Simpro MegaDumper, User Manual

Page 1: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 USER MANUAL...

Page 2: ...and international conformity this document uses Syst me International SI units These may be converted to Imperial units as follows 1 kilogram kg 2 2 pounds lb 1 metre m 1000 millimetres mm 39 37 inch...

Page 3: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 Page 2...

Page 4: ...C Cradle 11 Type M and Type N Cradles 12 Type X Custom Cradle 12 2 3 Operating the controls 13 Control Panel identification 13 Standard Control Panel 14 Autocycle Control Panel 14 VSD Control Panel 1...

Page 5: ...se mains 37 International conformance 37 Appliance inlet 37 Isolator switch 38 Transformer 38 Variable Speed Drive 38 4 8 Hydraulic System 38 Powerpack 38 Control valves 38 Lift rams 39 Hydraulic flui...

Page 6: ...e tipping action whereby bins are lifted straight up and then gently rolled forward around the lip of the receptacle being emptied into Benefits of this design cl h h b l ll f and a wide range of tipp...

Page 7: ...b Some machines may be specified with different capacities Refer to the rating plate to verify the f c Safe Lifting Capacity on any given machine Safe Lifting Capacity is a gross figure referring to t...

Page 8: ...B A assessment are taken at a point 1 6 metres above the h w k 1 8 Environmental restrictions The MegaDumper may be used indoors or outdoors However the following restrictions apply 1 Minimum floor ar...

Page 9: ...d and understand this manual before using the machine 4 If the machine is to be leased sold or otherwise transferred then this manual shall accompany the machine 5 This is a generic manual Simpro rese...

Page 10: ...indicator if fitted shows an acceptable level of charge 2 2 Emplacing and removing bins The MegaDumper cradle is designed to allow bins to be emplaced and removed easily while also holding them secur...

Page 11: ...aste and recycling applications EN840 mobile garbage bins wheelie bins 60L 80L 120L 140L 240L 360L 660L 770L 990L 1100L 2 2 3 Type M 1200x1000 Mega bin base lift cradle Food processing and logistics a...

Page 12: ...Trident Some smaller bin manufacturers use tyres which are too wide to fit inside the wheel catches Should this issue occur simply insert additional packers flat washers onto the wheel catch mounting...

Page 13: ...mm faces at the sides Bulk bins are held in place when inverted by l catches h f h c l These catches should be positioned to hold the top edges of the bin with a maximum free travel of 25mm 1 inch The...

Page 14: ...s normally atop the powerpack cover but on some models it is mounted onto a separate enclosure Control Panel Type Primary Usage Controls Image Refer Standard Standard machines RAISE LOWER KEY SWITCH V...

Page 15: ...nel How to operate the controls of a machine with an autocycle controller allowing bins to be emptied without continuous input MegaDumper models that are fitted with an autocycle control system may be...

Page 16: ...JOYSTICK SLIGHTLY BACK so that the material is poured from the bin in a controlled manner as desired Wait for the contents of the bin to empty Release the JOYSTICK to stop the cradle at any time 5 Pu...

Page 17: ...2 Open the door If the door is locked press the LOWER button to unlock it 3 Place the full bin onto the cradle taking care that it is properly positioned as per 2 2 then shut the door 4 Turn the mode...

Page 18: ...tandard MegaDumper design includes 1 Attempts to use the machine by untrained operators 2 Attempts to empty bins that the cradle is not specifically designed to hold 3 Attempts to bypass the door inte...

Page 19: ...ollowing table Risks evaluated as Very High Extreme or Unacceptable are likely to require additional or uprated safety functions as set out in 3 4 These must be specified at the time of order LO Likel...

Page 20: ...when the cradle is on the ground and the cradle cannot be raised unless the door is closed and locked Significant safety margins ensure that the probability of failure of any steel hydraulic or contr...

Page 21: ...y powered MegaDumpers is double insulated Contamination from tipping toxic powder and liquid Operator LO 2 FE 4 DPH 1 NP 1 Risk Factor 8 Great care should be taken when tipping powder or liquids If th...

Page 22: ...Operator LO FE DPH NP Risk Factor Other persons LO FE DPH NP Risk Factor Control measures Comments Application specific hazard Operator LO FE DPH NP Risk Factor Other persons LO FE DPH NP Risk Factor...

Page 23: ...h all powered lifting equipment some l h z b interlocks guarding or other safety systems that may be implemented The machinery owner has a legal responsibility to take all reasonable precautions to el...

Page 24: ...nly used to demonstrate the safety of ch H w v c h US l l l l b c l b l enforce workplace H S norms US companies who demonstrate machinery safety using ISO 13849 1 may be considered to have met their...

Page 25: ...an order Simpro can then specify and quote additional or uprated safety functions such as 1 CAT3 Kit to achieve PLd safety performance 2 CAT4 Kit to achieve PLe safety performance 3 Additional guardin...

Page 26: ...raised dock or platform unless designed for that application Never operate the machine with any covers or guards removed Never attempt to empty the contents of closed top drums unless the machine is...

Page 27: ...es to connect the machine to mains power Do not operate if power lead insulation or power plugs are damaged Do not connect a damp power plug or socket Ensure the power supply socket is fitted with a r...

Page 28: ...motor solenoid or 415VAC motor contactor S l c c h l cl ck when the UP button is pressed if not it may need to be replaced 24VDC Solenoid 0880050015 415VAC Contactor 0250050069 Interlock switch on doo...

Page 29: ...aDumper are the Type S cradle for wheelie bins up to 660L and the Type E cradle for wheelie bins up to 1100L These b l f c l are very simple and reliable but sometimes require minor adjustment to cons...

