Sterling Grinder BJ1 625 User Manual

$30.⁰⁰

Operation and Installation Manual

EX Series Screenless Granulator

Important! Read Carefully Before Attempting to Install or Operate Equipment

Bulletin No. BJ1-625

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Safety Considerations

Ball & Jewell EX Series Granulator Sprue and Runner Cutters are

designed to provide safe and reliable operation when installed and

operated within design specifications, following national and local

safety codes.

To avoid possible personal injury or equipment damage when

installing, operating, or maintaining this granulator, use good

judgment and follow these safe practices:

; ^{LEARN AND OBEY your company’s safety policy regarding}

granulating equipment.

; ^{MOVING OR LIFTING THE GRANULATOR: Although}

our equipment is built and engineered for great ruggedness in

operation, care must be taken when moving the machine along

the floor or lifting it. Damage may occur to sheet metal covers,

electrical cabinets, or small brackets if pressure is applied to

them when moving the granulator. When lifting the granulator,

be certain of total machine weight and the capability of the

lifting equipment (see the Granulator Specification Sheets for

machine weights and dimensions).

; ^{GRANULATOR LOCATION: Adequate area for routine}

maintenance should be provided in order to open the machine

for knife, screen, or cleanout service. Proper service area

clearances also should allow people who are working on the

machine to be clearly visible to others, thereby reducing the

potential safety hazards.

; ^{SAFE HOUSEKEEPING: The work area must be kept clean}

and uncluttered to allow personnel safe movement around the

granulator during periods of operation or maintenance. No

hand tools or other metal objects should be left on or about the

machine. Any tools or other metal objects which mistakenly

fall into the hopper feed opening can cause severe damage to

internal cutting chamber and screen chamber components.

; ^{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 iii

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; ^{EAR PROTECTION may be required when operating the}

machine during granulation of very hard/noisy materials. The

Occupational Safety and Health Act of 1970 has established

guidelines for Permissible Noise Exposures (OSHA 1910.95)

that should be followed.

; ^{NEVER attempt to operate the granulator unless it is fully}

assembled with all guards and interlocks in place and

functional.

; ^{OBSERVE all danger, warning, caution and safety labels on}

the equipment.

; ^{Upon completion of any machine maintenance, be certain ALL}

SAFETY GUARDS AND COVERS are securely and

properly fastened prior to resuming machine operation. All

fasteners must be in place and properly tightened. ANY

SHORTCUTS MAY RESULT IN INJURY TO

PERSONNEL OR DAMAGE TO EQUIPMENT.

; ^{NEVER wear any loose fitting clothes, neckties, or dangling}

items such as earrings, belts or shoestrings. Jewelry such as

wristwatches, bracelets, or rings should NEVER be worn.

Long hair must be tied back or placed in a tight fitting hairnet.

NEVER lean against or rest hands/feet on the granulator when

it is in operation or open for maintenance. NEVER stand on

the granulator when it is in operation.

; ^{ROTATION OF MOTORS: All rotating items in the}

granulator are clearly marked on the machine. Always check

for proper rotation of motors.

; ^{ELECTRICAL GROUNDING: All electrical equipment on}

the granulator must be grounded in accordance to all local

codes and Article 250 of the National Electric Code.

; ^{ALWAYS DISCONNECT AND LOCKOUT THE MAIN}

ELECTRICAL POWER TO THE GRANULATOR BEFORE

PERFORMING ANY SERVICE.

; ^{SAFETY INTERLOCKS MUST NOT BE BYPASSED.}

The mechanical and electrical safety interlocks ensure the

safety of personnel. They should never be tampered with or

removed for ANY reason. They should be checked frequently

by a qualified mechanic for proper operation.

; ^{NEVER modify the machine configuration or any individual}

component without written consent from Cumberland

Engineering Corp.

Page iv

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For further information on granulator safety, installation, and

operation, see the American National Standard for Plastics

Machinery - Granulators, Pelletizers, And Dicers Used For Size

Reduction of Plastics - Construction, Care, and Use. ANSI

B151.11-1982.

Ball & Jewell has long recognized the importance of safety and has

designed and manufactured its equipment with operator safety as a

prime consideration. We expect you, as a user, to abide by the

foregoing recommendations in order to make operator safety a

reality.

SAFETY IS NO ACCIDENT

Page v

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Table of Contents

Error! No table of contents entries found.

1 General Information

1-1 Introduction

1-1-1 How to Use This Manual

1-1-2 Safety Symbols Used in This Manual

1-2 Granulator Specifications

1-3 Standard Features

1-4 Available Options

2 Shipping Information

2-1 Unpacking and Inspection

2-2 In the Event of Shipping Damage

2-3 If the Shipment is Not Complete

2-4 If the Shipment is Not Correct

2-5 Returns

2-6 Uncrating Your Granulator

3 Installation

3-1 Scope

3-2 General Set-Up

3-3 Inspecting and Cleaning Granulator Components

3-4 Completing the Installation of Your Granulator

3-5 Electrical Considerations

3-6 Electrical Service Connections

3-7 Electrical Testing

3-7-1 Hopper Safety Disconnect

3-7-2 Motor Rotation Direction

3-7-3 Accessory Equipment

4 General Operation

4-1 Scope

4-2 Pre-Operational Checklist

4-3 Granulator Operation

4-4 Cleaning Out the Granulator

4-5 Shutdown Conditions

4-5-1 Emergency Stops

4-5-2 Temporary Machine Stops

4-5-3 Final Machine Stops

Page vi

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5 Maintenance

5-1 Maintaining Drive Components

5-2 Replacing Timing Belts

5-3 Lubrication Specifications and Considerations

5-4 Knife Recommendations and Adjustments

5-4-1 Removing, Replacing and Adjusting Granulator Combs

5.4.1.a. Removing Rotor Combs:

