Sterling EX Series manual

Operation and Installation Manual EX Series Screenless Granulator Important! Read Carefully Before Attempting to Install or Operate Equipment Bulletin No. BJ1-625 $30. 00[...]

Page ii Write down your granulat or ________________ ________________ serial numbers here ________________ ________________ for future reference ________________ ________________ Ball & Jewell can advise you on proper selection and sizing of systems for your operating environment. Ball & Jewell is committed to a conti nuing program of pr od[...]

Page iii Safety Considerations Ball & Jewell EX Series Granulator Sprue and Runner Cutters are designed to provide safe and reliab le operation when installed and operated within design specifica tions, following national and local safety codes. To avoid possible personal injury or equipment damage when installing, operating, or maintain ing th[...]

Page iv ; EAR PROTECTION may be required when operating the machine during granulation of very hard/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 [...]

Page v For further information on granul ator safety, installation, and operation, see the American National Standard for Plastics Machinery - Granulators, Pelletizers, And Dicers Used For Size Reduction of Plastics - Constr uction, Care, and Use. ANSI B151.11-1982. Ball & Jewell has long recognized th e im portance of safety and has designed a[...]

Page vi Table of Contents Error! No table of contents entries found. 1 General Information 11 1-1 Introduction 11 1-1-1 How to Use This Manual 11 1-1-2 Safety Symbols Used in This Manual 12 1-2 Granulator Specifications 13 1-3 Standard Features 13 1-4 Available Options 14 2 Shipping Information 15 2-1 Unpacking and Inspection 15 2-2 In the Event of[...]

Page vii 5 Maintenance 26 5-1 Maintaining Drive Components 26 5-2 Replacing Timing Belts 27 5-3 Lubrication Specificat ions and Considerations 27 5-4 Knife Recommendations and Adjustments 28 5-4-1 Removing, Replacing and Adjusting Granulator Combs 28 5.4.1.a. Removing Rotor Combs: 28 5.4.1.b. Removing Bed Combs: 29 5.4.1.c. Installing Bed Combs: 29[...]

Page viii List of Figures 1. Belt Tensioning Chart 27 2. Recommended Spare Parts List Categories 32 3. S Series Screenless Granulator (Front) 39 4. S Series Screenless Granulator (Back) 39 5. Segregation Chamber Access 40 6. Cutting Chamber Detail 40 7. Discharge Options 41 8. Knife Bolt/Screw Tightening Torque Specifications 42[...]

Page ix Ball & Jewell Warranty Information Thank you for your purchase of your new EX Series Screenless Granulator. We are confident that you will have excellent results and trouble-free operation with this machine. When the machine arrives at your plan t, in spect it carefully for shipping damage before uncrating and immediately report any dam[...]

Page x Ball & Jewell 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 S Series granulator without charge FOB factory, within one (1) year after date of original purchase, [...]

Page 11 1 General Information 1-1 Introduction The Ball & Jewell EX Series Screenless Granulators are designed to uniformly and consistently size-reduce so lid material scrap. They have been engineered to c onsistently deliver clean granulate with a minimum of fines and longs. The rotor on which the combs and breaker bars are mounted is a machi[...]

Page 12 standard shop procedures perfor med at shift, daily, and weekly intervals. The Operation chapter includes a description of electrical and mechanical controls, in addition to inform ation for operating the granulator safely and efficiently. The Maintenance chapter is in tended to serve as a source of detailed assembly and disassembly instruc[...]

Page 13 1-2 Granulator Specifications Table 1: Granulator Specifications EX909 EX913 EX918 Cutting Circle 9.7” (247 mm) 9.7” (247 mm) 9.7” (247 mm) Throughput 30 lbs./hr (14 kg/hr) 40 lbs ./hr (18 kg/hr) 50 lbs./hr (23 kg/hr) Cutting Chamber 9” x 9” (229 mm x 229 mm) 9” x 13” (229 mm x 330 mm) 9” x 18” (229 mm x 457 mm) Rotor Kniv[...]

Page 14 • No Tools Required to open the cutting chamber/segment chamber/hopper chute • Four (4) swivel casters 1-4 A vailable Options Available standard options for EX Series Granulators include: • Alternate feed chutes. • Alternative voltages : 208/3/60, 380/3/ 50, 415/3/50, 575/3/60 • Alternate comb tooth sizes .185”(~5MM) and .220”[...]

