nsc user manual

The disposal of galley and accommodation garbage on offshore platforms creates a unique waste management problem. Cramped decks, large numbers of personnel, transportation logistics and the need to comply with health, safety and environmental regulations require a solution to the dilemma that is safe, reliable and efficient.

Our company perceived a need for a waste compactor that was custom-designed for the offshore industry and not merely a modification of equipment used on land. After several years of design and development including service in the offshore environment we have a compactor that fully addresses the waste management requirements of the offshore operator.

The prime considerations during the design phase were the lack of deck space and the minimum power requirements to operate the machine. The base dimensions are minimised and structural weight saved by adopting a vertical compacting mode.

Compactor Base	5.5ft x 5.5ft (1690mm x 1690mm)
Compactor Height	9.43ft (2875mm)
Compactor Weight	3.0 tonnes (with Skip & empty)
Skip Volume	48cu.ft (1.4cu.metres)
Compaction Ratio	approx. 10 to 1

The Skip will carry up to 1.25 tonnes of refuse although it is structurally capable of carrying more.

The combined compactor and Skip have a tare weight of 3 tonnes and a gross weight rating of 4.25 tonnes in the case of transporting it with a full load.

The compactor and Skip are constructed and marked in accordance with the Supply of Machinery (Safety) regulations 1992 and the Provision and Use of Work Equipment Regulations 1998.

The limited availability of power offshore, particularly on the smaller platforms, led NSC to develop a fully pneumatic system to operate the compactor. The Platen is activated by an air-filled Bladder that exerts a load of 28,000 lbs (12,700 kgs) at maximum and requires only 15 cubic feet of air at 100 psi per cycle. The control circuitry is contained in a well laid out, weatherproof control box adjacent to the operator’s position.

The NSC Waste Compactor is economical to operate and has no hydraulic, electric or rotating parts; thus ensuring an absolute minimum of maintenance and intrinsic safety in hazardous environments.

To overcome the logistics problems in the shipment of full and empty Skips between platform and shore, our compactor was developed around the use of seal-able, disposable, hygienic bags that eliminate the need for storage of empty Skips offshore. There is no need to empty the compactor after shipment onshore and the risk of damage during transit is avoided.

The bags are rated for 1.25 Tonnes (1250 kgs) at a safety ratio of 5:1. Lifting straps (4 off) are sewn in at each corner. A light material skirt is attached to the top edge for tying off the full bag to prevent spillage.

The end product of our compactor is a woven, polypropylene bag containing garbage weighing up to 1.25 Tonnes with lifting straps attached. It is easily transported either itself or more usually on top of solid scrap material in half-height containers or Skips.

As an alternative the compactor can be used without the bags and the full Skip lifted off the air-powered, cantilevered Skip trolley to be replaced with another.

A deodoriser spray system is incorporated on all our models. The void above the load is filled with a mist of the chemical after each compacting cycle. The result is a load that is impregnated with the deodoriser reducing smell and health hazard. Full bags awaiting shipment can be stored with confidence outside the compactor.

The deodoriser is contained in a 5 litre plastic flask that is located to the right of the Skip.

INSTALLATION

The NSC Waste Compactor is a free-standing independent unit that only requires an air supply on site for normal operation.

The site for the compactor must be level and steady. It must be within reach of suitable craneage for the placement of the machine and the subsequent removal of full compactor bags (see Fig.1).

Solid decking or flooring is required as the Skip trolley wheels may foul on open grid or uneven deck plating. The Skip trolley may jam or be unable to move in or out freely if the base of the compactor is twisted on an uneven surface. Should the only available site for the compactor be uneven, the compactor base must be levelled using shims between the base and deck.

Consideration should be given to the seepage of fluids that are squeezed out of the bag as a consequence of the compacting process. The fluids run out of drainage holes in the base of the compactor on to the deck where suitable dispersal should be arranged.

The air supply required for the compactor is 100 psi (7 bar). The connection point is on the control panel side of the compactor at the lower rear corner (see Fig.1).

Compressed air from ring main pipelines offshore is invariably contaminated with water due to condensation or compressor problems. It is recommended that an in-line water trap be installed at the air main tapping point for the compactor to prevent damage to the control system by flooding.

NSC can fit any type of airline coupling that is requested by a client. The standard connector used by NSC is the Chicago or “Crow’s Foot” coupling that requires a quarter turn to lock or unlock.

