Sterling BP1012 manual

Operation and Installation Manual BP1000 Se ries Gr anulators Models BP1012 an d BP1018 Importan t! Read Carefully Befor e Attempting to Install or Op erate Equipment $30. 00[...]

Page ii of 53 Write down your granulator _____________ _______ _____________ _______ serial number s here _________ _____ ______ ______ _____ _______ __ for future re ference. _____ _______________ _____ _______________ Sterling can advise you on proper sele ction and sizing of systems for your op erating environme nt. Sterling is comm itted to a c[...]

Page iii of 53 Sterling Warranty Inform ation Thank you for your purchase of your new BP1000 Series Granul ator. We are confident that you will have excellent results and trouble-f ree operation with th is machine. When the machine arrives at your plant, inspect it carefull y for shipping damage before uncrating and immediately report an y damage t[...]

Page iv of 53 Sterling Warranty Inform ation We warrant our product t o be of the kind and qualit y quoted, and no other warrant y except of title shall be impli ed. Our company shall repair or replace, at our disc retion, an y manufactured item on your BP1000 Ser ies Granulator without charge FO B factory, within one (1) year after date of origina[...]

Page v of 53 Table of Contents 1 Safety Consideration s 9 1-1 Safety Gu idelines 9 1-2 Safety Proc edures 11 1-2-1 Guideline s for Moving the Granula tor 11 1-2-2 Clearing a Jamme d Cutting Chamb er 11 1-3 Safety Featu res 12 1-3-1 Safety Featu res Fitted On the Granu lator 12 1-3-2 Opening the Granulator 13 1-3-3 Sound Enclo sure 14 2 General Info[...]

Page vi of 53 5 Start Up and Op eration 30 5-1 Pre-Opera tional Checklist 30 5-2 Operation 31 6 Maintenance 32 6-1 Genera l Recommendations 32 6-2 Monthly Mainte nance Operations 33 6-2-1 Drive Belt Te nsion 33 6-2-2 Proper Belt Tens ion 33 6-2-3 Belt Rep lacement 34 6-3 Removal and Replacement of the S creen 34 6-4 Inspection an d Adjustment of Kn[...]

Page vii of 53 Table of Figures 1. Safety Switch 13 2. Control Panel 14 3. Noise Test Specifications 15 4. Average Sound Levels 15 5. Noise Test Method 16 6. Main Components of Standard Gran ulators 19 7. Overall Dimensions and Weights 20 8. Lifting the Granulator 23 9. Inserting the Bin 25 10. Electrical Connections 26 11. Removing the Screw Knob [...]

Page viii of 53 15. Removing The Screen 35 16. Inspection of Knives 37 17. Bed Knife Specifications 40 18. Rotor Knife Specifications 40 19. Cutting Chamber - Vertical Cross Section 45 20. Cutting Chamber - Longitudal Cross Section 46 21. Cutting Chamber - Front View 47 22. Cutting Chamber - Rear View 48[...]

Page 9 of 53 1 Safety Considerati ons 1-1 Safet y Guidelin es Our granulators are desi gned to provide safe and reliable oper ation when installed and operat ed within design specifications, followin g national and local safet y codes. To avoid possible person al injury or equipment dam age when installing, operating, or maint aining this granulato[...]

Page 10 of 53  EAR PROTECTION m ay be required when operating the machine during granulation of ver y hard or nois y materials. The Occupational Safet y and Health Act of 1970 has established guidelines for P ermissible Noise Ex posures (OSHA 1910.95) that should be f ollowed.  NEVER attempt t o operate the granulator unless i t is fully asse[...]

Page 11 of 53 For further information on granulator sa fety, installation, and operation, see the American N ational Standard for Plastics Machinery  Granulator s, Pelletizers, and Dicers Used for Size Reduction of Plastics  Construction, C are, and Use . ANSI B151.11-1982. Sterling has long recogni zed the importance of safet y and has desig[...]

Page 12 of 53 !! CAUTI ON !! NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING H ANDS ON ROTOR, ROTOR KNIV ES, OR WI THIN THE CUTTING CH AMBER. HANDS MUST BE KEP T CLEAR OF THE RO TATIONAL P A TH OF THE ROTOR KNIVES. A block of wood should be used to exert force on the rotor, usually in the direction opposite normal rotati on. Good footing on a cle[...]

