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User-/service manual

1. EL o E Fe Ex em o he E m Be H Figure 15 Electric diagram 400 480V 19 DT 1000B Green Ship Bale Compactor standard version Delitek Bale Compactor user service manual Ver 2 4 1 4 2 220 240V UID ng mu OWISAWH 60fT6 LG uAsauBupis PAD Hawapo 501 m a ul r cou AA ci Lou xoig FI AU C ui soyd c esn 8400jeq pejsn po eq S DAJD aanssead MNDAPAU jenw asoyd sO aboyor wa1m3 jo sabuoys p ygounou Buurs er soysodwor ay usum Anjas diuja jo jueunsn po au oino ocz 10 palog This drawing is the property of INKO AS and can not be altered without permission Figure 16 Electric Diagram 220 240V DT 1000B Green Ship Bale Compactor standard version 20 W d a PEISJEH 6076 N FU ig LG ueieAseuDuejs SV OMNI Aq pex eu 4 ZO 40 20 81989 OAd LL Od 70 0011 0 40 20 BI jo3u02 LL 71 001 L0 yms dos 607v 1 001 LO c0 40 40 Las dojs bw 0 FL 00L LO t L cO Z0 20 yopms Pes OL vL OOL 1O 14 0 40 20 puelb age DAd S EL Idi pS OOl 10 Z CO ZO 40 cert SX PRH STE ron 1G LL NOISIAZU NOILdIMOS3G YASWAN LHYd ALO Wal leued jonuoD p 4 004 LO v9 d ssejo aie sjueuoduuoo II W Delitek Bale Compactor user service manual Ver 2 4 1 B q SE VU dojs eo Aouabiefiaw3g ER c ul Q 9 E 8 Co SN Br LL ce AN ST Ak Figure 17 Electric panel p
2. Checking hydraulic oil level Disassemble the motor cover by unfastening the two nuts bolts that keeps it in place see figure 7 Replace the airtight filling cap with the enclosed standard dipstick Check the oil level in the hydraulic oil tank The oil level should normally be between 55mm and 65mm up on the dipstick in the hydraulic oil tank Start the bale compactor and run the piston to its outer lowest position and back again Check the oil level again and refill if necessary Oil with specifications similar to Nuto H32 Esso Univis N32 or equivalent must be used Avoid spill of hydraulic oil and also avoid the hydraulic system to be exposed for dust and dirt during maintenance of the hydraulic system Use certified protective clothing and equipment according to working environment law at site In addition each country s legislation regarding operation of this kind of products and Health Environment amp Safety regulations must be always followed IMPORTANT INFORMATION After installation the compaction cycle should be run approximately 10 times without waste in the compaction chamber This is to ensure that there is no air trapped in the hydraulic system DT 1000B Green Ship Bale Compactor standard version 8 Delitek Bale Compactor user service manual Ver 2 4 1 1 6 Installation procedure for detachable manometer The manometer is from the factory enclosed inside the el panel deliveries from Feb
3. 03 00 El motor IP 56 FR60B 400230 Noratel Trafo 40 VA 400 415 440 230 V FR60B 460230 Noratel Trafo 90 VA 460 480 500 231 V FR60B 660230 Noratel Trafo 90 VA 660 690 230V DT 100 14 03 Emergency switch complete with socket DT 100 59 Offshore brake system DT 100 01 01 Pump 2 ccm incl tank 5 liter DT 100 55 Safety switch for hatch DT 100 29 Covering for 600 cylinder DT 100 30 Covering for 700 cylinder DT 100 33 Covering for 900 cylinder DT 100 01 02 Hydraulic oil tank 5l DT 100 14 12 06 Timer relay DT 100 01 05 Valve block complete with magnetic coils DT 500 700 94 Complete hydraulic hose set for DT 1000B Bale compactor DT 1000B Green Ship Bale Compactor standard version 31
4. 4 1 1 0 INSTALLATION INSTRUCTIONS 1 1 Installation of the bale compactor to steel or wooden deck Before installation Note that the bale compactor must be placed in an environment with operating temperatures between minimum 25 degrees Celsius to maximum 45 degrees Celsius minimum 13 to maximum 113 degrees Fahrenheit Ensure that the control panel and the area around the compactor have sufficient lighting according to working environment law at site In addition each country s legislation and Health Environment amp Safety regulations regarding operation of this kind of products must be followed Installation If the compactor is installed on board a ship or offshore installation the mounting brackets must be welded to a steel surface or alternatively mounted to wooden deck with 8mm bolts WARNING It is very important to cover up the stainless steel surface on the waste compactor in order to avoid spatter from the welding onto the steel Welding and work with angle grinders nearby the bale compactor must always be avoided as this will damage the protective oxidizing coating on the waste compactor This again will cause surface corrosion Lifting of the bale compactor must be done with certified lifting straps around the compactor house only Do not attempt to lift the bale compactor by using holes on the compactor house or other parts of the compactor that is not suited for a lifting operation We recommend the following mounting p
