Write down your granulator ____________________ ____________________ serial numbers here ____________________ ____________________ for future reference. ____________________ ____________________ This granulator was designed, engineered, and manufactured by AEC/Nelmor, 116 Roddy Avenue, South Attleboro, Massachusetts 02703-7957, Telephone (508)3993000. AEC/Nelmor can advise you on proper selection and sizing of systems for your operating environment.
AEC/Nelmor Warranty Information Thank you for your purchase of your new WG Series 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.
AEC/Nelmor 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 WG 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.
Table of Contents 1 Safety Considerations 2 General Information 2-1 Introduction 2-2 Necessary Information 2-3 Description 2-3-1 Infeed Chute 2-3-2 Cutting Chamber 2-3-3 Drive System 2-3-4 Discharge System 2-3-5 Base 2-3-6 Specifications 3 Shipping Information 3-1 3-2 3-3 3-4 3-5 3-6 4 Unpacking and Inspection In the Event of Shipping Damage If the Shipment is Not Complete If the Shipment is Not Correct Returns Uncrating the Equipment Installation Operation 5-1 5-2 5-3 5-4 6 11 11 11 12 13 13 14
-2-1 Adjusting or Replacing the Bed Knives Upstroke Bed Knife Downstroke Bed Knives 6-2-2 Rotor Knife Clearance: 6-2-3 Knife Sharpening 6.2.3.a. 6.2.3.b.
List of Figures 1. Typical Granulator Features 13 2. Granulator Specifications 14 3. Floor Space and Plan Requirements 17 4. Periodic Maintenance Table 23 5. Upstroke Bed Knife Adjustment 24 6. Downstroke Bed Knife Adjustment 26 7. Minimum Knife Dimensions 30 8. Belt Tensioning Chart 31 9. Lubrication Requirements 32 10. Adjusting the Motor Base 33 11. Screen Replacement 34 12. Troubleshooting Table 39 13. Recommended Spares List 42 14.
1 Safety Considerations Our thermoforming 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 judgement 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 MachineryGranulators, Pelletizers, and Dicers Used for Size Reduction of PlasticsConstruction, Care, and Use. ANSI B151.11-1982. We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration. We expect you, as a user, to abide by the foregoing recommendations in order to make operator safety a reality.
2 General Information 2-1 Introduction This manual provides the necessary instructions for the installation, set-up, and maintenance of our thermoforming granulators. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting an applications engineer. 2-2 Necessary Information Use this manual as a guide and reference for installing, operating, and maintaining your thermoforming granulator.
The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions. The Spare Parts section contains a list of parts that may require replacement. A spare parts list with part numbers specific to your machine is provided with your shipping paperwork package. Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering.
Figure 1: Typical Granulator Features Spacer and Feed Roll Strippers Infeed Chute Locking Handle Bed Knife Cover Drive Chain/Tensioner Arm Safety cover Infeed Chute Screws Actuator Arm Screw Safety Switch Drive Belt Safety Cover Base Area Swivel Caster 2-3-1 Infeed Chute The V-shaped infeed chute is an upright enclosure that is bolted to the top of the feed roll assembly and easily removable for unobstructed access to the feed rolls.
The high-alloy steel rotor carries the rotor knives. High strength alloy steel screws are used for attachment of all knives to the rotor. 2-3-3 Drive System The drive system consists of a drip-proof 1200 RPM motor set on an adjustable sliding base that is mounted at the left end of the granulator. The motor drives the rotor directly and the feed rolls are driven through a gearbox for assured RPM control. A belt guard shields the motor drive sheave, feed roll reductor, rotor sheave and belts.
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.
; 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. 3-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact the shipping department immediately.
drawings, electrical schematics and manual from the base evacuation area. You can now have the machine lifted from the skid. Use a forklift as shown in Figure 3 on page 17. Do not lift the machine by the access panel handles or the cover guards. Figure 3: Floor Space and Plan Requirements Model 36” model 56” model A 36” (914.4 mm) 56” (1422.4 mm) Page 17 of 48 B 39 3/4 (1009.7 mm) 59 3/4” (1517.
4 Installation 4-1 Electrical Connections Granulator controls (if ordered) are shipped separately for mounting at a suitable location. The safety switches are connected to a common terminal box for ease of wiring. The customer is required to provide a suitable fused electrical supply with a disconnect switch and a cable for the incoming line to the starter (if ordered with the machine). Safety switches are wired to a common terminal box for ease of wiring.
