Sterling D48160s User Manual

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Sterling, Inc.
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2900 South 160
New Berlin, WI 53151
Tel: 1-262-641-8600
Fax: 1-262-641-8653
Parts and Service
1-800-229-2919
Street
MACHINE DATA
MODEL ___________________________________________________________
SERIAL NUMBER _____________________________________________________
CUMBERLAND CUSTOMER ORDER NUMBER___________________________________
REFER TO THIS SHEET WHEN ORDERING PARTS.
2
TABLE OF CONTENT
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TTAABBLLEE OOFF CCOONNTTEENNTTSS
TOPIC SECTION/PAGE
SECTION 2 – MACHINE PARTS AND CONTROLS…………………………………….…2-1
BP-Series granulators left front quarter view BP-Series granulators, right front quarter view..…………………………………………………….….2-2 BP-Series granulators, machine open front view BP-Series granulators, left rear quarter view …………………………..………………………………2-3 BP-Series granulators, right rear quarter view
SECTION 3 INSTALLATIONS
Overview…………………………………………………………………………………………….…..3-1 Machine weights Uncrate the granulator Move the granulator to its worksite……………………………………………………………………………………………….…3-2 Allow adequate workspace Level the granulator Work safely Remove protective coating………………………………………………………………………….…...3-3 Check knives and screen Power considerations Electrical wiring…………………………………………………………………………………………3-4 Work safely Check for mechanical interferences……………………………………………………………………..3-5 Set up the machine functions Check the rotation of motors If necessary, reverse the motor rotation Interlock switch test procedure………………………………………………………………………….3-6 Alternate test for the interlock switches Test the zero speed sensor………………………………………………………………………………3-7 Lubrication……………………………………………………………………………………………...3-8
SECTION 4 – SETTINGS AND ADJUSTMENTS
Adjusting or replacing the bed knives…………………………………………………………………..4-1 Basic facts about the knives Check all settings and adjustments before granulating any material Malfunction check Work safely Open the cutting chamber interlock…………………………………………………………………….4-2 Release the cutting chamber fasteners Care in handling knives ..…………………………………………………………………………….…4-3 Install the rotor-locating pin
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TOPIC SECTION/PAGE
SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page) Adjusting or replacing the bed knives (Continued from previous page)
Loosen the mounting screws……………………………………………………………………………..4-4 Remove the first knife clamp or shield Remove the bed knives Clean the knife mounting surfaces……………………………………………………………………….4-5 Mounting screws Replace the upstroke bed knife Replace the upstroke knife clamp Remove the down stroke bed knife………………………………………………………………………4-6 Replace the down stroke knife shields Check the bed knives Gap adjustment tips Measure the knife gap……………………………………………………………………………………4-7 Set the downstream knife shield Check the knife gap Tighten the screws to final torque………………………………………………………………………..4-8 Finalize installation of upstroke bed knife Fasten the cutting chamber……………………………………………………………………………….4-9 Close the cutting chamber safety interlock Restart the granulator
Adjusting or replacing rotor knives……………………………………………………………….4-10
Basic facts about the knives Work safely Open the cutting chamber interlock Release the cutting chamber fasteners…………………………………………………………………...4-11 Care in handling knives………………………………………………………………………………….4-12 Lock the rotor Remove the mounting screws Remove the rotor knives
Clean parts for reassembly……………………………………………………………………………....4-13
Mounting screws Rotors with replaceable knife seats Tighten the rotor knives to final torque…………………………………………………………………4-14 Check the bed knives Gap adjustment tips Measure the knife gap
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TOPIC SECTION/PAGE
SECTION 4 – SETTINGS AND ADJUSTMENTS (continued from previous page) Adjusting or replacing the bed knives (Continued from previous page)
Set the down stroke knife shield…………………………………………………………………...4-15 Check the knife gap Tighten the screws to final torque Fasten the cutting chamber …………………………………..……………………………………4-16 Close the cutting chambers safety interlock Restart the granulator
Drive belt replacement and adjustment….……………………………………………..…..4-17
