Tangential Feed 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
Safety Switches.................................................................................................. 11
Safety Tags........................................................................................................ 11
CHAPTER 3: INSTALLATION................................................... 12
3-1 Uncrating the Equipment.......................................................................................... 12
3-2 Electrical Connections.............................................................................................. 13
3-3 Accessing the Cutting Chamber ............................................................................... 14
3-4 Closing the Cutting Chamber ................................................................................... 15
3-5 Initial Start-up........................................................................................................... 16
CHAPTER 4: OPERATION........................................................ 17
4-1 Start-up.................................................................................................................... 17
4-2 Feeding the Granulator ............................................................................................ 17
4-3 Clearing a Jammed Cutting Chamber....................................................................... 18
4-4 Shut-down ............................................................................................................... 18
CHAPTER 5: MAINTENANCE .................................................. 19
5-1 Preventative Maintenance Schedule......................................................................... 19
5-2 Accessing the Hopper Clean-Out Area ..................................................................... 19
5-3 Lubrication ............................................................................................................... 20
5-4 Testing the Interlock Switches.................................................................................. 20
5-5 Replacing and Adjusting the Knives ......................................................................... 21
Knife Gap Settings ............................................................................................. 21
Rotor Knives ...................................................................................................... 22
Bed Knives......................................................................................................... 23
5-6 Sharpening the Knives ............................................................................................. 24
Rotor Knife Sharpening ...................................................................................... 24
Bed Knife Sharpening ........................................................................................ 24
Tangential Feed Granulators iv
Adjusting Belt Tension........................................................................................................ 25
5-8 Motor Drive Belt Replacement.................................................................................. 26
CHAPTER 6: TROUBLESHOOTING ........................................ 27
6-1 Introduction.............................................................................................................. 27
6-2 Electrical Faults ....................................................................................................... 28
6-3 Processing Faults .................................................................................................... 29
6-4 Mechanical Faults .................................................................................................... 30
CHAPTER 7: APPENDIX........................................................... 31
7-1 Customer Satisfaction Warranty Program................................................................. 31
7-2 Drawings and Specifications (including Options)....................................................... 32
Features ............................................................................................................ 32
Specifications..................................................................................................... 32
Dimensions ........................................................................................................33
7-3 Illustrated Parts Breakdown...................................................................................... 34
Parts Identification Table .................................................................................... 35
7-4 Spare Parts List ....................................................................................................... 36
7-5 Typical Wiring Diagram ............................................................................................ 38
7-6 Technical Assistance ............................................................................................... 39
Parts Department ............................................................................................... 39
Service Department............................................................................................ 39
Sales Department .............................................................................................. 39
Tangential Feed Granulators Safety 5 of 39
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.
Tangential Feed Granulators Safety 6 of 39
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.
Tangential Feed Granulators Safety 7 of 39
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.
Tangential Feed Granulators Safety 8 of 39
˛ 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.
Tangential Feed Granulators Functional Description 10 of 39
2-3 Typical Features and Components
Hopper
The hopper is a hinged, upright, enclosure with sound dampening. 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.
Tangential Feed Granulators Installation 12 of 39
Chapter 3: Installation
3-1 Uncrating the Equipment
The granulator is securely bolted onto a skid and fully covered with a wooden crate.
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.
Tangential Feed Granulators Installation 13 of 39
3-2 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.
The standard granulator is pre-wired to the remote motor control enclosure before shipment
and the only wiring required is a main power line to the electrical panel.
Refer to the wiring diagram on page 37 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:
1. 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.
2. Check that the limit switches are closed.
3. Turn the switch on at main power supply.
4. Jog the motor by pressing the Start and then the Off button. This starts and stops the
motor.
5. 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.
6. 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 7. If blower motor rotation is incorrect, complete the
following procedure:
a. Shut power OFF and disconnect incoming power supply line.
b. Reverse any two of the three power line connections to the blower motor.
c. Re-connect the incoming power supply line, and recheck the blower motor
rotation.
7. Allow all motors to run up to speed for at least 30 seconds.
Tangential Feed Granulators Installation 14 of 39
Granulate Deflector
Screens
Screen Cradles
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.
