Fusion Vario Variable Chamber Integrated Baler Wrapper
he McHale variable chamber baler range is made up of V6, V8 and Fusion Vario machines. The range consists of 5 models;
- V6740 – Non-Chopper Baler
- V6750 – Chopper Baler
- V8940 – High-Capacity Non-Chopper Baler
- V8950 – High-Capacity Chopper Baler
- Fusion Vario – Integrated Baler Wrapper
Offering innovative ideas to allow you to work smarter, whilst achieving more output, the McHale name has become synonymous with the production of robust and reliable machines, making McHale the number one choice for professional users.
The McHale Fusion Vario is a fully automatic variable chamber integrated baler wrapper, which consists of a high output baler and a vertical wrapping ring. The machine benefits from two unique patents; a patented bale transfer system and a patented vertical wrapping ring.
The Fusion Vario also has the ability to make bales of hay and straw from 0.6m to 1.68m (2′ – 5′ 6 “) but in haylage or silage, it produces bales from 1m to 1.45m (3′ 3 ” – 4′ 8 “) to allow for wrapping.
Advantages of the Fusion Vario
The Fusion Vario provides the operator with the flexibility to produce various size bales without the need to return to the yard to change machines for baling different types of crop over the course of a day. As it is an integrated baler wrapper, only one operator and tractor is required to carry out the task of baling and wrapping which leads to reduced costs in labour.
REDUCED CROP LOSS
The single belt on the McHale Fusion Vario reduces crop loss compared to multiple belts which is particularly beneficial when baling short chopped crops such as alfalfa.
BALE ONLY PROGRAMME
When baling hay or straw, the operator has the ability to carry and place bales in pairs of two for easy collection.
Built To Last
High Speed Transfer System
The McHale Fusion Vario is a unique machine which benefits from two McHale patents. As the transfer cradle moves the bale towards the wrapping ring, the wrapping roller closest to the bale chamber pivots out of the way which reduces the height the bale has to travel to get to the wrapper. This clever system saves time, as the patented system moves the bale quickly ensuring the McHale Fusion Vario delivers the highest possible output.
In normal working conditions, the ever efficient wrapping process is always completed ahead of the baler, meaning that the wrapping platform is always ready and waiting to capture the next ejected bale.
Two 750 mm Dispensers
The vertical wrapping ring on the Fusion Vario is fitted with two 750mm dispensers which take under 20 seconds to apply 4 layers of film and approximately 25 seconds to apply 6 layers of film. This means that the wrapping platform is always waiting for the next bale.
Easy Film Loading
Film can be loaded from the left hand side of the machine. After loading film on the first dispenser, the operator can push the index button and the dispensers will then rotate around and automatically stop at the loading position for the second dispenser. This allows the operator to easily load the second roll of film.
Film Break Sensors
The dispensers are fitted with film break sensors, which notify the operator through the control console in the tractor cab if one or both dispensers run out of film. If one dispenser runs out of film, the machine will continue working by automatically slowing bale rotation, increasing the number of rotations of the wrapping ring to ensure that the bale is wrapped correctly.
Reliable Cut and Holds
On the last rotation of the wrapping cycle, the cut and hold rails extend out and the wrapping film is gently supported within them. Once supported, the cut and hold gathers the wrapping film to one point where it is cut and held. By gathering the plastic to one point, this system makes the Fusion Vario’s performance even more reliable, particularly in hot or wet conditions.
The McHale Fusion Vario can produce bales of various sizes, from 1–1.45m (3′ 3″–4′ 8″), for wrapping with the high speed vertical wrapping ring. On adjustment of the bale size from the iTouch control console, the patented tip roller adjusts its height in line with the selected bale size to ensure the plastic always goes onto the centre of the bale, regardless of the bale diameter. This ensures the correct overlap is always achieved resulting in an even distribution of plastic on the bale.
Over the last decade, McHale has designed and developed various types of pick-ups. After extensive testing, McHale decided it will offer customers the choice of 2 pick-up options depending on their working conditions:
As standard, a cam operated 2.1m high-intake galvanised pick-up ensures excellent ground cleaning in all types of crop. The cam pick-up runs on a cam track that is fitted with double raced cam bearings to stand up to the most testing of conditions.
All cam pick-ups across the McHale Fixed Chamber Baler Range are fitted with 5 tine bars for excellent ground cleaning and delivery of crop to the bale chamber. A side inspection port allows the operator to quickly check and change the cam bearings if needed.
All McHale cam pick-ups have heavy-duty tine bar supports to ensure long service life. McHale have also developed a pick-up tine designed to lift even the shortest of crop
A 2.1m camless pick-up is available as an option on all machines in the McHale Fixed Chamber Baler Range. Six tine bars are fitted to all McHale camless pick-ups to provide excellent ground cleaning and fast delivery of crop to the bale chamber.
