Sterling BP814, BP810, BP818 User Manual 2

BP800 Series Beside-the-Press Granulators

Models BP810, BP814, BP818

Effective: 8.13.2008

Write Down Your Serial Numbers Here For Future Reference:

_________________________ _________________________

_________________________ _________________________

_________________________ _________________________

We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________
© Copyright 2011
All rights reserved.

ii

Shipping Info

Unpacking and Inspection

You should inspect your granulator for possible shipping damage.

Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

According to the contract terms and conditions of the Carrier, the responsibility of the
Shipper ends at the time and place of shipment.

Notify the transportation company’s local agent if you discover damage.

Hold the damaged goods and packing material for the examining agent’s inspection. Do not

return any goods before the transportation company’s inspection and authorization.

File a claim with the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.

Advise customer service regarding your wish for assistance and to obtain an RMA (return
material authorization) number.

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the packing list. You should have:

! Bill of lading

! Packing list

! Operating and Installation packet

! Electrical schematic and panel layout drawings

! Component instruction manuals

Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the parts and service department
immediately at [262] 641-8600. Have the order number and item number available.

Hold the items until you receive shipping instructions.

Returns

Do not return any damaged or incorrect items until you receive shipping instructions from the
shipping department.

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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 Typical Features and Components ............................................................................. 9

Main Components of Standard Granulators………………………………………….8
Optional Equipment………………………………………………………… ………… ..9

2-3 Safety Features ......................................................................................................... 10

CHAPTER 3: INSTALLATION .................................................. 13

3-1 Uncrating the Equipment ........................................................................................... 13

3-2 Installing the Granulator ............................................................................................ 14

3-3 Electrical Connections ............................................................................................... 14

3-4 Initial Start-up ............................................................................................................ 15

CHAPTER 4: OPERATION ....................................................... 20

4-1 Start-up ..................................................................................................................... 20

4-2 Operation Procedures ............................................................................................... 20

4-3 Shut-down ................................................................................................................. 21

CHAPTER 5: MAINTENANCE .................................................. 22

5-1 Preventative Maintenance Schedule ......................................................................... 22

5-2 Preventative and Corrective Maintenance ................................................................ 23

Monthly Maintenance Operations……………………………………………………22
Inspection and Adjustment of Knives……………………… …………… …………..24
Removing and Replacing Bed Knives………………………………… ……… …….26
Removing and Replacing Rotating Blades………………………………………….27
Specifications for Re-sharpening Bed Knives……………………… …… … … … … 28
Specifications for Re-sharpening Rotor Knives………………………… … … … ….29

CHAPTER 6: TROUBLESHOOTING ........................................ 31

6-1 Introduction ............................................................................................................... 31

General Problems……………………………………………………… ………… …..30
Electrical Problems……………………………… …… …… …… …… ……… …… …31

CHAPTER 7: APPENDIX .......................................................... 33

7-1 Returned Material Policy ........................................................................................... 32

7-2 Technical Specifications ............................................................................................ 33

7-3 Drawings and Diagrams ............................................................................................ 34

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7-4 Spare Parts List ......................................................................................................... 40

7-5 Technical Assistance ................................................................................................ 41

Chapter 1: Safety 5 of 41

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 indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property damage.

Chapter 1: Safety 6 of 41

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.

Chapter 1: Safety 7 of 41

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.

Chapter 1: Safety 8 of 41

! 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 Machinery!Granulators, Pelletizers, and Dicers Used for
Size Reduction of Plastics!Construction, 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.

Chapter 2: Functional Description 9 of 41

Chapter 2: Functional Description

2-1 Models Covered and General Description

The models covered in this operational manual include, from the 800 Series Beside-the­Press Granulators, BP810, BP814, and BP818. This family of granulators has been
designed to granulate plastic material such as sprues, runners, and small reject parts.

The granulator is comprised of an in-feed hopper into which the material to be granulated
is fed, mounted on a cutting chamber in which a series of rotary and bed knives reduce the
material to granules, the size of which is determined by the screen holes. The granules fall
and collect in the bin below. The operation of the granulator is controlled by a control
panel and powered by an electric motor.

2-2 Typical Features and Components

Main Components of Standard Granulators

Please refer to the following list and figure.

1. In-feed hopper

2. Cutting chamber

3. Bin for granulated material

4. Belt drive

5. Control panel

6. Electric motor

Chapter 2: Functional Description 10 of 41

Optional Equipment

The 800 Series Beside-the-Press granulators offer the following options:

• Conveyor

• Other screen hole sizes

• Blower/airveying system

• Vacuum bin

• Special operating voltages

Technical Data

In-feed

Front or top entry

In-feed hopper

For manual feeding

Cutting chamber

Upright bolted type

Rotor

3-knife rotor w/ lateral disks

Cutting system

Scissor action with double angle
cutting

Knives

Tool steel

NOTE: Refer to Drawings and Diagrams chapter for more information.

2-3 Safety Features

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

Safety Features Fitted on 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 cannot be fixed in the correct
position without special fastenings.

WARNING! Always make sure that the guard is in position before

starting the granulator!

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 (see figure below), which cuts off the electric supply to the motor and causes
the rotor to stop.

Chapter 2: Functional Description 11 of 41

The method of opening the granulator has been designed to restrict the operator access,
which allows the rotor and all moving knives to stop completely. Allowing operating
access more quickly could be dangerous because it is possible to make contact with the
granulator knives while they are still rotating.

Figure: Safety Switch

Opening the Granulator

The Start/Stop lighted push-button provide on the control panel (see figure below) 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, follow the procedure
below:

2. Turn off the granulator using the provided push-button.

3. Turn the disconnect switch to OFF and lock out power. (If you cannot lock out

power, then remove the power fuses in the control panel.)

4. Tag the machine as “Out of Service”.

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

WARNING! Wear protective gloves when exposed to knives!

Chapter 2: Functional Description 12 of 41

Figure: Control Panel

Start/Stop Push­Button

Disconnect
switch

Chapter 3: Installation 13 of 41

Chapter 3: Installation

3-1 Uncrating the Equipment

Prepare in advance the site you have selected for installation of the granulator. Be sure
the area the machine will occupy is clean, level, and free of obstruction. The selected site
must have a floor rating to adequately support the weight of the machine.

The granulator is mounted on a wooden skid and blocked and banded to secure it for
shipment. All non-painted items subject to corrosion are coated with a quality rust
preventative, and the machine is covered with heavy-duty polyethylene to protect it from
moisture and dirt. Granulators are normally shipped completely assembled unless the
size of the machine or an agreement for special shipping arrangements prompts partial
assembly.

If an inspection after shipment has revealed no shipping damage, unpack the unit by
removing the polyethylene protective covering and banding. Remove the envelope with
the parts list, assembly drawings, electrical schematics, and manual from the base
evacuation area.

You can now have the machine lifted from the skid. A forklift is ideal for this process,
but make sure to properly position the forks between the casters and the centrally
mounted evacuation pipe from the side of the machine (see figure below).

Figure: Lifting the granulator

CAUTION! Do not attempt to lift the granulator with a shaft or protruding member—
ESPECIALLY THE HOPPER!