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Sterling BP1640 manual

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Table of contents for the manual

  • Page 1

    Operation and Installation Manual Model BP1620, BP1628, & BP1640 Granulators Important! Read Carefully Before Attempting to In stall or Operate Equ ipment $30. 00[...]

  • Page 2

    BP1620, BP1628 & BP1640 Granulators Page 2 BP1600 Write down your gran ulator ________________ ________________ serial numbers h ere ________________ ________________ for futu re referenc e ________________ ________________ ________________ ________________ Sterling can advise you on proper sele ction an d sizing of system s for your operatin g[...]

  • Page 3

    BP1620, BP1628 & BP1640 Granulators Page 3 BP1600 Safety Consider ations Sterling granulators are designed to provide safe a nd 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 t[...]

  • Page 4

    BP1620, BP1628 & BP1640 Granulators Page 4 BP1600 to internal cutting chamber and screen chamber components.  SAFETY GLASSES OR A FACE SH IELD MUST ALWAYS BE W ORN when servicing or operating the machine. Although our machines are designed for the maximum in fly back control, caution must be used when operating near the ar ea of the hopper f[...]

  • Page 5

    BP1620, BP1628 & BP1640 Granulators Page 5 BP1600  AL WAYS DISCONNECT AND LOCKOUT THE MAIN ELECTRICAL POWER TO THE GRANULATOR BEF ORE PER FORMI NG 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 rea [...]

  • Page 6

    BP1620, BP1628 & BP1640 Granulators Page 6 BP1600 Table of Contents 1 General Info rmation 9 1-1 In troduction 9 1-2 Ge neral Descript ion 10 1-3 Gra nulator S pecifica tions 11 2 Shipp ing In formation 12 2-1 Unpacking and Inspectio n 12 2-2 In the Event of S hipping Dam ages 12 2-3 If the S hipmen t is Not Co mplete 13 2-4 If the S hipmen t i[...]

  • Page 7

    BP1620, BP1628 & BP1640 Granulators Page 7 BP1600 Table of Contents 7 Startup Checklist 24 7-1 In troduction 24 7-2 Fan Evacuation 24 7-3 Gra nulator S tartup Ch ecklist 24 8 Operation 26 8-1 Op eration I nstructions 26 8-2 T empo rary Machine Sto ps 26 8-3 Fina l Machine S tops 26 8-4 Em ergency Stop s 27 9 Routine Maintenance 28 9-1 Lu bricat[...]

  • Page 8

    BP1620, BP1628 & BP1640 Granulators Page 8 BP1600 Charts and Fi gures 1 Granulator Specificat ions Table Granulator Dimen sions 11-12 2 Belt Span and Def lection Belt Deflection F orce Table 33-34 3 Rotor Knife D rawings 36 4 Recommended Knife Replacement Blad es 37 5 Bed Knife Drawin gs 39 6 Recommended Bolt Torque 41 7 General Drawings 46[...]

  • Page 9

    BP1620, BP1628 & BP1640 Granulators Page 9 BP1600 1 General Informati on 1-1 Introdu ction This manual is intended to be used as a guide and reference for personnel who will be installing, operating, and maintaining the Sterling BP1600 Series Granulator. The purpose is to aid these individ uals in apply ing efficient, proven techniques, which w[...]

  • Page 10

    BP1620, BP1628 & BP1640 Granulators Page 10 BP1600 1-2 General Description Sterling granulators are designed to uniformly and consistently size reduce y our scrap. They have bee n 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 suppo[...]

  • Page 11

    BP1620, BP1628 & BP1640 Granulators Page 11 BP1600 1-3 Granulator Specifications Figure 1 Granulator Dimension s Model BP1620 BP1628 “A” Dim ension 51.25” (1301.8 m m) 59.25” (1505 m m) Weight 3025 lbs (1372 kg) 3400 lbs (1542.3 kg) Est. Throu ghput 900 lbs/hr (408 kg /hr) 1500 lbs/hr (680 k g/hr)[...]

  • Page 12

    BP1620, BP1628 & BP1640 Granulators Page 12 BP1600 2 Shipping Inf ormation 2-1 Unp acking an d Inspectio n You should inspect your Sterling BP1600 Series granulator for possible shipping damage. I f the container and packing materials are in re-usable condition, save them for reshipment if necessary . Thoroughly check the equipment for any dama[...]