Page 30: ...n and orientation allows about 200mm of vertical adjustment from 1070mm to 1270mm This is sufficient to suit almost all 4 wheel bins 5 Once the catches are correctly positioned re tighten the bolts to...

Page 31: ...ar operation typically 660L or 770L The procedure to adjust the Secondary Swing Arms is as follows 1 Lower the cradle completely to the ground and open the safety door 2 Place a sample of the second l...

Page 32: ...ast being bent or damaged jamming one of the mast rollers c Part of one of the curved tipping tracks being bent interfering with the correct movement of the follower rollers d Lack of lubrication of t...

Page 33: ...aced close the door and test the machine to see if the cradle now lowers correctly If the problem persists the lowering valve coil or cartridge may need to be replaced contact your agent for support 1...

Page 34: ...he cradle is lowered by gravity alone As a rule a full charge is sufficient to empty 15 tonnes of material but this is dependent on the tipping height and the condition of the batteries International...

Page 35: ...ng rules can help to maximize the life of the batteries Place the batteries on charge every night not just when they are flat Do not allow the machine to sit with flat batteries for more than 24 hours...

Page 36: ...3x35mm are mounted on adjustable steel brackets at the top of the mast and charge the battery via a 12V 24V digital regulator As per the table in 1 5 in ideal conditions the solar panels provide enoug...

Page 37: ...trical System 3 phase mains If you do not operate a 3 phase mains machine please disregard this section Machines powered by 3 phase mains electricity are generally the same as other models but use a 3...

Page 38: ...quency are specified to suit standard 3 phase mains power in the intended country of use 4 7 Electrical System 1 phase mains If you do not operate a 1 phase mains machine please disregard this section...

Page 39: ...ppropriate program and cable drivers loaded The VSD can be fitted with a joystick controller to provide progressive control over the lifting speed as set out in 2 3 4 Residual voltages may be retained...

Page 40: ...with a higher viscosity grade may be used but this will reduce the lowering speed of the cradle and increase the likelihood of jams The hydraulic fluid should have physical lubricating and chemical pr...

Page 41: ...locks The MegaDumper is fitted with two solenoid operated safety interlocks These are Idec HS5E D4403 G or HS5E F4403 G w to l ck models with four internal contacts which are used to determine whether...

Page 42: ...efore returning to service If the machine is fitted with a PLd or PLe safety monitored control system press the blue RESET button for two seconds to test and reset the safety functions Do not open the...

Page 43: ...al Instructions English v86 0 February 2022 Page 42 4 9 2 2 Interlock specifications A summary of the interlock specifications is included below The complete Idec user manual can be downloaded from th...

Page 44: ...ful reset If a fault has been detected in any of the safety equipment or connections the machine will not reset and cannot be operated the RESET lamp will continue to glow This documentation is to ass...

Page 45: ...recover after the fault is corrected Recoverable faults can be cleared by eliminating the cause of the fault and cycling the inputs associated with the fault The output that is connected to an input w...

Page 46: ...n lifting the MegaDumper 1 Check that the lifting equipment is in good condition and rated to lift at least 1000kg 2 Affix a sling or chain to the lifting lugs on either side of the top frame cross me...

Page 47: ...at least 1000kg ensuring it is fastened against lateral forces from any direction Never lie the machine onto its sides or back safety door as this may cause hydraulic fluid leaks and or damage to the...

Page 48: ...protective eyewear 2 Ensure there are no ignition sources nearby 3 Lower the cradle and remove bin 4 Turn off the key switch and unplug the charging lead 5 Remove the powerpack cover 6 Clean the power...

Page 49: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 Page 48 Date Service Person Location Checks complete Notes on repairs or maintenance required Parts and materials used...

Page 50: ...lead if fitted Check that the lead is in good condition Safety systems 5 Door interlock actuators 0250050065 Check that the actuators are securely attached to the door with security screws and enter t...

Page 51: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 Page 50 Date Service Person Location Checks complete Notes on repairs or maintenance required Parts and materials used...

Page 52: ...rely attached to the door with security screws and enter the interlocks freely and smoothly without force Check that the actuators lock the door while the cradle is raised above 100mm Mechanical syste...

Page 53: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 Page 52 Date Service Person Location Checks complete Notes on repairs or maintenance required Parts and materials used...

Page 54: ...ery MD only DOM 2015 0790050111 Power Supply 400VAC 24VDC 120W 5A 2 phase input 3 ph MD only 0790050374 Circuit Breaker 75A auto resetting battery MD only DOM 2019 16 0880050023 Motor 800W 24VDC batte...

Page 55: ...96 Steel Bush 16 22mm x 35mm long hardened steel MD secondary roller 7 0640200099 Sliding Plate welded and zinc plated without rollers 0220020131 Sliding Plate Pivot Block 10 0mm MS 8 0140120007 Mast...

Page 56: ...ms and conditions on custom built and non standard machines are generally specified on quotations and placing an order implies acceptance of the Warranty terms If no specific Warranty details have bee...

Page 57: ...he fault if it is not apparent This step is important so that if a site visit is necessary the correct tools and spare Parts can be taken It is also important to establish whether there may have been...

Page 58: ...nction Model Type Serial Number Function Bin Tipper Type Model MegaDumper Serial No Standards Used EN 349 1993 EN 574 1996 A1 200 EN 953 1997 EN ISO 4413 2010 EN ISO 12100 2010 EN ISO13849 1 2006 EN I...

Page 59: ...User Manual Simpro MegaDumper Original Instructions English v86 0 February 2022 Page 58 10 Notes...

Page 60: ...aste management S OE c w l around the world through a distribution network covering most large economies The product range continues to evolve thanks to a policy of continuous R D new ideas and new pa...