5.4.1.b. Removing Bed Combs:

5.4.1.c. Installing Bed Combs:

5-5 Adjusting the Sensitivity of the Optional Bin Level Monitor

5-6 Recommended Spare Parts List

6 Troubleshooting

7 Charts and Figures

Page vii

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List of Figures

Belt Tensioning Chart

Recommended Spare Parts List Categories

S Series Screenless Granulator (Front)

S Series Screenless Granulator (Back)

Segregation Chamber Access

Cutting Chamber Detail

Discharge Options

Knife Bolt/Screw Tightening Torque Specifications

Page viii

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Ball & Jewell Warranty Information

Thank you for your purchase of your new EX Series Screenless Granulator. We are confident

that you will have excellent results and trouble-free operation with this machine.

When the machine arrives at your plant, inspect it carefully for shipping damage before

uncrating and immediately report any damage to your transportation company. All shipments

are FOB South Attleboro, Massachusetts.

Customer Satisfaction Warranty Program for EX Series Screenless Granulator.

The terms and conditions of the warranty set forth are for one (1) year from the original date of

purchase by the original purchaser.

Ball & Jewell warrants to the original purchaser the product and/or goods to which this

disclaimer is attached, and manufactured by us, to be free from defects in material and

workmanship under normal use and service. THIS WARRANTY IS EXPRESSLY IN LIEU OF

ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, AND ALL

OTHER OBLIGATIONS AND LIABILITIES ON OUR PART.

This warranty shall not apply to any goods or product manufactured by us which has been

subject to accident, negligence, alteration of any kind, abuse or misuse. We further make no

warranty whatsoever in respect to accessories or parts not supplied by us. Any warranty of any

nature shall apply only to an “original purchaser” which shall be deemed to mean that person or

entity for whom the goods and/or product were originally ordered and installed.

We neither assume nor authorize any person to assume for us any liability in connection with the

sale or use of the products and goods sold hereunder, and shall not be responsible for damages

for which a purchaser may be liable to other persons, damages to property, or injuries to any

other persons.

Our sole obligation under this warranty shall be limited to replacing, repairing, or exchanging

any part or parts of goods and/or products sold which we determine are defective under normal

use and service within one (1) year of date of installation by the original purchaser. We shall not

be liable for any loss or damage resulting directly or indirectly from the use or loss of the goods

and/or products purchased. In no event shall we be liable for any general, direct, consequential,

incidental or special damages of any kind.

We do not warrant any of our products that are installed in other machines or apparatus as

meeting requirements of any safety code of any nature. The purchaser assumes all risks and

liabilities resulting from the installation and use of product sold by us in combination with other

machines or apparatus.

Page ix

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Ball & Jewell Warranty Information

We warrant our product to be of the kind and quality quoted, and no other warranty except of

title shall be implied. Our company shall repair or replace, at our discretion, any manufactured

item on your S Series granulator without charge FOB factory, within one (1) year after date of

original purchase, which is proved to be defective when shipped. Claims for labor or

consequential damages are not allowed.

Excluded from the above are knives, screens, and belts. Purchased items, including electrical

components, motors, etc., shall carry the warranty of the supplier and no extension of that

warranty is allowed.

Refer to this manual for assistance in installing and maintaining a highly efficient machine.

Questions regarding areas that are not covered in the manual should be referred to the Customer

Service Manager at the factory at (800) 229-2919.

Page x

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1 General Information

1-1

Introduction

The Ball & Jewell EX Series Screenless Granulators are designed

to uniformly and consistently size-reduce solid material scrap.

They have been engineered to consistently deliver clean granulate

with a minimum of fines and longs.

The rotor on which the combs and breaker bars are mounted is a

machined steel unit supported by bearings mounted outside the

cutting chamber. The rotor is driven by a gear motor capable of

producing high torque loads. The granulator is equipped with a

magnetic reversing starter protected by manually resettable

overload heaters. The rotor combs and bed combs create a

shearing cutting action, producing a very consistent particle size.

Motors are individually fused for maximum protection in

compliance with the National Electric Code. The control enclosure

houses all of the necessary wiring, fuses, overload heaters, and

motor starter coils, along with the 115V control transformer and

granulator operating controls. The control enclosure is built to

meet NEC regulations and also contains a fused disconnect switch.

1-1-1

How to Use This Manual

Use this manual as a guide and reference for installing, operating,

and maintaining your EX Series Granulator. The purpose is to

assist you in applying efficient, proven techniques that enhance

equipment productivity.

The General Information section outlines models covered, standard

features, and available options. Additional sections within the

manual provide instructions for installation, pre-operational

procedures, operation, preventive maintenance, and corrective

maintenance.

Installation instructions include all required data for receiving,

unpacking, inspecting, and setup of the granulator. We can

provide the assistance of a factory-trained technician to help train

your operator(s) for a nominal charge.

Pre-operational procedures include instructions, checks, and

adjustments that should be followed before operating the

granulator. These instructions are intended to supplement

Page 11

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standard shop procedures performed at shift, daily, and weekly

intervals.

