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Summary of Contents for HSM VK 4012
- Page 1 VK 4012 SIEMENS SIMATIC PANEL HELP HELP HOME SHIFT ENTER OPERATING MANUAL FULLY AUTOMATIC CHANNEL BALING PRESS HSM VK 4012 Keep this instruction for future use ! 01/2008 6.406.999.125...
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Page 2: Table Of Contents
VK 4012 Contents 1 Safety ..........................4 1.1 Safety devices ........................ 5 1.1.1 Checklist for inspecting safety devices ............... 6 2 Proper use ......................... 7 3 Technical data ........................8 4 Operation .......................... 9 4.1 Machine overview ......................9 4.1.1 Dimensions ....................... 10 4.2 Operating and indicating elements ................ - Page 3 VK 4012 5 Inspection and maintenance work ................... 39 5.1 Notes on maintenance ....................39 5.1.1 Maintenance intervals ....................40 5.1.2 Hydraulic oil selection table ..................40 5.1.3 Anti-friction bearing grease selection table ............... 40 5.2 Hydraulic unit ....................... 41 5.2.1 Changing the hydraulic fluid ..................
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Page 4: Safety
VK 4012 Safety – The baler HSM VK 4012 employs state-of-the-art technology and is safe in operation. However, this machine can become hazardous if used incorrectly by the instructed staff or for purposes other than those for which it was designed. -
Page 5: Safety Devices
VK 4012 Safety devices Check the safety devices: • at the start of every work shift (when operation was interrupted) • at least once a week when the operation is interrupted • after each maintenance or repair Check the safety devices for: •... -
Page 6: Checklist For Inspecting Safety Devices
5. The following warning signs (5) must be attached to the control cabinet. • Safety and maintenance instruction (6.661.999.020) • Flash symbol on yellow background If any signs are missing or illegible, order replacements from HSM and attach them. geprüft Datum ……………………………... -
Page 7: Proper Use
VK 4012 Proper use The HSM VK 4012 channel baling press is designed exclusively for compacting paper and cardboard and any other materials listed in the contract. Any other use is considered improper. The manufacturer accepts no liability for damage resulting from improper use. -
Page 8: Technical Data
VK 4012 Technical data Total weight approx. 7000 kg Wire dimensions ø 3,1 mm, oiled, 40 kg coil (Order no.: 6.661.993.100) Pressing power 450 kN Specific pressing power 69,4 N/cm Bale weight 250 – 350 kg Strapping x-fold 900 x 720 x 600 ÷ 1200 mm... -
Page 9: Operation
VK 4012 Operation Machine overview Switch and terminal box Wire station Hopper Wire brake Twisting unit Hydraulic unit Press channel Wire insertion unit Press channel adjustment Oil cooler Press cylinder Counting wheel Press wagon (= Press ram) Pre-compactor 01/2008 6.406.999.125... -
Page 10: Dimensions
VK 4012 4.1.1 Dimensions 6.406.999.125 01/2008... -
Page 11: Operating And Indicating Elements
VK 4012 Operating and indicating elements SIEMENS SIMATIC PANEL HELP HELP HOME SHIFT ENTER Not-Aus Emergency stop Betriebsbereit Ready for operation 0 0 0 0 1 Handbetrieb Manual operation Automatik Umreifen Automatic operation Strapping 4.2.1 Main switch The main switch is on when it is turned 90° to the right. -
Page 12: Ready" Lamp
VK 4012 4.2.3 “Ready” lamp The green lamp lights up when the baling press is ready for operation. -> The emergency stop button has not been pressed -> No safety switches have been actuated (protective covers, doors) -> No error message is present 4.2.4... -
Page 13: Op 77 Operating Panel
VK 4012 OP 77 operating panel The OP 77 operating panel is operated using a keypad. The keypad is composed of two functional blocks: • System keys (numerical block and control keys) • Function keys All operating conditions and malfunctions are shown on the keypad display. -
Page 14: Key Functions
VK 4012 4.2.1 Key functions Function Purpose Escape Field inputs can be cancelled provided they have not been confirmed by pressing the ENTER key. Acknowledge fault messages. Acknowledge The corresponding ACK LED • Flashes if there are any unacknowledged fault messages •... -
Page 15: K - Keys
VK 4012 4.3.2 K - keys SIEMENS SIMATIC PANEL HELP Length Precom- Strap- Prog. 2 of bale pactor ping HELP HOME SHIFT ENTER Set bale length By repeatedly pressing K1, you can set the bale length to 600 mm, 800 mm, 1000 mm or 1200 mm. -
