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3devo GP20 Hybrid User Manual

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GP20 Hybrid
Version 2.0 – October 2023
English user guide

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Summary of Contents for 3devo GP20 Hybrid

  • Page 1 GP20 Hybrid Version 2.0 – October 2023 English user guide...
  • Page 2 COMPANY INFO 3devo B.V. Atoomweg 478 3542 AB Utrecht The Netherlands www.3devo.com support.3devo.com...

  • Page 3: Table Of Contents

    INSTALLATION INSTRUCTIONS TROLLEY .............. 17 3.2.2. INSTALLATION INSTRUCTIONS GP20 SHREDDER ..........19 3.2.3. INSTALLATION INSTRUCTIONS GP20 GRANULATOR ........... 24 3.2.4. INSTALLATION INSTRUCTIONS GP20 HYBRID ............28 3.3. PREPERATION INSTRUCTIONS ..................34 3.3.1. MOUNTING THE CONTAINER ................. 35 3.3.2. MOUNTING THE HOPPER ..................37 3.3.3.
  • Page 4 3.3.4. CLEANING THE GP20 GRANULATOR ..............42 3.4. USER INTERFACE INSTRUCTIONS ................44 3.4.1 STARTING THE GP20 GRANULATOR ................44 3.5. ADJUSTING AND MAINTENANCE................. 46 3.5.1. HOPPER ADJUSTMENTS ..................46 3.5.1.1. ADJUSTING THE FEEDING APERTURE ..............46 3.5.1.2. ADJUSTING THE BELT SCRAPERS ................48 3.5.1.3.

  • Page 5: Safety Instructions

    The GP20 Hybrid is a powerful and effective plastic processing machine, processing your plastic waste plastic to granulate. The processing process inside the GP20 Hybrid consist of a multitude of moving components, moving at high speeds and/or great force. Which if improperly used can cause serious harm.
  • Page 6 Never modify or manipulate any of the safety switches or other components of the machine, this can cause extremely dangerous situations. ⚠ WARNING Only use the GP20 Hybrid with the 3devo hopper mounted on the machine. ⚠ WARNING Never change or remove guards when the machine is powered.
  • Page 7 ⚠ CAUTION The machine is designed to process plastics only. Any non-plastic materials that are inserted in the machine can cause the machine blades to wear out fast. Non-plastic materials can also damage the machine itself. Always make sure the plastic parts do not contain any non-plastic pieces or particles.

  • Page 8: Overview

    OVERVIEW 2.1. GP20 HYBRID OVERVIEW Hopper GP20 Shredder GP20 Granulator Trolley Container...

  • Page 9: Hopper Overview

    2.1.1. HOPPER OVERVIEW The hopper prevents the user from getting in contact with the shredder blades and prevents plastic waste from escaping the machine. The Hopper uses a flat belt drive that helps feeding material to the GP20 Shredder and/or GP20 Granulator Hopper connector Mounting slots Input...
  • Page 10 10) Conveyor belt 11) Thumb screw for fixing the belt cover 12) Hooks for toggle clamps 13) Safety sensor actuator Only for GP20 Granulators 14) Granule guard Read more about installing the Hopper in chapter 3.3.2...

  • Page 11: Gp20 Shredder Overview

    2.1.2. GP20 SHREDDER OVERVIEW Control box Shredder blades Hopper detection sensor Scraper comb Positioning pin for hopper Bolts for fixing scraping combs Positioning pin for container Control box connector Bolts for front cover (for removing/installing shredder blades)
  • Page 12 10) Toggle clamps 11) Thumb screw for safety actuator 12) Hooks for toggle clamp of Container or GP20 Granulator 13) Positioning holes for Trolley or GP20 Granulator 14) Motor 15) Bolts for front plate (for removing / installing shredder blades) Only used for GP20 Hybrids 16) Safety sensor actuator for GP20 Granulator Read more about installing the GP20 Shredder in chapter...

