000 Series Pipe Shredder Models Covered: APS, CPS, MPS, EPS, SPS Part Number: MAN-EPS-0001 Bulletin Number: GRN4-610 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 ................................................................ 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..................................................................... 6 General Safety Regulations ................................................................................................... 9 1-2 Responsibility ..
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: Safety Tags and warning features Hazard Alert Symbol GRN4-610 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.
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.
1-3 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.
Remaining Risks The machine is constructed so that you are able to operate it safely. Non-avoidable dangers are prevented as greatly as possible by the protective devices. Remaining risks always exist. Please be aware of the risks described below as this will help operators/staff avoid accidents. To further avoid danger, please adhere to all advice provided in the operational manual.
Type of Danger Direct/indirect contact with live parts in terminal box. Activity Maintenance; start-up. Possible Consequences • Preventative Measures Serious injury or death. • Only trained electricians may carry out work on the electrical equipment. • If work is necessary on parts that could conduct dangerous voltage, a second person should be present to break the power supply in case of an emergency. • The yellow-marked lines conduct voltage even when the machine is switched OFF.
For further information on granulator safety, installation, and operation, see the American National Standard for Plastics Machinery⎯Granulators, Pelletizers, and Dicers Used for Size Reduction of Plastics⎯Construction, Care, and Use. ANSI B151.11-1982. We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.
Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual covers the1000 Series pipe shredder which includes models APS, CPS, MPS, EPS and SPS. The 1000 Series pipe shredder is designed for size-reduction of plastic pipes made of PE, PP, and PVC etc. The user is responsible for consequences resulting from incorrect operation: This will lead to the loss of the warranty as well as any compensation claims.
Control The pusher feeds the rotor with as much material as it is able to process. Upon reaching 70-90 % of rated current, the feeding of the pusher will be stopped and automatically started again after the power consumption has fallen by 20 % in comparison with rated current. If the high current is applied for longer than 0.7 - 1.5 sec., the main drive motor switches off and runs back after about 3 sec. standstill time. The pusher plate also runs back whilst the rotor runs back.
Illustration: (1) Stage cylinder (2) Cover (3) Lock (4) Pusher 2 3 4 1 Optional (not included in standard machine) the feeding trough can be equipped with a hydraulic feeding device. Illustration: 5 (1) Base frame (2) Lower housing flap (3) Upper housing flap (4)Gear box (5) Drive motor (6) V-belt protection (7) Discharge conveyor 6 3 4 2 7 1 The machine housing is mounted on the base frame and the drive motor and the gear box are mounted on the machine housing.
Drive The drive of the rotor ensues by means of an electric motor via "V"-belts. The motor, which is mounted on sliding rails or a motor plate, can be adjusted for regulating the tension of the "V"-belts by means of tensioning screws. The "V"-belt pulley is attached with a special tensioning element to the motor shaft.
Rotor and Cutters The material is ground between the knives assembled on the rotor and the stator knives which are mounted in a fixed position in the machine lower section. All rotors are equipped with square knives. These knives make light work of the heaviest pieces. The knives have four corners, so that they can be easily turned once a comer has worn off. The design of the rotor has a significant influence on the quality of the grinding process and its results.
The ground material will be discharged by a conveyor belt. Hydraulic pusher The ram consists of a double-acting telescopic cylinder and the pusher itself, which is a heavy durable welding construction. The pusher is moving on 3 sets of high performance guide roller skids. Those adjustable skids are running on 3 independent guide rails. The position of the pusher is controlled by an optical distance sensor.
