INSTRUCTION MANUAL CGW Granulators Models 1418, 1424, 1436 and 1448 INSTRUCTION MANUAL UGG023-0107 CGW Granulator
INTRO / CONTENT We reserve the right to change designs, material and specifications without prior notice. © Copyright applies to all texts and images in this instruction manual, in full or in part.
Introduction DANGER! Read the instruction manual before installing and operating the machine. This instruction manual contains instructions how to install, operate and maintain the standard versions of the Conair CGW-series, Model number 1418, 1424, 1436 and 1448, along with additional options suffix (see suffix key below) -K, -U, -B, -RF. This manual also includes information on the optional wear kit and hardened chamber model and the economical Solo model.
1. SAFETY RULES 2. DESCRIPTION General rules, Safety................................................... 1:1 Warning signs on the machine............................ 1:1 Warnings in the instruction manual.................... 1:1 Safety rules, During Installing............................ 1:2 Safety rules, During start and operation............. 1:2 Safety rules, During service................................ 1:3 Transmission.............................................................. 2:11 Motor.........
4. INSTALLING 7. SERVICE Before first start.......................................................... 4:1 General rules, Installing...................................... 4:1 Reception inspection........................................... 4:1 Put the machine in place..................................... 4:1 Remove the rust preventer.................................. 4:1 Check the knife clearance................................... 4:1 Technical specifications . ...................................
CONTENT INTRO / CONTENT 9. SPARE PARTS General rules, Spare parts......................................... 9:1 Feed tray, Funnel ............................................... 9:2 Inlet .................................................................... 9:3 Flap(s) ................................................................ 9:4 Hopper ............................................................... 9:5 Hopper device ....................................................
1. SAFETY RULES General rules, Safety The machines are manufactured in accordance to the state of the art and legal safety regulations (guidelines, harmonised standards), which demand very low safety risk. But, if the machines are incorrectly operated, unexpected dangers can arise. Therefore it is very important that the safety rules on the following pages are carefully observed. If there are any questions, please contact Conair’s local distributor or Conair’s main office.
1. Safety rules • The machine must be installed by authorized, trained personnel. • All instructions must be observed to avoid machinery damage and personal injury. • The machine must be installed and connected to other equipment so that the entire installation complies with the stipulations of the Machinery Directive 98/37/EG. Safety rules, During start and operation • • • • • • • • • • • The instructions in the instruction manual must be followed.
1. Safety rules • • • • • • • • The instructions in the instruction manual must be followed. National environmental and employee safety regulations must be followed. First aid and eye shower must be within reach. Daily service and daily checks may be done by the operator. All other service and inspections must be done by authorised, trained personnel. Always work alone at the machine when service actions is performed. Use protective goggles and gloves.
2. DESCRIPTION Technical specifications General Data, Supplied machine: Serial No:............................................................................. Manufacturing year:........................................................... Motor: .................. V Electrical circuit diagram: ................................................ .................. Hz .................. kW General Data, CGW-series: Machine type: ............................................................................
2. DESCRIPTION Overview The performance of your supplied machine may vary from the standard machines described in this instruction manual. If there are any questions, please contact Conair’s local distributor or Conair’s main office. (1) (2) (3) (4) Hopper ......................................................................... (1) Inlet .............................................................................. (2) (5) Flap(s) ...................................................................
2.
2.
2.
2. DESCRIPTION Function Conair CGW-series (C) (A) 1. The plastic residue, which must be free from metal and contamination, is fed into the granulator’s inlet. The inlet may be provided with a feed tray or a funnel. 2. The plastic residue falls through the hopper and down into the cutter housing. The cutter housing contains fixed knives and a rotor. 3. Rotating knives are mounted on the rotor.
2. DESCRIPTION Function (continued from previous) Additional suffix -K (A) Granulator with additional suffix -K is provided with a sound insulating enclosure. >Page 9:19 “Enclosure” Additional suffix -U (C) Additional suffix -B Granulator with additional suffix -B is provided with a band conveyor. The band conveyor transports plastic residue to the granulator’s inlet / hopper. The band conveyor can be provided with a metal detector. >Page 9:24 “Material transport”.
