User Manual
Contents
1. Section Range Normal Inches Running 1160 to 1800 2 0 to 4 0 1160 to 1800 2 0 to 4 0 This deflection force value relates to a single V belt element Therefore if the belt is a 3 V element 3V banded this value must be multiplied by 3 Deflection Belt Span 64 It Span 3 2 W WHITAKER 800 243 9226 n 5 6 Motor Drive Belt Replacement Use the following procedure to replace the drive belts l 2 3 4 2 6 Ji Turn off the main power and remove fuses Remove the belt guard to gain access to the belts See Figure 7 Turn the adjusting screw on the motor slide base to release all tension from the belts Remove the belts Install the new belts and proceed to adjust the belt tension as instructed in Section 5 5 on page 23 Replace base panels and guards Replace the line fuses and turn main power on Figure 7 Adjusting the Motor Base Belt Guard Motor Slide Base Adjusting Screws W Drive Motor Motor Base Slide Mount Screws Motor Slide Base WHITAKER 800 243 9226 mn Chapter 6 Troubleshooting 6 1 Introduction The utmost in safety precautions should be observed at all times when working on or around the machine and the electrical components All normal trouble shooting must be accomplished with the power off line fuses removed and with the machine tagged as out of service The use of good quality test equipment cannot be over emphasized when troubleshoot2. Emergency service available 24 hours a day We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 508 399 6400 Monday through Friday 8am 5pm EST Our products are sold by a worldwide network of independent sales representatives Contact our sales department for the name of the sales representative nearest you 41 of 41
3. 4 Lol 3 3 4 E 7 LA Y HORIZONTAL y FEED HOPPER ei OPTIONAL 44 FEED HEIGHT Mounts to top of cutting chamber FA kd di Y P HE NENNEN A pe F pa poa B Lo am l el 7 de u P F AN E FEED ROLLS BP m f L x IN BOO A E 34 1 8 8 1 4 39 3 4 1009 7 mm 59 3 4 1517 7 mm 800 243 9226 31 of 41 Illustrated Parts Breakdown 7 3 36 Model fo po TPar Re rh Rotor ines 2 D Block Knife Upstroke ene 4 D Pivot Arm End Right Ilo DAN LAN Perm ER Z E Screw Hex Hd Cap HT Mi6 1 5 x 20 mm fi End Plate Drive Side esa 10 E Ball Bearing SRR LT 2SH 3 5433 11 E Retainer Ring Ext 3 54 SFT x 109 THK 12 Ji Cover Bearing R H 13 Eheave 4 GR 9 4 P D 14 H Bushing Rotor Sheave SK 55 Bore 15 H2 Screw Hex Hd Cap Ms M16 2 x 30 mm e eme 78 C 17 fi Bushing split 518 bore 18 D Bushing Woods 42 mm Bore O eee 2 C CC C a p e Bt ft aha 1 2M Screw MO x 1 5 x 40 mm 25 E Mo
4. knives rotor screen discharge system and exterior of the machine Do not use solvent on any of the painted areas as solvent may damage the paint Check all rotor knives to make sure they are properly seated on the rotor and securely fastened Although they are ground as a set one knife will probably be 001 to 002 higher than the others This should be marked and used when adjusting the bed knives for proper clearance Use a feeler gauge to check the clearance between the rotor and the bed knives by turning the rotor backwards Rotating the rotor backwards gives a better feel and does not cut the gauge should the knives be too close Check the knives on each end only Proper clearance is 0 15 mm 0 006 to 0 20 mm 0 0008 This clearance is slightly greater at the center of the knives Note Recheck knife clearance after the first 24 to 36 hours of operation 2 To make the adjustment on the bed knives the bed knife adjusting screws should be hand tightened to hold the knife firmly against the knife seat while adjusting the knife forward using push and pull screws After the clearance is set torque the 16 mm screws to 271 Nm 200 lbs ft Note All screw tightening torque figures are for un lubricated thread conditions Screw threads should be wiped with an oil dampened cloth before installation to prevent galling 6 With the exposed parts of the machine thoroughly clean and all knife clamping bolts securely
5. 5 Adjusting Belt Tension For continuous reliable operation of the granulator it is important that the belt tension is correct Correct tension reduces wear on rotor and motor bearings and keeps belt slip to a minimum Figure 6 gives the recommended force to deflect each belt by an amount equal to the belt span divided by 64 A gauge is available through the sales department to measure the deflection and force Use the following procedure to adjust the belt tension Tension new belts at the maximum run in force and check the tension at least two times during the first two days of operation There is normally a rapid decrease in the tension until the belts are run in Note The deflection force value shown must be multiplied by the number of V belt elements 1 Turn off the granulator at the main isolator switch and remove fuses Remove the belt guard to gain access to the belts Determine the type of belt required from the Spare Parts List on page 38 ps 2 e Determine the force required to deflect one belt 1 64 0 40 mm per 1 inch 25 4 mm of span length 5 Loosen the motor base slide mount screws and turn the adjusting screw on the base to tension the belts as required See Figure 6 6 Re tighten the screws making sure the sheaves are in correct alignment 7 Replace the covers Figure 6 Belt Tensioning Information V Belt Small Sheave Small Sheave Speed Ratio Recommended Deflection Cross Diameter RPM Range Range Force Lbs