Overview Work safely Remove the drive guard cover Inspect the drive belts……………………………………………………………………………..4-18 Remove the belts Install the matched belts Tighten the belt tension Check the pulley alignment…………………………………………………………………..…...4-19 Measure the belt span Calculate the allowable belt deflection Measure the deflection force Compare the measured force to the recommended force…………………………………………4-20 Adjust the belt tension Tighten the motor base bolts Replace the driver guard cover……………………………………………………………………4-21 Restart the granulator
Setting and adjusting the chamber jackscrews………………………….………………..4-22
Overview Work safely Open the cutting chamber interlock Release the cutting chamber fasteners…………….………………...…………………….………4-23 Jackscrew operation Cutting chamber open set point Open the cutting chamber…………………………………………………………………….…...4-24 Adjust the jackscrew open position limit switch Jackscrew operation Close the cutting chamber…………………………………………………………………….…..4-25 If the motor stops before the cutting chamber closes Set the jackscrew closed position limit switch
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TOPIC SECTION/PAGE
SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page)
Setting and adjusting the chamber jackscrew (Continued from the previous page)
The chamber stops before it closes but the motor continues to run……………………………..…..4-26 Set and test the mounting bracket limit switch Close the cutting chamber………………………………………………………………………..….4-27 Fasten the cutting chamber
Close the cutting chamber safety interlock……………………………………………………….....4-28
Setting and adjusting the cradle jackscrew………………………………………………….4-29
Overview Jackscrew operation Open the screen cradle interlock Retract the screen cradles retainers Jackscrew operation…………………………………………………………………………………4-30 Cradle open position Beware of rotor knives Lower the screen cradle Adjust the cradle open-position limit switch……………………………………………………..…4-31 Jackscrew operation Check the cradle closed-position limit switch……………………………………………...……….4-32 Raise the screen cradle Adjust the cradle closed position limit switch………………………………...…………………….4-33 Close the screen cradle retainers Close the screen cradle interlock
Zero speed sensors……………………………………………………………………….………4-34
Zero speed sensors operation Adjust the sensor position Control Circuit
Adjustable Rotor Knives…………………………………………………………………4-35
Rotor Knife Preparation Rotor Knife Installation Into Fixture Knife Length Setting, Knife Length Setting-Inspection Adjustable Rotor Knife Installation
Hydraulic opening position switches ………………………………………………………………4-36 Hydraulic pump operation
SECTION 5 – OPERATION
Initial startup………………………………………………………………………………..…….…5-1 Safety check Work safely Check for mechanical interferences
Check the motor rotation direction……………………………………………………………….....5-2
Run the motor Discharge air adjustment
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TOPIC SECTION/PAGE
SECTION 5 - (Continued from previous page)
Normal operation……………………………………………………………………………………..5-4
Feed the machine Shut down the machine Discharge cleanout safety Cleaning the discharge transition
Safely clearing the jam……………………………………………………………………….5-5
Work safely Jackscrew operation Open the cutting chamber Clear the jam……………………………………………………………………………………………..5-6 Malfunction check Restart the granulator
SECTION 6 – MAINTENANCE
Periodic maintenance…………………………………………………………………………………….6-1 Periodic maintenance schedule Lubrication……………………………………………………………………………………………….6-2 Knife screw torque Belt tension Screen condition Infeed flap condition……………………………………………………………………………………..6-3 Upper chamber pivot arms – screws Hydraulic cylinder/jackscrew inspection pivot pins & lockouts
Screen replacement…………………………………………………………………………………...6-4
Work safely Open the screen cradle interlock Retract the screen cradle retainers Jackscrew operation………………………………………………………………………………………6-5 Lower the screen cradle Beware of rotor knives Remove the screen………………………………………………………………………………………..6-6 Replace the screen Raise the screen cradle……………………………………………………………………………………6-7 Close the screen cradle retainers
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TTAABBLLEE OOFF CCOONNTTEENNTTSS
TOPIC SECTION/PAGE
SECTION - 6 – MAINTENANCE (continued)
Screen replacement (Continued from previous page)
