DOCUMENT TYPE: Instructions for use and maintenance

Transcription

1

2 MANUFACTURER: ENGIN PLAST ADDRESS: Via Per Zerbinate, 29/a - BONDENO (FE) - ITALY DOCUMENT TYPE: Instructions for use and maintenance CODE: BM-GB-0032 PRODUCT: Granulating mill for plastics MODEL: BM CONFORMITY: CE MARK

3 INDEX 1. GENERAL INFORMATION 2. MACHINE DESCRIPTION 3. SAFETY 4. INSTALLATION 5. SETTING UP 6. OPERATION 7. MAINTENANCE 8. TROUBLE-SHOOTING 9. WASTE DISPOSAL 10. SPARE PARTS LIST

4 GENERAL INFORMATION MAN-BM22-40-GB INDEX 1.1 Introduction Warranty Customer's responsibilities Technical assistance Spare parts list Glossary Figure index 5 1-1

5 GENERAL INFORMATION MAN-BM22-40-GB Introduction This manual is intended for operators and specialised personnel to ensure the correct use of this machine. In this manual the operator will find instructions and indications for: - correct machine installation - a functional description of the machine and its components - adjustments during setting up and start-up - correct routine maintenance - general safety rules and accident prevention The operator will thus have the opportunity to get to know the problems involved in using this machine and the product being produced. To make best use of this manual, please note that the following terms have been used: - DANGER ZONE: zone inside or near the machine in which the presence of an exposed person constitutes a risk for the safety and health of that person. - EXPOSED PERSON: any person who is wholly or partially inside a danger zone. - OPERATOR: person entrusted with the installation, operation, adjustment, routine maintenance or cleaning of the machine. - QUALIFIED EXPERT: specialised person, having received special training and authorized to carry out extraordinary maintenance or repairs requiring in-depth knowledge of the machine, how it works, the safety devices and how these act. ATTENTION: accident prevention specifications for the operator WARNING: there is a risk of damaging the machine and/or its components PRECAUTIONS: further information regarding the current process - NOTE: useful information It is essential that the operator and the qualified expert read and understand thoroughly the contents of this manual, which must be kept intact and forms an integral part of the machine itself. IMPORTANT NOTE - READ ALL THE TECHNICAL INSTRUCTIONS IN THIS MANUAL AND FOLLOW THE INDICATIONS CAREFULLY BEFORE ATTEMPTING TO SET THE MACHINE UP. - KEEP THIS MANUAL AND ALL ATTACHED PAPERS IN AN EASILY ACCESSIBLE PLACE THAT IS KNOWN TO ALL USERS (OPERATORS AND MAINTENANCE STAFF). 1-2

6 GENERAL INFORMATION MAN-BM22-40-GB Warranty A notification of damage or defect is to be made immediately to the manufacturing company which will conduct a verification on the reasons for the warranty conditions and if these apply ENGIN PLAST SRL guarantees its products for 12 months from delivery date and will supply free of charge parts as a replacement for those defective only after examination of the part and the nature of the damage. Transport charges, for the delivery of defective parts to the manufacturer are at the Customer s account. Such charges will be refunded if the damage comes from production. Warranty will cease its effect in case of nonauthorized tampering. Warranty does not include all parts subject to wearing or interventions needed due to non-respect of the regulations indicated on the instructional booklet or in any case for an improper/bad use of the machine. Warranty is in all cases- subject to a correct and systematic maintenance of the user, as indicated on the instructional booklet. Warranty is valid for the original buyer only Conditions for reparations under warranty as for the case of improper use of the machine are as follows: Reparation at our factory - transport charges from/to Engin Plast srl, labour and replaced parts charges are at the Client s account. Reparation at the Customer s factory by an Engin Plast technician (duration of the journey from/to your location, labour, accommodation, meals and replaced parts charges will be at the Client s account) ENGIN PLAST SRL is not responsible for irregularities caused by existing trouble on the supply mains, control and high-frequency generators, which can endanger the perfect working of electric and electronic appliances. 1.3 Customer's responsibilities Unless otherwise specified in the contract terms, the Customer is responsible for: - electricity supply, including a protective conductor, commonly called the "EARTH" - water supply - pneumatic supply - tools and expendable materials - necessary lubricants for machine operation 1.4 Technical assistance The Customer must contact the Customer Assistance Service directly if he requires the assistance of specialised technical staff. Such a request must be sent to Engin Plast by fax, or telephone (see the numbers given on the first page of this manual). 1.5 Spare parts The Customer must buy original spare parts. Any disassembly or assembly of the machine must be carried out in compliance with the manufacturer's instructions. 1-3

7 GENERAL INFORMATION MAN-BM22-40-GB Glossary - Blade granulator: machine that cuts the material inside the cutting/reduction chamber, so reducing the size until the product reaches the delivery area, by means of the holes in a suitably sized grid. - Cutting chamber: area of the machine where the material is cut/reduced. - Feed devices: the material can be fed by hand using an inlet, or automatically using devices installed on the machine or connected to it. Automatic feed can be by means of devices such as auger screws, belts etc., or suction devices etc., or a separate takeoff system fitted above the machine. - Delivery devices: devices that receive the granulate or finished products. Delivery can be by means of gravity effect, devices such as auger screws, belts, etc., or suction, airblasts, etc. - Rotor: rotary device inside the cutting chamber on which the blades are installed. - Fixed blades: single or multiple blades installed inside the cutting chamber. - Grid: sheet metal usually placed in the cutting chamber delivery area that allows the granulate or finished product of suitable size to pass. - Work platform: surface on which the person feeding the machine stands. - Feed table: surface used for placing the material to be introduced into the blade granulator on which the person feeding the machine cannot stand. (If it is possible to stand on this surface, it must be considered a work platform.) - Lump: piece introduced in the cutting chamber. - Size: product obtained by grinding. 1-4