6. Check direction of fan rotation check venturi and line or chute for blockage 27 of 41 6 4 Mechanical Faults Possible Cause Possible Remedy Bearing overheating Excessive tension on the belt Check tension of belt and drive adjust as necessary Lubrication fault Check lubrication frequency and recommended lubricant Visible cracks in knife Incorrect grinding or Check method of grinding grinding procedure and contact our technical sales department Knives moving on knife Uneven knife seat surfaces Clean up to provide seats maximum bearing surface Loose knife screws Knife screws should not be used more than six times Replace if there 1s evidence of stretch Knives breaking Cracks caused by incorrect Contact our technical sales grinding department Open knife setting Re set knives Screen breakage Incorrectly seated screen Check that the screen is seated correctly and fully in its cradle 28 of 41 WHITAKER 800 243 9226 W Chapter 7 Appendix 7 1 Customer Satisfaction Warranty Program The terms and conditions of the warranty set forth are for one 1 year from the original date of purchase by the original purchaser The manufacturer 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 I
7. Chevron SRI 2 2 Months or 1500 hours Grease idler sprocket Exxon Andok C when machine 1s stopped until Lidok EPI small bead appears at nut edge then wipe clean Rotor bearings Chevron SRI 2 2 Months or 1500 hours at 1 Exxon Andok C oz bearing Lidok EPI 18 of 41 WHITAKER 800 243 9226 SINCE 1945 W 5 3 Replacing and Adjusting the Knives During use the clearance between the rotor knives and the bed knives will increase due to wear This is a normal condition that requires re setting this clearance once or twice before it is necessary to remove the knives for regrinding Check the knives weekly for wear clearance exposure and screw tightness When new knives are fitted to the machine adjustment after eight hours of running time may be required Before assembling a new or reground set of knives make sure the knife seats and mounting holes are clean Do not use grease or oil on screws or tapped holes when assembling the knives Knives must be replaced in complete sets otherwise it will not be possible to obtain even clearance between the rotor knives and bed knives WARNING Before applying a wrench to any knife bolt be certain that the rotor is blocked to prevent rotation One such method is to use a block of wood at least I 1 2 thick between a knife and a fixed portion of the frame Rotor Knives We recommend that the rotor knife screws be replaced with new screws every sixth knife change to reduce the risk
8. 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 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 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 1s 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 29 of41 WHITAKER 800 243 9226 W 7 2 Drawings and Specifications including Options Features Model Throat Size Cutting Throughput Approximate Circle Weight Diameter 203 x 914 mm 200 mm 363 545 kg 1181 kg 8 x 56 7 9 1000 1500 Ibs hr 203 x 1422 mm 200 mm 454 681 kg 1305 kg Specifications Standard O
9. end shields the feed roll sprockets and other mechanisms for complete safety Discharge System The granulated material that falls through the screen is collected in a transitional section located at the bottom of the granulator and directed through the base area to the right side of the granulator for discharge with an airveyor system The transition section is connected to a blower airveyor system which conveys the granulated material through ducting to the cyclone separator The cyclone separator allows the granulated material to drop out of the air stream into a bin or container Base The base is caster mounted with four swivel two locking casters for easy positioning WHITAKER 800 243 9226 UT W 2 4 Safety Features Safety Switches Safety switches at all access covers are wired into the starter control circuit The machine cannot be started when these parts are open However for safety purposes the machine should be disconnected from the power lines by a disconnect switch or by removing the plug from its receptacle Check all safety switches periodically for proper operation Figure 1 shows some of the bolts interlocks and limit switches you may need to adjust during maintenance Refer to this diagram while performing the maintenance procedures Safety Tags A set of metal plates is attached to the machine to warn of potential danger Figure 1 Safety Features Interlocks and Limit Switches Drive Chain
