Summary of Contents for AEC GP1200 Series
- Page 1 $30. Operation and Installation Manual Model GP1212, GP1218, & GP1224 Granulators - 1 -...
- Page 2 ________________ ________________ ________________ ________________ AEC can advise you on proper selection and sizing of systems for your operating environment. AEC is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.
- Page 3 Safety Considerations AEC granulators 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...
- Page 4 SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN when servicing or operating the machine. Although our machines are designed for the maximum in flyback control, caution must be used when operating near the area of the hopper feed opening in order to guard against unexpected material flyback.
- Page 5 For Size Reduction of Plastics - Construction, Care, and Use. ANSI B151.11-1982. AEC has long recognized the importance of safety and has designed and manufactured it’s equipment with operator safety as a prime consideration. As a user, we expect you will abide by the foregoing recommendations in order to make operator safety a reality.
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Page 6: Table Of Contents
Table of Contents General Information 1-1 Introduction 1-2 General Description 1-3 Granulator Specifications Shipping Information 2-1 Unpacking and Inspection 2-2 In the Event of Shipping Damages 2-3 If the Shipment is Not Complete 2-4 If the Shipment is Not Correct 2-5 Returns 2-6 Uncrating Installation... - Page 7 Table of Contents Startup Checklist 7-1 Introduction 7-2 Fan Evacuation 7-3 Granulator Startup Checklist Operation 8-1 Operation Instructions 8-2 Temporary Machine Stops 8-3 Final Machine Stops 8-4 Emergency Stops Routine Maintenance 9-1 Lubrication Specifications 9-1-1 Description 9-1-2 Screw Jack Lubrication Instructions Error! Bookmark not defined.
- Page 8 Charts and Figures Granulator Specifications Table 11-12 Granulator Dimensions Belt Span and Deflection 33-34 Belt Deflection Force Table Rotor Knife Drawings Recommended Knife Replacement Blades Bed Knife Drawings Recommended Bolt Torque - 8 -...
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Page 9: General Information
This manual is intended to be used as a guide and reference for personnel who will be installing, operating, and maintaining the AEC GP1200 Series Granulator. The purpose is to aid these individuals in applying efficient, proven techniques, which will enhance productivity. -
Page 10: General Description
1-2 General Description AEC granulators are designed to uniformly and consistently size reduce your scrap. They have been 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 supported by bearings mounted outside the cutting chamber. -
Page 11: Granulator Specifications
1-3 Granulator Specifications Figure 1 Granulator Dimensions Model 1212X 1218X “A” Dimension 51.25” (1301.8 mm) 59.25” (1505 mm) Weight 3025 lbs (1372 kg) 3400 lbs (1542.3 kg) Est. Throughput 900 lbs/hr (408 kg/hr) 1500 lbs/hr (680 kg/hr) - 11 -... -
Page 12: Shipping Information
Shipping Information 2-1 Unpacking and Inspection You should inspect your AEC GP1200 Series granulator for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary. Thoroughly check the equipment for any damage that might have occurred in transit. -
Page 13: If The Shipment Is Not Complete
Notify AEC immediately of the shortage. 2-4 If the Shipment is Not Correct If the shipment is not what you ordered, contact the AEC shipping department immediately. For shipments in the United States and Canada, call 1 (800) 229-2919; for all other countries, call our international desk at (508) 399- 6400. -
Page 14: Uncrating
2-6 Uncrating GP1200 Series Granulator GP1200 Series granulators are shipped mounted on a wooden skid then blocked and banded to prevent movement. All non- painted items subject to corrosion are coated with a quality rust preventative and the machine is then covered with heavy duty polyethylene to protect it from moisture and dirt. - Page 15 GP1200 Series Granulators GP1200 Series Granulators are shipped mounted on a skid, enclosed in polyethylene, and open-crated on all four sides and top. 1. Pry the crating away from the skid. 2. Follow the instructions listed above. 3. Use a pry bar to remove the blocks securing the unit to the skid.