8. Unscrew the cutting chamber interlock actuator screw. Back the screw out as far as it
will go. When unscrewed, the interlock will still be captive on the door to prevent
loss.
9. Lift the hinged safety flap up.
10. Open the enclosure doors, exposing the screen cradles and granulate deflector. (See
Figure 2.)
11. Slide out the granulate deflector and set to one side.
12. Loosen the 2 cradle mounting screws, and remove them one at a time. When
removing the second screw, hold the cradle with one hand to prevent it from falling.
Note: Each cradle has different length screws, the longest one being to the left. This
is because the screws are held by the bed knife clamp, which tapers in
thickness.
13. Pivot the cradles down until they rest on the machine base or floor.
14. Remove the screens by rotating them out of the screen cradle pocket and lifting them
straight out.
15. Remove the screen cradles by unhooking the slotted ends from the cradle pivot rod
and lifting them out of the machine.
Figure 2: Granulate Deflector and Screens
Tangential Feed Granulators Installation 15 of 39
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. Replace the screen cradles by hooking the slotted ends onto the cradle pivot rod.
2. Replace the screens into the screen cradles by pushing the furthest end (bottom edge)
into the pocket of the screen cradle.
3. Pivot the cradles up and assemble the 2 cradle mounting screws while holding the
cradle in place with one hand. The bolting surface of the cradle should touch the bed
knife clamp without any interference.
4. Tighten the cradle mounting screws evenly and torque to 315 Nm (230 lbs. ft.).
5. Rotate the rotor backwards to be sure there is no binding.
6. Replace the granulate deflector
7. Close the enclosure doors.
8. Close the hinged safety flap and press down when while turning the interlock screw.
9. Tighten the interlock screw as far as it will go.
10. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
Tangential Feed Granulators Installation 16 of 39
3-5 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 described in Section 3-3 on page 14.
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. Check all rotor knives to make sure they are properly seated on the rotor and securely
fastened. Although they are ground as a set, one knife will probably be .001” to .002”
higher than the others. This should be marked and used when adjusting the bed
knives for proper clearance.
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. Check the knives on each end only.
Proper clearance is 0.15 mm (0.006”). This clearance is slightly greater at the center
of the knives.
Note: Recheck knife clearance after the first 24 to 36 hours of operation.
5. To make the adjustment on 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 bed knife
screws to 271 Nm (200 lbs./ft.) and the rotor knife screws to 315 Nm (230 lbs./ft.).
Note: All screw tightening torque figures are for un-lubricated thread conditions.
Screw threads should be wiped with an oil-dampened cloth before installation
to prevent galling.
6. 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 15.
Note: After initial start-up, the rotor knife retaining screws should be
checked after 8 hours running to be assured that 315 Nm (230 lbs./ft.).
Of 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.
Tangential Feed Granulators Operation 17 of 39
Chapter 4: Operation
4-1 Start-up
Before starting the machine, check that the rotor rotates freely by rotating it by hand from
outside the machine using either the coupling or the sheave depending on the type of drive.
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 12-16 for detailed set-up instructions. 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. The 20” x 24” model is rated at 1400 lbs./hr (636 Kg/hr), and the 20” x 36” model
is rated at 2000 lbs./hr (907 Kg/hr). 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.
Tangential Feed Granulators Operation 18 of 39
4-3 Clearing a Jammed Cutting Chamber
Never attempt to free a jammed machine by placing hands on the rotor, rotor knives, or inside
the cutting chamber. Hands must be kept clear of the rotational path of the rotor knives.
Good footing on a clean floor is essential and the body should be well braced to guard against
loss of balance should the jam suddenly come free. Use the following procedure to clear a
jammed cutting chamber:
1. Disconnect and lock out power.
2. Be certain that the rotor is motionless.
3. Open the machine as instructed in Section 3-3 on page 14.
4. Use a pry bar to exert force on the rotor, usually in the direction opposite normal
rotation. A leather mallet and a block of wood of sufficient length to keep hands
away from path of knives can be used if necessary.
5. Use pliers to remove material from the cutting chamber, keeping in mind that the
removal of material may cause rotation of the rotor and rotor knives.