Page 13 of 53 The upper part of the cuttin g chamber is protected b y the feed hopper, used to insert material to b e granulated while the lower part is protected by the screen, and screen suppo rt. These components are fixed b y a screw knob, unscrewing releas es a safety switch key (Figure 1), which cuts off the electric suppl y to the motor, cau[...]

Page 14 of 53 3. Tag the machine as Out of Service. 4. Make sure the rotor has c ome to a complete stop. Warning ! Wear protec tive gloves whe n exposed to knives. Figure 2: Control Pan el 1-3-3 Sound Enclos ure Research has been conducted to assess the noise generated b y the operation of Sound Enclos ed Granulator Models BP1012 and BP1018. The te[...]

Page 15 of 53 • S.P. I . Noise Test – Noise M easurement Procedure for Granulators, by the Societ y of the Plastic Industry. • UNI7712 – Machine Too ls – Determining Noise in the W orking Environment – 1977 • ISO3746 – Acoustics – Determination of Sound Power Level of Noise Sources – Enginee ring method for free field condit ion[...]

Page 16 of 53 Figure 5: Noise Test M et hod Machine bei ng tested Feeding Po in t Operator Position 1 2 3 4 1.0 m 1.0 m Position of the phonom etric detectors (h =1.5 m ) 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[...]

Page 17 of 53 2 General Information 2-1 Introductio n This family of granulators has been desi gned to granulate plasti c material such as sprues, runn ers, and small reject parts. The granulator is comprised of an infeed hopp er into which the material to be granulated i s fed, mounted on a cuttin g chamber in which a series of rotar y and bed kni[...]

Page 18 of 53 The Maintenance chapter is intended to serve as a source of detailed assembl y and disassembly instructions for those areas of the equipment requiring service. Prev entive maintenance section s are included to ensure that your granulator provides ex cellent, long service. The Troubleshooting chapter serves as a guide for identificatio[...]

Page 19 of 53 2-4-2 Main Components of Standard Gr anulators (See Figure 6) 1. Infeed hopper 2. Cutting chamber 3. Bin for granulated materi al 4. Belt drive 5. Control panel 6. Electric motor Figure 6: Main Componen ts of Stand ard Granulat ors 2-4-3 Optional Equi pment • Conveyor • Other screen hole sizes • Blower/airveying s ystem • Vacu[...]

Page 20 of 53 Figure 7: Overall Dim ensions and W eights Model A B C D Weight BP1012 12 1/4 (311 m m) 29 7/8 (759 m m) 27 (686 mm ) 30 (762 mm) 1200 lbs (5 00kg) BP1018 18 1/4 (464 m m) 35 7/8 (911 m m) 17 3/8 ( 441 mm ) 38 3/16 (970 m m ) 1350 lbs (5 80kg)[...]

Page 21 of 53 3 Shipping Inf ormation 3-1 Unp acking a nd Inspec tion You should inspect your granulator for possible ship ping damage. Thoroughly check the equi pment for any damage th at might have occurred in transit, such as broken or loo se wiring and components, loose hardware and mountin g screws, etc. 3-2 In the E vent of Shipping Dama ge I[...]

Page 22 of 53  Operating and Installation packet  Detailed recommended s pare parts list  Electrical schematic and p anel layout drawings  Component i nstruction manuals Re-inspect the container and packin g material to see if you missed any smaller items durin g unpacking. 3-4 If the Ship ment i s Not Correc t If the shipment is not wh[...]

Page 23 of 53 drawings, electrical sche matics, and manual from the base evacuation area. You can now have the machine lifted f rom the skid. A forklift is ideal for the purpose, but take care to properly po sition the fork s between the casters and t he centrally mounted evacuation pi pe from the side of the mach ine. (See Figure 8) Figure 8: Lift[...]

Page 24 of 53 4 Install ation 4-1 Lif ting Importan t! Before lifting or moving the granula tor, check the relative w eight shown on the shipping pape rs and in Figure 7. To facilitate the lifting o peration using forklift trucks, t he drop box has been removed from the granulator and is packed with an y spare parts. When using a forklift to m ove [...]

