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Sterling, Inc
Sterling, Inc
BP2400 SERIES GRANULATORS
BP2400 SERIES GRANULATORS
OPERATION AND MAINTENANCE MANUAL
OPERATION AND MAINTENANCE MANUAL
Sterling, Inc
Sterling, Inc
COPYRIGHT 2009
COPYRIGHT 2009
Size Reduction Division
Size Reduction Division
PART NO. D48160s
July 29, 2009 t th h PART NO. D48160s
July 29, 2009
2900 South 160 Street
2900 South 160 Street
B Bu ulllle et tiin n N No o. . G GR RN N3 3- -6 60 00 0
A AL LL L R RIIG GH HT TS S R RE ES SE ER RV
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Sterling, Inc. th 2900 South 160 Street New Berlin, WI 53151 Tel: 1-262-641-8600 Fax: 1-262-641-8653 Parts and Service 1-800-229-2919 MACHINE DATA MODEL ___________________________________________________________ SERIAL NUMBER _____________________________________________________ CUMBERLAND CUSTOMER ORDER NUMBER___________________________________ REFER TO THIS SHEET WHEN ORDERING PARTS. 2
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TABLE OF CONTENTS T TO OP PI IC C: : S SE EC CT TI IO ON N//P PA AG GE E F Fa ac ctto or ry y a ad dd dr re es ss s.. ……………………………………………………………….………2 INTRODUCTION INTRODUCTION What is a granulator?….………………………….………………………….….…1 11 1 What is a granulator?….………………………….………………………….….… A A g gr ra an nu ulla atto or r iis s… ….. The granulating of plastics… The granulating of plastics… S Siiz ze e o of f tth he e g gr ra an nu ulla atte e… … The
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION 2 – MACHINE PARTS AND CONTROLS…………………………………….…2-1 BP-Series granulators left front quarter view BP-Series granulators, right front quarter view..…………………………………………………….….2-2 BP-Series granulators, machine open front view BP-Series granulators, left rear quarter view …………………………..………………………………2-3 BP-Series granulators, right rear quarter view SECTION 3 INSTALLATIONS Overview………………………………
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page) Adjusting or replacing the bed knives (Continued from previous page) Loosen the mounting screws……………………………………………………………………………..4-4 Remove the first knife clamp or shield Remove the bed knives Clean the knife mounting surfaces……………………………………………………………………….4-5 Mounting screws Replace the upstroke bed knife Replace the upstroke knife clamp Remove th
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (continued from previous page) Adjusting or replacing the bed knives (Continued from previous page) Set the down stroke knife shield…………………………………………………………………...4-15 Check the knife gap Tighten the screws to final torque Fasten the cutting chamber …………………………………..……………………………………4-16 Close the cutting chambers safety interlock Restart the granulator Drive belt replacement an
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION 4 – SETTINGS AND ADJUSTMENTS (Continued from previous page) Setting and adjusting the chamber jackscrew (Continued from the previous page) The chamber stops before it closes but the motor continues to run……………………………..…..4-26 Set and test the mounting bracket limit switch Close the cutting chamber………………………………………………………………………..….4-27 Fasten the cutting chamber Close the cutting chamber safety interlock……………………
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION 5 - (Continued from previous page) Normal operation……………………………………………………………………………………..5-4 Feed the machine Shut down the machine Discharge cleanout safety Cleaning the discharge transition Safely clearing the jam……………………………………………………………………….5-5 Work safely Jackscrew operation Open the cutting chamber Clear the jam……………………………………………………………………………………………..5-6 Malfunction check Restart the granulator SEC
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION - 6 – MAINTENANCE (continued) Screen replacement (Continued from previous page) Close screen cradle interlock……………………………………………………………………………6-8 Restart granulator Cutting chamber access…………………………………………………………………………….6-9 Work safely Open the cutting chamber interlock Release the cutting chamber fasteners Jackscrew operation…………………………………………………………………………………….6-10 Open the cutting chamber with jackscrews O
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TABLE OF CONTENTS TABLE OF CONTENTS TOPIC SECTION/PAGE SECTION – 8 PARTS LISTS AND DRAWINGS Recommended spare parts………………………………………………………………………………… 8-1 Parts identification Sterling drawing no. A-48050 ……………………………………………………..….8-2 Overall dimensions Sterling drawing no. A-48150 ……………………………………………………......8-3 Parts identification Sterling drawing no. 348070C ………………………………………………………..8-4 Parts identification Sterling drawing no. 348185…………………………………………….…………….8-5
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THANK YOU FOR PURCHASING AN STERLING BP2400 SERIES GRANULATOR. READ THIS MANUAL to learn how to operate and service your granulator safely. It covers the family of granulators called the BP2400. This series of Sterling Granulators is designed for the big jobs in reclamation of large blow-molded and thin walled, injection molded plastic parts as well as film. This revision of the manual covers the improvements made since the introduction of the BP2400 Series Machines in 1993.