Page 16: Menu Structure
VK 4012 4.3.3 Menu structure 6.406.999.125 01/2008... -
Page 17: Operating Modes
VK 4012 Operating modes 4.4.1 Setup mode Setup mode enables you to perform individual movement sequences manually. It is mainly used for troubleshooting. Caution! In Setup mode, certain electrical safety functions are disabled. Only specially trained staff may operate the machine in Setup mode. -
Page 18: Manual Mode
VK 4012 4.4.2 Manual mode Turn on the main switch “Ready” • The green lamp lights up (otherwise the display shows a fault message) – Use K1 to set the nominal bale length to 600 mm, 800 mm, 1000 mm or 1200 mm (only if it needs to be changed) –... -
Page 19: Automatic Mode
VK 4012 4.4.3 Automatic mode “Ready” – Turn on the main switch. The green lamp lights up (otherwise the display shows an error message) – Use K1 to set the nominal bale length to 600 mm, 800 mm, 1000 mm or 1200 mm (only if it needs to be changed) –... -
Page 20: Error Messages
VK 4012 Error messages All error messages appear on the display. See also section „Menu structure“. If there are existing several errors at the same time you can scroll to the particular messages with the [Up] and [Down] keys. 4.5.1... -
Page 21: Working With The Control - Error Overview - Trouble Shooting
VK 4012 Warning! Faults in electrical components and supply cables may only be attended to by qualified electricians or HSM service engineers. Before any work on the control cabinet: Turn off the main switch! Note the warning signs: ACHTUNG ! Auch bei ausgeschaltetem Hauptschalter unter Spannung. -
Page 22: Reloading The Baling Press
VK 4012 Reloading the baling press If the baling press needs to be reloaded, i.e. if there is no material in the press channel (e.g. after maintenance work, etc.), proceed as follows: Precondition: • Wooden frame is braced in the press channel -> see "Emptying the press"... - Page 23 VK 4012 Note A first strapping procedure can only be intitated if a minimum bale is reached. length of approx. 400 mm "Strapping" – Press the K2 key to activate the strapping procedure "Strapping" • the blue indicator light lights up.
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Page 24: Threading The Strapping Wires
VK 4012 4.6.1 Threading the strapping wires – ;ove the press wagon to its initial position and turn off the main switch 4.6.1.1 Wires on the twisting side Undo the wires holding the wire coils together in the wire stations and pull the beginning of the wire out of the core of the coil. - Page 25 VK 4012 Thread the beginning of the wire through the openeing in the frame. Thread the wire behind the guide rollers and push it on towards the press channel. Push the wire through the opening in the frame and pull it up to the square tube on the press channel.
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Page 26: Wires On The Insertion Side
VK 4012 4.6.1.2 Wires on the insertion side Undo the wires holding the wire coils together in the wire stations and pull the beginning of the wire out of the core of the coil. Thread the wire through the wire brake (5). - Page 27 VK 4012 Push the wire through the slot in the frame and the guide bush behind. Pull the wire between the guide roller and guide pin and on towards the press channel. Push the wire through the opening in the frame and pull it up to the square tube on the press channel.
- Page 28 Strapping wire ø 3.1 mm / 40 kg coil / oiled Part. no.: 6.661.993.100 Caution! Always use special HSM strapping wire. The wire must be oiled and not rusty, otherwise components of the wire station may be damaged. Staff can cut themselves on sharp wire ends and should therefore always wear safety gloves.
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Page 29: Automatic Compression
VK 4012 Automatic compression – Turn on the main switch. “Ready” • The green lamp lights up (otherwise the display shows an error message) – Use K1 to set the nominal bale length to 600 mm, 800 mm, 1000 mm or 1200 mm (only if it needs to be changed) –... -
Page 30: Strapping Procedure
VK 4012 Strapping procedure The strapping is initiated by the counting wheel both in manual and fully automatic "Bale finished" operation. When the blue light symbol lights, the bale is strapped fully automatically when the press ram stops in its foremost position. - Page 31 VK 4012 The twisting fingers (14) perform one turn and the twisting disks (15) catch the wires. The shearing blades (16) in the twisting unit cut the wires. Subsequently the wires are twisted approx. 7 times. 01/2008 6.406.999.125...
