AEC MTF 3000 User Manual

Model MTF3030 & MTF3045

Granulators

Operation & Instruction Manual

We thank you for your purchase of a Colortronic granulator. We feel certain that you will have excellent results with this machine, along with trouble-free operation.

When the machine arrives at your plant, inspect it carefully for shipping damage before uncrating and immediately report any damage to your transportation company. All shipments are F.O.B. South Attleboro, Massachusetts.

Colortronic warrants that its products shall 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 which is proved to be defective when shipped without charge F.O.B. factory, within one (1) year after date of shipment. Claims for labor or consequential damages will not be allowed.

Excluded from the above are knives, screens, and V-belts. Purchased items, including electrical components, motors and etc., shall carry the warranty of the supplier and no extension of that warranty will be allowed.

This warranty shall be voided if the machinery is used for other than its intended purpose or if the machine has not received recommended maintenance attention.

Refer to this Operation, Service, and Maintenance 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 factory for reply.

GRANULATOR SAFETY RULES 4

1.0 INTRODUCTION 6

1.1 Scope 6

1.2 General Description 6

2.0 INSTALLATION 8

2.1 Scope 8

2.2 General 8

2.3 Shipping 8

2.4 Unpacking 8

2.5 Set Up 9

2.6 Electrical Service Connections 10

3.0 PRE-OPERATIONAL PROCEDURES 11

3.1 Scope 11

3.2 Electrical Test 11

3.3 Pre-Operational Checklist 12

4.0 ELECTRICAL SYSTEM NOTES 13

4.1 Start-Up or Operation Problems 13

5.0 OPERATING INSTRUCTIONS 14

5.1 Operating Instructions 14

6.0 GRANULATOR TROUBLESHOOTING 15

6.1 Investigating Causes 15

6.2 Suggested Actions 15

7.0 MOTOR AND BELTS - SERVICE INSTRUCTIONS 17

7.1 Procedure 17

Figure 1 Belt Span and Deflection 18 Table 1 - Belt Deflection Force 18

8.0 KNIFE RECOMMENDATIONS AND ADJUSTMENTS 19

8.1 Knife Removal and Adjustment Procedure 19

8.2 Rotor Knife Removal 19

8.3 Rotor Knife Installation Procedure 20

8.4 Bed Knife Installation and Setting Procedure 20

9.0 RECOMMENDED TORQUE FOR KNIFE BOLTS 22

10.0 PROCEDURE TO OPEN/CLOSE THE SCREEN CHAMBER 23

10.1 Procedure to Open Screen Chamber 23

10.2 Procedure to Close the Screen Chamber 23

11.0 FANS/BLOWERS - PNEUMATIC EVACUATION 24

11.1 Description 24

11.2 Pre-Operational Checklist 24

11.3 Troubleshooting and Suggested Actions 24

11.4 Bearing Lubrication 25

11.5 Belt Adjustment Procedure 25

11.6 Spare Parts 25

12.0 RECOMMENDED SPARE PARTS 26

13.0 LUBRICATION SPECIFICATIONS 27

13.1 Description 27

13.2 Recommended Grease Product Names 27

14.0 PROCEDURE TO OPEN HOPPER DOOR, EXTENDED FEED UNITS 28

14.1 Procedure 28

Granulator Safety Rules

The Colortronic granulator has been designed and constructed to provide the highest possible degree of safety for the operator and service personnel. However, the nature of the machine demands strict attention to the following safety requirements.

ΗΗΗΗΗΗΗ DANGER ΗΗΗΗΗΗ

All operating and service personnel must comply

with the safety requirements contained in this

manual as well as your company’s safety policies

and procedures. Failure to do so can result in

serious bodily injury or death.

1. BEFORE OPERATING THE MACHINE, read and understand all company safety

and operating procedures, and all safety requirements and operating instructions contained in this manual.

2. LEARN AND COMPLY WITH your company’s policies and procedures regarding the

processing of materials.

3. OBSERVE all DANGER, WARNING, CAUTION and SAFETY LABELS on the

equipment.

4. WEAR SAFETY GLASSES OR A FACE SHIELD AT ALL TIMES WHEN

OPERATING OR SERVICING THE GRANULATOR. The nature of material size reduction causes extreme turbulence of the granulated material in the cutting chamber. Flyback can propel particles at high velocity which can cause severe eye injury if not protected. Although our machines are designed for the maximum in flyback control, CAUTION must be used when operating near the area of the hopper feed opening in order to guard against unexpected material flyback.