6. After clearing the jam, be certain that the screen and all guards and covers are
secured in place before connecting power and starting the machine.
4-4 Shut-down
Use the following procedure to properly and safely shut down the machine:
1. Stop all feeding of material.
2. Allow the granulator to run until the cutting chamber is completely empty.
3. Press the drive motor “stop” button. This shuts off the rotor drive motor.
4. After the granulator has stopped, press the airveyor stop button (if applicable) located
at the blower motor.
5. Turn the main power switch to off.
Tangential Feed Granulators Maintenance 19 of 39
Chapter 5: Maintenance
5-1 Preventative Maintenance Schedule
Check
Frequency
Check tightness of cutting chamber hold-down fasteners
(Refer to Section 3-3 on page 14)
Daily
Check the tightness of screen cradle mounting screws
(Refer to Section 3-3 on page 14)
Daily
Check infeed flap position/condition (replace if necessary)
Daily
Check position and condition of interlock actuator screws
Daily
Do housekeeping around work area
Daily
Check knife clearance and wear.
(Refer to Section 5-5 on page 23)
Weekly
Check that rotor and bed knife bolts have proper torque
(Refer to Section 5-5 on page 23)
Weekly
Check lubrication. More frequent lubrication may be required
(Refer to Section 5-2 on page 19)
Monthly
Check belt tension (Refer to Section 5-7 on page 25)
Monthly
5-2 Accessing the Hopper Clean-Out Area
Use the following procedure to access the hopper clean-out area:
1. Turn the main power off, remove the line fuses, and tag the machine as out of
service.
2. Unscrew the hopper clean-out interlock screw. Back the screw out as far as it will go.
When unscrewed, the interlock will be captive on the door to prevent loss.
3. Remove the 6 cap screws at the top rim of the door. When removing the last screw,
hold the door with one hand to prevent it from falling.
4. Lower the door, and let it rest on the rear panel. Hand-hold cut-outs have been
provided in the upper lip of the door to prevent pinched fingers when the door
touches the rear panel.
Use the following procedure to close the hopper clean-out area:
1. Lift the door up, and hold it in place while hand-tightening the 6 cap screws.
2. Tighten the interlock screw as far as it will go.
3. Replace line fuses, turn power on, and remove the out of service tag from the
machine.
Tangential Feed Granulators Maintenance 20 of 39
5-3 Lubrication
The rotor bearings are self-aligning, spherical roller bearings that are packed with lubricant at
assembly. Grease fittings are provided for re-lubrication and are located on the right and left
hand panels. Lubricate every 2 months or 1500 hours while the machine is running, with
approximately 56 grams (2 oz.) of grease. Use a lithium-based grease conforming to NLGI
grade #1.
5-4 Testing the Interlock Switches
The cutting chamber and hopper clean-out interlock switches insure that the granulator
cannot be running when the cutting chamber or hopper clean-out area are open. When
disengaged, the interlocks open the electrical control circuit to the motor and prevent the
machine from running.
If an interlock does not work, the complete mechanism, including the switch, must be
removed and disassembled to determine the cause of the malfunction.
With the cutting chamber and hopper clean-out area closed and the power on, use the
following procedure to manually test the interlock switches:
1. Push the start button to start the granulator
2. Retract the cutting chamber interlock actuator screw by turning it counterclockwise.
Make sure that the end of the actuator screw is visible and clear of any contact. The
granulator should stop. If the granulator does not stop, the interlock is not working.
3. Engage the cutting chamber interlock actuator screw by turning it clockwise, and
restart the granulator.
4. Retract the hopper clean-out interlock actuator screw by turning it counterclockwise.
Make sure that the end of the actuator screw is visible and clear of any contact. The
granulator should stop. If the granulator does not stop, the interlock is not working.
5. Engage the hopper clean-out interlock actuator screw by turning it clockwise.
Tangential Feed Granulators Maintenance 21 of 39
5-5 Replacing and Adjusting the Knives
During use, the clearance between the rotor knives and the bed knives will increase due to
wear. This is a normal condition that requires re-setting this clearance once or twice before it
is necessary to remove the knives for regrinding. Check the knives weekly for wear,
clearance, exposure, and screw tightness.