2. DESCRIPTION Rotor General rules, Rotor (A) The rotor is designed and adapted to the type of plastic residue that the customer has specified before order. CGW-series can be provided with a 3-blade rotor or a 5blade rotor. >Page 9:11 “Rotor”. 3-blade rotor DESCRIPTION The 3-blade rotor has three knife rows with one rotating knife per row. 5-blade, rotor The 5-blade rotor has five knife rows with one rotating knife per row. Rotating knives Rotating knives are mounted on the rotor.
2. DESCRIPTION Cutter housing (A) (G) (F) (2nd) The cutter housing is designed and adapted to the type of plastic residue that the customer has specified before order. The cutter housing can be provided with two or three fixed knives, depending on type of cutter housing. There are two types of cutter housings, cutter housing Restricted Tangential; “First” and cutter housing Super Tangential; “Fifth”.
2. DESCRIPTION Knife grinding fixture The knife grinding fixture (optimal) is used when grinding the knives. The knife grinding fixture has two knife positions, one adapted for the fixed knife and one adapted for the rotating knife. >Page 7:11 “General rules, Grind the knives”. >Page 9:23 “Options / Knife grinding fixture”. DESCRIPTION (A) Knife clearance The knife clearance is the gap between the fixed knife and the rotating knife. Correct knife clearance is 0.008–0.016 in {0.20– 0.40 mm}.
2. DESCRIPTION Transmission Motor (G) DESCRIPTION The granulator is driven by an electric motor. The motor is installed on a motor mounting bracket. Optional motor speed: 1500 rpm (50 Hz) or 1800 rpm (60 Hz). Optional motor power: 10 Hp {7.5 kW}, 15 Hp {11.0 kW}, 25 Hp {18.7 kW}, 40 Hp {29.8 kW}, or 50 Hp {37.3 kW}. >Page 9:16 “Transmission”. Motor power and motor frequency are specified on the motor’s machine plate.
2. DESCRIPTION Safety equipment General rules, Safety equipment Inside the machine, knives rotate at high speed. For this reason, there is safety equipment which is intended to prevent access to hazardous components during operation. DESCRIPTION The safety equipment must not be changed or modified under any circumstances. If any part of the safety equipment is changed or left out, the machine can be dangerous to use.
2. DESCRIPTION Safety equipment (continued from previous) Inlet, Hopper (C) (A) The hopper is designed and adapted to the type of plastic residue that the customer has specified before order. >Page 9:5 “Hopper”. (B) The inlet is designed and adapted to the type of plastic residue that the customer has specified before order. >Page 9:3 “Inlet”. (D) The inlet may be provided with a feed tray or a funnel. >Page 9:2 “Feed tray, Funnel”.
2. DESCRIPTION Safety equipment (continued from previous) Main switch The main switch cuts all 3 phases of the supply voltage. The design and location of the main switch can vary. The granulator’s main switch must be locked in position ”0” during service. (A) (B) (C) Emergency stop(s) DESCRIPTION The emergency stop stops the machine in case of emergency. The machine may be provided with several emergency stops. The emergency stop(s) must be checked regularly.
2. DESCRIPTION Safety equipment (continued from previous) Safety switch The machine may be provided with several safety switches which stops the machine if an unsafe mode is detected. The safety switch(es) must be checked regularly. (D) Standard CGW models: To be able to release the switch key from the safety switch, the green LED on the safety switch must be lit. >Page 2:14 “Stand still monitor”. Standard CGW model The design and location of safety switches can vary.
2. DESCRIPTION Safety equipment (continued from previous) Safety relay Standard CGW models are provided with a button “Reset safety relay”. The button “Reset safety relay” is installed on the operating panel. To be able to start the machine the button “Reset safety relay” must be pressed and lit. >Page 5:1 “Start the granulator” point 5. (A) Reset safety relay If the button “Reset safety relay” does not light up, the safety relay has to be checked. >Page 7:3.
2. DESCRIPTION Level switch General rules, Level switch (A) The granule bin may be provided with a level switch (optional). The level switch monitors the granule bin’s granulate level. As the granulate level gets too high, the level switch takes one or several of the below listed actions: DESCRIPTION • Stops the optional feed equipment (such as a band conveyor or a roll feed). • Lights up an optional warning lamp. • Starts up an optional siren.