10. maintenance or adjustments inside the cutting chamber use the following procedure to close the cutting chamber and resume use of the granulator 1 Replace the screen in the cradle arms making sure that the far edges is trapped beneath the downstroke bed knife block Tighten the cradle arm screws 2 Replace the access panel and tighten in position making sure that the interlock screw sets the safety switch actuator arm into its correct operating position 3 Replace line fuses turn power on and remove the out of service tag from the machine 14 of 41 WHITAKER 800 243 9226 3 6 W Initial Start up This machine has been run under power and tested at the factory prior to shipment The necessary settings and adjustments have been made so that a minimum amount of setting up or re adjustment is required when starting up the machine in its new location With all electrical mechanical connections and lubrication requirements having been attended to the following start up steps should be carefully carried out before attempting to place any material into the infeed hopper Use the following procedure to prepare the machine for initial start up WARNING Before operating the granulator insure that the granulator has been correctly assembled and wired Access the cutting chamber as described in Section 3 4 on page 14 Thoroughly clean the rust preventative materials or grease from the hopper the inside of the cutting chamber
11. receipted transportation bill Advise customer service regarding your wish for assistance and to obtain an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list You should have MI Granulator Bill of lading Packing list Operating and Installation packet NAN N RI Flectrical schematic and panel layout drawings M Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the 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 Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department WHITAKER 800 243 9226 W Table of Contents CHAPTER 1 SAFE WEE 5 191 How to Use This Man 0al u uu bat P ko rapide uh ati pe ak bl AA NAO in do kin a da 5 Safety Symbols Used in this Manual aaa 5 1 2 General Safety Regulati0NsS occoccoccoccocnocnconconconooconcnonononnnnnnonnonnonnonnnnnnnnrnnnnncnnnns 6 JO Responsibly EE 6 1 4 Warnings and Re de E 7 CHAPTER 2 FUN
12. the machine 16 of 41 4 4 Shut down Use the following procedure to properly and safely shut down the machine W l 2 3 4 Stop all feeding of material Allow the granulator to run until the cutting chamber is completely empty Press the drive motor stop button This shuts off the rotor drive motor After the granulator has stopped press the airveyor stop button if applicable located at the blower motor Turn the main power switch to off BROTHERS WH 800 243 9226 l SINCE 1945 Chapter 5 Maintenance 5 1 Preventative Maintenance Schedule Operation of safety interlock switches Knife clearance 0 15 mm 0 20 mm 0 006 0 008 Weekly Knife retaining screws for tightness 271 Nm 200 lbs ft Weekly Knife exposure 1 0 mm 0 040 Weekly Belt tension Monthly 5 2 Lubrication The main drive motor rotor bearings feed roll reductor tension idler sprocket feed roll cartridge bearings and feed roll drive chain are all pre lubricated at the factory Check and re lubricate according to Figure 3 Figure 3 Lubrication Requirements Lubrication Point Refer to instruction plate on 4 months or 3000 hours motor Feed roll reductor 90 Lube oil Refill as needed Feed roll cartridge Chevron SRI 2 2 months or 1500 hours Grease bearings Exxon Andok C when machine is stopped until Lidok EPI small bead appears at bearing seal then wipe clean Feed roll tension arm
13. within 0 076 mm 0 003 of each other Greater dimensional variations will cause difficult when setting the knife gap and create other serious complications When sharpening it is not harmful to allow a few small nicks to remain in the cutting edge Grinding the cutting edge until perfectly clean can sometimes be wasteful Do not install rotor knives that are smaller than the minimum dimension shown because the fasteners that secure these knives will interfere with the cutting circle If the rotor cannot turn the bed knives will be damaged Bed Knife Sharpening Each bed knife is provided with four cutting edges When the exposed edges become blunt the knives can be turned and repositioned to present the new cutting edges When re sharpening is necessary refer to the diagram below It is not necessary to grind bed knives to the closely matched tolerance of rotor knives As with rotor knives small nicks in the cutting edges will not seriously affect knife cutting efficiency Bed knives smaller than the minimum dimensions shown must be replaced along with the fasteners that secure them Figure 5 Knife Sharpening Specifications Keen Edge Rotor Knife 3 Landed 55 2 ZAM these surfaces only Grand these rfaces only 089 min NG 2 3 307 new a ks ka 628 min Std Bed Knife 2 256 min 3 246 new 2 256 min 2 756 new 32 2 756 new 22 of 41 WRITAKER 800 243 9226 W 5