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Page 16: Installation
Installation 3-1 Scope This section contains all instructions required for experienced installation personnel to install the AEC granulator and prepare it for production. It is essential to follow all instructions carefully and in the sequence presented. Be sure to observe all DANGER, WARNING,... - Page 17 Opening the front latch allows access into chamber area. The pivoting door is allowed to swing open giving fast, and easy access to the major components. - 17 -...
- Page 18 CAUTION! The knives mounted on the rotor and also located at the edges of the cutting chamber are extremely sharp. Always wear heavy gloves and exercise care when working in the cutting chamber. Wipe out the inside of the hopper and upper cutting chamber.
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Page 19: Electrical Service Connections
3-4 Electrical Service Connections Carefully check the diagrams packed with the machine. All internal wiring has been done at the factory and safety interlocks have been verified for proper functioning before shipment. It is only necessary to connect the electrical power source to the machine at the control enclosure. -
Page 20: Accessing Cutting Chamber
Accessing Cutting Chamber 4-1 Opening Cutting Chamber 1. Allow material to run out of the cutting chamber. 2. Shut OFF and LOCKOUT all power, including the main disconnect switch. 3. If equipped with optional sound enclosure, open front doors. 4. Loosen fasteners on front of machine. They are designed to remain with the upper screen chamber. - Page 21 2. Shut OFF and LOCKOUT all power including the main disconnect switch. 3. Remove hopper located below the screen chamber. 1 fastener holds the screen cradle in position. 4. Loosen (1) fastener holding the screen cradle in position. As the fasteners are designed to remain with the screen chamber, it is not necessary to totally remove them from the screen chamber.
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Page 22: Closing Screen Chamber
WARNING! DO NOT LET THE SCREEN CHAMBER DROP!! Guide cradle to it’s resting position. 6. Remove the screen(s) and place them upright on their side. CAUTION! The knives mounted on the rotor, and the bed knives located at the edges of the cutting chamber, are extremely sharp. -
Page 23: Sequence Of Operation
The voltage should be the same as indicated on the silver tag in the control enclosure. If the voltage is not the same, contact the AEC Service Department for voltage modification instructions at 1-800-229- 2919. - Page 24 Once the rotation direction is correct, the remaining electrical controls need to be tested as follows: • Press the granulator stop pushbutton and allow the machine to stop. • For granulators equipped with conveyors, fans, etc., test their operation also by pressing the appropriate pushbutton.
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Page 25: Startup Checklist
7-2 Fan Evacuation AEC granulators can be supplied with an optional fan system to provide efficient, continuous evacuation of granulate from the machine. AEC offers a large variety of fan configurations. - Page 26 Have the cutting chamber and screen chamber been checked for foreign matter? Have the drive belts and optional fan drive belts been checked for alignment and tension? Is the machine properly closed with all visible fasteners tight? Are all accessory components electrically and mechanically connected with proper support and with all fasteners tight? Are cyclonic air separator and filter units empty? (optional equipment)
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Page 27: Operation
Operation 8-1 Operation Instructions 1. Prior to machine startup -- All doors, covers, guards, and limit switches must be in place, securely fastened, and functional. All accessory components must be properly connected. If the granulator has a bin, make sure it is installed. -
Page 28: Emergency Stops
8-4 Emergency Stops Feedstock must be cleaned out of the hopper and cutting chamber prior to restarting the machine. NOTE: The AEC GP1200 Series granulators are not designed for small purging, chunks of solid plastic or other heavy wall cross- sectional pieces. -
Page 29: Routine Maintenance
Routine Maintenance 9-1 Lubrication Specifications 9-1-1 Description All AEC GP1200 Series machines are equipped with rotor bearings that are pre-lubricated from the factory. Mounting of the bearings on the AEC GP1200 Series machines results in trouble free, low maintenance, and long lived bearing design. - Page 30 Belt pulleys (Located on left-hand side of unit, under the sheave guard.) 1. Verify that the alignment of the pulleys is correct. Utilizing a straightedge of sufficient length to span from one pulley to the other, place it along the sides of both pulleys.
- Page 31 Loosen these 4 nuts on the bolts holding the unit on the base. Slide the motor either backwards or forwards to achieve the proper belt tension and retighten the nuts. 6. There will normally be a drop in belt tension during the first 24 to 48 hours of operation due to stretch and the belts seating themselves in the sheave grooves.