Illustration: (1) Distance sensor (2) Reflecting area 2 1 Control Panel Illustration: Control panel (1) Emergency STOP (2) Ampere meters (3) Elapsed hour counter (4) Part 1 (5) Part 2 2 3 4 GRN4-610 Chapter 2: Functional Description 5 1 21 of 73
Illustration: Part 1 (1) Error lights (2) Control lights (3) Start buttons (4) Stop buttons (5) Control light hydraulic (6) Start/Stop switch hydraulic 1 2 5 3 6 4 Illustration: Part 2 (1) Error lights (2) Control lights (3) Star buttons (4) Stop buttons (5) Overload light shredder (6) Oil filter jam (7) Overload light Ram (8) Reset 1 5 6 2 7 3 8 4 GRN4-610 Chapter 2: Functional Description 22 of 73
Operator panel Illustration: Control panel (1) Part 1 (2)Part 2 (3)HMI operator panel (4)Emergency STOP 3 2 1 4 Illustration: Part 1 (1) System ON (2) Automatic/Manual switch (3) Error light Ram (4) System OFF (5) Half stroke (6) Manual rotor move (7) Reset (8) Pulse-push switch (9) Manual push button for Rotor move GRN4-610 1 2 3 4 5 6 7 8 Chapter 2: Functional Description 9 23 of 73
Illustration: Part 2 (1) Control light Overload reverse (2) Control light Ram PUSH (3) Control light Ram PULL (4) Lid open (5) Lock open (6) Ram PUSH (7) Lid close (8) Lock close (9) Ram PULL 1 2 3 4 5 6 7 8 9 Illustration: HMI operator panel GRN4-610 Chapter 2: Functional Description 24 of 73
Machine HMI operation manual Start menu Illustration: Operation panel start menu You can select the second menu what you want to read.
Machine running status Illustration: Operation panel running status You can read the ram position when the machine running.
Time setting menu Illustration: Operation panel time setting menu End holding: the ram reaches end position and delay time Standard push: When the ram pushes, this action lasts 30 seconds and then will has a 1 second pull action. So the 30 seconds is standard push time and the 1 second is standard pull. Standard pull: See above.
Position setting menu Illustration: Operation panel position setting menu Half position: the whole length of ram stroke is 7200mm, our setting is 3600mm, but it could be modified. Pulse position: to avoid current peak and motor overload, this setting is 6700mm, it could be modified.
Information menu Illustration: Operation panel position setting menu You can read information when the machine has alarm or stops automatically. When machine has 3 times overload in 2 minutes or 3 times hydraulic overload in 2 minutes, rotor will stop running automatically, and also has a message on the HNI, meanwhile the red LED will flash.
Pulse/Push function In normal process mode the pusher pushes forward continuously till the pusher arm reaches the proximity switch which reverses the function and the pusher moves backwards. By changing the switch (9) to “Pulse push” function on the main control board the pusher moves forward in steps. This means, after each step the pusher remains in his position for a small while before it moves forward again.
broken. If the housing flap will be opened during operation, the safety switch is activated, thus switching off the machine. "V"-belts and pusher protector "V"-belt and pusher protection are fixedly connected to the machine. They can be dismounted for installation and maintenance work. However, this may only then be carried out when all rotating parts have come to a complete standstill.
Safety Light grid The feeding trough in feed is safeguarded by a light grid. During opening and closing of the cover it is activated. If somebody walks inside this light grid, the hydraulic will be stopped. After the cover is opened or closed the light grid is deactivated. Illustration: Safety Light Grid Safety markings Safety markings are attached to the machine. If one of these markings becomes detached or is no longer recognizable, it must be replaced.
Personal Protective Gear The following protective gear must be worn when carrying out the outlined tasks. Use breathing equipment before inhaling substances that may be harmful to your health if necessary. Task Unloading machine Connecting machine Operation. Cleaning.
Chapter 3: Installation 3-1 Uncrating the Equipment Choosing Application Site The location of the machine and site of application must exhibit the characteristics listed below. • Enclosed space. • Sufficient load-bearing capacity. (Find the machine weight in Chapter 7: Technical Specifications.) • Machine must be freely accessible from all sides. • Sufficient available room for operating and service personnel. • Spatial requirements—refer to the assembly drawing.
Suspended load! Falling loads can cause serious injury or death! Only use a crane or forklift appropriate for the weight and dimensions of the load. Use suitable means to stop and pay attention to the center of gravity. Do NOT step under the suspended load. Wear a safety helmet in addition to the basic protective gear.