5. AND VG STHAPS 7 1 Ordering information Spare parts and VG straps for the Delitek bale compactor can be ordered from Delitek AS or from any of our agents Address Delitek AS Moloveien N 8432 ALSVAAG NORWAY Tel 47 76 13 47 00 Fax 47 76 13 42 77 E mail mail delitek no URL http www delitek no 7 2 Service and technical information INKO AS Stangnesveien 51 N 9408 HARSTAD NORWAY Tel 47 77 00 26 70 Fax 47 77 00 26 90 Contact Mr Leif Andersen E mail technical delitek inkoas no DT 1000B Green Ship Bale Compactor standard version 26 Delitek Bale Compactor user service manual Ver 2 4 1 8 0 WARRANTY 8 1 General conditions Delitek AS guarantees that this product is without defects regarding materials and workmanship for a period of 12 months from original retail purchase date To obtain warranty service the purchaser must first contact Delitek AS within the warranty period in order to obtain information and replacement of parts or unit All inquiries must be accompanied by a description of the problem and the serial number of the unit this is engraved on the nameplate found on the right side of the bale compactor Proof of purchase must be presented in the form of an original invoice or other documentation which shows that the product is within the warranty period The warranty does not cover claims for damages due to abuse neglected maintenance modifications or attempt of repairs b
6. compactor Disassemble the compactor in the opposite order to which it has been assembled 1 8 Pre installation checklist LI LI Place the bale compactor package as close as possible to the mounting area The compactor is normally packed on a wooden transport frame ISPM 15 and covered in plastic Unpack the bale compactor and remove all crating and plastics Check for any damages The compactor can be moved by using a jack up trolley or fork lift In addition lifting equipment such as a crane may be used but note that certified lifting straps around the compactor house must be used Do not attempt to lift the compactor by using any holes on the compactor house or other parts of the compactor that is not suited for a lifting operation Place the compactor on the exact mounting position See section 1 1 for mounting details Open the el panel and check that it contains the standard dipstick for the hydraulic oil tank and the manometer for service checks of hydraulic pressure Contact Delitek AS if these items missing See sections 1 5 and 1 6 for installation procedures for dip stick and manometer An authorized electrician must connect the compactor to the onboard el supply See section 1 2 and 1 3 Please check that the compactors el specifications comply with the onboard el supply The temporary transport cap on the tank for the hydraulic oil must be replaced with standard dipstick found in the el locker See section 1 5 for this proced
7. disconnect the el supply to the compactor before rewiring starts Two important procedures must then be performed 1 The el motor must be rewired from Y 440V to A 220V configuration or vice versa by rearranging the jumpers in the junction box on top of the el motor See also diagram in chapter 5 section 6 Remove the four screws in the lid on top of the el motor and remove the lid completely see fig 5 Arrange the jumpers according to the selected voltage CY 440V or 220V and diagram in chapter 5 section 6 2 he connections for the transformer for 380 440V voltages must be checked and reconfigured if necessary before el supply is connected again see fig 6 The transformer is located inside the el panel All components in the el panel are running on 220V only The transformer is used for transforming input voltages of 380 440V 480V down to 220V for the components in the el panel DT 1000B Green Ship Bale Compactor standard version 6 Delitek Bale Compactor user service manual Ver 2 4 1 Figure 5 Y Star configuration Figure 6 Transformer bypass a If the input voltage is 380 440V 480V the el supply for the el panel must be connected to the 220V output at the top of the transformer The jumpers on the el motor must be set for Y STAR 440V configuration according to Paragraph 1 b Ifthe input voltage is 220V the transformer must be bypassed Fig 6 shows a bypassed transform
8. function must be performed by qualified personnel only After the first 4 6 weeks e Check the oil level in the hydraulic oil tank The oil level should normally be between 55mm and 65mm up on the dipstick e Check the el panel for damages or leaks inside e Cables hydraulic hoses guide pistons gaskets and sealing on el panel and motor are checked and tightened up if necessary e Check the hydraulic pressure by reading the manometer See section 1 4 for installation procedure of the manometer and the preset pressure value After 12 months Main service every 12 months e Repeat the service points for the initial 4 6 months service e Disconnect electricity and remove the remove the hydraulic power pack cover and piston cover See also section 1 5 for this procedure e Inspect the hydraulic oil from the hydraulic unit take a sample If there are signs of pollution please change the oil Use a hydraulic oil similar or in conformance with Nuto Nuto H32 Esso Univis N32 e Check the hydraulic pump while in operation Observe whether there are any unusual sounds vibrations problems or leaks e Check the hydraulic piston and compactor for cracks or damages e Check hydraulic hoses for cracks and leaks e Function tests of safety switches in hatch and emergency stop function are performed The compaction cycle is supposed to stop immediately after the hatch is opened e Letacertified electrician check all el connections inside el panel