8 GENERAL INFORMATION MAN-BM22-40-GB Figure index Operating principle (Fig. 2-1) page 2-2 Main system assemblies (Fig. 2-2) page 2-3 Overall machine dimensions (Fig. 2-3) page 2-5 Machine base, motor and flywheel assembly (Fig. 2-4) page 2-6 Hinged dust flaps (Fig. 2-5) page 2-7 Rotor and cutting chamber assembly (Fig. 2-6) page 2-8 Delivery assembly (collection bin) (Fig. 2-7) page 2-9 Manual greasing (Fig. 2-8 : 2-9) page 2-10 Cooling system (Fig. 2-10) page 2-11 Cooling system diagram (Fig. 2-11) page 2-11 Electric wiring diagram (Fig. 2-12) page 2-12 Electrical panel controls (Fig. 2-13) page 2-13 Dismantling the machine (Fig. 2-14) page 2-16 Use protective gloves (Fig. 3-1) page 3-3 Do not wear jewellery (Fig. 3-2) page 3-3 Access to work area forbidden for unauthorised persons (Fig. 3-3) page 3-4 Keep work area free (Fig. 3-4) page 3-5 Control, work and danger zones (Fig. 3-5) page 3-6 Safety devices (Fig. 3-6) page 3-7 Plate locations (Fig. 3-7) page 3-9 Lifting with fork-lift truck (Fig. 4-1) page 4-3 Hoisting with bridge crane or tackle (Fig. 4-2) page 4-3 Incorrect lifting (Fig. 4-3) page 4-4 Overall machine dimensions (Fig. 4-4) page 4-5 Lifting with fork-lift truck (Fig. 4-5) page 4-6 Energy connections (Fig. 4-6) page 4-9 Hydraulic connections (Fig. 4-7) page 4-10 Greasing points (Fig. 4-8) page 4-11 Plate indicating motor rotation direction (Fig. 5-1) page 5-2 Control, work and danger zones (Fig. 6-1) page 6-3 Control panel commands and instruments (Fig. 6-2) page 6-4 Check that the collection bin is empty (Fig. 6-3) page 6-5 Hopper rotation (Fig. 6-4) page 6-5 Start-up sequence (Fig. 6-5) page 6-6 Emergency stop (Fig. 6-6) page 6-9 Cleaning the grid (Fig. 6-7) page 6-10 Replacing the fixed and mobile blades (Fig. 7-1) page 7-3 Grinding angles of the blade on the rotor. (Fig. 7-2) page 7-4 Checking the fixed/mobile blade clearance (fig. 7-3) page 7-4 Grinding angles of the fixed blade. (Fig. 7-4) page 7-5 Opening the protection covers by turning (Fig. 7-5) page 7-6 Manual greasing (Fig. 7-6) page 7-6 Removing the grid (Fig. 7-7) page 7-7 Fixed and mobile blades clearance control (fig. 7-8) page 7-8 Back fixed blade extractor (Fig. 7-9) page 7-9 Advice on tightening the V belts (Fig. 7-10) page 7-12 Symbols for dangerous or toxic products or materials (Fig. 9-1) page 9-2 Spare parts components (Fig. 10-1) page

9 MACHINE DESCRIPTION MAN-BM22-40-GB INDEX 2.1 General description Operating principle Main mill assemblies Technical characteristics Machine base and drive assembly Feed assembly (hopper + auger screw + belt) Takeoff rollers assembly Rotor and cutting chamber assembly Delivery assembly Lubrication Cooling system Electric plant Electrical panel and controls Standards-certifications-limits-ergonomy-ecology Applied technical standards Mill and component certification Working conditions Explosive and/or inflammable atmosphere Lighting Vibrations Noise Waste products and pollution Demolition of the granulator

10 MACHINE DESCRIPTION MAN-BM22-40-GB General description The blade granulator is a machine specifically designed for cutting, splitting and granulating plastic material pieces and waste with the minimum of energy consumption. The machine consists basically of a conveyor hopper, a cutting chamber and a material collection device. To ensure reliability, there is a high ratio of reduced revolutions between the motor and the rotor, to protect the system from critical inertial stress. A grid allows for the selection of the granulated material. The walls of the granulator have sound-proofing to avoid noise pollution Operating principle Granulation occurs as explained below. The matter to be re-ground is allowed to fall into the feed hopper (generally by means of mechanical power-assisted manipulators) and follows the path indicated by the arrows shown in fig Fig Operating principle The lump falls towards the cutting chamber, passing through the no-return channel which has been shaped in such a way as to stop the material from escaping during granulation. The lump is chopped inside the cutting chamber by a rotor fitted with sharpened blades. Cutting action is obtained by means of two fixed blades (or counter-blades) positioned diametrically opposite each other inside the chamber. A perforated grid under the rotor allows the treated material to flow into the collection bin. Obviously, the size of the holes in the grid determine the size of the chip. The recycled chips are then collected by suction or manually, depending on the automation level of the process of which the granulator is part. 2-2

11 MACHINE DESCRIPTION MAN-BM22-40-GB Main mill assemblies The main granulator assemblies are: - machine base assembly - feed assembly - rotor and cutting chamber assembly - collection and delivery assembly - lubrication assembly - motor assembly Fig Main system assemblies 2-3

12 MACHINE DESCRIPTION MAN-BM22-40-GB Technical characteristics The technical characteristics of the machine are as follows: Machine technical data DENOMINATION BM BM Motor - type Three-phase - voltage V voltage frequency Hz power KW ,5 4-5,5-7,5 - revolutions RPM 1425(4p) 1425(4p) 950(6p) 950(6p) - cos (4 poles) 0,83-0,83-0,85 0,83-0,83-0,85 - cos (6 poles) 0,80-0,80-0,79 0,80-0,80-0,79 Hopper opening mm 220 x x 210 Delivery device opening mm 220 x x 290 Mobile blades - number nr cutting edge size mm Fixed blades - number nr cutting edge size mm Blade and counter-blade clearance mm 0,3 0,5 0,3 0,5 Rotor motion diameter mm Standard grid holes diameter mm 8 8 Rotor revolutions RPM 275 (6p) 442 (4p) 275 (6p) 442 (4p) Granulator weight with suction device kg Noise level db(a) pag.2-16 pag.2-16 Average actual output kg/h Machine base overall dimensions mm 740 x x 680 Feed hopper height mm Vibrations m/s * * * * * * * * * * 2-4

13 Overall machine dimensions MACHINE DESCRIPTION MAN-BM22-40-GB Max. length mm 670 Max. width mm 530 Max. height mm 1296 Weight BM kg 256 Weight BM kg 319 Fig Overall machine dimensions. 2-5

14 MACHINE DESCRIPTION MAN-BM22-40-GB Machine base and drive assembly The blade granulator is supported by castors for easy movement. The rotor turns by means of an electric motor and transmission system consisting of two reduction pulleys and drive belts. The smaller diameter pulley is attached to the motor shaft, while the larger diameter pulley is attached to the rotor shaft in the cutting chamber. The number of revolutions on the rotor is thus reduced. The drive belts transfer the motor drive to the rotor, at the same time dampening any vibrations in the opposite direction. Fig Machine base, motor and flywheel assembly. 2-6

15 MACHINE DESCRIPTION MAN-BM22-40-GB Feed assembly (hopper + auger screw + belt) The machine is fed by means of the feed hopper. The material to be re-ground is allowed to fall through the feed inlet (generally by means of mechanical powerassisted manipulators, supplied separately) and then enters the cutting chamber. In order to avoid any dust from escaping, hinged dust flaps are used that allow the lump to enter but not the dust to escape from the feed inlet. Fig Hinged dust flaps. 2-7

16 MACHINE DESCRIPTION MAN-BM22-40-GB Rotor and cutting chamber assembly The cutting chamber is the internal area, inside of which the rotor chops the lump introduced by the feed hopper. The rotor holds the blades. The material is cut at the point where the fixed counter-blade is positioned. Fig Rotor and cutting chamber assembly. The rotor is driven by means of a motor and transmission system consisting of two gearmotor pulleys and the drive belts. The smaller diameter pulley is attached to the motor shaft, while the larger diameter one is attached to the rotor shaft in the cutting chamber. The number of revolutions on the rotor is thus reduced. 2-8

17 MACHINE DESCRIPTION MAN-BM22-40-GB Delivery assembly The delivery assembly consists of: - a grading grid - a collection bin for automatic delivery. Granulation continues until the material introduced into the cutting area acquires the required size: obtained when the granulate passes through the perforated grid at the bottom of the cutting area. The holes are evenly spaced on the grid to allow only granulated material to pass. The diameter of the holes determines the size of the granulate. The granulate falls into the delivery device, with either automatic or manual delivery (see fig. 2-8). Fig Delivery assembly (collection bin). 2-9

