AEC Granulator User Manual

1426-i Twin-Shear™ Granulator

Part Number: D-391210

Bulletin Number: CG6-605.2

Effective: 11/10/03

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 2004
All rights reserved.

Please note that our address and phone information has changed.
Please reference this page for updated contact information.

These manuals are obsolete and are provided only for their technical information, data and capacities.
Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance
and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied
upon. Please contact the ACS Group for more current information about these manuals and their
warnings and precautions.

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. ACS welcomes inquiries on all your parts needs and is dedicated to
providing excellent customer service.

For immediate assistance, please contact:

• North, Central and South America, 8am – 5pm CST [phone] for drying, conveying, heating and cooling
and automation. For size reduction: [phone].
North America, emergencies after 5pm CST [phone]

North America email: [e-mail]

• Mexico, Central & South America
Email: [e-mail]

• Europe, Middle East & Africa [phone]

Email: [e-mail]

• India [phone]

Email: [e-mail]

• Asia/Australia [phone]

Email: [e-mail]

Sales and Contracting Department

Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the
name of the sales representative nearest you.

Let us install your system. The Contract Department offers any or all of these services: project planning; system packages
including drawings; equipment, labor, and construction materials; and union or non-union installations.

For assistance with your sales or system contracting needs please Call:

North, Central and South America [phone] or [phone] Monday–Friday, 8am–5pm CST

Europe/Middle East/Africa [phone]
India [phone]
Asia/Australia [phone]

Facilities:

ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at
www.acscorporate.com

United States:

ACS Schaumburg – Corporate Offices

1100 E. Woodfield Road
Suite 588
Schaumburg, IL 60173
Phone: + 1 847 273 7700
Fax: + 1 847 273 7804

ACS New Berlin – Manufacturing Facility

2900 S. 160th Street
New Berlin, WI 53151
Phone : [phone]
Fax: + 1 262 641 8653

Asia/Australia:

ACS Suzhou

109 Xingpu Road SIP
Suzhou, China 215126
Phone: + 86 8717 1919
Fax: [phone]

Europe/Middle East/Africa:

ACS Warsaw

Ul. Działkowa 115
02-234 Warszawa
Phone: + 48 22 390 9720
Fax: [phone]

India

ACS India

Gat No. 191/1, Sandbhor Complex
Mhalunge, Chakan, Tal Khed,
Dist. Pune 410501, India
Phone: [phone]
Fax: + 91 20 40147576

1426-i Granulator ii

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
shipments in the United States and Canada, call 1 [phone]; for all other countries, call
our international desk at [phone]. Have the order number and item number available.
Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

1426-i Granulator iii

Table of Contents

CHAPTER 1: SAFETY.................................................................. 5

1-1 How to Use This Manual ............................................................................................ 5

Safety Symbols Used in this Manual.....................................................................5

1-2 General Safety Regulations........................................................................................ 6

1-3 Responsibility............................................................................................................. 6

1-4 Warnings and Precautions .........................................................................................7

CHAPTER 2: FUNCTIONAL DESCRIPTION............................... 9

2-1 Models Covered in This Manual .................................................................................9

2-2 General Description ................................................................................................... 9

2-3 Typical Features and Components ........................................................................... 10

Hopper...............................................................................................................10

Cutting Chamber ................................................................................................10

Drive System...................................................................................................... 10

Discharge System ..............................................................................................10

Base ..................................................................................................................10

2-4 Safety Features ....................................................................................................... 11

Motor Starter ...................................................................................................... 11

Safety Switches..................................................................................................11

Safety Tags........................................................................................................11

CHAPTER 3: INSTALLATION.................................................... 12

3-1 Uncrating the Equipment.......................................................................................... 12

3-2 Belt Tensioning ........................................................................................................ 12

3-3 Electrical Connections.............................................................................................. 13

3-4 Accessing the Cutting Chamber ...............................................................................14

3-5 Closing the Cutting Chamber ...................................................................................14

3-6 Initial Start-up........................................................................................................... 15

CHAPTER 4: OPERATION......................................................... 16

4-1 Start-up.................................................................................................................... 16

4-2 Feeding the Granulator ............................................................................................ 16

4-3 Clearing a Jammed Cutting Chamber....................................................................... 16

4-4 Shut-down ............................................................................................................... 17

CHAPTER 5: MAINTENANCE ................................................... 18

5-1 Preventative Maintenance Schedule......................................................................... 18

5-2 Lubrication ...............................................................................................................18

5-3 Interlock Switches .................................................................................................... 19

5-4 Replacing and Adjusting the Knives ......................................................................... 20

Rotor Knives ......................................................................................................20

Bed Knives.........................................................................................................21

5-5 Sharpening the Knives ............................................................................................. 22

Rotor Knife Sharpening ...................................................................................... 22

Bed Knife Sharpening ........................................................................................ 22

1426-i Granulator iv

5-6 Adjusting Belt Tension ............................................................................................. 23

5-7 Motor Drive Belt Replacement.................................................................................. 24

CHAPTER 6: TROUBLESHOOTING ......................................... 25

6-1 Introduction.............................................................................................................. 25

6-2 Electrical Faults ....................................................................................................... 26

6-3 Processing Faults .................................................................................................... 27

6-4 Mechanical Faults .................................................................................................... 28