  • Page 13: Gp20 Granulator Overview

    2.1.3. GP20 GRANULATOR OVERVIEW Control box Handlebar Toggle clamp Rotary knife...
  • Page 14 10) Granulator stationary knife 11) Positioning pins for Container 12) Actuator for door detection sensor 13) Toggle clamps for hopper (or GP20 Shredder for GP20 Hybrid setup) 14) Bolt for removing/installing the Rotor 15) Hook for Container toggle clamps 16) Positioning holes for Trolley...

  • Page 15: Control Box Overview

    Motor cable port 10) Mounting holes (only used for GP20 Shredder) 11) Mounting holes (only used for GP20 Granulator) 12) Positing hole for Trolley (or Control box / Granulator in GP20 Hybrid mode) 13) Positioning pin (Only used in GP20 Hybrid mode)

  • Page 16: Trolley Overview

    14) Handlebar (Only used for GP20 Shredder or GP20 Granulator) 15) Machine link port (Only used in GP20 Hybrid mode) 2.1.5. TROLLEY OVERVIEW Positioning pins for GP20 Shredder or GP20 Granulator 2x Wheel with brakes 2x Wheel without brakes Wheel assembly Read more about installing the Trolley in chapter 3.2.1...

  • Page 17: Container Overview

    2.1.6. CONTAINER OVERVIEW Positioning slots for GP20 Granulator or GP20 Shredder Actuator for GP20 Shredder or GP20 Granulator safety sensor Toggle clamps Handlebar Container lid Read more about installing the Container in chapter 3.3.1...

  • Page 18: Accessories

    2.2. ACCESSORIES 2.2.1. GENERAL ACCESSORIES 1x Hopper • 1x Trolley • 2x Wheel assembly without brake • 2x Wheel assembly with brake • 16x Button head screw M6 x 20 • 16x M6 washer • 16x M6 lock nut • 1x Container •...

  • Page 19: Gp20 Hybrid Accessories

    2.2.4. GP20 HYBRID ACCESSORIES 1x Machine link cable • 3x Positioning studs • 3x Hexagon head screws M8 x 14 • 3x M8 washer • 2.2.5. OPTIONAL ACCESSORIES 2 teeth shredder blades • 3 teeth shedder blades • 7 teeth shredder blades...

  • Page 20: Technical Specifications

    Energy consumption shredder (USA) AC 110-120Vac 50/60Hz – 1500 Watt Dimensions 95 x 75 x 145 cm Dimensions of top hopper opening 120 x 114 mm Weight GP20 Hybrid 125 kg Weight GP20 Shredder 85 kg Weight GP20 Granulator 70 kg...

  • Page 21: Instructions

    For the fast starters out there we have made a short and simple out of the box quick start guide. This is shipped in your GP20 accessory box, or you can download it from www.3devo.com/manuals 3.2. INSTALLATION INSTRUCTIONS 3.2.1. INSTALLATION INSTRUCTIONS TROLLEY Step 1) Mount the Wheel assemblies to the Trolley using 4x button head screws M6 4x washers and 4x lock nuts per Wheel assembly.
  • Page 22 Step 2) If all the Wheel assemblies are in place, tighten the bolts fully...

  • Page 23: Installation Instructions Gp20 Shredder

    3.2.2. INSTALLATION INSTRUCTIONS GP20 SHREDDER Step 1) Remove the four bolts on top of the Control box / Shredder assembly Step 2) Slide the Control box / Shredder away from the motor to create space around the motor flange.
  • Page 24 Step 3) Mount the motor on the Shredder compartment and secure the two items with 4x hexagon head screws M6 x 20 (10mm wrench) Step 4) Slide the Control box / Shredder back on and attach the Control box / Shredder to the motor using 4x button head screws M6x20 (4mm Allen key)
  • Page 25 Step 5) Insert the Scraper combs in the Shredder compartment and tighten the 4 bolts on the sides using an 8mm Allen key. This will secure the Scraper combs in place. More information about this can be found in chapter 3.5.2.1. Step 6) Place the Trolley on a flat and stable place on the floor close to a power socket.
  • Page 26 Step 7) Make sure the brakes on the wheels are secured. Locate the three mounting holes on the bottom of the GP20 Shredder. The holes should be positioned on the three threaded positioning studs on top of the Trolley Step 8) Carefully lift the GP20 Shredder with two persons on top of the threaded positioning studs of the Trolley.
  • Page 27 Step 9) Secure the GP20 Shredder in place by placing M8 washers and nuts on the threaded positioning studs...

