5 Start Up and Operation 5-1 Pre-Operational Checklist 5-2 Operation 6 Maintenance Troubleshooting 41 43 Spare Parts 44 8-1 Table 1: Recommended Spare Parts List 9 31 32 32 32 33 33 34 36 38 39 40 41 7-1 General Problems 7-2 Electrical Problems 8 29 30 31 6-1 General Recommendations 6-2 Monthly Maintenance Operations 6-2-1 Drive Belt Tension 6-2-2 Proper Belt Tension 6-2-3 Belt Replacement 6-3 Removal and Replacement of the Screen 6-4 Inspection and Adjustment of Knives 6-5 Removing and Repl
15. Removing The Screen 35 16. Inspection of Knives 37 17. Bed Knife Specifications 40 18. Rotor Knife Specifications 40 19. Cutting Chamber - Vertical Cross Section 45 20. Cutting Chamber - Longitudal Cross Section 46 21. Cutting Chamber - Front View 47 22.
1 Safety Considerations 1-1 Safety Guidelines 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.
; EAR PROTECTION may be required when operating the machine during granulation of very hard or noisy materials. The Occupational Safety and Health Act of 1970 has established guidelines for Permissible Noise Exposures (OSHA 1910.95) that should be followed. ; NEVER attempt to operate the granulator unless it is fully assembled with all guards and interlocks in place and functional. ; OBSERVE all danger, warning, caution and safety labels on the equipment.
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. Cumberland has long recognized the importance of safety and has designed and manufactured its equipment with operator safety as a prime consideration.
!! CAUTION !! NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING HANDS ON ROTOR, ROTOR KNIVES, OR WITHIN THE CUTTING CHAMBER. HANDS MUST BE KEPT CLEAR OF THE ROTATIONAL PATH OF THE ROTOR KNIVES. A block of wood should be used to exert force on the rotor, usually in the direction opposite normal rotation. Good footing on a clean floor is essential and the body should be well braced when performing this act. Guard against loss of balance should the jammed conditions suddenly come free.
The upper part of the cutting chamber is protected by the feed hopper, used to insert material to be granulated while the lower part is protected by the screen, and screen support. These components are fixed by a screw knob, unscrewing releases a safety switch key (Figure 1), which cuts off the electric supply to the motor, causing the rotor to stop. The method of opening the granulator has been designed to restrict operator access, allowing the rotor and all moving knives to stop completely.
Warning! Wear protective gloves when exposed to knives.
2 General Information 2-1 Introduction This family of granulators has been designed to granulate plastic material such as sprues, runners, and small reject parts. The granulator is comprised of an infeed hopper into which the material to be granulated is fed, mounted on a cutting chamber in which a series of rotary and bed knives reduce the material to granules, the size of which is determined by the screen holes. The granules fall and collect in the bin below.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your granulator provides excellent, long service. The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions.
2-4-2 Main Components of Standard Granulators (See Figure 3) 1. Infeed hopper 2. Cutting chamber 3. Bin for granulated material 4. Belt drive 5. Control panel 6.
3 Shipping Information 3-1 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. 3-2 In the Event of Shipping Damage Important! According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment.
drawings, electrical schematics, and manual from the base evacuation area. You can now have the machine lifted from the skid. A forklift is ideal for the purpose, but take care to properly position the forks between the casters and the centrally mounted evacuation pipe from the side of the machine.
4 Installation 4-1 Lifting Important! Before lifting or moving the granulator, check the relative weight shown on the shipping papers and in Figure 4. To facilitate the lifting operation using forklift trucks, the drop box has been removed from the granulator and is packed with any spare parts. When using a forklift to move the granulator, make sure it is suitable for the weight and dimensions of the granulator. When moving, take care not to damage delicate parts.
water. The granulator should be installed in an inside covered, weather-proof environment and away from any areas where water collects on the floor. Once the granulator is in position, the front panel must be opened in order to insert the bin as illustrated in Figure 6. Figure 6: 4-3 Inserting the Bin Electrical Connection It is extremely important that the machine is correctly wired into the plant power source by a licensed electrician. See Section 9 for a wiring diagram.