Close screen cradle interlock……………………………………………………………………………6-8 Restart granulator
Cutting chamber access…………………………………………………………………………….6-9
Work safely Open the cutting chamber interlock Release the cutting chamber fasteners Jackscrew operation…………………………………………………………………………………….6-10 Open the cutting chamber with jackscrews Open the cutting chamber with hydraulics Close the cutting chamber with jackscrews…..………………………………………………………..6-11 Close the cutting chamber with hydraulics Fasten the cutting chamber Close the cutting chamber safety interlock Restart the granulator Jackscrew operation ……………………………………………………………………………………6-12 Lowering the screen cradle with jackscrews Lowering the screen cradle with hydraulics Jackscrew operation ……………………………………………………………………………………6-13 Raising the screen cradle with jackscrews Raising the screen cradle with hydraulics
Knife sharpening ………………..………………………………………………………………….6-14
Rotor knife sharpening Bed knife sharpening…………………………………………………………………………………..6-15
SECTION – 7 - TROUBLESHOOTING Overview…………………………………………………………………………………………..…..7-1
Test equipment Locating trouble Troubleshooting chart
Processing faults……………………………………………………………………………..………….7-2
Mechanical faults……………………………………………………………………………..…………7-3
Electrical faults………………………………………………………………………………..………...7-4
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TOPIC SECTION/PAGE
SECTION – 8 PARTS LISTS AND DRAWINGS
Recommended spare parts………………………………………………………………………………… 8-1
Parts identification Sterling drawing no. A-48050 ……………………………………………………..….8-2
Overall dimensions Sterling drawing no. A-48150 ……………………………………………………......8-3
Parts identification Sterling drawing no. 348070C ………………………………………………………..8-4
Parts identification Sterling drawing no. 348185…………………………………………….…………….8-5
Parts identification Sterling drawing no. 1554-460 ……...…………………………………….………..…8-6
Wiring diagram Sterling no. A-399598 ……………………………………………………………….…...8-7
Parts identification Sterling drawing no. 348078-1………………………………………….………..……8-8
Wiring diagram for Hydraulics Sterling no. D-499061………………………………………………..…...8-9
Wiring diagram Sterling no. D-499044 …………………….……………………………………………..8-10
Metric knife bolt/screw tighten torque specifications ………..…………………………………………....112
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THANK YOU FOR PURCHASING AN STERLING BP2400 SERIES GRANULATOR.
READ THIS MANUAL to learn how to operate and service your granulator safely. It covers the
family of granulators called the BP2400. This series of Sterling Granulators is designed for the big jobs in reclamation of large blow-molded and thin walled, injection molded plastic parts as well as film.
This revision of the manual covers the improvements made since the introduction of the BP2400 Series Machines in 1993.
NOTE: This manual covers light maintenance only. No further maintenance should be performed without first contacting the Sterling Service Department at the mailing address and phone number shown on page 2.
When calling the factory for service information and parts, please have the model and serial number of your machine on hand. The serial number is stamped on the plate mounted on the center at the back of the granulator just below the hopper.
11
T
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ROODDUUCCTTIIOONN
IINNT
WHAT IS A GRANULATOR?
A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips or granulate.
The machine can be fed either by hand through a hopper opening in the front or automatically from a special hopper opening, which can be specially designed.
DISPOSAL OF THE PLASTIC GRANULATE takes place after it passes through the screen and
drops into the discharge area, where it is removed from the machine by a discharge blower and conveyed by air to a remote side of the machine. This discharge blower is available as optional equipment.
THE GRANULATING OF PLASTIC is achieved by the cutting action of sharp rotating knives in
close adjustment to one or more stationary knives called bed knives. The rotary knife assembly is called a rotor. You will see the references to it as you read through this manual. There are two bed knives in the machines covered by this manual. The heavy-duty rotor and bed knife assemblies, combined with the screen (explained below) and their enclosing cutting chamber are the heart of the granulator.