  • Page 28: Installation Instructions Gp20 Granulator

    3.2.3. INSTALLATION INSTRUCTIONS GP20 GRANULATOR Step 1) Remove the four bolts on top of the Control box / Granulator assembly.
  • Page 29 Step 2) Slide the Control box / Granulator away from the motor to create space around the motor flange. Step 3) Mount the motor on the Granulator compartment and secure the two items with 4x hexagon head screws M6 x 20 (10mm wrench)
  • Page 30 Step 4) Slide the Control box / Granulator back on and attach the Control box / Granulator to the motor using 4x button head screws M6 x 20 (4mm Allen key. Step 5) Place the Trolley on a flat and stable place on the floor close to a power socket.
  • Page 31 Step 6) Make sure the brakes on the wheels are secured. Step 7) Locate the three mounting holes on the bottom of the GP20 Granulator. The holes should be positioned on the three threaded positioning studs on top of the Trolley Step 8) Carefully lift the GP20 Granulator with two persons on top of the threaded positioning studs of the Trolley.

  • Page 32: Installation Instructions Gp20 Hybrid

    Step 9) Secure the GP20 Granulator in place by placing M8 washers and nuts on the threaded positioning studs. 3.2.4. INSTALLATION INSTRUCTIONS GP20 HYBRID Step 10) Place the Trolley on a flat and stable place on the floor close to a power socket.
  • Page 33 Step 12) Locate the three mounting holes on the bottom of the GP20 Granulator. The holes should be positioned on the three threaded positioning studs on top of the Trolley Step 13) Carefully lift the GP20 Granulator with two persons on top of the threaded positioning studs of the Trolley.
  • Page 34 Step 15) Prior to placing the GP20 Shredder, mount three positioning studs on the GP20 Granulator using three M8 x 14 hexagon bolts and three washers. Step 16) Locate the three mounting holes on the bottom of the GP20 Shredder. The holes will be positioned on the three threaded positioning studs on top of the GP20 Granulator.
  • Page 35 Step 17) Carefully lift the GP20 Shredder with two persons on top of the threaded positioning studs of the GP20 Granulator...
  • Page 36 Step 18) Secure the GP20 Shredder in place by placing M8 washers and nuts on the threaded positioning studs For Hybrid mode, the safety switches must be configured correctly.
  • Page 37 Step 19) Loosen the thumbscrew as shown below. Slide the safety actuator from the GP20 Shredder down until it clicks. Tighten the thumb screw. Step 20) Loosen the thumb screw of the Granulator like shown below. Slide the safety actuator from the GP20 Granulator up until it clicks. Tighten this thumb screw as well.

  • Page 38: Preperation Instructions

    Remove as much as possible to prevent any damage to the machine and keep the output material as pure as possible. If the GP20 Hybrid has contaminations from previous material runs, and the machine is used for recycling purposes, make sure to properly clean the machine prior to using it again.

  • Page 39: Mounting The Container

    Break the material down to chunks that fit through the hopper opening. The smaller the chunks, the easier the shredder can process the material. 3.3.1. MOUNTING THE CONTAINER The Container ensures the following; Collecting output material • Removing access to danger zones of the machine •...
  • Page 40 Step 2) Insert the safety actuator in the designated slot. Step 3) Place the U-shaped brackets on the right side of the Container around the hooks of the GP20 Granulator OR GP20 Shredder and fasten the toggle clamps. Before applying any power to the toggle clamps, ensure that the mounting slots of the Container are all the way to the left side of the...