2. DESCRIPTION Current relay General rules, Current relay The granulator may be provided with a current relay (optional). The current relay monitors the granulator’s current consumption. (A) As the granulator’s current consumption exceeds the upper current level (LVA), the current relay trips and stops the feed equipment (such as a band conveyor or a roll feed).
2. DESCRIPTION Current relay (continued from previous) Time delay during start up (T2) The time delay during start up is the preset period of time that determines how long the current consumption is allowed to exceed the upper current level during start. (When starting a machine the current consumption may temporarily exceed the upper current level (LVA).) (A) (B) The function “Time delay during start up” is not used on Conair granulators.
3. TRANSPORT / LIFT / STORE Transport / Lift General rules, Transport / Lift The machine must only be transported / lifted by trained personnel. All instructions must be observed to avoid machinery damage and personal injury. Transport TRANSPORT / LIFT 1. If the machine will be transported exposed to weather and wind: Treat all components that could rust with a rust preventer. Wrap the machine in plastic foil. 2.
4. INSTALLING Before first start General rules, Installing 1. Read page 1:2 “Safety rules, During installing”. 2. Read all of chapter 4 before continuing installing. 3. Sign the completed installation, in the end of this chapter. Reception inspection 1. Check the packing slip to ensure that the delivery is complete. 2. Check that the machine has not been damaged during transport. Any damage must be reported to the forwarding agents. Put the machine in place INSTALLING 1.
4. INSTALLING Before first start (continued from previous) Install the hopper A granulator with a heavy voluminous hopper may (due to lack of space during transport) be delivered with uninstalled hopper and/or inlet. The following instructions only applies to granulator that have been delivered with uninstalled hopper and/or inlet. 6. 7. 8. 9. Put the machine in place. >Page 4:1. Open the enclosure (-K). >Page 6:1. Open the cutter housing. >Page 6:2 point 1–3 & 5–8.
4. INSTALLING Before first start (continued from previous) Install the hopper (F) (B) (G) INSTALLING 10. Before the jack can be installed, the granulator must be connected to the mains. >Page 4:4 “Connect the granulator to the mains”. 11. Lift the hopper as shown in figure on the right. 12. Operate the jack. >Page 6:3 “Open a heavy hopper” point a–f. Adjust the jack so that it aligns with the holes in the hopper’s jack bracket. 13. Fix the jack on the hopper.
4. INSTALLING Electrical connection General rules, Electrical connection 1. Read page 4:1 “General rules, installing” 2. The granulator must be disconnected from the mains before electrical repairs or installing is began. 3. The machine must be installed in accordance to EN 954-1 Category 3. This means that all cables must be installed so that they will not get damaged during operation. 4. When replacing electrical components, only use CONAIR original spare parts. >Page 9:1 “Spare parts”.
4. INSTALLING Start the granulator 1. Check that all actions in page 4:1–4:4 are done. 2. Close the granulator. >Page 6:4. 3. Start the granulator. >Page 5:1. Check immediately after first start INSTALLING 1. Check that the rotating direction of the granulator motor corresponds to the arrow on the motor. 2. Additional suffix -U (Blower): Check that the blower’s rotating direction corresponds to the arrow on the blower.
5. START / STOP Start the granulator (A) (B) (C) (E) (D) START / STOP 1. Read page 1:2 “Safety rules, During start and operation” 2. Check that there is no material in hopper or cutter housing. Important! The granulator must not be started if there is material left in the hopper and cutter housing. When starting, remaining material may brake the rotor and overload the motor. The overload protection will trip and the granulator will stop. Important! Granulator with additional suffixes -U (Blower).
6. OPEN / CLOSE Open the granulator General rules, Open the granulator 1. Read page 1:3 ”Safety rules, During service”. 2. Additional suffix -B (Band conveyor): Remove the band conveyor. 3. Granulator with feed tray: Fold the feed tray up. Open the enclosure (-K) (B) 1. Read page 6:1“General rules, Open the granulator” 2. Open the enclosure’s door/s. Pull the enclosure’s handle. Open the door/s 180° 3. Open the enclosure’s rear cover. Unscrew the rear cover’s tightening screws. Remove the rear cover.