The Operation chapter includes a description of electrical and

mechanical controls, in addition to information for operating the

granulator safely and efficiently.

The Maintenance chapter is intended to serve as a source of

detailed assembly and disassembly instructions for those areas of

the equipment requiring service. Preventive maintenance sections

are included to ensure that your EX Series Granulator provides

excellent, long service. The Customer-Recommended Spare Parts

section in the Maintenance chapter contains a list of parts that may

require replacement. A spare parts list with part numbers specific

to your machine is provided with your shipping paperwork

package. Refer to this section for a listing of spare parts for

purchase. Have your serial number and model number ready when

ordering.

The Troubleshooting chapter serves as a guide for identification of

most common problems. Potential problems are listed, along with

possible causes and related solutions.

1-1-2

Safety Symbols Used in This Manual

The following safety alert symbols are used to alert you to

potential personal injury hazards. Obey all safety messages that

follow these symbols to avoid possible injury or death.

DANGER indicates an imminently hazardous situation, which, if

not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation or practice

which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation or practice

which, if not avoided, may result in minor or moderate injury, or in

property damage.

Page 12

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1-2

Granulator Specifications

Table 1: Granulator Specifications

EX909

9.7” (247 mm)

EX913

9.7” (247 mm)

40 lbs./hr (18 kg/hr)

EX918

9.7” (247 mm)

50 lbs./hr (23 kg/hr)

Cutting Circle

Throughput

30 lbs./hr (14 kg/hr)

Cutting Chamber

9” x 9” (229 mm x 229

mm)

9” x 13” (229 mm x 330

mm)

9” x 18” (229 mm x 457

mm)

Rotor Knives

Bed Comb

Hardened 8620 alloy

steel

Reversible 1/4” (6.4 mm) Reversible 1/4" (6.4 mm) Reversible 1/4" (6.4 mm)

Hardened 8620 alloy

steel

Hardened 8620 alloy

steel

comb

Discharge Bin

0.70 cu. ft. (.0198 cu.

meters)

0.85 cu. ft. (.0241 cu.

meters)

1.00 cu. ft. (.0283 cu.

meters)

Motor

Drive

1 hp (.75 kW)

2 hp (1.5 kW)

Cyclodial speed reducer Cyclodial speed reducer Cyclodial speed reducer

– 34rpm

Electrical

Start/stop pushbutton

Components

Controls

Feed Height

Length

NEMA type 12

52” (1321 mm)

25.25” (641 mm)

19” (483 mm)

NEMA type 12

52” (1321 mm)

25.25” (641 mm)

23” (584 mm)

NEMA type 12

52” (1321 mm)

25.25” (641 mm)

28” (711 mm)

Width

Weight

550 lbs (250 kg)

650 lbs (295 kg)

750 lbs (341 kg)

1-3

Standard Features

Standard features of the EX Series Granulator are

• 34 RPM rotor speed

• 230 or 460 voltages

• Segmented rotor comb design

• Timing belt drive system with taper lock bushings

• Totally-enclosed fan-cooled gear motor

• Front hopper cleanout door

• NEMA 1 drop-down rear access electrical enclosure with fused

disconnect switch

• Start-stop control button mounted on NEMA 12 box

• Front-access bed comb cam adjusting system

• 8620 heat treated cutter segments

• Manual discharge bin

• Positive break safety switch to interlock hopper and chute doors

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• No Tools Required to open the cutting chamber/segment

chamber/hopper chute

• Four (4) swivel casters

1-4

Available Options

Available standard options for EX Series Granulators include:

• Alternate feed chutes.

• Alternative voltages: 208/3/60, 380/3/50, 415/3/50, 575/3/60

• Alternate comb tooth sizes .185”(~5MM) and .220”(~6MM),

• Vacuum bin design

• Bin level-sensing proximity switch and light

• Abrasion resistance package

• Compressed air venturi

Page 14

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Shipping Information

2-1

2-2

Unpacking and Inspection

You should inspect your Ball & Jewell EX Series Screenless

Granulator for possible shipping damage.

Thoroughly check the equipment for any damage that might have

occurred in transit, such as broken or loose wiring and

components, loose hardware and mounting screws, etc.

In the Event of Shipping Damage

Important!

According to the contract terms and conditions of the Carrier, the responsibility

of the Shipper ends at the time and place of shipment.

; ^{Notify the transportation company’s local agent if you discover}

damage

; ^{Hold the damaged goods and packing material for the}

examining agent’s inspection. Do not return any goods to

Ball & Jewell before the transportation company’s

inspection and authorization.

; ^{File a claim with the transportation company. Substantiate the}

claim by referring to the agent’s report. A certified copy of our

invoice is available upon request. The original Bill of Lading

is attached to our original invoice. If the shipment was

prepaid, write us for a receipted transportation bill.

; ^{Advise Ball & Jewell regarding your wish for assistance and to}

obtain an RMA (return material authorization) number.

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2-3

If the Shipment is Not Complete

Check the packing list as back-ordered items are noted on the

packing list. You should have:

; ^{Ball & Jewell EX Series Screenless Granulator}

; ^{Bill of lading}

; ^{Packing list}

; ^{Operating and Installation packet}

; ^{Detailed recommended spare parts list}

; ^{Electrical schematic and panel layout drawings}

; ^{Component instruction manuals}

Re-inspect the container and packing material to see if you missed

any smaller items during unpacking.