Connection of Emergency Stop Button The machine must only be operated with installed Emergency Stop buttons. If the Emergency Stop buttons are not installed prior to delivery, one Emergency Stop button must be installed at the control cabinet and a second one at the grinding material in-feed. NOTE: 3-2 The control panel with the switches and Emergency Stop button should be installed near the machine; the distance should not exceed 16 ft (5 m).
Start-up Checklist þ When the housing panel is opened, check the cutter mounting screws using a torque wrench. þ Search the grinding chamber for foreign matter. þ Check oil level of the gearbox motor. þ Examine in-feed device for foreign matter. þ Check that they Emergency Stop buttons are unlocked. þ Check all safety devices for proper function.
Chapter 4: Operation 4-1 Start-up Machine Checks Prior to Start-up þ The cutters are properly set and the screws are tightened with the specified torque. þ The grinding chamber is free of foreign matter. þ The housing panel is closed. þ All safety devices, including devices for the grinding material in-feed and discharge devices, are checked for proper function. Switching Machine ON 1. 2. 3. 4. 5. 6. 7. 4-2 Switch on the grinding material discharge device.
4-3 Shut-down Switching Machine OFF 1. Wait until the cycle is finished and the cover has opened. 2. Then switch off the shredder, (main switch to 0). 3. If you want to close the cover of the feeding trough, close it manually by pressing the button cover close. 4. Switch off the grinding material discharge device.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule Only trained personnel may perform maintenance on the machine. The maintenance must be performed within the specified time and also documented for records. Regular maintenance is important to the continued effectiveness and efficiency of the machine. Electrical voltage causes danger while starting the machine for maintenance—the main switch MUST be turned to 0, the machine must be safeguarded with a padlock, and a warning sign must be attached.
5-2 Preventative & Corrective Maintenance Checking the Protective Devices Check all safety devices for stipulated condition, location, and function; verify they have safe mountings. Danger results from non-functioning protective devices! Serious injury or death can result. Eliminate all defects before you put the machine into operation! If defects occur during operation, stop the machine immediately and eliminate the defect! Do NOT change or remove any protective devices.
Replacing the Rotor The rotor has a heavy-duty design, which makes replacement necessary only after a crash, i.e. a hammer falls inside the machine. Dismounting and mounting the rotor requires specialized knowledge. Dismounting the rotor Follow the steps below to dismount the rotor. 1. Dismount the gearbox motor. 2. Remove the rotor mounting slot cover plates from the housing. 3. Screw in hooks on both shaft ends. 4. Remove the bearing housing mounting bolt. 5.
Dismounting the main bearings Follow the steps below to dismount the main bearings. 1. Dismount the gearbox motor. 2. Pull the distance sleeve from the rotor axis. 3. Remove the rotor cover plates from the housing. 4. Screw in hooks/eye bolts on both shaft ends. 5. Hang the rotor from hooks/eye bolts on both shaft ends. 6. Remove the bearing housing mounting bolt. 7. Carefully lift out the complete rotor using suitable lifting equipment. 8. Place the rotor in a safe location (timber beams are recommended).
Lubricating the Main Bearings A correct lubricant supply is an important requirement for operational safety and long service life of bearings. Every machine is greased and test runs are performed before delivery. NOTE: Unsuitable lubricant, lubricant deficiency, excessive lubricant, or impurities in the lubricant lead to overheating and extreme wear of the bearings. Lubrication intervals Use the following table to determine when to check and replace the lubricant.
Refilling lubricant The grease travels through the circulating grooves and bores via lubrication nipples into the interior of the bearing. The greasing quantity is 2 oz. (60g) to 3.5 oz. (100g) roller bearing grease F3 per bearing. Grease nipple Replacing lubricant Renewing the lubricant between the specified intervals is only necessary when unusual bearing noises or overheating occurs. Mounting and dismounting the bearings must be performed according to the instruction in the operation manual.