14. CTIONAL DESCRIPTION 9 2 1 Models Covered in This Manual 9 22 Orl DOS Ip r NAA 9 2 3 Typical Features and Components a ar 10 A aaa ANA ANAN 10 GUN ee 10 DWE E 10 Discharge System seas Gan kna r sa daas sas aa raa a 10 zc 10 24 i um 11 SMS NOS AA a io os a a ane eki 11 SANON EE 11 CHAPTER 3 INSTALLATION 12 oT EES 12 32 Belt LENSIONING E 12 39 Electrical enee de e 13 3 4 Accessing the Cutting Chamber 14 3 5 Closing the Cutting Chamber fs sco yi ak et al kk ta a n le a eda pa tl e t BA 14 SO att KE E e EE 15 CHAPTER 4 OPERATION 16 s LU ERREUR 16 42 EE e e Le Une E un e MT E o o SERE 16 4 3 Clearing a Jammed Cutting Chamber 16 GA IA OW NEE 17 CHAPTER 5 MAINTENANGCGE 18 5 1 Preventative Maintenance Gchecdule nenne 18 A C 02 u u u uuu E E as 18 5 3 Replacing and Adjusting the Knives mn 19 KOO AIME EE 19 BED Ee 20 A OSG ANE A NEE 22 Rotor Knife Sharpening 22 Bed Knife Sharpening sense nnn nnn nnn nu inna sna ssa hasaan 22 5 5 A
15. MPLIED INCLUDING WARRANTIES OF MERCHANT ABILITY 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 watranty 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
16. Tensioner Arm Safety cover J 1 Infeed kali Infeed Chute Sen Drive Belt e Cover 1 3 f w FP ES DANGER ki v Ea awang S 5 ess d m N Floor Locks Bed Knife Cover Actuator Arm Screw Safety Switch Base Area Swivel Caster W WHITAKER 800 243 9226 Ka Chapter 3 Installation 3 1 Uncrating the Equipment The complete granulator including accessory and auxiliary equipment is packed in a special wooden case for shipment Refer to the Appendix for detailed dimensional data and pertinent weights 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 machine should be set on a concrete floor and care must be taken when moving the machine across a hollow timber floor so that the point loading of the casters does not cause damage The site you have selected must have a floor rating to adequately support the weight of the machine If necessary use steel shims to level the machine Locate the machine so that access is given to electrical components screen and hopper Maintenance personnel should have unobstructed access to the units on which they will be working To avoid squeezing people working near a machine there should be adequate clearance maintained between machines walls or partitions Hinged doors and covers should have full swing Restrictions may force work in cramp
17. Tighten the bed knife screws evenly and torque the 16 mm screws to 271 Nm 200 Ibs ft Replace the bed knife shield and adjust the shield using its push and pull screws so that its front edge is within 1 0 mm 0 040 of the bed knife edges If strip material is to be cut reduce the knife exposure to less than the strip thickness to prevent material built up on the bed knives Make sure all screws bolts and nuts are properly tightened Reset the downstroke cover in position and tighten in place with the downstroke cover screws Make sure the safety switch actuator arm screw sets the arm in the correct switch operating position WHITAKER 800 243 9226 n Figure 4 Downstroke Cover and Bed Knife Rotor Knife Locking Screws Rotor Knife Rotor Downstroke Cover Locking Screws Downstroke Bed Knife Adjustment screws and Lock Nuts Figure 5 Upstroke Bed Knife and Screens Upstroke Bed Knife Adjusting Screw and Lock Nut Upstroke Bed Knife Locking Screws 21 of 41 mae 800 243 9226 SINCE 1945 5 4 Sharpening the Knives Under normal operating use the cutting edge of the knives will eventually become dulled resulting in reduced cutting efficiency The blunt knives may either be re ground to restore the cutting edge or replaced with new knives when regrinding 1s not possible Rotor Knife Sharpening The rotor knife can be re sharpened to the diagram below The three knives must be sharpened to
18. cify Drive Belts Specifiy 1 Set Specify Feed Roll Cartridge Bearings Screen Cradle Bolts Chain Feed Roll Drive 38 of 41 WHITAKER 800 243 9226 W 7 7 Typical Wiring Diagram Disconnect by others pp AAA 7 ILI ti o 230 460V E Ti EP d 112 To 30 e pan 60 Hz Le pe ds bs uu ee nee Connect Control Transformer to suit j Primary Voltage FU1 T 20L l H A eg OR NEN ML FU3 2L3 LI la FU4 SEA BECH 115V El A e e EI e e e e O Y 1LS 2LS 3LS 1PB 2PB SES Chute Cutting E Stop Stop Hopper 4 Cover Chamber g 6 7 m2 Blower M1 4PB 5PB I Granulator 39 of 41 WHITAKER 800 243 9226 SINCE 1945 W 7 8 Recommended Torque for Screws Grade 10 9 fine thread screws in un lubricated conditions Note Threads must be dry Screw threads should be wiped with an oil dampened cloth before installation to prevent galling 40 of 41 WHITAKER 800 243 9226 W 7 9 W WRITAMER 800 243 9226 Technical Assistance Parts Department Call Spare Parts Express toll free 8am 8pm EST 800 229 2919 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
19. djusting Belt Tension Ia 23 5 6 Motor Drive Belt Hepnl acement nee nnns 24 WHITAKER 800 243 9226 i W CHAPTER 6 TROUBLESHOOTING 25 c UGANI io doit bo 25 S MEME edd Le LTE 26 o5 POCOS SIMO AE AL NS AAAH 27 6 4 Mechanical FaUul s u u u uuu tk tn ant ol a fa ama PIGA GANANG 28 CHAPTER 7 APPENDIX ener 29 7 1 Customer Satisfaction Warranty Program 29 7 2 Drawings and Specifications including Options 30 FOROS APA 30 PECO 110 ee 30 BUT OPI 31 7 3 Illustrated Parts Breakdownm nennen nennen 32 JO MOUSE 5 tan pa kt ee ke ke e e a e S ae re NIMES 32 TO MODO EE 33 14 Vertical Cross SECU sitiya ba aba ga AA NAA ni 34 Nee 34 S0 Uj ee 35 f Longitudinal Cross eclesiales 36 e 00 S O A 36 DO MOU A A 37 FS pate Pako LS tarada nd consi 38 rr Typical Wiring Daraan aa i bi a tedio 39 7 8 Recommended Torque for Gcrewe Aa 40 H9 IECHAICHLASSISLAN CE EE 41 EE 41 Service Department 41 Sales Department 41 WHITAKER 800 243 9226 i W Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This man