  • Page 13

    BP1620, BP1628 & BP1640 Granulators Page 13 BP1600 2-3 If the Shipment i s Not Complete Check the packing list. You should have:  Sterling BP 1600 Series granulator  Bill of lading for equipment shipped  Operating and I nstallation packet  Electrical schematic and panel lay out drawings Re-inspect the container and packing material [...]

  • Page 14

    BP1620, BP1628 & BP1640 Granulators Page 14 BP1600 2-6 Uncrating BP1600 Series Granulator BP1600 Series granulators are shipped mounted on a wooden skid then blocked and banded to prevent movement. All no n- painted items subject to corrosion are coated with a quality rust preventative and the machine is then covered with heavy duty poly ethyle[...]

  • Page 15

    BP1620, BP1628 & BP1640 Granulators Page 15 BP1600 3 Install ation 3-1 Scope This section contains all inst ructions required for experienced installation personnel to ins tall the Sterling granulator and prepar e it for production. It is essential to follow all instructions carefully and in the sequence presented. Be sure to observe all DANGER[...]

  • Page 16

    BP1620, BP1628 & BP1640 Granulators Page 16 BP1600 Loosen the fa stener in the right side front door. Note that this fastener does not need to be completely removed from the front access door, as it is designed to be captive for convenience. NOTE: DO NOT USE ANY OTHER MEANS T O CRANK OPEN THE MACHINE OT HER THAN TH E HAND CRANK PROVIDED . Using[...]

  • Page 17

    BP1620, BP1628 & BP1640 Granulators Page 17 BP1600 CA UTION! The knives mounted on the rotor and a lso locate d at the front and re ar of the cutting chambe r are e xtremely sharp. Always we ar heavy glov es a nd exerc ise care w he n w orking in the c utting chamber . Wipe out the insi de of the hopper and upper cutting chamber. Carefully insp[...]

  • Page 18

    BP1620, BP1628 & BP1640 Granulators Page 18 BP1600 interlocks have been verified for proper functioning bef ore shipment. It is only necessary to connect the electrical power source to the machine at the control enclosure. WA RNING! A ll equipm ent must be grounde d in compli ance w ith Article 250 of the National Electric Code. The customer’[...]

  • Page 19

    BP1620, BP1628 & BP1640 Granulators Page 19 BP1600 4 Accessing Cutti ng Chamber 4-1 Openin g Cuttin g Chamber 1. Allow material to run out of the cuttin g chamber. 2. Shut OFF and LOCKOUT all power, including the main disconnect switch. 3. Release latch that holds (2) front doors closed. Loosen the handle (knob) on the front right hand door. Th[...]

  • Page 20

    BP1620, BP1628 & BP1640 Granulators Page 20 BP1600 5 Accessing Screen Cham ber 5-1 Openin g Screen Chamber 1. Allow all material to run out of the cutti ng chamber and screen chamber. 2. Shut OFF and LOCKOUT all power including the main disconnect switch. 3. Remove discharge chute located below the screen c hamber. 4. Loosen (2) f asteners hold[...]

  • Page 21

    BP1620, BP1628 & BP1640 Granulators Page 21 BP1600 WA RNING! DO NOT LET THE SCREEN CHAM BER DRO P!! Gu ide cradle to it’s restin g position. 6. Remove the screen(s) and place them upright on their side. CA UTION! The knives mounted on the rotor, and the bed knives loca ted at the ed ges of the cutting chambe r, are e xtremely sharp. Always w [...]

  • Page 22

    BP1620, BP1628 & BP1640 Granulators Page 22 BP1600 6 Sequence of O peration 6-1 Scope This section contains the information required to carry out pre- operational procedures, and the checklist of items, which should alway s be reviewed prior to a production run. DA NGER! Bef ore und ertaking any ma chine rep airs or ma intenan ce, always make c[...]

  • Page 23

    BP1620, BP1628 & BP1640 Granulators Page 23 BP1600 • For granulators equipped with convey ors, fans, etc., test their operation also by pressing the appropriate pushbutton. Check fan outlets for proper airflow. • For granulators with em ergency stop pushbutt ons, test the buttons to ins ure all motion stops. • With the granulator running,[...]