To facilitate connection or disconnection of the air supply a sliding sleeve valve is fitted immediately behind the air supply coupling on the compactor (see Fig.2). When the sleeve is fully pushed IN the air supply is ON to the compactor. The sleeve at the midway position will allow air to bleed from the connection hose (turn the air OFF at the supply end) and ease pressure on the coupling for disconnection. The air supply is OFF when the sleeve is fully pulled OUT. A notice describing this feature is attached to the compactor alongside the air connection point (see Fig.3).

LAYOUT OF CONTROLS

The operator’s position (as shown in Fig.1) is designed to keep the operator safely out of the path of the door or skip while they are in motion. It also allows the operator to look across the face of the compactor to ensure that no other personnel are near the door or skip while they are moving.

Three control buttons are located on the front of the compactor (see Fig.2). They are DOOR OPEN, DOOR CLOSE, and EMERGENCY STOP.

The control panel is on the side of the compactor and the layout is shown in Fig.3a.

The EMERGENCY STOP and DOOR CLOSE buttons perform the same task as those on the front of the compactor. The EMERGENCY STOP is repeated for convenience. The DOOR CLOSE button on the panel must be pressed at the same time as the one on the front of the compactor for the door to close. The strategy is to keep the operator’s hands occupied while the door is in motion.

The RESET button will return the compactor to its stand-by condition after an EMERGENCY STOP has been pressed or to check that the compactor is ready for operating.

NOTE - The EMERGENCY STOP buttons stay depressed when pushed and require a twist to reset them before pressing the RESET button.

The SKIP IN/OUT handle is used to roll out the skip for a bag change or whenever an item is to be retrieved from the skip or a large item loaded.

The SKIP RELEASE button must be held in before the SKIP IN/OUT handle is activated and allow the skip to move. Another strategy to occupy the hands of the operator while the skip is moving.

The BAG LOAD INDICATOR is a signal device, which normally shows green at its centre. It changes to red when the compactor bag is full. It will return to green on opening the door but will change to red after each subsequent compaction cycle until the bag has been changed.

COMMISSIONING

A step-by-step procedure for the commissioning of the compactor is posted alongside the control panel and is reprinted overleaf (see Fig.4).

It is of vital importance that the RESET button is pressed IMMEDIATELY after the air supply is turned on to the compactor. The RESET button purges the control system of any residual air pockets that remain in the system after a shutdown. The actuation of the RESET button will ensure that the compactor is primed and ready for the start of its normal cycle.

The compactor is protected during transit by the fitting of two different locking brackets (see Fig.2):

The bracket is a small piece of steel angle that is bolted immediately under the Platen in its raised position. The purpose of this device is to prevent the Platen assembly and the Counterweight, which are both connected by a chain, from “bouncing” during handling operations and causing the chain to break.

The bracket is hidden behind the closed door on delivery and the air supply must be connected before the door can be opened. It is vital that the RESET is pressed as soon as the air is turned ON to prevent the compactor going into its cycle before the bracket has been removed. On pressing the DOOR OPEN button the door will rise and the bracket exposed on the right hand wall of the Skip chamber.

On most of our models this bracket activates a valve, which isolates the operating circuits until the bracket is removed.

A long strut is bolted diagonally across the front face of the Skip to prevent it rolling out during transit. Once the compactor is its final position the bracket should be removed and stored for future use. If the Skip is bearing hard on the strut, move the Skip lever on the control panel to the ‘Skip In’ position for a few seconds to return the Skip to its normal position.

The normal bag change procedure should be followed (see Operation section) and the compactor is then ready for use.

OPERATION

Instructions for the operation of the compactor are posted alongside the control panel to provide a quick guide to personnel who have not operated the compactor previously or as a ready reference to others. A copy of the instructions is shown in Fig.5. Please read it before continuing with this section.

The NSC waste compactor has been designed with ease of operation and safety of the operator as primary considerations.

The compactor should be in its normal standby condition at all times other than loading or changing the bag. In the standby condition the air supply is ON and the door is CLOSED. The RESET button can be depressed to check that the compactor is in the standby condition.

To load the compactor the DOOR OPEN button is depressed whereby the door will rise under air power.

SAFETY WARNING - Do NOT put any part of head or body into the compactor. To retrieve items roll out the Skip using the Skip Lever.

The compactor will accept any load that will pass through the loading aperture. The operator must ensure that any item loaded into the compactor is compressible.

