TG-Series Thermoforming Granulator Models: TG1244, TG1256 & TG1274 Part Number: U-0040-S Bulletin Number: BJ6-625 Effective: May 6, 2009 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement.
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 ...................................
CHAPTER 6: TROUBLESHOOTING ....................................... 25 6-1 6-2 6-3 6-4 Introduction................................................................................................................ 25 Electrical Faults ......................................................................................................... 26 Processing Faults...................................................................................................... 27 Mechanical 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.
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 TG1244 (44”), TG1256 (56”) and TG1274 (74”) thermoforming granulators. 2-2 General Description The thermoform granulator is a rugged, low-profile, rotary-cutting machine, designed to cut, chip, and granulate the toughest thermoforming materials with a minimum expenditure of horsepower.
2-3 Typical Features and Components Hopper The V-shaped in-feed chute is an upright enclosure that is bolted to the top of the granulator and is easily removed for unobstructed access to cutting chamber or the feed rolls where applications require a feed roll assembly. It is designed to direct continuous reclamation of skeletal web directly from the thermoform trim process.
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. Figure 1 shows some of the bolts, interlocks, and limit switches you may need to adjust during maintenance.
Chapter 3: Installation 3-1 Uncrating the Equipment The complete granulator, including accessory and auxiliary equipment, is packed in a special wooden case 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 interlock 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 control (if ordered with the machine).
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 access panel bolts. (This includes the safety switch actuator arm bolt), and lift up and out to remove the access panel. The panel has a bottom internal skirt that must be lifted clear of the base strip. 3.
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 in-feed 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, such as bolts or tools. 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.
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 Operation of safety interlock switches Daily Knife clearance (0.15 mm – 0.20 mm; 0.006” – 0.008”) Weekly Knife retaining screws for tightness (271 Nm; 200 lbs./ft.) Weekly Knife exposure (1.0 mm; 0.
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 14.
Figure 4: Downstroke Cover and Bed Knife Rotor Knife Locking Bolts Rotor Knife Rotor Downstroke Cover Locking Bolts Downstroke Bed Knife Adjustment Screws and Lock Nuts Figure 5: Upstroke Bed Knife and Screens Upstroke Bed Knife Adjusting Screw and Lock Nut Upstroke Bed Knife Locking Bolts T-Series Thermoforming Granulators Maintenance 21 of 37
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. Rotor Knife Sharpening The rotor knife can be re-sharpened to the diagram below. The three knives must be sharpened to within 0.076 mm (0.003”) of each other.
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 7 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.
5-6 Motor Drive Belt Replacement Use the following procedure to replace the drive belts: 1. Turn off the main power and remove fuses. 2. Remove the belt guard to gain access to the belts (See Figure 8). 3. Turn the adjusting screw on the motor slide base to release all tension from the belts. 4. Remove the belts 5. Install the new belts and proceed to adjust the belt tension as instructed in Section 5-5 on page 23. 6. Replace base panels and guards. 7. Replace the line fuses and turn main power on.
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 Drawings and Specifications (including options) Features Model TG1244 (44”) TG1256 (56”) TG1274 (74”) Throat Size 12” x 44” (305 x 1118 mm) 12” x 56” (305 x 1422 mm) 12” x 74” (305 x 1880 mm) Cutting Circle Diameter 12” (305 mm) Throughput (estimated – material dependent) Up to 1,600 lbs./hr. (Up to 726 kg./hr.) Approximate Weight 4,000 lbs. (1814 kg.) 12” (305 mm) Up to 2,000 lbs./hr. (Up to 907 kg./hr.) 5,300 lbs. (2404 kg.) 12” (305 mm) Up to 2,800 lbs./hr. (Up to 1270 kg./hr.) 8,000 lbs.
Dimensions T-Series Thermoforming Granulators Appendix 31 of 37
7-3 Illustrated Parts Breakdown T-Series Thermoforming Granulators Appendix 32 of 37
T-Series Thermoforming Granulators Appendix 33 of 37
7-4 Spare Parts List Item Rotor Knives Rotor Knife Bolts Bed Knives Bed Knife Bolts Bed Knife Washers Bearings Bearing Housings Screens Screen Cradle Bolts V-Belts Casters T-Series Thermoforming Granulators TG1244 3RH / 3LH 30 4 20 20 2 2 2 4/4 (8) 3 4 Appendix Quantity TG1256 5RH / 5LH 60 4 24 24 2 2 2 4/4 (8) 4 4 TG1274 12 48 8 32 32 2 2 3 6/6 (12) 5 4 34 of 37
7-5 Typical Wiring Diagram T-Series Thermoforming Granulators Appendix 35 of 37
7-6 Recommended Torque for Screws (Grade 10.9 fine thread screws in un-lubricated conditions) Screw Size M8 M10 M12 M14 M16 M18 M20 M24 Torque NM. 38 73 135 210 315 460 640 860 Torque Ft. Lbs. 28 54 100 155 232 340 472 810 Note: Threads must be dry. Screw threads should be wiped with an oil-dampened cloth before installation to prevent galling.
7-7 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.
