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MSH Series 2039
User Manual
53 pgs29.95 Mb0

AEC MSH Series 2039 User Manual

C Series Granulators 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
Zero Speed Sensor ............................................................................................ 11
Safety Switches.................................................................................................. 11
Safety Tags........................................................................................................ 11
3-1 Uncrating the Equipment.......................................................................................... 13
3-2 Assembling the Motor Base Plate............................................................................. 14
3-3 Attaching the Drive Parts.......................................................................................... 14
3-4 Installing the Infeed Hopper...................................................................................... 14
3-5 Electrical Connections.............................................................................................. 15
3-6 Accessing the Cutting Chamber ............................................................................... 16
3-7 Closing the Cutting Chamber ................................................................................... 17
3-8 Initial Start-up........................................................................................................... 18
4-1 Start-up.................................................................................................................... 19
4-2 Feeding the Granulator ............................................................................................ 19
4-3 Clearing a Jammed Cutting Chamber....................................................................... 20
4-4 Shut-down ............................................................................................................... 20
5-1 Preventative Maintenance Schedule......................................................................... 21
5-2 Lubrication ............................................................................................................... 22
5-3 Adjusting the Discharge Air Flow.............................................................................. 22
5-4 Removing and Replacing the Screen........................................................................ 23
Removing the Screen......................................................................................... 23
Replacing the Screen ......................................................................................... 24
5-5 Testing the Interlock Switches.................................................................................. 25
C Series Granulators iv
Using and Ohmmeter to Test the Interlock Switches ........................................... 25
Manually Testing the Interlock Switches ............................................................. 25
5-6 Adjusting the Jackscrew Setpoints ........................................................................... 26
Testing the Mounting Bracket Limit Switch.......................................................... 26
Adjusting the Mounting Limit Switch....................................................................26
Adjusting the Chamber Open Setpoint................................................................27
Adjusting the Chamber Closed Limit Switch........................................................ 27
Adjusting the Screen Cradle Open Setpoint........................................................28
Adjusting the Screen Cradle Closed Setpoint...................................................... 28
5-7 Testing and Adjusting Zero Speed Sensor................................................................ 29
Testing the Zero Speed Sensor .......................................................................... 29
Adjusting the Sensor Position............................................................................. 29
5-8 Replacing and Adjusting the Knives ......................................................................... 30
Knife Gap Settings ............................................................................................. 30
Rotor Knives ...................................................................................................... 31
Bed Knives......................................................................................................... 32
5-9 Sharpening the Knives ............................................................................................. 33
Rotor Knife Sharpening ...................................................................................... 33
Bed Knife Sharpening ........................................................................................ 33
Adjusting Belt Tension........................................................................................................ 35
5-11 Motor Drive Belt Replacement.................................................................................. 36
6-1 Introduction.............................................................................................................. 37
6-2 Electrical Faults ....................................................................................................... 38
6-3 Processing Faults .................................................................................................... 39
6-4 Mechanical Faults .................................................................................................... 40
7-1 Customer Satisfaction Warranty Program................................................................. 41
7-2 Drawings and Specifications (including Options)....................................................... 42
Features ............................................................................................................ 42
Specifications..................................................................................................... 42
Dimensions ........................................................................................................43
7-3 Illustrated Parts Breakdown...................................................................................... 44
Cutting Chamber Vertical Cross-Section.............................................................44
Cutting Chamber Longitudinal Cross-Section...................................................... 45
Granulator Front View ........................................................................................ 46
Granulator Rear View......................................................................................... 47
Parts Identification Table .................................................................................... 48
7-4 Spare Parts List ....................................................................................................... 49
7-5 Typical Wiring Diagram: Jackscrew Controls ............................................................ 50
7-6 Recommended Torque for Screws ........................................................................... 52
7-7 Technical Assistance ............................................................................................... 53
Parts Department ............................................................................................... 53
Service Department............................................................................................ 53
Sales Department .............................................................................................. 53
C Series Granulators Safety 5 of 53
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.
C Series Granulators Safety 6 of 53
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.
C Series Granulators Safety 7 of 53
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.
C Series Granulators Safety 8 of 53
˛ 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.
C Series Granulators Functional Description 10 of 53
2-3 Typical Features and Components
Hopper
The hopper is a hinged, upright, 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 TEFC 1800 RPM motor set on an adjustable sliding base that is mounted at the right side of the granulator. A belt guard shields the motor drive sheave, rotor sheave and belts.
Discharge System
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 floor mounted airveyor type supporting the cutting chamber on its top surface and the airveyor chute from below the top surface. This base should be fastened securely to the surface beneath it.
C Series Granulators Functional Description 11 of 53
2-4 Safety Features
Zero Speed Sensor
The zero speed sensor detects the motion of the rotor assembly. The sensor is interlocked to the control circuits of the two machine jackscrews. If the rotor is turning, then the jackscrews should not operate. Check the zero speed sensor periodically for proper operation.
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.
Figure 1 shows some of the bolts, interlocks, and limit switches you may need to adjust during maintenance. Refer to this diagram while performing the maintenance procedures.
Safety Tags
A set of metal plates is attached to the machine to warn of potential danger.
C Series Granulators Functional Description 12 of 53
Figure 1: Safety Features, Interlocks, and Limit Switches
C Series Granulators Installation 13 of 53
Chapter 3: Installation
3-1 Uncrating the Equipment
As shipped, the granulator, motor assembly, motor drive assembly, and hopper are securely bolted onto separate skids and covered with a wooden crate. The electrical cabinet, an optional item, is similarly packaged when ordered. 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 granulator’s weight 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.
We recommend that the machine be lagged to the floor using the through-holes provided in the base plate. Vibration isolation pads may be mounted between the base plate and the flooring.
