AEC M103 User Manual

Model M103

Granulator

Part Number:

Bulletin Number: CO2-660

Effective: 3/31/04

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.

4 Inch Granulator i

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:

þ Granulator

þ Bill of lading

þ Packing list

þ Operating and Installation packet

þ Electrical schematic and panel layout drawings

þ 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 (800) 229-2919; for all other countries, call our international desk at (508) 399-6400. 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.

4 Inch Granulator ii

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 ............................................................................9

Infeed Devices ................................................................................................................................ 9

Cutting Chamber............................................................................................................................. 9

Screen.............................................................................................................................................. 9

Discharge System............................................................................................................................ 9

Base................................................................................................................................................. 9

2-4 Safety Features .......................................................................................................10

Safety Switches............................................................................................................................. 10

Safety Tags.................................................................................................................................... 10

Level Sensor (optional)................................................................................................................. 10

CHAPTER 3: INSTALLATION.................................................. 11

3-1 Uncrating the Equipment .........................................................................................11

3-2 Making the Electrical Connections...........................................................................12

3-3 Accessing the Cutting Chamber...............................................................................13

3-4 Closing the Cutting Chamber...................................................................................13

3-5 Preparing for Initial Start-up.....................................................................................14

CHAPTER 4: OPERATION....................................................... 15

4-1 Starting the Granulator ............................................................................................15

4-2 Feeding the Granulator............................................................................................15

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

4-4 Making an Emergency Stop.....................................................................................17

4-5 Shutting Down the Granulator..................................................................................17

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

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

5-2 Replacing the Screen ..............................................................................................18

5-3 Replacing and Adjusting the Knives.........................................................................19

Bed Knives.................................................................................................................................... 19

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

5-4 Sharpening the Knives.............................................................................................21

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

Rotor Knives ................................................................................................................................. 21

4 Inch Granulator iii

Cleaning the Granulator...........................................................................................22

5-5

CHAPTER 6: TROUBLESHOOTING ....................................... 23

6-1 Introduction..............................................................................................................23

6-2 Electrical Faults .......................................................................................................23

6-3 Processing Faults ....................................................................................................24

6-4 Mechanical Faults....................................................................................................25

CHAPTER 7: APPENDIX.......................................................... 26

7-1 Customer Satisfaction Warranty Program................................................................26

7-2 Installing the Optional Level Sensor ........................................................................27

7-3 Spare Parts List.......................................................................................................28

7-4

T Models.............................................................................................................31

SW Models……………………………………………………………………………...32 7-5 Drawings and Diagrams…………………………………………………………………..33

T Models ............................................................................................................33

SW Models.........................................................................................................34

RT Models..........................................................................................................

Parts Department ...............................................................................................44

Service Department............................................................................................44

Sales Department………………………………………………………………………44

Technical Data.........................................................................................................31

Electrical Diagrams..................................................................................................40

7-6 Technical Assistance...............................................................................................44

4 Inch Granulator iv

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.

4 Inch Granulator Chapter 1: Safety 5 of 47

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.

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.

4 Inch Granulator Chapter 1: Safety 6 of 47

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 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.)

þ 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.

þ 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.

þ 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.

þ 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.

þ NEVER attempt to operate the granulator unless it is fully assembled with all guards

and interlocks in place and functional.

þ OBSERVE all danger, warning, caution and safety labels on the equipment.

þ 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.

þ 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.

4 Inch Granulator Chapter 1: Safety 7 of 47

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.

þ 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.

þ 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 Machinery¾Granulators, Pelletizers, and Dicers Used for Size Reduction of Plastics¾Construction, 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.

4 Inch Granulator Chapter 1: Safety 8 of 47

Chapter 2: Functional Description

2-1 Models Covered in This Manual

This manual covers M103 beside-the-press granulator. T models are for use with a sprue removal device and feature a hopper so that material can be dropped directly from the sprue removal device into the granulator. RT Models are fitted with an extended hopper. SW models are for use underneath the discharge shaft of your processing machine. SW models feature a steel auger feeder.

2-2 General Description

This granulator is specially designed for use next to or directly under the processing machine. The low construction and noise level make this an ideal application. This granulator cuts at a slow rotational speed, resulting in an extremely low noise level with minimal dust build-up. All parts that come into contact with the material are easily accessible through large cleaning openings.