2-4

2-5

If the Shipment is Not Correct

If the shipment is not what you ordered, contact the Ball & Jewell

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. Have the order

number and item number available.

Hold the items until you receive shipping instructions.

Returns

Important!

Do not return any damaged or incorrect items until you receive shipping

instructions from Ball & Jewell.

2-6

Uncrating Your Granulator

Prepare in advance the site you have selected for installation of the

granulator. Be certain that the area to be occupied by the machine

is clean, level, and free of obstructions. The site you have selected

must have a floor rating to adequately support the weight of the

machine. A concrete floor of 4” (10.2cm) minimum thickness is

recommended.

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Your EX Series Screenless Granulator is mounted on a wooden

skid and blocked and banded to secure it for shipment. All non-

painted items subject to corrosion are coated with a quality rust

preventative, and the machine is covered with heavy-duty

polyethylene to protect it from moisture and dirt. Granulators are

normally shipped completely assembled unless the size of the

machine or an agreement for special shipping arrangements

prompts partial assembly.

If inspection after shipment has revealed no shipping damage,

unpack the unit by removing the polyethylene protective covering

and banding. Remove the envelope with the parts list, assembly

drawings, electrical schematics, and manual from the base

evacuation area.

You can now have the machine lifted from the skid. A forklift is

ideal for the purpose, but take care to properly position the forks

between the casters and the centrally mounted evacuation pipe

from the side of the machine.

! CAUTION !

Do not attempt to lift the granulator by means of any shaft or protruding member,

ESPECIALLY THE HOPPER

Page 17

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Installation

3-1

Scope

This chapter contains all instructions required for experienced

installation personnel to install the granulator and prepare it for

production. You must follow all instructions carefully and in the

sequence presented. Be sure to observe all DANGER,

WARNING, CAUTION, and NOTE statements to prevent

personal injury or machine damage. These statements are designed

to make installation procedures safe and easy.

3-2

3-3

General Set-Up

1. Make certain the floor is clean, level, and free of obstructions

before placing the machine into position.

2. Visually inspect the hopper infeed opening to ensure that no

stray packing material or debris is present.

Inspecting and Cleaning Granulator Components

! CAUTION !

The cutting chamber combs are EXTREMELY SHARP. Always wear heavy gloves

and exercise care when working in the cutting chamber.

1. Open the front base door and the hopper access door by

unlatching the two (2) latches and swinging the doors into their

open positions. Carefully inspect the interior of the hopper and

above the rotor for foreign material or debris. Slowly and

carefully turn the rotor by hand to verify that it rotates

freely and without obstruction. Make sure that the rotor does

not make any contact with the bed combs. Wipe the inside of

the hopper and cutting chamber clean.

With the hopper door opened, the cutting chamber safety

switch located in the base of the machine will automatically

disengage the switch body from the main switch assembly in

the base.

2. Ensure that nothing has been left inside the machine.

Page 18

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3. Look inside the base evacuation area. Spare parts, such as

combs, are often placed inside this area for shipping purposes.

! CAUTION !

The cutting chamber combs are EXTREMELY SHARP. Always wear heavy gloves

and exercise care when working in the cutting chamber.

4. Carefully inspect the interior of the cutting chamber and

evacuation area for foreign material or debris.

5. Noting the location of each segmented chamber, lower and

remove them from the cutting chamber by loosening the

handknob on each. Lift the rear of each segmented chamber

off of the rear support bar to aid removal. Carefully inspect the

interior of each segmented chamber for material or debris. See

Figure 5.

6. Wipe all interior surfaces clean.

7. Place the three (3) segmented chambers back into their original

position and tighten each handknob securely.

8. Verify that no material has been left inside the machine

9. Close the front base door and the hopper access door and

secure the latches.

! CAUTION !

Do not run granulator until upper machine assembly is fully latched down.

3-4

Completing the Installation of Your Granulator

1. Open the drive guard by removing the bolts that attach the

guard cover to the timing belt backing plate.

2. Check the timing belt for proper tension and alignment.

3. Upon completion, close the guard by placing the cover back

into position, insert all the bolts originally removed, and

tighten them fully.

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4. Position and connect any optional accessory equipment such as

vacuum lines, conveyors, and separators. Ensure all tubing

joints are securely clamped and supported.

3-5

Electrical Considerations

!!! DANGER !!!

Improper electrical connections can damage the granulator and CAUSE SERIOUS

OPERATOR INJURY OR DEATH!

EX Series Screenless Granulators are designed for three-phase

voltage operation. Refer to the unit nameplate or ID plate for

proper voltage and amperage requirements.

NOTE: Make sure to provide a correctly-sized and protected supply of

electrical power to the unit.

Maintain a safe ground and disconnect the power supply before

servicing the unit. A qualified electrician should make electrical

connections, and disconnect and lock out electrical power

following OHSA 29CFR 1910.147.

Check serial tag voltage/amperage requirements and make sure

your electrical service conforms before making any electrical

connections. Full load amps for EX Series Granulators are listed

on the nameplate or ID plate. Make sure that all three phases are

wired correctly.

Bring properly sized power leads and grounds from a fused

disconnect to the unit. Provide external overcurrent protection to

the unit, using circuit breakers or fuses. If you use fuses, make

sure that they are dual-element time-delay fuses, sized according to

your electrical code. Make sure all electrical connections are tight.