Page 15 2 Shipping Information 2-1 Unpacking and Inspection You should inspect your Ball & Jewell EX Series Screenless Granulator for possible shipping damage. Thoroughly check the equipment for any damage that m ight have occurred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. 2-2 In the Eve[...]

Page 16 2-3 If the Shipment is Not Complete Check the packing list as back-ordered items are noted on the packing list. You should have: ; Ball & Jewell EX Series Screenless Granulator ; Bill of lading ; Packing list ; Operating and Installation packet ; Detailed recommended spare parts list ; Electrical schematic a nd panel layout drawings ; C[...]

Page 17 Your EX Series Screenless Granulator is mounted on a wooden skid and blocked and banded to secure it for shipment. All non- painted items subject to corros ion are coated with a quality rust preventative, and the machine is covered with heavy-duty polyethylene to protect it from mois ture and dirt. Granulators are normally shipped completel[...]

Page 18 3 Installation 3-1 Scope This chapter contains all inst ructions required for experienced installation personnel to install the granulator and prepare it for production. You must follow all instructions carefully and in the sequence presented. Be sure to observe all DANGER, WARNING, CAUTION, and NOTE statements to prevent personal injury or[...]

Page 19 3. Look inside the base evacuation area. Spare parts, such as combs, are often placed inside this area for sh ipping purposes. ! CAUTION ! The cutting chamber combs are EXTREMELY SHARP. Always w ear heavy gloves and exercise care when worki ng in the cutting chamber . 4. Carefully inspect the interior of the cutting chamber and evacuation a[...]

Page 20 4. Position and connect any optional accessory equipment such as vacuum lines, conveyors, and se parators. Ensure all tubing joints are securely clamped and supported. 3-5 Electrical Considerations !!! DANGER !!! Improper electrical connections can dama ge the granulator and CAUSE SERIOUS OPERATOR INJURY OR DEATH! EX Series Screenless Granu[...]

Page 21 Make certain all electrical connections are properly made and supported between accessories and the control enclosure (refer to the wiring diagram for wire and terminal connections). !!! DANGER !!! Before undertaking any machine repairs or maintenance, always make certain that the machine disconnect switch is tu rned to the OFF position or [...]

Page 22 Department at 1-800-229-2919 for voltage modification instructions. 3-7-1 Hopper Safety Disconnect 1. Turn the main disconnect to the ON position. 2. Press the granulator START button to start the m achine. 3. Test the front base door and the hopper access door: unlatch the two (2) latches and open th e doors approximately two (2) inches to[...]

Page 23 4 General Operation 4-1 Scope This chapter contains the inform ation required to carry out pre- operational procedures, as well as general operation. The checklist of items listed below s hould always be reviewed prior to a production run. 4-2 Pre-Operational Checklist To ensure the granulator is r eady for operation, perform the tasks list[...]

Page 24 ; Are all electrical enclosure box es tightly closed and clamped shut? ; Are all personnel clear of the machine? 4-3 Granulator Operation The machine is ready for operation when all doors, covers, guards, and limit switches are in place, securely fasten ed and functional, and all accessory components are properly connected. 1. Turn the main[...]

Page 25 ! CAUTION ! Never close the chamber access doors wi thout checking that all three (3) segregation chambers are in place and hand knobs are tight. Never attempt to run machine without all three (3) segrega tion chambers in place and tightened. Always wear heavy gloves and exercise care w hen working in the cutting chamber. 4-5 Shutdown Condi[...]

Page 26 5 Maintenance 5-1 Maintaining Drive Components For continuing reliable operation of the granulator, it is of the utmost importance that the mo to r drive belt tens ion is correct. Correct tension reduces wear on th e rotor and motor bearings and reduces slip to a minimum. Belt drives must be tensioned at the “Run-In” recommended force. [...]

Page 27 Figure 1: Belt Tensioning Chart New Belt Used Belt Design HP Min Max Min Max 1 442 443 438 440 2 466 469 459 462 3 490 495 480 485 5-2 Replacing Timing Belts 1. Remove the guard cover. 2. Find and loosen the two (2) interi or guard plate screws near the gearmotor timing belt drive from inside the sprocket guard housing. 3. Loosen the gear m[...]