THE SIZE OF THE GRANULATE resulting from the cutting action described is controlled by a
screen, which fits tightly around the rotary knives in the cutting chamber. This screen retains the plastic granulate until it is reduced to a small enough size to fall through the holes in the screen. Screens with various hole sizes are available for the granulator. The standard screen hole size for the X-Series is 3/8” diameter. Screens are available with either smaller or larger hole sizes. For a given machine, the throughput capacity of the granulator is dependent upon the size of the screen utilized.
12
SAFETY SECTION 1-1
Safety Symbols and Plates
LEARN MACHINE SAFETY
Read this manual. Learn how to operate and how to use the control.
DO NOT ALLOW ANYONE TO OPERATE THIS MACHINE WITHOUT PROPER INSTRUCTIONS.
THIS SAFETY alert symbol MEANS ATTENTION…BE ALERT!
YOUR SAFETY IS INVLOVED!
This symbol appears frequently in this manual and on your machine. It is used to alert you to the possibility of personal injury or death. Follow the instructions in the safety messages identified with this symbol.
UNDERSTAND THE SIGNAL WORDS….
A signal words such as – DANGER, WARNING OR CAUTION, is always used with the safety alert symbol to indicate the level of hazard. These safety words are in accordance with ANSI Z535.5.
DDAANNGGEERR
DDiissrreeggaarrdd ooff tthhiiss hhaazzaarrdd wwiillll rreessuulltt iinn sseevveerree ppe oorr ddeeaatthh.. TThhiiss ssiiggnnaall wwoorrdd iiss pprriinntteedd oovveerr aa rreedd bbaacckkggrroouunndd.
WWAARRNNIINNGG iiddeennttiiffiieess aa ppootteennttiiaall hhaazzaarrdd oorr uunnssaaffee pprra
DDiissrreeggaarrdd ooff tthhiiss hhaazzaarrdd ccoouulldd rreessuulltt iinn sseevveerree iin ddeeaatthh.. TThhiiss ssiiggnnaall wwoorrdd iiss pprriinntteedd oovveerr aa rreedd bbaacckkggrroouunnd
CCAAUUTTIIOONN
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iiddeennttiiffiieess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn..
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SAFETY
SECTION 1-2
Safety Symbols and Plates
FOLLOW THE SAFETY INSTRUCTIONS:
Read all safety messages in this manual and on your machine safety plates. Follow the recommended precautions and safe operating practices. Keep safety plates in good condition. Replace missing or damaged plates.
ROTATING KNIVES SAFETY PLATE (Located below the infeed opening at the front of the machine) DO NOT, UNDER ANY CIRCUMSTANCES, place your hands into the feed opening beyond the curtain while the machine is capable of running. Disconnect and lock out all power when it becomes necessary to work beyond this point. Make sure the rotor has come to a full stop
before reaching through the curtain.
WARNING–PAUSE AFTER SHUT-DOWN (Located at the front of the cutting chamber)
Pause, as suggested, after shutting the machine down and locking out the power even though safety interlocks are in place to prevent injury. Develop good safety habits by adhering to the messages on all the warning plates. The best safety provision is your own careful concentration of safety.
OPENING HOPPER, GUARDS, COVERS SAFETY PLATE
(Located on the screen cradle on the front panel, left of the machine center.) The hopper, guards and safety covers are in place for your protection during machine operation. Be sure not to remove them until the rotor has come to a complete stop and you have disconnected and locked out all power. Be sure to replace all guards before reconnecting power.
14
SAFETY
y
ROTATING MACHINERY SAFETY PLATE (One located
on the machine guard on the left side of the machine, one on the screen cradle on the front panel, to the right of the machine center.)
Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before removing a machine guard. A motion sensor monitors the rotor and disables the jackscrew motors if there is rotor movement. If you see the rotor spinning after opening the machine, immediatel
OPENING HOPPER SAFETY PLATE
(Located on center at the lower, front side of the hopper)
Take the time for safety by disconnecting and locking out the power before opening the hopper. Work carefully and beware of all hazards with the hopper open and the knives exposed.
shut down and call for service.