SAFETY WARNING - Do NOT load pieces of metal or timber longer than half a metre or 18 inches into the machine as damage may result if they become jammed between the Platen and the Skip.

Large thin-walled catering cans, boxes and cardboard cartons should be positioned in the centre of the Skip to allow them to be embedded into the compacted mass. Smaller items should be evenly distributed around the edges and across the top of the Skip to maximise the compacting effect.

Very large cartons which cannot pass through the door aperture can be accommodated by rolling out the Skip for loading and returning the Skip for compacting. Please ensure that large items will be easily crushed before using this method and that the Skip is not too full to accommodate the load.

There are no limitations to the nature of garbage that the compactor will accept, however, as containers may be ruptured during compaction the effects of paints, solvents, solutions or chemicals on the structure and coating of the compactor and surrounding area must be taken into account before placing such items in the machine.

The compactor bags are of a woven construction and will allow fluids to pass through the walls/base of the bag under the pressure of compaction. The resulting seepage is expelled through holes in the bottom of the Skip and base of the compactor to drain away. Provision must be made for this seepage on the platform/rig deck area.

To start the compaction cycle the operator must use a hand on each of the DOOR CLOSE buttons and press them simultaneously until the door is fully closed. The positions of the buttons (one on the front face of the compactor and the other on the control panel) ensure that the operator is in a safe position to supervise all the actions of the compactor.

SAFETY WARNING - If more than one person is in attendance at the compactor during the loading operations, the operator must ensure that other personnel are not in close contact with the front of the compactor when the DOOR CLOSE buttons are activated. Keep hands clear of door - risk of trapped fingers!

SAFETY WARNING - No personnel or objects should be in the path of the Skip trolley when the SKIP OUT lever is operated. Stand clear of front area of compactor - risk of trapped legs and feet!

Any object that prevents the door closing on to the top of the Skip will halt the travel of the door and cause it to return to its open position.

During the closing of the door the air supply to the door cylinders is of low pressure. When the door is fully closed further pressure is added to “lock” the door during the compaction cycle. The door cannot be opened directly during the compaction phase (see Emergency Procedure).

Once the door has closed and “locked” the control system begins an automatic sequence which fills the air bellows above the Platen bringing it down on to the garbage load. The operator can leave the compactor at this point as no further manual inputs are required.

The air bellows pushes the Platen down to a position a few inches into the top of the Skip. Any garbage above this point will be compressed down to this level. No compression of the garbage will occur until the load is above the top of the Skip, however, the compactor will go through its complete cycle once the door is closed.

After the load is compressed a void is created between the top of the load and the Platen into which further loads should be placed.

During each subsequent cycle the Platen will push the loaded garbage down into the Skip/bag until the density of the load will not allow the operation of the limit switch that triggers the return of the Platen to its standby position. The control system will sense this condition, open the exhaust valves and return the Platen to its standby position. A pneumatic indicator on the control panel will change from green to red to signal that the bag is full and requires to be changed. The indicator will reset to green when the DOOR OPEN button is pressed but will change to red again after subsequent compaction cycles.

BAG CHANGE

When the control panel indicator has changed from green to red the bag is considered to be full and should be changed.

The Skip tray will only operate when the door is open, therefore, press the DOOR OPEN button.

SAFETY WARNING - The operator must ensure that no other person or object is in the path of the Skip tray as it rolls out i.e. an area equal to the width of the compactor and five feet (1.5 metres) in front of the machine.

Press and hold the SKIP RELEASE button while moving the SKIP LEVER on the control panel to the SKIP OUT position and hold it there until the Skip is fully out.

Untie the bag lifting straps from the tabs at the sides of the Skip and pull them through the corner apertures of the bag. Draw the bag closing skirt up and over the garbage and tie to close with the strings provided near the top edge of the skirt. The garbage will then be protected from scavenging birds and dispersal by the wind.

Using the four lifting straps and the platform/rig crane remove the bag and store at a convenient location prior to shipment ashore.

The weight of the bag will depend upon the nature of the garbage enclosed. The bag rating of 1250kg is based upon the worst case of very wet food scraps and galley refuse. In practice, a high proportion of the load will consist of packaging (cardboard and plastic) which is generally dry and light in weight. A full bag of packaging materials will probably weigh between 500kg and 1000kg, however, the reduction in volume will be in the order of 10 to 1.