! CAUTION !

Electrical connections must comply with all applicable electrical codes. Voltage

must be within plus or minus ten percent (+/- 10%) of the nameplate rating. Make

sure your installer provides external protection.

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Make certain all electrical connections are properly made and

supported between accessories and the control enclosure (refer to

the wiring diagram for wire and terminal connections).

!!! DANGER !!!

Before undertaking any machine repairs or maintenance, always make certain

that the machine disconnect switch is turned to the OFF position or that the

control enclosure is disconnected from the main power source.

LOCK OUT all sources of power, including the main disconnect switch, and

follow all of your plant lockout procedures.

3-6

Electrical Service Connections

Carefully check the diagrams packed with the machine. All

internal wiring has been done at the factory. All safety interlocks

have been verified to be functional before shipment. It is only

necessary to connect the electrical power source to the machine at

the control enclosure. A straight screwdriver is required to open

the enclosure door.

!!! DANGER !!!

All equipment must be grounded in compliance with Article 250 of the National

Electric Code and all local codes.

Customer's means of disconnection and branch circuit protection must also be in

compliance with the National Electric Code and all local codes.

3-7

Electrical Testing

Before applying power to the machine, check the incoming voltage

from L1 to L2, L2 to L3, and L1 to L3 (see the wiring diagram

packed with the machine). The voltage should be the same as

indicated on the silver or red tag in the control enclosure. If the

voltage is not the same, contact the Ball & Jewell Service

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Department at 1-800-229-2919 for voltage modification

instructions.

3-7-1

Hopper Safety Disconnect

1. Turn the main disconnect to the ON position.

2. Press the granulator START button to start the machine.

3. Test the front base door and the hopper access door: unlatch

the two (2) latches and open the doors approximately two (2)

inches to verify that the machine shuts off.

4. Latch the (2) latches to close the doors and re-engage the

cutting chamber safety switch.

!!! DANGER !!!

If the machine does not shut off as a result of this test, disconnect the machine

from the power source immediately and call the Ball & Jewell Service Department

at 1-800-229-2919.

3-7-2

Motor Rotation Direction

1. Turn the main disconnect to the ON position.

2. Press the granulator START button to start the machine.

3. Note the direction of the rotor rotation. It should be

counterclockwise when viewed from the right hand side of the

machine. If the rotor rotation is not as described, turn off the

machine, turn the main disconnect to OFF, and reverse any two

(2) incoming power leads.

3-7-3

Accessory Equipment

For granulators equipped with conveyors, vacuum systems, etc.,

test their operation by pressing the appropriate button.

Page 22

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General Operation

4-1

4-2

Scope

This chapter contains the information required to carry out pre-

operational procedures, as well as general operation. The

checklist of items listed below should always be reviewed prior to

a production run.

Pre-Operational Checklist

To ensure the granulator is ready for operation, perform the tasks

listed on the following pre-operational checklist. Make sure that

all electrical and mechanical machine elements are inspected and

any defects corrected first.

; ^{Have all installation and preparation instructions been read and}

followed?

; ^{Have the granulator operators and all other necessary}

personnel, such as the cleanout, maintenance and service

persons, been fully trained on machine operation and all

machine safety mechanisms?

; ^{Have the granulator operators and all other necessary}

personnel, such as the cleanout, maintenance and service

persons, read the Operation and Installation Manual?

; ^{Have sufficient location clearances been allowed?}

; ^{Has the equipment been grounded as required by local codes}

and/or Article 250 of the National Electric Code?

; ^{Have all motors been checked for proper rotation?}

; ^{Have all machine controls, pushbuttons, and limit switch}

interlocks been checked for proper functioning?

; ^{Have the cutting chamber and breaker segregation chambers}

been checked for foreign matter?

; ^{Have the drive components 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?

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; ^{Are all electrical enclosure boxes tightly closed and clamped}

shut?

; ^{Are all personnel clear of the machine?}

4-3

Granulator Operation

The machine is ready for operation when all doors, covers, guards,

and limit switches are in place, securely fastened and functional,

and all accessory components are properly connected.

1. Turn the main disconnect to the ON position.

2. Start the granulator by pressing the start button at the operator

station.

3. Load feedstock at a uniform rate that does not exceed the

capacity of the machine; see Table 1: Granulator

Specifications.

4. For color and/or material changes, allow all existing material to

clear the granulator and any downstream equipment before

stopping the machine. Doing so reduces cleaning

requirements.

4-4

Cleaning Out the Granulator

To open the granulator and obtain access to the cutting chamber

and base for cleanout, follow these steps:

1. Shut OFF and LOCK OUT all power including the main

disconnect switch.

2. Open the cutting chamber doors.

3. Loosen the hand knobs on the segregation chambers and swing

down. Lift up from rear mounting bar and remove for easy

cleaning.

4. After cleaning each segregation chamber, replace in its former

position on the cutting chamber. Swing hand knob into

position and tighten securely.

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! CAUTION !

Never close the chamber access doors without checking that all three (3)

segregation chambers are in place and hand knobs are tight. Never attempt to run

machine without all three (3) segregation chambers in place and tightened.

Always wear heavy gloves and exercise care when working in the cutting

chamber.

4-5

Shutdown Conditions

4-5-1

Emergency Stops

Feedstock must be cleaned out of the hopper and cutting chamber

prior to restarting.