List of lubricants Name/ Country of Manufacturer Roller Bearing Grease ARAL ARAL Grease HL 3 BP BP ENERGREASE LS 3 CASTROL CASTROL SPHEEROL AP 3 ESSO Beacon 3 FUCHS FUCHS Grease 1200; FUCHS Grease FWA 220 SHELL SHELL Alvania Grease 3 MOBIL-OIL MOBILUX 3 WISURA WISURA Liba L 3 Zeller & Gmelin ZET GE Grease M 50 FAG FAG L 71 ANTAR Petroles de l’Antantique ROLEXA Holland, Beverol Beverol Multi-Purpose Grease Italy, Agip AGIP Grease 33 FD Sweden, NYNAS Nynas FI 3-42 GRN4-610 Chapt
Mounting and dismounting TAPER-LOCK tensioning element The motor- and the gear-"V"-belt pulleys are attached onto the shaft by means of a TAPER-LOCK tensioning element. The disks must be dismounted for certain maintenance work.
Mounting the TAPER-LOCK tensioning element Proceed as follows: • Remove the protective coating from the bore and outside of bushing, and bore of hub. After ensuring that the mating tapered surfaces are completely clean and free from oil or dirt. Insert bushing in hub so that holes line up. • Sparingly oil thread and point of grub screws, or thread and under head on cap screws. Place screws loosely in holes threaded in hub, shown thus ◎ in.
1. Verify that the alignment of the pulley is correct. Utilizing a straightedge of sufficient length to span from one pulley to the other, place it along the sides of both pulleys. The entire face of each pulley should fully contact the straightedge. 2. Measure the belt SPAN with a measuring tape. Record this dimension in your note book. 3. Using the deflection tester, apply a perpendicular force at the midpoint of any one of the belts to deflect the belt 1/64th of an inch. 4.
BELT CROSS SECTION SMALL SHEAVE DIAMETER RANGE SPA 3.9-‐5.2 SPA SPB DEFLECTION FORCE (Lbs) 5.9 5.5-‐7.9 7.7 6.2-‐8.9 11 SPB 9.2-‐12.4 14.3 SPC 8.8-‐14.0 19.8 SPC 14.7-‐22.
Torque Value Table Bolt Type Grade 8.8 Grade 10.9 Grade 12.9 Nm lb. ft. Nm lb. ft. Nm lb. ft. M8 25 18.4 35 25.8 41 30.2 M10 49 36 69 60 83 61.2 M12 86 63.4 120 88.5 145 106 M16 210 154 295 271 355 261 M20 410 302 580 428 690 508 M24 710 523 1000 737 1200 885 Checking the condition of the cutters The cutters become blunt after a certain number of operation hours. They need to be checked regularly.
1 4 (1) (2) (3) (4) Cutter Cutter mounting screw Cutter holder Cutter mounting screws 3 2 NOTE: It is possible to reach the cutting shaft by climbing into the feeding chamber; however, it is strongly recommended that the cutters are accessed through the front size door. The shaft can be rotated manually by turning the motor V-belt pulley. Sharp knives are dangerous even while the rotor is at standstill.
Sharp knives are dangerous even while the rotor is at standstill. Serious injury can result—especially to the hands and fingers—wear protective gloves! Dismounting the bed knives Follow the steps below to dismount the bed knives. (See image below.) 1. Switch OFF the shredder at the main switch. 2. Safeguard main switch with padlock. 3. Open the upper housing panel. 4. Safeguard the housing panel. 5. Clean the hexagon head socket of the knife mounting bolts (2) and the cover plates mounting bolts. 6.
6 1 (1) Bed knife (2) Bed knife mounting screws (3) Bed knife holder (4) Cover plates (5) Bed knife adjusting screw (6) Cover plate holder (7) Cover plate mounting screws 5 3 4 7 6 Mounting the cutter holders Follow the steps below to mount the cutter holders. 1. Clean the knife pocket and the cutter holder. 2. Insert the cutter holder into the pocket. NOTE: Cutter holder must slide in easily. Do NOT damage the cutter holder surfaces with a hammer. 3.
Mounting the cutters NOTE: The cutters and bed knives—especially the cutters—should only be sharpened or replaced in sets. There is a danger of balance error if a combination of cutters from different sets is used. Follow the steps below to mount the cutters. 1. Clean the knife support surface and the hole on the cutter holder. 2. Insert sharp cutter or turn old cutter and push against the cutter holder surface. 3. Attach the cutter mounting bolt (DIN912 – M12x40 – 12.