CHAPTER 7: APPENDIX............................................................ 29

7-1 Customer Satisfaction Warranty Program................................................................. 29

7-2 Drawings and Specifications (including Options)....................................................... 30

Features ............................................................................................................30

Specifications.....................................................................................................30

Dimensions ........................................................................................................ 31

Vertical Cross Section ........................................................................................ 33

Longitudinal Cross Section.................................................................................34

7-3 Spare Parts List ....................................................................................................... 35

7-4 Typical Wiring Diagram ............................................................................................ 36

7-5 Technical Assistance ............................................................................................... 37

Parts Department ...............................................................................................37

Service Department............................................................................................37

Sales Department ..............................................................................................37

1426-i Granulator Chapter 1: Safety 5 of 37

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! DANGER indicates an imminently hazardous situation that, if not avoided,

will result in death or serious injury.

WARNING! WARNING indicates a potentially hazardous situation or practice that, if

not avoided, could result in death or serious injury.

Caution! CAUTION indicates a potentially hazardous situation or practice that, if

not avoided, may result in minor or moderate injury or in property damage.

1426-i Granulator Chapter 1: Safety 6 of 37

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.

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 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 because vibration does not easily loosen them, you should
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, and 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.

1426-i Granulator Chapter 1: Safety 7 of 37

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:

˛ 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 the 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 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 flyback control, caution must be used when operating near the hopper
feed opening in order to guard against unexpected material flyback.

˛ 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.

1426-i Granulator Chapter 1: Safety 8 of 37

˛ 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.

˛ 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 MachineryæGranulators, Pelletizers, and Dicers Used for
Size Reduction of PlasticsæConstruction, 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.

1426-i Granulator Chapter 2: Functional Description 9 of 37

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 14 x 26 granulator.

2-2 General Description

This granulator is a rugged, rotary-cutting machine specifically designed to cut, chip, and
granulate the toughest plastic materials with a minimum expenditure of horsepower.

A massively built, low RPM, high inertia rotor with chevron knives accepts large parts with
ease and assures long, trouble-free service. The bed knife block is made of heavy steel, and
the cutting chamber is made of a thick steel plate with integral oversize bearing housings.

The hopper is designed to tilt back, and the screen cradle to swing down for quick access into
the cutting chamber.

Reclamation of sprues, runners, and small parts for inclusion and application in any type of
molding or extrusion equipment is designed-in capability and depending on screen size used,
this machine will provide pellets or chips to meet most requirements.

With no enclosures, this granulator sets the industry standard for noise reduction with 85
DBA or less in almost all applications.

1426-i Granulator Chapter 2: Functional Description 10 of 37

2-3 Typical Features and Components

Hopper

The hopper is a hinged, upright, tray-feed enclosure with sound dampening. It tilts
completely out of the way for unobstructed access to the cutting chamber. It is designed to
facilitate feeding of material to the rotary knives and to prevent chips thrown from the cutting
chamber from reaching the operator.

Cutting Chamber

The cutting chamber is a rectangular enclosure comprising the main frame, the bed knives,
the bed knife shields, a balanced rotor, and a screen.

The main frame of the cutting chamber carries the bed knives and the bed knife shields. Both
the bed knives and shield are adjustable, and the bed knives have reversible cutting edges for
extended life.

The internal surfaces of the solid steel cutting chamber are machined to an exceptionally
smooth finish for ease of clean-out. The scissor-type cutting action of the chevron rotary
knives gives optimum cutting efficiency with low power consumption.

The screen is mounted in a swing-down cradle, positioned just below the rotor and acts as a
separating barrier to the granulated material, retaining the material in the cutting chamber
until the particle size is such that it will pass through the screen holes.

The open-type, high-alloy steel rotor carries the rotary knives. High-strength alloy steel
screws are used for attachment of all knives.

Drive System

The drive system consists of a drip-proof 1800 RPM motor set on an adjustable sliding base
that is mounted below the granulator cutting chamber. The motor drives the rotor with banded
V-belts for insured RPM control. Safety guards shield the motor shaft pulley, V-belts and the
rotor shaft pulley for complete operator safety.

Discharge System

The granulated material that falls through the screen is collected by a discharge chute beneath
the cutting chamber and directed into a bin. The bin can be removed from the front or left
side of the granulator for emptying.

On models fitted with an airveying system (optional), the granulated material that has fallen
through the screen is collected in a transition piece located beneath the cutting chamber. The
transition piece is connected to a blower, which conveys the granulated material through
ducting to the cyclone separator. The cyclone separator allows the granulated material to drop
out of the air system into a container.

Base

The base is a tube-mounted, bin-type construction with tubes located for forklift pick-up.

1426-i Granulator Chapter 2: Functional Description 11 of 37

2-4 Safety Features

Motor Starter

A magnetic motor starter with control transformer must be used when safety switches are
installed. Manual starters should not be used under any conditions.

Safety Switches

Safety switches at all access covers are wired into the starter control circuit. The machine
cannot be started when these parts are open. However, for safety purposes, the machine
should be disconnected from the power lines by a disconnect switch or by removing the plug
from its receptacle. Check all safety switches periodically for proper operation.

Safety Tags

A set of metal plates is attached to the machine to warn of potential danger.