  • Page 24

    BP1620, BP1628 & BP1640 Granulators Page 24 BP1600 7 Startup Checkl ist 7-1 Introdu ction After all electrical and mechanical machine ele ments have been inspected and any defects corrected, the machine can be put into production once the start-up checklist has been referred to. 7-2 Fan Eva cuatio n Sterling granulators can be supplied with an [...]

  • Page 25

    BP1620, BP1628 & BP1640 Granulators Page 25 BP1600  Are all accessory components electrically and mechanically connected with proper support and with all fasteners tight?  Are cy clonic air separator and filter units empty ? (optional equipment)  Has the fan (optional) been verified for proper rotation direction?  Are all electrical[...]

  • Page 26

    BP1620, BP1628 & BP1640 Granulators Page 26 BP1600 8 Oper ation 8-1 Operation Instruction s 1. Prior to m achin e startup -- All doors, covers, guards, and interlock switches must be in place, securely fastened, and functional. All accessory components must b e properly connected. I f the granulator has a bin, make sure it is installed. 2. Turn[...]

  • Page 27

    BP1620, BP1628 & BP1640 Granulators Page 27 BP1600 8-4 Emergency S top s Feedstock must be cleaned out of the hopper and cutting chamber prior to restarting the machine. NOTE : The Sterling BP1600 Series granulators are not designed for small purging, chunks of solid plastic or other heavy wall cross- sectional pieces.[...]

  • Page 28

    BP1620, BP1628 & BP1640 Granulators Page 28 BP1600 9 Routine Maintenance 9-1 Lubricatio n S pecifi cations 9-1-1 Descripti on All Sterling BP1600 Series machines are equipped with rotor bearings that are pre- lubricated & sealed from the factory . Mounting of the bearings on the Sterling BP1600 Series machines results in trouble free, low m[...]

  • Page 29

    BP1620, BP1628 & BP1640 Granulators Page 29 BP1600 9-1-2 Screw Jack Lubricati on Instructions Lifting screws should be checked periodically to ensure that they are adequately lubricated. I t is recommended that t he screw jack be lubricated at monthly intervals, unless experience indicates that re-grea sing should occur at more regular interval[...]

  • Page 30

    BP1620, BP1628 & BP1640 Granulators Page 30 BP1600 1. Verify that the alignment of the pulley s is correct. Utilizing a straightedge of sufficient length to span from one pulley to the other, place it along the sides of both pulley s. The entire edge of each pulley should fully contact the straightedge. 2. Measure the belt span (see Figure 2). [...]

  • Page 31

    BP1620, BP1628 & BP1640 Granulators Page 31 BP1600 6. There will normally be a drop in belt tensi on during the first 24 to 48 hours of operation due to st retch and the belts seating themselves in the sheave grooves. 7. After this initial “RUN IN” period, the machine should be stopped and the belts should be re-checked for tension. The mot[...]

  • Page 32

    BP1620, BP1628 & BP1640 Granulators Page 32 BP1600 Table 2 Belt Deflection Force BELT DEFLECTION FORC E (in lbs.) BELT SMALL SHEAVE DIAMETER (INCHES) A RUN IN B RUNNING 2.65 to 4. 0 6.00 4.00 3V 4.12 to 7. 0 8.25 6.75 7.10 to 10.9 21.00 14.25 5V* 11.80 to 16.0 25.75 17.00 12.50 to 16.0 51.00 34.50 18.00 to 22.4 58.00 39.50 3.00 to 3 .6 4.90 3. [...]

  • Page 33

    BP1620, BP1628 & BP1640 Granulators Page 33 BP1600 DA NGER! Bef ore und ertaking any ma chine rep airs or ma intenan ce, always make certain th at the m achine d isconnec t switch is turned to the OFF positio n or tha t the co ntrol enclosure is disconn ected f rom t he ma in power source . Either p lace a sign indicating that th e ma in discon[...]

  • Page 34

    BP1620, BP1628 & BP1640 Granulators Page 34 BP1600 9-5 Rotor Kni fe Sharpening The rotor knives must be sharpened to within .003 ” (0.076 mm) of each other. Greater dimensional variations prevent the proper setting of the knife ga p and may cre ate other serious complications. Grinding the cutting edge until it is free of nicks can be wastefu[...]