4-5-2

4-5-3

Temporary Machine Stops

To temporarily stop the machine, first allow all material to run out

of the cutting chamber. Never try to restart the machine with

material remaining inside the cutting chamber.

Final Machine Stops

To shut the machine down, allow all material to pass through the

transition before pressing the STOP pushbutton to stop the

machine.

! CAUTION !

This model series of granulator is NOT designed to grind purgings, large chunks

of solid plastic, or other heavy cross-sectional pieces.

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Maintenance

5-1

Maintaining Drive Components

For continuing reliable operation of the granulator, it is of the

utmost importance that the motor drive belt tension is correct.

Correct tension reduces wear on the rotor and motor bearings and

reduces slip to a minimum.

Belt drives must be tensioned at the “Run-In” recommended force.

Check the tension at least twice during the first two days’

operation. After the belts have seated themselves in the sheave

grooves and the initial stretch is removed, re-tension the belts to

the “Normal Running” recommended force.

A gauge is available from customer service or the belt

manufacturer which facilitates the measurement of belt deflection

and force.

The Belt Tensioning Chart in Figure 1 gives the recommended

force required to deflect teach belt by an amount equal to the belt

span divided by 64. The Deflection Force Value relates to a single

V-belt element.

1. Verify that the alignment of the sprockets is correct. Using a

straightedge of sufficient length to span from one sprocket to

the other, place it along the sides of both sprockets. The entire

edge of each sprocket should contact the straightedge.

2. Measure the timing belt sag. See Figure 1.

3. Determine the force required to deflect one belt 1/64” (0.40

mm) per 1 inch (25.4 mm) of span length as follows:

a. Measure span length (t) of your drive.

b. At the center of span (t), apply a force perpendicular to

the span large enough to deflect one belt on the drive

1/64” (0.40 mm) span length from its normal position.

4. Compare this deflection force with range of forces in the Belt

Tensioning Chart as follows:

a. If it is less than the minimum recommended force, belts

should be tightened.

b. If it is more than the maximum recommended

deflection force, the drive is as tight as it needs to be.

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Figure 1: Belt Tensioning Chart

Design HP

New Belt

Used Belt

Min

Max

443

469

495

Min

438

459

480

Max

440

462

485

442

466

490

Deflection = Belt Span

Belt Span

5-2

Replacing Timing Belts

1. Remove the guard cover.

2. Find and loosen the two (2) interior guard plate screws near the

gearmotor timing belt drive from inside the sprocket guard

housing.

3. Loosen the gear motor hold-down screws and move the motor

towards the granulator rotor to allow more slack in the belt.

4. Remove the old timing belt.

5. Install the new timing belt over the sprockets.

6. Move the motor back from the granulator to reduce belt sag.

7. Verify the alignment between the gear motor and rotor

sprockets; then tighten the gear motor hold-down screws.

8. Adjust the interior guard plate to re-center the opening around

the gearmotor shaft and tighten the two (2) mounting screws.

9. Replace the guard cover.

5-3

Lubrication Specifications and Considerations

All beside-the-press granulators and accessories are supplied with

bearings that are pre-lubricated at the factory.

Mounting the bearings external to the cutting chamber results in

low maintenance and trouble-free operation.

The bearings used require a high quality, lithium-based EP

(extreme pressure) type of grease, which conforms to the NGLI

Grade 2 consistency. This grease has been chosen due to its

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suitability for use in heavy-duty applications under heavy shock

loads. It also contains rust inhibitors, has high temperature

stability, and exhibits good water resistance.

Bearings should be lubricated with care. Too much grease applied

to the bearings at one time can rupture bearing seals. Under

normal operating conditions, a moderate amount of grease applied

every 2,000 hours should be adequate to ensure long life. Severe

operating conditions require more frequent lubrication

intervals.

5-4

Knife Recommendations and Adjustments

IMPORTANT!

The rotor and bed combs are subjected to severe conditions, and you should

inspect combs periodically for sharpness. The sharper the combs are kept, the

better the machine operates, producing quality regrind. If the combs become

severely rounded, chipped, or otherwise damaged, the granulator experiences

heavy shock loads during operation causing additional and significant reduction

in comb life.

5-4-1

Removing, Replacing and Adjusting Granulator Combs

5.4.1.a.

Removing Rotor Combs:

1. Shut OFF and LOCK OUT all power, including the main

disconnect switch.

!!! DANGER !!!

Before undertaking any machine repairs or maintenance, always make certain

that the machine disconnect switches are turned to the OFF position or that the

control enclosure is disconnected from the main power source.

Lock out all sources of power, including the main disconnect switch, and follow

all of your plant lockout procedures.

2. Remove the bolts that hold the hopper on the cutting chamber.

3. Remove the timing belt drive.

4. Remove the timing belt guard.

5. Remove the rotor blocks.

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6. Lift the rotor out of cutting chamber

7. Remove the three (3) socket head cap screws that hold the rotor

assembly together.

8. Slide the cutters and spacers from the hex shaft.

9. Replace the necessary cutter(s). (Make sure the cutters are

staggered by indexing the clearance hold 1 turn clockwise for

each cutter.)

10. Re-install the three (3) socket head cap screws.

11. Replace the rotor in the chamber.

12. Re-install the rotor blocks

13. Re-install the timing belt guard.

14. Re-install the timing belt drive.

15. Bolt the hopper to the cutting chamber.

! CAUTION !