  • Page 41: Mounting The Hopper

    positioning pins of the GP20 Granulator OR GP20 Shredder. 3.3.2. MOUNTING THE HOPPER The hopper can be easily installed and removed. ⚠ WARNING Turn off the power switch when the hopper cable needs to be connected or disconnected.
  • Page 42 Step 1) Place the Hopper on top of the GP20 Granulator OR GP20 Shredder. Step 2) Hook the mounting slots on the bottom of the Hopper to the positioning pins of the GP20 Granulator OR GP20 Shredder.
  • Page 43 Step 3) Insert the safety actuator carefully into its designated slot. Step 4) Place the U-shaped brackets of the GP20 Granulator OR GP20 Shredder around the hooks of the Hopper. Before applying any power to the toggle clamps, ensure that the mounting slots of the Hopper are all the way to...
  • Page 44 the right side of the positioning pins of the GP20 Granulator OR GP20 Shredder. Step 5) Insert the connector of the cable attached to the Hopper in the Control Box / Shredder Removing the hopper is useful in the following situation:...
  • Page 45 Resolving an obstruction in the hopper • Machine is overloaded • Gaining access to the machine during the cleaning process. •...

  • Page 46: Cleaning The Gp20 Shredder

    3.3.3. CLEANING THE GP20 SHREDDER ⚠ WARNING Make sure the machine is turned off and the power plug is removed before proceeding with the next steps! Step 1) Remove the Hopper from the machine Step 2) Remove the Container from the machine ⚠...
  • Page 47 ⚠ WARNING Make sure the machine is turned off and the power plug is removed before proceeding with the next steps! Step 2) Remove the Hopper from the machine Step 3) Remove the Container from the machine ⚠ WARNING Always wear cut resistant gloves when working around and inside the cutting chamber. Step 4) Open the granulator door to gain access to the cutting chamber Step 5)

  • Page 48: User Interface Instructions

    3.4. USER INTERFACE INSTRUCTIONS 3.4.1 STARTING THE GP20 GRANULATOR Step 1) Make sure all components are locked into place, as explained in chapter Step 2) Plug in the power cable. (Make sure the voltage of the power supply matches the voltage indicated on the sticker next to the power socket.) Step 3) Press the on switch.
  • Page 49 Step 6) Feed the material or parts into the hopper. Make sure the parts are not too big to be fed into the opening of the granulator. Step 7) Press “Stop Granulating” in the main menu if you are finished granulating.

  • Page 50: Adjusting And Maintenance

    3.5. ADJUSTING AND MAINTENANCE For all adjustments and maintenance activities to the machine, make sure to turn the machine off and remove the power cable. 3.5.1. HOPPER ADJUSTMENTS 3.5.1.1. ADJUSTING THE FEEDING APERTURE The feeding aperture of the hopper can be adjusted to control the amount of material that is allowed to pass through to the machine.

  • Page 52: Adjusting The Belt Scrapers

    3.5.1.2. ADJUSTING THE BELT SCRAPERS The conveyor belt can be customized by for example adding flaps. The belt scrapers will need to be adjusted accordingly to prevent the conveyor belt from being blocked. Simply loosen the two screws of each belt scraper and set to the desired distance.

  • Page 53: Removing And Installing Granule Guard

    3.5.1.3. REMOVING AND INSTALLING GRANULE GUARD If you have a GP20 Granulator without a GP20 Shredder, the hopper should have a granule guard installed. The granule guard stops granules from flying up. When the granule guard is not installed, the rotor will “scoop” all of the plastics out of the cutting chamber after which all the plastic will fall down at once.
  • Page 54 When reinstalling, keep in mind to insert the tabs inside the cut-outs before tightening the screws.

  • Page 55: Removing The Belt Cover

    3.5.1.4. REMOVING THE BELT COVER The belt cover can be removed to gain access to the belt. This can be useful when the belt requires cleaning. Step 1) Untighten, the thumb screws partially Step 2) Remove the cover by first sliding the cover horizontally followed by a vertical movement down.

  • Page 56: Gp20 Shredder Cutting Chamber

    3.5.2. GP20 SHREDDER CUTTING CHAMBER In this chapter, all necessary information will be provided regarding adjustments and maintenance to the cutting chamber of the GP20 Shredder. ⚠ WARNING Make sure the machine is turned off and the power plug is removed before proceeding with the next steps! ⚠...