9. operator must visually check the size of the bale The bale is considered finished and ready for strapping when the quantity of compacted waste reaches the lower part of the loading opening However it is the operator that decides the final size of the bale When the compactor is approaching fully loaded the operator will discover that the unit builds up pressure earlier in the compaction cycle This is also an indication that the bale is ready to be deployed Press the stop button to stop the compaction cycle and let the press plate return to its upper position Unlock the two door locks and follow the strapping procedure that is described in section 2 5 If waste with a high degree of expansion is compacted it is recommended to push the STOP switch see fig 13 after the compactor has built up pressure in its lower position Leave the press plate in its lower position as long as possible This will remove any air pockets in the waste By doing this you will also achieve a higher degree of compaction WARNING In case of an accident the emergency switch must be pushed immediately so that the electric power is being cut In order to let the hydraulic piston return to its upper position again reset the unit by pushing the start button DT 1000B Green Ship Bale Compactor standard version 15 Delitek Bale Compactor user service manual Ver 2 4 1 2 5 Strapping the bale When the bale is ready for strapping please follow
10. piping diagram un E CH ed f d n T X zl CH T m CH S ET m A m m T C m Ti Se pulli 4 E EA m AT e T Al z Oo Ka T Zr I k 1 009 HN 315l144AL1S i pa Ti O c al EA D c I mi pa kal p m i 5 N MNINNALANNNVSOAH EJ AA de ou Figure 14 Hydraulic piping diagram DT 1000B Green Ship Bale Compactor standard version 18 QVISMVH 60 6 LG uAsaubunris tere mom ejnoogs 00 10 Voeloid Delitek Bale Compactor user service manual Ver 2 4 1 4 0 ELECTRIC DIAGRAMS 4 1 400 480V doy u yas quu MOST OOTF MODA jou x38 FI JO DWUS SUB L weg E END MN HE 5 lo A N OO TE Ee EN Ui asoyd c e r q m dn se E a a ai ze peuso H ol 6 8 Lj pou HB ON e Si mE Ww H an a id ERUNT ea TEE 71 yopas 6 B Daun UH EL uad Bap jen l r Eis wn es ande an eni EI pos 2109535319 umop AIDA WN Yr T Way EUJn 9 y peuso but venue cou Om 0r T ou CLE amp l een ai0jaa pejsn po aq gADMID BINEEBAd syncup y jenw espud ic bpyoa uan jo sebuoys Ji Ayouuou uwumi er Joysedwos y usum Anjas mwa pO jusuusn po Dui E 9 u 2 E k v A ar 2 e E Ka a LU q E o oq Be MF CH C c i VW Ke C a ui ef ce x z w o Be ke o a H
11. the compactor Check for damages on door gasket or water leakages into the el locker The el locker must always be closed except from maintenance purposes 1 3 Checking phase el motor direction of rotation Figure 3 Connection terminals Figure 4 Direction of rotation DT 1000B Green Ship Bale Compactor standard version 5 Delitek Bale Compactor user service manual Ver 2 4 1 The 3 phase main el supply is connected to the connection terminals 1 2 amp 3 as showed in fig 3 After the connection of the el wires it is crucial to check the direction of rotation of the el motor If the connection is done correct the el motor will turn in the same direction as the arrow indicates counter clockwise see fig 4 If the el motor turns in the opposite direction the phases are wrongly connected The motor will start but the hydraulic system will not function properly Please swap wires of terminals 1 2 amp 3 in order to correct this To visually inspect the direction of rotation you will need to remove the cover for the motor and hydraulic power pack See section 1 5 to see how this is done 1 4 Changing the electric configuration Normally the compactor is configured for either 220V or 380 440VAC 480VAC with special transformer However the electric configurations can be changed afterwards from one to the other option This procedure must always be performed by a qualified electrician WARNINC Be sure to completely
12. the procedure as described below Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Run the press plate to its upper position see section 2 4 Pull the VG straps towards you and stretch them over the front of the bale Cut the VG straps to the desired length Ensure that the VG straps have enough length see section 2 3 step 4 in order to reach and tie them up with the VG straps that already lies in front of the bale Tread the loose ends of the VG straps through the channel iron under the press plate and pull them towards you to remove any slack Close the hatch and secure the door Run the compaction cycle and press the stop button when the compactor reaches maximum pressure on the bale Open the door and tie together the VG straps see two alternatives below The compactor is equipped with an ejection frame see fig 13 for easy unloading of bales from the press chamber When the compaction plate is in its lowest position loosen the loop that is attached to the hook at the rear wall inside the press chamber Attach the loop to the hook that is placed at the rear side on top of the press plate Run the compactor in order to move the press plate to its upper position Warning Be sure that nobody stands in front of the compactor during this procedure The ejection frame will now eject the strapped bale from the press chamber Run the compactor again in order to move the press plate to its lowe