SECTION 1-3
Safety Symbols and Plates
ROTATING KNIVES SAFETY PLATE (One located near the
discharge port and one located near the vent port on each side of the machine.)
Never reach into the vent or discharge areas without shutting down the machine and locking out the power. Wear protective gloves whenever you work around the rotor knives and do not open the access doors to them until you are certain that the rotor has stopped and you have disconnected and locked out the power. To clear a jam, refer to the topic entitled Safely Clearing a Jam later in this section.
WARNING SHEAR HAZARD (Located on the right side of the
machine near the zero speed sensor to the rear of the right rotor bearing housing)
With the zero speed sensor removed, there is a potential hazard because the sensor probe extends into close proximity of the rotor. If you should place anything within this hole while the machine is running, the passing rotor would likely shear it off. In addition, without this component installed the safety interlock, which disables the jackscrew motors, is out of service, thus creating another serious safety hazard.
15
SAFETY
SECTION 1-4
Safety Symbols and Plates
JACKSCREW REVERSING OPERATION
(Located on the jackscrew operating console) This information plate reminds you of the important procedure for reversing the direction of jackscrew operation. Be sure to pause as advised. This allows the jackscrew drive the necessary time to coast to a stop before reversing. Without this pause, the jackscrew may be severely damaged.
GUARDS SAFETY PLATE
(Located on the drive guard cover on the left side as you face the machine)
By keeping the guards in place at a11 times you are promoting good safety practices and avoiding
needless hazard and injury.
16
SAFETY INSTRUCTION PLATE
(Located on the front of the drive guard)
The safety instruction plate summarizes the most important safety rules that you need to operate this machine safely. Read it care­fully and observe it always to promote safe machine operation.
SAFETY
SECTION 1-5
Safety Symbols and Plates
HAZARDOUS VOLTAGE SAFETY PLATE
(Located on the door of the jackscrew console)
Always call for the services of a licensed electrician when you think that there is an electrical problem. Never open any electrical panel if you are not a licensed electrician. Touching the wrong terminals may result in serious injury or death.
17
SAFETY
ROTATING KNIVES SAFETY PLATE
(One located on the front of the cutting chamber and one on the front of the cradle)
The rotating knives are razor-sharp to the touch. Always verify that the rotor is not moving. Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before opening the machine. A motion sensor monitors the rotor and disables the hydraulic cylinder/jackscrew controls if there is movement. If you see the rotor spinning after opening the machine, immediately shut down the machine and call for service.
Wear protective gloves whenever you work around the rotor knives. To avoid jamming your fingers between the rotor knives and the bed knives, refer to the information for safely clearing a jammed cutting chamber later in this section.
SECTION 1-6
Safety Symbols and Plates
MOTOR ROTATION SAFETY PLATE
(Located on the door of the jackscrew console)
A REMINDER TO THE ELECTRICIAN to check the motor rotation. It is important to check the motor rotation whenever electrical connections to the motor are being made or have been disturbed for maintenance. The wrong rotation direction can cause personal injury (by throwing debris back toward the feed hopper opening) and/or by damaging the knives. NOTE: The drive motor direction arrow plate is located on the top surface of the drive guard toward the front of the machine.
18
SAFETY
SECTION 1-7
Safety Clothing & Practices
(Located above the infeed opening at the front of the machine) It is recommended that hearing protection be used at all times when operating this equipment. It is mandatory that hearing protection be worn when noise exposure exceeds OSHA Standards Section
1910.95.
(Located above the infeed opening at the front of the machine)
Always wear proper eye protection when operating and/or servicing this equipment. Wear safety glasses with side shields or full-face safety shields.
19
SAFETY
SECTION 1-8
Safety Clothing & Practices
WEAR PROTECTIVE CLOTHING
Never wear neckties, dangling jewelry, loose-fitting clothing, watches, bracelets, or rings. Tie back long hair or restrain it with a hair net to ensure your safety.
