000 Series Granulators 10 x 12 and 10 x 18 Models Models Covered: GP, BP, 1000X, MTG Part Number: MAN-CA025490 Bulletin Number: GRN1-635 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 ......................................................................................
5-5 Adjusting Belt Tension .............................................................................................. 28 CHAPTER 6: TROUBLESHOOTING ....................................... 30 6-1 6-2 6-3 6-4 Introduction ............................................................................................................... 30 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: Safety Tags and warning features Hazard Alert Symbol 1000 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 the machine or job the rotor unless the cutting chamber’s covers, discharge chute, and guards are in place and secure.
þ LEARN AND OBEY your company’s safety policy regarding granulating equipment. þ MOVING OR LIFTING THE GRANULATOR: Although our equipment is built and engineered for great ruggedness in operation, care must be taken when moving the machine along the floor or lifting it. Damage may occur to sheet metal covers, electrical cabinets, or small brackets if pressure is applied to them when moving the granulator.
þ ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service. þ SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and electrical safety interlocks ensure the safety of personnel. They should never be tampered with or removed for ANY reason. They should be checked frequently by a qualified mechanic for proper operation. þ NEVER modify the machine configuration or any individual component without written notice from the factory.
4. Based on the characteristics of the material being processed, consider the use of fire suppression/explosion detection equipment in conjunction with your granulator.
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 10 x 12 and 10 x 18 granulators, which covers models: GP, BP, 1000X & MTG.
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 comprised the main frame, the bed knives, the bed knife shields, a balanced rotor, and a screen.
2-4 Safety Features 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. Check all safety switches periodically for proper operation. Safety Tags A set of metal plates are attached to the machine to warn of potential danger.
Figure 2: Noise Test Specifications Model 1012 1018 Motor Power kW 5.5 7.5 Impeller Speed Rev./min. 340 340 Production ∗ Kg/h 140 200 75% Production Test Supply (SPI Method) Pcs. No./min. Kg/h 24 99.5 36 149.0 Kg/h 105 150 Figure 3: Average Sound Levels Model 1012 Sound Enclosed Position Sound Levels in dB(A) 1 84.3 2 83.6 3 82.6 4 82.2 Lpm 93.2 Model 1018 Sound Enclosed Position Sound Levels in dB(A) 1 86.0 2 85.6 3 84.1 4 84.1 Lpm 85.0 Figure 4: Noise Test Method Operator Position 1 S.P.
Chapter 3: Installation 3-1 Uncrating the Equipment The complete granulator is skidded for shipment. The bin has been removed from the granulator to facilitate lifting with a forklift truck. The bin is packed with spare parts if required. 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 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. Open the front panel and remove the bin. 3. Unscrew the cutting chamber fastener, and carefully lower the screen. 4. Remove the screen, keeping it in a horizontal position. 5. Open the rear cover. 6.
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 18-21 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 Shield retaining screws for tightness Weekly Screen cradle screws for tightness Weekly Lubrication of drive motor bearings Monthly Screen Wear Monthly Belt tension Monthly Hopper and cutting chamber screws are tight Monthly Testing the Interlock Switch The cutting chamber interlock switch ensures that the granulator cannot be running when the
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 20.
5-4 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. The minimum dimensions given for the rotor knife and bed knife cannot be combined to produce a cutting combination.
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 6 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 6: Belt Tensioning Information BELT CROSS SECTION 3VX DEFLECTION FORCE (Lbs) SMALL SHEAVE DIAMETER RANGE 1000 Series Granulators 3.65-‐4.12 3.7 4.50-‐5.
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.
6-3 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 Technical Specifications Features Model Throat Size 1012 10” x 12” (254 x 300 mm) 10” x 18” (254 x 457 mm) 1018 Cutting Circle Diameter 10” (254 mm) Throughput 450 lbs./hr. (203 kg.) 550 lbs./hr. (248 kg.) 10” (254 mm) Approximate Weight 1275 lbs. (579 kg.) 1440 lbs. (655 kg.
Dimensions MODEL 1012 1018 1000 Series Granulators A 12 1/4 (311 mm) 18 1/4 (464 mm) B 29 7/8 (759 mm) 35 7/8 (911 mm) Chapter 7: Appendix C 27 (686 mm) 17 3/8 (441 mm) D 30 (762 mm) 38 3/16 (970 mm) 34 of 45
7-2 Parts Breakdown Cutting Chamber 1000 Series Granulators Chapter 7: Appendix 35 of 45
Table 1: Cutting Chamber Parts Breakdown Ref. # Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Bearing end cap NDE Retaining ring UNI 7435-Ø45 Bearing SKF 6209 ZZ (2RS) Side plate LH Rotary disc Knife screws TE UNI 5740-65 10.9 M12x1, 25x40 Rotor Knife Impeller Side plate RH Bearing cap DE Pulley operation 3V-6 grooves Keying instrument RCK 11 60x90 Bed knife Knife screws TE UNI 5739-65-10.
Basis and Protection Kit 1000 Series Granulators Chapter 7: Appendix 37 of 45
Table 2: Basis and Protection Kit Ref. # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description LH Shoulder Product drawer Bridge handle ac 0313 Transparent plate Rear sheet Stiffening square RH Shoulder Switchboard case h.
1000 Series Granulators Chapter 7: Appendix 39 of 45
Table 3: Silenced Hopper Kit Ref.
Silenced Protections Kit 1000 Series Granulators Chapter 7: Appendix 41 of 45
Table 4: Silenced Protections Kit Ref. # 1 2 3 4 5 6 7 8 9 10 11 Description Square for feeding hole closing Transparent plate Rear fixed protection Rear protection that can be opened Black hinge that can be screwed 1056-U10 Gasket angle piece Bridge handle AC0313 Central pipe closing h.
7-3 Typical Wiring Diagram 1000 Series Granulators Chapter 7: Appendix 43 of 45
7-4 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.
1000 Series Granulators Chapter 7: Appendix 45 of 45
