BP800 Series Beside-the-Press Granulators Models BP810, BP814, BP818 Effective: 8.13.2008 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.
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 ..................................................................................................
7-4 7-5 Spare Parts List ......................................................................................................... 40 Technical Assistance ................................................................................................
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: 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 and General Description The models covered in this operational manual include, from the 800 Series Beside-thePress Granulators, BP810, BP814, and BP818. This family of granulators has been designed to granulate plastic material such as sprues, runners, and small reject parts.
Optional Equipment The 800 Series Beside-the-Press granulators offer the following options: • Conveyor • Other screen hole sizes • Blower/airveying system • Vacuum bin • Special operating voltages Technical Data In-feed Front or top entry In-feed hopper For manual feeding Cutting chamber Upright bolted type Rotor 3-knife rotor w/ lateral disks Cutting system Scissor action with double angle cutting Knives Tool steel NOTE: Refer to Drawings and Diagrams chapter for more information.
The method of opening the granulator has been designed to restrict the operator access, which allows the rotor and all moving knives to stop completely. Allowing operating access more quickly could be dangerous because it is possible to make contact with the granulator knives while they are still rotating. Figure: Safety Switch Opening the Granulator The Start/Stop lighted push-button provide on the control panel (see figure below) is used to operate the granulator.
Figure: Control Panel Start/Stop PushButton Disconnect switch Chapter 2: Functional Description 12 of 41
Chapter 3: Installation 3-1 Uncrating the Equipment Prepare in advance the site you have selected for installation of the granulator. Be sure the area the machine will occupy is clean, level, and free of obstruction. The selected site must have a floor rating to adequately support the weight of the machine. The granulator is mounted on a wooden skid and blocked and banded to secure it for shipment.
3-2 Installing the Granulator NOTE: Before lifting or moving the granulator, check the relative weight shown on the shipping papers. 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 the machine, make sure NOT to damage delicate parts.
3-3 Electrical Connections It is extremely important that the machine is correctly wired into the plant power source by a licensed electrician. (See wiring diagram.) All electrical equipment must be properly grounded in accordance with local and national codes to protect personnel from electrical shock. A fusible, lockable disconnect between the plant power source and the machine electrical cabinet is highly recommended.
3-4 Initial Start-up Start-up Checks Checking the Cutting Chamber Before starting the granulator, open the cutting chamber to ensure that no foreign objects have fallen in during transportation and installation. The use of heavy gloves is recommended to avoid injury when exposed to 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 of foreign objects by following these steps: 1.
9. Remove the drive belt guard by unscrewing the ten (10) fastening screws. 10. Manually give the rotor at least one complete turn using the rotor pulley. 11. If there are no warning noises or signs of friction, then the cutting chamber is completely clear. Replace the belt guard, remove lock out devices, and turn power ON. Checking Rotation Direction Check to make sure the direction of the rotor is correct using the following steps: 1. Turn the main disconnect switch to ON. 2.
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 hand knob 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 malfunction must be determined. 3. Turn OFF and lock out the power. 4.
NOTE: The distance set by the manufacturer for normal application is 0.006" to 0.008" (0.15 mm to 0.20 mm). If the gap between the bed knives and the rotor knives is greater than this range, an adjustment must be made. (See “Inspection and Adjustment of Knives”.) Once you have checked the knife gap, close the hopper and secure it with the appropriate swing bolt. Reinsert the bin and close the front panel.
Chapter 4: Operation 4-1 Start-up Pre-operational Checklist To ensure the granulator is ready for operation, perform the outlined tasks in the following pre-operational checklist. All electrical and mechanical machine elements MUST be inspected and any defects MUST first be corrected. ü Make sure the operational manual has been read and followed.
WARNING! Never push material into the hopper with hands! If the hopper becomes blocked, the granulator must be turned OFF, and the power must be locked out or the fuses removed. 4-3 Shut-down Before stopping the granulator for the end of a working shift or for any other reason, stop feeding the material and leave the granulator running for several minutes to allow the cutting chamber to completely granulate and empty the material inside.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule Before carrying out any work on the granulator, carefully read the instructions provided in this manual. NOTE: Only specialist and competent personnel should carry out these operations. 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 safety instructions outlined in this manual may pose a threat to both personnel and equipment.
