HORTICULTURE EQUIPMENT & SERVICES OPERATOR S MANUAL PEAT BALE PROCESSOR Model Number: LH00 Serial Number: 30000 & UP
Contents Introduction Page Safety Safety 2 Safety Decal Instructions 2 Specifications 2 Specifications & Features 2 Setup & Control Panel 3 Set Up 3 Control Panel Descriptions 3 System Adjustments 4 Chain & Flight 4 Drive Chain 4 Auto-Call Fine Adjustment 4 Elevator Limited Switch 5 Operation 5 Operating the Elevator 5 Water Routing & Valving 6 Hydraulic Power Unit 6 Loading & Processing Peat Bale 7 Warranty 8 Introduction Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Horticulture Equipment designs and produces safe products, you are responsible for operating the product properly and safely. Whenever you need service, genuine Hort Equipment parts, or additional information, contact an Authorized Service Dealer or Hort Equipment Customer Service and have the model and serial numbers of your product ready. You will find the model and serial number on a plate located just above the electrical control panel. Write the product model and serial numbers in the space below: Model No. Serial No. This manual identifies potential hazards and has special safety messages that help you and others avoid personal injury and even death. Danger, Warning and Caution are signal words used to identify the level of hazard. However, regardless of the hazard, be extremely careful. PAGE Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended precautions. Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. Caution signals a hazard that may cause minor or moderate injury if you do not follow the recommended precautions. This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE: emphasizes general information worthy of special attention. Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and those in the units operator s manual. Always pay attention to the safety alert symbols, which mean CAUTION, WARNING OR DANGER personal safety instruction. Failure to comply with the instructions may result in personal injury or death. DANGER Contact with a moving auger can cause entanglement, severe wounds, and or death. Keep all others away from the auger during operation. Also, do not replace the supplied bolts which secures any or all types of shielding providing protection away from an auger as this will increase the chance for entanglement. DANGER Contact with a moving chain, sprocket or gears can cause entanglement, severe wounds, and or death. Keep all others away from the mechanical moving parts during operation. Also, do not replace the supplied bolts which secures any or all types of shielding providing protection away from an auger as this will increase the chance for entanglement. WARNING Before turning the power on to the unit, make sure there is no one in or around the machine as this could cause serious injury when the machine starts. Always use caution when operating the machine.
Safety and Instruction Decals WARNING Always discount the main power from the machine and lock out the main control panel before working in or around the machine for maintenance or adjustments and any electrical boxes or servicing any electrical components including but not limited to electrical motors, switches or wiring. Only use a certified electrician for any electrical maintenance required. Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. Specifications Note: Specifications and design are subject to change without notice. Features Overall Length Elevator Down 84 Overall Length Elevator Up 57 Overall Width 73 Overall Height 06 Approximate Weight 4500 lbs Total Amps 25 Voltage 240v Discharge Height 6 Bale Size Auger Clean Out on Start Water Discharge Up to 35 cu.ft. 5 Seconds Automatic Emergency Stops 2 Safety Switches Auto Call System Processing Time Incline Drive Processing Head Drive Overload System Elevator Closed Ready Up to 75 Cubic Yards Per Hr. 3 HP Gear Reduced Motor 2 HP Gear Reduced Motor Yes These are common informational decals you will see on your equipment. For your safety, please follow these instructions. PAGE 2
Setup and Control Panel When you first receive you system, take a good overall look at the product and make sure there are no damages during shipping and if there are any damages immediately correct the problem areas before operating your machine. Unless specified in the initial order your system will need to be wired to your existing electrical system. All electrical connections and specifications should be handled by a certified electrician. Horticulture Equipment will not be held in anyway responsible for your electricians negligence. Be sure to give plenty of clearance around the machine for loading media in the hopper, and for loading, offloading the filling conveyor. Be sure to check inside the hopper and soil returns for any obstructions before your initial start up to be make certain they are clear for operation. Electrical Control Panel: Figure 2 3 5 6 4 NO. DESCRIPTION MAIN POWER DISCONNECT 2 MACHINE ON / OFF SWITCH 3 FAULT BUZZER 4 POWER LIGHT 5 CHAIN - MANUAL/AUTOMATIC CONTROL 6 AUTO CALL OFF/ON 7 EMERGENCY STOP BUTTON 8 RESET BUTTON 9 AUGER - MANUAL/AUTOMATIC CONTROL 0 WATER OFF/ ON SWITCH AUTO CALL FINE ADJUSTMENT 8 7 0 9 Control Panel Component Description. Main Power Disconnect: Use this switch when turning the main power on to the machine for operation. 