18 MACHINE DESCRIPTION MAN-BM22-40-GB Lubrication The only points that require lubricating are the bearings supporting the rotor. As can be seen from fig. 2-9, grease needs simply to be added to the two greasing nipples. The lubrication procedure is explained in the Maintenance chapter. Fig Manual greasing 2-10

19 MACHINE DESCRIPTION MAN-BM22-40-GB Cooling system The upper part of the cutting chamber can be fitted (on request) with a cooling chamber to remove the heat created by the rubbing of the material to be ground against the internal walls: too much heat could cause degradation of the material, in the case of heat-sensitive material, as well as over-heating and clogging of the grinder. This granulator uses a flow of mains water as shown in the figure. Fig Cooling system Fig Cooling system diagram. 2-11

20 MACHINE DESCRIPTION MAN-BM22-40-GB Electric plant The electric plant, shown in the attached wiring diagram, needs to suit the mains network of the country of destination and is therefore supplied at voltage rates that are not the same for all models. To find the voltage rating of the granulator supplied with this manual, see page 2-4. The plant consists of a overload switch and a 24V AC electromechanical control logic, consisting of relays and a safety micro-switch. This last serves to protect the opening of the feed hopper and the removal of the grading grid. Topological lay-out is shown in the picture below. Fig Electric wiring diagram Electrical plan of granulators with motor power 7,5 kw is an separate folder. 2-12

21 MACHINE DESCRIPTION MAN-BM22-40-GB Electrical panel controls Electrical panel controls are shown in the pictures below: A) Control panel for granulator B) Control panel for granulator with motor power up to 5,5 kw with motor power 7,5 kw Fig Electrical panel controls. RM1 SB1 SB2 EM MAIN SWITCH BUTTON GRANULATOR START BUTTON GRANULATOR STOP BUTTON EMERGENCY STOP BUTTON 2-13

22 MACHINE DESCRIPTION MAN-BM22-40-GB Standards-certifications-limits-ergonomy-ecology Applied technical standards This machine has been designed and built to comply with the following standards and papers: EEC MACHINE DIRECTIVE 98/37 EN Standard 12100/1: Machine safety. Basic concepts, main programming principles. EN Standard 12100/2: Machine safety. Basic concepts, main programming principles. Specifications and technical principles. EN Standard 294: Machine safety. Safety distances to avoid having upper limbs in the danger zones. EN Standard 60204: Machine safety. Electrical equipment. General requirements. ISO Standard 3744: Acoustic - Determination of noise levels from noise sources using technical sound pressure methods and monitoring a free field on a flat reflective surface. ISO Standard 11201: Acoustic - Noise levels coming from machines and systems. EN Standard 953: Machine safety. Design and construction safety requirements. EN Standard 954/1: Parts concerned with machine control systems safety -Design and construction safety requirements. EN Standard 12012: Machines for rubber and plastics. Safety. Machines for reducing size Mill and component certification Attached to the technical machine documentation is the certificate of conformity to the relevant laws; also indicated on the machine plate Working conditions For trouble-free and proper machine operation, the machine must be used in areas with a room temperature of between 0-20 C, protected from the weather (rain, hail, snow, etc.) Explosive and/or inflammable atmosphere This granulator must not be used in an explosive atmosphere. It is forbidden for the user to install the granulator in explosive or partially explosive atmospheres (eg., grinding materials that cause gas emissions capable of creating sacks of explosive gas) Lighting The machine room must be given sufficient lighting in order to see the control panel and the emergency stop pushbutton for normal operation. For maintenance work, the lighting level must be such that the maintenance can be carried out in safety. In particular, the cutting chamber and the electric box must be sufficiently well lit. The user must provide for the laying on of the lighting in accordance with the local laws in this regard. 2-14

23 MACHINE DESCRIPTION MAN-BM22-40-GB Vibrations Vibrations are not a cause for danger if the indications for correct use given in this manual are complied with. Vibrations leading to conditions of danger have, however, been measured adopted using the methods in ISO standard If this should occur, the operator must stop the machine immediately and notify the assistance service of the phenomena (telephone and address on the front page) Noise This system has been designed and constructed to reduce the noise levels to the following: - Standard noise level when empty db (A) = 78 - Standard noise level when working db (A) = 95 - Standard noise pressure level at 1 m when working db (A) = 85 These data have been established in accordance with ISO Standard Waste products and pollution If the material treated is as intended, there are no toxic by-products as indicated in the standard EN 626-1: dust emissions can only occur through the feed inlet. To avoid this, the machine is fitted with hinged dust flaps to block the feed inlet of the blade granulator so stopping dust emissions. ATTENTION If the granulator is to be used for the grinding of toxic or harmful material (eg., containers used for transporting such materials), the operator must wear protection gloves and a suitable face mask. A ventilator must also be fitted in the feed area. The purchaser is responsible for informing the operators of the rules of behaviour and the means of individual protection to be adopted when treating such materials Demolition of the granulator FOREWORD: As each single country has its own rules and regulations, the user must follow those that are applicable to his own country. ATTENTION The machine must be demolished by specialised staff, electrical and mechanical. Before starting the demolition, clear a wide space around the machine for free access to all parts, without creating further risks. 2-15

24 MACHINE DESCRIPTION MAN-BM22-40-GB Steps: - Disconnect the electricity and water supplies at the mains. - Disconnect all electric cables from the granulator. - Disconnect all supply cables from the control box. - Close the water tap on the cooling system. Disconnect all water intake and out take piping. ATTENTION After doing this, there will be a wet area around the machine: dry the ground before proceeding. - Remove the electric box. - Remove the sound-proofing panels. - Remove the fixed and mobile blades. - Remove the main components of the machine - Separate the machine components by type (eg. metal, plastic parts, etc.) and send to differential collection points. NOTE: Follow all local legal requirements when disposing of the machine parts. Fig Dismantling the machine 2-16

25 SAFETY MAN-BM22-40-GB INDEX 3.1 General information - uses - areas General information Intended, unintended and incorrect use Work, control and danger zones Risks, safety devices, warnings and cautions General safety Risks in the granulator installation area Onboard machine risks (see risk analysis) Risks (listed by analysis) Accident prevention (see Fig. 3-7) 9 3-1

26 3.1 General information - uses - areas General information SAFETY MAN-BM22-40-GB The employer must give all personnel adequate training on the risks to health, on the safety devices, on the risks of noise exposure and the general safety regulations set down by international laws or those in the country of destination. The behavior of the operators, maintenance workers, cleaners, test personnel and so on, must meet with the local safety regulations. ATTENTION Before starting any work, the operator must be thoroughly familiar with the position and operation of all the controls and characteristics of the machine, and must also have read this manual thoroughly. WARNING This machine must only be used by operators who have received on-site training by technicians and who have thoroughly understood the contents of this manual. WARNING The instructions, warnings and general safety rules in this manual must be followed scrupulously. ATTENTION Any tampering or unauthorized replacement of any part of this machine, not to mention the use of any accessory, tool or expendable material other than those recommended by the manufacturer can constitute a risk and, in such a case, the manufacturer declines to accept any civil or criminal liability. ATTENTION The operator's clothing, and that of the maintenance staff, must conform to local safety regulations, as indicated in EEC Directive 89/656 and 89/686 concerning the adoption of individual protective devices. 3-2