Fit a new bag into the Skip and tie down the lifting straps to each of the four lugs provided at the sides of the Skip. Do not put a strain on the straps as this will tension the top edge of the bag along the rim of the Skip and prevent the door closing fully.

Note - It is necessary to tie the bag on to the Skip to prevent the Platen pushing it down into the Skip and jamming up the sides of the Platen during the compaction cycle.

SAFETY WARNING - Ensure that all personnel are clear of the Skip area before operating the Skip Lever.

Press and hold the SKIP RELEASE button while moving the SKIP LEVER to the SKIP IN position and hold until the Skip is fully in. Hold for a further few seconds to ensure that the Skip tray has activated the valve which cuts out the compaction cycle while the Skip is out.

Press the RESET button to put the compactor into the standby condition. The compactor is now ready for use.

EMERGENCY PROCEDURE

EMERGENCY STOP buttons (red colour) are positioned at the bottom rear corner of the control panel and on the front of the compactor at the right hand side of the door opening.

Depression of either button will immediately cut off and exhaust the supply of air and freeze the compactor at its current position.

To restore the circuits and the Platen to the standby condition press the RESET button.

* The compaction cycle can be only be stopped by using the EMERGENCY STOP buttons and reversed using the RESET button.

SAFETY WARNING - For NSC Waste Compactors rented to installations in the UK North Sea sector there is no need to undertake any maintenance functions other than good housekeeping, i.e. see ‘Every Week’ below. Any problems should be communicated to North Sea Compactors who will arrange a change-out of the compactor.

Do not tamper with any control settings - risk of upsetting control logic.

Every Week

It is very important that attention is paid to the cleanliness of the compactor to prevent the onset of smells, odours and the health hazard of decaying food scraps lying around the base of the machine. Good housekeeping practice should be applied and all spillages and splashes cleaned up as soon as they occur.

During a bag change, or weekly, the base area and Skip of the compactor should be hosed out and allowed to drain. An occasional scrub by brush with a general detergent/disinfectant solution will keep the compactor in prime condition.

Every Three Months

All the rollers and wheels on the compactor are made of nylon compound and run on stainless steel axles, therefore, no lubrication is required.

The cleanliness of the air supply is vital to the reliability of the compactor and regular attention should be paid to the water trap (if fitted) at the branch line to the compactor to ensure that it is not blocked or passing contaminants through to the machine. Similar procedures should be applied to the filter/regulator in the control box; check that the auto-dump valve at the base of the filter bowl is operating effectively.

Mechanical dismantling of the compactor will be required to inspect and replace the Guide Post Seal and the Air Bellows. Repair of a broken chain will also involve this procedure.

* Platen Maintenance Lugs - to rest the Platen on during the dismantling procedure.

* Bellows Top Plate Lifting Bolts - to aid the raising and lowering of the Bellows Top Plate. (They may already be fitted.)

* Platen Guide Post Spanner - to remove and tighten the Platen Guide Post locking rings.

The procedure will also require the use of an overhead gantry hoist, crane or fork-lift truck to lower the Platen on to the maintenance lugs and lift it again during assembly. The service personnel will need a safe form of access into the top of the compactor, i.e. ladder or climbing tower.

SAFETY WARNING – ENSURE THAT LADDERS OR CLIMBING TOWERS ARE ADEQUATELY SECURED BEFORE ASCENDING.

Open the compactor door and fit the Door Holding Bolts into the holes exposed on the compactor frame at the bottom corners of the door.

Move the Skip to the fully out position and remove the Skip from the Skip tray trolley using the lifting points provided. Set the Skip aside.

Fit the Platen Maintenance Lugs, 4 off, to the underside of the compactor frame as shown in Fig.7. Two tapped holes are provided on each side of the compactor frame under the lower edge of the internal wall of the Platen space.

Remove the two large exhaust valves complete with their connecting elbows (Fig.8). The elbows are of the “KEYLORING” hydraulic coupling design and require the hexagonal locking nuts to be loosened sufficiently to allow the couplings to be lifted off the exhaust pipes. Lay the valves to the side while still connected.

Disconnect the Bellows Air Inlet pipe by pushing the rim of the collet into the fitting and gently extracting the tube (Fig.8).

Remove the Bellows Top Plate fixing nuts (on the flange of the Guide Tube) and allow the Bellows Top Plate to fall on to the top of the Platen.

