400 Series Granulators 14 x 56 and 14 x 62 Models Models Covered: WG, 1400, MT, TG Part Number: MAN-484249 Bulletin Number: GRN2-610 Effective: August 1, 2012
Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No. ____________ © Copyright 2013 All rights reserved.
Shipping Info Unpacking and Inspection You should inspect your granulator for possible shipping damage. Thoroughly check the equipment for any damage that might have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department. Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMA number will be assigned for the equipment to be returned. Reason for requesting the return must be given. ALL returned material purchased from the manufacturer returned is subject to 15% ($75.00 minimum) restocking charge. ALL returns are to be shipped prepaid.
Table of Contents CHAPTER 1: SAFETY ................................................................ 7 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................. 7 Safety Symbols Used in this Manual ..................................................................... 7 General Safety Regulations ......................................................................................
5-6 Rotor Bearing Replacement ...................................................................................... 27 CHAPTER 6: TROUBLESHOOTING ....................................... 28 6-1 6-2 6-3 6-4 Introduction ............................................................................................................... 28 Electrical Faults .........................................................................................................
Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your granulator. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and safety features.
Figure 1: Belt Tensioning Information Hazard Alert Symbol 1400 Series Granulators Description/Explanation Preventative Maintenance High Voltage Hazard. The electrical enclosure is supplied with 3-phase electrical power. Use caution when using or maintaining this product. Every six months inspect all electrical connections for secure attachment. For further information see the Maintenance Chapter in this manual Hands could be exposed to a crushing movement.
Mandatory Symbol Description/Explanation Read Operators Manual. This equipment must be operated and maintained by properly trained personnel. The information contained within this manual must be read and understood prior to operating this equipment. Lock Out. This equipment is operated with 3-phase electrical power. Therefore, when performing any maintenance operations we recommend following the local standards for performing a lock-out/tag-out procedure. Wear Safety Gloves.
1-2 General Safety Regulations This machine uses knives for the performance of its intended use. Consequently, it can be a dangerous machine to operate and maintain unless these safety regulations are followed. These regulations should be read, understood, and periodically reviewed by all personnel involved in any way with this machine. Never operate or remove any machine components that are secured by wrench-type fasteners unless the motor is electrically locked out and the rotor is motionless.
1-4 Warnings and Precautions Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintaining this granulator, use good judgment and follow these safe practices: þ LEARN AND OBEY your company’s safety policy regarding granulating equipment.
þ ROTATION OF MOTORS: The correct rotating direction for the granulator motor is clearly marked on the machine. Always check for proper rotation of motors. Incorrect rotation direction can cause severe damage. þ ELECTRICAL GROUNDING: All electrical equipment on the granulator must be grounded in accordance to all local codes and Article 250 of the National Electric Code. þ ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides the necessary instructions for the installation, set-up, and maintenance of our 14 x 56 and 14 x 62 granulators. 2-2 General Description This granulator is a rugged, rotary-cutting machine specifically designed to cut, chip, and granulate the toughest plastic materials with a minimum expenditure of horsepower.
2-3 Typical Features and Components Hopper The hopper is an upright enclosure bolted to the top of the cutting chamber. The hopper is designed to facilitate the feeding of material to the rotary knives and to protect the operator from material that may be thrown out. Cutting Chamber The cutting chamber is a rectangular enclosure comprise of the main frame, the bed knives, the bed knife shields, a balanced rotor, and a screen.
2-4 Safety Features Motor Starter A magnetic motor starter with control transformer must be used when safety switches are installed. Manual starters should not be used under any conditions. Safety Switches Safety switches at all access covers are wired into the starter control circuit. The machine cannot be started when these parts are open. However, for safety purposes, the machine should be disconnected from the power lines by a disconnect switch or by removing the plug from its receptacle.
Chapter 3: Installation 3-1 Uncrating the Equipment The complete granulator, including accessory and auxiliary equipment, is skidded for shipment. Refer to the Appendix for detailed dimensional data and pertinent weights. Prepare in advance the site you have selected for installation of the granulator. Be certain that the area to be occupied by the machine is clean, level, and free of obstructions.
3-3 Electrical Connections Granulator controls (if ordered) are shipped separately for mounting at a suitable location. The safety switches are connected to a common terminal box for ease of wiring. The customer is required to provide a suitable fused supply with a disconnect switch and a cable for the incoming line to the starter. Refer to the technical specifications in the Appendix for horsepower, voltage, phase, and frequency requirements to determine the size and rating of the supply cable required.
3-4 Accessing the Cutting Chamber You will need to access the cutting chamber before initial startup and for various maintenance procedures. Use the following procedure to access the cutting chamber: 1. Turn the main power off, remove the line fuses, and tag the machine as out of service. 2. Remove the hex head bolts along the top of the cutting chamber downstroke covers and inside covers. 3. Swing covers downward using the handle that is provided on each cover.