Mounting the bed knives Follow the steps below to mount the bed knives. 1. Clean the knife supporting surface and the holes on the knife holder. 2. Insert sharp knife or turn old knife. 3. Attach the knife adjusting bolts. 4. Attach the knife mounting bolts (DIN912 – M12x55 – 12.9) and tighten lightly at first. 5. Adjust the gap between the cutters and bed knives to 0.03 in. to 0.04 in. (.8 – 1mm). 6. Tighten the knife mounting bolts using a torque wrench.
Sharpening cutters and bed knives Shredder cutters have four cutting edges, which means they can be turned three times. After the third turn, they should be replaced with new ones. Bed knives can be turned two times and can be re-sharpened for as long as they can be mounted with the long hole. NOTE: Specialist sharpening of the cutters and bed knives is available through customer service. NOTE: The cutters and bed knives—especially the cutters—should only be sharpened or replaced in sets.
Setting the cutters and bed knives Rotor knives used in this machine don’t have to be adjusted. All adjustments have to be done with the bed knives. To simplify knife setting and shorten the standstill, the bed knives have four adjusting screws—two for pulling and two for pushing the knife. Standstill needs to be avoided/reduced if there are multiple cutter sets. Setting the gap between the cutters and bed knives carefully and correctly is an important requirement for the productivity of the shredder.
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.
Problem Possible Cause Possible Remedy Motor doesn’t work Electric source Correct wire connection Motor damage Replace motor Motor not working Correct wire connection Pump damage Replace pump Filter jam Clean the filter Hydraulic oil to thick Change hydraulic oil Poor hydraulic oil quality Change hydraulic oil Pipe leaking Tighten pipe connectors Pump damage Change pump Oil pump doesn’t work Oil pump noise Motor and pump misalignment Working pressure abnormal Pressure maintain abnorm
Chapter 7: Appendix 7-1 Technical Specifications Feeding chamber opening: Rotor dimension: Data in mm: Diameter in mm: 6720x840 980 Width of cut in mm: 1210 Rotor knives: No. of rotor knives: 108 Stator knives: No.
7-3 Drawings and Diagrams (See corresponding spare parts lists) Rotor knife fixing GRN4-610 Chapter 7: Appendix 62 of 73
Stator knife fixing 607 604 602 603 601 606 605 GRN4-610 Chapter 7: Appendix 63 of 73
Rotor assembly GRN4-610 Chapter 7: Appendix 64 of 73
Drive 410 GRN4-610 Chapter 7: Appendix 65 of 73
Guidance GRN4-610 Chapter 7: Appendix 66 of 73
Hydraulic Diagram GRN4-610 Chapter 7: Appendix 67 of 73
Hydraulic Pump GRN4-610 Chapter 7: Appendix 68 of 73
7-4 Spare Parts List Pos.
402 403 404 405 406 407 408 409 410 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 2 2 2 8 2 2 2 2 1 1 1 2 8 16 8 2 40 2 2 2 6 2 2 2 2 2 2 2 2 Gear pulley SPC375-4 Gear pulley taper bush TB 3535 - 48 Key V-Belt SPC3350 Motor pulley SPC375-4 Motor pulley taper bush TB 3535 - 60 Key Pulley cover + support Base frame for motor Gear box SEW MC3PLHF06SD – 14 (i=41) Gear box SEW MC3PLHF05SD – 23 (i-41) Torque arm plate Bolt DIN933 – M24x140 – 12.
Pos. Pc 700 701 702 703 704 705 706 707 708 709 710 711 712 1 1 6 6 12 12 12 12 18 18 18 3 1 Pusher complete Stage cylinder 100x140x180x225-7000 Support roller NATV40PPA Shaft for bearing Lock washer DIN5406 – MB8 Slotted nut DIN981 – KM8 Fixing bolt support roller DIN933 – M16 – 12.9 Washer DIN125 – 16 – 300HV Support roller KR80PPA Nut DIN934 – M30x1.
7-5 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.
GRN4-610 Chapter 7: Appendix 73 of 73
