ACS BP, 1000X, MTG, GP User Manual
1000 Series Granulators
10 x 12 and 10 x 18 Models
Models Covered:
GP, BP, 1000X, MTG
Part Number: MAN-CA025490
Bulletin Number: GRN1-635
Effective: August 1, 2012
1000 Series Granulators ii
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
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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.
1000 Series Granulators iii
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.
Notify the transportation company’s local agent if you discover damage.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization.
File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.
If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
! Granulator
! Bill of lading
! Packing list
! Operating and Installation packet
! 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.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately. For
immediate assistance, please contact the correct facility located in the technical assistance
section of this manual. Have the order number and item number available. Hold the items
until you receive shipping instructions.
1000 Series Granulators iv
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.
The invoice number and date or purchase order number and date must be supplied.
No credit will be issued for material that is not within the manufacturer’s warranty period
and/or in new and unused condition, suitable for resale.
Warranty 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 returns are to be shipped prepaid.
The invoice number and date or purchase order number and date must be supplied.
After inspecting the material, a replacement or credit will be given at the manufacturer’s
discretion. If the item is found to be defective in materials or workmanship, and it was
manufactured by our company, purchased components are covered under their specific
warranty terms.
1000 Series Granulators v
Table of Contents
CHAPTER 1:! SAFETY ................................................................ 7!
1-1! How to Use This Manual ............................................................................................. 7!
Safety Symbols Used in this Manual ..................................................................... 7!
1-2! General Safety Regulations ...................................................................................... 10!
1-3! Responsibility ............................................................................................................ 10!
1-4! Warnings and Precautions ........................................................................................ 10!
Additional Warning: ............................................................................................. 12!
CHAPTER 2:! FUNCTIONAL DESCRIPTION ........................... 14!
2-1! Models Covered in This Manual ................................................................................ 14!
2-2! General Description .................................................................................................. 14!
2-3! Typical Features and Components ........................................................................... 15!
Hopper ................................................................................................................. 15!
Cutting Chamber ................................................................................................. 15!
Drive System ....................................................................................................... 15!
Discharge System ............................................................................................... 15!
Base .................................................................................................................... 15!
2-4! Safety Features ......................................................................................................... 16!
Safety Switches ................................................................................................... 16!
Safety Tags ......................................................................................................... 16!
Sound Reduction Equipment .............................................................................. 16!
CHAPTER 3:! INSTALLATION .................................................. 18!
3-1! Uncrating the Equipment ........................................................................................... 18!
3-2! Belt Tensioning ......................................................................................................... 18!
3-3! Electrical Connections ............................................................................................... 19!
3-4! Accessing the Cutting Chamber ................................................................................ 20!
3-5! Closing the Cutting Chamber .................................................................................... 20!
3-6! Initial Start-up ............................................................................................................ 21!
CHAPTER 4:! OPERATION ....................................................... 22!
4-1! Start-up ..................................................................................................................... 22!
4-2! Feeding the Granulator ............................................................................................. 22!
4-3! Clearing a Jammed Cutting Chamber ....................................................................... 22!
4-4! Shut-down ................................................................................................................. 23!
CHAPTER 5:! MAINTENANCE ................................................. 24!
5-1! Preventative Maintenance Schedule ......................................................................... 24!
5-2! Testing the Interlock Switch ...................................................................................... 24!
5-3! Replacing and Adjusting the Knives .......................................................................... 25!
Rotor Knives ........................................................................................................ 25!
Bed Knives .......................................................................................................... 26!
5-4! Sharpening the Knives .............................................................................................. 27!
Rotor Knife Sharpening ....................................................................................... 27!
Bed Knife Sharpening ......................................................................................... 27!
1000 Series Granulators vi
5-5! Adjusting Belt Tension .............................................................................................. 28!
CHAPTER 6:! TROUBLESHOOTING ....................................... 30!
6-1! Introduction ............................................................................................................... 30!
6-2! Electrical Faults ......................................................................................................... 30!
6-3! Processing Faults ...................................................................................................... 31!
6-4! Mechanical Faults ..................................................................................................... 32!
CHAPTER 7:! APPENDIX .......................................................... 33!
7-1! Technical Specifications ............................................................................................ 33!
Features .............................................................................................................. 33!
Specifications ...................................................................................................... 33!
Dimensions.......................................................................................................... 34!