When new knives are fitted to the machine, adjustment after eight hours of running time may
be required.
Before assembling a new or reground set of knives, make sure the knife seats and mounting
holes are clean. Do not use grease or oil on screws or tapped holes when assembling the
knives.
Knives must be replaced in complete sets, otherwise it will not be possible to obtain even
clearance between the rotor knives and bed knives.
WARNING! Place a block of wood within the rotor to prevent it from rotating.
Knife Gap Settings
The standard knife gap setting is between 0.006” (0.15 mm). The standard adjustments and
settings are made prior to shipment, but the machine may require re-adjustment or re-setting
depending on the application.
Set the knife gaps to the high side unless you process thin materials that require closer
settings. If you experience rapid deterioration of the knives, increase the knife gaps in
increments of 0.0002” (0.05 mm) until the performance improves.
For heavy materials, such as heavy section purgings or other heavy cross-sections, you can
set gaps as large as 0.016” to 0.018” (0.41 mm to 0.46 mm).
Tangential Feed Granulators Maintenance 22 of 39
Rotor Knives
We recommend that the rotor knife screws be replaced with new screws every sixth knife
change to reduce the risk of screw failure due to overstretching. Screws must be replaced
with the type specified in the spare parts list. Improper substitution could lead to premature
failure, equipment damage, and serious injury to personnel.
Caution! Rotor knives should be changed one seat at a time to prevent rotor from
being rotated in an out-of-balance condition.
1. Access the cutting chamber as directed in Section 3-3 on page 14.
2. Set back the bed knives to clear the rotor knives so that the rotor can revolve freely.
3. Loosen and remove the rotor knife screws. Make sure you have solid footing while
you apply the breaking force.
Note: These screws are tightened to a torque of 315 Nm (230 lbs./ft.), so make sure
you have the proper breaker bar.
4. Lift the knife off of the rotor.
5. Thoroughly clean the knife seats with a stone or other non-marring tool, and wipe the
screws with a lightly oiled cloth. Do not leave an oil film on the screws, as
lubrication can adversely affect the stress on a screw installed to a fixed torque value.
6. Place each knife section onto the rotor with the chamfered edge facing into the knife
seat, making sure that the backside of the knife is sitting squarely against the back of
the knife seat on the rotor.
7. Lightly tighten the screws and check that a 0.04 mm (0.0015”) feeler gauge will not
pass between the back of the knife and the knife seat. Tap the knife gently with a
rawhide hammer if necessary to close the gap.
8. Tighten the screws evenly and torque the screws to 315 Nm (230 lbs./ft.)
9. Re-check the gap between the back of the knife and the knife seat. If necessary,
readjust the knife.
10. Repeat steps 4 through 9 for each of the remaining knives.
11. Adjust the clearance between the bed knives and rotor knives. (See “Bed Knives” on
page 23.)
Tangential Feed Granulators Maintenance 23 of 39
Bed Knives
We recommend that the same screws and washers be re-used only when the bed knives have
been repositioned or re-ground. When blunt knives are discarded and replaced with new
knives, use new screws and washers. This will reduce the risk of screw failure due to their
overstretching. Screws and washers must be replaced with the type specified in the Spare
Parts List.
1. Access the cutting chamber as directed in Section 3-3 on page 14.
2. Loosen and remove the bed knife screws. Make sure you have solid footing while
you apply the breaking force.
Note: These screws are tightened to a torque of 271 Nm (230 lbs./ft.), so make sure
you have the proper breaker bar
3. Remove the bed knife clamps and mounting screws.
4. With an open-end wrench, back off the bed knife adjusting screws.
5. Replace each bed knife and clamp.
6. Use the adjustment screws to set the knife clearance to 0.15 mm (0.006”). The
clearance should be measured with a feeler gauge at the ends of the knife, by rotating
the rotor sheave backwards by hand. The clearance is slightly greater at the center of
the knives. Check both the upstroke and downstroke knife gaps.
Note: Adjust the knife gradually from end to end. Adjusting one side completely and
then the other side will cause the adjusted side to tip slightly.
