INSTALLATION OPERATIONAL AND

SERVICE MANUAL

Customer:- SUNRISE BUMI TEXTILES

JI. Raya Bekasi KM.28,
Bekasi, Jawa Barat 17124,
Indonesia.

Manufactured by:-

INDO TEXNOLOGY (P) LTD.,

1-B, Irugur Road,
Ondipudur
Coimbatore -641016,

INDEX
Oil Hydraulic Auto Baler

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 INSTALLATION AND OPERATIONAL MANUAL
SI.No. CONTENTS PAGE.No.
1 APPLICATION 3
2 PRESS OPERATION AND WORKING 4
3 SILO OPERATION & SPECIFICATIONS 5
4 PRESS SAFETY FEATURES 7
5 INTERLOCKS 8
6 PRESS SPECIFICATIONS AND OPERATING PARAMETERS 10
7 PRE DRY RUN CHECKS 11
8 MAINTENANCE 12
9 MAINTENANCE SPARES 12
10 DO’S AND DON’T’S 13
11 TROUBLE SHOOTING 14
12 GENERAL ARRANGEMENT OF MACHINE ASSY. 19
13 LIMIT SWITCH POSITIONS 20
14 PRESS POWER CIRCUIT 21
15 PRESS CONTROL CIRCUIT 22
16 PRESS PLC LOGIC CIRCUIT 23
17 SILO POWER CIRCUIT 25
18 AUTO/OFF/MANUAL CIRCUIT 28
19 SILO PLC LOGIC CIRCUIT 29
20 HYDRAULIC CIRCUIT 31
21 BALE XPRESS ASSLY. 33
22 MAIN CYLINDER ASSLY. 34
23 SIDE CYLINDER ASSLY. 35
24 EJECTOR CYLINDER ASSLY. 36
25 CONVEYOR SPROCKET AND BEARING SPARES 37
26 ROLLER BEARING SPARES 38
27 PNEUMATIC CIRCUIT 39
28 SILO PARTS AND SPARES 40

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OIL HYDRAULIC SINGLE STAGE AUTO BALER WITH FIXED BOX

APPLICATION

Oil Hydraulic Single Stage Baling System is for packing cotton fibres into bales
of weight 150 to 175 kg and size of 1220 (L) x 570 (W) x 750 (Ht) ± 50mm

CONFIGURATION AND GENERAL ARRANGEMENT

This is a down packing system of vertical disposition, designed to install at shop

floor level without any special foundation/pit.

It mainly comprises of press frame, fixed box, Moving box, Main double acting
oil hydraulic cylinder (at the top) with a platform (moving) attached to the
piston rod, Side double Acting Cylinders attached to the moving box for Up and
Down Movement of the box, Bottom fixed platform is mounted on the bottom
member of the frame.

The fixed box is connected to the conveyor mechanism which is operated by a

gear box arrangement to feed the materials into the press.

Hydraulic power-pack with all the valves and controls is mounted on the tank
separately. The hydraulic tank can be kept beside the press to the convenience
of the operator.

The control panel is a separate unit with all the controls fixed to it and can be
placed to the side of the press to the convenience of the operator.

PRESS OPERATION AND WORKING

This press is configured for AUTO feeding.

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The fixed box is connected to the conveyor which transports the material from
the condenser to the box. A timer is set for the actual filling time required for
the box to get filled.

Once the box is filled, the moving platform connected to the piston rod of the
main hydraulic cylinder will press the material against the bottom platform.
During this time the conveyor will be operating in the reverse direction and all
the materials will be stored in the conveyor itself. Once the moving platform
reaches the top position the conveyor is moved in the forward direction
enabling the material to fall in the box.

This operation continues until the pressure is achieved to the requirement.

The pressure switch energizes the solenoid of the side cylinders and the box is
taken up automatically once the set pressure is reached. During the box
upward movement a hooter will give annunciation to the operator that the
bale is ready for hooping.

The hooping is done manually. During the hooping process the materials is
collected in the conveyor and stored in the conveyor itself we have provided a
storage space for 5 minutes of waste generation.

After hooping the platform is released to required height so as to remove the

bale. Once the bale is removed the operator just needs to press the BOX
DOWN push button which will bring the box to the down position and the
platform automatically goes back to its original position, and the next cycle
starts.

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SILOS:

Silos are basically storage bins which are designed to store the waste cotton for
150 kgs each. These are manufactured out of MS plates and are assembled to
the conveyor frame by means of a vertical leg.

The silos are fitted with 2 sets of spiked rollers and drive through a gear box
with chain and sprockets.