20. e 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 M NEVER modify the machine configuration or any individual component without written notice from the factory 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 We have long recognized the importance of safety and have designed and manufactured our 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 8 of 41 WHITAKER 800 243 9226 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides the necessary instructions for the installation set up and maintenance of our 36 and 56 thermoforming granulators 2 2 General Description The thermoform granulator is a rugged low profile rotary cutting machine designed to cut chip and granulate the toughest thermoforming materials with a minimum expenditure of horsepower A massively built high inertia rotor with inclined knives gives more linear inches of cut greater capacity and assures long trouble free service This extra capacity not needed for normal operation pr
21. ed quarters An off balance operator with an awkward reach into a partially obscured area is unsafe If inspection after shipment has revealed no shipping damage unpack the unit by removing all hold downs tie downs bolts nuts etc Remove the envelope with the electrical schematics and instruction manual from the base evacuation area You can now have the machine lifted from the skid To lift and move the granulator safely and correctly cover any sharp corners or edges and use the type of equipment that has the most appropriate features and capacity Use the designated lifting points and do NOT lift the machine by the hopper handles or guards 3 2 Belt Tensioning Belt drives should initially be tensioned at the run in recommended force Check the tension at least twice during the first two days of operation After the belts have seated themselves in the sheave grooves and the initial stretch is removed re tension the belts to normal running and check periodically to maintain tension at the recommended value See Section 5 5 on page 23 for the belt tensioning procedure 12 of 41 WHITAKER 800 243 9226 W 3 3 Electrical Connections Granulator controls if ordered are shipped separately for mounting at a suitable location The safety interlock switches are connected to a common terminal box for ease of wiring The customer is required to provide a suitable fused supply with a disconnect switch and a cable for the inco
22. eners unless the motor 1s electrically locked out and the rotor is motionless Never operate the machine or jog the rotor unless the cutting chamber covers discharge chute or any guards or covers are in place and secure Do not circumvent the safety interlocks Prior to clearing a jam or performing any maintenance the motor should be turned off and electrically locked out Be sure that the rotor has come to a stop Hands must not be inserted into the machine to clear the jam Do not extend any part of the body into feed roll openings or discharge area unless the motors are electrically locked out and the rotor and feed rolls are motionless Never extend fingers through holes in screen Be sure that the v belts are properly aligned and that tension is at its maximum Extreme care should be taken to see that all bolts are properly tightened at all times During the operation of the machine rotor knife bolts may come loose Although fine threads are used on the rotor knife bolts because vibration does not easily loosen them you should inspect the tightness of the bolts frequently This machine is designed for the granulation of plastic materials Do not feed any other materials into the machine 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in the maintenance and operation of the machine All personnel engaged in
23. fastened close the cutting chamber as described in Section 0 on page 14 Note After initial start up the rotor knife retaining screws should be checked after 8 hours running to be assured that 271 Nm 200 Ibs ft Of torque is maintained Thereafter rotor knife retaining screws should be checked weekly Note The rotor must be rotated at least two rotations every 30 days to prevent brinnelling and corrosion of raceways WHITAKER 800 243 9226 nod Chapter 4 Operation 4 1 W WHITAKER 800 243 9226 Start up Before starting the machine check that the rotor rotates freely by rotating it by hand from outside the machine using either the coupling or the sheave depending on the type of drive Inspect the cutting chamber carefully to insure that nothing has fallen into it Make sure all screws and bolts are properly secured Check all electrical connections and motor rotations See Chapter 3 on pages 12 15 for detailed set up instructions Allow all motors to run up to speed for at least 30 seconds Feeding the Granulator Feed the granulator through the V chute opening in the hopper The method of feeding the granulator depends on the physical form and nature of the material being processed For maximum efficiency the granulator should be fed at a rate that is consistent with its capacity Le if the granulator is rated at 60 kg hr 132 Ibs hr then the general feed rate is 1 kb min 2 2 Ibs min Under these operating co