7. Tighten all of the mounting screws to a torque of 271 Nm (200 lbs./ft.), and re-check
the knife gap.
Tangential Feed Granulators Maintenance 24 of 39
5-6 Sharpening the Knives
Under normal operating use, the cutting edge of the knives will eventually become dulled,
resulting in reduced cutting efficiency. The blunt knives may either be re-ground to restore
the cutting edge, or replaced with new knives when regrinding is not possible.
Rotor Knife Sharpening
The rotor knife can be re-sharpened to the diagram below. The three knives must be
sharpened to within 0.076 mm (0.003”) of each other. Greater dimensional variations will
cause difficulty when setting the knife gap and create other serious complications.
When sharpening, it is not harmful to allow a few small nicks to remain in the cutting edge.
Grinding the cutting edge until perfectly clean can sometimes be wasteful.
Do not install rotor knives that are smaller than the minimum dimension shown, because the
fasteners that secure these knives will interfere with the cutting circle. If the rotor cannot turn,
the bed knives will be damaged.
Bed Knife Sharpening
Each bed knife is provided with two cutting edges. When the exposed edges become blunt,
the knives can be turned and repositioned to present the new cutting edges. When resharpening is necessary, refer to the diagram below.
It is not necessary to grind bed knives to the closely matched tolerance of rotor knives. As
with rotor knives, small nicks in the cutting edges will not seriously affect knife cutting
efficiency. Bed knives smaller than the minimum dimensions shown must be replaced along
with the fasteners that secure them.
Figure 3: Knife Sharpening Specifications
Tangential Feed Granulators Maintenance 25 of 39
5-7 Adjusting Belt Tension
For continuous reliable operation of the granulator, it is important that the belt tension is
correct. Correct tension reduces wear on rotor and motor bearings and keeps belt slip to a
minimum. Figure 4 gives the recommended force to deflect each belt by an amount equal to
the belt span divided by 64. A gauge is available through the sales department to measure the
deflection and force.
Tension new belts at the maximum run-in force, and check the tension at least two times
during the first two days of operation. There is normally a rapid decrease in the tension until
the belts are run in.
Note: The deflection force value shown must be multiplied by the number of V-belt
elements.
1. Turn off the granulator at the main isolator switch and remove fuses.
2. Remove the left, right, and rear covers to gain access to the belts and motor.
3. Determine the type of belt required from the Spare Parts List on page 36.
4. Determine the force required to deflect one belt 1/64” (0.40 mm) per 1 inch (25.4
mm) of span length.
5. Loosen the motor base slide mount screws and turn the adjusting screw on the base to
tension the belts as required (See Figure 4).
6. Re-tighten the screws, making sure the sheaves are in correct alignment.
7. Replace the covers.
Figure 4: Belt Tensioning Information
Recommended Deflection Force
V-Belt Cross
Section
Small O.D. Range
Run-In
Normal
Running
5V Banded
5.9
2.0
12
*This deflection force value relates to a single V-belt element. Therefore, if the belt is a 3-V
element (3V-banded), this value must be multiplied by 3.
Deflection = Belt Span
64
Belt Span=37”
Tangential Feed Granulators Maintenance 26 of 39
5-8 Motor Drive Belt Replacement
If replacement of any V-belt is necessary, you must replace all belts at the same time with a
set of matched belts. To replace the belts, proceed as follows:
1. Turn off the main power and remove fuses.
2. Remove the left, right, and rear covers to gain access to the belts and motor.
3. Loosen the four motor base screws.
4. Turn the adjusting screw on the motor slide base to release all tension from the belts.
5. Remove the belts.
6. Check the pulley alignment as follows:
a. Open the drive pulley access panel.
b. Tug outward on the motor pulley to verify that it is tight on its shaft. If the
motor pulley is loose, tighten it to its shaft after completing the alignment.
c. Check whether the pulleys are parallel by holding a straight edge against the
edge of the large pulley and verifying that it is parallel to the edge of the
small pulley. The straight edge must be placed on the face of the large pulley
closest to the cutting chamber. If the pulleys are not parallel, use the
adjusting screws to make the pulleys parallel.
d. Check the pulley grooves for alignment. Measure the distance from the
straight edge to the first groove in each pulley. If they are not the same, move
the motor pulley to correct the alignment.