13. the source for the el supply The electric connection in the el panel is wrong or out of phase Solution Check if the main el cable has been unplugged Check if external fuses may be blown An authorized electrician must inspect the cable and plugs for breaches or failure Replace the lamp Close the loading hatch properly An authorized electrician must inspect and measure the coils on the solenoid valve block on the hydraulic aggregate in order to verify if the coils or solenoid valves are defect Contact Delitek AS for spare parts See chapter 8 Check that the electricity output connection conforms to the bale compactors specification For instance 440V 60Hz 3 Phase An authorized electrician must inspect the bale compactor and make sure that the el motor rotates counter clockwise when operating Remove the covering of the el motor on top of the compactor and make a visually check of the el motor when operating If the el motor turns clockwise the electricity connection is wrongly connected The bale compactor will seemingly operate as normal but will not be able to build up sufficient pressure to do normal compaction Please re wire el connection according to electricity diagram found in the user manual A qualified electrician must do this If the el motor turns counter clockwise and as indicated by the arrow symbol on the motor the el connection is correct DT 1000B Green Ship Bale Compactor st
14. Delitek Bale Compactor user service manual Ver 2 4 1 reen shi G SND ramo Systems Model DT 1000B STANDARD VERSION User service manual s Delitek as Delitek AS Moloveien N 8432 ALSVAAG NORWAY Tel International 47 76 13 47 00 Fax International 47 76 13 42 77 E mail mail delitek no url http www delitek no DT 1000B Green Ship Bale Compactor standard version l Delitek Bale Compactor user service manual Ver 2 4 1 IMPORTANT SAFETY INSTRUCTIONS Please follow these precautions when using this product 1 Read carefully through and follow the instructions given in this manual 2 Pay attention to all warnings 3 Installation must be done in accordance to this manual 4 Protect and avoid the power cable from being walked on driven over etc Do not bend the power cable close to the connections 5 Use only original spare parts approved and recommended by Delitek AS 6 Qualified personnel must perform repairs and services 7 WARNING Do not expose the el locker or el engine with direct spurt of flushing water 8 The compactor must be placed in an environment that has an operating temperature between minimums 25 degrees Celsius to maximum 40 degrees Celsius minimum 13 to maximum 104 degrees Fahrenheit 9 WARNING The compactor is usually transported horizontally packed in a wooden transport frame ISPM 15 The transport frame is lifted relocated by using a
15. and on the motor e he guide pistons may be lubricated with silicone spray Note Do not use lubrication oil or grease e Check the functionality of the gas pistons on the hatch and wheels on container s 5 2 Surface treatment In order to keep a nice and shining surface it is very important that the waste compactor is washed and cleaned with regular intervals and at least once every second month This is to avoid discolouring and corrosion Wash the compactor with a strong neutral detergent for industrial use Acid washing of extra exposed parts may also be done Be sure to take all necessary precautions and read the data sheet for the detergent and any acid wash very carefully before use It is recommended to use a high pressure washer in order to flush the compactor after washing Note Avoid flushing directly on the el locker and el motor DT 1000B Green Ship Bale Compactor standard version 24 Delitek Bale Compactor user service manual Ver 2 4 1 6 0 TECHNICAL SPECIFICATIONS 6 1 DT 1000B Volume 1 5 m Loading opening 600 mm x 1000 mm Total height incl plunger 2493 mm External dimensions Wx DxH 1315 mm x 936 mm x 2493 mm Length of stroke 700 mm Compression force 10 tonn El Motor 1 5 kW El Power 220V 380 440V 480V 690V 50 60Hz 16A 3 phase Weight 350Kg DT 1000B Green Ship Bale Compactor standard version 25 Delitek Bale Compactor user service manual Ver 2 4 1 7 0 SPARE PARTS
