$30.00 Operation and Installation Manual EX Series Screenless Granulator Important! Read Carefully Before Attempting to Install or Operate Equipment Bulletin No.
Write down your granulator ________________ ________________ serial numbers here ________________ ________________ for future reference ________________ ________________ Ball & Jewell can advise you on proper selection and sizing of systems for your operating environment. Ball & Jewell is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. Bulletin No. BJ1-625 Effective 7/10/02 DCN No.
Safety Considerations Ball & Jewell EX Series Granulator Sprue and Runner Cutters 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/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. Ball & Jewell has long recognized the importance of safety and has designed and manufactured its equipment with operator safety as a prime consideration.
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5 Maintenance 5-1 5-2 5-3 5-4 26 Maintaining Drive Components 26 Replacing Timing Belts 27 Lubrication Specifications and Considerations 27 Knife Recommendations and Adjustments 28 5-4-1 Removing, Replacing and Adjusting Granulator Combs 28 5.4.1.a. Removing Rotor Combs: 5.4.1.b. Removing Bed Combs: 5.4.1.c.
List of Figures 1. Belt Tensioning Chart 27 2. Recommended Spare Parts List Categories 32 3. S Series Screenless Granulator (Front) 39 4. S Series Screenless Granulator (Back) 39 5. Segregation Chamber Access 40 6. Cutting Chamber Detail 40 7. Discharge Options 41 8.
Ball & Jewell Warranty Information Thank you for your purchase of your new EX Series Screenless Granulator. We are confident that you will have excellent results and trouble-free operation with this machine. When the machine arrives at your plant, inspect it carefully for shipping damage before uncrating and immediately report any damage to your transportation company. All shipments are FOB South Attleboro, Massachusetts. Customer Satisfaction Warranty Program for EX Series Screenless Granulator.
Ball & Jewell Warranty Information We warrant our product to be of the kind and quality quoted, and no other warranty except of title shall be implied. Our company shall repair or replace, at our discretion, any manufactured item on your S Series granulator without charge FOB factory, within one (1) year after date of original purchase, which is proved to be defective when shipped. Claims for labor or consequential damages are not allowed. Excluded from the above are knives, screens, and belts.
1 General Information 1-1 Introduction The Ball & Jewell EX Series Screenless Granulators are designed to uniformly and consistently size-reduce solid material scrap. They have been engineered to consistently deliver clean granulate with a minimum of fines and longs. The rotor on which the combs and breaker bars are mounted is a machined steel unit supported by bearings mounted outside the cutting chamber. The rotor is driven by a gear motor capable of producing high torque loads.
standard shop procedures performed at shift, daily, and weekly intervals. The Operation chapter includes a description of electrical and mechanical controls, in addition to information for operating the granulator safely and efficiently. The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service.
1-2 Granulator Specifications Table 1: Granulator Specifications Cutting Circle Throughput Cutting Chamber Rotor Knives Bed Comb Discharge Bin Motor Drive Electrical Components Controls Feed Height Length Width Weight 1-3 EX909 9.7” (247 mm) 30 lbs./hr (14 kg/hr) 9” x 9” (229 mm x 229 mm) Hardened 8620 alloy steel Reversible 1/4” (6.4 mm) comb 0.70 cu. ft. (.0198 cu. meters) 1 hp (.75 kW) Cyclodial speed reducer – 34rpm Start/stop pushbutton EX913 9.7” (247 mm) 40 lbs.
• No Tools Required to open the cutting chamber/segment chamber/hopper chute • Four (4) swivel casters 1-4 Available Options Available standard options for EX Series Granulators include: • Alternate feed chutes. • Alternative voltages: 208/3/60, 380/3/50, 415/3/50, 575/3/60 • Alternate comb tooth sizes .185”(~5MM) and .
2 Shipping Information 2-1 Unpacking and Inspection You should inspect your Ball & Jewell EX Series Screenless 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. 2-2 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.
2-3 If the Shipment is Not Complete Check the packing list as back-ordered items are noted on the packing list. You should have: ; Ball & Jewell EX Series Screenless Granulator ; Bill of lading ; Packing list ; Operating and Installation packet ; Detailed recommended spare parts list ; Electrical schematic and panel layout drawings ; Component instruction manuals Re-inspect the container and packing material to see if you missed any smaller items during unpacking.