Attach a lifting strap (rated at a minimum of 500kg/0.5ton safe working load) to the Platen Guide Post using the bridge piece to which the Guide Chain is attached. Take the strain off the chain by using the crane or lifting tackle. Dismantle the secondary wire hawser restraint. Disconnect the Guide Chain from the Chain Adjustment Screw and lower the Platen down on to the Platen Maintenance Lugs.

Unscrew the Platen Guide Post Locking Rings (2 off) using the special spanner/wrench.

Raise the Guide Post itself using the crane/lifting tackle to expose the Guide Post Seal (3mm/1/8^th Neoprene or equivalent).

To remove the Bellows completely remove the ring of nuts visible in the cavity on the underside of the Platen around the housing of the Guide Post Locking Rings.

Disengage the Bellows Clamping Ring from the Platen by tapping the protruding screw threads with a soft hammer.

Separate the Top Plate and Top Clamping Ring by unscrewing the remaining ring of nuts on the Top Plate and remove from the Bellows.

The dismantling of the main mechanical elements of the compactor is now complete.

This component should last the lifetime of the machine. Check for tearing at the welds or nips in the material and replace with a new unit, if no longer airtight.

When the Guide Post has been raised up through the Guide Tube a hydraulic-type seal is exposed at the lower rim of the Guide Tube.

Remove the seal by prising it out of its holding groove with a thin, blunt lever. Replace the seal carefully and ensure that it locates securely in the holding groove.

Guide Post Seal

Remove the Guide Post Seal from the bottom of the Guide Post. If it shows signs of compression or ageing, replace it with new material cut from 3mm(1/8^th) thk. Neoprene rubber sheet.

Platen/Counterweight Chain

Inspect the chain for stretching or wear. Make any repairs as necessary or replace the chain. Always use new connectors to join the chain to the adjusting screws. Ensure that the valve cam near the mid point of the chain will operate the Platen Up Lever Valve if a new chain is fitted.

Once all the checks have been completed the compactor should be re-assembled as follows:

Introduce the Bellows assembly on to the top of the Platen and check that the alignment of the Top Plate is correct.

Secure the bottom Clamping Ring to the top of the Platen and tighten the ring of nuts under the Platen.

NOTE – The Air Bellows acts as its own sealing gasket between the Platen, the Top Plate and the Clamping Rings. Ensure that all mating surfaces are clean and free of particles which could affect the integrity of the air-tight joints.

Lower the Guide Post down through the Guide Tube ensuring that it does not distort or dislodge the GACO hydraulic seal. Before it comes in contact with the top of the Platen, check the positioning of the Guide Post Seal to ensure an air-tight joint.

Ensure that the locating pin at the bottom of the Guide Post enters the matching hole on the top of the Platen.

Apply the Platen Guide Post Locking Rings using the first to securely tighten the Guide Post to the Platen and the second to lock off the first ring.

Raise the Platen to its maximum height using the lifting straps previously attached to the Guide Post. Hitch the secondary wire hawser restraint to the top of the Guide Post. Connect the chain to the Guide Post and lower the Platen until its weight is taken by the chain and the Counterweight.

Lift the Bellows Top Plate using the lifting bolts provided and locate the screwed studs into the holes on the flange of the Guide Tube. Apply the nuts and tighten securely.

Fit the G2 Exhaust Valves with the elbows on to the Exhaust Pipes and tighten the locking nuts.

Press the RESET button and then the Door Open button. Remove the Door Holding Bolts.

Move the Skip Trolley to the fully out position and replace the Skip on to the Skip Trolley. Fit a new Compactor Bag. Return the Skip Trolley to the fully in position.

Press the DOOR CLOSE buttons and when the door has closed press the RESET button.

PNEUMATIC CIRCUITS

The NSC Waste Compactor requires an air supply of 90 – 100 psi (6.2 – 6.9 bar) which is connected to a single coupling containing a Slide Valve for ease of line bleeding during disconnection.

Air at mains pressure is then passed through an automatic drain filter and pressure regulator with gauge indication.

The compactor is normally found in its standby/dormant condition i.e. Door closed, Skip Trolley in and Platen up.

To ensure that the control system is ready to commence the loading cycle it is advisable to press the Reset button (V21) which will ensure that the Main Air valve (V1) has not been previously activated by the Door Down valve (V16) and that Group 2 air has been selected at the Group Air valve (V5). Group 2 air pilots the Bladder Valve (V2) to ensure that no air reaches the Bladder and passes through the Platen Up valve (V14) which is open to supply the Door Open valve (V22).

