PTR Vertical Baler Mnaual.pdf

PDF 3 MB Posted May 7, 2024

Attached to: MCBH Machine Maintenance Solicitation Federal contract opportunity
Solicitation number: M00318MACHINEMAINTENANCESOLICITATION
Issued by: United States Marine Corps

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Written by GovTribe AI · May 7, 2024

This document appears to be an operations and safety manual for a PTR vertical baler machine. The manual provides detailed information on the installation, operation, maintenance, and troubleshooting of the baler. It covers safety procedures, operating instructions, control layout, baling wire information, troubleshooting guides, and replacement part details. The manual emphasizes operator safety as the top priority and provides comprehensive training guidelines. It also outlines the warranty coverage for the equipment.

The related federal contract opportunity is a solicitation from the United States Marine Corps for quarterly maintenance services on 10 industrial machines at Marine Corps Base Hawaii. The solicitation provides details on the Performance Work Statement, submission requirements, and pricing information. Offerors are instructed to complete the attached quote spreadsheet and CLIN lines within the solicitation.

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2207 EAST ONTARIO STREET, PHILADELPHIA, PA. 19134

VERTICAL BALERS

FOR DEPENDABLE, COST-SAVING RECYCLING

ENGINEERED FOR SUPERIOR DURABILITY & MAXIMUM SAFETY

Model #_______________

Serial #_______________

TABLE OF CONTENTS

INTRODUCTION 3

GENERAL 4

WARRANTY 5

SAFETY/TRAINING INFORMATION 6-10

CONTROL LAYOUT 11

BALER OPERATING MODES 12

OPERATING INSTRUCTIONS 13-16

SAFE BALE EJECTION PROCEDURE 17-18

BALING WIRE IMFORMATION 19

PLC TROUBLESHOOTING 20-25

GENERAL TROUBLESHOOTING 26-30

LOCKOUT PROCEDURES 31-32

BALER MINIMUM CLEARANCE CHART 33

INSTALLATION INFORMATION 34-36

MAINTENANCE INSTRUCTIONS 37-40

ELECTRICAL INFORMATION 41-48

ELECTRICAL CIRCUITS 49-54

HYDRAULIC SCHEMATIC 55-56

PRESSURE SETTING & CHECKING PROCEDURES 57-58

BALER CYLINDER REPLACEMENT 59

DECAL & INSTRUCTION PLATES PLACEMENT 60

PARTS & SERVICE 61

WALL BRACKET KIT 62

MECHANICAL PARTS INFORMATION 63

LIMIT SWITCH INFORMATION 64

BALER PARTS DESCRIPTION & NUMBERS 65-67

Revised 10/2016

Congratulations on your purchase of a PTR Baler.

PTR is known for producing balers with the highest safety and quality standards in the industry.

All PTR Balers are factory tested and receive a vigorous quality assurance inspection to insure top performance and safety in the field.

Many of the advanced design features on our balers make operation easy without sacrificing safety.

At PTR Baler and Compactor, operator safety is our number one priority. We ask that all operators read and fully understand this manual and view the provided safety/operational video. All baler operators must be at least 18 years old.

UL Approved and CUL Approved.

***IMPORTANT***

A. The operating keys are located inside of the control panel. A tool is required to open the control box and only trained and authorized service personnel should enter following proper lockout/tagout procedures.

B. When power has been properly connected, press the Down/Up button and observe the direction of the rotation of the motor. Look at the motor fan, proper rotation is clockwise. (As indicated by arrow on motor). If fan rotation is not clockwise, follow lock out/tag out procedures and interchange any two of the three power conductors, re-check for proper rotation. This should correct the problem.

GENERAL

PTR’s vertical downstroke baler is designed with the operator’s safety in mind.

However, as with most industrial equipment, the ultimate responsibility for safety rests with the operator.

It is the operator’s duty to be thoroughly familiar with this manual and video before operating the baler.

Additional operator responsibilities are to insure that the units’ operation is in accordance with safety requirements and codes, especially all applicable Occupational Safety and Health Administration (O.S.H.A) standards and American National Standard Institute (A.N.S.I) Regulations.

PTR strongly recommends that current, completed, applicable ANSI and OSHA standards are available to operators at all times.

PTR Baler and Compactor Company strongly recommends: Keep the baler clean and free of contaminant. Failure may cause illness or death. Bale clean Cardboard only.

Note:

The information contained herein is subject to change without notice.

We reserve the right to make changes, and alterations to the equipment and information contained herein at anytime.

WARRANTY

PTR BALER AND COMPACTOR COMPANY warrants all equipment when operated, maintained and installed, and used in normal service for a period of three hundred sixty-five

(365) days after the date of installation to be free from defects in material and workmanship.

The responsibility of PTR BALER AND COMPACTOR COMPANY, under this warranty to the purchaser, except as to title, shall not in any case exceed the cost of correcting defects in the equipment. Warranty repair or replacements shall not extend the initial warranty period.