6. OPEN / CLOSE Open the granulator (continued from previous) Open the cutter housing 1. Read page 6:1“General” 2. Granulator with additional suffix -K (Enclosure): Open the enclosure’s door/s. >Page 6:1 point 2. 3. Remove the granule bin’s quick coupling ring. >Page 6:3 image (A). 4. Release the switch key from the safety switch. >Page 2:15 “Safety switch” Standard CGW: a) Start the granulator’s current supply. >Page 5:1 “Start the granulator” point 3–4.
6. OPEN / CLOSE Open the granulator (continued from previous) Open the granule bin 1. Open the cutter housing. >Page 6:2. 2. Remove the granule bin. Move the granule bin along the grooves in the cutter housing’s front. 3. The granule bin is opened. Open the screen box 1. 2. 3. 4. Open the granule bin. Remove the screen. Remove the screen box. The screen box is opened. (B) (A) (C) Open the hopper Information! A granulator with a heavy hopper is opened / closed by means of an electric jack.
6. OPEN / CLOSE Close the granulator General rules, Close the granulator 1. Read page 1:3 “Safety rules, During service”. 2. Check that all surfaces which are going to touch are clean before closing. 3. Additional suffix -B (Band conveyor): After closing the granulator, put the band conveyor close to the granulator’s hopper / inlet. 4. Granulator with feed tray: After closing the granulator, fold the feed tray down.
6. OPEN / CLOSE Close the granulator (continued from previous) Close the cutter housing 1. Read page 6:4 “General, Close the granulator” 2. Granulator with additional suffix -K (Enclosure): Close the enclosure’s door/s. >Page 6:1 point 2. 3. Close the hopper. >Page 6:4. 4. Close the granule bin. >Page 6:4. 5. Close the cutter housing’s front. Let the locking bolts pass through the holes in the lock plate. Push the cutter housing’s handle until the cutter housing is closed. 6.
7. SERVICE General rules, Service 1. Read page 1:3 ”Safety rules, During service”. 2. Check / service the machine in accordance with the service schedule. 3. Always sign inspections / service in a service report. Copy the original service report, sign it and save it in a separate service binder. >Page 8:1. Emergency stop(s) 1. Read page 7:1 “General rules, Service” 2. Read page 2:14 ”Emergency stop(s)”. Check the emergency stop(s): a) Start the granulator. >Page 5:1. b) Stop feeding material.
7. SERVICE Safety equipment 1. Read page 7:1 “General rules, Service” 2. Read page 2:12 “General rules, Safety equipment”. Check that all parts of the safety equipment are installed. 3. Read page 2:15 “Safety switch”. Check that safety switch(es) is/are functioning: a) Start the granulator. >Page 5:1. b) Stop feeding material. Wait until all material has been fully granulated. c) Standard CGW: Gently try to release the switch key from the safety switch. >Page 6:2 point 4 c “Standard CGW”.
7. SERVICE Safety relay 1. 2. 3. 4. Read page 7:1 “General rules, Service”. Read page 2:16 “ Reset safety relay”. Reset the emergency stop(s). Check that the main switch is in position “1”. Danger! Do not put the main switch in position “0”. (When the main switch is put in position “0” the safety relay-button resets, but a possible failure remains). 5. Press the button “Reset safety relay”. 6. Check that the button “Reset safety relay” is lit.
7. SERVICE Current relay 1. 2. 3. 4. 5. Read page 7:1 “General rules, Service”. Read page 2:18 “Current relay” Set the wanted reaction time (T1). Set the time delay during start up (T2) to 0 sec. Check following points in the electrical circuit diagram: • Rated current. • Current transformer size. • Y/D-start or Direct-start. (A) (B) (C) (D) 6. Calculate the limit value in Ampere (LVA). 7. Calculate the limit value percentage (LV%). Set the limit value percentage. 8. Set the hysteresis percentage (H%).
7. SERVICE Band conveyor 1. Read page 7:1 “General rules, Service” 2. Read page 2:7 “Additional suffix -B”. 3. Check the band’s rotation direction. If the rotation direction is wrong: a) Stop the granulator. >Page 5:2. b) Read page 4:4 “General rules, Electrical connection”. c) Switch over two incoming phases. d) Start the granulator. >Page 5:1. 4. Check that the band runs straight. If the band runs obliquely: a) Stop the band conveyor. b) Open the covers at the band’s turn drum.