24. hen 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 M 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 M SAFE HOUSEKEEPING The work area must be kept clean and uncluttered during periods of operation or maintenance No hand tools or other metal objects should be left on or around the machine Any tools or other metal objects that mistakenly fall into the hopper feed opening can cause severe damage to internal cutting chamber rotor and screen components M 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 hopper feed opening in order to guard against unexpected material flyback M EAR PROTECTION may be required when operating the machine during granulation of very hard or noisy materials The Occupational Safety and Health Act of 1970 has established guidelines for Permissible Noise Exposures OSHA 1910 95 that should be followed M NEVER attempt to operate the granulator unless it is fully assemb
25. in power switch to recheck motor drive rotation l If Airveying system optional is fitted press the Airveyor START button and check the blower motor rotation The blower motor should rotate in a counterclockwise direction If blower motor rotation is correct continue to step 6 If blower motor rotation is incorrect complete the following procedure d Shut power OFF and disconnect incoming power supply line e Reverse any two of the three power line connections to the blower motor f Re connect the incoming power supply line and recheck the blower motor rotation 6 Allow all motors to run up to speed for at least 30 seconds 13 of 41 WRITAKER 800 243 9226 W 3 4 Accessing the Cutting Chamber You will need to access the cutting chamber before initial startup and for various maintenance procedures Use the following procedure to access the cutting chamber 1 Turn the main power off remove the line fuses and tag the machine as out of service 2 Remove the access panel screws This includes the safety switch actuator arm screw and lift up and out to remove the access panel The panel has a bottom internal skirt that must be lifted clear of the base strip 3 Remove the cradle arm bolts and swing the screen cradle arms down See Figure 2 4 Remove the screen Figure 2 Screen Cradle and Screens Cradle Arm Screws Cradle Arms Screens etu AS d 3 5 Closing the Cutting Chamber After completing any
26. ing 1s indicated Use a good ammeter that can measure at least twice the AC and DC current that can be encountered for the machine Be sure that the voltmeter has at least minimum impedance of 5 000 OHMS per volt on AC and 20 000 OHMS per volt on DC scales Popular combination meters VOM and VTVM can be selected to provide the necessary functions Before making haphazard substitutions and repairs when defective electrical components are malfunctioning we recommend that you check the associated circuitry and assemblies for other defective devices It is common to replace the obviously damaged component without actually locating the real cause of the trouble Such hasty substitutions will only destroy the new component Refer to wiring diagrams and schematics Locating mechanical problems should they occur is relatively straightforward When necessary refer to the parts catalog section 25 of 41 WRITAKER 800 243 9226 W 6 2 Electrical Faults Possible Cause Possible Remedy Motor Fails to Start Supply failure Check fuses Starter inoperative Check main supply Starter overloads or cuts out Check motor requirements and adjust accordingly Safety switches inoperative Check and adjust as needed Motor starts but will not take Too much belt tension Check belt tension and adjust load as necessary Incorrectly connected motor Check terminal connection with manufacturer s connection diagram and adjust as necessary Defect
27. ive starter winding Check current in each phase with ammeter if there is a marked difference in current in one phase contact motor manufacturer Motor will start when Worn bearings Check and replace if disconnected from load but necessary according to not when connected manufacturer s literature 26 of 41 Wee 800 243 9226 W 6 3 Processing Faults Problem Stalling Material overheating WHITAKER BROTHERS SINCE 1945 W Overfeeding Partial or complete screen blockage Insufficient tension on v belt drive causing belt slip and burning Badly blunted or damaged knives Knife setting too wide Installation fault motor running in reverse direction Safety switch cut out where fitted Check all possible causes under stalling Screen size too small When granulating rubber insufficient talc causes freshly cut surfaces to re adhere Blockage in aiveyor 800 243 9226 Possible Cause Possible Remedy Reduce feed rate Remove screen clear and inspect for damage Check tension of the belt and adjust as necessary Check that the motor slide base screws are secure Fit re sharpened or new knives as required Check clearances given and adjust as required Check with direction arrow and re fit electrical connections to give the correct direction Tighten safety switch setting screw Remedy as shown above Increase screen size Increase talc percentage rate of infeed
