be no guaranty obligation on the part of the manufacturer

for personal and property damages.

The persons instructed and authorised for the use of the unit have to be entered into the

following table

Name registered on Signature Person in charge

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The machine operator confirms by the registration in the following table that he has taken over

the machine as responsible operator of the machine.

Name Taken over on Signature

This sheet may be copied. See to a complete documentation by leaving the full pages in the file.

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11.2. Maintenance and inspection list

Every machine operator properly enters all performed maintenance and inspection works into the

list and has this confirmed by the person in charge. The list has to be presented to the control

authorities of the social insurance against occupational accidents or to the Engineering Control

Association duly completed and signed.

Maintenance on: Inspection on: Date: Signature

machine

operator:

Confirmed by

person in charge

This sheet may be copied. See to a complete documentation by leaving the full pages in the file.

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11.3. Special equipment

11.3.1. Funnel

For the use under different ambient

conditions the manufacturer offers adapted

tunnel types. An installation may be required

e.g. in case of wall connection or ramp

charging. In any case it is ensured that the

minimum safety distance ensures that the

minimum safety height of the charging shaft

of 1100 mm is not fallen short of.

The construction of the funnel is carried out

by the manufacturer. When installing the

funnel it has to be taken into consideration

that a safety switch might become necessary.

The installation of a security switch can be

effected by our service technician during

taking into operation of the machine.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 11-5

11.3.2. Special equipment, miscellaneous

---

11.4. Wiring diagrams

11.4.1. General

Any works at the electrical

system of this unit have to

be carried out by our service

department or by an

appropriate qualified

electrician. The person responsible for the

work must have the necessary specialised

knowledge of the unit and the electrical

system. Furthermore the person must be

familiar with the valid safety regulations and

the general technical rules.

11.4.2. Wiring diagrams for the channel-type

baling press

The enclosed wiring diagrams are valid only

for the unit supplied with these operating

instructions.

PRESTO

GmbH & Co. KG

Bad Laer

04/2012 11-6

11.5 Disposal

Contribute to environmental protection, by

supplying valuable raw materials of the recycling

and preserving thus resources. In all other

respects we refer to the respective disposal

guidelines of the countries.

What is to be

disposed? Material How is it to be disposed?

Transportation

material

Packing

Pallets

Paper and cardboard

boxes

Plastics

Back to the manufacturer or carrier

To the waste paper

Plastic recycling and/or yellow bag

Clothes

Material

Oil and greasy wastes

Construction units Control units

Electronic devices and

construction units

Metal

Plastics

Electronics scrap iron

Electronics scrap iron

Metal recycling

Plastic recycling

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