7. Install the new belts and proceed to adjust the belt tension as instructed in Section 5-7
on page 25.
8. Tighten down the motor base screws.
9. Replace base panels and guards.
10. Replace the line fuses and turn main power on.
Tangential Feed Granulators Troubleshooting 27 of 39
Chapter 6: Troubleshooting
6-1 Introduction
The utmost in safety precautions should be observed at all times when working on or around
the machine and the electrical components. All normal trouble-shooting must be
accomplished with the power off, line fuses removed, and with the machine tagged as out of
service.
The use of good quality test equipment cannot be over-emphasized when troubleshooting is
indicated. Use a good ammeter that can measure at least twice the AC and DC current that
can be encountered for the machine. Be sure that the voltmeter has at least minimum
impedance of 5,000 OHMS-per-volt on AC and 20,000 OHMS-per-volt on DC scales.
Popular combination meters, VOM and VTVM can be selected to provide the necessary
functions.
Before making haphazard substitutions and repairs when defective electrical components are
malfunctioning, we recommend that you check the associated circuitry and assemblies for
other defective devices. It is common to replace the obviously damaged component without
actually locating the real cause of the trouble. Such hasty substitutions will only destroy the
new component. Refer to wiring diagrams and schematics.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to the parts catalog section.
Tangential Feed Granulators Troubleshooting 28 of 39
6-2 Electrical Faults
Problem
Possible Cause
Possible Remedy
Supply failure
Check fuses
Starter inoperative
Check main supply
Starter overloads or cuts out
Check motor requirements
and adjust accordingly
Motor Fails to Start
Safety switches inoperative
Check and adjust as needed
Too much belt tension
Check belt tension and adjust
as necessary
Incorrectly connected motor
Check terminal connection
with manufacturer’s
connection diagram and
adjust as necessary
Motor starts but will not take
load
Defective starter winding
Check current in each phase
with ammeter, if there is a
marked difference in current
in one phase, contact motor
manufacturer
Motor will start when
disconnected from load but
not when connected
Worn bearings
Check and replace if
necessary according to
manufacturer’s literature
Tangential Feed Granulators Troubleshooting 29 of 39
6-3 Processing Faults
Problem
Possible Cause
Possible Remedy
Overfeeding
Reduce feed rate
Partial or complete screen
blockage
Remove screen, clear and
inspect for damage
Insufficient tension on v-belt
drive causing belt slip and
burning
Check tension of the belt and
adjust as necessary
Check that the motor slide
base screws are secure
Badly blunted or damaged
knives
Fit re-sharpened or new
knives as required
Knife setting too wide
Check clearances given and
adjust as required
Installation fault; motor
running in reverse direction
Check with direction arrow
and re-fit electrical
connections to give the
correct direction
Stalling
Safety switch cut out where
fitted
Tighten safety switch setting
screw
Check all possible causes
under “stalling”
Remedy as shown above
Screen size too small
Increase screen size
When granulating rubber,
insufficient talc causes
freshly cut surfaces to readhere
Increase talc percentage rate
of infeed
Material overheating
Blockage in aiveyor
Check direction of fan
rotation, check venturi and
line or chute for blockage
Tangential Feed Granulators Troubleshooting 30 of 39
6-4 Mechanical Faults
Problem
Possible Cause
Possible Remedy
Excessive tension on the belt
drive
Check tension of belt and
adjust as necessary
Bearing overheating
Lubrication fault
Check lubrication frequency
and recommended lubricant
Visible cracks in knife
Incorrect grinding or
grinding procedure
Check method of grinding
and contact our technical
sales department
Uneven knife seat surfaces
Clean up to provide
maximum bearing surface
Knives moving on knife
seats
Loose knife screws
Knife screws should not be
used more than six times.