- Page 32 VK 4012 The wire insertion cylinders (12) return to their initial position. The twisting fingers (14) proceed three backward rotations and eject the twisted wire ends. The press ram(11) is unlocked and returns to its rear limit position. 6.406.999.125 01/2008...
- Page 33 VK 4012 Caution! Never put the baling press out of operation during the strapping process! Exception: the machine can be switched off in an emergency using the emergency stop button. Before you switch off the press, always move it to the initial position so that the piston rods can retract into the cylinders.
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Page 34: End Of Wire
- Join and twist the ends of the old and new wires. - Swivel twisting resp. insertion unit towards the press and screw it tight - Turn on the main switch “Automatic mode” - Press HSM strapping wire ø 3.1 mm (oiled) Part no.: 6.661.993.100 / 40 kg coil 6.406.999.125 01/2008... -
Page 35: Clearing The Press Channel
VK 4012 4.10 Clearing the press channel Caution! Work in Setup mode may only be carried out by authorised, instructed staff. When the press channel needs clearing proceed as follows: • The press ram must be in the initial position •... -
Page 36: Bracing The Wooden Frame
VK 4012 4.10.1 Bracing the wooden frame 900 mm 80 x 120 mm Before starting up the press again: - Place a wooden frame inside the press channel (roughly below the press channel adjustment apparatus) and lower the cover again - Close the press channel ->... -
Page 37: Relieving The Press Channel
VK 4012 4.11 Relieving the press channel After shearing, the material is compressed and pushed into the conical press channel. The pressure in the press cylinder is monitored by a pressure transducer on the control block. The opening and closing of the press channel adjustment unit depends on the properties of the material or the pressing power. -
Page 38: Shutdown
VK 4012 Manually Loosen the lock nuts and unscrew the throttle screw N (= emergency drain) by roughly one turn -> The adjusting cylinder lowers. Seat valve block 3SW8HZ01X-350V/G24-Z4 Part. no. 6.657.195.029 4.12 Shutdown Caution! Never shut down the baling press during the strapping process! Exception: in an emergency ->... -
Page 39: Inspection And Maintenance Work
VK 4012 Inspection and maintenance work Notes on maintenance Malfunctions which are due to inadequate or incorrect maintenance can lead to expensive repairs and long machine down-times. Regular maintenance is therefore essential. For this purpose, we recommend a maintenance and inspection contract. -
Page 40: Maintenance Intervals
VK 4012 5.1.1 Maintenance intervals The maintenance intervals listed here apply to single-shift operation. 1 - Shift - Operation 3 - Shift - Operation 170 h = 1 month 500 h = 1 month 500 h = 3 months 1500 h = 3 months... -
Page 41: Hydraulic Unit
VK 4012 Hydraulic unit 5.2.1 Changing the hydraulic fluid Interval: 2000 operating hours or once a year Note Systems with a circulation ratio of no more than (in this case: ~ ) and which are well filled and ventilated can attain 0.33... - Page 42 VK 4012 • With the press ram in the rear limit position - Empty the hydraulic fluid tank -> Unscrew the oil drain plug and catch the oil in a collecting vessel or completely remove the venting filter and siphon off the oil...