27 SAFETY MAN-BM22-40-GB For maintenance work in areas emitting heat, use special fireproof gloves as shown in fig Fig Use protective gloves. ATTENTION Special care should be taken when wearing bracelets, watches, rings or chains (Fig. 3-2) which should not hang or hinder the operator's movements. We recommend that these are not worn to ensure maximum safety. Fig Do not wear rings, bracelets or watches. 3-3

28 SAFETY MAN-BM22-40-GB ATTENTION The work area must NEVER be used for other objects that may hinder the free movement of the operator or that may block immediate access to the machine by the relevant person in an emergency. ATTENTION All persons who have not been specifically authorized may not access this area (Fig. 3-3) to prevent the risk of danger arising from inattention or neglect when carrying out a task. Fig Access to work area forbidden for unauthorized persons 3-4

29 SAFETY MAN-BM22-40-GB PRECAUTION We therefore recommend that the persons entrusted with the maintenance of this machine should keep it free of any unnecessary objects and should prohibit access to unauthorized persons (fig. 3-4)in order to maintain the ideal machine operation safety conditions. Fig Keep work area free Intended, unintended and incorrect use WARNING This granulator must be used for granulating the product specified in the contract and within the prescribed capacity limits. Any use of this blade granulator outside these specifications will be considered "INCORRECT USE". The manufacturer therefore declines to accept any liability for damage to property or injury to persons arising from such use and will consider no longer valid all machine warranties. 3-5

30 SAFETY MAN-BM22-40-GB Work, control and danger zones ATTENTION The work areas within which the operator must stay are those within the machine control area and the material feed area. ALL OTHER AREAS SHOULD NOT BE ENTERED BY THE OPERATOR. The maintenance worker can work around and inside the machine only once he has activated the active and passive safety devices that the manufacturer has supplied to allow the maintenance worker to work in complete safety. Fig Control, work and danger zones. 3-6

31 SAFETY MAN-BM22-40-GB Risks, safety devices, warnings and cautions General safety To guarantee the health and safety of exposed persons, the machine has the following safety devices (see fig. 3-6): - passive safety devices - active safety devices PASSIVE SAFETY DEVICES: - Protection covers, eg., sound-proofing box, low voltage controls, metal distribution boxes. ACTIVE SAFETY DEVICES: - Safety micro-switch. By tilting the hopper, you can access the rotor which, if moving, would represent a very serious risk factor. During normal maintenance and changing the grid, the operator is allowed to reach the rotor as the removal of the grid gives direct access to the blades. There is thus a risk that could increase in seriousness if the granulator is started up again without replacing the grid. To avoid such a risk, a safety micro-switch has been fitted connected to start up command. As soon as the hopper loader and the grid holder are opened, this trips. As the panels come away from the machine base, they release the micro-switch which cuts out the motors and at the same time signals the danger by switching off the motor start indicators on the control panel. The micro-switch used is a PIZZATO model FP 6R2-F Fig Unblocking Safety devices. 3-7

32 SAFETY MAN-BM22-40-GB Fig. 3-8 Opening the collector bin. - Hopper: The lump to be recycled accesses the cutting chamber following a path from the feed inlet and the protection located vertically above the chamber itself. In such a situation, it may happen that an operator, through an imprecise movement, allows an arm to enter inside this channel. Here too, the current regulations (EN 264) are observed, guaranteeing minimum machine safety requirements. The micro-switch used is a PIZZATO model FP 6R2-F N.B. FOR OPENING THE HOPPER, OPEN THE SOUND-PROOF COVER IN FRONT OF THE COLLECTOR BIN, FOR NOT DAMAGE THE COVER ITSELF. Fig Opening cover and closed micro-switch. 3-8

33 SAFETY MAN-BM22-40-GB Fig Opening micro-switch and opening the hook s hopper Risks in the granulator installation area When processing special materials, it may become necessary to take certain precautions to safeguard the work environment. This is the case, for instance, of materials that release harmful or irritating substances after granulation. In such cases, an adequate forced ventilation system needs to be installed and/or such harmful emissions need to be eliminated. The most common situations where the work environment can be adversely affected, even with proper use of the granulator, are the following: - excessive dust emissions owing to material type - emission of harmful substances after granulation of special materials - excessive noise levels due to very hard materials - excessive wear and subsequent reduction in machine performance owing to the granulation of materials with fiber glass (even in part). In such situations or similar ones, the user must take steps to ensure the quality of the environment in conformity with current regulations and must intensify extraordinary maintenance if necessary. 3-9

34 3.2.3 Onboard machine risks (see also Risk analysis) The machine risks that cannot be eliminated are: - Tipping of the granulator - Cutting edges of the blades - Danger of being cut - Danger of being crushed when the hopper is lowered Risks (listed by analysis) SAFETY MAN-BM22-40-GB Despite the precautions taken at the design stage, certain risks still exist during operation and maintenance work. ATTENTION - Tipping of the granulator: When the hopper is tipped, the granulator is less stable than when the hopper is closed. In this position, you must take special care as the machine may tip over very easily. - Cutting edges of the blades: When it is necessary to access the mobile blades, be careful of the cutting edges of these blades as their sharpness is such that they could cause injury. - Danger of being cut: This exists when the rotor is turned by hand. In fact, even though safety micro-switches have been fitted, there are no mechanical interlocks on the rotor. As a result, on accessing the cutting chamber, you must be careful of the rotor which, even when turned manually, can cut or injury seriously if part of the body is inadvertently inside the chamber. - Danger of being crushed when the hopper is lowered: When lowering the hopper to close it, take care not to crush any part of your body that is between the hopper and the machine. 3-10

35 3.3 Accident prevention (see fig. 3-7) SAFETY MAN-BM22-40-GB On the control panel there is a "CE" mark plate. On the right-hand side of the hopper is a notice (red on a yellow background) warning against inserting your hands: "DANGER - DO NOT INSERT HANDS". On the control panel is a plate (silver on red) advising you to check the blocks frequently: "ATTENTION - REGULARLY CHECK THAT ALL SCREWS AND STOP RINGS ARE TIGHT TO AVOID BREAKAGE". On the electric motor there is an arrow indicating the sense of rotation. On the electric panel door above the main door switch is a plate (black on yellow) bearing a lightning symbol advising you to disconnect the voltage first: "DISCONNECT VOLTAGE BEFORE OPENING DOOR". On the bottom part of the electric panel door is a plate indicating: the component supplier's name and address, main circuit voltage, control circuit voltage, frequency, installed Kw and diagram no. WARNING "REMEMBER THAT IT IS ABSOLUTELY FORBIDDEN TO TAMPER WITH OR REMOVE THE SAFETY DEVICES. THE MANUFACTURER DECLINES TO ACCEPT ANY LIABILITY FOR MACHINE SAFETY IF THIS PROHIBITION IS IGNORED." 3-11

36 SAFETY MAN-BM22-40-GB Fig Plate locations 3-12

37 INSTALLATION MAN-BM22-40-GB INDEX 4.1 Packaging, handling, shipping and transport Choosing the site for installation location and requisites Preparing for installation Assembly Removing the protective oils Mains connection Electric mains connection Compressed air mains connection Cooling water mains connection Lubrication before first start-up