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INTRODUCTION INTRODUCTION WHAT IS A GRANULATOR? A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips or granulate. The machine can be fed either by hand through a hopper opening in the front or automatically from a special hopper opening, which can be specially designed. DISPOSAL OF THE PLASTIC GRANULATE takes place after it passes through the screen and drops into the discharge area, where it is removed from the machine by a discharge blower an
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SAFETY SECTION 1-1 Safety Symbols and Plates LEARN MACHINE SAFETY Read this manual. Learn how to operate and how to use the control. DO NOT ALLOW ANYONE TO OPERATE THIS MACHINE WITHOUT PROPER INSTRUCTIONS. THIS SAFETY alert symbol MEANS ATTENTION…BE ALERT! YOUR SAFETY IS INVLOVED! This symbol appears frequently in this manual and on your machine. It is used to alert you to the possibility of personal injury or death. Fol
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SAFETY SECTION 1-2 Safety Symbols and Plates FOLLOW THE SAFETY INSTRUCTIONS: Read all safety messages in this manual and on your machine safety plates. Follow the recommended precautions and safe operating practices. Keep safety plates in good condition. Replace missing or damaged plates. ROTATING KNIVES SAFETY PLATE (Located below the infeed opening at the front of the machine) DO NOT, UNDER ANY CIRCUMSTANCES, place your hands into the feed opening beyond the curtain
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SAFETY SECTION 1-3 Safety Symbols and Plates ROTATING MACHINERY SAFETY PLATE (One located on the machine guard on the left side of the machine, one on the screen cradle on the front panel, to the right of the machine center.) Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before removing a machine guard. A motion sensor monitors the rotor and disables the jackscrew motors if there is rotor movement. If you see the r
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SAFETY SECTION 1-4 Safety Symbols and Plates JACKSCREW REVERSING OPERATION (Located on the jackscrew operating console) This information plate reminds you of the important procedure for reversing the direction of jackscrew operation. Be sure to pause as advised. This allows the jackscrew drive the necessary time to coast to a stop before reversing. Without this pause, the jackscrew may be severely damaged. GUARDS SAFETY PLATE (Located on the drive guard cover on the lef
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SAFETY SECTION 1-5 Safety Symbols and Plates SAFETY INSTRUCTION PLATE (Located on the front of the drive guard) The safety instruction plate summarizes the most important safety rules that you need to operate this machine safely. Read it care- fully and observe it always to promote safe machine operation. HAZARDOUS VOLTAGE SAFETY PLATE (Located on the door of the jackscrew console) Always call for the services of a licensed electrician when you think that there
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SAFETY SECTION 1-6 Safety Symbols and Plates ROTATING KNIVES SAFETY PLATE (One located on the front of the cutting chamber and one on the front of the cradle) The rotating knives are razor-sharp to the touch. Always verify that the rotor is not moving. Avoid personal injury by making sure that the rotor is stopped and the power is disconnected and locked out before opening the machine. A motion sensor monitors the rotor and disables the hydraulic cylinder/jackscrew controls
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SAFETY SECTION 1-7 Safety Clothing & Practices (Located above the infeed opening at the front of the machine) It is recommended that hearing protection be used at all times when operating this equipment. It is mandatory that hearing protection be worn when noise exposure exceeds OSHA Standards Section 1910.95. (Located above the infeed opening at the front of the machine) Always wear proper eye protection when operating and/or servicing this equipment
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SAFETY SECTION 1-8 Safety Clothing & Practices WEAR PROTECTIVE CLOTHING Never wear neckties, dangling jewelry, loose-fitting clothing, watches, bracelets, or rings. Tie back long hair or restrain it with a hair net to ensure your safety. KEEP YOUR WORK AREA SAFE Keep your work area clean and uncluttered. Store your maintenance tools away from the granulator to prevent them from falling into the machine and causing severe internal damage to the cutting chamber.