KEEP YOUR WORK AREA SAFE
Keep your work area clean and uncluttered. Store your maintenance tools away from the granulator to prevent them from falling into the machine and causing severe internal damage to the cutting chamber.
KEEP CO-WORKERS OFF THE MACHINE
Never lean or rest on the granulator. Do not let co-workers lean on your machine while it is running. A moving part or shower of material many cause unexpected injury.
20
SAFETY
SECTION 1-9
Safety Clothing & Practices
TURN OFF AND LOCKOUT
(Lockout/Tag-out of Energy Sources).
If it is not possible to lock out the power, have an electrician remove the fuses.
Make sure the rotor has come to a complete stop.
The hydraulic cylinders or jackscrews, which open the machine, should not operate until the rotor is completely stopped.
If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it.
Wear gloves to protect against injury from the rotor or bed knives.
the power per OSHA 1910.147 OR ANSI Z244.1-1982
MACHINE OPENING DEVICES
The BP 2400 Series of granulators have been supplied with two different types of opening devices. These devices provide access to the Cutting Chamber for both the area above the rotor, mainly for cleaning/knife maintenance and below the rotor for cleaning/screen maintenance.
The system supplied on your machine may be either an electro-mechanical design (electric jackscrews) or of a hydraulic design (hydraulic cylinders & power supply). References to both systems appear throughout this manual. Be sure to follow the instructions that pertain to the system as supplied on your machine.
BE SURE THE ROTOR IS MOTIONLESS BEFORE OPENING MACHINE
Never open or remove any machine components unless the motor is electrically locked out and the rotor is completely motionless.
The BP 2400 Series machine has a zero speed sensor that detects motion of the rotor. This sensor is inter- locked to the controls of the two hydraulic cylinders or jackscrews. If it detects motion in the rotor, it cuts the power to the hydraulic cylinder/jackscrew controls.
If you ever notice that the hydraulic cylinders or jackscrews operate while the rotor is turning, have a mechanic and electrician check the speed sensor per the procedure in Section 4, entitled Zero Speed Sensor.
21
SAFETY
SECTION 1-10
Safely Cleaning A Jam
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982
(Lockout/Tag-out of Energy Sources).
If it is not possible to lock out the power, have an electrician remove the fuses.
Make sure the rotor has come to a complete stop.
The hydraulic cylinders or jackscrews, which open the machine, should not operate until the rotor is completely stopped.
If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it.
When you REVERSE the jackscrew operating direction, always ALLOW THE JACKSCREW MOTOR TO COME TO A COMPLE1E STOP. Release the control switch and allow a minimum of 5 seconds before switching to the opposite operating position. If you don't allow this pause, the JACKSCREW AND OTHER COMPONENTS MAY BE SEVERELY DAMAGED.
OPEN THE CUTTING CHAMBER
Open the screen cradle per instructions in Section 6-6 entitled Screen Replacement.
Open the cutting chamber per instructions in Section 6-9 entitled Cutting Chamber Access.
NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING YOUR HANDS ON THE ROTOR, ON THE KNIVES, OR INSIDE THE CUTTING CHAMBER.
KEEP YOUR HANDS CLEAR OF THE ROTATIONAL PATH OF THE ROTOR KNIVES.
22
SAFETY
g
SECTION 1-11
Safely Cleaning A Jam
CLEAR THE JAM
A leather mallet and block of wood of sufficient length to keep
hands away from the path of the knives can be used if required.
Use the block of wood to exert force on the rotor, usually in the
direction opposite normal rotation.
Make sure you have secure footing on a clean floor and keep
your body well braced while prying on the rotor. Guard against
loss of balance should the jammed condition suddenly come free.
Use pliers to remove material from the cutting chamber, keep in mind that the removal of material may
cause rotation of the rotor and rotor knives.