On depression of the Door Open button (V22), Group 2 air pilots the Door valve (V4) to cut off mains air to the Door Down circuit allowing the Door Up valve (V7) to shuttle over and supply air to the Door Up side of the cylinders. At the same time Group 2 air is supplied to the Door Up valve (V17), which will, once made, allow air to pilot the Skip Isolation valve (V3) to open the circuit to the Trolley Control valve (V23).

A Group 2 air supply is also sent to the Bag Full valve (V9) to return the indicator eyeball to the bag OK position.

When mains air passes through the Skip Isolation valve (V3) it also supplies the Trolley In valve (V18). If the Skip trolley is OUT, no air is supplied to the Door Close valve (V20) an the compactor cannot be operated. When the Skip trolley is IN, air is sent to the Door Close valve (V20) and to the pilot of the Group Air valve (V5), which shuttles over to Group 1 air. The Door Down valve (V16) is then supplied.

To initiate the compaction cycle both the Door Close valves (V20) must be pressed simultaneously. The signal is analysed by the Two Hand Control (V8) and if either or both buttons are released before the Door Down valve (V16) is activated, the door will return to the open position.

If the signal is accepted, mains air is supplied to the Door Down valve (V6) and the Door Up valve (V6) via the Shuttle valve (V11), which has the effect of closing off the mains air to the Door Up side of the door cylinders and supplying low pressure air (5-10 psi) to the Door Down side of the cylinders via the Regulator (R2).

When the door is fully closed, the Door Down valve (V16) sends Group 1 air to pilot the Door valve (V4), turning mains air on to the down side of the door cylinders and locking the door down under low air pressure.

The Skip Isolation valve (V3) is closed to prevent operation of the Skip trolley while the door is closed. Group 1 air is also supplied to the pilot of the Bladder valve (V2) allowing reduced pressure air (25 psi) from the Regulator (R1) to close the Exhaust diaphram valves (V32) and inflate the air bladder.

The inflation of the air bladder pushes the Platen down to compact the garbage load in the Skip. At a preset limit of travel the Platen counterweight will trip the Weight Compaction valve (V15), which sends a pilot signal to the Group Air valve (V5), via the Shuttle valve (V12), to switch off Group 1 air and activate Group 2 air. The bladder air supply is cut off at the Bladder valve (V2) causing the Exhaust valves (V32) to open and deflate the bladder.

Simultaneously, at the Bladder valve (V2), air is switched to the Platen cylinder, which returns the Platen to its raised position. On reaching its raised position the Platen will open the Platen Up valve (V14) to supply air to the Door Open valve (V22) and also to the Deoderant Timer valve (V25) via the Flow Control valve (V30) to deliver a measured dose of deoderant spray to the cavity above the compacted load.

The compactor will now maintain its standby/dormant condition until the door is opened to admit another load for compaction.

The compactor will undergo several cycles as described above until the density of the garbage load will not allow the counterweight to rise high enough to trip the Weight Compaction valve (V15). The pressure in the bladder supply line will build up until the Regulator (R3) opens at a preset pressure of 23 psi. Although the restrictors in the line will dissipate the pressure, the surge will change the Bag Full valve (V9) to give an indication at the control panel that the bag is full. The surge will also pilot the Group Air valve (V5) via the Shuttle valves (V13 & V12) to close the Bladder air supply at the Bladder valve (V2) by selecting Group 2 air as explained in the previous paragraphs.

The compactor will move to its standby/dormant position and can be operated again, however, the Bag Full indicator will show red (i.e. full) after each cycle and it will become difficult to introduce more garbage into the compactor. The bag should be changed.

When the Door Open button is pressed, the Skip Isolation valve (V3) is opened and the Trolley Control handle can be used to roll out the trolley to perform a bag change. As the trolley begins its movement out, it closes the dual Trolley In valves (V18) to shut off the air supply to the Door Close valve (V20) rendering the compactor inoperable while the Skip trolley remains out.

Once the full bag has been removed and a fresh bag fitted, the Skip trolley is returned using the Trolley Control handle (V23) and the Trolley In valves (V18) are opened to allow operation of the Door Close buttons (V20). The compactor can be returned to its standby/dormant condition by pressing the Door Close buttons until the door is completely closed and then immediately pressing the Reset button.