16. andard version 28 Delitek Bale Compactor user service manual Ver 2 4 1 Symptoms Cause Solution The compaction force seems to Blocked air vent wrong filler On the hydraulic oil tank Please check be insufficient or very low cap that the air vent airing on the filling cap continued are not blocked A blocked air vent can eventually cause the hydraulic system to malfunction Alternatively if the hydraulic oil tank was delivered with an airtight temporary filling cap replace this with the original dipstick Hydraulic oil level is to low Please ensure that the bale compactor contains sufficient hydraulic oil in the hydraulic oil tank found on the hydraulic aggregate The oil tank must contain 3 2 liters hydraulic oil or be 3 4 full Univis 32 Check the oil level by controlling the dipstick The oil level should be between 55mm and 65mm up on the dipstick Air pockets in the hydraulic If the bale compactor hydraulic system system have been forced to operate with insufficient hydraulic oil level air pockets may have occurred in the system Check and refill oil as described above Start the bale compactor and run the compaction cycle a few times in order to automatically empty the system for entrapped air The piston does not return to its Solenoid valve s or coils Coils or solenoid valves must be upper position 0 position may be defect replaced Contact Delitek AS The switch on the press plate Contact D
17. art 1 DT 1000B Green Ship Bale Compactor standard version 21 Delitek Bale Compactor user service manual Ver 2 4 1 4 4 Electric panel part 2 PEISIEH SOTEN FLOOL id LG ualaAsaubueis SV OMNI Oase Sauer Bes us o A3 pautar 20 10 20 es Bununow PO ZL 0OL LOT L kb ZO 10 40 dwejs lespunoig 60 CL FL 00L LO L OL ZO 10 40 xoqasn 5 80 CL FL 00L LQ Ad cO 40 40 y G z sdwel9 20 CL FL 00L 10 8 cO 40 40 90 zL tL 00L 10 b Z cO 40 40 res Bununopy GO Zl PlL OOl LG 9 cO 20 LO JO EUloJsugJ gOrcil FL OOL 10 S cO 40 40 Aea owa EOEKFLOOL AO L b cO 4040 SEL SHIEWa UNA OL el PL OOL LO E cO 40 40 uogoq suid LO EL PL OOL LO E 2 SO 40 40 Jo 2ejuoo O0 L FL 00L 10 b k 8 NOISIA3M NOILAIHOS3O HIAWNN Liv L 00L LO Sueuoduio3 79 d Ssej eie sjueuoduioo Uu NE dk IN Figure 18 Electric panel part 2 DT 1000B Green Ship Bale Compactor standard version 22 Delitek Bale Compactor user service manual Ver 2 4 1 4 5 Wiring diagram 400V 230V Y or A configuration Figure 19 Wiring diagram for el motor DT 1000B Green Ship Bale Compactor standard version 23 Delitek Bale Compactor user service manual Ver 2 4 1 5 0 SERVICE MAINTENANCE 5 1 Service Maintenance plan NOTE For every service interval and other regular controls function test of safety switches and emergency stop
18. de escape from hazards which are described in the vessel offshore facility manual b Place for operating the compactor gives adequate attention towards alarm signals and PA announcements C Necessary information training and signboards to be provided by the responsible officer onboard WARNING The standard version of DT 1000B must be installed in an unclassified zone onboard ships or offshore rigs Only Ex proof versions of the Delitek compactors can be used in hazardous areas DT 1000B Green Ship Bale Compactor standard version 2 Delitek Bale Compactor user service manual Ver 2 4 1 Note All following dimensions are in metric millimetres TABLE OF CONTENTS 10 INSTALLA TION FNEl 1 1 Installation of the bale compactor to steel or wooden deck nnn 1 2 C onnecHom to electric SUNY etit tot tbt eph ed tive geredet tnde cebat beta ge gah 1 3 Checking phase el motor direction of rotation esses 1 4 Changing the electric configuration EE Ee ko BADANE DT 216 OT Ee EG EE EE SE E tele arce dE ee ee 1 6 Installation procedure for detachable manometer cccccccccssssseeccceeeeeeaeeeseeeeeeeeeeaas 1 7 Disassemblinig tie compacto e Gs ctus ide siqua ques ease 158 Pre insiollation EE AOOPERA TING ENS TRUG ONS od ES ees See oe Gee sed oe NE ie eken se de eek ee Us 2A Iastructioss for use BIS EE 2 2 List ol components D Pa LOOT i
19. elitek As and have the may be defect switch replaced The loading hatch refuse to rest in One or both of the gas Contact Delitek AS and order for spare open position pistons on the hatch are parts See chapter 8 defect DT 1000B Green Ship Bale Compactor standard version 29 Delitek Bale Compactor user service manual Ver 2 4 1 10 APPENDIX 1 10 1 DnV Certification Te INA DET NORSKE VERITAS STATEMENT OF CONFORMITY Application of Council Directive 98 37 EC of 22 June 1998 issued as Forskrift for Maskiner by the Norwegian Directorate of Labour Inspection Statement no AACAAJHI This is to certify that the technical documentation for the product Avfallskomprimatorer og emballasjepresser Identification DT 80 DT 100 DT 500 DT 1500 DT 1000B Dt 1500B DT 500 COMBI DT 2000 Responsible manufacturer DELITEK AS Havnegata 7 8430 Myre Norway Manufactured by INKO AS PB 772 9487 Harstad Norway complies with the requirements applicable to it The manufacturer s Technical Construction File TCF and the product has been reviewed and found to comply with the requirements in Annex V section 3 Limitations Any modifications made to the machine shall immediately be reported to Det Norske Veritas AS in order to examine whether this Certificate remains valid Harstad 13 November 2002 for Det Norske Veritas AS Harstad Maritime Dag Julian Eilertsen District Manager Any sign