Replace if there is evidence
of stretch
Knives breaking
Cracks caused by incorrect
grinding
Contact our technical sales
department
Excessive knife wear
Open knife setting
Re-set knives
Screen breakage
Incorrectly seated screen
Check that the screen is
seated correctly and fully in
its cradle
Tangential Feed Granulators Appendix 31 of 39
Chapter 7: Appendix
7-1 Customer Satisfaction Warranty Program
The terms and conditions of the warranty set forth are for one (1) year from the original date
of purchase by the original purchaser.
The manufacturer warrants to the original purchaser the product and/or goods to which this
disclaimer is attached, and manufactured by us, to be free from defects in material and
workmanship under normal use and service. THIS WARRANTY IS EXPRESSLY IN LIEU
OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, AND ALL OTHER OBLIGATIONS AND LIABILITIES ON OUR PART.
This warranty shall not apply to any goods or product manufactured by us which has been
subject to accident, negligence, alteration of any kind, abuse, or misuse. We further make no
warranty whatsoever in respect to accessories or parts not supplied by us. Any warranty of
any nature shall apply only to an “original purchaser” which shall be deemed to mean that
person or entity for whom the goods and/or product were originally ordered and installed.
We neither assume nor authorize any person to assume for us any liability in connection with
the sale or use of the products and goods sold hereunder, and shall not be responsible for
damages for which a purchaser may be liable to other persons, damages to property, or
injuries to any other persons.
Our sole obligation under this warranty shall be limited to replacing, repairing, or exchanging
any part or parts of goods and/or products sold which we determine are defective under
normal use and service within one (1) year of date of installation by the original purchaser.
We shall not be liable for any loss or damage resulting directly or indirectly from the use or
loss of the goods and/or products purchased. In no event shall we be liable for any general,
direct, consequential, incidental, or special damages of any kind.
We do not warrant any of our products that are installed in other machines or apparatus as
meeting requirements of any safety code of any nature. The purchaser assumes all risks and
liabilities resulting from the installation and use of product sold by us in combination with
other machines or apparatus.
We warrant our product to be of the kind and quality quoted, and no other warranty except of
title shall be implied. Our company shall repair or replace, at our discretion, any
manufactured item on your granulator without charge FOB factory, within one (1) year after
date of original purchase, which is proved to be defective when shipped. Claims for labor or
consequential damages are not allowed.
Excluded from the above are knives, screens, and belts. Purchased items, including electrical
components, motors, etc., shall carry the warranty of the supplier and no extension of that
warranty is allowed.
Refer to this manual for assistance in installing and maintaining a highly efficient machine.
Questions regarding areas that are not covered in the manual should be referred to the
customer service manager at the factory at (800) 229-2919.
Tangential Feed Granulators Appendix 32 of 39
7-2 Drawings and Specifications (including Options)
Features
Model
Throat Size
Cutting
Circle
Diameter
Throughput
Approximate
Weight
2024
20” x 24”
(508 x 610 mm)
20” (508 mm)
1400 lbs./hr. (630 kg.)
5,200 lbs. (2363 kg.)
2036
20” x 36”
(508 x 914 mm)
20” (508 mm)
2000 lbs./hr. (907 kg.)
7,000 lbs. (3221 kg)
Specifications
2024
2036
Standard
Standard
Options
Standard
Standard
Options
Infeed
Tray/Conveyor
feed, sound
treated
Tray feed, sound
treated
Conveyor feed
Cutting
Chamber
Tangential 2-bed
knives
Tangential 2-bed
knives
Rotor
Open 3-knife
slant cut
Open 3-knife slant
cut
Rotor
Knives
3 HCHC, 55° (2
pcs)
3 HCHC, 55° (3
pcs)
Bed Knives
2 HCHC, 2 edge
reversible (2 pcs)
2 HCHC, 2 edge
reversible (3 pcs)
Screen
5/16”, dropdown, pull-out (2
pcs)
3/8” and larger
5/16”, drop-down,
pull-out (3 pcs)
3/8” and larger
Base
Sound enclosed,
fork lift
Sound enclosed,
fork lift
Discharge
6” Airveyor
chute
8” Airveyor chute
Motor
30 HP, TEFC,
1800 rpm,
3/60/230/460
40 HP, 50 HP
40 HP, TEFC, 1800
rpm, 3/60/230/460
50 HP, 60 HP
Drive Parts
V-belt, single
flywheel
Dual flywheel
V-belt, Dual
flywheel
Electrical
Components
NEMA 12 with
safety interlocks
Diagnostic panel
NEMA 12 with
safety interlocks
Diagnostic
panel
Controls
230 or 460 volt
230 or 460 volt
Labels
Safety/caution/op
eration
French/Spanish
Safety/caution/oper
ation
French/Spanish
Accessories
Blower,
Separator, Stand
Blower, Separator,
Stand
Nonsoundproofed
Tangential Feed Granulators Appendix 33 of 39
Dimensions
Model
ABC
20 x 24
24” (609.6 mm)
52 5/8” (1336.7 mm)
6” (152.4 mm)
20 x 36
36” (914.4 mm)
62 5/8” (1590.7 mm)
8” (203.2 mm)
Tangential Feed Granulators Appendix 34 of 39
7-3 Illustrated Parts Breakdown
Tangential Feed Granulators Appendix 35 of 39
Parts Identification Table
This table refers to the diagrams on the previous pages.
