bergmann ALPHA-PACK-BIN Operating Instructions Manual
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bergmann ALPHA-PACK-BIN Operating Instructions Manual

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Operating Instructions
Translation of the original
ALPHA - PACK - BIN
I M P O R T A N T
D O C U M E N T
APB 616
Machine model
Serial - no.
Year
179 02
Operating instructions - No.
P.O.Box 11 52 • Von-Arenberg-Straß e 7 • D-49762 Lathen/Ems • Phone +49 / 5933 / 955-0 • Fax +49 / 5933 / 955-294
eMail info@bergmann-online.com• www.bergmann-online.com

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Summary of Contents for bergmann ALPHA-PACK-BIN

  • Page 1 APB 616 Machine model Serial - no. Year 179 02 Operating instructions - No. P.O.Box 11 52 • Von-Arenberg-Straß e 7 • D-49762 Lathen/Ems • Phone +49 / 5933 / 955-0 • Fax +49 / 5933 / 955-294 eMail info@bergmann-online.com• www.bergmann-online.com...

  • Page 3: Table Of Contents

    Table of contents Use for intended purpose ......................1.01 Introduction ........................... 2.01 View of the machine ......................2.01 Background, benefits and features ................2.02 Principle safety considerations ....................3.01 List of symbols and notes ....................3.01 Principle safety rules ...................... 3.02 3.2.1 Organizational measures ................
  • Page 4 Table of contents The remote control ......................7.08 The hydraulic lid opener ....................7.09 The electric lid opener ....................7.10 Preliminary setup for a GSM unit ................7.10 7.10 The GSM complete package ..................7.11 7.11 The ozone generator ....................... 7.11 7.12 The RESET button ......................

  • Page 5: Use For Intended Purpose

    The ALPHA-PACK-BIN has been designed only for the compaction of valuable substances and wastes and may be used for this purpose only. Any other use or application beyond this must be considered as improper use.

  • Page 7: Introduction

    2. Introduction View of the machine APB 616 Pick-up hook Compaction Hydraulic system Unloading door Shunting hook chamber with control cabinet Mains Service shaft Isolator Rails Hinge connection Hydraulic system Switch cabinet Control panel Control panel Door lock Transportrollers...

  • Page 8: Background, Benefits And Features

    Optical and acoustic level indicators or a spring releasing cover beyond the charging hole can be useful extra equipment. The BERGMANN ALPHA-PACK-BIN APB 616 has been designed in order to be taken up by a roller tipper. The take-up hooks can be matched to the corresponding vehicle type as required by the respective customer.

  • Page 9: Principle Safety Considerations

    3. Principle safety considerations List of symbols and notes The following signs for hazards are used in the operating instructions and on the machine: This symbol stands for a possible hazard for the life and health of persons. The non-observance of these instructions can result in serious effects to health and even life-threatening injuries.

  • Page 10: Principle Safety Rules

    3. Principle safety considerations The following pictograms have validity for machines and special equipment : Machines with a cover above the feed opening : This symbol warns that reaching into the pivoting area of the covers is prohibited. This symbol points out the danger of injury in case of improper use of the covers. Machines with a BIN-LIFT-TIP DEVICE : This symbol warns that staying in the pivoting area as well as underneath the raised lift-and-tilt device is prohibited.

  • Page 11: Safety And Protective Devices

    It is not allowed to make any modifications, extensions or reconstructions on the machine without the prior written consent of BERGMANN. This is also valid for welding works at load bearing parts. If the machine is combined with other machines (e.g. conveyor belts, etc.), a separate risk assessment has to be created by the operator.

  • Page 12: Safety Installations

    3. Principle safety considerations All handles, steps, railings, pedestals, platforms and ladders must be kept free of soiling, snow and ice. The safety and danger instructions on the machine have to be kept in a legible condition and must be replaced if necessary. Operation of the PACK-BIN in publicly accessible areas such as market places etc.

  • Page 13: Hazards Through Hydraulic Energy

    3. Principle safety considerations The electrical equipment of the machine must be inspected at regular intervals. Any faults such as loose connections and/or scorched cables must be cleared immediately. In the event of a defect on the electrical equipment, further operation of them machine is prohibited. That is valid until authorised expert staff confirms that all faults have been successfully eliminated.