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Page 32: Knife Removal & Adjustment
Table 2 Belt Deflection Force BELT DEFLECTION FORCE (in lbs.) SMALL SHEAVE BELT DIAMETER (INCHES) RUN IN RUNNING 2.65 to 4.0 6.00 4.00 4.12 to 7.0 8.25 6.75 7.10 to 10.9 21.00 14.25 11.80 to 16.0 25.75 17.00 12.50 to 16.0 51.00 34.50 18.00 to 22.4... -
Page 33: Rotor Knife Removal
DANGER! 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. When extensive work is anticipated, either place a sign indicating that the main disconnect switch is to remain off on the switch or lock the switch to prevent accidental activation by someone unaware of work in progress. -
Page 34: Rotor Knife Sharpening
It is important to note that the minimum dimensions given for the rotor knife and bed knife cannot be combined simultaneously to produce a cutting combination. NOTE: Replacement knife sets and knife re-sharpening services are available from AEC Engineering. Contact the Customer Service Department at (800) 229-2919. Figure 3... -
Page 35: Recommended Knife Design Per Material
9-6 Recommended Knife Design Per Material Table 4 Recommended Knife Replacement Blades Physical Material Material High 55° Quality Shear ABS (High Imp’t) Energy Impt ABS (Med. Imp’t) Energy Impt ABS (Low Imp’t) Energy Impt ACETAL Energy Impt ACRYLIC Energy Impt NYLON (Non-filled) Energy Absb NYLON (Filled) -
Page 36: Bed Knife Sharpening
9-7 Rotor Knife Installation 1. Carefully block the rotor with a piece of wood 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. -
Page 37: Bed Knife Installation & Setting
NOTE: Replacement knife sets and knife resharpening services are available from AEC Engineering. Contact the Customer Service Department at (800) 229-2919. Figure 5 Bed Knife Sharpening 9-9 Bed Knife Installation &... -
Page 38: Rotor Knife Installation
2. Align a rotor knife with the primary bed knife, in the front of the granulator. With a .006” feeler gauge 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 forth checking the clearance. -
Page 39: Preventative Maintenance Service
(refer to Section 4-2). 9-10 Preventative Maintenance Service Follow a systematic preventative maintenance program to help avoid costly down time. Call the AEC Engineering Service Department to arrange a schedule of inspections. This service can be tailored to fit your maintenance requirements. -
Page 40: Troubleshooting
**The above listed torque values are standard specifications. ***Metric Knife Bolt/Screw Tightening Torque for Grade 10.9 Fine Thread Troubleshooting Problem Possible Cause Solution Verify that the correct pushbuttons are being No power. depressed and that the main disconnect switch is in the ON position. - Page 41 Bearings sound noisy or Overloading of the feedstock put into the are excessively hot machine machine per unit of time. Consult the AEC Service Bearings have exceeded Department for their rated life. replacement instructions. Tighten per maintenance Belts are too loose instructions.
- Page 42 Transition or tubing is Reduce the amount of clogged due to feedstock put into the overloading of machine. machine per unit of time. Return air vents are Ensure the vents are covered or too small. open. Problem Possible Cause Solution Fan wheel is loose on Tighten set screws as shaft.
- Page 43 Sharpen or replace Knives are dull. knives and reinstall. Reduce the amount of Overloading of feedstock. feedstock put into the machine per unit of time. Problem Possible Cause Solution Sharpen knives (refer to Knives are dull. Section 9) and re-install. Plastic is clogging the screens or transition, Shut the machine down...
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Page 44: Spare Parts
The serial number of the machine will be required when ordering parts from AEC. This listing of recommended parts does not include all parts, which are available for purchase. The AEC Parts Department can be reached via a toll free number (1-800-229-2919). - Page 45 Service Notes - 45 -...
- Page 46 Service Notes - 46 -...
- Page 47 ADDENDUM TO MODEL GP1200 SERIES GRANULATOR OPERATIONAL MANUAL When a special feed hopper and or feed roll unit is provided, access to the cutting chamber and screen chamber requires the following additional instructions. 1. Follow the steps outlined in section 4 & 5 of the standard instruction manual.