  • Page 35

    BP1620, BP1628 & BP1640 Granulators Page 35 BP1600 9-6 Rotor Kni fe Inst allation 1. Carefully lock the rotor with the lockin g pin to prevent it from turning. 2. Re-install the rotor knives onto the rotor. Do not torque the hex head rotor knife bolts fully at this point -- snug them down only. CA UTION! New or res harpened k nives should be ha[...]

  • Page 36

    BP1620, BP1628 & BP1640 Granulators Page 36 BP1600 I t is i mportant to note that the mini mum dimensions given for the rotor knife and bed knife cannot be combined simultaneously to produce a cutting combination. NOTE: Replacement knife sets and knife resharpening services are available from Sterling . Contact the Custo mer Service Department [...]

  • Page 37

    BP1620, BP1628 & BP1640 Granulators Page 37 BP1600 2. Align a rotor knife with the primary bed knife, in the front of the granulator. With a .006” feeler ga uge between the rotor and bed knife, start to adjust the bed knife into the rotor knife using the adjusting screw. During the movement of the bed knife, slowly rotate the rotor back and f[...]

  • Page 38

    BP1620, BP1628 & BP1640 Granulators Page 38 BP1600 7. After the clearance settin g of both the primary and secondary bed knives is complete and checked, turn the rotor by hand to ensure that none of the rotor knives hit the bed knives. 8. Double check inside the machine to make sure no tools or other articles are left in the cutting chamber or [...]

  • Page 39

    BP1620, BP1628 & BP1640 Granulators Page 39 BP1600 10 Troubleshooti ng Problem Possible Caus e Solution No power. Verify tha t the co rrect pushb uttons a re being depressed and t hat the main d isconnect switch is in the ON position . Try to loca te grounds, a locked rot or or oth er reasons. Fuses are blown. Replace fuses with the size and ty[...]

  • Page 40

    BP1620, BP1628 & BP1640 Granulators Page 40 BP1600 Machine h as loose or thrown belts. Inspect , and if accepta ble f or use, reinstall an d tighten per instruction s. Machine s talls/(option al) fan stalls (Optiona l) Fan wheel is loose o n shaf t. Tighten screws as required. Overloading of the machin e Reduce the amount of fee dstock pu t int[...]

  • Page 41

    BP1620, BP1628 & BP1640 Granulators Page 41 BP1600 Problem Pos sible Caus e Solution Fan wheel is lo ose on shaf t. Tighte n set screws as required. Transitio n or cyclonic air separat or tubing is clogged. Clean as required. Granulat e builds u p in the tran sition or tu bing Fan is no t evacuatin g properly. Check f or loose fan wheel on sh a[...]

  • Page 42

    BP1620, BP1628 & BP1640 Granulators Page 42 BP1600 Problem Pos sible Caus e Solution Knives are d ull. Sharpe n knives (ref er to Section 9) and re-install. Plastic is clogging the screens o r transition, preventing prop er fa n evacuation . Shut t he ma chine do wn and clean. Rotor spe ed is too fast . Change th e pulleys. Fines Screen s ize i[...]

  • Page 43

    BP1620, BP1628 & BP1640 Granulators Page 43 BP1600 (1) set of rotor knives and bolts (1) set of bed knives and bolts (1) screen or set of scree ns, (depending if y our model requires multiple screens) (1) set of belts (1) set of fuses (1) set of motor starter heaters (1) cy clone filter bag (optional) 12-2 A ddition al Part s I f additional sp [...]

  • Page 44

    BP1620, BP1628 & BP1640 Granulators Page 44 BP1600[...]

  • Page 45

    BP1620, BP1628 & BP1640 Granulators Page 45 BP1600[...]

  • Page 46

    BP1620, BP1628 & BP1640 Granulators Page 46 BP1600[...]

  • Page 47

    BP1620, BP1628 & BP1640 Granulators Page 47 BP1600 Service Notes[...]

  • Page 48

    BP1620, BP1628 & BP1640 Granulators Page 48 BP1600 Service Notes[...]