  • Page 14: Instructions In Case Of Emergency

    3. Principle safety considerations Maintenance work must be carried out on the stations intended for this purpose. As far as necessary the repair area must be secured. If maintenance personnel have to access the machine through the unloading door, this door must be secured by means of an arresting cable.

  • Page 15: Emergency Procedure "Person Trapped In The Compaction Chamber

    3. Principle safety considerations Emergency procedure "Person trapped in the compaction chamber" If a person is trapped in the compaction chamber, proceed as follows: Actuate the EMERGENCY STOP button Pull the mains plug. Call emergency services. Clear the filling area of waste and refuse as much as possible and secure the filling area prior to any further filling.

  • Page 17: Commissioning

    4. Commissioning Commissioning must only be carried out by a BERGMANN authorized dealer. The following instructions have to be observed for the commissioning and in case of a later change in location: Prior to lifting the machine, ensure that the COMPACTION BOX is disconnected from the mains.
  • Page 18 4. Commissioning 3) If the voltage is the same connect the PACK-BIN to the mains. 4) Switch on the isolator. 5) Release the two EMERGENCY SHUTOFF button by turning the buttons to the right. In case of danger imme- diately press the EMERGENCY SHUTOFF EMERGENCY SHUTOFF EMERGENCY SHUTOFF...
  • Page 19 4. Commissioning 6) Actuate the RESET button. 7) After the connection to the electrical mains the rotational direction of the motor must be tested. For this purpose press the ON switch. If the rotational direction is correct the com- pacting piston will move backward. If this is not the case, the ma- chine must be disconnected from the mains immediately and the...

  • Page 21: Operation

    5. Operation Filling and starting the machine 1) Switch on the isolator. 2) Release the two EMERGENCY SHUTOFF button by turning the buttons to the right. In case of danger immedi- ately press the EMERGENCY EMERGENCY EMERGENCY EMERGENCY EMERGENCY SHUTOFF SHUTOFF SHUTOFF SHUTOFF...
  • Page 22 5. Operation 4) A green lamp indicates that the machine is ready for use. 5) Fill the machine with material. An optimal compaction result can be achieved when material is filled in the middle. 6) Press the ON button to start the compac- tion process.

  • Page 23: The Full Signal

    5. Operation The full signal Breaking edge compaction part 1) The PACK-BIN is full when the front side of the compaction piston is no more visible and disappears under the breaking edge of the compaction part. Throw-over blade Front side of the piston 2) Some machines are fitted with additio- nal full signals : * A lamp on the control panel indicates...

  • Page 24: Emptying The Machine

    5. Operation Emptying the machine 1) When the PACK-BIN is full, it can be trans- ported by means of a roller tipper and then be emptied. To pick up the BOX, a suspension hook is attached to the front side of the machine. The suspension hook on the unloading door is only used for manoeuvring.
  • Page 25 5. Operation 3) Once the locking hooks have released the door, you can loosen the arresting cable and fully open the door (about 260°). An eyelet is welded onto the underside of the container base. In order to avoid that the door returns the rope has to be hung in there.

  • Page 26: Emptying The Machine With A Pendulum-Type Flap

    5. Operation Emptying the machine with a pendulum-type flap 1) When the PACK-BIN is full, it can be trans- ported by means of a roller tipper and then be emptied. To pick up the BOX, a suspension hook is attached to the front side of the machine. The suspension hook on the unloading door is only used for manoeuvring.
  • Page 27 5. Operation 3) Once the locks are open, the PRESS BOX can be tilted and emptied using the A receiving vehicle. 4) After emptying, the lock, the container, the door frame as well as the rubber seal (if any) must be cleaned thoroughly. For this purpose, use the pendulum flap protection device (1).

  • Page 29: Electrical Circuit

    6. Electrical Circuit General Maintenance or repairs on the electrical supply system may only be carried out by a qualified electrician with corresponding know-how. On this occasion the machine must be disconnected from the mains and be secured against reclosure. The wiring diagram for this machine can be found in the switch cabinet.