7. SERVICE Cleaning 1. Read page 7:1 “General rules, Service”. 2. When granulating material that generates dust: a) Clean the granulator’s parts once every day or at least once every week. (B) (A) In normal operation: a) Clean the granulator parts at colour change or at least once every 300 hours. 3. Open the granulator. >Page 6:1. 4. Clean the granulator parts. Use a vacuum cleaner.
7. SERVICE Knives General rules, Knives 1. 2. 3. 4. 6. 7. 8. 9. (5th) (5th) Remove the rotating knives 1. 2. 3. 4. 5. (2nd) (2nd) Read page 7:1 “General rules, Service”. Read page 2:8 “Rotor” and “Rotating knives”. Read page 2:9 “Cutter housing” and “Fixed knives” Read page 2:10 “Knife grinding fixture”, “Knife clearance” and “Knife setting fixture”. Read page 7:7 “General rules, Knives”. Open the cutter housing. >Page 6:2. Open the hopper. >Page 6:3.
7. SERVICE Knives (continued from previous) Install the fixed knives (2nd) (5th) (5th) cutteR HOUSING Restricted tangential; 1st cutteR HOUSING super tangential; 5th (E) (2nd) (D) (1st) (A) (B) (C) (1st) (5th) (C) (B) (A) SERVICE Read page 7:7 “General rules, Knives”. Remove the fixed knives. >Page 7:7. Preset the fixed knives. >Page 7:10. Install the front fixed knife (2nd). Rotate the rotor to an appropriate position. Lock the rotor’s position with a piece of wood. 6.
7. SERVICE Knives (continued from previous) Install the rotating knives (2nd) (2nd) (5th) (5th) cutteR HOUSING restricted tangential; 1st cutteR HOUSING super tangential; 5th (E) (2nd) (D) (1st) (A) (B) (C) (1st) (5th) (C) (B) (A) SERVICE 1. Install the front fixed knife (2nd). >Page 7:8 point 1–11. 2. Preset the knives. >Page 7:10. 3. Install one rotating knife at the time. 4. Rotate the rotor to an appropriate position. Lock the rotor’s position with a piece of wood. 5.
7. SERVICE Knives (continued from previous) Preset the rotating knives 1. 2. 3. 4. 5. Read page 7:7 “General rules, Knives”. Remove the rotating knives. >Page 7:7. Grind the rotating knives. >Page 7:12. Tighten the rotating knives’ adjusting screws. Install the rotating knife in the knife setting fixture as shown in the upper figure on the right. 6. Put a feeler gauge between the knife setting fixture and the rotating knife’s edge. 7.
7. SERVICE Knives (continued from previous) General rules, Grind the knives 1. Read page 7:1 “General rules, Service”. 2. Always begin grinding the worst and most blunt knife. 3. Grind the knives with accurate precision. It is very important that the relief angle and the cutting angle becomes correct. Respect the specified measures. 4. Always cool the knives during grinding. Grind slowly. Make sure that no heat is developed.
7. SERVICE Knives (continued from previous) Grind the rotating knives (E) 50° (A) (B) (C) (F) 3mm (G) 55° (G) 55° (E) 50° SERVICE 1. Read page 7:11 ”General rules, Grind the knives” 2. Install the distance in the knife grinding fixture as shown in the upper figure on the right. 3. Install the rotating knife in the knife grinding fixture as shown in the upper figure on the right. Install the knife grinding fixture’s washers.
7. SERVICE Drive belt(s) General rules, Drive belt(s) 1. Read page 7:1 “General rules, Service” 2. Read page 2:11 “Transmission” 3. Open the transmission. >Page 6:1. (H) (G) (E) Check the drive belts(s) 1. Read page 7:13 “General rules, Drive belt(s)” 2. Check the condition of the drive belt(s). Rotate the rotor pulley a few turns. Check that the drive belt(s) is/are intact and does/do not have any cracks. 3. Check the belt tension. Check one drive belt at the time.
7. SERVICE Drive belt(s) (continued from previous) Belt tension table Deflection depth 8 mm 10 Hp {7.5 kW} 15 Hp {11 kW} Old drive belt New drive belt Old drive belt New drive belt 50 Hz / 60Hz N N 15 N 19 N (H) (G) (E) Deflection depth 8 mm 25 Hp {18.7 kW} 40 Hp {29.8 kW} Old drive belt New drive belt Old drive belt New drive belt 50 Hz / 60Hz 23 N 30 N N N (F) (A) Deflection depth 8 mm 50 Hp {37.
