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Write down your granulator ____________________ ____________________ serial numbers here ____________________ ____________________ for future reference. ____________________ ____________________ Sterling can advise you on proper selection and sizing of systems for your operating environment. Sterling is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. DCN No.
Sterling Warranty Information Thank you for your purchase of your new BP1000 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.
Sterling 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 BP1000 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 1-1 Safety Guidelines 1-2 Safety Procedures 1-2-1 Guidelines for Moving the Granulator 1-2-2 Clearing a Jammed Cutting Chamber 1-3 Safety Features 1-3-1 Safety Features Fitted On the Granulator 1-3-2 Opening the Granulator 1-3-3 Sound Enclosure 2 General Information 2-1 2-2 2-3 2-4 3 Shipping Information 3-1 3-2 3-3 3-4 3-5 3-6 4 Introduction Using This Manual Safety Symbols Used in This Manual Description 2-4-1 Technical Data 2-4-2 Main Components of Standar
5 Start Up and Operation 5-1 Pre-Operational Checklist 5-2 Operation 6 Maintenance Troubleshooting 41 43 Spare Parts 44 8-1 Table 1: Recommended Spare Parts List 9 32 33 33 33 34 34 35 37 38 39 40 41 7-1 General Problems 7-2 Electrical Problems 8 30 31 32 6-1 General Recommendations 6-2 Monthly Maintenance Operations 6-2-1 Drive Belt Tension 6-2-2 Proper Belt Tension 6-2-3 Belt Replacement 6-3 Removal and Replacement of the Screen 6-4 Inspection and Adjustment of Knives 6-5 Removing and Repl
Table of Figures 1. Safety Switch 13 2. Control Panel 14 3. Noise Test Specifications 15 4. Average Sound Levels 15 5. Noise Test Method 16 6. Main Components of Standard Granulators 19 7. Overall Dimensions and Weights 20 8. Lifting the Granulator 23 9. Inserting the Bin 25 10. Electrical Connections 26 11. Removing the Screw Knob 27 12. Checking the Knife Gap 29 13. Periodic Maintenance Table 32 14.
15. Removing The Screen 35 16. Inspection of Knives 37 17. Bed Knife Specifications 40 18. Rotor Knife Specifications 40 19. Cutting Chamber - Vertical Cross Section 45 20. Cutting Chamber - Longitudal Cross Section 46 21. Cutting Chamber - Front View 47 22.
1 Safety Considerations 1-1 Safety Guidelines 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: 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. Sterling has long recognized the importance of safety and has designed and manufactured its equipment with operator safety as a prime consideration.
!! CAUTION !! NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING HANDS ON ROTOR, ROTOR KNIVES, OR WITHIN THE CUTTING CHAMBER. HANDS MUST BE KEPT CLEAR OF THE ROTATIONAL PATH OF THE ROTOR KNIVES. A block of wood should be used to exert force on the rotor, usually in the direction opposite normal rotation. Good footing on a clean floor is essential and the body should be well braced when performing this act. Guard against loss of balance should the jammed conditions suddenly come free.
The upper part of the cutting chamber is protected by the feed hopper, used to insert material to be granulated while the lower part is protected by the screen, and screen support. These components are fixed by a screw knob, unscrewing releases a safety switch key (Figure 1), which cuts off the electric supply to the motor, causing the rotor to stop. The method of opening the granulator has been designed to restrict operator access, allowing the rotor and all moving knives to stop completely.
3. Tag the machine as Out of Service. 4. Make sure the rotor has come to a complete stop. Warning! Wear protective gloves when exposed to knives. Figure 2: Control Panel Start/Stop Push Button Disconnect Switch 1-3-3 Sound Enclosure Research has been conducted to assess the noise generated by the operation of Sound Enclosed Granulator Models BP1012 and BP1018. The testing is intended to determine a General Noise Level during the operation of the granulator.
• S.P.I. Noise Test – Noise Measurement Procedure for Granulators, by the Society of the Plastic Industry.
Figure 5: Noise Test Method Operator Position 1 S.P.I Material Sample Feeding Point Type: PVC 1120 SCH40 ASTMD-1785 Length: 145 mm Outer Dia.: 33.5 mm Inner Dia.: 26.5 mm Thickness: 3.5 mm Mass: 0.069 kg Position of the phonometric detectors (h=1.5 m) Machine being tested 2 1.0 m 1.