Depending on the requirements, the granulated material can be re-introduced into the process by a conveyor system with a two-components proportioning valve or a dosing and blending unit.

2-3 Typical Features and Components

Infeed Devices

Hopper. The hopper is an upright enclosure bolted to the top of the cutting chamber. The hopper is designed to facilitate feeding of material to the rotary knives and to prevent chips thrown from the cutting chamber from reaching the operator.

Auger. The steel auger is meant for use underneath the processing machine.

Extended Hopper. If different types of tools are being used, it may be necessary to install an

additional collecting funnel on the opening of the hopper of the granulator. We recommend that this sheet metal work be carried out on site.

Cutting Chamber

The rotor features 6 staggered horizontal HSS steel rotor blades that are designed for sprues, and small molded parts.

Screen

The screen is 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.

Discharge System

The granulated material that falls through the screen is collected by a discharge chute beneath the cutting chamber and directed into a large capacity vacuum bin.

Base

The base is caster-mounted, with four swivel casters for easy positioning. The height of each caster can be adjusted individually. As a result, the granulator can be positioned at an angle without affecting its function.

4 Inch Granulator Chapter 2: Functional Description 9 of 47

2-4 Safety Features

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.

Level Sensor (optional)

Level sensors monitor the level in the cutting chamber, automatically shutting off the granulator in case of overfilling.

4 Inch Granulator Chapter 2: Functional Description 10 of 47

Chapter 3: Installation

3-1 Uncrating the Equipment

The granulator is delivered completely assembled and wired, except for the casters. Make sure the casters are fitted to the baseframe underneath the motor. To lift and move the granulator safely and correctly, cover any sharp corners or edges, and use the type of equipment that has the most appropriate features and capacity. Use the designated lifting points, and do NOT lift the machine by the hopper handles or guards. Refer to the Appendix for detailed dimensional data and pertinent weights.

Prepare in advance the site you have selected for installation of the granulator. Be certain that the area to be occupied by the machine is clean, level, and free of obstructions. The machine should be set on a concrete floor, and care must be taken when moving the machine across a hollow timber floor, so that the point loading of the casters does not cause damage. The site you have selected must have a floor rating to adequately support the weight of the machine. If necessary, use steel shims to level the machine.

Locate the machine so that access is given to electrical components, screen, and hopper. Maintenance personnel should have unobstructed access to the units on which they will be working.

To avoid squeezing people working near a machine, there should be adequate clearance maintained between machines, walls, or partitions. Hinged doors and covers should have full swing. Restrictions may force work in cramped quarters. An off-balance operator with an awkward reach into a partially obscured area is unsafe.

Before lifting the granulator, remove the discharge box. Make sure that the limit switch and the cable of the discharge box is not damaged.

4 Inch Granulator Chapter 3: Installation 11 of 47

3-2 Making the Electrical Connections

Check serial tag voltage/amperage requirements and make sure your electrical service conforms before making any electrical connections. Make sure that all three phases are wired correctly.

A separate fuse system is recommended but not absolutely necessary. Bring properly sized power leads and grounds from a fused disconnect to the unit. If you use fuses, make sure that they are dual-element, time-delay fuses, sized according to your electrical code. Refer to the technical specifications in the Appendix for horsepower, voltage, phase, and frequency requirements to determine the size and rating of the supply cable required.

Carefully check the diagrams packed with the machine. All internal wiring has been done at the factory. All safety interlocks have been verified to be functional before shipment. The only connection left to be made, is the electrical power source to the machine at the control enclosure.

Use the following procedure to complete the electrical connections:

1. Check that the limit switches are closed.

2. Turn switch ON at main power supply.

3. Press the ON switch for at least 3 seconds.

4. With the electrical power ON, check that the motor rotates in a clockwise direction at the viewing window. If the direction of rotation is incorrect interchange any two power lines. Verify the direction of rotation for all available sockets.

Caution! Incorrect motor rotation reduces the quality of grinding considerable and

may damage the motor.

4 Inch Granulator Chapter 3: Installation 12 of 47

3-3 Accessing the Cutting Chamber

You will need to access the cutting chamber before initial startup and for various maintenance procedures.