  • Page 30: The Motor Overload Protection

    6. Electrical Circuit The temperature in the control cabinet should not exceed +60°C or go below -10°C. Where there are considerable minus temperatures, a heating element must be installed in the control cabinet (contact manufacturer with requirements). The motor overload protection The motor protection switch (1) is an electronic component which switches off the machine auto- matically in case of motor overload.

  • Page 31: The Electrical Control

    6. Electrical Circuit The electrical control In the switch cabinet there is a special control which determines the working sequence of your machine. If the PACK-BIN is started by means of the ON button the machine compacts until the running time has ended.

  • Page 32: The Working Hour Counter

    6. Electrical Circuit The working hour counter There is a counter (1) in the switch cabinet indicating the performed working hours. This is connected to the master contactor of the machine and is activated together with the electric motor. The isolator Next to the connector plug there is the main switch.

  • Page 33: Switch Mechanism For Container Opening

    6. Electrical Circuit Switch mechanism for container opening An oil-pressure switch for the limit stop of the compaction piston is screwed into the hydraulic valve. This oil-pressure switch causes the piston to remain in the top position of the compaction room when the machine is switched off.

  • Page 35: The Additional Equipment

    7. The additional equipment The PRESS-BOX can be equipped with additional devices on request. These will be optionally adjusted to the machine. You will find the exact equipment of your machine on our order confirmation and on the delivery note. The covering hood A lid can be mounted in order to prevent the penetration of rain water into the compaction...

  • Page 36: The Container Full Signal

    7. The additional equipment The container full signal The time interval between a full container and collection by the waste contractor can sometimes be unacceptably long, which means that waste may continue to accumulate. This problem can be avoided to a large extent with the hydraulic/electric container full signal. There are useful warnings of how full the container is.

  • Page 37: The Hub-Tilting Device

    7. The additional equipment The HUB-TILTING DEVICE Container types according to DIN EN 840, with a width of 1,260 mm, a cone height of 980 to 1,280 mm or a neck height of 820 to 1,120 mm, may be tipped. This is to be inspected prior to use.
  • Page 38 7. The additional equipment 3) Activate then both push-buttons LIFT at the same time. The operator of the HUP- TILTING-DEVICE must assure that there is no person within the danger zone. Residing on or below the lifted HUP-TILTING-DEVICE is prohibited. A flashing light as an optical signal or an acoustic horn signal the operation of the LIFT-TILT...

  • Page 39: The Automatic Lid Opener (Optional)

    7. The additional equipment 7.5.1.1 The automatic lid opener (optional) Optionally, your PRESS-BOX with integrated HUP-TILTING-DEVICE can be equipped with an automatic lid opener. Depending on the equipment, that will be activated by means of one or two push rods. That must be mounted during the commissioning.

  • Page 40: The Automatic Swinging Lid Opener (Optional)

    7. The additional equipment During transport of the PRESS-BOX, principally dismount the push rod and fix it again at an lateral part of the machine. During the dismounting the HUP-TILTING-DEVICE must be moved into its lowest position. For safety reasons no the push rod can be extended. For the transport, the HUP-TILTING-DEVICE must be moved into its highest position.
  • Page 41 7. The additional equipment While tilting the container, the cone of the swinging lid must reach into the swinging lid opener and open him. Due to tolerance deviations of different manufacturers, the swinging lid opener can be adjusted for a correct function by lengthening or shortening the chain (1) with the help of the screws.

  • Page 42: The Remote Control

    7. The additional equipment The remote control Additionally, the machine can only be operated by means of a remote control (1). That is possible as soon as the remote control is connected. Proceed as follows: 1) Open the lid of the lower housing (2). This device is located at the side of the machine.

  • Page 43: The Hydraulic Lid Opener

    7. The additional equipment The hydraulic lid opener hydraulic lid opener If required, the cover over the compaction chamber can be hydraulically opened and closed. You find the operating keypad at the front or lateral part at the machine. The hook can only be moved when the compacting process was started.

  • Page 44: The Electric Lid Opener

    7. The additional equipment The electric lid opener electric lid opener If required, the cover over the compaction chamber can be hydraulically opened and closed. The operation is carried out via an addi- tional keypad. The lid opener is ready for us when both EMERGENCY STOP buttons are unlocked.