PTR BALER AND COMPACTOR COMPANY shall under no circumstances be responsible for any loss of business or profit to the purchaser or any other consequential damages in connection with the sale of such equipment or any obligation under this warranty. The foregoing shall constitute the sole remedy of the purchaser, and the responsibility of PTR BALER AND

COMPACTOR COMPANY.

Warranty repairs and/or replacements (at our option), will be made for both parts and labor. The authorized service center must use PTR BALER AND COMPACTOR COMPANY authorized parts. Labor will be allowed at a maximum of ($40) hourly rate. Premium rates will be at the customer’s accountability. All warranty calls must be called into PTR BALER AND COMPACTOR COMPANY for dispatch. 1-800-523-3645

All parts, components or accessories requiring repair or replacement, within the warranty period, shall be returned PREPAID, to the PTR BALER AND COMPACTOR COMPANY at the expense of the buyer, lessee, or consignee. The PTR BALER AND COMPACTOR COMPANY will return at its expense replacement parts, components or accessories found to be defective.

Shipment of parts under warranty shall be made via United Parcel Service or Parcel Post. Cost of any other means or transportation shall be paid by the equipment user.

PTR BALER AND COMPACTOR COMPANY does not assume any responsibility of liability for improper use of the equipment or improper installation of any unit, part or accessory which may cause damage to the unit. The installation of parts or accessories manufactured or sold by any other supplier shall be deemed to void all warranties.

Warranty claims for equipment will not be proceeded unless a properly completed and signed warranty card (attached to the installation checklist) has been received.

NON-WARRANTABLE REPAIRS

1. Routine adjustments; limit switches, pressure switch, or relief valve.

2. Tightening of hydraulic fittings and terminal connections.

3. Electrical fuses, tripped over loads or breakers.

4. Power to the unit, phase change, motor rotation change, facility electrical problems, or damage by customer from improper electrical hook up to unit.

5. Addition of hydraulic oil.

6. Ejector system parts such as chains, t-hooks, and shackles.

7. Repairs necessitated by improper use such as failure to follow instructions and abuse of equipment.

8. Operator error (example: chamber door not closed tight enough or gate not pulled down flush to top of chamber door)

9. Damage or install errors from customer supplied installer.

NOTE: Always have Serial and Model Number of unit ready when calling for service.

Baler Safety and Training Outline

I. Scope - Employers should designate a Safety/Risk Manager or equivalent person that has qualifications necessary to evaluate and manage safety and operational training issues related to the operation of baling equipment as part of their operator safety and training program. Each individual baler owner should develop their own training program specific to their equipment, personnel, processes, environment, and unique site application.

A. Your company safety official should conducted a hazard assessment of the various baling equipment utilized at your facility and use the information from the hazard assessment to develop a company specific baler safety training program. The hazard assessment should include at a minimum the following:

1) Identification of material being baled. (clean cardboard only)

2) Hazards associated with the baling equipment and material baled.

3) An initial and then periodic review of the capabilities, qualifications, and training of any person who may potentially encounter the identified hazards.

B. Your company safety official should evaluated the means and methods of controlling the hazards identified in the hazard assessment; including information such as industry and regulatory requirements, instructions for the operation, inspection and maintenance of balers, and other information appropriate to the identified hazards.

1) Your company safety official should ensure compliance with applicable OSHA Code of

Federal Regulations under 29 CFR 1910 and applicable ANSI baling equipment standards under ANSI Z245.5 and Z245.51.

2) Your company safety official should ensure that all employees (including supervisors) engaged in the operation, cleaning, maintenance, service, or repair of the baling equipment are properly trained according to their assigned jobs or tasks. The Baler

Safety Video supplied by PTR should be shown to all potential operators and the manual should be read thoroughly.

3) Contractors should not be permitted to operate in-house baling equipment unless they have been properly trained and authorized.

C. As a leading baler manufacture we recommend that your company utilizes the following baler safety training outline and baler safety video which cover the following:

1) Pre-start up

2) Operation – (operation procedures are also posted on front of control box)

3) Safe bale ejection

4) Inspection / maintenance (see baler safety inspection checklist included in this manual)

5) Operator Safety / Prohibited practices

6) Training requirements (necessary training as identified from hazard assessment and use of baler safety video.

7) Record keeping – (see Attachment A)

D. Your company safety official should periodically review their company specific program to ensure the effectiveness of your safety program and make revisions as necessary.

Heed & Obey Warning Signs

Signs such as Danger, Caution, Warning, and Attention are on the machine for your protection.

Warning signs must remain in place and be kept in readable condition. Report and replace all damaged or missing warning signs.

Operational carelessness and safety shortcuts can cause serious injury or death! Follow safety

Guidelines and be safety conscious.

Every operator should read operators manual and the operating instructions posted on the front of the control box.

The operating key should not be left in the machine when the machine is left unattended.