Page 28 suitability for use in heavy-dut y applications under heavy shock loads. It also contains rust inhibitors, has high temperature stability, and exhibits good water resistance. Bearings should be lubricated with care. Too much grease applied to the bearings at one time can rupture bearing seals. Under normal operating conditions, a moderate a[...]

Page 29 6. Lift the rotor out of cutting chamber 7. Remove the three (3) socket head cap screws that hold the rotor assembly together. 8. Slide the cutters and space rs from the hex shaft. 9. Replace the necessary cutter(s). (Make sure th e cutters are staggered by indexing the cleara nce hold 1 turn clockwise for each cutter.) 10. Re-install the t[...]

Page 30 the hex cams have a “dot” machined on the cam face to show the high point when installed. 3. Assemble a washer and hex cap screws into each adjustm ent cam hole and finger tighten them. 4. Slowly turn the rotor back and forth. Using the right hand and left hand adjustment cams, m ove the bed comb in or out as required to clear the rotor[...]

Page 31 Step 1: Fill the bin with granulate of th e material you intend to run through the granulator. Make sure the bin is filled to a level that covers the front face of the latex sensor c overing located on the rear wall of the bin. Step 2: Make sure that power is supplied to the machine by turning the main disconnect switch to th e ON position [...]

Page 32 available when calling Spare Pa rts Express at 1-800-229-2919 for new replacement OEM parts. NOTE: Refer to part numbers when ordering replacement parts. Check the parts carefully, as they may have numbers etched or stam ped on them. The recommended spare pa rts list does not include all parts that are available for purchase  just the pa[...]

Page 33 6 Troubleshooting Problem Possible Cause Solution Feedstock may be hung up inside the hopper. Shut machine down and chec k. No granulate Vacuum line may be clogged. Clean as needed. Comb gap is too large. Adjust to proper gap specification. Stringy granulate Combs are dull. Reverse bed comb or replace combs and re-in stall. Fines Combs are [...]

Page 34 Problem Possible Cause Solution Combs are dull. Reverse bed comb or replace combs and re-in stall. Overloading of the machine. Regulate the infeed of scrap to uniformly feed the machine. Transition tubing is clogg ed. Clean as required. Granulate builds up in the transition or tubing Vacuum is not evacuating properly. Check per manufacturer[...]

Page 35 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ____________[...]

Page 36 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ____________[...]

Page 37 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ____________[...]

Page 38 Parts Department Call Spare Parts Express toll-free 8am – 8PM EST (800) 229 -2919. Ball & Jewell OEM quality replacement and spare parts ensure oper ation at design specifications. Please have the model and serial number of your equipment when you ca ll. Consult the Customer Parts List included in your information packet for replaceme[...]

Page 39 7 Charts and Figures Figure 3: EX Series Screenless Granulator (Front) Figure 4: EX Series Screenless Granulator (Back) Doors Opened for Service/Cleaning Discharge Area Segregation Chambers Cutting Chamber/Rotor Combs Timing Belt Drive Robot Chute (4) way opening Limit Switch Electrical Control Enclosure Gear Motor[...]

Page 40 Figure 5: Segregation Chamber Acce ss Figure 6: Cutting Chamber Detail Discharge Area Rotor cutters Segregation Chambers (Removable) Hand Knobs Small Breakers Rotor Combs & Spacers Bed Comb Adjustment CAMS- Comb located under s hield Large breaker[...]

Page 41 Figure 7: Discharge Options Rear- Vacuum Compressed Air Venturi Manual[...]

Page 42 Figure 8: Knife Bolt/Screw Tightening Torque Spe cifications Tightening Torque Screw Size Lbs./Ft. NM. M8 28 38 M10 54 73 M12 100 135 M14 155 210 M16 232 315 M18 340 460 M20 472 640 M24 810 860 Specifications are for Grade 10.9 Fine Th reads, in un-lubricated conditions.[...]

Warranty Sterling, Inc. warrants all equipment manufactu red by it to be free from defects in workmanship and material when used under recomme nded conditions. The Company’s obli gation is limited to repair or replace (FOB the factory) any parts for a peri od of 12 months from initial start-up or 18 months from the date of start-up, whichever is [...]

Auxiliary Equipment for the Process Industries PO Box 245018 5200 West Clinton Avenue • Milwaukee, WI 53224-9518 (414) 354-0970 • Fax (414) 354-6421 Scrap Process Heating/ Automated Recovery Systems Cooling Parts Removal[...]