20. er The el supply to the el panel is parallel connected to the input el supply l e the voltage is not passing through the transformer The jumpers on the el motor must be configured for A Delta 220V configuration according to paragraph 1 3 When the reconfiguring of the el system is completed please reattach the cover for the hydraulic power pack and re connect the waste compactor to the selected el supply See also chapter 5 for connection diagrams and schematics regarding rewiring DT 1000B Green Ship Bale Compactor standard version 7 Delitek Bale Compactor user service manual Ver 2 4 1 1 5 Final preparation Fillercap dipstick Must be installed before Ihe pump is started IMPORTANT INFORMATION gt The hydraulic power pack is delivered with an airtight temporary filling cap see fig 7 in order to avoid oil spill during transport To avoid damages or breakdown of the hydraulic system it is necessary to replace the temporary filling cap with the enclosed standard dipstick before the compactor is set into normal operation The temporary filling cap is located on top of the hydraulic oil tank on the el motor see figure 7 Replace the airtight filling cap with the enclosed standard dipstick that should be found inside the el panel NOTE If the dipstick is missing from the package please contact Delitek AS immediately See chapter 8 contact information Figure 7 Dipstick
21. forklift or a jack trolley by the indicated lifting pockets If the bale compactor needs to be lifted after the compactor is unpacked this must be done with certified lifting straps around compactor the house 10 WARNING Do not lift the compactor by using holes on the compactor house or other parts of the compactor that is not suited for a lifting operation 11 WARNING The safety distance for the compactor operator must be at least 1 metre No persons must be standing in front of the compactor opening during the compaction cycle 12 The compactor is designed to compress recyclable materials such as paper plastic paperboard carton PVC materials etc 13 WARNING Waste that is considered as hazardous or special category waste must never be deployed or compressed in the container Because of fire and explosion hazard never deploy hot ashes or any type of gas domes into the bale compactor 14 Ensure that the control panel and the area around the compactor have sufficient lighting according to working environment law at site 15 Qualified personnel must perform a function test of security switches emergency switches at regular intervals See chapter 6 for service maintenance of the compactor If a malfunction appears when the system is running and pressurized contact Delitek AS to get a description on how to get the pressure balanced 16 The placing of the waste compactor to be such that a Escape routes are adequate and do not impe
22. ide the bar to the left or right and thread the 2 VG strap rolls onto the bar Mount the magazine bar again and tighten up the locking knobs Loosen the ends from the VG strap rolls and tread the VG straps through the holes on top of the compactor house right beneath the magazine bar see fig 6 Open the compactor door and stretch the VG straps further at the rear wall inside the press chamber Standing in front of the compactor stretch the VG straps all the way down to the bottom of the compactor house and further over the compactor floor Ensure that the VG straps reach approximately 20 cm beyond the front of the compactor floor you will need this when it is time to strap the bale Note See chapter 8 for ordering information for VG straps DT 1000B Green Ship Bale Compactor standard version 13 Delitek Bale Compactor user service manual Ver 2 4 1 2 4 Operating the compactor Note The control panel el panel must be connected and controlled by a qualified electrician before use All cable glands and gaskets should also be inspected before first use and also with regular intervals see also chapter 6 The DT 1000B is designed to compress bales of recyclable materials such as paper plastic paperboard carton PVC materials etc The DT 1000B compactor is equipped with an ejector frame device for easy unloading of bales see fig 13 Figure 13 Ejector frame For best results and for keeping the bale firml
23. ificant changes in design or construction of the product or amendments to the Directive or Standards referenced above may render this receipt invalid The product liability rests with the manufacturer or his representative in accordance with Council Directive 85 374 EEC DT 1000B Green Ship Bale Compactor standard version 30 Delitek Bale Compactor user service manual Ver 2 4 1 11 APPENDIX 2 11 1 Spare part list Part Number Description DT 100 34 Cover for hydraulic unit DT 100 56 Limit switch press plate DT 100 03 Gas damper for hatch AISI 304 DT 100 19 Hinge AISI 304 complete DT 100 36 01 Wheel rubber fixed action DT 100 37 01 Wheel rubber revolving DT 100 600 65 Hydraulic piston 600mm stroke DT 100 700 65 Hydraulic piston 700mm stroke DT 100 900 65 Hydraulic piston 900mm stroke DT 100 06 Rev A Pipe bushing nylon for cylinder guides 48 3 DT 100 06 Pipe bushing nylon for cylinder guides 50 DT 100 14 10 limpulse switch start DT 100 14 09 limpulse switch Stop DT 100 14 EL panel 90 VA trafo complete DT 100 05 04 Contact magnetic coils DT 100 14 12 00 Contactor LCIDO9P99A DT 100 14 11 Control lamp DT 100 01 05 06 Magnetic coil ATOS 17 7 DT 100 01 05 02 Magnetic coil Diplomatic 20 5 DT 100 01 Hydraulic acregate complete DT 100 01 05 00 Bracket for magnetic valve block DT 100 01 00 El motor IP 55 1 8 KW DT 100