Page 25 of 53 water. The granulator should be in stalled in an inside covered, weather-proof environment and away from an y areas where water collects on the floor. Once the granulator is in position, the front panel must be opened in order to insert the bin as illustrated in Figure 9. Figure 9: Inserting the Bin 4-3 Electrical C onn ection It is e[...]

Page 26 of 53 1. Open the back cover, and i nsert the power cable from underneath the granulator. 2. Pass the power cable thro ugh the appropriate hole, and i nsert it into the control panel thr ough a connector placed at t he base. 3. Connect the three phase wi res to the appropriate terminals o f the main switch, and connect the ground wire to th[...]

Page 27 of 53 4. Pivot back the feed hopper to gain fr ee access to the cutting chamber. 5. Check that there are no f oreign objects in the cutting chamber. 6. Check to be sure the bed knife and rotor knife bolts are at the proper torque and the knife gap is set according to specifications. See Sections 4 -4-4 and 6-4. 7. After completing the check[...]

Page 28 of 53 If the rotation direction is correct, t he granulator is read y to use. If the rotation direction is incorrect, rev erse the rotor direction as follows: !!Warning !! A LICENSED ELECTRICI AN must carry out this operation. 1. Disconnect and lockout the power to th e machine at the incoming power source. If the disconnect is not lockable[...]

Page 29 of 53 Before undertaking an y ty pe o f work on the machin e, use a feeler gauge to check the distance betw een the bed knives and the rotor knives (the knife gap). To access the cutting chamber, follow t he same procedure and observe the precautionary steps given in Section 4-4-1. Befor e proceeding to the checks, it is advisable to block [...]

Page 30 of 53 5 Start Up and Operat ion 5-1 Pre-Opera tional C hecklist To ensure the granulator is ready for operation, perform the tasks listed on the following pre-operati onal checklist. Make sure that all electrical and mechani cal machine elements are inspected and any defects corrected first .  Have all installation and preparation instru[...]

Page 31 of 53 5-2 Operatio n The granulator can be op erated in a vertical top feed pos ition or in a horizontal front feed posit ion. Before starting the granul ator, always check for and remove tools or any other objects placed on t he granulator. Turn the P ower disconnect switch to “ON”, pull the Start button, and release it when the motor [...]

Page 32 of 53 6 Maintenance 6-1 General Re comme ndations Before carrying out an y work on the granulator, carefull y read the instructions contained in thi s manual. NOTE: Only specialist and competent personnel sh ould carry out this operation. All maintenance work must be carried out with the granulator switched off and with the power suppl y di[...]

Page 33 of 53 6-2 Monthl y Maintenance Opera tions 6-2-1 Drive Bel t Tension NOTE: Thi s operation should be carried out by an operator / mechanical maintenance engin eer. For the granulator to function correctly, it is extremely important that the drive belt is always tight. Correct tension reduces the load of the rotor bearings and m inimizes wea[...]

Page 34 of 53 Figure 14: Belt T ension Ch art Belt Cross Section Small O.D. R ange ∗ ∗ ∗ ∗ Deflection Fo rce Lbs/V-belt Run-In Normal Runnin g 3VX 3.7 7.0 4.7 For best performance, the force measu red on the gauge should be between the minimum an d maximum values shown on the chart. If there is not enough defle ction force, the belts should[...]

Page 35 of 53 4. Remove the screw knob that hol ds the hopper on top of th e cutting chamber. Carefull y lower the screen cradle assembl y, resting it on the base. 5. Remove the screen, keep ing it in a horizontal posi tion. (See Figure 15.) 6. Replace the screen with a new one, tighten the screw kno b, reposition the bin, and cl ose the front pane[...]

Page 36 of 53 4. Using a feeler gauge, me asure the gap between th e rotor and knife cutting edges. Check each rotor kni fe to find the “high knife” or the knife that m easures the smallest gap. If the gap is substantiall y greater than the specified 0.006” - 0.008” (0.15 mm – 0.2 mm), th e knives need readjustment. 5. Loosen the bed knif[...]