Your EX Series Screenless Granulator is mounted on a wooden skid and blocked and banded to secure it for shipment. All nonpainted items subject to corrosion are coated with a quality rust preventative, and the machine is covered with heavy-duty polyethylene to protect it from moisture and dirt. Granulators are normally shipped completely assembled unless the size of the machine or an agreement for special shipping arrangements prompts partial assembly.
3 Installation 3-1 Scope This chapter contains all instructions required for experienced installation personnel to install the granulator and prepare it for production. You must follow all instructions carefully and in the sequence presented. Be sure to observe all DANGER, WARNING, CAUTION, and NOTE statements to prevent personal injury or machine damage. These statements are designed to make installation procedures safe and easy. 3-2 General Set-Up 1.
3. Look inside the base evacuation area. Spare parts, such as combs, are often placed inside this area for shipping purposes. ! CAUTION ! The cutting chamber combs are EXTREMELY SHARP. Always wear heavy gloves and exercise care when working in the cutting chamber. 4. Carefully inspect the interior of the cutting chamber and evacuation area for foreign material or debris. 5. Noting the location of each segmented chamber, lower and remove them from the cutting chamber by loosening the handknob on each.
4. Position and connect any optional accessory equipment such as vacuum lines, conveyors, and separators. Ensure all tubing joints are securely clamped and supported. 3-5 Electrical Considerations !!! DANGER !!! Improper electrical connections can damage the granulator and CAUSE SERIOUS OPERATOR INJURY OR DEATH! EX Series Screenless Granulators are designed for three-phase voltage operation. Refer to the unit nameplate or ID plate for proper voltage and amperage requirements.
Make certain all electrical connections are properly made and supported between accessories and the control enclosure (refer to the wiring diagram for wire and terminal connections). !!! DANGER !!! Before undertaking any machine repairs or maintenance, always make certain that the machine disconnect switch is turned to the OFF position or that the control enclosure is disconnected from the main power source.
Department at 1-800-229-2919 for voltage modification instructions. 3-7-1 Hopper Safety Disconnect 1. Turn the main disconnect to the ON position. 2. Press the granulator START button to start the machine. 3. Test the front base door and the hopper access door: unlatch the two (2) latches and open the doors approximately two (2) inches to verify that the machine shuts off. 4. Latch the (2) latches to close the doors and re-engage the cutting chamber safety switch.
4 General Operation 4-1 Scope This chapter contains the information required to carry out preoperational procedures, as well as general operation. The checklist of items listed below should always be reviewed prior to a production run. 4-2 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.
; Are all electrical enclosure boxes tightly closed and clamped shut? 4-3 ; Are all personnel clear of the machine? Granulator Operation The machine is ready for operation when all doors, covers, guards, and limit switches are in place, securely fastened and functional, and all accessory components are properly connected. 1. Turn the main disconnect to the ON position. 2. Start the granulator by pressing the start button at the operator station. 3.
! CAUTION ! Never close the chamber access doors without checking that all three (3) segregation chambers are in place and hand knobs are tight. Never attempt to run machine without all three (3) segregation chambers in place and tightened. Always wear heavy gloves and exercise care when working in the cutting chamber. 4-5 Shutdown Conditions 4-5-1 Emergency Stops Feedstock must be cleaned out of the hopper and cutting chamber prior to restarting.
5 Maintenance 5-1 Maintaining Drive Components For continuing reliable operation of the granulator, it is of the utmost importance that the motor drive belt tension is correct. Correct tension reduces wear on the rotor and motor bearings and reduces slip to a minimum. Belt drives must be tensioned at the “Run-In” recommended force. Check the tension at least twice during the first two days’ operation.
Figure 1: Belt Tensioning Chart Design HP New Belt Min 442 466 490 1 2 3 Belt Span 5-2 Used Belt Max 443 469 495 Min 438 459 480 Max 440 462 485 Deflection = Belt Span 64 Replacing Timing Belts 1. Remove the guard cover. 2. Find and loosen the two (2) interior guard plate screws near the gearmotor timing belt drive from inside the sprocket guard housing. 3. Loosen the gear motor hold-down screws and move the motor towards the granulator rotor to allow more slack in the belt. 4.