3-6 Initial Start-up This machine has been run under power and tested at the factory prior to shipment. The necessary settings and adjustments have been made so that a minimum amount of setting up or re-adjustment is required when starting up the machine in its new location. With all electrical, mechanical connections and lubrication requirements having been attended to, the following start-up steps should be carefully carried out before attempting to place any material into the infeed hopper.
Chapter 4: Operation 4-1 Start-up Before starting the machine, check that the rotor rotates freely by rotating it by hand from outside the machine using either the coupling or the sheave depending on the type of drive. Inspect the cutting chamber carefully to insure that nothing has fallen into it. Make sure all screws and bolts are properly secured. Check all electrical connections and motor rotations. See Chapter 3 on pages 16-19 for detailed set-up instructions.
4-4 Shut-down Use the following procedure to properly and safely shut down the machine: 1. Stop all feeding of material. 2. Allow the granulator to run until the cutting chamber is completely empty. 3. Press the drive motor “stop” button. This shuts off the rotor drive motor. 4. After the granulator has stopped, press the airveyor stop button (if applicable) located at the blower motor. 5. Turn the main power switch to off.
Chapter 5: Maintenance 5-1 5-2 Preventative Maintenance Schedule Check Frequency Knife clearance Weekly Knife retaining screws for tightness Weekly Knife exposure Weekly Shield retaining screws for tightness Weekly Screen retaining studs for tightness Weekly Lubrication of drive motor bearings Monthly Lubrication of rotor bearings Monthly Screen Wear Monthly Belt tension Monthly Hopper and cutting chamber screws are tight Monthly Lubrication When the machine is shipped, the bearings
5-3 Replacing and Adjusting the Knives During use, the clearance between the rotor knives and the bed knives will increase due to wear. This is a normal condition that requires re-setting this clearance once or twice before it is necessary to remove the knives for regrinding. Check the knives weekly for wear, clearance, exposure, and screw tightness. When new knives are fitted to the machine, adjustment after eight hours of running time may be required.
Bed Knives We recommend that the same screws and washers be re-used only when the bed knives have been repositioned or re-ground. When blunt knives are discarded and replaced with new knives, use new screws and washers. This will reduce the risk of screw failure due to their overstretching. Screws and washers must be replaced with the type specified in the Spare Parts List. Use the following procedure to replace or adjust the bed knives: 1. Access the cutting chamber as directed in Section 3-4 on page 18.
5-5 Adjusting Belt Tension For continuous reliable operation of the granulator, it is important that the belt tension is correct. Correct tension reduces wear on rotor and motor bearings and keeps belt slip to a minimum. Figure 2 gives the recommended force to deflect each belt by an amount equal to the belt span divided by 64. A gauge is available through the sales department to measure the deflection and force. Use the following procedure to adjust the belt tension: 1.
7. In no case should the belts be over tensioned, as this can significantly reduce belt and/or bearing life Figure 2: Belt Tensioning Information BELT SMALL CROSS SHEAVE SECTION DIA. A B C D E DEFLECTION FORCE: LBS. STANDARD SUPER GRIPBELTS GRIPBELTS 4.25 GRIPNOTCH BELTS STEEL CABLE GRIPBELTS 3.0-‐3.6 3.5 3.8-‐4.8 4.25 5.0-‐7.0 4.75 3.4-‐4.2 4.375 5.5 8 5.5 4.4-‐5.6 6 7.125 9.125 7.25 5.8-‐8.6 7.75 8.75 10.125 8.75 7.0-‐9.4 12.25 14.375 17.875 14 9.
5-6 Rotor Bearing Replacement Use the following procedure to remove and replace the rotor bearings: 1. Shut off the machine and the main power disconnects. 2. Remove the flywheel guard and drive belts. 3. Disconnect the thermal sensors. 4. Loosen the flywheel sheave bushings and bolts, and remove the shaft end cap. Remove the flywheel and bushing. Loosen bolts on the bearing end cap and sheave spacer. 5. Clean grease and dirt from the bearing’s exposed surfaces and shaft surfaces. 6.
Chapter 6: Troubleshooting 6-1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components. All normal trouble-shooting must be accomplished with the power off, line fuses removed, and with the machine tagged as out of service. The use of good quality test equipment cannot be over-emphasized when troubleshooting is indicated.