7. SERVICE Troubleshooting Problem The granulator or any optional equipment does not start / stops unexpectedly. Probable cause The emergency stop is activated The granulator / the optional equipment is not connected to the mains. Solution 1. Reset the emergency stop(s). >Page 5:1. 1. Connect the granulator to the mains. >Page 4:2. 2. Connect the mains plug on the band conveyor to the electrical outlet (Band conveyor = optional). The main switch is in position “0”. 1.
8. SERVICE REPORT Day ......... / ......... 20 ......... Name:................................. Emergency stop good Flaps good / Replaced Day ......... / ......... 20 ......... Name:................................. Emergency stop good Flaps good / Replaced Day ......... / ......... 20 ......... Name:................................. Emergency stop good Flaps good / Replaced Day ......... / ......... 20 ......... Name:.................................
8. SERVICE REPORT Week .... 20 ... Name:............................................ Safety equipment checked Electrical components checked Week .... 20 ... Name:............................................ Safety equipment checked Electrical components checked Week .... 20 ... Name:............................................ Safety equipment checked Electrical components checked Week .... 20 ... Name:............................................
8. SERVICE REPORT Service actions, Once every month Rotating knife: Fixed knife: Screen: Existing knives are good Existing knives are good Existing screen is good Month ......... 20 ......... Rotating knife: Fixed knife: Screen: Fixed knife: Existing knives are good Fixed knife: Screen: Fixed knife: Screen: Fixed knife: Support rules are replaced Other remarks:.............................................................
8. SERVICE REPORT Other remarks Date ......... / .......... 20 .................... Name:..................................................................................................................... Other remarks:...................................................................................................................................................................... ........................................................................................................................
9. SPARE PARTS General Note! When replacing machinery parts, only use Conair original spare parts. Spare parts orders should be sent to Conair’s Parts (1-800-458-1960, outside of the United States, call: 814-437-6861). The following must be specified when spare parts are ordered: • Manufacturing No according to the machine’s type plate. • Machine type according to the machine’s type plate. • Manufacturing year. • Part description, Specification, Article No and Q according to this spare part catalog.
9.
9.
9. SPARE PARTS Flap(s) (2) (1) (3) FLAPS MANUAL FEED (4) FLAPS SOLO FLAPS BELT CONVEYOR MODULE NO: 3-34788-C02, 3-34945-C02, 3-37068-C01 MODULE NO: 3-53147-B01 MODULE NO: 3-29210-C02, 2-29214-C02, 3-37077-C01 P SE FR DE english SPECIFICATION ART NO Q M 1 LÅSHAKE Pêne de ver Verriegelu LATCH EXP.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9.
9. SPARE PARTS Options, Level switch, Hours counter, Stand still/Speed monitor, Current relay (1) (2) LEVEL SWITCH, TYPE PADDLE SWITCH (3) HOURS COUNTER STANDSTILL MONITOR / SPEED MONITOR (5) (4) TOOLS MODULE NO: 3-53152-C01, 3-53113-C01 CURRENT RELAY (7) (8) 0.2 (6) KNIFE SETTING FIXTURE LONG KNIFE SETTING FIXTURE BASIC MODULE NO: XXXXXXXXX MODULE NO: 3-53113-C01 MODULE NO: 3-53113-C01 P SE FR DE english SPECIFICATION ART NO 1 NIVÅVAKT Indic.
9. SPARE PARTS Material transport, Blower, (1) BLOWER : Belt Conveyor, Dust separator system (3) BAND CONVEYOR: (2) CYCLONE: (7) (5) (4) (6) (8) (11) DUST SEPARATOR SYSTEM : (10) (9) BAND CONVEYOR MODULE NO: 2-29464-C05, 2-23962-C05, 3-37088-C02 SE FR DE english SPECIFICATION ART NO Q REFER TO PAGE 9:25 1 U AX 1 FLÄKT VENTILATEUR GEBLÄSE BLOWER complete f7 F15 F25 2 Cyklon CYCLONE Cyklon CYclone AX7.
9.