Prior to Start Up

1. Wear proper safety equipment as recommended by your company safety official.

2. Never allow yourself or anyone involved with the baling system to be under the influence intoxicants or narcotics while the baler is operating.

3. Walk around the baling system to check for proper equipment condition. Open hopper door and check inside the baler.

4. Be positive no one is working on the baler or adjoining equipment. With ram in up position, lift gate and look inside main chamber area to be sure no one is inside.

5. The following operational check should be conducted prior to each shift:

· With the gate raised, press all buttons in any order or combination. No motion should occur.

· Close gate and start machine, open gate during downward motion. Machine should immediately stop.

· Close gate and start machine. Gate will automatically open with upward ram travel. During this time, raise the gate off the ram. Machine should immediately stop.

· Demonstrate that the machine will not operate in “automatic” if the main bale door is open.

Operator should do this by having the ram in the up position and with the gate closed set the selector switch to down and push. Release the button and the ram should stop.

6. It is imperative that proper housekeeping is performed in the area behind and around the baler.

· The areas behind the baler must be kept clean and free of debris, pallets and any other material.

· PTR recommends that this area be inspected daily to maintain the safe operation of vertical balers.

· Bale wire stored in the area of the baler must be stored in an approved horizontal storage system.

7. If anything does not function as indicated, immediately report problems to supervisor, remove key, lockout machine, and call for service.

Operator Safety

Always Use Lockout/Tagout

Power must always be disconnected and locked out before working within or performing maintenance on the baler or associated equipment. Standard Lockout/Tagout procedures should be followed in accordance with the OSHA standard 1910.147 “The control of hazardous energy”.

A group safety lock should be used when multiple employees are working on the machine at one time so that all locks need to be removed in order to be able to re-energize the baler. Every employee who works on or with the baler should have his own lock and key. Never assume you are protected by another employee’s safety lock.

Keep Safety Guards in Place

Safety guards must be kept in place and secure at all times. Keep the guards in good repair with periodic maintenance. Keep limit switches free of debris or obstructions. Do not override of bypass safety switches or features.

If feed gate becomes difficult to open or close, maintenance should be informed.

Operators should be instructed on how to conduct a brief visual safety inspection that includes areas door hinges and latch. Also how to conduct a visual inspection of the ejector chains, t-hooks, and shackles. Operator should know that maintenance should be called if there is any evidence of damage or if anything looks “different” as opposed to prior inspections.

Practice Fire Prevention

· Keep fire extinguishers accessible at all times. Use the extinguisher recommended for the material being baled. It should be rated safe for use of electrical fires.

· Never smoke close to combustible material.

· Clean the area before welding or other repair activities that produce sparks or source of ignition.

· Keep tank and motor areas free of oil, dust, or paper accumulations.

Keep a Clean Machine

1. Bale only clean cardboard.

2. Clean motor area monthly.

3. Remove any wedged cardboard from sides and back of ram. Remove any cardboard on the top of the ram daily.

4. Remove any cardboard stuck on retainer dogs and limit switches.

5. Keep baler clean and free of dirt and other contaminants. Failure to do so may cause illness or death.

6. The areas behind the baler must be kept clean and free of debris, pallets and any other material.

7. PTR recommends that the area behind the baler be inspected daily to maintain the safe operation of vertical balers.

Remember! All possible Dangers cannot be predicted. Your own safety attitude and habits are your best protection.

Additional Safety Guidelines for Baler Operation

1. Only authorized personnel 18 years of age or older, who are trained in baler operation are permitted to operate the baler.

2. The owner and operator are responsible for the safety of the employees and should be familiar with applicable OSHA and ANSI standards.

3. Operate in accordance with the owner’s manual supplied with your baler.

4. Do not set the hydraulic pressure above factory specs. Specified pressures are listed inside the control box. Severe baler damage and/or personal injury could result.

5. Bale only the specified material for which the baler was built. And also for which the hazard assessment was conducted for.

6. Never overload the baler chamber.

7. Never enter the main chamber area unless the power is disconnected and locked out.

8. If work on or in the baler is required, disconnect the power to the baler, and lockout. Never assume that you are protected by another employee’s safety lock. Before restarting, repeat the

“Prior to Start Up” procedures.

9. Anytime the baler is shut down, the “Prior to Start up” procedures should be repeated.

10. Never bale aerosol cans or containers filled with liquid.

11. Use of safety glasses and forearm length leather gloves are strongly recommended when handling baling wire.

12. The areas behind the baler must be kept clean and free of debris, pallets and any other material.

13. PTR recommends that the area behind the baler be inspected daily to maintain the safe operation of vertical balers.

14. Bale wire stored in the area behind of the baler must be stored in an approved horizontal storage system.

Attachment A

TRAINING RECORD

Employee Name Description of Training and other Notes Date of

Training

Seen Video Yes/No

Employee Signature

Store name and location: ______________________ Training Video Present at Store: ____________________

Manual present at Store: __________________

Store #: _______

Name or Trainer: ____________________

Store Manager Name: _________________________ Signature of Trainer: ___________________

Signature and Date: ____________________________

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BALER MODES

There are three basic modes of operation a downstroke vertical baler will perform

– loading, compression, and ejection.