24. r position again Unhook the loop from the press plate and attach it to the hook at the rear wall of the compactor Run the compactor once again and return the press plate to its upper position Prepare the compactor for a new bale by repeating step 3 4 and 5 in section 2 3 installations of VG straps Note There are two alternatives for strapping the bale tying the VG straps together By using a strapping tool 2 Simply by tying the VG strap ends together DT 1000B Green Ship Bale Compactor standard version 16 Delitek Bale Compactor user service manual Ver 2 4 1 3 0 HYDRAULIC SYSTEM 3 1 Hydraulic system DT 1000B INCO 5L Mini aggregate Electric Motor Bevi 90 4 Insulation class F IP 55 56 Guaranteed output 1 5 kW 2hk Rotation speed 1415 rpm Rated current 220V 6 5A 380V 3 7A 440V 2 8A Starting torque 2 4M A Starting current 5 3 VA Net weight 15 3 Kg Colour code RAL 5005 Pump HPI 2 ccm Gear Pump Adjustable safety valve 0 315 bar Hydraulic oil reservoir tank 5 liters Flow factor 3L min Two way valve Borch Hydraulic oil UNIVIS N32 Nuto H32 or similar Cylinder DT 1500B 60 40 700 180bar All cylinders with flange in front External threads M24x2 on piston rod 60 40 700 60 mm piston head 40 mm piston rod 700 mm cylinder stroke DT 1000B Green Ship Bale Compactor standard version 17 Delitek Bale Compactor user service manual Ver 2 4 1 3 2 Hydraulic
25. rocedure 1 Place the bale compactor exactly where it is planned to be installed 2 Align the mounting brackets to the corners of the waste compactor The mounting brackets are then spot welded onto deck Remove the upper nuts on mounting brackets see fig 1 The bale compactor is lifted aside and covered to avoid splatter from welding etc The mounting brackets are all welded to the steel surface The compactor is then lifted in position again and carefully placed upon the mounting brackets 7 Please check that the waste compactor is levelled to the deck If necessary adjust the bale compactor by turning the lower nuts on the mounting brackets 8 Replace the upper nuts on the mounting brackets Top view Side view Figure 1 Mounting brackets DT 1000B Green Ship Bale Compactor standard version 4 Delitek Bale Compactor user service manual Ver 2 4 1 Figure 2 Sketch DT 1000B bottom view of mounting brackets 1 2 Connection to electric supply Connection of el supply must de done by a qualified electrician Be sure to check that the voltage specified for the waste compactor complies with the el supply at site Check the voltage specification on the compactors nameplate and on the attached Factory Acceptance Test sheet Note guide tubes nipples bushings gaskets and sealing on the el locker should be inspected during installation This equipment must also be checked during maintenance and function tests of
26. ruary 2007 and beyond together with the dipstick for the hydraulic tank and FAT Factory Acceptance Test certificate Hydraulic pressure is preset to 160Bar for the DT 1500B model with two pistons and should not be altered without authorization from Delitek AS The manometer is enclosed inside the el panel Installation procedure for checking the hydraulic pressure 1 Locate the detachable manometer inside the el panel 2 Switch off the main power supply to the waste compactor 3 Disassemble the motor covering by unfastening the two nuts bolts that keeps it in place see figure 4 Locate and detach the protection cap on top of the hydraulic power pack see fig 8 5 Attach the manometer firmly on the screw thread coupling see fig 9 6 Run a few compacting tests with a container fully loaded with waste Read out the manometer when the waste compactor reaches full pressure during the compaction cycle If the hydraulic pressure for some reason not conforming to the preset value from the factory please contact Delitek AS Do not attempt to adjust the pressure without authorization from Delitek AS 7 To prevent from damages on the manometer it must be detached again right after the testing procedure and stored in an appropriate place 8 Attach the motor covering again DT 1000B Green Ship Bale Compactor standard version 9 Delitek Bale Compactor user service manual Ver 2 4 1 1 7 Disassembling the