SILO WORKING :

Each silo consist of a level sensor which senses the level of the cotton inside
the silo for the upper limit, once the limit set is reached the particular silo is
switched on and the material falls into the conveyor which in turn pushes the
material into the press box. The conveyor running time and the silo running
time is matched through a timer and once the set time limit reaches the silo as
well as the conveyor is switched off. This will provide time for the platform to
move up and down.

The silo will start operating based on the level switch and weight achieved in
the press box sensed by hydraulic pressure. An interlock is provided in such a
way that once a silo is switched on, even if the other waste silo level is reached
this will remain switched off to protect from mix up of waste. Once one type of
waste baling is over only then the other waste silo will get switched on.

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CONVEYOR –CLEANUP:

This option is provided to avoid mix up of waste. Once a particular waste is

baled the material in the conveyor during the last one before pressing stroke
will be again put into the bale press thus cleaning the conveyor.

SPECIFICATIONS:

Material Handled in Silo’s Comber Noils, Card waste, Blow room Droppings
Storage Capacity 150 to 175 kgs
Motor HP 3 HP
Roller speed 3.3 rpm ( Adjustment Optional if required )

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SAFETY FEATURES:

 High quality limit switches are provided with standby, to limit platform

travel.

 Limit switches are provided for the moving box up and down movement.

 Pressure switch is provided to cut-off motor when the operating

pressure pre-set limit and protect the hydraulic system.

 Preset relief valves are provided to protect power pack and cylinder

units from overloading. They also act as standby to pressure switch.

 Motor is protected against short circuit and overload, through fuses and

overload relay.

 Guide rods are hard chrome plated and are guided properly by PB2

bushes for smooth movement of the platform.

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INTERLOCKS

 Material feeding is inter locked with the movement of the main platform as

well as the moving box.

1. The conveyor will run in the forward direction if the moving

platform is up and the moving box is down.

2. If the platform is in the down position or moving down the conveyor

will be running in the reverse direction.

 The time for material filling is interlocked with the timer.

 Audio alarm is made through the pressure switch to indicate the readiness

of the bale for hooping purpose.

 Once the box push button is pressed after hooping and Bale ejection

process is over the box comes down and once it reaches the bottom

position the platform automatically gets UP.

 Emergency push button is provided to bring the system to stand still in

case of emergency.

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SPECIFICATIONS AND OPERATING PARAMETERS

SPECIFICATIONS

Box size (inside) : 1250 (L) x 570 (W)

Clear height : 2300

Clear height is the maximum distance available between the fixed and moving
platforms.

Platform travel : 1850 (max.)

Power : 15 HP + 1.5 HP for Conveyor + 3

3 HP for Silos

Overall size of the press : 4300(L) x 2220(W) x 5500(H)

aprox. Hydraulic Oil : Servo System 68 or equivalent.

Qty. of oil to be filled in the tank : 500 ltrs.

No. Of grooves for hooping : 11 Nos.

OPERATING PARAMETERS

Material for baling : Cotton Waste

Finished bale size : 1270(L) x 570(W) x 700(Ht.)

±50mm. Bale weight : 150 kgs. ± 10kgs

Bale density : 150 to 175 kgs. per cu.mtr.

Productivity : 1 to 2 bales/hour

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NOTE: Productivity is mainly based on the feed rate and other manual
operations, hooping etc. which are dependent on the skill/experience of
manpower.

PRE DRY RUN CHECKS

 All the fasteners to be checked for tightness.

 After assembly kindly ensure the uprightness and the horizontal
members are parallel to the levelled floor.
 The cylinders to be properly anchored to the top of the horizontal
member of the press frame.
 All the hydraulic fittings and connections should be properly tightened.
 Electrical terminations should be thoroughly checked for their grip.
Ensure there are no loose connections in any terminations.
 Electrical circuit to be checked in sequence as per the circuit diagram.
 Motor should be checked for its direction of its rotation as per the
marking in the housing (motor and pump coupling).
 The hydraulic system should be primed and checked for its flow. If any
air lock is found the same can be removed by bleeding some quantity of
oil from the output of the pump.
 Positioning and anchoring of limit switches is to be checked, including
condition of the limit switches for their snappy movements.
 The cylinders should be activated to check for the movement of the
platform and the box.
 While carrying out these movement checks, watch out for activation of
limit switches.
 The sequence of the above should be repeated three to four times to
ensure smooth movement of the platform and moving box.