Material is evenly loaded into the baler chamber while the safety charging gate and ram are in the UP position. The baler chamber door is closed and locked.

COMPRESSION

With the safety gate down, the ram pushes the material down into the bottom of the baler chamber area. Retainer Dogs located on baler chamber door help hold the compressed material down while the ram travels up to the loading position, opening the baler safety charging gate as it travels up.

EJECTION

When full bale indicator arrows on the ram face and baler frame match, the bale is the proper size. Lift gate, unlatch and open chamber door at least 110 degrees, slide baling wire through slots and tie off all wires.

Close feed gate by pulling it down completely.

Attach the ejector “T” hooks at back of baler to ram ejector lugs, set the

UP/DOWN switch located on baler electrical box to the UP position, press and hold button in until the bale ejects. Keep clear of ejecting bale.

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PTR Baler & Compactor Co.

2207 E. Ontario St Philadelphia, PA 19134

PHONE: 215-533-5100 * FAX 215-533-8907

Quality * History * Service* Value

Baling wire recommendation for PTR Baler and Compactor Company’s standard built balers producing bales of ordinary cardboard. Consult PTR Baler and Compactor for wire recommendations for non-cardboard applications.

MODELS: 1800HD, 2318, 2300HD, 3400HD, 3600HD, 7230

Minimum of 14 Ga galvanized steel wire approximately 14’ long with one end looped for bale tie off.

Wire is to have a tensile strength of approximately 70,000 to 85,000 psi or more and a break strength of approximately 380 to 420 pounds or more.

MODELS: 360, 420

Minimum of 15 Ga galvanized steel wire approximately 9’ long with one end looped for bale tie off.

Wire is to have a tensile strength of approximately 75,000 to 80,952 psi or more and a break strength of approximately 300 to 340 pounds or more.

MODELS: 5000HD, 7200HD

Minimum of 12 Ga galvanized steel wire approximately 16’ long with one end looped for bale tie off.

Wire is to have a tensile strength of approximately 70,588 to 76,136 psi or more and a break strength of approximately 600 to 670 pounds or more.

Additional Information:

At least four baling wires must be used per bale. Slots are available for five or more bailing wires to be used.

Care should be exercised when handling any potentially sharp objects such as bailing wire.

Follow appropriate precautions and procedures.

Always stand clear of ejecting bale.

Baling wire recommendation is based on industry standard and past history of success with this wire in a wide variety of customer environments and usages of balers and other vertical balers with comparable compression yielding bales of comparable size and weight.

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TROUBLE SHOOTING GUIDE

BALER WILL NOT OPERATE

POSSIBLE CAUSE POSSIBLE REMEDY

A) No Power 1. Check main power source

1. Check if power key switch is on

2. Reset Overloads

3. Check motor starter contacts for extreme wear

4. Check if gate is down

5. Check bale chamber door is closed

B) Limit Switch (Ram) 1. Upper Limit Switch malfunction

1. Upper Limit Switch needs adjustment

C) Motor Overload Tripped 1. Reset overload on motor starter

2. Check current Load (Amps)

D) Blown Fuses 1. Replace fuses – Turn power off at wall disconnect switch

E) Electrical Malfunction 1. Perform electrical system continuity check

BALER WILL NOT OPERATE IN AUTO

(All the above can be applied to the Auto Mode)

A) Door Switch 1. Main door may not be closed properly against switch

2. Door Switch loose

3. Door Switch malfunction

B) Pressure Switch 1. Improper pressure setting

2. Bad electrical contact

RAM WILL NOT TRAVEL DOWN

A) Directional Valve 1. Check valve solenoid

Malfunction 2. Push in manual override, pins are on each end of solenoid

B) Electrical Malfunction 1. Perform electrical system continuity check

C) Material Jamming Ram 1. Remove all jamming material from ram

D) Ram Switch 1. Ram Switch not in proper position

2. Limit Switch malfunction.

3. Adjust Limit Switch

4. Pedal Switch jammed in down position.

E) Pressure Switch 1. Improper pressure setting

F) Solenoid 1. Check for shifting of solenoid (check light)

G) Proximity Switch 1. Proximity switch must detect plate mounted on gate counter weight

2. Proximity switch malfunction

RAM WILL NOT TRAVEL UP

A) Hydraulic Fluid Level Low 1. Check hydraulic fluid level gauge on reservoir, add hydraulic fluid.