5. EAR PROTECTION MAY BE REQUIRED when granulating certain hard or noisy

materials. Follow the guidelines established in The Occupational Safety and Health Act of 1970 contained in OSHA 1910.95, Permissible Noise Exposure.

6. WARNING - DO NOT

AREA WHILE THE MACHINE IS OPERATING. SEVERE INJURY OR DEATH CAN RESULT FROM BEING CAUGHT BY THE KNIVES. In addition, flyback of material being granulated can have sharp edges which can injure the face, hands and arms.

7. NEVER WEAR loose fitting clothes, neckties or jewelry when operating the granulator.

Operators with long hair must either tie the hair back or confine it with a hair net.

8. NEVER lean on or rest your hands or feet on the granulator when it is operating.

NEVER climb on the granulator when it is in operation or is open for service. NEVER stand on the granulator when it is operating.

9. NEVER attempt to operate the granulator unless it is fully assembled with all guards and

interlocks in place and functional.

REACH INTO THE INFEED HOPPER OR DISCHARGE

10. KEEP THE WORK AREA AROUND THE UNIT CLEAN AND UNCLUTTERED at all

times. Never leave maintenance tools or other metal objects on the machine that could fall into the cutting chamber. This could cause damage to the machine.

11. DISCONNECT AND LOCK OUT ELECTRICAL POWER BEFORE OPENING ANY

AREA OF THE MACHINE FOR CLEANING OR MAINTENANCE.

12. NEVER RELY SOLELY ON SAFETY LIMIT SWITCHES. (Limit switches are

provided to remove power from the machine if the unit is opened inadvertently.)

13. NEVER BYPASS SAFETY LIMIT SWITCHES. Mechanical and electrical interlocks

are provided for the safety of personnel and must never be tampered with for any reason.

14. FOLLOWING MAINTENANCE OPERATIONS, CHECK THAT ALL SAFETY

GUARDS AND COVERS ARE IN POSITION AND PROPERLY SECURED BEFORE APPLYING POWER TO THE MACHINE. Check that all fasteners are in place and fully tightened.

15. NEVER MODIFY THE MACHINE, its configuration or any of its components without

first consulting Cumberland Engineering

16. ROTATION OF MOTORS: All rotating items in the granulator are clearly marked on the

machine. Always check for correct rotation of the motor(s) before operating.

17. ELECTRICAL GROUNDING: All electrical equipment associated with the granulator

must be grounded in accordance with all local codes and Article 250 of the National Electric Code.

18. SHORTCUTS CAN INJURE PEOPLE AND EQUIPMENT!

19. READ the following document for further information on granulator safety, installation

and operation: American National Standard for Plastic Machinery - Granulators, Pelletizers and Dicers Used for Size Reduction of Plastics - Construction, Care and Use; ANSI B151.11-1982.

Colortronic has long recognized the importance of safety and has designed and manufactured it’s equipment with operator safety as a prime consideration. As a user, we expect you will abide by the foregoing recommendations in order to make operator safety a reality.

SAFETY IS NO ACCIDENT

1.0 Introduction

1.1 Scope

This manual is intended to be used as a guide and reference for personnel who will be installing, operating and maintaining the Colortronic MTF3000 Series Granulators. The purpose is to aid these individuals in applying efficient, proven techniques which will enhance equipment productivity.

This introduction includes a brief functional description, a physical description, and machine specifications for these Granulators. Additional sections within the manual provide instructions for installation, pre-operational procedures, operation, preventative maintenance, and corrective maintenance.

Installation instructions include all required data for receiving, unpacking, inspecting, and setup of the granulator. Also included are illustrations which will aid in utilizing techniques to accomplish these tasks efficiently. We can provide the assistance of a factory trained technician, for a nominal charge, who will help in training your operator(s).

Pre-operational instructions include procedures, checks, and adjustments which 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 Section includes a description of electrical and mechanical controls, in addition to information for operating the granulator safely and efficiently.

The Maintenance Section is intended to serve both as a guide for identification and location of most common problems and as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service.

The Spare Parts Section contains a partial list of recommended parts which may require replacement. Refer to the Spare Parts Manual for a comprehensive listing of spares which can be purchased.

1.2 General Description

Colortronic granulators are designed to uniformly and consistently size reduce your scrap. They have been engineered to consistently deliver clean granulate with a minimum of “fines”.