The camless pick-up has been designed to increase output, reduce levels of maintenance and perform better in certain conditions.
All camless pick-ups are fitted with a fully welded tine bar. McHale have also developed a pick-up tine designed to lift even the shortest of crop
The specially designed McHale pick-up is positioned close to the rotor to improve delivery of the crop through the rotor to the bale chamber. Large diameter lateral feed augers help direct crop to the bale chamber ensuring a consistent and even crop flow for producing high density bales.
Over the course of a baling season, machines have to work with different volumes of crop. McHale have designed an adaptive intake which allows the intake area to automatically adjust for light and heavy crops to facilitate a smooth crop flow into the chamber.
Split Drive GearBox
A 540rpm Split Drive Gearbox is fitted to all machines in the McHale Variable Chamber Range as standard. The gearbox design ensures that power is evenly distributed to both sides of the machine.
Optimal Power Distribution
The rollers in the bale chamber are driven from the left-hand side of the machine and the pick-up and chopper unit are driven from the right-hand side of the machine. This system ensures direct, short transfer paths, leading to optimal power distribution.
1000rpm Gearbox (Optional)
In order to optimise machine performance, a 1000rpm gearbox is available as an optional upgrade on all machines in the McHale fixed chamber baler range. We recommend you speak with your local dealer or distributor regarding which gearbox is best suited to your requirements, based on your working conditions.
The star shaped feed rotor ensures a high-capacity flow of crop into the bale chamber. McHale have designed 3 rotors for the Variable Chamber Baler Range.
The flights on the rotor are laid out in a spiral formation to achieve consistent crop flow. As crop enters the rotor, rotating flights feeds it to the bale chamber. These ensure high output, while the star layout reduces the load peaks as the machines work in heavy swaths.
- The feed rotor or chopping unit boasts a heavy-duty rotor and comb.
- The flights are welded on both sides for superior strength and on the drive side the rotor is fitted with a double row bearing with a long service life.
V8950 Rotor Types
15 Knife Chopper Rotor (Standard)
|Number of Knives||15|
25 Knife Chopper Rotor (Optional)
|Number of Knives||25|
Selectable Knife System
All McHale Fusion machines have the option to be fitted with a selectable knife system. Various knife configurations can be chosen depending on the knife bank specification.
25 Knife Bank Options
0, 12, 13, 25 Knifes
The knives in the chopping unit are made from hardened tool steel, which ensures long life and maximum productivity by reducing the downtime associated with knife sharpening.
The serrated knife edge creates multiple points of contact with the crop to ensure a consistent chop quality is achieved.
To ensure that the machine always delivers a good chop quality, two monitoring systems have been put in place on the Fusion Vario.
- Knife working pressure is monitored and displayed on the control console.
- A sensor monitors the distance between the top of the knife and the spine on the rotor.
The knives in the chopping unit can be engaged and disengaged from the tractor cab. When engaged, the knives extend into the spine of the rotor, which ensures a consistent chop quality.
- A primary hydraulic knife protection system protects the knife bank(s) should it encounter a foreign object.
- A secondary protection system is in place on each individual knife.
For over a decade, all machines in the Variable Chamber Baler Range are fitted with the McHale Drop Floor Unblocking System, a feature which operators have come to love for it’s simplicity of use and effective unblocking cycle.
The McHale variable chamber baler range is fitted with a drop floor unblocking system, which means blockages can be fed through in three simple steps.
1 – Drop the Floor
Should a blockage occur, the sound of the slip clutch alerts the operator, who can hydraulically lower the floor from the tractor cab. When operating the drop floor cycle, the knives and the drop floor drop together during the unblocking process, giving even more clearance to allow the blockage to be fed through.
2 – Re-engage the PTO
This widens the feed channel at both the front and rear of the drop floor where the blockage is more likely to occur. By lowering the front and rear of the drop floor, the blockage can be fed through and effectively cleared when the PTO is re-engaged.
3 – Reset the Floor
The floor can then be reset to its original position and baling can resume. On the F5500,F5600 and F5600 Plus the drop floor is equipped with a drop floor sensor to ensure the chop quality is consistent by indicating to the operator via the control box if the drop floor is open and the knives are down.
Bale Chamber & Bale Sizes
The bale chamber on the McHale variable chamber baler range is comprised of heavy-duty endless belt(s). The belts are extremely hard wearing and are reinforced with synthetic material, which ensures that the belt(s) can absorb and apply high pressure to the material in the Bale chamber.
The Fusion Vario can make bales of hay or straw from 0.6m (2 ‘) to 1.68m (5 ‘6″)
but in haylage or silage, produces bales from 1m (3 ‘3 “) to 1.45m (4 ‘8 “) to allow for wrapping.