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Page 43: Changing The Pressure Filter
VK 4012 5.2.2 Changing the pressure filter Interval: after malfunctions, otherwise at least every 2000 operating hours or once a year The contamination of the pressure filter is monitored by a pressure transducer. If the contamination reaches a certain degree an malfunction message is displayed on the display. -
Page 44: Press Wagon
• If the shearing blades are damaged, they must be repaired or replaced. Caution! Special skills are required for adjusting the blade clearance or press wagon guide. Only allow adjustments to be performed by HSM `s specialist staff. 6.406.999.125 01/2008... -
Page 45: Press Wagon With Manual Central Lubrication
VK 4012 5.3.2 Press wagon with manual central lubrication Interval: 40 operating hours or once a week • With the press ram in the rear limit position Warning! Crushing and shearing elements are now uncovered. The danger area must be sufficiently guarded. -
Page 46: Checking The Steel Stripper For The Roller Tracks
VK 4012 5.3.3 Checking the steel stripper for the roller tracks Interval: 170 operating hours or once a month • Press wagon in starting position Warning! Exposed crushing and shearing points. Switch off main switch and save it with a padlock. -
Page 47: Twisting Unit
VK 4012 Twisting unit 5.4.1 Inspecting and cleaning the shearing blades Interval: 170 operating hours or once a month • With the press ram in the rear limit position - Unscrew the eye bolts on the twisting unit and swivel it through 90°... -
Page 48: Inspecting The Twisting Disks
VK 4012 5.4 .2 Inspecting the twisting disks Interval: 170 operating hours or once a month If twisting is poor or does not take place at all, the twisting disks (8) should be inspected immediately. • With the press ram in the rear limit position - Unscrew the eye bolts on the twisting unit and swivel itthrough 90°... -
Page 49: Lubricating The Twisting Drive
VK 4012 5.4.3 Lubricating the twisting drive Interval: 1000 operating hours or everry 3 months - Unscrew the metal lid of the protective cover • The gears and drive chains are now visible - Lubricate the gear wheels and cylinder bearing with multi-purpose grease... -
Page 50: Wire Insertion Unit
VK 4012 Wire insertion unit Interval: 40 operating hours or once a week • With the press ram in the rear limit position - Unscrew the eye bolts on the wire insertion unit and swing it through 90° - Clean any dirt from the area... -
Page 51: Lubricating The Press Cylinders
VK 4012 Lubricating the press cylinders Interval: 500 operating hours or every 3 months - Remove the protective covers on both sides of the baling press - Lubricate the bearings of the cylinders with bearing grease - Re-install the protective covers 01/2008 6.406.999.125... -
Page 52: Precompactor
VK 4012 Precompactor 5.7.1 Lubricating the bearings Interval: 500 operating hours or every 3 months - Using a grease gun pump approximately 3 strokes of bearing grease into the two grease nipples on both sides of the baling press 5.7.2... -
Page 53: Wire Brake
VK 4012 Wire brake Interval: 1000 operating hours or every 6 months - Check the wire guide rollers (12) for smooth operation and change them if they are damaged - Check the drill bushes (13, 14) for wear and change them if necessary pos. -
Page 54: Oil/Air Cooling Unit
VK 4012 Oil/air cooling unit Interval: 500 operating hours or every 3 months - Keep the ventilation grilles free of dirt. If necessary clean them with a vacuum cleaner! 6.406.999.125 01/2008... -
Page 55: Adjusting The Safety Ripcord
VK 4012 5.10 Adjusting the safety ripcord See the checklist for inspecting the safety devices The safety ripcord is activated when the button (C) on the ripcord switch is pushed in. The button must come out when the rip cord is pulled. -
Page 56: Electric Motors
Warning! Faults in electrical components and supply cables may only be attended to by qualified electricians or HSM service engineers. Before any work on the control cabinet: Turn off the main switch! Note the warning plates:... -
Page 57: Screw Connections
VK 4012 5.12 Screw connections Check firmness of screw connections with a torque wrench every 1000 operating hours and retighten if necessary. Employed screws: Property class 8.8 / 10.9 Thread sizw Tightening torque (Nm) Property class Property class Property class 10.9... -
Page 58: Inspection Schedule
VK 4012 5.13 Inspection schedule Pos. Interval Component Action 40 h Manual central lubrication Lubricate 40 h Wire insertion unit Clean / lubricate needle heads 170 h Wire insertion unit Clean / check wire guide rollers 170 h Roller track stripper (rear press ram) -
Page 59: Hydraulic Diagrams
VK 4012 Hydraulic diagrams Hydraulics with dual internal gear pump / 9,2 kW 01/2008 6.406.999.125... - Page 60 VK 4012 6.406.999.125 01/2008...
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Page 62: Hydraulics With Axial Piston Pump / 15 - 22 Kw
VK 4012 Hydraulics with axial piston pump / 15 - 22 kW 6.406.999.125 01/2008... - Page 63 VK 4012 01/2008 6.406.999.125...
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Page 65: Hydraulics With Sliding Vane Pump / 15 - 22 Kw
VK 4012 Hydraulics with sliding vane pump / 15 - 22 kW 01/2008 6.406.999.125... - Page 66 VK 4012 6.406.999.125 01/2008...
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Page 68: Wiring Diagrams
VK 4012 Wiring diagrams Note The wiring diagrams are supplied separately with the machine. (in the control cabinet) 6.406.999.125 01/2008...
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