  • Page 57: Removing And Installing Scraper Combs

    3.5.2.1. REMOVING AND INSTALLING SCRAPER COMBS The scraper combs serve a few important functions during the shredding process; Preventing material from wrapping around the shredder spacers and • therefore; Preventing the machine from overloading due to material wedging • Self-cleaning the cutting chamber •...
  • Page 58 Step 3) Carefully pull the scraper comb up and lift it out.
  • Page 59 For installing the Scraper combs, the same steps can be done in reverse as shown above. Step 1) Lower the Scraper combs inside of the machine. Step 2) Tighten the bolts on the side using an 8mm Allen key. This will keep the scraper combs in place.

  • Page 60: Removing And Installing Shredder Blades

    3.5.2.2. REMOVING AND INSTALLING SHREDDER BLADES Step 1) Remove the scraper combs as explained in the previous chapter. Step 2) Unscrew the two bolts on the front of the machine using an 8mm Allen key and remove the black casing plate.
  • Page 61 Step 3) The ends of the shredder shafts are now exposed. Remove all four hexagon nuts from both shafts. Step 4) Unscrew the four bolts using an 8mm Allen key and slide the front plate towards you.
  • Page 63 Step 5) Now, you can remove the shredder blades and spacers one by one. ⚠ CAUTION Before reinstalling the shredder blades, it is very important to make sure that the shredder shafts, all shredder blades and shredder spacers are cleaned properly. If dust or contaminant get stuck between the blades, the right clearance cannot be ensured which may result in extreme damage to the shredder blades and scraper combs.
  • Page 64 Step 1) Start by sliding a shredder blade on the left shaft. Make sure the teeth are pointing in the clockwise direction. Step 2) Slide one shredder spacer on the right shaft opposing the shredder blade Step 3) Slide another shredder blade on the right shaft. Make sure the teeth are pointing in the counterclockwise direction.
  • Page 65 Step 5) In case of the 7 teeth-blade: In order to keep track of the rotational configuration of the stacked blades, it is advised to use the small cut-out located on the outer contour of the shredder blade for your reference. Step 6) The recommended configuration for 7 teeth blades is to stack each subsequent blade one-sixth turn with respect to the previous blade of...
  • Page 66 Step 7) Repeat step 1 until 4 until all blades are placed. Step 8) The hexagon shaped part of the shaft should be completely covered with shredder blades and spacers. In the illustration below, the blade and spacer have an 1,3mm overlap. The overlap may vary as long as there is some overlap.
  • Page 67 Step 9) Slide the front plate back on the shafts. Make sure the front plate is cleaned properly around the cylindrical bushings. Step 10) Start by placing one thin nut per shaft and tighten the nuts a little bit at a time. Even tightening is important to avoid imbalances in the stacked blades.
  • Page 68 Step 12) Screw in the four bolts in the corners of the front plate using a 8mm Allen key. Step 13) Mount the black casing plate back on the machine by screwing in the two bolts also using a 8mm Allen key.

  • Page 69: Gp20 Granulator Cutting Chamber

    3.5.3. GP20 GRANULATOR CUTTING CHAMBER In this chapter, all necessary information will be provided regarding adjustments and maintenance to the cutting chamber of the GP20 Granulator. 3.5.3.1. OPEN GRANULATOR DOOR The granulator door is locked in place with two toggle clamps. Release the safety hooks from the toggle clamps by pressing the red lever.

  • Page 70: Removing And Installing Filter Screen

    3.5.3.2. REMOVING AND INSTALLING FILTER SCREEN If the granulator door is opened as instructed in chapter 3.5.3.1 and the Container is removed from the machine, the filter screen can be removed from the GP20 Granulator. Simply slide the filter screen towards you.

  • Page 72: Removing And Installing Granulator Rotor

    3.5.3.3. REMOVING AND INSTALLING GRANULATOR ROTOR ⚠ WARNING Always wear cut resistant gloves when working around and inside the cutting chamber. Step 1) Open the granulator door. More information about this in chapter 3.5.3.1 Step 2) Remove the Container. Step 3) Remove the Filter screen as instructed in chapter 3.5.3.2 Step 4) Block the rotor by placing a piece of rubber between the rotary...
  • Page 73 Step 5) Carefully slide the rotor out of the cutting chamber. Step 6) When installing the rotor, it is important to properly clean the cutting chamber first to ensure proper alignment of the rotor. Step 7) Locate the keyway inside of the hole of the rotor Step 8) Locate the key inside of the shaft...
  • Page 74 Step 9) Slide the rotor fully on the drive shaft Step 10) Insert the bolt through the hole in the center of the rotor and tighten it. Step 11) Manually turn the rotor to verify that the rotor runs smoothly.

