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.
Table of Contents CHAPTER 1: SAFETY ................................................................. 5 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................ 5 Safety Symbols Used in this Manual.....................................................................5 General Safety Regulations........................................................................................ 6 Responsibility.....................................
5-9 Sharpening the Knives ............................................................................................. 25 Rotor Knife Sharpening ......................................................................................25 Bed Knife Sharpening ........................................................................................25 CHAPTER 6: TROUBLESHOOTING ........................................ 27 6-1 6-2 6-3 6-4 Introduction...............................................................
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.
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: ˛ LEARN AND OBEY your company’s safety policy regarding granulating equipment.
˛ 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. ˛ 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. ˛ 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 auger-fed granulators. 2-2 General Description The auger-fed granulator is a gravity-loaded, auger-hopper-fed, medium-duty, plastic material cutting unit. The granulator is fully portable and automatic, with a small footprint.
2-3 Typical Features and Components Infeed The auger and trough assembly is constructed with the throat opening and an independently chain-driven auger for the transfer from process machine to the cutting chamber of irregular shapes of plastic material. A removable trough cleanout cover is provided to fully expose the auger for maintenance purposes. Cutting Chamber The cutting chamber consists of a belt-driven three-blade rotor and two adjustable bed knives.
2-4 Safety Features Safety Switches The cutting chamber viewport, auger infeed opening, and the screen drawer assemblies are safety interlocked to allow the auger and the rotation of the rotor to completely stop before physical access to the cutting chamber can be made. Unthreading the mechanical interlock disengages an electric limit switch, which in turn disengages the rotor and auger drive motors.
Chapter 3: Installation 3-1 Uncrating the Equipment The granulators are shipped mounted on a wooden skid, then blocked and banded to prevent movement. All non-painted items subject to corrosion are coated with a quality rust preventative and the machine is then covered with heavy-duty polyethylene to protect it from moisture and dirt. Refer to the Appendix for detailed dimensional data and pertinent weights. Prepare in advance the site you have selected for installation of the granulator.
3-2 Installing the Safety Switches Auger granulators are designed and intended for use under the mold of your injection molding machine. Do not use this equipment for any other applications without consulting the factory with application details for specific recommendations on guarding and safety. Control Panel. An open contact is provided on the terminal strip in the granulator control panel.
3-3 Electrical Connections Check serial tag voltage/amperage requirements and make sure your electrical service conforms before making any electrical connections. Make sure that all three phases are wired correctly. Bring properly sized power leads and grounds from a fused disconnect to the unit. Provide external overcurrent protection to the unit, using circuit breakers or fuses. If you use fuses, make sure that they are dual-element, time-delay fuses, sized according to your electrical code.
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. Unthread the cutting chamber safety interlock. 3. Remove the bolts from the face of the screen drawer, and pull the drawer assembly out of the cutting chamber.
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. 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 12-15 for detailed set-up instructions. The door-mounted pushbutton controls are arranged from left to right for sequential starting of the system’s motors.
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 at least three minutes 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. Note: 6.
Chapter 5: Maintenance 5-1 5-2 Preventative Maintenance Schedule Check Frequency Check tightness of cutting chamber interlock screw Do housekeeping around work area Check knife clearance and wear. (Refer to Section Check that rotor and bed knife bolts have proper torque (Refer to Section 7-3 on page 34) Check lubrication.
5-4 Removing the Auger Use the following procedure to remove the granulator auger: 7. Turn the main power off, remove the line fuses, and tag the machine as out of service. 8. Remove the drive belt guard, drive chain and chain sprocket from the drive end of the auger shaft. 9. Unbolt the end plate from the trough and pull the auger from the assembly. Caution! 5-5 Support the auger during withdrawal to prevent it from dragging on and excessively scoring the flight edges and/or the trough bar.
5-6 Lubrication Requirements All granulator and motor bearings are shipped pre-lubricated from the factory. The bearings used require a high quality, lithium-based EP (extreme pressure) type of grease, which conforms to the NGLI Grade 2 consistency. This grease has been chosen due to its suitability for use in heavy-duty applications under heavy shock loads. It also contains rust inhibitors, has high temperature stability, and exhibits good water resistance.