38 4.1 Packaging, handling, shipping and transport The machine can be supplied in one of the ways as follows: INSTALLATION MAN-BM22-40-GB a) Without packaging on truck, blocked and covered. b) In a normal crate with tarred paper lining and bolted to the truck floor. c) As b) above, but with vacuum sealed plastic protection for shipment by ship. d) In containers, with internal no-roll blocking. The above packaging options depend on the distance, the customer s specifications and the storage times. For packaging types b-c-d, the following data are marked on all 4 sides: - Destination - Contract no. - Codes (if any) - Weight: net - gross - tare - Dimensions: length - width - height - Barycentre along width and hoisting belt attachment point - Packing-list plate. (a copy of the packing-list is inside the crate, fixed to the machine) ATTENTION Follow the steps below for unloading, transport and unpacking: UNLOADING The packed machine must be kept in the position indicated by the pictogram and wording on the outside of the packaging. We recommend using a fork-lift truck with 1,000 kg lifting power and forks of 1200 mm. Unload using suitable equipment (capable of withstanding the weight of the machine + packaging). WARNING THE BLADE GRANULATOR WEIGHS ABOUT : BM Kg, BM Kg, WITHOUT PACKAGING. WHEN UNLOADING AT LEAST TWO EXPERT TECHNICIANS MUST BE PRESENT (lift truck operators or crane operators). ATTENTION KEEP HANDS AND BODY OUT OF THE WAY WHEN THE MACHINE IS BEING LOWERED. SEVERE INJURIES MAY OCCUR OTHERWISE. 4-2

39 INSTALLATION MAN-BM22-40-GB Fig Lifting with fork-lift truck. Fig Hoisting with bridge crane or tackle. 4-3

40 INSTALLATION MAN-BM22-40-GB Fig Incorrect lifting. 4-4

41 INSTALLATION MAN-BM22-40-GB Choosing the site for installation location and requisites The granulator must be installed in a suitable area providing the conditions necessary for normal operation and maintenance. The room must therefore: - have an electricity supply - be sufficiently well-lit - have good ventilation in order to eliminate any residual grinding powder. Fig Overall machine dimensions. 4-5

42 BM INSTALLATION MAN-BM22-40-GB A mm 587 B mm 415 C mm 1672 D mm 670 E mm 2672 F mm 1087 G mm 915 H mm 1290 L mm 530 M mm 58 N mm 617 O mm 1205 P mm 2205 Fig. 4-4bis. Overall machine dimensions. Fig Lifting with fork-lift truck. 4-6

43 4.3 Preparations for installation INSTALLATION MAN-BM22-40-GB Before the machine arrives, the user must prepare: - a smooth non-slip and perfectly even suspended surface - suitable lighting, conforming to EN an earth connection, conforming to CEI an electricity supply, conforming to EN WARNING Use a fork-lift truck or trans-pallet truck in perfect condition to move the granulator + packaging: the manufacturer declines to accept all liability concerning the adequate nature of the handling equipment used. The lift capacity of the handling equipment must be sufficient to withstand the weight for movement. All handling must be done slowly, in perfect light and with adequate room for maneuver in the installation area. ATTENTION Staff may not pass under the load or near the load for any reason, not even the person in charge of indicating where to move the load. The manufacturer declines to accept any liability for this stage of installation, which should be carried out by industrial machinery handling specialists (lift truck operators, slingers) with the appropriate protective clothing (overalls, shoes, work gloves and helmets). UNPACKING 1 Open the crate or external packing containing the machine and place it on the floor after having first loosened the fixing straps. 2 Identify all the various parts and check that they show no signs of damage. The basic version does not include auxiliary parts, so installation is particularly quick and easy. Special versions may have some components packed separately from the machine. In this case, check that all parts show no signs of damage on receipt. NOTE: The user must dispose of the packaging materials in compliance with the local laws. The packaging materials can be demolished as follows: - cutting the straps (be careful that the ends do not hit the operator, especially his eyes); - cutting or sliding off the wrapping; - cutting the internal strap (be careful that the ends do not hit the operator, especially his eyes) - removing the machine from the pallet. NOTE: Once the packaging has been removed, there must be no signs of tampering. If there are, contact Assistance Service. 4-7

44 INSTALLATION MAN-BM22-40-GB Assembly The machine is supplied ready assembled in the following components: - Machine base + cutting chamber assembly - Feed hopper assembly - Sound-proofing assembly ATTENTION Check that the floor can withstand the weight of the machine. After anchoring the machine, check that it is perfectly level Removing the protective oils The unpainted hopper and cutting chamber parts are treated with a special protective oil: to prevent these parts from rusting, follow these steps: - Carefully clean the machine, removing all traces of dust, foreign bodies and dirt. - Remove the rust-proofing oil from the treated areas, using rags soaked in a solvent. Do not use the solvent on the painted parts. ATTENTION WHEN CLEANING THE CUTTING CHAMBER, AVOID CONTACT WITH THE ROTOR BLADES AS THESE COULD SERIOUSLY CUT YOUR HANDS. PROTECTIVE GLOVES MUST BE WORN FOR THIS OPERATION. 4-8

45 INSTALLATION MAN-BM22-40-GB Mains connection Electric mains connection WARNING This operation must be carried out by a qualified technician (electrician) in compliance with CEI Before connecting the machine to the mains: - check that the mains voltage and frequency rates are correct - check that the earth connection works properly - adjust the max. mains voltage rate: + 10% - adjust the max. mains frequency rate: + 2% - use the correctly sectioned power cable, as indicated in the table on the wiring diagram - connect the power cable (3-phase + PE) to the terminal indicated in the wiring diagram in compliance with local laws - check that the plug to be attached to the machine has a higher or at least adequate power value to match the maximum machine absorption and the motor surge current - check that the equipment is not resting on the power cable - protect the supply line from excess voltage (eg. atmospheric discharge) - protect the supply line from thermal or magnetic overcurrent with coordinated special devices (eg. automatic switches) - the neutral conductor is not needed Fig Energy connections. 4-9

46 4.5.2 Cooling water mains connections INSTALLATION MAN-BM22-40-GB The figure below shows the attachment point for the cooling water supply for the rotor: Fig Hydraulic connections. 4-10

47 4.5.4 Lubrication before first start-up INSTALLATION MAN-BM22-40-GB The granulator is normally supplied already lubricated in all its parts. The purchaser should, however, lubricate these components for safety s sake. Inject the grease with a manual pump at the points indicated below. During routine maintenance, make sure that the O-rings on the bearings are not damaged. Fig Greasing points. Use one of the following grease types: AGIP BP ESSO MOBIL SHELL TOTAL GR MU EP2 LTX EP2 GREASE BEACON EP2 MOBILUX EP2 GREASE ALVANIA EP2 GREASE MULTIS EP2 4-11

48 SETTING UP MAN-BM22-40-GB INDEX 5.1 Preparation, checks and tests before start-up Motor rotation direction Grid Blades 3 5-1