2 General Information 2-1 Introduction This family of granulators has been designed to granulate plastic material such as sprues, runners, and small reject parts. The granulator is comprised of an infeed hopper into which the material to be granulated is fed, mounted on a cutting chamber in which a series of rotary and bed knives reduce the material to granules, the size of which is determined by the screen holes. The granules fall and collect in the bin below.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service. Preventive maintenance sections are included to ensure that your granulator provides excellent, long service. The Troubleshooting chapter serves as a guide for identification of most common problems. Potential problems are listed, along with possible causes and related solutions.
2-4-2 Main Components of Standard Granulators (See Figure 6) 1. Infeed hopper 2. Cutting chamber 3. Bin for granulated material 4. Belt drive 5. Control panel 6.
Figure 7: Model BP1012 BP1018 Overall Dimensions and Weights A 12 1/4 (311 mm) 18 1/4 (464 mm) B 29 7/8 (759 mm) 35 7/8 (911 mm) C 27 (686 mm) 17 3/8 (441 mm) Page 20 of 53 D 30 (762 mm) 38 3/16 (970 mm) Weight 1200 lbs (500kg) 1350 lbs (580kg)
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. A forklift is ideal for the purpose, but take care to properly position the forks between the casters and the centrally mounted evacuation pipe from the side of the machine.
4 Installation 4-1 Lifting Important! Before lifting or moving the granulator, check the relative weight shown on the shipping papers and in Figure 7. 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, take care not to damage delicate parts.
water. The granulator should be installed in an inside covered, weather-proof environment and away from any areas where water collects on the floor. Once the granulator is in position, the front panel must be opened in order to insert the bin as illustrated in Figure 9. Figure 9: 4-3 Inserting the Bin Electrical Connection It is extremely important that the machine is correctly wired into the plant power source by a licensed electrician. See Section 9 for a wiring diagram.
1. Open the back cover, and insert the power cable from underneath the granulator. 2. Pass the power cable through the appropriate hole, and insert it into the control panel through a connector placed at the base. 3. Connect the three phase wires to the appropriate terminals of the main switch, and connect the ground wire to the terminal provided near the main disconnect switch. (See Figure 10.
4. Pivot back the feed hopper to gain free access to the cutting chamber. 5. Check that there are no foreign objects in the cutting chamber. 6. Check to be sure the bed knife and rotor knife bolts are at the proper torque and the knife gap is set according to specifications. See Sections 4-4-4 and 6-4. 7. After completing the checks, close the hopper and screen, and fasten them with the corresponding knobs; reinsert the bin. Then close both the rear cover and the front panel. 8.
If the rotation direction is correct, the granulator is ready to use. If the rotation direction is incorrect, reverse the rotor direction as follows: !!Warning!! A LICENSED ELECTRICIAN must carry out this operation. 1. Disconnect and lockout the power to the machine at the incoming power source. If the disconnect is not lockable, remove the fuses. 2. Reverse any two of the three power line conductors to the machine.
Before undertaking any type of work on the machine, use a feeler gauge to check the distance between the bed knives and the rotor knives (the knife gap). To access the cutting chamber, follow the same procedure and observe the precautionary steps given in Section 4-4-1. Before proceeding to the checks, it is advisable to block the rotor to avoid any inadvertent rotation.
5 Start Up and Operation 5-1 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.
5-2 Operation The granulator can be operated in a vertical top feed position or in a horizontal front feed position. Before starting the granulator, always check for and remove tools or any other objects placed on the granulator. Turn the Power disconnect switch to “ON”, pull the Start button, and release it when the motor has started. It is quite normal for the motor not to start immediately, as the electronic system must check all the micro switches before enabling start up procedures.
6 Maintenance 6-1 General Recommendations Before carrying out any work on the granulator, carefully read the instructions contained in this manual. NOTE: Only specialist and competent personnel should carry out this operation. 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 the safety instructions in Section 1 may pose a threat to both personnel and equipment.
6-2 Monthly Maintenance Operations 6-2-1 Drive Belt Tension NOTE: This operation should be carried out by an operator / 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, carry out the following procedure: 1.
Figure 14: Belt Tension Chart Belt Cross Section Small O.D. Range 3VX ∗Deflection Force Lbs/V-belt Run-In 7.0 3.7 Normal Running 4.7 Belt Span Deflection = Beltspan 64 Belt Deflection Guage For best performance, the force measured on the gauge should be between the minimum and maximum values shown on the chart. If there is not enough deflection force, the belts should be tightened. If there is too much deflection force, the belts should be loosened.
4. Remove the screw knob that holds the hopper on top of the cutting chamber. Carefully lower the screen cradle assembly, resting it on the base. 5. Remove the screen, keeping it in a horizontal position. (See Figure 15.) 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 back on.