B) Pump Taking Air 1. Check fittings to see if they are tight

C) Directional Valve 1. Check valve solenoid

Malfunction 2. Push in manual override, pins are on each end of solenoid

D) Electrical Malfunction 1. Perform electrical continuity check

E) Material Jamming Ram 1. Remove all jamming material from ram

F) Incorrect Pump Rotation 1. Check fan rotation on motor (fan should turn clockwise)

G) Relief Valve 1. Check setting

2. Replace valve

H) Pump Not Building Pressure 1. Replace pump

I) Hydraulic System Pressure 1. Check pressure setting

Is Low 2. Check relief valve for malfunction

3. Worn pump

J) Pressure Switch 1. Improper pressure setting

K) Cylinder 1. Check for internal/external cylinder leakage

L) Up Stop Limit Switch 1. Check arm is free and not activated

M) Gate 1. Make sure gate is down

2. Check switch

RAM DRIFTS DOWN

A) Directional Valve 1. Spool may be jammed

B) Cylinder 1. Seals may be damaged (Replace seals or replace cylinder)

C) (optional) Regenerative Hydraulic Valve 1. Hoses may be reversed. Verify “A” to extend and “B” to retract.

D) Hydraulic Leak 1. Check all connections for leaks.

MOTOR DOES NOT STOP WHEN RAM

RETURNS TO THE UP POSITION

A) Limit Switch 1. Check for broken limit switch arm

2. Improper switch adjustment

3. Bad contacts in motor starter.

HYDRAULIC PRESSURE NOT OBTAINABLE

A) Worn Pump

B) Cylinder bypass

C) Relief valve malfunction

D) Improper pressure setup

E) Loose fitting

BALER IS NOISY

A) Ram Rubbing 1. Cylinder and ram may not be centered in chamber

2. Cylinder rod may be bent

B) Noise at Directional Valve 1. Directional valve worn

2. Check for broken springs inside valve

PUMP NOISE

A) Oil Reservoir Level Low 1. Check oil level gauge on reservoir

(add oil if necessary)

B) Worn Pump 1. Check hydraulic system pressure

C) Restricted Inlet Strainer 1. Replace strainer

D) Air Leakage in Oil 1. Check for foamy hydraulic fluid in reservoir oil level gauge

Baler Operational And Repair Safety Instructions

WARNING: DO NOT OPERATE BALER WITHOUT THOROUGH

UNDERSTANDING OF INSTRUCTIONS.

DAILY: PERFORM SAFETY CHECK TO ENSURE PROPER INTERLOCK FUNCTION

ONLY AUTHORIZED PERSONNEL SHOULD BE ALLOWED TO OPERATE THIS

BALER

Keys to this machine should be removed between uses to prevent unauthorized operation.

Federal regulation prohibits use of this machine by people under the age of 18.

DO NOT ATTEMPT TO DEFEAT THE PURPOSE OF ANY SAFETY SWITCH!

Immediately replace any switches that are found not to be in proper working condition

DO NOT OPERATE BALER UNLESS GATE IS FULLY CLOSED

KEEP CLEAR OF THE BALER WHILE EJECTING A BALE

THE BALER SHOULD NEVER BE ENTERED OR SERVICED

WITHOUT FOLLOWING THE LOCK-OUT TAG-OUT

PROCEDURE

The baler should not be restarted until all workers have exited the baler and moved out of the way of all moving components.

Lock-out procedure is listed on the following page.

ONLY AUTHORIZED PERSONNEL SHOULD BE ALLOWED TO

OPEN THE PANEL BOX

Baler operates with high voltage, and should not be serviced by people who are not certified to do so.

Lock-out procedure must be used before opening panel box.

BEWARE OF MOVING COMPONENTS

The gate and door should not be opened at anytime while the ram is advancing under pressure. The user should stand away from baler while in operation, and should never reach into the machine in any way.

DO NOT CLIMB THE BALER UNDER ANY CIRCUMSTANCE

User should also be familiar with applicable safety codes, including those issued by ANSI, OSHA, UL, NFPA, etc.

NOTICE: WHEN CHANGING CYLINDER, PERFORMING

HYDRAULIC SERVICE, OR PERFORMING STRUCTURAL

REPAIRS Be absolutely sure to fully support the ram. Suggested method shown on drawing AB340367 in the user manual

DANGER: THE AREAS BEHIND THE BALER MUST BE KEPT CLEAN AND

FREE OF ANY DEBRIS, PALLETS, AND ANY OTHER MATERIAL

Balers that are found not to be operating safely, must be

IMMIEDIATELY reported to PTR Baler and Compactor

AT: (800) 523-3654

LOCKOUT/TAGOUT PROCEDURE DEVELOPMENT INFORMATION

Warning! Before performing maintenance or service work on the baler, the OSHA

(Occupational Safety and Health Administration) 29 CFR (Code of Federal Regulations)

1910.147 requires that each company develop, maintain, and follow a lock-out / tag-out procedure for employees and equipment.(standard should be referenced for definitions to various terms such as isolation, affected, and authorized.) This procedure must be followed prior to performing maintenance or service work or entering any hazard area that may exist.