49 5.1 Preparation, checks and tests before start-up SETTING UP MAN-BM22-40-GB ATTENTION The machine must be prepared for first start-up by an expert technician who must carry out the following checks. The blade granulators are supplied ready checked in the manufacturer s factory. If, during shipment, the structure of the machine has been damaged, the damage must first be identified to avoid the start-up of the machine in an imperfect condition. The checks required are as follows: - check that the control panel is not damaged - check that the emergency stop light is not damaged - check that the electrical cable is not damaged (i.e. cut, worn, etc.) - check that the safety lever for opening the hopper is thoroughly closed (screwed down). If there are any signs of tampering, contact the Assistance Service immediately Motor rotation direction WARNING Do not remove any protective covers to check the sense of rotation. The sense of rotation is indicated by the arrow on the motor. Fig Plate indicating motor rotation direction. 5-2

50 SETTING UP MAN-BM22-40-GB If the motor turns in the wrong direction during first start-up, follow the procedure below. Start up the granulator and check the sense of rotation of the motor cooling fan. If this corresponds to the direction indicated by the arrow on the cover, the rotation is correct and no further action is required. OTHERWISE, if the fan turns in the opposite direction, invert the rotation as follows: ATTENTION a. Disconnect the electrical supply above the machine using the switch relative to the line to which the granulator is connected. b. Use the emergency stop button to prevent the machine from accidentally starting up when switched back on. c. Open the electric box by loosening the screws. d. Take any two of the three phase conductors and loosen the clamps until two wires can be removed. e. Invert the two wires and replace in the clamps. f. Tighten the clamps. g. Close everything. h. Reset the emergency stop button. i. Reconnect the switch. j. Start the granulator up, checking that the motor turns in the right direction Grid Before starting the machine up, check that the grid is fixed securely to the support and that it is suitable for the size required Blades Before starting the machine up, check that the blades are fixed securely to the support and that they are suitable for the size required. 5-3

51 OPERATION MAN-BM22-40-GB INDEX 6.1 General information Uses, zones and operators Operating controls and indicators and alarms General information Control panel commands and instrument list Starting up the blade granulator Initial checks Start-up sequence Normal operation: control/indicator sequences and status Machine start-up Performance checks and adjustment General information Safety device operation checks and tests Malfunctions, emergencies and alarms General information Possible machine-stops list Machine stops Voluntary stops Emergency stops Resetting Cleaning and putting out of service

52 OPERATION MAN-BM22-40-GB General information If the operations described above have all been carried out, the machine is ready to be started up. The granulator can be started up for production and lumps introduced only after switching the machine on. ATTENTION For correct machine operation, we recommend that the operator has read the instructions and thoroughly understood these. If in doubt, contact our Assistance Service. 6.2 Uses, zones and operators Intended, unintended and incorrect use The blade granulator is intended for the granulation of the product specified in the contract and within the capacity levels provided for. Use of the granulator for the granulation of any other materials or for greater capacity levels than those provided for is considered INCORRECT USE. Work, control and danger zones. ATTENTION The work zones, within the operator must act, are those between the control panel and the material feed areas. ALL OTHER AREAS MUST NOT BE ENTERED BY THE OPERATOR. Fig Control, work and danger zones. The operator in charge of the machine must be qualified for running the machine, after having read or been trained as to the operating procedures. The operator MUST NOT CARRY OUT controls or maintenance, these to be carried out by specialist personnel. 6-2

53 OPERATION MAN-BM22-40-GB Operating controls and indicators and alarms General information The processes of start-up, adjustment and machine stop in normal and emergency modes are run by the electric control panel. See the figure and the tables below for details of the control panel component names and functions Control panel commands and instrument list The commands and instruments on the control are: INSTRUMENT WORDING FUNCTION MAIN SWITCH (Q1) POS.1 powers up the control panel POS.0 cuts out the panel. Allows panel to be opened EMERGENCY (S1) START Suction-granulator (S3) STOP Suction-granulator (S2) Stops all machine s parts in motion Starts the corresponding machine. Stops the corresponding machine. Table

54 OPERATION The control panel commands are set out in the figure below: MAN-BM22-40-GB Fig Control panel commands and instruments. Q1 S1 S2 S3 MAIN SWITCH EMERGENCY STOP BUTTON GRANULATOR AND SUCTION STOP BUTTON GRANULATOR AND SUCTION START BUTTON 6-4

55 OPERATION MAN-BM22-40-GB Starting up the blade granulator Initial checks Before start-up: - check that the collection bin is empty; Fig Check that the collection bin is empty. - tip the hopper and check that the cutting chamber is empty; Fig Hopper rotation. 6-5

56 OPERATION MAN-BM22-40-GB check that all connections have been made, and especially that the voltage and frequency of the supply corresponds to that required; - check that the sound-proofing box is shut properly so that the safety micro-switch allows the granulator to start up. See Trouble-shooting chapter if there are problems Start-up sequence The granulator is started up following this procedure (Fig. 6-5): - Turn the MAIN SWITCH to position 1 Fig Start-up sequence Press the granulator starting button (S3) and the suction one (if present). 6-6

57 OPERATION MAN-BM22-40-GB Normal operation: controls/indicators sequences and status Machine start-up The controls status should be as follows: - Main switch Q1 on position 1 - Starting button S3 on 6.6 Performance checks and adjustment General information The granulator, once started up, does not require adjustment. During operation, it is good practice to check: - The feeder on the hopper works regularly, without jerks. - The pneumatic conveyor ensures proper evacuation of the granulated material. - The machine does not produce unusual sounds or that the noise level exceeds the average Safety device operation checks and tests The efficiency check of the safety devices on the machine MUST be carried out before starting the machine up with material loaded. - The check is carried out by starting the machine up and making it run empty. - Check that the safety system (micro-switch) works properly by simply opening the sound-proofing panels. - THE SAFETY SYSTEM WITH MICRO-SWITCH CAN BE CONSIDERED EFFICIENT ONLY IF THE MAIN MOTOR POWER SUPPLY IS CUT OUT WHEN THIS TRIPS. 6.7 Malfunctions, emergencies and alarms General information WARNING If a malfunction described in the trouble-shooting guide occurs, the operator must remember that he/she is only allowed to operate the machine stop and then ask specialist personnel to remove the cause of the malfunction. 6-7

58 OPERATION MAN-BM22-40-GB Alarm list and description All alarm situations recorded by the granulator are indicated by the switching off of the orange start indicator. This is due to the fact that as soon as any malfunction occurs, the machine stops. The possible causes for an alarm are: PROTECTION COVER NOT CLOSED The sound-proofing panel has not been correctly shut and so the safety micro-switch has tripped, cutting off the electrical supply. Reposition the cover and fix the solid pin with the micro-switch. Fig Hopper not closed. Fig Bin not closed MOTOR OVERCURRENT Here the possible causes are various. Those more probable are described here. The granulator has been fed with more material than its production capacity (pieces per second) or not in conformity (material size and composition) with the indications given in this manual. In this case, the machine jam has caused the cutting chamber to become clogged up and so needs to be emptied. ATTENTION All action must be carried out by an expert technician. 6-8

59 OPERATION MAN-BM22-40-GB Machine stops Voluntary stops To stop the granulator intentionally, press the corresponding STOP button Emergency stops The blade generator stops in an emergency as shown in the figure below. During normal operation, the granulator automatically stops if the fan stops Resetting To reset and prepare the granulator to start again: Fig Emergency stop - release the emergency button - check that the collection bin is empty - check that the hopper is closed so that the safety micro-switch allows start-up - continue with the start-up procedure. 6-9