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MAINTAINENCE

 Filter elements to be checked and cleaned / replaced after 300 hours of

working.
 Lubricate the guide rods of the main platform and side cylinder guides
once in a week.
 Lubricate the moving box guide flat by grease, once in a week.
 Check for function of limit switches once in a week
 Overall checking of the pipelines and power pack assembly for any
leakages to carried out once in a fortnight.
 Check the motor coupling and fastness once in a fortnight.
 Check for the tightness of the chain drive once in 2 days week.
 Check the tightness and alignment of the conveyor belt fortnightly.
 Clean the reverse rollers once in a week.
 Check for the gear box oil level fortnightly.
 Check for the belt condition once in three months.
 Check for fan rotation and breakage of motor fan fortnightly.
 Clean the machine daily.
 Clean the panel with air every week.

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MAINTAINENCE SPARES

Seal kit for cylinders 1 Set

Filter elements 1 Set
Ferrules for pressure line fittings 2 Nos. each size
(6,22,28,35,38,42)
Copper washer (1/4” – 1 1/2”) 2 Nos. each size
Solenoid coil for DC valve (24 V DC) 1 No.
Fuses and indicating lamp 1 Set
Limit switch 1 No.
O – rings for cylinder and filters 1 Set
Control Relay 2 Nos.
Contactor 1 No.
Conveyor Bearing Unit Y-Type 2 No.
Conveyor Idler Roller Bearing 1 No.
Silo Flanged Bearing Unit 2 No.

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DO’S AND DONT’S

DO:

 Follow the routine maintenance as per schedule.

 Check the physical and electrical condition of the limit switches for their
proper functioning.
 Use correct size spanners for tightening the fasteners.
 Check for leaks in the pipeline, and tighten the fittings appropriately.
 Keep the power pack clean and dry.
 Use only recommended Oil for the power pack as well as gear box.

DONT’S:

Exceed operating pressure 1000 PSI for the Comber and Blowroom main
cylinder and 1500 PSI for Carding Main Cylinder.
Tamper the relief valve and pressure switch settings.
Over tighten pipeline fittings.
Leave defective / broken limit switches un-attended.
Operate the press with the oil level in the tank below the indicated level.
Change the fuse ratings.
Continue operation of the press with the oil leaking from any pipeline.
Operate the power pack without filter elements.

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TROUBLE SHOOTING

S.No Problem Cause Solution

1. Main Motor not MPCB TRIPPED Check and RESET
working Over load relay OLR Reset the OLR to correct
1 would have tripped setting
Contactor failed. Check the contactor and
replace
Check for power supply If any loose connection is
from panel to motor there correct it.
2. Platform does not Limit switch struck up Check and correct it
move UP and (LS1,2,3,4)
DOWN Solenoid valve S1 & S2 Check the solenoid valve
does not switch ON connection
Relay RL 1 and RL 2 is not Check relay
functioning
3. Platform does not Same checks as in POINT Check and correct
move DOWN 2.Check PLC output
even after the
conveyor is
running in the
reverse direction
4. Platform is not Limit switch LS1 is not in Check and rectify
moving UP closed condition check

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 automatically PLC
after pressing.
5. Platform Check the solenoid valve. Check and rectify
movement slow Suction strainer clogged.
Return line filter clogged
6. Box does not go Relay RL 3 may be faulty Check and rectify
UP
7. Box does not Limit switch LS7 and Check and rectify
move DOWN relay RL4 may be faulty
8. Conveyor not Check Contactor C2 Replace it faulty
running in a check MPCB tripped Replace if blown with
forward direction correct rating
Reset.

9. Platform Relief valve may be mal- Check the valve by rotating

movement functioning the Knob and increasing the
stopped in the pressure. Pressure note
middle of the that the pressure should
pressing not exceed 1200 PSI
operation with
less pressure.

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10. Movement is Pressure Switch may be Check the Pressure Switch
stopped before mal-functioning. setting by rotating the Knob
reaching the with Allen Key and
required pressure increasing the pressure.
Pressure note that the
pressure should not
exceed 1200 PSI
11. Platform is not Check PLC output & also Check and rectify
moving up even RL 1 & RL 4
after the Moving
Box is down

12. Conveyor Oil level in the gear box Check the oil level and fill if
movement may be low required.
creates abnormal Chain may be struck
noise
13. The system is Check Emergency Push Check & rectify
fully OFF button & transformer
output.

14. Silo 1 not working Check PLC input I 3, PLC Check & rectify
Output Q7 & RL7
15. Silo 2 not working Check PLC input I 4, PLC Check & rectify
Output Q8 & RL8
16. Condenser Check PLC output Q7 & Check & rectify
output problem Q8

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17. Silo not resetting Check PLC input I2 Check & rectify
18. Noise in the Air entry in the suction Check for any leakages in
pump the suction line.
19. Oil coming along The Ram side seal may Tighten through wiper seal
with the Rams. be worn out. flange. If still the problem
persists change the seal.
20. Platform is Piston Side seal may be Change the seal.
moving UP worn out.
without holding
during the
material is under
pressure

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