!!Caution!! Before connecting the power, check that the power cable size and capacity corresponds to the horsepower and amp load indicated on the granulator label and that the disconnect switch is in the OFF position. (See Figure 2.) Unless otherwise specified, the granulator has been wired for 480 volts, 60 Hz, 3 ph. The power cable from the plant source can be run directly to the control panel or through the base of the machinery.
fallen in. The use of heavy gloves is recommended to avoid injury when exposed to the knives in the cutting chamber. NOTE: This operation must be carried out by an operator / mechanical maintenance engineer. Check that the cutting chamber is free from foreign objects as follows: 1. Turn off and lockout the machine power to the granulator or remove the fuses from the main control panel. 2. Open the front panel, and remove the bin. Unscrew the screw knob, and carefully lower the screen. (See 3. Figure 8.) 4.
Figure 8: Removing the Screw Knob 4-4-2 Checking Rotation Direction Check the correct direction of the rotor as follows: 1. Turn the main disconnect switch to “ON”. 2. Pull the Start button until the motor comes up to speed; then push the button to stop the granulator motor. 3. Check via the appropriate window that the rotor direction corresponds to that shown on the arrow label that is located above the guard. If the rotation direction is correct, the granulator is ready to use.
4-4-3 Test the Interlock Switch With the cutting chamber and screen cradle closed and power On, perform the following tests: 1. Push the start button to start the granulator. 2. With the granulator running, loosen the handknob on the front access door to verify the safety interlock switch shuts the machine off. If the hand knob is completely loose and the power does not disconnect, the interlock switch is not working and the cause of the malfunction must be determined. 3.
Once you have safely accessed the cutting chamber, check the current distance between the bed knives and the rotor knives using a feeler gauge. (See Figure 9.) NOTE: The distance set by the manufacturer for normal application is 0.006”-0.008” (0.15-0.20 mm). If the gap between the bed knives and the rotor knives is found to be greater than that, an adjustment must be made. (See Section 6-4: Inspection and Adjustment of Knives.
5 Start Up and Operation 5-1 Pre-Operational Checklist To ensure the granulator is ready for operation, perform the tasks listed on the following pre-operational checklist. Make sure that all electrical and mechanical machine elements are inspected and any defects corrected first.
5-2 Operation The granulator can be operated in a vertical top feed position or in a horizontal front feed position. Before starting the granulator, always check for and remove tools or any other objects placed on the granulator. Turn the Power disconnect switch to “ON”, pull the Start button, and release it when the motor has started. It is quite normal for the motor not to start immediately, as the electronic system must check all the micro switches before enabling start up procedures.
6 Maintenance 6-1 General Recommendations Before carrying out any work on the granulator, carefully read the instructions contained in this manual. NOTE: Only specialist and competent personnel should carry out this operation. All maintenance work must be carried out with the granulator switched off and with the power supply disconnected and locked out. Conduct that is not in accordance with the safety instructions in Section 1 may pose a threat to both personnel and equipment.
6-2 Monthly Maintenance Operations 6-2-1 Drive Belt Tension NOTE: This operation should be carried out by an operator / mechanical maintenance engineer. For the granulator to function correctly, it is extremely important that the drive belt is always tight. Correct tension reduces the load of the rotor bearings and minimizes wear and stretching of the belt. To check and adjust belt tension, carry out the following procedure: 1.
Figure 11: Belt Tension Chart Belt Cross Section 3VX Small O.D. Range Run-In 6.4 7.5 3.65-4.12 4.50-5.60 Deflection = Beltspan 64 ∗Deflection Force Lbs/V-belt Normal Running 5.7-4.4 6.6-5.1 Belt Span Belt Deflection Guage 6-2-3 Belt Replacement Important! It is very important to replace all belts at the same time. If the drive belts have to be replaced, follow the procedure in Section 6-2-1 up to Step 6. Then release the belt from tension by fully unscrewing the tie rods.