If prying on the rotor is unsuccessful, remove the bed knife and the rotor knife at the jam. For
information about bed knives, refer to Section 4, Settings and Adjustments.
Close the screen cradle per instructions in Section 6-4 entitled Screen Replacement.
Close the cutting chamber per instructions in Section 6-9 entitled Cutting Chamber Access.
A malfunction of the machine, such as a jam, may cause undue strain or damage to any part. Do not restart the machine after such a malfunction without checking to see whether damage was done or whether settings were
ed by the malfunction.
chan
RESTART THE GRANULATOR
If necessary to replace the fuses, call an electrician to do it.
UNLOCK AND TURN ON the main power.
Remove the OUT OF SERVICE tag
Start the granulator by depressing the start pushbutton on the electrical cabinet.
23
MACHINE AND CONTROLS
SECTION 2-1
BP 2400 Series Granulator -Left Front Quarter View
1.
Hold-down clamps - cutting chamber
2. Screen cradle retainers
3. Interlock actuator screw - cutting chamber
4. Safety plates
5. Feed hopper
6. Rotor bearing housing
Discharge duct (pipe not shown-optional mount to either side)
7.
8. Start/stop pushbuttons are located on the electrical cabinet, not shown. (The electrical cabinet is
optional equipment.)
9. Cover, mounting bracket limit switch, jackscrew opening only.
BP 2400 Series Granulators The BP 2400 Series Granulators have a common cutting diameter of
23.6"(600mm) and a common throat size of 24" (610mm) by widths ranging up to 56" (1420mm). They are designed for reclamation of large blow-molded and thin-walled injection molded-parts, films, and fibers.
The machines in the BP-Series can be fitted with screens having hole sizes to suit the particular application. The BP-Series machines conform to ANSI Standards: B 151.11 and NFPA 79.
24
BP 2400 Series Granulator Right Front Quarter View
1. Drive guard
2. Drive guard cover
3. Inlet vent -discharge blower
4. Safety plates
5. Interlock actuator screw screen cradle
6. Infeed flap
MACHINE AND CONTROLS
SECTION 2-2
BP 2400 Series Granulator Machine Open Front View
1. Screen
2. Rotor Knife
3. Bed knife (down stroke)
4. Rotor locating pin
25
MACHINE AND CONTROLS
SECTION 2-3
BP 2400 Series Granulator Left Rear Quarter View
I. Hydraulic cylinder/ jackscrew console
2. Hydraulic cylinder or jackscrew- cutting chamber
3. Cleanout- discharge transition
4. Discharge outlet (pipe not shown-optional mount to either side)
5. Rotor bearing housing
6. Rotor zero speed sensor
7. Upper chamber pivot arm screws
BP 2400 Series Granulator
Right Rear Quarter View
1. Hydraulic cylinder or jackscrew -cutting chamber
2. Machine serial number plate
3. Drive guard
4. Drive guard cover
5. Inlet vent, discharge blower
6. Drive motor
7. Hydraulic cylinder or jackscrew pivot pins and locknuts
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INSTALLATION
SECTION 3-1
OVERVIEW
This section deals with the procedures required to place your BP 2400 Series Granulator into service after you receive it at your plant. The following basic steps need to be accomplished.
Uncrating the machine
Accounting for all necessary parts
Inspecting for damage and reporting any damage to the carrier
Cleaning the protective coating from the machine
Moving the machine to its service location
Checking and, if necessary, adjusting mechanical parts before applying electrical power
Connecting electrical power to the machine control panel and hydraulic
cylinder/jackscrew control panel located on the machine
Performing the start-up procedure
PLEASE FOLLOW THESE STEPS, AS OUTLINED TO ACHIEVE A SAFE AND SUCCESSFUL START- UP OF YOUR GP-SERIES GRANULATOR.
The machine weights for the BP-Series Granulators are as follows: BP 2428-10000 pounds
BP 2439-13000 pounds BP 2456-16000 pounds
UNCRATE THE GRANULATOR
As shipped, the granulator and the hopper are securely bolted onto separate skids and covered with a wooden crate. The electrical cabinet, an optional item, is similarly packaged when ordered.