5-7 Adjusting Belt Tension Belts should be checked on a weekly basis for nicks, cuts, tension, or excessive wear. Any belt of a multi-belt system showing damage or excessive wear should be replaced with a belt of equal strength and size. For best results, replace belts in matched sets. 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.
5-8 Replacing and Adjusting the Knives The rotor and bed knives are subjected to severe conditions, and you should inspect knives periodically for sharpness. The sharper the knives are kept, the better the machine operates, producing quality regrind. If the knives become severely rounded, chipped, or otherwise damaged, the granulator experiences heavy shock loads during operation causing additional and significant reduction in knife life.
Bed Knives Use the following procedure to replace or adjust the bed knives: 1. Access the cutting chamber as directed in Section 3-4 on page 15. 2. Remove the bed knives by unbolting the bed knife bars and dropping the bars and bed knives from the cutting chamber frame (See Figure 5). 3. Thoroughly clean the knife seats with a stone or other non-marring tool, and wipe the screws with a lightly oiled cloth.
5-9 Sharpening the Knives Under normal operating use, the cutting edge of the knives will eventually become dulled, resulting in reduced cutting efficiency. The blunt knives may either be re-ground to restore the cutting edge, or replaced with new knives when regrinding is not possible. Note: The minimum dimensions given for the rotor knife and bed knife cannot be combined to produce a cutting combination.
Figure 7: Recommended Knife Replacement Blades Material Physical Material Quality ABS (High Imp’t) ABS (Med. Imp’t) ABS (Low Imp’t) Acetal Acrylic Nylon (non-filled) Nylon (filled) Polybutylene PET (Bottles) PET (Preform) Polyethylene (PE. Low) Polyethylene (PE. Med.) Polyethylene (PE. High) E.V.A. Polypropylene (P.P.) Polypropylen Oxide (P.V.D.C) Styrene (G.P.) Styrene (M ID) Styrene (HI) Polysulfone (GLS. REIN) P.V.C. (Rigid) P.V.C.
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 Customer Satisfaction Warranty Program The terms and conditions of the warranty set forth are for one (1) year from the original date of purchase by the original purchaser. The manufacturer warrants to the original purchaser the product and/or goods to which this disclaimer is attached, and manufactured by us, to be free from defects in material and workmanship under normal use and service.
7-2 Technical Specifications Features Model Throat Size 6x8 8 x 12 12 x 16 6” x 8” (15 x 20 cm) 8” x 12” (20 x 30 cm) 12” x 16” (30 x 40 cm) Cutting Circle Diameter 6” (152 mm) 8” (203 mm) 12” (305 mm) Throughput 175 lbs./hr. (79 kg.) 250 lbs./hr. (113 kg.) 450 lbs./hr. (204 kg.) Approximate Weight 650 lbs. (296 kg.) 1300 lbs. (591 kg.) 2400 lbs. (1090 kg.
Dimensions A B C D E F G H 6.5” Granulators 6x8 55” 49.25” 18” 8” 20-3/4” 28” 43-3/4” 19-1/2” 8 x 12 82-1/2” 57” 25.25” 11” 43-1/2” 34-1/2” 51-3/4” 21-1/2” Chapter 7: Appendix 12 x 16 87-1/2” 68.5” 32.25” 14” 44” 48” 66” 29.
7-3 Recommended Torque for Screws When using bolts in tapped holes equal or less than the bolt diameter in thread engagement, reduce torque by one-half. For flat-head socket head screws, use the column for grade 5 bolts. Torque sheave bushings to grade 5 specifications.
7-4 Technical Assistance Parts Department Call Spare Parts Express toll-free 8am-8pm EST (800) 229-2919. OEM quality replacement and spare parts ensure operation at design specifications. Please have the model and serial number of your equipment when you call. Consult the Customer Parts List included in your information packet for replacement part numbers. Service Department Call toll free (800) 966-8664 8am-8pm EST – Emergency service available 24 hours a day.