Sterling BP1018, BP1012 User Manual

$30.

00

Operation and Installation Manual

BP1000 Series Granulators

Models BP1012 and BP1018

Important! Read Carefully Before Attempting to Install or Operate Equipment

Write down your granulator ____________________ ____________________

serial numbers here ____________________ ____________________

for future reference. ____________________ ____________________

Sterling can advise you on proper selection and sizing of systems for your operating

environment.

Sterling is committed to a continuing program of product improvement. Specifications,

appearance, and dimensions described in this manual are subject to change without

notice.

Effective: 9/27/2005

DCN No. __________

© Copyright Sterling 2002

All rights reserved.

Page ii of 53

Sterling Warranty Information

Thank you for your purchase of your new BP1000 Series Granulator. We are confident that you
will have excellent results and trouble-free operation with this machine.

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
FOB South Attleboro, Massachusetts.

Customer Satisfaction Warranty Program for BP1000 Series Granulators:

The terms and conditions of the warranty set forth are for one (1) year from the original date of
purchase by the original purchaser.

Sterling 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.

Page iii of 53

Sterling Warranty Information

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 BP1000 Series 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 [phone].

Page iv of 53

Table of Contents

1 Safety Considerations 9

1-1 Safety Guidelines 9
1-2 Safety Procedures 11

1-2-1 Guidelines for Moving the Granulator 11
1-2-2 Clearing a Jammed Cutting Chamber 11

1-3 Safety Features 12

1-3-1 Safety Features Fitted On the Granulator 12
1-3-2 Opening the Granulator 13
1-3-3 Sound Enclosure 14

2 General Information 17

2-1 Introduction 17
2-2 Using This Manual 17
2-3 Safety Symbols Used in This Manual 18
2-4 Description 18

2-4-1 Technical Data 18
2-4-2 Main Components of Standard Granulators 19
2-4-3 Optional Equipment 19

3 Shipping Information 21

3-1 Unpacking and Inspection 21
3-2 In the Event of Shipping Damage 21
3-3 If the Shipment is Not Complete 21
3-4 If the Shipment is Not Correct 22
3-5 Returns 22
3-6 Uncrating Your Granulator 22

4 Installation 24

4-1 Lifting 24
4-2 Positioning the Granulator 24
4-3 Electrical Connection 25
4-4 Start-Up Checks 26

4-4-1 Checking the Cutting Chamber 26
4-4-2 Checking Rotation Direction 27
4-4-3 Test the Interlock Switches 28
4-4-4 Checking Knife Position 28

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5 Start Up and Operation 30

5-1 Pre-Operational Checklist 30
5-2 Operation 31

6 Maintenance 32

6-1 General Recommendations 32
6-2 Monthly Maintenance Operations 33

6-2-1 Drive Belt Tension 33
6-2-2 Proper Belt Tension 33

6-2-3 Belt Replacement 34
6-3 Removal and Replacement of the Screen 34
6-4 Inspection and Adjustment of Knives 35
6-5 Removing and Replacing Bed Knives 37
6-6 Removal and Replacement of Rotating Blades 38
6-7 Specifications for Resharpening Bed Knives 39
6-8 Specifications for Resharpening Rotor Knives 40

7 Troubleshooting 41

7-1 General Problems 41
7-2 Electrical Problems 43

8 Spare Parts 44

8-1 Table 1: Recommended Spare Parts List 44

9 Typical Wiring Diagram 49

10 Contact Information 50

Page vi of 53

Table of Figures

1.

2.

3.

4.

5.

6.

7.

8.

Safety Switch 13

Control Panel 14

Noise Test Specifications 15

Average Sound Levels 15

Noise Test Method 16

Main Components of Standard Granulators 19

Overall Dimensions and Weights 20

Lifting the Granulator 23

9.

10.

11.

12.

13.

14.

Inserting the Bin 25

Electrical Connections 26

Removing the Screw Knob 27

Checking the Knife Gap 29

Periodic Maintenance Table 32

Belt Tension Chart 34

Page vii of 53

15.

Removing The Screen 35

16.

17.

18.

19.

20.

21.

22.

Inspection of Knives 37

Bed Knife Specifications 40

Rotor Knife Specifications 40

Cutting Chamber - Vertical Cross Section 45

Cutting Chamber - Longitudal Cross Section 46

Cutting Chamber - Front View 47

Cutting Chamber - Rear View 48

Page viii of 53

1 Safety Considerations

1-1 Safety Guidelines

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 which
mistakenly fall into the hopper feed opening can cause severe
damage to internal cutting chamber and screen chamber
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.

Page 9 of 53

 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.

 ROTATION OF MOTORS: All rotating items in the

granulator are clearly marked on the machine. Always check
for proper rotation of motors.

 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 consent from Sterling Corp.

Page 10 of 53

For further information on granulator safety, installation, and
operation, see the American National Standard for Plastics

MachineryGranulators, Pelletizers, and Dicers Used for Size
Reduction of PlasticsConstruction, Care, and Use. ANSI

B151.11-1982.

Sterling has long recognized the importance of safety and has
designed and manufactured its 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.

SAFETY IS NO ACCIDENT

1-2 Safety Procedures

1-2-1 Guidelines for Moving the Granulator

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.

Before lifting, check that there are no items that could fall during
lifting.

Before positioning the granulator, check that the floor is level and
is strong enough to support the load, that there is adequate space in
the installation area to allow the movement of equipment necessary
to the task and to enable any necessary maintenance work to be
carried out unhindered.