The bale size can be adjusted up from the minimum setting in increments of 10mm (2/5″)
Bale Chamber – Belt Options
A single full width endless belt is also available as standard on the Fusion Vario.
This full width belt reduces crop loss, particularly in alfalfa and provides better belt traction for the operator compared to multiple endless belts.
Bale Chamber Bale Formation
McHale have developed a bale chamber that can quickly form the bale from the start. The operator can commence baling at full speed as the progressive density system can quickly adjust to ensure that pressure is exerted on the crop right from the core of the bale, regardless of bale size.
This is done by four heavy-duty springs that pressurise the crop at the start of the baling process. The tension placed on the crop by these large springs allows for the perfect start to the bale. The spring tension on the belts ensures easy bale formation and a properly formed core.
As the bale is forming inside the chamber, the hydraulics take over the tensioning of the belt(s) from the four large springs. Two hydraulic rams control the tension on the chamber belt(s) as the bale forms inside the chamber.
Just like the core of the bale, the outer layers are compressed at the same consistent pressure using both springs and hydraulics until the set bale density and size is reached.
Bale Chamber Double Drive
Double Drive Features
In more difficult conditions, such as wet heavy grass, if the primary drive slips slightly, the double drive will engage in order to aid belt and material rotation in the chamber. This double drive helps bale formation as a constant pressure is kept on the chamber belts which results in the production of a solid and uniform bale even when dealing with a wet and heavy crop.
A cleaning auger is fitted to the double drive system in order to prevent crop build up and allow the double drive to aid bale rotation when working in wet or sugary crops.
Bale Shape Indicators
Ultra-sonic bale shape indicators are fitted to all McHale Variable Chamber Balers and indicate to the operator via the control console which side of the chamber needs to be filled.
Mechanical Tailgate Locking System
The tailgates on all McHale variable chamber balers are fitted with a pair of mechanical locks, which keep the bale chamber securely closed. These locks remain activated until, the progressive density system reaches the preset bale size and density and the required amount of net has been applied. This eliminates the need for the chamber door to rely on hydraulic pressure when making high density bales.
Oiling & Greasing
The McHale variable chamber baler range of balers are all fitted with a continuous oiling system. Once the PTO is engaged, the continuous oiling system constantly lubricates the chains to ensure a long lifetime. A lube alarm sounds after 300 bales to inform the operator to refill the oil tank.
Continuous Oiling System
The continuous oiling system on the machine is driven off the gearbox and delivers oil to the following chains:
- Chamber Drive Side Chains
- Rotor Drive Chain
- Pick-Up – Drive Chains
- Pick-Up – Cam Track
- Pick-Up – Drive Gears
All machines come fitted with a number of manual greasing points which are easily accessible throughout the baler either individually or through a centralised greasing block. The following bearings highlighted below are greased:
- Bale Chamber – Drive Side
- Bale Chamber – Non-Drive Side
- Rotor Bearings – Drive Side
- Rotor Bearings – Non-Drive Side.
Automatic greasing is standard on all McHale Fusion Vario. A pressurised system delivers a measured amount of grease around the baler every time a bale is ejected from the bale chamber. Automatic greasing saves time as it reduces the amount of manual greasing to be done by the operator. The grease cartridge should be refilled after 1200 bales
High Performance Netter
A high performance netter has been designed and developed for the McHale Variable Chamber Baler Range. This netter is very reliable and comprises of a moving roller which allows the roll of net to rotate as it is being applied to ensure even net application.
A simple yet very effective netting system comprising of a moving roller allows the roll of net to rotate as it is being applied to ensure even net application. Net is stretched around the bale using a hydraulic brake. The brake places a resistance on the speed at which the roll of net can rotate, the greater the resistance the more stretch that is applied to the net. The operator can adjust net tension without having to leave the comfort and safety of the tractor cab.
McHale V6 & V8 balers are fitted with a bale discharge sensor, which notifies the driver when the bale has left the bale chamber and has passed over the heavy-duty bale kicker ensuring a clean separation between the machine and the netted high-density bale. Storage for two extra rolls of net is also provided on the baler platform.
The high performance netter is extremely reliable and features:
Endless adjustment of tension to ensure optimum bind material usage and bale shape
Up to 1300 mm
Capacity to take rolls of net wrap up to 1300 mm in width and 4500m in length.
180-degree wrap around on the rubber feed roller, eliminating any net or film slippage while feeding
iTouch Control Console
The McHale “iTouch System” is a modern control console featuring the latest in touch screen technology, boasting a large 7″ colour screen, in a rugged, hard-wearing enclosure displaying all the information that a user requires to monitor how the machine is performing.
The iTouch control console is fitted to the McHale Fusion Vario. This touch screen monitor features a 7″ colour screen with easy to understand icons that control various functions on the machine.