The following is merely a guideline for creating a company/equipment specific lock-out / tag-out procedure and is not intended to supplant either the specific company procedure or

OSHA standard 29 CFR 1910.147 and 29 CFR 1910.147 appendix A.

1. All “affected” employees shall be notified that equipment is being shut down and locked out prior to performing service or maintenance.

2. The equipment, if operating, shall be shut down by normal means and the energy-isolating device shall be de-activated to isolate the equipment from the energy source by an “authorized” employee. Isolation shall include:

a) Removing the key from the key-lock ON-OFF switch on the baler control box

b) turning off disconnect and affixing a lock, securing disconnect in the off position

c) Affixing a tag to the lock, clearly identifying the individual who locked out the machine, warn against hazardous conditions, and actions required to avoid hazardous conditions, such as, “Do not operate”

d) Placing operating equipment in such a position as not to be subject to possible free fall and/or installing additional blocking devices to prevent freefall. See drawing number AB340367 in user manual

e) Relieving stored hydraulic or pneumatic pressure, after blocking devices are installed

3. Equipment isolation shall be verified by activating the normal operating controls, ensuring first that no personnel are exposed (insure operating controls are returned to the neutral or “off” position after verifying the isolation of the equipment).

4. When the servicing or maintenance is completed, only after checking that the equipment is ready to operate, ensuring that the surrounding area is clear, that employees are safely positioned or removed from the area, and verifying that controls are in neutral, shall the lockout devices be removed and the equipment be re-energized.

Tags and locks must be removed by the same person who attached them.

5. Affected employees shall be notified that the servicing or maintenance has been completed and the equipment is ready for use.

PTR Baler & Compactor strongly recommends that current and applicable ANSI and

OSHA standards be made available to operators at all times. At the time of printing the applicable OSHA Standard 29 CFR1910.147 / 1910.147 Appendix A applied. Also reference ANSI Z245.5, others may also apply.

DIMENSIONS AND MINIMUM CLEARANCES

. OF INSTALLED BALERS: .

MODEL 360 420 1800HD 2300HD 3400HD 3600HDLP 5000HD 7200HD

A 7' -11 1/2" 7' -11 1/2" 11' -6" 12' - 8" 12' - 7" 7' - 11.5" 12' - 6" 12' - 6"

B 4' - 2" 4' - 10" 5' - 7" 6' - 3" 6' - 5" 6' - 9" 6" - 5" 7' - 3"

C 2 '- 10" 2 '- 10" 3 '- 7" 3- ' 9" 3' - 10.5" 4' - 5" 3' - 11" 4' - 10"

D 5' - 3" 5' - 4" 7' - 4.5" 8' 8" 8' - 7" 6' - 2" 8' - 7" 8' - 7"

E 6' - 8" 7' - 2" 9' - 7.5" 10' - 9.5" 10' - 8" 7' - 12" 10' - 11" 10' - 11"

F 3' - 11" 4' - 6" 5' - 1" 5' - 8.5" 5' - 10" 5' - 11" 5' - 11" 6' - 9"

G 1' - 10 1/2" 2' - 2" 2' - 16.5" 3' - 5" 3' - 5" 3' - 5" 3' - 5" 3' - 5"

H 2' - 8" 2' - 8" 3' - 7" 4' - 8.5 4' - 6" 2' - 9" 1' - 5" 4' - 5"

D im e n s io n

I 1' - 7" 1' - 7" 2' - 1" 2' - 3" 2' - 4 1' - 7" 2' - 2" 2' - 2"

J 5' - 6" 6' - 2" 7' - 2" 8' - 5" 8' - 9" 9' - 4" 9' - 1" 10' - 8"

K 3' - 2" 3' - 8" 4' - 11" 5' - 10" 5' - 10" 5' - 10" 5' - 10" 6' - 6"

L 0' - 5" 0' - 5" 0' - 5" 0' - 7" 0' - 7" 0' - 7" 0' - 7" 0' - 7"

M 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6"

C le a r a n c e

N 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6" 1' - 6"

BALER INSTALLATION GUIDE

1. Place the Baler in the location desired by the customer. While doing so, be sure to maintain the minimum clearances, listed in dimension table, otherwise, the baler will not be able to function properly.

2. After the baler has been placed, it must then be anchored to the floor using the 4 supplied anchors through the mounting holes on the bottom of the baler.

3. Run power to the control panel from the customer supplied wall disconnect.

NOTE: The disconnect must adhere to local, state, and federal electrical and safety codes and must be located within line of sight of the Baler start controls. The manual electrical section can be referred to for minimum wire size, amperage requirements and fuse specifications. Wire sizes given are for runs of under 25 ft, longer runs require heavier wire. Line must be fused with time delay fuses.