1-2-2 Clearing a Jammed Cutting Chamber

1. Disconnect and lockout power.

2. Be certain that the rotor is motionless.

3. Open the front panel and remove the bin.

4. Unscrew the screw knob, which keeps the hopper and screen

cradle in place.

5. Remove the screen.

Page 11 of 53

!! CAUTION !!

NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING HANDS ON

ROTOR, ROTOR KNIVES, OR WITHIN THE CUTTING CHAMBER.

HANDS MUST BE KEPT CLEAR OF THE ROTATIONAL PATH OF THE ROTOR

KNIVES.

A block of wood should be used to exert force on the rotor, usually
in the direction opposite normal rotation.

Good footing on a clean floor is essential and the body should be
well braced when performing this act. Guard against loss of
balance should the jammed conditions suddenly come free.

A leather mallet and block of wood of sufficient length to keep
hands away from the path of knives can be used if required.

Use pliers in removing material from the cutting chamber, keeping
in mind that the removal of material may cause rotation of the rotor
and rotor knives.

After clearing the jam, be certain that the hopper screen, and all
guards and covers are secured in place before connecting power
and starting the machine.

1-3 Safety Features

The granulators are equipped with safety features intended to
protect personnel and the granulator. Do NOT remove or tamper
with such equipment.

1-3-1 Safety Features Fitted On the Granulator

All moving drive parts, including the two pulleys and the belt, are
contained in a guard, which may only be removed using specific
tools and moreover cannot be fixed in the correct position without
special fastenings.

Warning!

Always make sure that the guard is in position before starting the granulator.

Page 12 of 53

Figure 1: Safety Switch

The upper part of the cutting chamber is protected by the feed
hopper, used to insert material to be granulated while the lower
part is protected by the screen, and screen support. These
components are fixed by a screw knob, unscrewing releases a
safety switch key (Figure 1), which cuts off the electric supply to
the motor, causing the rotor to stop.

The method of opening the granulator has been designed to restrict
operator access, allowing the rotor and all moving knives to stop
completely. To allow operator access more quickly could be
dangerous as it might be possible to make contact with the
granulator knives while they are still rotating.

1-3-2 Opening the Granulator

The Start/Stop lighted pushbutton provided on the control panel
(Figure 2) is used to operate the granulator. The button must be
pressed to stop the granulator and pulled out to start.

Before performing any maintenance or opening the granulator,
perform the following procedure:

1. Turn off the granulator using the pushbutton provided.

2. Turn the disconnect switch to OFF and lockout power. (If you

cannot lock out power, remove the power fuses in the control
panel.)

Page 13 of 53

Wear protective gloves when exposed to knives.

Disconnect Switch

Figure 2: Control Panel

Start/Stop Push Button

3. Tag the machine as Out of Service.

4. Make sure the rotor has come to a complete stop.

Warning!

1-3-3 Sound Enclosure

Research has been conducted to assess the noise generated by the
operation of Sound Enclosed Granulator Models BP1012 and
BP1018.

The testing is intended to determine a General Noise Level during
the operation of the granulator. Although the operating noise
levels vary with different processed materials, material
configurations, throughputs, and conveying methods, the
information presented here will give the user an average noise
level that operators may be exposed to.

Reference was made to the following technical regulations to
establish the noise emitted by the machine:

Page 14 of 53

• S.P.I. Noise Test – Noise Measurement Procedure for

Granulators, by the Society of the Plastic Industry.

• UNI7712 – Machine Tools – Determining Noise in the Working

Environment – 1977

• ISO3746 – Acoustics – Determination of Sound Power Level of

Noise Sources – Engineering method for free field conditions
over a reflecting plane – 1981

• ISO3746 – Acoustics – Determination of Sound Power Level of

Noise Sources – Survey method – 1979

• DIN45635 – Measurements of airborne noise emitted by

machines – Enveloping measuring method – 1972.

The technical specifications of the Sound Enclosed Granulator
Models BP1012 and BP1018 (Figure 3) and the test methods used
to establish the noise level generated are described below (Figure

5). Figure 4 gives the mean sound levels Lpm in dB(A) for each
model of machine, as well as an average of the sound levels
measures at the four positions shown on the diagram below.

Figure 3: Noise Test Specifications

Model Motor Power Impeller Speed

BP1012
BP1018

Figure 4: Average Sound Levels

kW Rev./min. Kg/h Kg/h Pcs. No./min. Kg/h

5.5 340 140 105 24 99.5

7.5 340 200 150 36 149.0

Model BP1012 Sound Enclosed Model BP1018 Sound Enclosed

Position Sound Levels in dB(A) Position Sound Levels in dB(A)

1 84.3 1 86.0
2 83.6 2 85.6
3 82.6 3 84.1
4 82.2 4 84.1

Lpm 93.2 Lpm 85.0

Production ∗∗∗∗

75% Production

Test Supply (SPI

Method)

∗ All Granulators provided with 5/16” (8 mm) Diameter Hole Screen.

Page 15 of 53

Feeding Poin

t

Position

detectors (h=1.5 m)

Figure 5: Noise Test Method

Operator

Position of the
phonometric

2

1.0 m

Machine being tested

1

S.P.I Material Sample

Type: PVC 1120
SCH40 ASTMD-1785

Length: 145 mm
Outer Dia.: 33.5 mm
Inner Dia.: 26.5 mm
Thickness: 3.5 mm
Mass: 0.069 kg

4

1.0 m

3

Page 16 of 53