  • Page 45: The Gsm Complete Package

    The customer has to provide a SIM card. Programming of the call number and/or text messages are carried out online via the BERGMANN GSM module programming. You will find more information on our website: www.bergmann-online.com (service).

  • Page 46: The Reset Button

    7. The additional equipment 7.12 The RESET button If your machine is equipped with safety limit switches (e.g. on service doors, etc.), it must also be equipped with a RESET button. For safety reasons, the button must be pressed as soon as the mains plug is pulled, the EMERGENCY STOP button is actuated or the safety limit switch is triggered.

  • Page 47: The Hydraulic Power Pack

    8. The Hydraulic Power Pack General The heart of the BERGMANN PACK-BIN is the hydraulic power pack. It mainly consists of a valve block, an oil filter as well as an electric motor with oil pump. The oil pump, an ecologically friendly and quiet gear pump, conveys oil from the tank into the hydraulic system.

  • Page 48: Oil Change On The Hydraulic Power Pack

    8. The Hydraulic Power Pack Oil change on the hydraulic power pack Only personnel with special know-how and experience of hydraulics may work on the hydraulic system. Prior to the oil change the hydraulic cylinders must be driven in completely, i.e. the compacting piston must be at the top.
  • Page 49 8. The Hydraulic Power Pack 3) Unscrew the filter cap and remove the filter element. Fill with 77 litres of hydraulic oil. You can read the oil level by referring to the adhesive label which is located on the right of the front of the compacting part. If 77 litres are filled up the oil should be just below the MAXIMUM mark.

  • Page 51: Technical Data

    9. Technical Data APB 616 - SN / 15 SN / 18 SN / 20 SN / 23 Machine type Capacity [m³/yd³ ] 14,6/19.1 17,5/22.9 20,3/26.6 23,0/30.1 Forward cycle 34 sec. (20 sec. - with double pump) Return cycle 36 sec. (21 sec. - with double pump) Force of pressure of the cylinder approx.

  • Page 53: Dimensions

    10. Dimensions Illustration standard version (deviations are possible)

  • Page 55: Maintenance And Care

    If no appropriate personnel is at your disposal, our company or one of our service partners will be glad to help you. In order to preserve the efficiency and reliability in service of your BERGMANN - machine, we would recommend annual maintenance by our company or by one of our service partners.

  • Page 56: Maintenance And Inspection List

    11. Maintenance and Care 11.2 Maintenance and inspection list Interval Description of work Procedure see chapter / note prior to every check main switch and function check see ch. 3.2.3 switching on both EMERGENCY SHUTOFF buttons after the check all hydraulic connections visual check, retighten screwed first 20 - 50 for leakages...

  • Page 57: Lubrication Of The Bearings

    11. Maintenance and Care every 6 years replace pressure hoses enter replace- ment into main- tenance plan in one-shift operation (8 hours per day) yearly, in case of several shift operation 10.3 Lubrication of the bearings A proper lubrication of your machine is absolu-tely necessary to ensure a trouble-free operation and to avoid expensive repairs.

  • Page 58: Cleaning Of Electric Motor

    11. Maintenance and Care 11.4 Cleaning of electric motor Motor cover The motor should be cleaned quarterly to prevent it from burning out. To do so, initially open both of the tank room doors. Lift off the motor cover and clean the fan as well as the cover and the motor cooling fins.
  • Page 59 11. Maintenance and Care Crane 2) Then secure the door by proceeding as follows: - Lift the pendulum-type flap by using the crane. - Then secure the pendulum-type flap by means of a support (bearing load 1.5 tonnes). 3) Once the pendulum-type flap is secured, you can begin with the work in the interior of the Support machine.

  • Page 61: Trouble-Shooting

    12. Trouble - Shooting All maintenance and repair works may only be carried out by qualified personnel with corresponding know how. It is absolutely necessary to consider the safety instructions in Chapter 3. Problem Source Solution The machine cannot 1.1 No power available Check supply voltage be switched on 1.2 Plug faulty...
  • Page 62 12. Trouble - Shooting Problem Source Solution Green lamp on control 2.1 Lamp defect Replace lamp panel does not light up Motor running, 3.1 Supply incorrectly Change 2 of the 3 supply phases compacting piston does connected (see fig. 2) not start to move 3.2 Not enough operating The pressure must be checked;...
  • Page 63 12. Trouble - Shooting Problem Source Solution Machine does not 4.1 Time relay for running Replace time relay switch off automa- time defective (see fig. 1, pt. 3) tically Compacting piston 5.1 The pressure at the Please contact dealer stops at top edge of hydraulic valve is not charging opening and adjusted correctly...