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.
If inspection after shipment has revealed no shipping damage, unpack the unit by removing all hold-downs, tie-downs, bolts, nuts, etc. Remove the envelope with the electrical schematics and instruction manual from the base evacuation area.
You can now have the machine lifted from the skid. 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.
C Series Granulators Installation 14 of 53
3-2 Assembling the Motor Base Plate
Use the following procedure to assemble the motor base plate:
1. Move the motor base plate into position, as shown in Figure 2.
2. Use the two connecting plates (part number 53253) with the hardware supplied to
fasten the two base plates.
3. Check that the motor base plate is level and resting firmly on the floor.
4. Lag the motor base plate to the floor through the holes provided.
Note: Vibration isolation pads may be used between the base plate and the floor.
Figure 2: Motor Base Plate
3-3 Attaching the Drive Parts
Use the following procedure to attach the drive parts:
1. Attach the motor sheave cover with the hardware supplied.
2. Slip the belts into the grooves, one at a time, making sure that the motor base has
been adjusted enough to allow the belts to be installed without danger of overstressing them by forcing them over the edges of the V-grooves.
3. Tension the drive belts as instructed in Section 5-10 on page 35.
Note: Belt drives should initially be tensioned at the “run-in” recommended force.
Check the tension at least twice during the first two days of operation. After the belts have seated themselves in the sheave grooves and the initial stretch is removed, re-tension the belts to “normal running” and check periodically to maintain tension at the recommended value.
4. Fasten the guard cover over the drive.
3-4 Installing the Infeed Hopper
When installing the infeed hopper, check the weight of the hopper and make sure to size the hoist and accessories accordingly. Use the following procedure to install the hopper:
1. Thread two 3/4-16 UNF eyebolts into the two tapped blocks at the top of the hopper.
2. Run strapping or chains of appropriate lifting capacity to the eyebolts.
3. Use a hoist of appropriate capacity to lift the hopper into position.
4. Fasten the hopper to the upper cutting chamber using the hardware supplied.
C Series Granulators Installation 15 of 53
3-5 Electrical Connections
Before operating the granulator, it is extremely important that the machine is correctly wired into the plant power source by a licensed electrician. All electrical equipment must be properly grounded in accordance with local and national codes to protect personnel from electrical shock. A fusible, lockable disconnect between the plant power source and the machine electrical cabinet is highly recommended.
To wire the granulator, run power from the plant source through a lockable, fusible disconnect to the machine electrical control panel. From the main electrical control panel, make the necessary control circuit connections to the jackscrew control panel, main drive motor, and any auxiliary motors or connections.
To wire the jackscrew motors, run power from plant source through a fusible disconnect to the machine-mounted jackscrew control panel. Wiring from the jackscrew control panel to the safety switches, zero speed sensor, cutting chamber jackscrew and screen cradle jackscrew is done at the factory.
Refer to the wiring diagram on page 50 for wiring connections for typical machine applications. Check the wiring diagram supplied for any wiring that is specific to your application.
Use the following procedure to complete the electrical connections:
a. Check to be certain that the starter heater elements correspond with the
motor requirements. If controls are not supplied, the limit switches supplied on the machine must be wired into the circuit at the common terminal box.
b. Check that the limit switches are closed.
c. Turn the switch on at main power supply.
d. Jog the motor by pressing the Start and then the Off button. This starts
and stops the motor.
e. With the electrical power on, check that the motor rotates in a clockwise
direction at the viewing port in the belt guard. If motor rotation is correct, continue to the next step. If rotation is incorrect, complete the following procedure:
a. Shut power OFF and disconnect incoming power supply.
b. Reverse any two of the three power line connections to the machine.
c. Re-connect the incoming power supply line and turn ON the main power
switch to recheck motor drive rotation.
f. Press the Airveyor START button, and check the blower motor rotation.
The blower motor should rotate in a counterclockwise direction. If blower motor rotation is correct, continue to step g. If blower motor rotation is incorrect, complete the following procedure:
d. Shut power OFF and disconnect incoming power supply line.
e. Reverse any two of the three power line connections to the blower motor.
f. Re-connect the incoming power supply line, and recheck the blower motor
rotation.
g. Allow all motors to run up to speed for at least 30 seconds.
C Series Granulators Installation 16 of 53
3-6 Accessing the Cutting Chamber
You will need to access the cutting chamber before initial startup and for various maintenance procedures. Before accessing the cutting chamber, make sure no one is near the jackscrew or hopper. The jackscrews should not operate until the rotor is completely stopped. If the jackscrews do operated while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it.
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. Unscrew the cutting chamber interlock actuator screw with a box wrench or ratchet
wrench. Make sure the end of the interlock actuator screw is visible and clear of any contact. When disengaged, the interlock opens the electrical control circuit to the motor and prevents the machine from running.
3. Turn the cutting chamber hold-down fasteners counterclockwise to remove them, and
place them on the lip of the upper cutting chamber.
4. Start the cutting chamber jackscrew from the jackscrew control panel by turning the
CC/Hopper switch to the “Raise” position and pressing the button in the center of the switch. Hold the button until the hopper stops, and then release the button and return the switch to the off position.
Caution! Allow the jackscrew motor to come to a complete stop, and wait at least 5
seconds before reversing the motor. The jackscrew and other components may be severely damaged if the jackscrew motor is reversed before it has completely stopped.
5. Position the rotor so that a blade is at the top center, and lock the rotor by inserting
the rotor locking pin into the hole on the right side bearing housing.
Note: Apply light pressure against the pin while turning the rotor toward you
approximately 10 degrees. The pin will drop into the hole when it is properly aligned.
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