2. Machine On / Off Switch: Use this switch when you need intermittent power stop and start to the system. NOTE: Use this switch for all stop and starts and not the main power switch unless finished for the day. Other wise you will need to push the reset button after turning the main power off and on. 3. Fault Buzzer: This light will turn a continuous bright red color when a system fault has happened, for example a motor failure, an electrical malfunction to the electrical drive system or components power overload. This will require the use of the Reset button and possibly to analyze the system status for other problems. 4. Power Light: When Lit, indicates the system is ready 5. Chain-Manual/Automatic Control: This switch should be in the Manual Position unless your machine is equipment with the auto call system along with the Low Level Indicator located in the machine the bale processor is filling. If you have the auto call system and items listed above you can put this in the Automatic position and will move the chain and other components automatically, when the receiving machine is low on material. 6. Auto Call Switch: This switch should be in the hand operation at all times unless used in special applications. The Auto Switch would be used in a fully automated type operation, this is provided for future use in that type of scenario. WARNING: Do not turn the switch from off to hand or hand to Auto or in any other combination unless waiting at least minute between operations as this could damage the drive components of this system. 7. E-Stop Button: Use this button when there is an emergency and need to shut the system / machine down completely. Note: to start system reset the E-Stop Button by twisting the button. 8. Reset Button: You will press this button when your machine has a fault or other conditions that stop the machine without using the stop start switch, for example, machine has a fault code, loss of power, etc.. 9. Auger-Manual/Automatic Control: This switch should be in the Manual Position unless your machine is equipment with the auto call system along with the Low Level Indicator located in the machine the bale processor is filling. If you have the auto call system and items listed above you can put this in the Automatic position and will move the chain and other components automatically, when the receiving machine is low on material. 0. Water Off / On Switch: This switch turns the water system off and on for the control system to use.. Auto Call Fine Adjustment: This switch is used in conjunction with the auto call system. When the low level indicator located in the receiving machine starts to call for material, the auto call system will automatically start and fill the machine until the low level indicator paddle stops rotation. However, in some cases it may not completely fill the receiving machine to a satisfactory level. By turning the proximity knob this will increase or decrease the run time after the low level indicator has stop, to give maximum fill levels. Please See Informational Note on page 4 under Auto Call Fine Adjustment. PAGE 3
System Adjustments 3 Processing Head or Auger Chamber Figure 4 Chain & Flight Take-Up 2 Figure 2 There are no adjustments for the Processing Head Unit, as this is a direct drive system The Chain and Flight are set from the factory and should not need any adjustment when received, however during the course of operation, this area should be checked daily before operations to be sure of optimal chain wear. To adjust, (as shown in Figure 2) area #3 between the nut and frame put in an object such as a screw drive to prevent the allthread rod from turning when adjusting the nut, next loosen nut # away from the angle iron to leave room for adjustment, next turn Nut #2 clockwise to tighten, counter clockwise to loosen, once complete tighten # nut.. 3 Auto Call Fine Adjustment Figure 5 Drive Chain Adjustment All tension is adjusted at the factory, if needed the main drive chain that provides power to the incline drag chain can be adjusted by adjusting the all thread rod nuts provided on the take-up plate in the illustration above, by loosening 4 bolts and nuts shown in # and then adjusting the nuts shown in #2 and #3. (as shown in figure 3) 2 Figure 3 - PAGE 4 The auto call system is designed to automatically fill the receiving machine (Flat Filler, Hopper etc..) once the material has passed a particular level in that machine. Horticulture Equipment uses a Low Level Indicator or Bendicator in which a rotary motor and paddle are used. When material has passed the level which this paddle will move, it sends