Remove the strapping.
Remove the packages and parts from the skid or inner sides of the crate. Remove the hold-
down bolts, nuts, etc.
Inspect for damage during transit and notify the carrier immediately of any damage.
Check the packing list and notify Sterling if there are any shortages.
27
INSTALLATION
SECTION 3-2
MOVE THE GRANULATOR TO ITS WORK SITE
If lifting the machine is necessary, use appropriately rated lifting equipment. Always lift the unit from beneath the base plate.
The machine weights for the BP-Series Granulators are as follows: BP 2428-10000 pounds
ALLOW ADEQUATE WORK SPACE
Adequate clearance must be maintained so that all areas of the granulator are accessible and unobstructed for servicing, maintaining, or operating the equipment. Space must be allowed for removing guards and screens.
Allow three feet (91 cm) on all sides of the machine for access.
BP 2439-13000 pounds BP 2456-16000 pounds
LEVEL THE GRANULATOR
Once the granulator is at its final installation site, ensure that the machine is on a level surface and resting firmly on its base plate. If necessary, use shims to level it.
It can be mounted on isolation pads or it can be lagged to the floor through holes provided in the base plate.
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources).
If it is not possible to lock out the power, have an electrician remove the fuses. Make sure the rotor has come to a complete stop.
(Continued on next page)
28
INSTALLATION
SECTION 3-3
The hydraulic cylinders or jackscrews, which open the machine should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders or jackscrews DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it.
Wear gloves to protect against injury from the rotor or bed knives.
REMOVE THE PROTECTIVE COATING
The machine is shipped with a protective wax coating, which must be removed prior to start-up. The coating can be removed with an acceptable solvent, such as mineral spirits.
Clean the following areas:
Inside the feed hopper
Inside the cutting chamber (knives, rotor, etc.)
Inside the discharge area.
Be sure that the screens are properly installed into the cutting chamber and that nothing has fallen into the cutting chamber during transportation and/or installation. Refer to Section 6, Maintenance, for the procedure entitled Screen Replacement and Cutting Chamber Access. Check to be sure the bed knife and rotor knife hold-down screws are tight and knife clearances are correct. Refer to Section 4, Settings and Adjustments.
Before operating the granulator, it is extremely important that a licensed electrician correctly wires the machine into the plant power source. See Section 8, for wiring diagram.
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.
29
INSTALLATION
SECTION 3-4
ELECTRICAL WIRING
To wire the granulator, run power (of the proper voltage) from the plant source through a lockable, fusible disconnect to the machine electrical control panel.
To wire the jackscrew motors, run power (of proper voltage) from the plant source through a fusible disconnect to
the machine-mounted jackscrew control panel.
From the main electrical control panel, make the necessary control circuit connections to the hydraulic cylinders/jackscrew control panel. Refer to the wiring diagrams supplied with the machine.
Wiring from the hydraulic cylinders/jackscrew console to the safety switches, zero speed sensor and hydraulic pump/valves or cutting chamber/screen cradle jackscrew is done at the factory.
From the main electrical panel, make the necessary wiring connections to the main drive motor and any auxiliary motors or control connections.
Refer to the wiring diagram appended to this manual for wiring connections for typical machine applications. Check the wiring diagram supplied for any wiring that is specific to your application. This diagram is part of the documentation shipped with the machine.
After power is connected, do not make any adjustments to the machine without performing the following operations.
TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag­out of Energy Sources).
If you cannot lock out the power, have an electrician remove the fuses.
Tag the machine as OUT OF SERVICE.
Make sure the rotor has come to a complete stop.
The hydraulic cylinders/jackscrews, which open the machine, should not operate until the rotor is completely stopped. If you discover that the hydraulic cylinders/jackscrews DO operate while the rotor is still turning, immediately shut down the machine and call for maintenance to adjust it.
Wear gloves to protect against injury from the rotor or bed knives.
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