3. Remove the bin. 4. Remove the screw knob that holds the hopper on top of the cutting chamber. Carefully lower the screen cradle assembly, resting it on the base. Remove the screen, keeping it in a horizontal position. (See 5. Figure 12.) 6. Replace the screen with a new one, tighten the screw knob, reposition the bin, and close the front panel. Unlock the power and turn the machine back on.
Important! Before carrying out any maintenance on the cutting chamber, the operator must wear work gloves thick enough to avoid injury to the hands while touching sharp parts or the cutting edges of the blades. To inspect blades, remove the screen by following steps 1-0 in Section 6-3. Then, proceed as follows: 1. Open the rear-closing panel by releasing the locking latch. 2.
10. When adjustment is complete, tighten the lock nuts on the adjustment screws. 11. Torque the bed knife and bed knife shield bolts to 95 lbs./ft. (13 Kgm., 128 Nm) using a torque wrench. 12. Repeat the steps 4-11 to adjust the rear (or down stroke) bed knife. Turn the rotor slowly for one complete revolution, checking the exact distance between all the rotary knives and the bed knives. 13. Close the hopper and replace the screen and screen cradle, securing them in place using the swing bolt provided. 14.
3. Pivot the in-feed hopper completely back to gain clear access to the cutting chamber, and clear any process material or foreign objects from between the knives. 4. Rotate the rotor so that the rotor knives will not interfere with the removal of the bed knife. Using a wooden block, block the rotor to prevent it from rotating while removing the knives. 5. Loosen the lock nuts and back off the adjustment screws. (See Error! Reference source not found..) 6.
13. Close the machine, following Steps 12-14 in Section 6-4. 6-6 Removal and Replacement of Rotating Blades NOTE: A qualified operator / maintenance mechanic should perform this operation. Protective gloves must be worn to avoid injury when handling the cutting knives. To remove and replace rotor knives, complete the following procedure: 1. Open the granulator by following Steps 1-0 in Section 6-3. 2. Open the rear-closing panel by releasing the locking latch. 3.
10. Tighten each set of the knife bolts; making sure that the knife is seated against the back heel in the rotor seat. Before torquing the bolts, check that a 0.001” feeler gage cannot fit between the heel and the back of the knife. 11. Torque the rotor knife bolts to 100 Lbs./ft. (14 Kgm, 135 Nm). 12. Adjust the knife gap with the bed knives and close the machine, following Steps 8-14 in Section 6-4. 6-7 Specifications for Re-sharpening Bed Knives Every bed knife has two cutting edges, one on each side.
7 Troubleshooting The following tables list problems that could occur when using the granulator. This general information may help to locate the cause of the problem and allow it to be resolved promptly. When a problem arises, it is advisable to perform the simplest checks before proceeding to more complicated ones, which may subsequently prove unnecessary.
Problem Possible Causes Abrasive material Rotor Jamming Excessive infeed material Possible Remedies Contact the supplier for special knives Reduce amount of material being fed to the machine Total or partial obstruction of the screen holes Remove the screen and clear the holes Insufficient belt tension Check and/or adjust belt tension Knives worn Replace with new knives Distance between the knives too small or too large Check distance between knives Screen holes too small Increase screen hole
7-2 Electrical Problems Problem Machine stops for no apparent reason Possible Causes Safety switch has stopped power Possible Remedies Check that the knobs that operate the safety switch are tightened Electric motor does not start No power Check fuses Overload failure Check amperage of electric motor Check and replace Safety switch not working Empty cutting chamber Motor starts but does not speed up or take a load Motor starts, but does not gain speed Cutting chamber too full Excessive drive bel
Figure 16: Cutting Chamber – Vertical Cross Section DRAWING CA039060S2 Page 45 of 54
Figure 17: Cutting Chamber – Longitudal Cross Section DRAWING CA039060S1 Page 46 of 54
Figure 18: Cutting Chamber – Front View DRAWING CA039060S3 Page 47 of 54
Figure 19: Cutting Chamber – Rear View DRAWING CA039060S4 Page 48 of 54
9 Typical Wiring Diagram Page 49 of 54
DRAWING D05991100000 Page 50 of 54
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