a signal to our control box to automatically start the processor for material to discharge into the receiving machine. Subsequently, in order for this to work properly, the chain, auger and water switches must be put in the Auto position, along with the Auto Call Switch turn to ON. Once the material has reached a certain level the paddle will not turn in which the machine will stop, however, the material may not reach the level needed for optimal fill, this is where you would rotate the proximity knob (as shown in figure 5 above) to time the soil to fill beyond the stop point of the paddle to fine tune the fill. Once this is set it is rare that it will be turned again. Informational Note: Some of the Hort Machines may have the Auto Call Fine Adjustment located inside the control box. However, All Hort Machine have this feature either outside or inside the control panel
System Adjustments Continued Elevator Safety Limited Switch Operating the Elevator Figure 7 Figure 8 Figure 6 The limited Switch device (as shown in figure 6 above) is for operator and bystander safety. This is located on the side of the hopper at the lower part of the elevator on the control panel side. This device has been adjusted at the factory, however, during shipping or continuous vibrations of the machine could put this device out of adjustment. The limited switch is the main power engagement device. The system will not run unless the elevator is at its full upright position and pressing the limited switch button. If this device needs adjustment, be sure the elevator is in the full upright position, turn the main power lever and circuit breaker is off, loosen the two adjustment screws and adjust until the switch makes a click sound to indicate a circuit connection, do not press the devices button completely to the frame as this could cause damage to the switch. In order for the elevator to operate, you must hold the hydraulic system engagement button in (as shown in Figure 7 above) while either pulling the hydraulic valve lever (as shown in figure 8 above) either up to close the elevator (as shown in figure 9 below) or down to open the elevator (as shown in figure 0 below ). The combination of holding the button while moving the valve lever is a safety feature to be sure that the lever would not be accidentally pulled, which could put someone in danger. Figure 9 Informational Note: The hydraulic system could leak down overnight if there is a load of peat remaining in the hopper. When starting the system the next day, make it a good practice to be sure the elevator is in the full upright position for the machine to operate. PAGE 5 Figure 0
Processing Head Warning! Shown above the processing head is guarded for a reason, this area is very dangerous and no one should every put hands, limbs or loose clothing anywhere near this area while machine is in use, never remove the shield. When maintenance is necessary, always turn the main disconnect to the off position and the machines breaker at the power panel. Water Routing & Valving The photo below shows the water solenoid valve, where the water line will be connect. The valve is integrated into the system to automatically mix the water with the material. Shown above is the water hose routing that supplies the water to the 4 injection heads located inside the processing head. Hydraulic Power Unit Shown below is the hydraulic power unit that powers the cylinders that raise and lower the elevator. This units fluid level should be check once a week and can be refilled with AW Hydraulic Fluid ISO32. PAGE 6
General Operation for Loading and Processing a Peat Bale. Turn on the main power switch 2. Lower the Elevator as described on page 5 as show in Figure below. 3. With a Fork Lift, load the bale on the elevator base as shown in Figure 2 (at this point the plastic will still be on the bale) making sure the pallet will be up against the back of the elevator. 4. Cut the plastic from the bale and discard as show in figure 3. 5. After making sure all is clear around the elevator, raise the elevator to the upright position as described on page 5 of this manual. 6. When the elevator is in the full upright position and makes the connection to the limited switch as described in this manual and if your system has an auto call, then set all switches that apply to the auto position and making sure your water line is hooked up and turn on to the solenoid valve on the control panel. 7. Turn the start button on, the processing head (auger) will start for a 5 second clean out first, then the chain flight will engage and start processing the bale as shown in Figure 4. 8. The machine will run automatically with the auto call system as described in this manual and settings. Figure 2 Informational Note: If you system does not have the auto call system then all switches should be in the manual position and the start and stop switch will have to be used when you obtain the output you desire. Figure 3 Figure Figure 4 PAGE 7