EXERCISE EXTREME CARE when rotating the rotor and handling combs.

5.4.1.b. Removing Bed Combs:

1. Working on either side of the cutting chamber, remove the two

(2) hex cap screws on each bed comb adjustment cam. (refer to

Figure 6)

2. Remove the two (2) washers, adjustment cams, and bushings.

3. Remove the bed comb.

5.4.1.c.

Installing Bed Combs:

1. Install a bed comb by positioning it onto either cutting chamber

seat. Take care to orient the bed comb with the "short" slot

(approximate 1.0" deep x .75" wide) towards the outside of the

cutting chamber.

2. While holding the comb, place the bushing and adjustment cam

into each of the two (2) bed comb adjustment holes. In order to

simplify bed comb adjustment, orient the adjustment cams in

the outboard comb holes with the eccentrics "out". Locate the

middle adjustment cam with the eccentric "down". Note that

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the hex cams have a “dot” machined on the cam face to show

the high point when installed.

3. Assemble a washer and hex cap screws into each adjustment

cam hole and finger tighten them.

4. Slowly turn the rotor back and forth. Using the right hand and

left hand adjustment cams, move the bed comb in or out as

required to clear the rotor combs. The rotor/bed comb

clearance is normally set to approximately .005". Once the in

or out position is determined, lightly tighten the left hand and

right hand adjustment cam screws. Check that the clearance

left to right between the rotor and bed combs is approximately

.005". Position the bed comb by using the center adjustment

cam. Once positioned, lightly tighten the adjustment cam

screw.

5. Turn the rotor through 360^oin both rotation directions to

ensure clearance with the bed comb. Once clearance is

established, fully tighten the adjustment cam screws.

6. Repeat steps 1 through 5 for all bed combs.

7. Fully tighten all bed comb adjustment screws to 12 ft/lbs.

5-5

Adjusting the Sensitivity of the Optional Bin Level

Monitor

!!! DANGER !!!

Because electrical power must be supplied to the sensor to permit testing and

adjustment, it is EXTREMELY VITAL that you secure the machine for normal

operations.

Do so by closing the cutting chamber and hopper access door, which returns the

safety limit switch to the closed position, PRIOR to beginning any sensor

adjustments to ensure the safety of personnel.

Although the bin level sensor was installed and tested at the

factory to ensure reliable operation, variations in the physical

properties of the material run through the granulator require that

you adjust the sensor to suit your particular requirements. Follow

these steps during initial pre-operational electrical testing and

whenever you change the type of material run through the

granulator.

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Step 1:

Fill the bin with granulate of the material you intend to run through

the granulator. Make sure the bin is filled to a level that covers the

front face of the latex sensor covering located on the rear wall of

the bin.

Step 2:

Make sure that power is supplied to the machine by turning the

main disconnect switch to the ON position and connecting the

control enclosure to the main power source.

DO NOT START THE MACHINE.

Step 3:

Locate the sensor on the rear wall of the machine base.

Using a small screwdriver, locate and turn the potentiometer

located on the rear face of the sensor.

• Turning the potentiometer clockwise (CW) increases sensitivity

and activates the alarm.

• Turning counterclockwise (CCW) decreases sensitivity and

shuts off the alarm.

With the bin in place, turn the potentiometer so that the alarm

sounds, then rotate counterclockwise (CCW) until the alarm just

goes off. Now rotate clockwise (CW) one-half to one ( ½ to 1)

turn.

The sensor is now set and the unit is ready to granulate new

material

5-6

Recommended Spare Parts List

A Recommended Spare Parts List is part of the operation and

installation package that arrives with your new machine. Look for

a Recommended Spare Parts List to find the specific part numbers

that pertain to the categories listed in Figure 2: Recommended

Spare Parts List Categories. The list in Figure 2: Recommended

Spare Parts List Categories reflects a general list of spare parts that

should be kept on hand to keep your new granulator running at

optimum performance.

Please keep the Recommended Spare Parts List in a place where

you can easily retrieve it. Please have the machine serial number

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available when calling Spare Parts Express at 1-800-229-2919 for

new replacement OEM parts.

NOTE: Refer to part numbers when ordering replacement parts. Check

the parts carefully, as they may have numbers etched or stamped

on them. The recommended spare parts list does not include all

parts that are available for purchasejust the parts most

appropriate for your particular machine.

See your machine shipment package for recommended spare parts

list specific to your machine. Part numbers are listed on that

specific list for your reference.

Figure 2: Recommended Spare Parts List Categories

Description

Set of rotor combs and wedge screws

Set of bed combs and cap screws

Set of fuses

Overload relay

Motor reversing contactor

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Troubleshooting

Problem

Possible Cause

Solution

Feedstock may be hung up inside the

hopper.

Shut machine down and check.

No granulate

Vacuum line may be clogged.

Comb gap is too large.

Combs are dull.

Clean as needed.

Adjust to proper gap specification.

Reverse bed comb or replace

combs and re-install.

Reverse bed comb or replace

combs and re-install.

Stringy granulate

Fines

Combs are dull.

Overloading of the machine.

Combs are dull.

Reduce amount/size of feedstock

put into the machine.

Reverse bed comb or replace

combs and re-install.

Excessive power required;

blown fuses

Comb gap is too large.

Overloading of machine.

Adjust to proper gap specification.

Reduce amount/size of feedstock

put into the machine.

Pieces of feedstock jammed in the

rotor.