The rotor on which the cutting knives are mounted, is a fabricated, steel unit supported by bearings mounted outside the cutting chamber. The rotor is driven by a motor which will accept high torque loads, is equipped with a magnetic starter, and is protected by manually resettable overload heaters.

Motors are individually fused for maximum protection in compliance with the National Electric Code.

The control enclosure houses all of the necessary wiring, fuses, overload heaters, motor starter coils, along with the 115V control transformer and granulator operating controls. The control enclosure is built to meet NEC, JIC (M.T.), ANSI-B, and OSHA regulations.

2.0 Installation

2.1 Scope

This section contains all instructions required for experienced installation personnel to install the Colortronic granulator and prepare it for production. It is essential to follow all instructions carefully and in the sequence presented. Be sure to observe all DANGER, WARNING, and CAUTION statements in order to prevent personal injury or machine damage and to observe all NOTE statements which are designed to assist in the performance of procedures.

2.2 General

The site selected for installation of the granulator should be prepared in advance. Be certain that the area to be occupied by the machine is clean, level, and free of obstructions. The site selected must have a floor rated to easily support the weight of the machine and a concrete floor of 4” minimum in thickness is recommended.

2.3 Shipping

To prepare the granulator for shipment, it is mounted on wooden skids, then blocked and banded to prevent movement. All non-painted items subject to corrosion are coated with a quality rust preventative and the machine is then covered with heavy duty polyethylene to protect it from moisture and dirt.

Colortronic granulators are normally shipped completely assembled unless the size of the machine or an agreement for special shipping arrangements causes partial disassembly.

2.4 Unpacking

NOTE: When the machine arrives at your plant, inspect the crate carefully for shipping damage BEFORE uncrating. Report any damage immediately to the transporting company that delivered it. Sign the freight bill -- noting the damage.

If inspection revealed no shipping damage, unpack the unit by removing the outer crate and then removing the banding and polyethylene protective covering. Attached to the machine will be an envelope containing “Installation Instructions”. The usual contents of this envelope are Floor Plan, Parts List, Motor Instruction Manuals, Assembly Drawings, Electrical Diagrams, and a copy of this manual.

The machine may now be lifted from the skid. A fork lift is ideal for the purpose, but care must be taken to properly position the forks between the base foot pads, from the front (door side) of the machine.

DO NOT ATTEMPT TO LIFT THE GRANULATOR BY MEANS OF ANY SHAFT OR

PROTRUDING MEMBER, ESPECIALLY THE HOPPER.

Η Η Η Η Η CAUTION Η Η Η Η Η

2.5 Set Up

Make certain the floor is clean, level, and free of obstructions before placing the machine into position.

Visually inspect the hopper infeed opening to insure that no stray packing material or debris is present.

Open the front doors and remove the fan transition on the front of the screen chamber by releasing the clip fasteners at the top front edge of the chamber. Wipe out the inside of the transition and then place it to one side.

Η Η Η Η Η CAUTION Η Η Η Η Η

The knives mounted on the rotor and also located at the edges of

the cutting chamber are extremely sharp. Always wear heavy gloves

and exercise care when working in the cutting chamber

Carefully inspect the interior of the cutting chamber for foreign material or debris. Slowly turn the rotor by hand to verify that it rotates freely without obstruction or contact between rotor and bed knives. Wipe the inside of the cutting chamber clean. Before closing the screen chamber, check the chamber carefully to insure nothing has been left inside the machine.

Place the screen back into it’s original position and close the chamber securely. Insert all bolts initially removed and tighten them fully.

Replace the fan transition, making sure that nothing has been left inside, and secure it to the screen chamber with the clip fasteners.

Connect the fan transfer tube (optional) to the exhaust side of the transition by inserting it through the transfer tube opening on the side cover of the machine. Fasten it securely with clamps.

Position and connect any optional accessory equipment such as fans, conveyors, and separators. Ensure all tubing joints are securely clamped and supported.

Make certain all electrical connections are properly made and supported between accessories and the control enclosure (refer to the wiring diagram for wire and terminal connections).

Open the sheave guard (LH) by removing the bolts attaching the cover. Check the belts for proper tension and alignment (refer to section 7). Upon completion, close the sheave guard by placing the cover back into position by inserting all of the bolts originally removed and tightening them fully.

Before closing the front doors, recheck all components to insure that they are properly fastened.

+ 19 hidden pages