Item
Qty
Material
12Plate-End
22Block-Knife
31Rotor-3 Knife (w/carriers)
41Cover-Top-Cutting Chamber
52Retaining Ring
61Deflector-Cutting Chamber
72Housing-Bearing
81Cap-Bearing-Drive End
92Bearing-Roller-Spherical Self-Aligning
101Cover-Bearing
1116Screw-Hex HD CAP-MS-M16
1228Washer-Lock-MS-M16
136Screw-Hex HD CAP-MS-M10
1412Washer-Lock MS-M10
156Screw-Hex HD CAP-MS-F/THD-M10
168Pin-Dowel-ASHT-20MMX50MM
176Screw-Hex HD CAP-MS-M12
1812Washer-Lock-MS-M12
196Screw-Hex HD CAP-MS-M12
2016Screw-Hex HD CAP-MS-M16
26
2 or 3
Cradle-Screen
271Rod-Pivot Cradle
282Ring-Retaining-External
292Clamp-Knife-Bed –1
302Clamp-Knife-Bed –2
312Clamp-Knife-Bed –3
3212Screw-SQ HD SET-MS-M8
332Screw-Hex HD CAP-MS-M16
3430Washer-Flat-21/32IDX1-3/8ODx3/16T
3524Screw-Hex HD CAP-MS-M16
36
18 or 27
Screw-Hex HD CAP-HT-F/THD-M16
371Support-Door-Enclosure-RH
381Support-Door-Enclosure-LR
3914Screw-Hex HD CAP-MS-M10
4014Washer-Lock-MS-M10
412Fitting-Lub-1/8NPT-STR-9/16
422Tubing-Nylon-1/4OD-REF.44P
434Fitting-Compression-Connector-Male-Brass-1/4 OD Tube
442Screw-Hex HD CAP-MS-M16
452Screw-Hex HD CAP-MS-M16
462Shim-Support-(Door/Enclosure)
Tangential Feed Granulators Appendix 36 of 39
7-4 Spare Parts List
Quantity
Item
Material Specifications
20 x 24
20 x 36
Rotor Knives
(Depending on Rotor)
HCHC
6
9
Rotor Knife Screws
(Depending on Rotor)
Grade 8
18
27
Rotor Bearings
2
2
Bed Knives
HCHC
4
6
Bed Knife Screws
Grade 8
16
24
Bed Knife Washers
Case Hardened
16
24
Screens
Mild steel, 5/16 dia. Hole standard
2
3
Drive Belts
5V x 1120
3-5
5
Tangential Feed Granulators Appendix 37 of 39
7-5 Recommended Torque for Screws
(Grade 10.9 fine thread screws in un-lubricated conditions)
Screw Size
M8
M10
M12
M14
M16
M18
M20
M24
Torque NM.
3873135
210
315
460
640
860
Torque Ft. Lbs.
2854100
155
232
340
472
810
Note: Threads must be dry. Screw threads should be wiped with an oil-dampened
cloth before installation to prevent galling.
Tangential Feed Granulators Appendix 38 of 39
7-6 Typical Wiring Diagram
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