Clear the jammed material then

visually inspect the rotor to insure

it is not damaged and that the

comb gaps are correct.

Machine stalls

Lack of lubrication.

Lubricate per maintenance

instructions.

Overloading of the machine.

Reduce amount/size of feedstock

put into the machine.

Bearings sound noisy or are

hot

Bearings have exceeded their rated

life.

Consult with Ball & Jewell Service

Department at 1-800-966-8664 for

replacement instructions.

Bearings are not properly installed or

tightened.

Consult Ball & Jewell Service

Department at 1-800-966-8664 for

installation instructions.

Fuses are blown.

Replace fuses with the size and

type shown on the wiring diagram

(located in the control enclosure).

A limit switch is open.

Check the limit switch at the

machine front and any hopper

cleanout door. Ensure proper

actuation and adjust or replace as

needed.

Motor does not start

Verify that the correct pushbuttons

are being depressed and that the

main disconnect switch is in the

ON position.

Overload relay tripped

Reset by electrician/technician.

Material being placed into the machine Reduce the initial size of the

Feedstock hangs up in the

hopper or cutting chamber

for processing is too large for the

hopper, cutting chamber, or rotor

diameter.

feedstock.

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Problem

Possible Cause

Combs are dull.

Solution

Reverse bed comb or replace

combs and re-install.

Overloading of the machine.

Regulate the infeed of scrap to

uniformly feed the machine.

Clean as required.

Transition tubing is clogged.

Granulate builds up in the

transition or tubing

Vacuum is not evacuating properly.

Check per manufacturer

specifications.

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Service Notes

______________________________________________________________________________

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Service Notes

______________________________________________________________________________

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Service Notes

______________________________________________________________________________

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Parts Department

Call Spare Parts Express toll-free 8am – 8PM EST (800) 229-2919. Ball & Jewell OEM quality

replacement and spare parts ensure operation at design specifications. Please have the model

and serial number of your equipment when you call. Consult the Customer Parts List included in

your information packet for replacement part numbers.

Service Department

Call toll free (800) 966-8664 8am – 8pm EST- Emergency service available 24 hours a day.

Ball & Jewell has a qualified service department ready to help. Service contracts are available for

most Ball & Jewell products.

Sales Department

Call (508) 399-3100 Monday – Friday, 8am – 5pm EST

Ball & Jewell products are sold by a worldwide network of independent sales representatives.

Contact our Sales Department for the name of the sales representative nearest you.

Ball & Jewell

124 Roddy Avenue

South Attleboro, MA 02703

Tel:

(508) 399-3100

Fax:

(508) 399-3050

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Charts and Figures

Figure 3: EX Series Screenless Granulator (Front)

Doors Opened for

Service/Cleaning

Timing Belt

Drive

Cutting

Chamber/Rotor

Combs

Discharge Area

Segregation

Chambers

Figure 4: EX Series Screenless Granulator (Back)

Robot Chute (4)

way opening

Limit Switch

Electrical Control

Enclosure

Gear Motor

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Figure 5: Segregation Chamber Access

Rotor cutters

Segregation

Chambers

(Removable)

Discharge Area

Hand Knobs

Figure 6: Cutting Chamber Detail

Bed Comb

Adjustment

CAMS- Comb

located under

shield

Large breaker

Small Breakers

Rotor Combs &

Spacers

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Figure 7: Discharge Options

Rear- Vacuum

Compressed Air

Venturi

Manual

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Figure 8: Knife Bolt/Screw Tightening Torque Specifications

Screw Size

Tightening Torque

Lbs./Ft.

NM.

M10

M12

M14

M16

M18

M20

M24

100

155

232

340

472

810

135

210

315

460

640

860

Specifications are for Grade 10.9 Fine Threads, in un-lubricated conditions.

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Warranty

Sterling, Inc. warrants all equipment manufactured by it to be free from defects in workmanship and

material when used under recommended conditions. The Company’s obligation is limited to repair or

replace (FOB the factory) any parts for a period of 12 months from initial start-up or 18 months from the

date of start-up, whichever is less, which in the Company’s opinion, are defective.

This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs, or

any other work. This warranty does not apply to any equipment which, in the Company’s opinion, has

been subjected to misuse, negligence, or operation in excess of recommended limits, including freezing

or which has been repaired or altered without the Company’s express authorization. If the serial number

has been defaced or removed from the component, the warranty on that component is void. Defective

parts become the property of the warrantor and are to be returned.

The Company is not liable for any incidental, consequential, or special damages or expenses. The

Company’s obligation for parts not furnished as components of its manufactured equipment is limited to

the warranty of the manufacturers of said parts.

Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is the

responsibility of the purchaser.

The company neither assumes nor authorizes any other persons to assume for it any liability in

connection with the sale of its equipment not expressed in this warranty.

Many types of Sterling, Inc. equipment carry an additional one-year service policy. Consult your

Sterling/Sterlco sales representative for specific details.

PO Box 245018 • 5200 West Clinton Avenue • Milwaukee, WI 53224-9518

Phone (414) 354-0970 • Fax (414) 354-6421

http://www.sterlco.com

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Auxiliary Equipment for the Process Industries

PO Box 245018

5200 West Clinton Avenue • Milwaukee, WI 53224-9518

(414) 354-0970 • Fax (414) 354-6421

Scrap

Process Heating/

Cooling

Automated

Recovery Systems

Parts Removal

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