Beside-the-Press Granulators 810, 814, 818 Models Covered: GP, BP, X, MTG Part Number: MAN-CA039205 Bulletin Number: GRN1-625 Effective: August 1, 2012
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: SAFETY ................................................................ 6 1-1 1-2 1-3 1-4 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..................................................................... 6 General Safety Regulations ........................................................................................
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 800 Series beside-the-press 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.
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 jog the rotor unless the cutting chamber’s covers, discharge chute, and guards are in place and secure. Do not circumvent the safety interlocks.
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.
2 1 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, GP810, GP814, and GP818. 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 Refer to Drawings and Diagrams chapter for more information.
Figure: Safety Switch Opening the Granulator The Start/Stop lighted push-button provided on the control panel (see figure below) is used to operate the granulator. The button must be pressed to stop the granulator and pulled out to start. Before performing any maintenance or opening the granulator, follow the procedure below: 1. Turn off the granulator using the provided push-button. 2. Turn the disconnect switch to OFF and lock out power.
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 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. 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.
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. Have an electrician check the interlock switch on the hopper to correct the malfunction. 5. If necessary, engage the screen cradle interlock actuator screw. After completing the above procedures, close the control panel. Unlock the power or return the fuses in the supply panel, turning the disconnect switch to ON.
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.
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. Press the lighted Start/Stop button to immediately turn off the granulator.
Chapter 5: Maintenance 5-1 Preventative Maintenance Schedule Before carrying out any work on the granulator, carefully read the instructions provided in this manual. Only specialists 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 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.
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.
BELT CROSS SECTION DEFLECTION FORCE (Lbs) SMALL SHEAVE DIAMETER RANGE 3VX 3.65-‐4.12 3.7 4.50-‐5.60 6.4 7 7.
Figure: Removing the screen Inspection and Adjustment of Knives This operation must be performed by a qualified operator or mechanical maintenance technician. Before carrying out any maintenance on the cutting chamber, the operator must put on work gloves thick enough to avoid injury to the hands while touching sharp parts and the cutting edges of blades. To inspect the blades, remove the screen following the procedure in “Removal and Replacement of Screen.” Then proceed as follows: 1.
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. Check that the distance between the fixed and rotating knife is the same at both ends of each knife. Move the bed knife using the push adjusting screws a little at a time on each end. 11.
Removing and Replacing Bed Knives This procedure should be performed only by 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.
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. Replace the shields in position above the bed knives. The shield on the front (downstroke) bed knife should be positioned so that the inside edge is set back approximately 1/32" from the cutting edge below it.
9. Before re-installing the knife bolts, wipe them clean with a light, oildamped 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. 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.
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.
General Problems Problem Overheating of bearings Knives moving in their seats Broken Knife Possible Cause Possible Remedy Dirt or contamination in the bearing Correct source of contamination Excessive belt tension Adjust belt tension No lubrication Check bearing seals May be foreign matter on the knives Carefully clean seat Knife screws loose Tighten screws with torque wrench at values specified Knife screws weakened Screws must not be used more than 6 times Improper re-sharpening Check k
Electrical Problems Problem Machine stops for no apparent reason Electric motor does not start Motor starts but does not speed up or take a load Motor starts, but does not gain speed 800 Series beside-the-press Possible Cause Possible Remedy Safety switch has stopped power Check that the knobs that operate the safety switch are tightened No power Check fuses Overload failure Check amperage of electric motor Safety switch not working Check and replace Cutting chamber too full Empty cutting ch
Chapter 7: Appendix 7-1 Technical Specifications Overall Dimensions (CA039016) 800 Series beside-the-press Chapter 7: Appendix 36 of 43
7-2 Drawings and Diagrams Cutting Chamber—Vertical Cross Section (CA039060S2) 800 Series beside-the-press Chapter 7: Appendix 37 of 43
Cutting Chamber—Longitudinal Cross Section (CA039060S1) 800 Series beside-the-press Chapter 7: Appendix 38 of 43
Cutting Chamber—Front View (CA039060S3) Cutting Chamber—Rear View (CA039060S4) 800 Series beside-the-press Chapter 7: Appendix 39 of 43
800 Series beside-the-press Chapter 7: Appendix 40 of 43
Typical Wiring Diagram 800 Series beside-the-press Chapter 7: Appendix 41 of 43
7-3 Spare Parts List Recommended Spare Parts Item GP810 Quantity GP814 Quantity GP818 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 Rotor Knife Rotor Knife Screw Bed Knife Bed Knife Screw Bed Knife Washer Screen Rotor Bearing Drive Belt Bed Knife Adj. Screw Interlock Switch Material HCHC GR 10.9 M12 x 40MM HCHC GR 10.9 M12 x 60MM Hardened Specify Hole Size Required 65MM Bore Qty.
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.