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. Bearings should be lubricated with care. Too much grease applied to the bearings at one time can rupture bearing seals. Under normal operating conditions, a moderate amount of grease applied every 2,000 hours should be adequate to ensure long life. Severe operating conditions require more frequent lubrication intervals.
6. Lift the rotor out of cutting chamber 7. Remove the three (3) socket head cap screws that hold the rotor assembly together. 8. Slide the cutters and spacers from the hex shaft. 9. Replace the necessary cutter(s). (Make sure the cutters are staggered by indexing the clearance hold 1 turn clockwise for each cutter.) 10. Re-install the three (3) socket head cap screws. 11. Replace the rotor in the chamber. 12. Re-install the rotor blocks 13. Re-install the timing belt guard. 14.
the hex cams have a “dot” machined on the cam face to show the high point when installed. 3. Assemble a washer and hex cap screws into each adjustment cam hole and finger tighten them. 4. Slowly turn the rotor back and forth. Using the right hand and left hand adjustment cams, move the bed comb in or out as required to clear the rotor combs. The rotor/bed comb clearance is normally set to approximately .005".
Step 1: Fill the bin with granulate of the material you intend to run through the granulator. Make sure the bin is filled to a level that covers the front face of the latex sensor covering located on the rear wall of the bin. Step 2: Make sure that power is supplied to the machine by turning the main disconnect switch to the ON position and connecting the control enclosure to the main power source. DO NOT START THE MACHINE. Step 3: Locate the sensor on the rear wall of the machine base.
available when calling Spare Parts Express at 1-800-229-2919 for new replacement OEM parts. NOTE: Refer to part numbers when ordering replacement parts. Check the parts carefully, as they may have numbers etched or stamped on them. The recommended spare parts list does not include all parts that are available for purchasejust the parts most appropriate for your particular machine. See your machine shipment package for recommended spare parts list specific to your machine.
6 Troubleshooting Problem No granulate Stringy granulate Fines Possible Cause Feedstock may be hung up inside the hopper. Vacuum line may be clogged. Comb gap is too large. Combs are dull. Combs are dull. Overloading of the machine. Excessive power required; blown fuses Combs are dull. Comb gap is too large. Overloading of machine. Machine stalls Pieces of feedstock jammed in the rotor. Lack of lubrication. Overloading of the machine.
Problem Possible Cause Combs are dull. Overloading of the machine. Granulate builds up in the transition or tubing Transition tubing is clogged. Vacuum is not evacuating properly. Page 34 Solution Reverse bed comb or replace combs and re-install. Regulate the infeed of scrap to uniformly feed the machine. Clean as required. Check per manufacturer specifications.
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Parts Department Call Spare Parts Express toll-free 8am – 8PM EST (800) 229-2919. Ball & Jewell 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.
7 Charts and Figures Figure 3: EX Series Screenless Granulator (Front) Doors Opened for Service/Cleaning Timing Belt Drive Cutting Chamber/Rotor Combs Discharge Area Segregation Chambers Figure 4: EX Series Screenless Granulator (Back) Robot Chute (4) way opening Limit Switch Electrical Control Enclosure Gear Motor Page 39
Figure 5: Segregation Chamber Access Rotor cutters Segregation Chambers (Removable) Discharge Area Hand Knobs Figure 6: Cutting Chamber Detail Bed Comb Adjustment CAMS- Comb located under shield Large breaker Small Breakers Rotor Combs & Spacers Page 40
Figure 7: Discharge Options Rear- Vacuum Compressed Air Venturi Manual Page 41
Figure 8: Knife Bolt/Screw Tightening Torque Specifications Screw Size M8 M10 M12 M14 M16 M18 M20 M24 Tightening Torque Lbs./Ft. 28 54 100 155 232 340 472 810 Specifications are for Grade 10.9 Fine Threads, in un-lubricated conditions. Page 42 NM.
Warranty Sterling, Inc. warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace (FOB the factory) any parts for a period of 12 months from initial start-up or 18 months from the date of start-up, whichever is less, which in the Company’s opinion, are defective.
Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue • Milwaukee, WI 53224-9518 (414) 354-0970 • Fax (414) 354-6421 Scrap Process Heating/ Automated Recovery Systems Cooling Parts Removal