6-2 Electrical Faults Problem Possible Cause Possible Remedy Motor Fails to Start Supply failure Check fuses Starter inoperative Check main supply Starter overloads or cuts out Check motor requirements and adjust accordingly Safety switches inoperative Check and adjust as needed Too much belt tension Check belt tension and adjust as necessary Incorrectly connected motor Check terminal connection with manufacturer’s connection diagram and adjust as necessary Defective starter winding Check
6-3 Processing Faults Problem Possible Cause Possible Remedy Stalling Overfeeding Reduce feed rate Partial or complete screen blockage Remove screen, clear and inspect for damage Insufficient tension on v-belt drive causing belt slip and burning Check tension of the belt and adjust as necessary Badly blunted or damaged knives Fit re-sharpened or new knives as required Knife setting too wide Check clearances given and adjust as required Installation fault; motor running in reverse direction C
6-4 Mechanical Faults Problem Possible Cause Possible Remedy Bearing overheating Excessive tension on the belt drive Check tension of belt and adjust as necessary Lubrication fault Check lubrication frequency and recommended lubricant Visible cracks in knife Incorrect grinding or grinding procedure Check method of grinding and contact our technical sales department Knives moving on knife seats Uneven knife seat surfaces Clean up to provide maximum bearing surface Loose knife screws Knife scr
Chapter 7: Appendix 7-1 Recommended Torque for Screws (Grade 8 alloy steel heat-treated screws) MM Screw Size 6 8 10 Inch Screw Size 1/4 5/16 3/8 Torque Ft. Lbs. 13 26 46 12 16 19 20 24 7/16 1/2 5/8 3/4 7/8 1 76 110 220 400 635 870 Threads must be dry. Screw threads should be wiped with an oil-dampened cloth before installation to prevent galling.
7-2 Technical Specifications Features Model Throat Size 14x56 14” x 56” (356 x 1422 mm) 14x62 14” x 62” (356 x 1568 mm) Cutting Circle Throughput Diameter 14” (360 mm) 2200 lbs./hr. (1000 kg.) 14” (360 mm) 3000 lbs./hr. (1363 kg.) Approximate Weight 11,500 lbs. (5227 kg.) 17,000 lbs. (7727 kg.
7-3 Drawings Dimensions (14 x 56 model) 1400 Series Granulators Chapter 7: Appendix 34 of 43
7-4 Pneumatic Hopper Actuator Assembly The pneumatic cylinder actuators are used to open the hopper on the granulator for accessibility to the cutting chamber for knife change and adjustment. It is important that the safety instructions in this manual be read before proceeding to operate the hopper pneumatic actuator assembly.
Closing the Tilt Plate and Hopper Use the following procedure to close the hopper: 1. Be sure that all inside fasteners are properly tightened. 2. Be sure that all tools are removed from the cutting chamber. 3. Be sure that all personnel, including you, are clear of the tilt plate and granulator. 4. Disengage the safety strut. 5. Rotate the manual pneumatic valve handle to the proper position to lower/close the tilt plate and hopper. 6. Be sure that the tilt plate is in its full down (closed) position. 7.
Pneumatic Actuator Assembly Typical Wiring Diagram 1400 Series Granulators Chapter 7: Appendix 37 of 43
7-5 Feed Roll Assembly The two counter-rotating pinch rolls in the feed roll assembly control the rate at which material is to be fed into the granulator. The lower roll is a stationary roll mounted by two flange bearings and the upper roll, which has its position pneumatically controlled, is mounted on two slide bearings. The feed roll assembly can accommodate material up to 56” wide at a thickness range from 0” to 1”. The feed rolls are driven by a roller chain.
Cleaning the Feed Roll Assembly Disconnect the main air line and electrical power. For normal vacuum cleaning, removing the front plate from the feed roll assembly will provide adequate access to the feed roll area. However, it may be necessary to remove any attachments assembled to the front plate. If feed rolls must be removed, follow the procedure for disassembling the feed rolls in the next section.
Feed Roll Assembly Spare Parts List (14 x 56 Model) Quantity Name 2 Brg Stationary F/R 1-3/4 B. Brng. FB-210 2 Brg. Sliding F/R 1-3/4B Brng WSTU-220 2 Coupler Linear Alignment LC-1-07 1 Gear Reducer 40:1 BSTN GR F732B 40JL 2 Sheave – Timing Belt P40-14M-40SF 1 Bushing Taper Lock 2” Bore SFQD 1 Bushing 1-3/8 Bore SFQD 1 Belt-Timing-Woods HTD 1190-14M 1 Unit Airline FRL/Gage (628.
7-6 Load Sensing System The granulator load sensing system stops the feed roll motor and turns on a red light when the motor current load exceeds the 100% setting on the relay. The load sensing system consists of three main components. The current transformer, which is wired to the granulator, senses the motor current. The load relay receives a signal from the current transformer.
7-7 Technical Assistance Parts and Service Department The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience.
1400 Series Granulators Chapter 7: Appendix 43 of 43