5-2 Preventative and Corrective Maintenance Monthly Maintenance Operations Drive Belt Tension NOTE: This operation should be carried out by an operator or 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, use the following procedure: 1.
Belt Cross-Section 3VX Small O.D. Range Deflection Force, lbs/V-belt ** Run-in Normal running 3.65 – 4.12, 6.4 5.7 – 4.4, 4.50 – 5.60 7.5 6.6 – 5.1 ** The Deflection Force Value shown is for each belt and must be multiplied by the number of V-belt elements if all are deflected.
5. Remove the screen, keeping it in a horizontal position (see figure below). 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 ON. Figure: Removing the screen Inspection and Adjustment of Knives NOTE: This operation must be performed by a qualified operator or mechanical maintenance technician.
7. Leave the screws that hold the bed knife just tight enough to allow the bed knife to move. 8. Loosen the adjustment screws and lock nuts. 9. Insert a 0.006 in. to 0.008 in. (0.15 mm to 0.2 mm) thickness gauge between the cutting edge of the bed knife and that of the high rotor knife. 10. Adjust the bed knife into the rotor knife using the adjustment screws. Make sure to leave enough space for the thickness gauge to move.
Removing and Replacing Bed Knives NOTE: This procedure should be performed only be a qualified operator or maintenance engineer. Protective gloves must be worn to avoid injury when handling the cutting knives! To remove and replace bed knives, use the following procedure. 1. Open the granulator by following the steps “Removal and Replacement of the Screen.” 2. Open the rear-closing panel by releasing the locking latch. 3.
NOTE: It is recommended that the knife bolts be replaced with each new set of knives. This will reduce the risk of bolt failure due to overstretching. Always use the specified replacement bolts. 10. Tighten the bolts that hold just the bed knife enough to keep the knife in place at the same time allowing the adjusting screws to move the knife forward. 11. Adjust the knife gaps with the rotor knives following steps 8-12 in “Inspection and Adjustment of Knives.” 12.
8. Install knew or sharpened knives on each knife seat, making sure that the rotor is still blocked to prevent it from rotating while installing the knives. 9. Before re-installing the knife bolts, wipe them clean with a light, oil-damped cloth. Do not leave an oil film on the bolt since lubrication can adversely affect the stress on the bolt when torqued to the specified values. NOTE: It is recommended that the knife bolts be replaced with each new set of knives.
Specifications for Re-sharpening Rotor Knives All the rotor knives must be re-sharpened in sets. Each knife within a set must have a tolerance within 0.003" (0.05 mm) for the total height, heel to cutting edge. Greater variations within a set will result in improper knife gap settings and other operational problems. (See “Rotor Knife Specifications.
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.
Improper knife re-sharpening Check dimensions with figures included in this manual.
Chapter 7: Appendix 7-1 Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must given. All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking charge. All returns are to be shipped prepaid. The invoice number and ate or purchase order number and date must be supplied.
7-2 Technical Specifications Overall Dimensions (CA039016) Chapter 7: Appendix 34 of 41
7-3 Drawings and Diagrams Cutting Chamber—Vertical Cross Section (CA039060S2) Chapter 7: Appendix 35 of 41
Cutting Chamber—Longitudinal Cross Section (CA039060S1) Chapter 7: Appendix 36 of 41
Cutting Chamber—Front View (CA039060S3) Chapter 7: Appendix 37 of 41
Cutting Chamber—Rear View (CA039060S4) Chapter 7: Appendix 38 of 41
Typical Wiring Diagram Chapter 7: Appendix 39 of 41
7-4 Spare Parts List Recommended Spare Parts Item Rotor Knife Rotor Knife Screw Bed Knife Bed Knife Screw Bed Knife Washer Screen Rotor Bearing Drive Belt Bed Knife Adj. Screw Interlock Switch BP810 Quantity BP814 Quantity BP818 Quantity 3 9 2 8 8 1 2 2 4 1 3 12 2 10 10 1 2 2 4 1 3 15 2 10 10 1 2 2 4 1 Material HCHC GR 10.9 M12 x 40MM HCHC GR 10.9 M12 x 60MM Hardened Specify Hole Size Required 65MM Bore Qty.
7-5 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [847] 273-7700, Fax [847] 273-7812 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.