4. Using a feeler gauge, measure the gap between the rotor and knife cutting edges. Check each rotor knife to find the “high knife” or the knife that measures the smallest gap. If the gap is substantially greater than the specified 0.006” - 0.008” (0.15 mm – 0.2 mm), the knives need readjustment. 5. Loosen the bed knife locking bolts. (See Figure 16.) 6. Leave the two outside bolts just tight enough to allow the bed knife to move. 7. Loosen the adjustment screws and lock nuts. (See Figure 16.) 8.
Figure 16: Inspection of Knives Bed Knife Locking Bolts Bed Knife Adjusting Screws Rotor Knife Locking Bolts 6-5 Removing and Replacing Bed Knives NOTE: This procedure should be performed by a qualified operator / maintenance mechanic. Protective gloves must be worn to avoid injury when handling the cutting knives. To remove and replace bed knives, complete the following procedure: 1. Open the granulator by following Steps 1-5 in Section 6-3. 2.
8. Install new or sharpened bed knives on each knife seat, making sure that the rotor is blocked to prevent it from rotating while installing each knife. Be sure to place the bed knives in the correct positionsthe rear (down stroke) bed knife must be placed with the extended cutting edge on top, and the front (upstroke) bed knife should be placed with the cutting edge on the bottom. 9. Replace the upper shields in position above the bed knives.
5. Loosen and remove the knife bolts and lift the knife off the knife seat removing it from the cutting chamber. 6. Perform the above steps until all the rotor knives are removed. NOTE: Before replacing the rotor knife with new or sharpened knives, wipe the knife seats on the rotor, being sure to clean off all process material. The tapped holes in the rotor (used for holding the knives in place) should be clear of any dirt, oil, or process material. 7.
Figure 17: Bed Knife Specifications Model BP1012 BP1018 X 2.433” 61.8 mm 2.402” 61.0 mm Y 2.748” 69.8 mm 2.717” 69.0 mm Grind these surfaces only 20° Minimum Length (X) 0.158” (4 MM) 6-8 0.158” (4 MM) New Knife Length (Y) 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.
7 Troubleshooting The following tables list problems that could occur when using the granulator. This general information may help to locate the cause of the problem and allow it to be resolved promptly. When a problem arises, it is advisable to perform the simplest checks before proceeding to more complicated ones, which may subsequently prove unnecessary.
Problem Possible Causes Abrasive material Rotor Jamming Excessive infeed material Possible Remedies Contact the supplier for special knives Reduce amount of material being fed to the machine Total or partial obstruction of the screen holes Remove the screen and clear the holes Insufficient belt tension Check and/or adjust belt tension Knives worn Replace with new knives Distance between the knives too small or too large Check distance between knives Screen holes too small Increase screen hole
7-2 Electrical Problems Problem Machine stops for no apparent reason Possible Causes Safety switch has stopped power Possible Remedies Check that the knobs that operate the safety switch are tightened Electric motor does not start No power Check fuses Overload failure Check amperage of electric motor Check and replace Safety switch not working Empty cutting chamber Motor starts but does not speed up or take a load Motor starts, but does not gain speed Cutting chamber too full Excessive drive bel
8 Spare Parts When requesting spare parts, always quote the granulator model and serial number (from the granulator label), as well as the table number and reference number (from the spare parts tables) and the quantity required. 8-1 Table 1: Recommended Spare Parts List Item Rotor Knife Rotor Knife Screw Bed Knife Bed Knife Screw Bed Knife Washer Screen Rotor Bearing Drive Belt Bed Knife Adj.
Figure 19: Cutting Chamber – Vertical Cross Section Page 45 of 53
Figure 20: Cutting Chamber – Longitudal Cross Section Page 46 of 53
Figure 21: Cutting Chamber – Front View Page 47 of 53
Figure 22: Cutting Chamber – Rear View Page 48 of 53
9 Typical Wiring Diagram Page 49 of 53
10 Contact Information Parts Department Call Spare Parts Express toll-free 8am – 8PM EST (800) 229-2919. Sterling 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) 229-2919 8am – 8pm EST- Emergency service available 24 hours a day.
Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ________________________
Warranty Sterling 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 that are returned prepaid within one year of equipment shipment to the original purchaser, and which, in the Company’s opinion, are defective. Any replacement part assumes the unused portion of this warranty.
124 Roddy Avenue • South Attleboro, MA 02703-7900 (508) 399-3100 • Fax (508) 399-3150