60 OPERATION MAN-BM22-40-GB Cleaning and putting out of service At the end of each shift, the machine and its components must be cleaned to ensure correct use and low running costs. ATTENTION THE MACHINE MUST BE AT A STANDSTILL AND THE POWER OFF DURING CLEANING. - Remove the collection bin and clean, without knocking, bending or scraping it. - Loosen the screws and lower the grid holder to remove the grid. Clean as indicated in the figure below, without scraping or bending. - Clean the grid holder (suck to remove stuck material) without knocking, bending or scraping it. Fig Cleaning the grid. ATTENTION These operations must be carried out by expert technicians. PUTTING OUT OF SERVICE To avoid the risk of personal injury, the rotor blades and counter-blades must be removed. If the machine must be stored, follow these steps: ATTENTION These operations must be carried out by expert technicians. 1. Unplug the granulator at the mains. 2. Disconnect the power cable from the electric panel. 3. Remove any remaining material from the cutting chamber. 4. Remove the collection bin. 5. Remove any remaining material from the collection bin. 6. Close everything. 7. Cover the feed inlet with nylon sheeting or similar. 8. Store the granulator in a suitable place, making sure that it is properly secured. 9. Lubricate all machined metal parts. 6-10

61 MAINTENANCE MAN-BM22-40-GB INDEX 7.1 Safety devices, precautions and maintenance General information Routine maintenance Sharpening the mobile blades Sharpening the fixed blades Lubrication Cleaning and replacing the grading grid Checking the fastness of the mobile blades Adjusting the fixed/mobile blades clearance Back fixed blade extractor Extraordinary maintenance Replacing the fuse Replacing the mobile blades Checking the drive belt

62 7.1 Safety devices, precautions and maintenance MAINTENANCE MAN-BM22-40-GB ATTENTION Carefully read the instructions in this manual and the notices on the equipment itself before carrying out any operation or maintenance. PRECAUTION All routine and extraordinary maintenance work must be carried out with the machine switched off and the emergency button inserted. 7.2 General information Routine and extraordinary maintenance work must be carried out at different periods, depending on the type of material being ground. Generally speaking, the user must decide for himself, taking into account the factors that have the greatest effect on the state of the machine. These factors are basically: - noise levels - granulate quality - hourly production rate When the conditions of use are particular, the noise level, the breaking up of the ground material and the hourly production rate must be evaluated when deciding on maintenance times. If the materials and work environment do not render maintenance critical, the routine maintenance described in paragraph 7.3 should be adopted. 7-2

63 7.3 Routine maintenance Sharpening the mobile blades MAINTENANCE MAN-BM22-40-GB IN ORDER TO HAVE AN OPTIMAL PERFORMANCE OF THE GRANULATOR IT IS NECESSARY TO GUARANTEE THE CORRECT SHARPENING OF THE BLADES. IT IS NOT POSSIBLE TO INDICATE PRE-ESTABLISHED INTERVALS OF TIME FOR CONTROLLING THE BLADES SHARPENING BECAUSE EACH TYPE OF PLASTIC MATERIALS DIFFERENTLY AFFECTED IN SHARPENING CONSUMPTION. THE NECESSITY OF BLADES SHARPENING MUST BE ASSESSED FROM THE MAINTENANCE SERVICE OF THE CUSTOMER, CONSIDERING THE PROPER WORKING CONDITIONS OF THE GRANULATOR. WE RECOMMEND, THEREFORE, THE PERIODIC CHECK OF THE BLADES, WITH FREQUENCY, TO BE DETERMINED IN ACCORDANCE WITH THE METHOD OF USE. SYMPTOMS OF IMPROPER SHARPENING BLADES: Average increase of power consumption of the granulator s motor (verifiable observing during the time the indication of the amperometer) Dust increase of the grinded material Decrease of production capacity of the granulator OBSERVATION OF THESE PHENOMENA HELPS TO ESTABLISH THE CORRECT RANGE OF TIME FOR CONTROLLING AND FOR THE RELATIVE SHARPENING. ATTENTION THE CONTINUOUS USE OF THE GRANULATOR, EQUIPPED WITH BLADES WITHOUT THE CORRECT SHARPENING, CAN GENERATE: Greater energy consumption Mechanical stress that can damage to the granulator ENGIN PLAST S.R.L. DECLINES ALL RESPONSABILITY FOR POSSIBLE DAMAGES TO THE GRANULATOR USING BALDES WITH AN INCORRECT SHARPENING. ATTENTION 1. Disconnect the electrical supply above the machine using the switch relative to the line to which the granulator is connected. 2. Use the emergency stop button to prevent the machine from accidentally starting up when switched back on. 3. Tip the hopper. 4. Loosen and remove the setscrews (see fig. 7-1), thus freeing the blade clamp and the blade to be sharpened. Repeat for all blades. 7-3

64 MAINTENANCE MAN-BM22-40-GB Fig Replacing mobile blades. Fig Replacing the fixed blades. 7-4

65 MAINTENANCE MAN-BM22-40-GB PRECAUTION 5. Sharpen the blade, following the instructions given in fig. 7-2, which indicates the angles required for best cutting conditions. If these instructions are not followed, there may be a reduction in the machine performance in terms of quality and production capacity. Fig Grinding angles of the blade on the rotor. and record for BM Remount the blades, making sure that they are right up against the back so that they do not move during machine operation. 7. Return the blade clamp and thoroughly tighten the screws. TIGHTENING TIMES TORQUE SCREW (UNI 5739) SCREW DIMENSION DRY COUPLEMENT RESISTENCE CLASS Tightening torque (Nm) M M M M M M M M Tab Table of the tightening times.. 7-5

66 MAINTENANCE MAN-BM22-40-GB Check with a thickness gauge that the clearance between the blade and the blade clamp is correct. To adjust this, adjust the depth of the fixed blades by using the adjustment screws on the outside of the granulator. Fig Checking the fixed/mobile blade clearance. 9. Slowly turn the rotor assembly to check that it turns freely. 10. Close everything. 7-6