Page 37 of 53 Figure 16: Inspection of Kniv es 6-5 Remo ving and Replacing Bed Kni ves NOTE: Thi s procedure should be performed by a qualifi ed operator / maintenance mechani c. Protective gloves must be worn to avoid injury when handlin g the cutting knives. To remove and replace bed kniv es, complete the fol lowing procedure: 1. Open the granula[...]

Page 38 of 53 8. Install new or sharpened bed kni ves on each knife seat, making sure that the rotor is blocked to prevent it from rotating while installing each knife. Be sure to pl ace the bed knives in t he correct positions  the rear (down strok e) bed knife must be placed with the extended cutt ing edge on top, and th e front (upstroke) bed[...]

Page 39 of 53 5. Loosen and remove the k nife bolts and lift the knife off the knife seat removing it from t he cutting chamber. 6. Perform the above steps until all the rotor knives are removed. NOTE: Before replacin g the rotor knife with new or sharpened knives, wipe the knife seats on th e rotor, being sure to clean off all process material. Th[...]

Page 40 of 53 Figure 17: Bed Knife Specificatio ns 6-8 Specifications for Re-sharp ening Ro tor Kni ves All the rotor knives must be re-sh arpened in sets. Each knife within a set must have a tolerance withi n 0.003” (0.05 mm) for the tot al height, heel to cutting edge. Greater v ariations within a set will result in improper knife gap setti ngs[...]

Page 41 of 53 7 Troublesh ooting The following tables list probl ems that could occur when usin g the granulator. This general in formation ma y help to locate the cause of the problem and allow it to be resolved promptly. When a problem arises, it is advisable to perfo rm the simplest checks before proceeding to mor e complicated ones, whic h may [...]

Page 42 of 53 Problem Possible Cau ses Possible Re medies Abrasive m aterial Contact the su pplier for special knives Rotor Jamm ing Excessive infeed m aterial Total or part ial obstr uction of the screen ho les Insuff icient belt tensio n Knives worn Distance bet ween the knives too small or too l arge Screen holes too sm all Failure of air c onve[...]

Page 43 of 53 7-2 Electrical P robl ems Problem Possible Cau ses Possible Re medies Machine sto ps for no apparent re ason Safety switch h as stop ped power C heck that the knobs that operate the safet y switch are ti ghtened Electric m otor does not start No power Overload fai lure Safety switch n ot work ing Cutting cham ber too f ull Check fuses[...]

Page 44 of 53 8 Spare Part s When requesting spare parts, alwa ys quote the granulator model and serial number (from the granulator l abel), as well as the table number and reference nu mber (from the spare parts tables) and the quantity required. 8-1 T able 1: Re com mended Sp are Par t s List Item 1012 Quantity 1018 Quantity Mat erial Rotor Knife[...]

Page 45 of 53 Figure 19: Cutting C hamber – Vertical C ross Sectio n[...]

Page 46 of 53 Figure 20: Cutting C hamber – Lo ngitudal Cross S ection[...]

Page 47 of 53 Figure 21: Cutting C hamber – F ront Vi ew[...]

Page 48 of 53 Figure 22: Cutting C hamber – Rear View[...]

Page 49 of 53 9 Typical W iring Diagram[...]

Page 50 of 53 10 Contact Inf ormati on Parts Department Call Spare P arts Exp ress t oll-free 8am – 8PM EST (800) 2 29-2919. St erling O EM quality replacement and spa re parts en sure op eration at design spe cification s. Please hav e the m odel and serial num ber of your equip ment w hen you call . Consult th e Custom er Parts L ist includ ed [...]

Page 51 of 53 Service N otes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ _____[...]

Warranty Sterling war rants all eq uipm ent m anufactured b y it to be f ree from defects in workm anship and m aterial when used under rec omm ended conditions . The Com pany’s ob ligation is limited to repair or rep lace FOB the factor y any parts t hat are return ed prepa id within o ne year of equipm ent shipm ent to the or iginal purchaser, [...]

124 Roddy Avenue • South Attleboro, MA 02703 -7900 (508) 399-3100 • Fax (508) 399-3150[...]