27. s An GE Fe bored N EE Deo NE REN OR Ee 25 asta ah On EE ee 24 Opetatne the PA AA ee Zot Te D le se EG DE N E SUHYDRAULIC SYSTEM gee es GEED ee Se oo ee ee Ge N EA E dese ed eue event Sd Hydraulicsy Stem D ESTOO0B etus EE RE E hed ER Ge IE es 22 ydre pipine did SEA ees EG aD a a a DE N IG SUERG KEE eege UE EE BD 2202 ON vanette eene eegene 2 plectic pinel PAL DEE AA Ele ti pinel AA SE N GE N Ee 4 5 Wiring diagram 400V 230V Y or A configuratiOn esse sesse esse ee ee ee S SERVICE MAINTINAINGE iv Se Ge Oe ee oe eek ei eie ove deep oras S I 5ervice Matitemanee plani ao sop EE e ces ED teni ees eoa o ote cU PU ODE Led SIDE CEU le EE TE TT DOE ee a 6 0 TECHNICAL SPECIFICATIONS 5550904594 eg edan gang dE hb REN Eege SPI DTS OOB mc t PO EOS 7 0 SPARE PARTS AND VG STRAPS ssssssss KAO ya Ee aa eer os aen NE 1 2 service and technical ISA LOS AA SOWARRANI EE e EE e e E 9 0 TROUBLESHOOTING GUIDE sssssssseseeeeeee 9 1 PROUDIES MOO EE iss WA WAA TIE ee Ge BEN Ee De UNE ee RE E ende en ee DR id LOS dy chit DL P Sr EE RR EE SE KOSA TIGAN rr rrr Ob Din C ertt AMON aa aaa ag anata aa eneen Ee Ee DER d ia IT dy UN EE N RR OE EE EE N IT TI Spate Dart list ee DT 1000B Green Ship Bale Compactor standard version 3 4 Delitek Bale Compactor user service manual Ver 2
28. ure Check the rotating direction on the el motor according to section 1 3 If the el supply is correctly connected the el motor will rotate counter clockwise according to the arrow symbol on the el motor CONGRATULATIONS WITH YOUR NEW WASTE COMPACTOR DT 1000B Green Ship Bale Compactor standard version 10 Delitek Bale Compactor user service manual Ver 2 4 1 2 0 OPERATING INSTRUCTIONS 2 1 Instructions for use Quick start Figure 10 Instructions for use DT 1000B DT 1000B Green Ship Bale Compactor standard version 11 Delitek Bale Compactor user service manual Ver 2 4 1 2 2 List of components DT 1000B List of components 5 sj Pressplate complete 6 1 2 Cylinder S 7 Mountinghraeket 0 0 0 2 JLekiggknb 10 A LElnang Figure 11 Delitek DT 1000B bale compactor list of components DT 1000B Green Ship Bale Compactor standard version 12 Delitek Bale Compactor user service manual Ver 2 4 1 2 3 Installation of VG straps The Delitek DT 1000B bale compactor has 2 VG strap rolls for strapping bales included in the delivery The VG straps are installed on the magazine bar at the rear side on top of the compactor see fig 12 Figure 12 VG strap magazine bar When installing replacing the VG strap rolls please follow the procedure as described below Step 1 Step 2 Step 3 Step 4 Loosen the two locking knobs on the magazine bar Sl
29. y together it is recommended to start with a bigger cardboard flake at the bottom of the compactor house Note It is also recommended to finish the bale by placing a cardboard flake on top of the bale when it is ready for strapping for the same reason as mentioned above The compactor is now ready to compress bales Note In order to let the compactor build up sufficient pressure you must first fill the press chamber with waste see important safety instructions point 12 before running the compaction cycle Repeat the procedure until the bale has reached the desired size Close the compactor door and remember that the two door locks always must be secured when the compacter is being operated The compactor has an emergency switch in the loading hatch that not allows operation as long as it is open Start the compactor aggregate by pushing the start button in 2 3 seconds see fig 13 The compactor will now run trough the compaction cycle If the compactor is switched off by using the emergency switch stop button or if the safety switch in the loading hatch is triggered the press plate will return to its upper position and the system will reset The control lamp voltage on is lit whenever there is voltage coming into the el panel DT 1000B Green Ship Bale Compactor standard version 14 Delitek Bale Compactor user service manual Ver 2 4 1 START la Mee ST 606 Figure 13 El panel Em The
30. y unauthorized personnel Delitek AS will not be liable for and denies any responsibility for accidental indirectly or other damages on amongst other property or personal injuries as the result of wrong use or neglected maintenance of the product See section 7 1 for contact information DT 1000B Green Ship Bale Compactor standard version 27 Delitek Bale Compactor user service manual Ver 2 4 1 9 0 TROUBLESHOOTING GUIDE 9 1 Troubleshooting If you experience problems while operating the bale compactor please use the following table to check for possible causes and solution before contacting Delitek AS Service for assistance Symptoms The indicator light for VOLTAGE ON on the el panel is not lit and the compactor does not respond when the start button is pressed see fig 8 page 10 The indicator light for VOLTAGE ON on the el panel does not light but the compactor starts when the start button is pressed The indicator light for VOLTAGE ON on the el panel is lit but compaction does not start after pressing start button on the el panel The compaction force seems to be insufficient or very low Cause No voltage to the unit Failure or breaches in main electric cable The indicator lamp for VOLTAGE ON is defect The loading hatch is not closed properly and the security switch in the hatch is not activated Solenoid valve or coils on the hydraulic aggregate may be defect Problems with

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