4. Once the power has been properly connected, press the Down/Up button and observe the direction of the rotation of the motor. Look at the motor fan, proper rotation is clockwise. (As indicated by the arrow on the motor) If the fan rotation is not clockwise, follow the lock-out / tag-out procedures and interchange, any two, and only two of the three power connecters and re-check for proper rotation. This should correct the problem.

5. Affix the provided seal across the control box opening. This sticker must then be ripped to access the control box after the initial install. The sticker reads “Danger –

High Voltage – Danger, Do Not Open This Control Box, Can Only Be Serviced By

Authorized Personnel.”

6. Any scrap material should be picked up and discarded after the completion of the installation. All scratches and exposed metal on the baler must be touched up.

7. Fill out the Operating and Safety Checklist, the Preventative Maintenance

Checklist, and the Baler Installation Information sheet.

8. Supply the customer with the operation manual and video. Also, get them to sign them the two checklists and the Baler Installation Information sheet which must be completed and mailed or faxed to PTR.

TO BE COMPLETED BY INSTALLER 2207 E Ontario St.

Please complete and mail/fax this form along with the Philadelphia, PA, 10134 completed Baler Safety Checklist, immediately after installation Fax: (215) 533 - 8907

PTR Baler and Compactor Company Baler Installation: Information / Check List

Baler Information:

Model No: . Serial No: .

Installed By: Date: .

Signature of Installer: .

Customer Information:

Customer and Store No:

Address

Phone No:

Operation and Maintenance Manual Received By:

Name & Signature:

Individuals Instructed In Safety Procedures And Operation Of Machine:

Names & Signatures:

Keys Received By:

Name & Signature:

Operation Video Tape Received By:

Name & Signature:

Verify The Following:

ELECTRICAL HYDRAULIC

1. All connections made ( ) 1. Oil Level ( )

2. All terminals tight ( ) 2. All (4) hose fittings re-tightened ( )

3. Fuse clips tight ( ) after unit was set in place

4. Limit switches tight (door and gate) ( ) 3. Motor/pump coupling tight ( )

5. Proximity switch tight ( ) 4. Directional valve shifting ( )

6. All switch buttons (selectors) ( ) smoothly and quietly tight and properly aligned 5. Pressure settings ( )

7. Seal the control box with the ( )

High Voltage Sticker

8. Push relay tight to relay base ( )

PHYSICAL OPERATIONAL

1. Anchored to floor ( ) 1. Power to machine ( )

2. Ejector chain assys. In place ( ) 2. Run to check proper operation ( ) properly aligned 3. Demonstrate proper operation ( )

3. Cylinder bolts tight ( ) to customer –See baler safety checklist in manual

4. All gate hardware tight ( )

5. Touch up paint if required ( )

6. All safety signs in place ( )

7. Gate moves up/down easily ( )

See sticker location drawing in manual

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*+!A,�A@>�.A@)�*-1B, ELECTRICAL INFORMATION

The unit “as shipped” is pre-wired to a specific voltage, as shown on the cover of its control panel. The standard baler is intended for indoor installations only. Please contact

PTR Baler and Compactor Co. if a baler is required for an outdoor application.

CAUTION

If your power supply voltage does not agree with the voltage stated on the Compactor control panel cover, DO NOT CONNECT THEM; damage may occur. Have an authorized electrician reset the unit to match your power supply voltage. By “code”, the control panel wire harness must be connected to a properly sized fused disconnect switch. The disconnect switch should be “time delay fuse type” and must be located less than 15 feet and adjacent to the compactor while always within clear view of its operator.

MINIMUM SIZING REQUIRED

* “Wire size” denotes wire to be used from power supply to disconnect switch, use heavier wire if distance is more than 25 feet.

CONVERSION VOLTAGE: In order to convert the compactor from high to low voltage, or vise versa, the following components must be changed: Motor connection as indicated by diagram on motor. Transformer connection as indicated by diagram on transformer. Overload size as indicated by voltage requirements.

IMPORTANT MOTOR ROTATION

When power has been properly connected, press the START button momentarily and observe the direction of the rotation of the motor. Look at the motor fan, proper rotation is clockwise. (If fan rotation is not clockwise, interchange any two of the three power conductors). This should correct the rotation.

CHECK OPERATION

Check by following the operating instructions listed on the cover plate of the unit’s control panel.

ELECTRICAL INFORMATION

GROUNDING INSTRUCTIONS

The baler must be connected to a grounded, metal, permanent wiring system; or an equipment-grounding conductor must be run with the circuit conductors and connected to the equipment-grounding terminal or lead on the baler. A qualified electrician should be consulted if there is any doubt as to whether an outlet box or the machine is properly grounded.

