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Sterling BJ1-625 Installation Manual

Sterling screenless granulator operation and installation manual
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$30.
Operation
Installation Manual
and
EX Series Screenless Granulator
Important! Read Carefully Before Attempting to Install or Operate Equipment
Bulletin No. BJ1-625

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  Summary of Contents for Sterling BJ1-625

  • Page 1 $30. Operation Installation Manual EX Series Screenless Granulator Important! Read Carefully Before Attempting to Install or Operate Equipment Bulletin No. BJ1-625...
  • Page 2 Ball & Jewell can advise you on proper selection and sizing of systems for your Ball & Jewell is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to Bulletin No. BJ1-625 © Copyright Ball & Jewell Corp. 2002 ________________...
  • Page 3 Safety Considerations Ball & Jewell EX Series Granulator Sprue and Runner Cutters 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...
  • Page 4 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 and interlocks in place and functional.
  • Page 5 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. Ball & Jewell has long recognized the importance of safety and has designed and manufactured its equipment with operator safety as a prime consideration.
  • Page 6: Table Of Contents

    Table of Contents Error! No table of contents entries found. General Information 1-1 Introduction 1-1-1 How to Use This Manual 1-1-2 Safety Symbols Used in This Manual 1-2 Granulator Specifications 1-3 Standard Features 1-4 Available Options Shipping Information 2-1 Unpacking and Inspection 2-2 In the Event of Shipping Damage 2-3 If the Shipment is Not Complete 2-4 If the Shipment is Not Correct...
  • Page 7 Maintenance 5-1 Maintaining Drive Components 5-2 Replacing Timing Belts 5-3 Lubrication Specifications and Considerations 5-4 Knife Recommendations and Adjustments 5-4-1 Removing, Replacing and Adjusting Granulator Combs 5.4.1.a. Removing Rotor Combs: 5.4.1.b. Removing Bed Combs: 5.4.1.c. 5-5 Adjusting the Sensitivity of the Optional Bin Level Monitor 5-6 Recommended Spare Parts List Troubleshooting Charts and Figures...
  • Page 8 List of Figures Belt Tensioning Chart Recommended Spare Parts List Categories S Series Screenless Granulator (Front) S Series Screenless Granulator (Back) Segregation Chamber Access Cutting Chamber Detail Discharge Options Knife Bolt/Screw Tightening Torque Specifications Page viii...
  • Page 9 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 plant, inspect it carefully for shipping damage before uncrating and immediately report any damage to your transportation company.
  • Page 10 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, which is proved to be defective when shipped.
  • Page 11: General Information

    1 General Information Introduction The Ball & Jewell EX Series Screenless Granulators are designed to uniformly and consistently size-reduce solid material scrap. They have been engineered to consistently deliver clean granulate with a minimum of fines and longs. The rotor on which the combs and breaker bars are mounted is a machined steel unit supported by bearings mounted outside the cutting chamber.
  • Page 12: Safety Symbols Used In This Manual

    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.
  • Page 13: Granulator Specifications

    Granulator Specifications Table 1: Granulator Specifications Cutting Circle 9.7” (247 mm) Throughput 30 lbs./hr (14 kg/hr) Cutting Chamber 9” x 9” (229 mm x 229 Rotor Knives Hardened 8620 alloy steel Bed Comb Reversible 1/4” (6.4 mm) comb Discharge Bin 0.70 cu.
  • Page 14: Available Options

    • No Tools Required to open the cutting chamber/segment chamber/hopper chute • Four (4) swivel casters Available 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”(~6MM), •...
  • Page 15: Shipping Information

    Unpacking and Inspection 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. Shipping Information You should inspect your Ball & Jewell EX Series Screenless Granulator for possible shipping damage.
  • Page 16: If The Shipment Is Not Complete

    If the Shipment is Not Complete Check the packing list as back-ordered items are noted on the packing list. You should have: 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 Ball &...
  • 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 corrosion are coated with a quality rust preventative, and the machine is covered with heavy-duty polyethylene to protect it from moisture and dirt.
  • Page 18: Installation

    Scope General Set-Up Inspecting and Cleaning Granulator Components The cutting chamber combs are EXTREMELY SHARP. Always wear heavy gloves and exercise care when working in the cutting chamber. This chapter contains all instructions required for experienced installation personnel to install the granulator and prepare it for production.
  • Page 19: Completing The Installation Of Your Granulator

    The cutting chamber combs are EXTREMELY SHARP. Always wear heavy gloves and exercise care when working in the cutting chamber. Do not run granulator until upper machine assembly is fully latched down. Completing the Installation of Your Granulator 3. Look inside the base evacuation area. Spare parts, such as combs, are often placed inside this area for shipping purposes.
  • Page 20: Electrical Considerations

    Electrical Considerations Improper electrical connections can damage the granulator and CAUSE SERIOUS OPERATOR INJURY OR DEATH! NOTE: Make sure to provide a correctly-sized and protected supply of Electrical connections must comply with all applicable electrical codes. Voltage must be within plus or minus ten percent (+/- 10%) of the nameplate rating. Make sure your installer provides external protection.
  • Page 21: Electrical Service Connections

    Before undertaking any machine repairs or maintenance, always make certain that the machine disconnect switch is turned to the OFF position or that the control enclosure is disconnected from the main power source. LOCK OUT all sources of power, including the main disconnect switch, and follow all of your plant lockout procedures.
  • Page 22: Hopper Safety Disconnect