Two Emergency Stop buttons (V19) are provided at the front and control panel of the compactor. Depression of either button will close the Main Air valve (V1) isolating the the compactor at its current condition and exhausting any air pressure in the circuits. To re-activate the compactor, the Reset button (V21) is pressed to provide air to the pilot of the Main Air valve (V1), which selects Group 2 air at the Group Air valve (V5). The compactor will then return to the standby/dormant condition.

During transport of the compactor a support bracket is bolted below the Platen to prevent undue strain on the mechanical linkage between the Platen and the counterweight. The support bracket holds the Transit valve (V24) closed to prevent the compactor entering the compaction cycle before removal of the support bracket. The Transit valve (V24) prevents Group 1 air piloting the Bladder valve (V2) into the position of supplying air to the Bladder.

FAULT FINDING

SAFETY WARNING - The purpose of this section is to give the user a quick guide to simple faults without removing any cover plates on the compactor. Where stated or, if in any doubt, please contact North Sea Compactors Ltd. for advice before attempting to dismantle or make any adjustments to the compactor. The following numbers can be used:

Check the main air supply from the Installation’s ring main or compressor. Ensure that all the valves in the pipeline to the Compactor are open, filters are not blocked or flexible hoses are not snagged. The air supply to the Compactor should be in the range of 90-120 psi.

The Slide Valve at the air supply connection to the Compactor should be fully pushed in towards the Compactor.

During transport of the Compactor the Emergency Stop buttons are pressed in to prevent damage to them. Ensure that they have been twisted to pop out into their normal working position. If an Emergency Stop button has stuck in, it will prevent air passing to the Main Air valve (V1).

The Trolley In valves (V18) at the rear of the Skip Trolley may be damaged or the Trolley may not be fully in.

Press the DOOR OPEN button and on release listen for the exhaust noise from the valve:

Ensure that both EMERGENCY STOP buttons are in the released position by twisting them clockwise and pressing the RESET button.

Press one EMERGENCY STOP button and release it. Press the RESET button. Repeat the procedure several times (this will ensure that the platen is in the fully up position).

Check that the skip is fully back inside the compactor. If not, push or lever the skip trolley back while someone holds the SKIP CONTROL lever at the ‘skip in’ position.

Check that the compactor is in its ‘stand-by’ position by pressing both DOOR CLOSE buttons simultaneously and then press the RESET button.

Still No Exhaust Noise

Exhaust Noise from DOOR OPEN Button on Release (but door will not open)

Check that the door has not jammed. Press and hold the DOOR OPEN button and get someone to prise the door upwards using a lever or large screwdriver.

Check that the panel above the door for damage during transport i.e. it has been pushed in or dented thus interfering with the passage of the door.

Press the DOOR CLOSE buttons at the same time and listen for the warning horn. Press each button in turn and listen for the valve exhaust noise:

Ensure that both EMERGENCY STOP buttons are in the released position by twisting them clockwise and then pressing the RESET button.

Check that the skip is fully back inside the compactor. If not, push or lever the skip trolley back while someone holds the SKIP CONTROL lever at the ‘skip in’ position.

Still No Exhaust Noise from the DOOR CLOSE buttons

Horn Noise When the DOOR CLOSE Buttons are Pressed (but the door does not close)

Check that the panel above the door for damage during transport i.e. it has been pushed in or dented thus interfering with the passage of the door. Ensure that nothing is obstructing the side runners of the door.

Door Will Not Remain Closed

If the Compactor Bag is tied too tightly to the Skip, it will prevent the Door reaching its fully down position and cause it to rise again. Loosen the front tie straps.

Door is Lopsided in Operation

Check that the panel above the door has not been damaged and forced into the door.

Door Closes but Compaction Cycle does not Start

Trolley will not Operate

Ensure that the SKIP RELEASE button is depressed while using the SKIP IN/OUT lever (horn will sound).

If No noise is Heard

If Horn Noise is Heard but Skip Trolley will not Operate

SAFETY WARNING - Ensure that no person is standing in front of the skip as it may move out suddenly.

Press the SKIP RELEASE button and push the SKIP IN/OUT lever to the ‘Skip Out’ position. An assistant should then lever the skip out using an appropriate bar or piece of timber.

Check that the deck surface in front of the compactor is level and free from obstruction and that the skip runners are clean.