The McHale iTouch system was specifically designed and tested to be user friendly and this approach is reflected in its full colour screen and graphic display of all machine settings and functions.
iTouch Control Console Overview
iTouch Control Console Functions
The iTouch control console is fitted with a camera as standard on the McHale Fusion Vario.
- In manual mode, the operator can switch to camera mode to view the wrapper and rear of the machine.
- In automatic mode, the camera image will appear at different predetermined times on the screen such as when the bale is being transferred or being tipped.
Customer Data System
The McHale iTouch control console is primarily for monitoring and configuring machine performance but also contains additional features that the professional farmer and contractor will find invaluable in their day to day activities.
- The McHale iTouch contains a built-in database for storing customer profiles and work performed which can be displayed on the 7″ screen or alternatively sent to an optional receipt printer for printing.
- Information such as customer name, bales produced per hour, number of bales wrapped/un-wrapped & number of bales chopped/un-chopped can be easily viewed or printed, providing full visibility of all jobs completed. A contractor can customise receipts with their details such as business name, address and contact details.
- Up to 10 job totals can be stored on the iTouch. The console also features a reset total reminder to prompt the operator to reset the customer total when changing between fields.
McHale machines work in different conditions around the world. To optimise performance, we offer a number of options in the McHale Fusion 4 range. We recommend you speak with your local dealer/distributor as regards the best features or options to meet your requirement
Options Fusion Vario
The 2.1m camless pick-up runs smoothly, particularly in short crop, and requires less maintenance due to a reduced number of rotating parts. All camless pick-ups in the McHale variable chamber baler range are fitted with six tine bars and a double crop roller to provide excellent ground cleaning and fast delivery of crop to the rotor.
Rotor / Chopper Unit
The 25 knife rotor and chopper unit is available as an option on the McHale V6750,V8950 and Fusion Vario variable chamber machines and delivers a chop length of approximately 46mm.
A selectable knife system consists of two knife banks which allow for various knife configurations to be chosen depending on the knife bank specification. If a machine is equipped with 25 knives, then a bank of 12 and a bank of 13 knives are available to be chosen from. Where a machine is equipped with a 15 knife chopping unit, then a bank of 7 and a bank of 8 knives are available to be selected. If no chopping is required then the operator can select for no knives to be engaged. On all Fusion Vario machines, knife selection can be decided from the tractor cab.
McHale machines work in different conditions around the world so in order to optimise machine performance, a 1000rpm gearbox is available as an optional upgrade on all machines in the McHale baler range.
All McHale Fusion Vario machines come fitted with hydraulic brakes as standard but can be specified with air brakes as an optional extra.
A single, full width, endless belt exerts a high pressure on the crop in order to form a dense bale in the chamber. Heavy-duty belts are manufactured to the highest of standards using layers of synthetic and rubber material to form a durable endless belt with no joins. This full width belt reduces crop loss, particularly in alfalfa and provides better belt traction for the operator compared to multiple endless belts.
Automatic greasing is standard on all Fusion Vario machines but is available as an option on all McHale V8950 machines. Automatic greasing saves time as it reduces the amount of manual greasing to be done by the operator. All drive and non-drive side chamber bearings and rotor bearings are greased as the machine is working through the automatic greasing cycle. A measured amount of grease is distributed around the machine every time the bale chamber door opens on the McHale Fusion Vario. The grease cartridge should be replaced after 1200 bales.
ISOBUS is available as an optional extra on all McHale V6750 and V8950 machines. When the machine is fitted with ISOBUS, it can be plugged into any ISOBUS tractor connection and operated through the terminal in the cab.
McHale offer a number of tyre upgrades depending on customer preferences and ground conditions.
Dimensions & Weight
(9’ 8” )*
|Length||6.3 m (20’ 8”)|
|Height||3.3 m (10’9″)|
|*Width will depend on tyre selection|
|Working Width||2100 mm (6’11”)|
|Pick Up Guide Wheels||Standard|
|Short Crop Guard||Optional|
|Number of Knives||
|Theoretical Chop Length||65mm|
|Knife Deactivation||Hydraulic from Cab|
|Unblocking System||Drop Floor|
|Width||1.23 m (4′)|
|Diameter||0.6 m (2’) to 1.68 m (5’ 6”)|
|Bale Chamber Feed||15 Knife Chopper Feed Rotor|
|Number of Belts||1|
|Net Adjustment||In Cab|
|Net System||High Performance Netter|
|Net Roll Capacity||1+2 Storage
|Control||Manual or Automatic|
|Main Drive Protection||Cam Clutch|
|Pick Up Protection||Slip Clutch|
|Bale Chamber||Double Drive|
|Bale Size Adjustment||In Cab|
|Electronics||12 Volt DC, 20 amp approx.|
|Minimum Hydraulic Flow||45 l/min @ 180 bar|
|Hydraulic System||Open, Closed or Load Sensing|
|Minimum Power Requirements