4-3 Start-Up Checks 4-3-1 Check the Cutting Chamber Before starting the granulator, open the cutting chamber to ensure that during transportation or installation, no foreign objects have fallen in. The use of heavy gloves is recommended to avoid injury when exposed to the knives in the cutting chamber. 1. Turn the Main Power switch to Off, lock out power, and remove line fuses. 2.
If the direction is incorrect, perform the following procedure: 1. Shut the power off and disconnect the incoming power supply. 2. Reverse any two of the three power line connections to the machine. 3. Re-connect the incoming power supply line and turn the Main Power switch to On. 4. Re-check the motor drive rotation. 4-3-1 Check the Airveying System If your machine is fitted with an airveying system, the following additional operations must be performed: 1.
5 Operation 5-1 Introduction 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, in starting up the machine in its new location, a minimum amount of setting up or re-adjustment is required.
5-3 Feeding the Granulator Warning! Under no circumstances should the operator attempt to reach into the infeed chute to dislodge any bridged or jammed material while the granulator is in operation. To clear the infeed chute of bridged or jammed material, the machine’s Main Power switch must be turned to Off and the machine isolated. Feed the granulator through the V-chute opening in the top of the machine.
6 Maintenance 6-1 Introduction This section covers the Lubrication Points and their Frequencies of Application. The use of proper lubricants will help reduce wear and down time. This section also delineates the Preventative and Corrective maintenance procedures required to ensure proper functioning of the machine.
6.2.1.a. Upstroke Bed Knife Figure 5: Upstroke Bed Knife Adjustment Upstroke Bed Knife Adjusting Screw and Lock Nut Upstroke Bed Knife Locking Screws 1. Turn the Main Power switch off, lock out power, and remove line fuses. 2. Remove the access panel screws, including the safety switch actuator arm screw (see Figure 5), 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.
need to be set to approximately 1/2 the anticipated thickness of the material to be processed. NOTE: The above clearance is slightly greater at the center of the knives. This is a normal condition when the rotor knives are mounted on a slant rotor. 7. Turn the rotor backwards while checking the clearances to avoid cutting the feeler gauge. 8. With the clearance set, tighten the bedknife screws evenly and torque the 16 mm screws to 200 Lbs./Ft (271 Nm).
6.2.1.b. Downstroke Bed Knives Figure 6: Downstroke Bed Knife Adjustment Rotor Knife Locking Screws Rotor Knife Rotor Downstroke Bed Knife Locking Screws Downstroke Bed Knife Adjustment screws and Lock Nuts 1. Turn the Main Power switch to Off, lockout the power supply, and remove the line fuses. 2. Remove the downstroke cover screws at the rear of the machine (this includes the safety switch actuator arm screw), and carefully slide the cover(s) out of the machine. (See Figure 6.) 3.
clearance may need to be set to approximately 1/2 the anticipated thickness of the material to be processed. NOTE: The above clearance is slightly greater at the center of the knives. This is a normal condition when the rotor knives are mounted on a slant rotor. 6. Turn the rotor backwards while checking the clearances to avoid cutting the feeler gauge. 7. Using the bed knife shield adjusting push screws, adjust the shield until the bed knife exposure is 0.040” (1.0 mm).
2. Remove the downstroke cover screws at the rear of the machine (this includes the safety switch actuator arm screw), and carefully slide the cover(s) out of the machine. NOTE: Under normal operating use, the cutting edge of the rotor knives will eventually become dulled, thereby 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. Maximum regrind is 1/4” 3.
11. Reset the downstroke cover(s) in position and tighten in place with the downstroke cover screws, which were removed in Step 2. Make sure that the safety switch interlock screw sets the safety switch actuator arm into the correct position to set the switch. 12. Replace the line fuses, unlock the power, and turn the Main Power switch to On. 6-2-3 Knife Sharpening 6.2.3.a. Rotor Knife Sharpening The rotor knife can be re-sharpened to the diagram below. The three knives must be sharpened to within 0.
Figure 7: Minimum Knife Dimensions Keen Edge Std. Rotor Knife 35° 32 Grind these surfaces only Landed (55°) Std. Rotor Knife 35° 20° 3.089 (min.) Std. Bed Knife 3.307 (new) 32 6-2-4 2.256 (min.) 2.756 (new) 32 Grind these surfaces only 32 Std. Bed Knife 3.028 (min.) 3.246 (new) 32 2.256 (min.) 2.756 (new) Drive Belt Tension For continuing reliable operation of the granulator, it is of the utmost importance that the motor drive belt tension is correct.
b. At the center of span (t), apply a force perpendicular to the span large enough to deflect one belt on the drive 1/64” (0.40 mm) span length from its normal position. 5. Compare this deflection force with range of forces in the Belt Tensioning Chart as follows: a. If it is less than the “Normal Running” recommended force, belts should be tightened. b. If it is more than the “Run-In” recommended deflection force, the drive is as tight as it needs to be. 6.