    3-7-1 Hopper Safety Disconnect If the machine does not shut off as a result of this test, disconnect the machine from the power source immediately and call the Ball & Jewell Service Department 3-7-2 Motor Rotation Direction 3-7-3 Accessory Equipment Department at 1-800-229-2919 for voltage modification instructions.
  • Page 23: General Operation

    Scope Pre-Operational Checklist General Operation This chapter contains the information required to carry out pre- operational procedures, as well as general operation. The checklist of items listed below should always be reviewed prior to a production run. To ensure the granulator is ready for operation, perform the tasks listed on the following pre-operational checklist.
  • Page 24: Granulator Operation

    Granulator Operation The machine is ready for operation when all doors, covers, guards, and limit switches are in place, securely fastened and functional, and all accessory components are properly connected. 1. Turn the main disconnect to the ON position. 2. Start the granulator by pressing the start button at the operator 3.
  • Page 25: Shutdown Conditions

    Never close the chamber access doors without checking that all three (3) segregation chambers are in place and hand knobs are tight. Never attempt to run machine without all three (3) segregation chambers in place and tightened. Always wear heavy gloves and exercise care when working in the cutting Shutdown Conditions 4-5-1 Emergency Stops...
  • Page 26: Maintenance

    Maintaining Drive Components For continuing reliable operation of the granulator, it is of the utmost importance that the motor drive belt tension is correct. Correct tension reduces wear on the rotor and motor bearings and reduces slip to a minimum. Belt drives must be tensioned at the “Run-In”...
  • Page 27: Replacing Timing Belts

    Figure 1: Belt Tensioning Chart Design HP Belt Span Replacing Timing Belts Lubrication Specifications and Considerations New Belt Deflection = Belt Span 1. Remove the guard cover. 2. Find and loosen the two (2) interior guard plate screws near the gearmotor timing belt drive from inside the sprocket guard housing.
  • Page 28: Knife Recommendations And Adjustments

    suitability for use in heavy-duty 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 amount of grease applied every 2,000 hours should be adequate to ensure long life.
  • Page 29: Removing Bed Combs

    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 spacers from the hex shaft. 9. Replace the necessary cutter(s). (Make sure the cutters are staggered by indexing the clearance hold 1 turn clockwise for each cutter.) 10.
  • Page 30: Adjusting The Sensitivity Of The Optional Bin Level Monitor

    Adjusting the Sensitivity of the Optional Bin Level Monitor Because electrical power must be supplied to the sensor to permit testing and adjustment, it is EXTREMELY VITAL that you secure the machine for normal Do so by closing the cutting chamber and hopper access door, which returns the safety limit switch to the closed position, PRIOR to beginning any sensor adjustments to ensure the safety of personnel.
  • Page 31: Recommended Spare Parts List

    Step 1: Fill the bin with granulate of the 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 covering located on the rear wall of the bin.
  • Page 32: Recommended Spare Parts List Categories

    available when calling Spare Parts 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 stamped on them. The recommended spare parts list does not include all parts that are available for purchasejust the parts most appropriate for your particular machine.
  • Page 33: Troubleshooting

    Problem Feedstock may be hung up inside the hopper. No granulate Vacuum line may be clogged. Comb gap is too large. Stringy granulate Combs are dull. Combs are dull. Fines Overloading of the machine. Excessive power required; Combs are dull. blown fuses Comb gap is too large.
  • Page 34 Problem Combs are dull. Overloading of the machine. Transition tubing is clogged. Granulate builds up in the Vacuum is not evacuating properly. transition or tubing Possible Cause Reverse bed comb or replace combs and re-install. Regulate the infeed of scrap to uniformly feed the machine.
  • Page 35 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Page 35...
  • Page 36 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Page 36...
  • Page 37 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ Page 37...
  • 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 operation at design specifications. Please have the model and serial number of your equipment when you call. Consult the Customer Parts List included in your information packet for replacement part numbers.
  • Page 39: Charts And Figures

    Figure 3: EX Series Screenless Granulator (Front) Timing Belt Drive Discharge Area Figure 4: EX Series Screenless Granulator (Back) Charts and Figures Cutting Chamber/Rotor Combs Segregation Chambers Page 39 Doors Opened for Service/Cleaning Robot Chute (4) way opening Limit Switch Electrical Control Enclosure Gear Motor...
  • Page 40: Segregation Chamber Access

    Figure 5: Segregation Chamber Access Segregation Chambers (Removable) Hand Knobs Figure 6: Cutting Chamber Detail Large breaker Page 40 Rotor cutters Discharge Area Bed Comb Adjustment CAMS- Comb located under shield Small Breakers Rotor Combs & Spacers...
  • Page 41: Discharge Options

    Figure 7: Discharge Options Rear- Vacuum Compressed Air Manual Venturi Page 41...
  • Page 42: Knife Bolt/Screw Tightening Torque Specifications

    Figure 8: Knife Bolt/Screw Tightening Torque Specifications Screw Size Specifications are for Grade 10.9 Fine Threads, in un-lubricated conditions. Tightening Torque Lbs./Ft. Page 42...
  • Page 43 Warranty Sterling, Inc. warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace (FOB the factory) any parts for a period of 12 months from initial start-up or 18 months from the date of start-up, whichever is less, which in the Company’s opinion, are defective.
  • Page 44 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...

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