7-2! Parts Breakdown ....................................................................................................... 35!
Cutting Chamber ................................................................................................. 35!
Basis and Protection Kit ...................................................................................... 37!
Silenced Hopper Kit ............................................................................................ 38!
Silenced Protections Kit ...................................................................................... 41!
7-3! Typical Wiring Diagram ............................................................................................. 43!
7-4! Technical Assistance ................................................................................................ 44!
Parts and Service Department ............................................................................ 44!
Sales and Contracting Department ..................................................................... 44!
1000 Series Granulators Chapter 1: Safety 7 of 45
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. Additional sections within the manual provide instructions for installation, preoperational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the granulator. We can also provide the assistance of a factory-trained technician to help
train your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the granulator.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in
addition to information for operating the granulator safely and efficiently.
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.
The Appendix contains technical specifications, drawings, schematics, parts lists, and
available options. 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.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided, will
result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if not
avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation or practice that, if not
avoided, may result in minor or moderate injury or in property damage.
1000 Series Granulators Chapter 1: Safety 8 of 45
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. For further information
see the Maintenance Chapter
in this manual
When equipped with belts
and sheaves, hands could
become entangled.
Every month inspect the
belt(s) for any type of wear.
For further information see
the Maintenance Chapter in
this manual.
Hands can become
entangled or cut if they
enter the danger zone of
gears or cutting shears.
Every month inspect the
shears/blades for any type of
wear. For further information
see the Maintenance Chapter
in this manual.
The unit can produce
continuous noise above 85
dBA and/or produce
projectiles under normal
operating conditions.
Always wear eye and ear
protection when the machine
is in operation or performing
maintenance.
1000 Series Granulators Chapter 1: Safety 9 of 45
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. This equipment operates with sharp blades
and rotors. We recommend that technicians use safety gloves
while performing maintenance to protect hands from being
exposed to these sharp surfaces.
Wear ear and eye protection. This unit may produce loud and
continuous noise and may produce projectiles.
Do not reach into unit. Reaching into a unit is prohibited while the
unit is in operation and may cause serious injury.
1000 Series Granulators Chapter 1: Safety 10 of 45
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 the machine or job the rotor unless the cutting chamber’s covers, discharge
chute, and guards are in place and secure. Do not circumvent the safety interlocks.
Never operate the machine or jog the rotor unless the cutting chamber covers, discharge
chute, or any guards or covers are in place and secure. Do not circumvent the safety
interlocks.
Prior to clearing a jam or performing any maintenance, the motor should be turned off and
electrically locked out. Be sure that the rotor has come to a stop. Hands must not be inserted
into the machine to clear the jam.
Do not extend any part of the body into feed roll openings or discharge area unless the motors
are electrically locked out and the rotor and feed rolls are motionless.
Never extend fingers through holes in the screen.
Be sure that the v-belts are properly aligned and that tension is at its maximum.
Extreme care should be taken to see that all bolts are properly tightened at all times. During
the operation of the machine, rotor knife bolts may come loose. Although fine threads are
used on the rotor knife bolts, you should still inspect the tightness of the bolts frequently.
This machine is designed for the granulation of plastic materials. Do not feed any other
materials into the machine.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Becoming familiar with materials, inspection, speed limitations, screens, guard maintenance
and total user responsibility will assist you in learning potential areas in need of observation
for danger.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. All actual or potential
danger areas must be reported to your immediate supervisor.
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:
1000 Series Granulators Chapter 1: Safety 11 of 45
! LEARN AND OBEY your company’s safety policy regarding granulating
equipment.
! MOVING OR LIFTING THE GRANULATOR: Although our equipment is built
and engineered for great ruggedness in operation, care must be taken when moving
the machine along the floor or lifting it. Damage may occur to sheet metal covers,
electrical cabinets, or small brackets if pressure is applied to them when moving the
granulator. When lifting the granulator, be certain of total machine weight and the
capability of the lifting equipment. (See the Granulator Specification Sheets for
machine weights and dimensions.)
! GRANULATOR LOCATION: Adequate area for routine maintenance should be
provided in order to open the machine for knife, screen, or cleanout service. Proper
service area clearances also should allow people who are working on the machine to
be clearly visible to others, thereby reducing potential safety hazards.
! SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine. Any tools or other metal objects that mistakenly fall
into the hopper feed opening can cause severe damage to the internal cutting
chamber, rotor and screen components.
! SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when
servicing or operating the machine. Although our machines are designed for the
maximum in fly back control, caution must be used when operating near the hopper
feed opening in order to guard against unexpected material fly back.
! 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.
! Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS
AND COVERS are securely and properly fastened prior to resuming machine
operation. All fasteners must be in place and properly tightened. ANY
SHORTCUTS MAY RESULT IN INJURY TO PERSONNEL OR DAMAGE
TO EQUIPMENT.
! NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should
NEVER be worn. Long hair must be tied back or placed in a tight fitting hairnet.
NEVER lean against or rest hands or feet on the granulator when it is in operation or
open for maintenance. NEVER stand on the granulator when it is in operation.
! 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.
! 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.
1000 Series Granulators Chapter 1: Safety 12 of 45
! ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the
granulator before performing any service.
! SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and
electrical safety interlocks ensure the safety of personnel. They should never be
tampered with or removed for ANY reason. They should be checked frequently by a
qualified mechanic for proper operation.
! NEVER modify the machine configuration or any individual component without
written notice from the factory.
For further information on granulator safety, installation and operation, see the American
National Standard for Plastics Machinery!Granulators, Pelletizers, and Dicers Used for
Size Reduction of Plastics!Construction, 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.
Additional Warning:
The process of granulating and conveying materials inevitably creates dust levels that could
potentially cause a hazard if certain procedures or precautions are not followed. Hazardous
dust is defined as any material particle 420 microns or smaller (less than 40 mesh or .0164”)
which is dispersed in air or collected on surfaces more than 1/32” thick.
The following are some precautions that should be followed to avoid any dust related hazards.
1. Always use the largest granulator screen or regrind particle size for your process. The
larger the screen size, the less dust will be generated.
2. Know the specifics of the material you are granulating. If your material is especially
dusty, inquire about other equipment that may help in controlling the dust levels.
3. Keep the area around the granulator clean by minimizing leaks from the machine or
conveying/collection system. It is suggested that an industrial vacuum be used as needed
to keep the area clean.
4. When cleaning the granulator for color or material changes, an industrial vacuum is
recommended. Do not use compressed air to blow off material on machine surfaces.
5. Establish frequent knife gap maintenance procedures. Different materials have different
effects on knife wear and ultimately the operating knife gap. Large knife gaps (2 or 3
times the original setting) can generate higher dust levels.
Also note that the granulating process can generate heat sufficient to melt materials and
potentially cause fires or explosions.
The following are some precautions that should be followed to avoid any fire/explosion
related hazards.
1. Feed process materials at the appropriate rate consistent with the granulator throughput
capacity and screen size used for your material. Overfeeding can cause jam ups and/or
melting of process material which can outgas potentially explosive gas.
2. Monitor pneumatic conveying systems used to convey granulate from the granulator.
Loss of conveying can cause a material back up and ultimate melting and gas offing.
3. Maintain proper knife gaps on the granulator. Small knife gaps can result in knife
collisions which can then cause excessive friction, which heats the process material, and
may cause potential ignition.
1000 Series Granulators Chapter 1: Safety 13 of 45
4. Based on the characteristics of the material being processed, consider the use of fire
suppression/explosion detection equipment in conjunction with your granulator.
Applicable Published Standards:
• NFPA 650 Standard for Pneumatic Conveying Systems for Combustible Particulate
Solids
• NEPA 69 Standard on Explosion Prevention Systems
• NFPA 654 Standard for the Prevention of Fire and Dust Explosion from the
Manufacturing, Processing & Handling of Combustible Solids
• NFPA 499 Recommended Practice for the Classification of Combustible Dust
1000 Series Granulators Chapter 2: Functional Description 14 of 45
Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides the necessary instructions for the installation, set-up, and maintenance
of our 10 x 12 and 10 x 18 granulators, which covers models: GP, BP, 1000X & MTG.
2-2 General Description
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 operation of the granulator is controlled by a control panel and
powered by an electric motor.
The hopper is designed to tilt back, and the screen cradle to swing down for quick access into
the cutting chamber.
These compact, easily movable, soundproofed, low-speed granulators are designed for
beside-the-press granulation, engineered for hand feed, robot feed, or conveyor feed. The
1000 Series granulators are ideal for reject components from injection, blow molding. And
extrusion processes.
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