Heavy Duty Granulators 20”x62” and 20”x72” Models Covered: B, GMB, HDG, MSH Bulletin Number: GRN2-605 Effective: 3/1/13
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: 1-1 1-2 1-3 1-4 How to Use This Manual ...........................................................................................................6 Safety Symbols Used in this Manual ................................................................................. 6 General Safety Regulations ......................................................................................................9 Responsibility .....................................
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 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. Every month inspect the shears/blades for any type of wear.
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 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: þ LEARN AND OBEY your company’s safety policy regarding granulating equipment.
þ 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. þ 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. þ 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 2-2 General Description This manual provides the necessary instructions for the installation, setup and maintenance of our 20”x62” and 20”x72” models This granulator is a rugged, rotary-cutting machine specifically designed to cut, chip, and, granulate the toughest plastic materials with a minimum expenditure of horsepower. B Series granulators feature a massively built, low RPM high inertia rotor with chevron knives.
Discharge System The granulated material that falls through the screen is collected by the customer’s Gaylord box. On models fitted with an airveying system (optional), the granulated material that has fallen through the screen is collected in a transition piece located beneath the cutting chamber. The transition piece is connected to a blower, which conveys the granulated material to drop out of the air system into a container.
Chapter 3: Installation 3-1 Uncrating the Equipment The complete granulator, including accessory and auxiliary equipment, is skidded 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.
When the customer is providing either the motor or the starter, the machine must be wired in accordance with the basic electrical diagram and the starter manufacturer’s instructions. Use the following procedure to complete the electrical connections: 1. Check to be certain that the starter heater elements correspond with the motor requirements. If controls are not supplied, the limit switches supplied on the machine must be wired into the circuit at the common terminal box. 2.
3-5 Closing the Cutting Chamber After completing any maintenance or adjustments inside the cutting chamber, use the following procedures to close the cutting chamber and resume use of the granulator: 1. Replace the screen and activate the pneumatics to raise the screen cradle 2. Reinsert the bolt wedges to lock in the screen cradle. (5 on 72B per side) 3. Swing the cutting chamber doors back into their closed position and replace bolts. 4.
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 and Operation 4-2 Feeding the Granulator 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.
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 Knife exposure Weekly Shield retaining screws for tightness Weekly Screen retaining studs for tightness Weekly Lubrication of drive motor bearings Monthly Lubrication of rotor bearings Monthly Screen Wear Monthly Belt Tension Monthly Hopper and cutting chamber screws are tight Monthly Lubrication Lubrication of rotor bearings should be b
The period during which a grease-lubricated bearing will function satisfactorily without relubrication depends on the bearing type, size, speed, operating temperature, and the grease used. Re-lubrication intervals (hours of operation) are valid for bearings in machines where loading conditions are normal: an age-resistant, average quality grease is used and the operating temperature is below 158°F (70°C) measured at the outer ring.
6. Remove rotor knife bolts and knives on one seat. This should be done from the downstroke side of the cutting chamber. 7. Thoroughly clean knife set. 8. Install new knife on seat and tighten knife bolts. See Section 7-2 on page 30 for torque recommendations. Note: Bolt threads should be oiled. Wipe thread with an oil-dampened cloth. 9. Repeat steps 6 through 8 for each rotor knife.
Adjustment bolts 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. When sharpening, it is not harmful to allow a few small nicks to remain in the cutting edge. Grinding the cutting edge until perfectly clean can sometimes be wasteful.
1. Verify that the alignment of the pulley is correct. Utilizing a straightedge of sufficient length to span from one pulley to the other, place it along the sides of both pulleys. The entire face of each pulley should fully contact the straightedge. 2. Measure the belt SPAN with a measuring tape. Record this dimension in your note book. 3. Using the deflection tester, apply a perpendicular force at the midpoint of any one of the belts to deflect the belt 1/64th of an inch. 4.
Figure 2: Belt Tensioning Information V-BELT CROSS SMALL SHEAVE SMALL SHEAVE SPEED RECOMMENDED SECTION DIAMETER RANGE RPM RANGE RATIO DEFLECTION RANGE FORCE (LB) (INCHES) 3V 5V 8V 5-6 MIN MAX 2.65-2.80 1200-3600 2.00 TO 3.0 4.3 3.00-3.15 1200-3600 4.00 3.3 4.8 3.35-3.65 1200-3600 3.7 5.4 4.12-5.00 900-3600 4.4 6.4 5.30-6.90 900-3600 4.8 7.1 7.10-8.00 600-1800 2.00 TO 11 16 8.50-10.90 600-1800 4.00 13 18 11.80-16.00 400-1200 14 21 12.50-17.
10. Pack grease between the bearing rollers and re-install the sheave spacer and bearing end cap. Tighten the ½-20 bolts to 58 ft. lbs. 11. Replace the flywheel/sheave bushing without tightening the bushing bolts. Replace the shaft end place and tighten the 5/8-18 bolts to 144 ft. lbs. so that the flywheel bushing and sheave spacer are locking the bearing inner race to the shaft shoulder. 12. Tighten the sheave bushing to the flywheel/sheave. Replace and adjust the belts. Replace the covers.
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 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 screws
Chapter 7: Appendix 7-1 Recommended Torque for Screws (Grade 8 alloy steel heat-treated screws) MM Screw Size 6 8 10 Inch Screw Size 1/4 5/16 3/8 Torque Ft. Lbs. 13 26 46 12 16 19 20 24 7/16 1/2 5/8 3/4 7/8 1 76 110 220 400 635 870 Note: Threads must be dry. Screw threads should be wiped with an oil-dampened cloth before installation to prevent galling. 7-2 Technical Specifications Features Model Throat Size Cutting Circle Diameter Throughput Approx.
Specifications Infeed Standard Standard Options Conveyor Feed Tray and sheet feed; Tray and feed rolls; Pipe Feed 2-Bed Knife Cutting Chamber Rotor Open 3-Knife high shear Rotor Knives Bed Knives Screen Drive Parts (3) HCHC (2) HCHC 3/8" N.H.T.
7-3 Drawings 62B 72B Chapter 7: Appendix 32 of 37
Chapter 7: Appendix 33 of 37
Chapter 7: Appendix 34 of 37
Chapter 7: Appendix 35 of 37
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.
Chapter 7: Appendix 37 of 37