67 7.3.2 Sharpening the fixed blades MAINTENANCE MAN-BM22-40-GB IN ORDER TO HAVE AN OPTIMAL PERFORMANCE OF THE GRANULATOR IT IS NECESSARY TO GUARANTEE THE CORRECT SHARPENING OF THE BLADES. IT IS NOT POSSIBLE TO INDICATE PRE-ESTABLISHED INTERVALS OF TIME FOR CONTROLLING THE BLADES SHARPENING BECAUSE EACH TYPE OF PLASTIC MATERIALS DIFFERENTLY AFFECTED IN SHARPENING CONSUMPTION. THE NECESSITY OF BLADES SHARPENING MUST BE ASSESSED FROM THE MAINTENANCE SERVICE OF THE CUSTOMER, CONSIDERING THE PROPER WORKING CONDITIONS OF THE GRANULATOR. WE RECOMMEND, THEREFORE, THE PERIODIC CHECK OF THE BLADES, WITH FREQUENCY, TO BE DETERMINED IN ACCORDANCE WITH THE METHOD OF USE. SYMPTOMS OF IMPROPER SHARPENING BLADES: Average increase of power consumption of the granulator s motor (verifiable observing during the time the indication of the amperometer) Dust increase of the grinded material Decrease of production capacity of the granulator OBSERVATION OF THESE PHENOMENA HELPS TO ESTABLISH THE CORRECT RANGE OF TIME FOR CONTROLLING AND FOR THE RELATIVE SHARPENING. ATTENTION THE CONTINUOUS USE OF THE GRANULATOR, EQUIPPED WITH BLADES WITHOUT THE CORRECT SHARPENING, CAN GENERATE: Greater energy consumption Mechanical stress that can damage to the granulator ENGIN PLAST S.R.L. DECLINES ALL RESPONSABILITY FOR POSSIBLE DAMAGES TO THE GRANULATOR USING BALDES WITH AN INCORRECT SHARPENING. ATTENTION 1. Disconnect the electrical supply above the machine using the switch relative to the line to which the granulator is connected. 2. Use the emergency stop button to prevent the machine from accidentally starting up when switched back on. 3. Tip the hopper. 4. Loosen the setscrews to remove the hopper (see fig. 7-1), thus freeing the blade. Repeat for both blades. 5. Sharpen the blade, following the instructions given in fig. 7-4 which indicate the angles required for best cutting conditions. If these instructions are not followed, there may be a reduction in the machine performance in terms of quality and production capacity. 7-7

68 MAINTENANCE MAN-BM22-40-GB Fig Grinding angles of the fixed blade. 6. Remount the counter-blades, adjusting the adjustment screws. 7. Check with a thickness gauge (see fig. 7-3) that the clearance between the blade and the counter-blade is correct. To adjust this, adjust the depth by using the adjustment screws on the outside of the granulator. 8. Place the blade-bar on top and fasten the screws into their holes with NORD-LOCK washer with the help of a dynamometric wrench that must be suitably calibrated according to the values in the table. TIGHTENING TIMES TORQUE SCREW (UNI 5739) SCREW DIMENSION 9. Slowly turn the rotor assembly to check that it turns freely. 10. Close everything. DRY COUPLEMENT RESISTENCE CLASS Tightening torque (Nm) M M M M M M M M Tab Table of the tightening times.. WARNING Make sure that the fixed blades are oriented correctly to meet the mobile blades. WARNING 7-8

69 MAINTENANCE MAN-BM22-40-GB If any metal bodies have accidentally entered the granulator and have chipped the cutting edges, replace the blades Lubrication The parts to be lubricated are the following: Crankshaft bearings In order to allow this intervention, the rotor shaft supports, are fitted with nipples that are accessed by opening the doors of the soundproofing. Engin Plast granulators are supplied already lubricated in the parts requiring lubrication. Testing operations run before any shipment ensure an adequate lubrication. ATTENTION! IT IS USER S RESPONSIBILITY TO MAINTAIN LUBRICATED AND/OR GREASED ROTOR BEARINGS. FAILING TO DO SO MAY CAUSE SERIOUS DAMAGES TO THE MACHINE. ENGIN PLAST DOES NOT RECOGNIZE SUCH DAMAGES EVEN IF OCCURRED DURING THE WARRANTY PERIOD. ATTENTION! FREQUENCY OF SUCH MAINTENANCE OPERATIONS DEPENDS ON GRANULATORS USE, IT IS THEREFORE USER S RESPONSIBILITY TO DETERMINE CORRECT LUBRICATION INTERVALS. ATTENTION! LUBRICATION AND/OR GREASING OPERATIONS HAVE TO BE CARRIED OUT BY PERSONNEL WITH MECHANICAL KNOWLEDGE. Proceed as shown below: ATTENTION 1. Disconnect the electrical supply above the machine using the switch relative to the line to which the granulator is connected. 2. Open the access door as shown below (fig. 7-7). Fig Opening the protection covers by rotation. 7-9

70 3. Inject the grease in the greasing nipples (fig. 7-8). MAINTENANCE MAN-BM22-40-GB Fig Manual greasing. 4. Close everything and reconnect to the mains. Top quality grease should be used. AGIP BP ESSO MOBIL SHELL TOTAL GR MU EP2 GREASE LTX EP2 BEACON EP2 MOBILUX GREASE EP2 ALVANIA GREASE EP2 MULTIS EP2 7-10

71 7.3.4 Cleaning and replacing the grading grid MAINTENANCE MAN-BM22-40-GB There are basically two situations where the grid needs to be removed, coinciding with the following operations: - regular cleaning of the grid to ensure that the filtering function of the holes is uniform; - replacement of the grid for one with different-sized holes for a different granulate size. The procedure to be followed is essentially the same for both situations, as explained below: ATTENTION 1. Switch the main off at the main switch to prevent the machine from inadvertently starting up again when the mains electricity is reconnected. 2. Open the cutting chamber access door. 3. Extract the grading grid by pulling it outwards, as shown in figure If cleaning, use a jet of compressed air at right-angles to the holes so that any blockage is removed. Then check that the grid is in good working order and not worn. If replacing, simply remove the part to be replaced. 5. Return the grid to its seat. 6. Close everything. Fig Opening Micro-switch. 7-11

72 MAINTENANCE MAN-BM22-40-GB Fig Opening the collector Bin. Fig Extracting the Grid. 7-12

73 7.3.5 Checking the fastness of the mobile blades MAINTENANCE MAN-BM22-40-GB The mobile blades are fixed to the rotor by three screws that secure the blade clamp. It is important that the fastness of these screws is regularly checked to prevent the rotor from becoming blocked due to the collision of the blades and the counterblades. To do this: ATTENTION 1. Switch the main off at the main switch to prevent the machine from inadvertently starting up again when the mains electricity is reconnected. 2. Tip the feed hopper. 3. Tighten the mobile blade setscrews to the rotor. Repeat for all blades. 4. Slowly turn the rotor assembly to check that it turns freely. 5. Close everything Adjusting the fixed/mobile blades clearance The optimum distance between the blade and the counter-blade can be adjusted by wear factors such as the consumption rate of the cutting edge or the sliding of the mobile blade. To adjust: ATTENTION 1. Switch the main off at the main switch to prevent the machine from inadvertently starting up again when the mains electricity is reconnected. 2. Tip the feed hopper. 3. Check with a thickness gauge that the clearance between the fixed blade and the mobile blade is correct. To adjust this, adjust the cutting depth of the fixed blades by using the adjustment screws on the outside of the granulator. 4. Slowly turn the rotor assembly to check that it turns freely. 5. Close everything. Fig Checking the fixed/mobile blade clearance. 7-13

74 7.3.7 Back fixed blade extractor MAINTENANCE MAN-BM22-40-GB The granulator is equipped with an extractor that is to be used to help the operator during extraction of the back fixed blade. ATTENTION 1. Before undertaking any type of intervention, disconnect the electrical power of the machine. Make sure the cut-out switch in on to avoid the unintentional starting of the machine when it is connected to the mains outlet. 2. Remove the screws A fixing the blade covering plate B. 3. Lift the blade cover B. 4. Unscrew the locking nuts di'estrazione C screws (supplied to the granulator) and remove the fixed rear blade. During this operation, having care to slide the blade keeping it in axis with the drilling.. Fig Back fixed blade extractor 7-14