Use the following procedure to access the cutting chamber:

1. Turn the main power off, remove the line fuses, and tag the machine as out of service.

2. Open the toggle fasteners.

3. Remove the discharge box.

4. Open the cutting chamber door.

5. Carefully remove the screen.

3-4 Closing the Cutting Chamber

After completing any maintenance or adjustments inside the cutting chamber, use the following procedure to close the cutting chamber and resume use of the granulator:

1. Carefully install the screen.

2. Close the cutting chamber door.

3. Replace the discharge box.

4. Close the toggle fasteners.

5. Replace line fuses, turn power on, and remove the out of service tag from the machine.

4 Inch Granulator Chapter 3: Installation 13 of 47

3-5 Preparing for Initial Start-up

This machine has been run under power and tested at the factory prior to shipment. The necessary settings and adjustments have been made so that a minimum amount of setting up or re-adjustment is required when starting up the machine in its new location.

With all electrical, mechanical connections and lubrication requirements having been attended to, the following start-up steps should be carefully carried out before attempting to place any material into the infeed hopper. Use the following procedure to prepare the machine for initial start-up:

WARNING! Before operating the granulator, insure that the granulator has been

correctly assembled and wired.

1. Access the cutting chamber as describe in Section 3-3 on page 13.

2. Thoroughly clean the rust preventative materials or grease from the hopper, the inside of the cutting chamber, knives, rotor, screen, discharge system, and exterior of the machine. Do not use solvent on any of the painted areas, as solvent may damage the paint.

3. Tighten down all the bolts of the rotor blades using a torque wrench (36 Nm).

4. Use a feeler gauge to check the clearance between the rotor and the bed knives by turning the rotor backwards. Rotating the rotor backwards gives a better feel and does not cut the gauge, should the knives be too close. Proper clearance is 0.004”-0.016” (0.1mm-0.4mm), depending on material.

Note: Recheck knife clearance after the first 24 to 36 hours of operation.

5. To adjust the bed knives, the bed knife adjusting screws should be hand tightened to hold the knife firmly against the knife seat while adjusting the knife forward using push and pull screws. After the clearance is set, torque the screws to 36 Nm.

6. Manually turn the rotor for one complete rotation using an Allen key inserted in the central bolt of the rotor.

7. Check that the cutting chamber does not contain any foreign objects or tools.

8. With the exposed parts of the machine thoroughly clean, and all knife clamping bolts securely fastened, close the cutting chamber as described in Section 3-4 on page 13.

Note: After initial start-up, the rotor knife retaining screws should be checked after 8

hours running to be assured that the proper torque is maintained. Thereafter, rotor knife retaining screws should be checked weekly.

Note: The rotor must be rotated at least two rotations every 30 days to prevent

brinnelling and corrosion of raceways.

4 Inch Granulator Chapter 3: Installation 14 of 47

Chapter 4: Operation

4-1 Starting the Granulator

Before starting the machine, check that the rotor rotates freely by rotating it by hand. Inspect the cutting chamber carefully to insure that nothing has fallen into it. Make sure all screws and bolts are properly secured. Check all electrical connections and motor rotations. See Chapter 3 on pages 11-14 for detailed set-up instructions.

WARNING! The cutting chamber knives are extremely sharp. Always wear heavy gloves

and exercise care when working in the cutting chamber.

Use the following procedure to begin operation:

1. Check that the limit switches are closed.

2. Turn the main power supply switch to the “on” position. The yellow warning light lights up.

3. Press the “On” switch for at least 3 seconds. The yellow warning light turns off and the rotor starts to turn.

4. Allow all motors to run up to speed for at least 30 seconds.

4-2 Feeding the Granulator

Feed the granulator through the opening in the hopper. The method of feeding the granulator depends on the physical form and nature of the material being processed.

For maximum efficiency, the granulator should be fed at a rate that is consistent with its capacity; i.e., if the granulator is rated at 30 lbs./hr (15 kg/hr), then the general feed rate is 0.5 lbs./min. (0.25 kg/min). Under these operating conditions, the correct proportions of cut and uncut particles will be present in the cutting chamber.

WARNING! Under no circumstances should the operator attempt to reach into the

hopper to dislodge any bridged or jammed material while the granulator is in operation. To clear the hopper of bridged or jammed material, the machine main power must be turned off and the machine isolated.

4 Inch Granulator Chapter 4: Operation 15 of 47

+ 32 hidden pages