  • Page 75: Adjusting/Replacing The Granulator Knives

    The easiest way to do this is to; Step 1) In the case of a GP20 Hybrid, the GP20 Shredder should be lifted off GP20 Granulator first in order to gain access to the bolts responsible for...
  • Page 76 5mm Allen key in order to adjust the left Stationary knife. Step 3) Adjust the position of the left Stationary knife by tightening or untightening the set screws from the side using a 3mm Allen key. A good starting point is to offset the cutting edge of the stationary knife by 10mm with respect to the block it is mounted on.
  • Page 77 Step 4) Fix the left stationary knife in position by tightening the two bolts on top of the machine. Make sure the stationary knife does not move while tightening.
  • Page 78 The left stationary knife can now be used as a reference for adjusting the rotary knives Step 5) Remove the rotor as instructed in chapter 3.5.3.3 Step 6) Slightly loosen the hexagon bolts of the rotary knives so that the rotary knives are free to slide along the surface.
  • Page 79 Step 8) Manually turn the rotor so that the cutting edge of one rotary knife is touching the cutting edge of the left stationary knife. Use a thin piece of paper or set the right gap between the rotary knives and the left stationary knife.
  • Page 80 Step 12) Carefully remove the Rotor again and place it on a workbench. Now, fully tighten all the bolts. Step 13) Place the rotor back in the machine Step 14) Loosen the two M8 bolts using a 5mm Allen key in order to adjust the right stationary knife.
  • Page 81 Step 15) Use a 3mm Allen key on the right side of the machine to adjust the right stationary knife with respect to the rotary knives. Use a thin piece of paper to set the right gap. Step 16) Carefully tighten the bolts on top without moving the stationary knife.

  • Page 83: Troubleshooting

    TROUBLESHOOTING Troubleshoot information about most common problems. 4.1. ISSUE SITUATIONS Issue Probable cause Measures The material is stuck in The conveyor belt does Fill the hopper less full, the hopper, and the not have enough grip on adjust the feed aperture, hopper conveyor belt is the material.

  • Page 84: Safety Before Motor Start Messages

    4.2. SAFETY BEFORE MOTOR START MESSAGES Safety switch Information Measures Door panel not Please close the door, See chapter 3.5.3.1 secured properly secure the clip further instructions. and start again via the main menu. Emergency stop Please rotate the red The red emergency switch pressed emergency button...

  • Page 85: Runtime Error Messages

    VFD – no Could not Make sure the latest communication communicate with the firmware is installed or VFD motor controller. contact the manufacturer to resolve this situation. Check support.3devo.com.
  • Page 86 Check support.3devo.com. Error has occurred The external supply First check if the voltage of voltage is too low or the machine matches your absent.
  • Page 87 Error has occurred Failure reading a Contact us via thermocouple. support.3devo.com. Error has occurred Could not Try turning the machine off communicate with the and on again. Contact us via VFD. Power might be support.3devo.com. off.
  • Page 88 properly. See chapter 3.3.2 for further instructions. Error has occurred Outlet no longer As a safety mechanism, secured. machine will not start if the outlet is not connected properly. Error has occurred Door panel not As a safety mechanism, secured. machine will not start if the door is not closed properly.
  • Page 89 Error has occurred Contactor is not Contact us via enabled. support.3devo.com. Error has occurred Contactor contacts are The contactor fused fused together. message may occur when the contactor is worn out or after power outage. Contact us via support.3devo.com.

  • Page 90: Transportation

    TRANSPORTATION Keep the original packaging. When the machine is shipped back to 3devo for service or maintenance the machine should be packed in the same way as how it arrived. For additional questions, please contact support.3devo.com.

  • Page 91: Notes

    NOTES...

  • Page 92: Company Info

    COMPANY INFO 3devo B.V. Atoomweg 478 3542 AB Utrecht The Netherlands www.3devo.com support.3devo.com...

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