  • Page 65: Lubrication Chart

    13. Lubrication chart We draw our customer’s attention to the importance of using the correct lubricants in our machines. The proper application of appropriate lubricants will enhance performance and avoid breakdowns. We therefore recommend the use of Hydraulic oil HLP to DIN 51 524, part 2. The hydraulic tank of the machine is filled with BP Energol HLP-HM 32.

  • Page 67: Guarantee And Liability

    God. 14.3 Copyright BERGMANN maintain the copyright for these operating instructions. The instructions are only intended for the user and his staff. It contains regulations and notes, which may neither completely nor partially be •...

  • Page 69: Ce - Declaration Of Conformity

    DIN EN 60204-1 : 2006 / A1 : 2009 DIN EN 16486 : 2014 Responsible for the compilation of the technical documents : V. Adam, Tel.: 0049 (0) 5933 / 955 - 0 Lathen, 01.02.2016 Heinz Bergmann ( Owner of the above firm )

  • Page 71: Additional Information

    16. Additional information 16.1 Circuit diagram and program numbers Circuit diagram: The program number: Hydraulic circuit: The wiring diagram for this machine can be found in the switch cabinet. The circuit diagram and program numbers are to be entered by the responsible persons during acceptance.
  • Page 73 Bei Ersatzteilbestellungen bitte unbedingt die Serien-Nr. der Maschine angeben! Please quote the serial-no. of the machine when ordering spare parts! P.O.Box 11 52 • Von-Arenberg-Straß e 7 • D-49762 Lathen/Ems • Phone +49 / 5933 / 955-0 • Fax +49 / 5933 / 955-294 eMail info@bergmann-online.com• www.bergmann-online.com...
  • Page 75 Tastatur komplett (Standard) Control panel complete (standard) BA17901_13 Schaltschrank komplett (Standard) Switching cabinet complete (standard) P.O.Box 11 52 • Von-Arenberg-Straß e 7 • D-49762 Lathen/Ems • Phone +49 / 5933 / 955-0 • Fax +49 / 5933 / 955-294 eMail info@bergmann-online.com• www.bergmann-online.com...
  • Page 77 BA17901_1-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen schruppen Allgemeintoleranzen nach DIN ISO 2768 - mittel geschliffen über 1000 2000 4000 1000 2000...
  • Page 79 Bolzen kpl. flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen 000007004 Kegel-Schmiernippel z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen 000000066 Sechskantschraube geschliffen über 1000 2000 4000...
  • Page 81 BA17901_3-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 83 BA17901_4-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 85 BA17901_5-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 87 Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen 179009000 Endschalter Inspektionstür R z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen 179004000 Endschalter Inspektionstür L geschliffen über 1000...
  • Page 89 BA17901_7-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 91 Sicherungsmutter flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen 1.10 000001066 Tensilock-Schraube geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com 1.11 000003004 U-Scheibe flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen 1.12 000002025 Sicherungsmutter geschliffen über...
  • Page 93 EinstellL.-Verschr. flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen 003004059 Öldruckschalter geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com 003001122 Einstell W.-Verschr. flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen 003001126 EinstellT.-Verschr. geschliffen über 1000...
  • Page 95 BA17901_10-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 97 BA17901_11-Z kontrolliert flächenschleifen Von-Arenberg-Straße 7 D-49762 Lathen/Ems schruppen geschliffen Telefon: +49 5933 955 0 Fax: +49 5933 1826 gesehen z 16 www.bergmann-online.com flächenschleifen Allgemeintoleranzen nach DIN ISO 2768 - mittel schruppen geschliffen über 1000 2000 4000 1000 2000...
  • Page 98 BERGMANN Maschinen für die Abfallwirtschaft Von-Arenberg-Straße 7 49762 Lathen Tel. +49 5933 955-0 Fax. +49 5933 955-294 info@bergmann-online.com...

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