3 HP MOTOR, 3 PHASE, 60 CYCLE

Voltage F.L.A. Type Fuse Wire Size Disconnect Switch

200V-208V 10 amp Time Delay 14 30 amp

220V-230V 9 amp Time Delay 14 30 amp

440V-460V 5 amp Time Delay 14 20 amp

550V-575V 4 amp Time Delay 14 20 amp

5 HP MOTOR, 3 PHASE, 60 CYCLE

200V-208V 16 amp Time Delay 12 30 amp

220V-230V 14 amp Time Delay 12 30 amp

440V-460V 7 amp Time Delay 14 30 amp

550V-575V 6 amp Time Delay 14 30 amp

10 HP MOTOR, 3 PHASE, 60 CYCLE

200V-208V 29 amp Time Delay 8 60 amp

220V-230V 26 amp Time Delay 8 60 amp

440V-460V 14 amp Time Delay 12 30 amp

550V-575V 11 amp Time Delay 12 30 amp

15 HP MOTOR, 3 PHASE, 60 CYCLE

200V-208V 43 amp Time Delay 6 60 amp

220V-230V 39 amp Time Delay 6 60 amp

440V-460V 20 amp Time Delay 8 60 amp

550V-575V 16 amp Time Delay 10 30 amp

20 HP MOTOR, 3 PHASE, 60 CYCLE

200V-208V 57 amp Time Delay 4 100 amp

220V-230V 51 amp Time Delay 4 100 amp

440V-460V 30 amp Time Delay 8 60 amp

550V-575V 21 amp Time Delay 8 60 amp

Electrical Information For 50Hz power

GROUNDING INSTRUCTIONS

The compactor must be connected to a grounded, metal, permanent wiring system; or an equipment-grounding conductor must be run with the circuit conductors and connected to the equipment-grounding terminal or lead on the compactor. A qualified electrician should be consulted if there is any doubt as to whether an outlet box or the machine is properly grounded.

3 HP MOTOR – 3 PHASE – 50 CYCLE

Voltage F.L.A. Type Fuse Wire Size* Disconnect Switch 380V 5.4 amp Time Delay 14 30 amp 415V 5.2 amp Time Delay 14 30 amp 440V 5.0 amp Time Delay 14 30 amp

5 HP MOTOR – 3 PHASE – 50 CYCLE

380V 8.7 amp Time Delay 12 30 amp 415V 8.0 amp Time Delay 12 30 amp 440V 7.8 amp Time Delay 14 30 amp

10 HP MOTOR – 3 PHASE – 50 CYCLE

380V 17 amp Time Delay 8 30 amp 415V 16.1 amp Time Delay 8 30 amp 440V 15 amp Time Delay 12 30 amp

15 HP MOTOR – 3 PHASE – 50 CYCLE

380V 23.1 amp Time Delay 8 60 amp 415V 22 amp Time Delay 8 60 amp 440V 21.5 amp Time Delay 8 60 amp

20 HP MOTOR – 3 PHASE – 50 CYCLE

380V 29.2 amp Time Delay 8 60 amp 415V 28 amp Time Delay 8 60 amp 440V 27.5 amp Time Delay 8 60 amp

* - “Wire Size” denotes minimum wire size required to be used from power supply to disconnect switch. Use a heavier wire if distance is more than 25 feet.

PRESSURE SETTING PROCEDURE

1. Locate relief valve & loosen locking nut

2. Turn adjustment screw counter-clockwise to lower pressure setting

3. Locate the set screw on the pressure switch & loosen it

4. Turn the adjustment ring on the pressure switch clockwise to raise pressure switch setting

5. Note reverse timer setting in PLC, and adjust the reverse timer setting to the maximum allowable value

6. Press ram down button until ram bottoms out

7. After the ram bottoms out, turn the relief valve adjustment clockwise until desired working pressure setting is displayed on gauge

8. Adjust pressure switch counter-clockwise until ram stops and reverses

9. Run ram again to verify the ram reverses due to maximum pressure and not the reverse timer

10. Remove wire #7 on terminal strip

11. Start baler and run ram down

12. After ram bottoms out, adjust relief valve until the pressure gauge reads desired relief pressure

13. Lock relief valve at that point & lock the pressure switch

14. Reconnect wire #7

15. Reset the reverse timer to the original value

Note: If baler door is open, baler controls are fully manual – machine will not cycle automatically

PRESSURE CHECKING PROCEDURE

1. Note reverse timer setting in PLC, and adjust the reverse timer setting to the maximum allowable value

2. Run the machine & watch the pressure gauge as the cylinder reaches maximum pressure (ram fully extended)

3. The pressure on the pressure gauge should spike towards an area around the labeled working pressure

4. Disconnect wire #7 on the terminal strip

5. Start baler & run ram down

6. Watch the pressure gauge as the cylinder reaches maximum pressure (ram fully extended)

7. The pressure on the pressure gauge should settle at an area around the labeled relief pressure

8. Reconnect wire #7

9. Reset the reverse timer to the original value

Note: In either case, if the needle did not spike around the desired working…

This is the start of the file's text. The full file is on GovTribe.

File details come from the government source that posted it. Updated May 7, 2024.