28. led with all guards and interlocks in place and functional M OBSERVE all danger warning caution and safety labels on the equipment Y 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 M 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 or feet on the granulator when it is in operation or open for maintenance NEVER stand on the granulator when it is in operation 7 of 41 WHITAKER 800 243 9226 W W M ROTATION OF MOTORS The correct rotating direction for the granulator motor is clearly marked on the machine Always check for proper rotation of motors Incorrect rotation direction can cause severe damage M 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 M ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the granulator before performing any service M SAFETY INTERLOCKS MUST NOT BE BYPASSED The mechanical and electrical safety interlocks ensure th
29. me with an access panel that lifts off to fully expose the upstroke bed knives a balanced rotor with split offset rotor knives and removable screens one screen in the 36 model two screens in the 56 model The covers on the opposite side can easily be removed to expose the downstroke bed knife shields and knives Both the bed knives and bed knife shields are adjustable and the bed knives have reversible cutting edges for extended life The internal surfaces of the solid steel cutting chamber are machined to an exceptionally smooth finish for ease of clean out The scissor type cutting action of the angled rotor knives gives optimum cutting efficiency with lower power consumption The screens are mounted in a swing down cradle positioned just below the rotor and act as a classifier for the granulated material retaining the material in the cutting chamber until the particle size is such that it will pass through the screen holes The high alloy steel rotor carries the rotor knives High strength alloy steel screws are used for attachment of all knives to the rotor Drive System The drive system consists of a TEFC 1200 RPM motor set on an adjustable sliding base that is mounted at the left end of the granulator The motor drives the rotor directly and the feed rolls are driven through a gearbox for assured RPM control A belt guard shields the motor drive sheave feed roll reductor rotor sheave and belts Another guard at the opposite
30. mend that the same screws and washers be re used only when the bed knives have been repositioned or re ground When blunt knives are discarded and replaced with new knives use new screws and washers This will reduce the risk of screw failure due to their overstretching Screws and washers must be replaced with the type specified in the Spare Parts List Use the following procedure to replace or adjust the bed knives l Ze 10 11 l W Access the cutting chamber as directed in Section 3 4 on page 14 Remove the downstroke cover screws at the rear of the machine this includes the safety switch acutator arm screw and carefully slide the covers out of the machine See Figure 4 on page 21 Remove the bed knife shield screws and lift off the bed knife shield Remove the screws holding the bed knives and remove the bed knives Before installing and adjusting the bed knives check all rotor knives to make sure they are properly seated on the rotor and securely fastened Thoroughly clean the knife seats Replace the bed knives on the bed knife seat and tighten the screws until they are finger tight Use the adjustment screws See Figure 4 and Figure 5 on page 21 to set the knife clearance to 0 15 mm 0 20 mm 0 006 0 008 The clearance should be measured with a feeler gauge at the ends of the knife by rotating the rotor sheave backwards by hand The clearance is slightly greater at the center of the knives
31. ming line to the control if ordered with the machine Refer to the technical specifications in the Appendix for horsepower voltage phase and frequency requirements to determine the size and rating of the supply cable required If optional controls are required an electrical wiring diagram will be provided with the machine in addition to the basic electrical diagram When the customer is providing either the motor or the control the machine must be wired in accordance with the basic electrical diagram and the starter manufacturer s instructions Use the following steps to complete the electrical connections 1 Check to be certain that the starter heater elements correspond with the motor requirements If controls are not supplied the limit switches supplied on the machine must be wired into the circuit at the common terminal box 2 Check that the limit switches are closed Turn switch ON at main power supply 4 Jog motor by pressing the START and then the OFF button This starts and stops the motor 5 With the electrical power ON check that the motor rotates in a clockwise direction at the viewing port in the belt guard If motor rotation is correct continue to the next step If rotation is incorrect complete the following procedure a Shut power OFF and disconnect incoming power supply b Reverse any two of the three power line connections to the machine c Re connect the incoming power supply line and turn ON the ma