Rotor Bearings: The flanged piloted rotor bearings are prelubricated and double-sealed, but they should be re-lubricated as stipulated in Figure 9 on page 32. Airveying System: This system should be lubricated as indicated in the literature dealing with the system. Feed Roll Reductor: The feed roll reductor has been filled with #90 lube oil at assembly, but it should be refilled as stipulated in Figure 9 on page 32.
3. Loosen the motor base slide mount screws, and turn the adjusting screws on the motor slide base to release all tension from the belts (See Figure 10). Remove the belts. 4. Install new belts (refer to the Recommended Spares List on page 42), and proceed to adjust the belt tension as instructed in Section 6-2-4 on page 30. 5. Replace the belt guard. 6. Replace the line fuses, unlock the power supply, and turn the Main Power switch On.
5. Replace the screen, avoiding any hand contact with the rotor knives, and make sure that the far edge of the screen is “trapped” beneath the downstroke bed knife block. Tighten the cradle screws. 6. Check that cutting chamber is clear of any parts or materials. 7. Replace the access panel and tighten the screw on the safety switch actuator arm to ensure it is activating the switch. 8. Replace the line fuses, unlock the power supply, and turn the Main Power switch to On.
8. Remove the socket cap screws from the front feed roll frame, and slightly tap the front frame evenly on the ends to pull it away from the dowels. 9. Remove the front frame from the machine. 10. Remove the socket cap screws from the back of the feed roll frame. Remove the end mount from only one side of the machine. 11. Slide the feed rolls off of the frame assembly. 12. Replace the feed rolls if required. Refer to the Spare Parts list on page 42 for the correct replacement part numbers. 13.
2. Remove the access panel screws (this includes the safety switch actuator arm screw), and lift up and out to remove the access panel. 3. Remove the bolts and swing the screen cradle arms and screen(s) down. This will permit additional clearance for handling the rotor and knives. 4. Using the pull screws, withdraw the upstroke and downstroke bed knives and downstroke shield away from the rotor knives as far as possible. This will avoid any possible damage to the rotor knives and bed knives.
14. Reposition the bearing housings and fasten them into place. Be sure that the flat surface is to the top of the cutting chamber. 15. Replace the cartridge bearings if necessary. See the Spare Parts List on page 42 for the correct chamber. 16. Reposition the bearings and tighten evenly with screws that were previously removed. Tighten set screws on bearings. 17. Install rotor knives as instructed in Section 6-2-2 on page 28.
7 Troubleshooting 7-1 Introduction Part failure of a mechanical or electrical component may occur, therefore, this section has been prepared to serve as a guide to trouble-shooting possible malfunctions. 7-2 Safety The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components.
Figure 12: Troubleshooting Table 7-5-1 Processing Faults Problem Stalling Material Overheating Probable Cause Overfeeding Possible Remedy Reduce feed rate. Partial or complete screen blockage Remove screen, clear and inspect for damage. Insufficient tension on the belt drive causing belt slippage and burning Check tension of belt and adjust as necessary. Check that the motor slide base screws are secure. Badly blunted or damaged knives Fit re-sharpened or new knives as required.
7-5-2 Mechanical Faults Problem Bearing overheating Probable Cause Excessive tension on belt drive Possible Solution Check tension of belt, adjust as necessary. Check lubrication frequency and the recommended lubricant (except pre-packed bearings). Visible cracks in knives Incorrect grinding procedure or incorrect grinding wheels Check method of grinding and contact an applications engineer. Knives moving on knife seats Uneven knife seat surfaces Clean up to provide maximum bearing surface.
7-5-3 Electrical Faults Problem Motor fails to start Motor starts but will not take loads Motor will start when disconnected from load but not when connected Probable Cause Power supply failure Possible Remedy Check fuses. Starts inoperative Check Main Supply. Check starter contacts for burning and replace if necessary. Starter overloads cut out Check motor requirements and adjust accordingly. Safety switches inoperative Check and adjust as needed.
8 Spare Parts List When alternate items or quantities are listed, consult the Specification Sheet to determine the exact item or quantity required.
9 Appendix Figure 14: 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 43 of 48 NM.
10 Contact Information Parts Department Call Spare Parts Express toll-free 8am – 8PM EST (800) 229-2919. AEC/Nelmor 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.
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Warranty AEC, 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. This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or any other work.
801 AEC Drive • Wood Dale, IL 60191-1198 USA (630) 595-1060 • Fax (630) 595-6641 http://www.aecinternet.