32. nditions the correct proportions of cut and uncut particles will be present in the cutting chamber WARNING Under no circumstances should the operator attempt to reach into the hopper to dislodge any bridged or jammed material while the granulator is in operation To clear the hopper of bridged or jammed material the machine main power must be turned off and the machine isolated Clearing a Jammed Cutting Chamber Never attempt to free a jammed machine by placing hands on the rotor rotor knives or inside the cutting chamber Hands must be kept clear of the rotational path of the rotor knives Good footing on a clean floor is essential and the body should be well braced to guard against loss of balance should the jam suddenly come free Use the following procedure to clear a jammed cutting chamber 1 Disconnect and lock out power 2 Be certain that the rotor is motionless 3 Open the machine as instructed in Section 3 4 on page 14 4 Use a pry bar to exert force on the rotor usually in the direction opposite normal rotation A leather mallet and a block of wood of sufficient length to keep hands away from path of knives can be used if necessary 5 Use pliers to remove material from the cutting chamber keeping in mind that the removal of material may cause rotation of the rotor and rotor knives 6 After clearing the jam be certain that the screen and all guards and covers are secured in place before connecting power and starting
33. of screw failure due to overstretching Screws must be replaced with the type specified in the spare parts list Use the following procedure to replace or adjust the rotor knives Caution Rotor knives should be changed one seat at a time to prevent rotor from being rotated in an out of balance condition l Access the cutting chamber as directed in Section 3 4 on page 14 2 Remove the downstroke cover screws at the rear of the machine this includes the safety switch actuator arm screw and carefully slide the covers out of the machine See Figure 4 on page 21 Set back the bed knives to clear the rotor knives so that the rotor can revolve freely Remove the screws holding the knives to the rotor and remove the rotor knives Thoroughly clean the knife seats and replace the knives 2 M D Lightly tighten the screws and check that a 0 04 mm 0 0015 feeler gauge will not pass between the back of the knife and the knife seat Tap the knife gently with a rawhide hammer if necessary to close the gap 7 Tighten the screws evenly and torque the high tensile 16 mm screws to 271 Nm 200 Ibs ft Note Bolt threads should not be oiled Wipe thread with and oil dampened cloth 8 Re check the gap between the back of the knife and the knife seat If necessary readjust the knife 9 Adjust the clearance between the bed knives and rotor knives See Bed Knives on page 20 WHITAKER 800 243 9226 UT W Bed Knives We recom
34. ovides some surge capacity for handling any incorrectly thermoformed material as at initial start up which has not been trimmed The access panel easily lifts off to fully expose the removable screen s the upstroke bed knives and rotor knives Covers on the opposite side can be removed to expose the downstroke bed knife shields and knives Reclamation of skeletal webs sheet and small parts for inclusion and application in any type of thermoforming or extruding equipment is a specifically designed capability and depending on the screen size used this machine will provide granulate or chips to meet most requirements With no special enclosures this granulator sets the industry standard for noise reduction with 90 dbA or less in most applications Our traditional ruggedness includes heavy steel knife blocks and a cutting chamber made of thick steel plate with oversize bearing housings Safety interlock switches prevent starting the machine with the infeed chute or front access door removed 9 of 41 WHITAKER 800 243 9226 W 2 3 Typical Features and Components Hopper The V shaped infeed chute is an upright enclosure that 1s bolted to the top of the feed roll assembly and easily removable for unobstructed access to the feed rolls It is designed to direct continuous reclamation of skeletal web directly from the thermoform trim process Cutting Chamber The cutting chamber is a rectangular enclosure comprising the main fra
35. ptions Infeed Feed Rolls Poly smooth Paddle Rolls Horizontal infeed hopper Cutting Chamber 2 Bed knives drop down cradle Rotor 3 knife Chevron 56 Open 3 knife slant cut scooped 36 Rotor Knives HCHC keen edge Bed Knives HCHC 2 edge reversible Screen 5 16 2 piece reversible 56 1 4 3 8 and larger 5 16 1 piece reversible 36 Base Low profile caster Discharge So le Motor 7 1 2 HP 10 HP 15 HP 20 HP TEFC 1800 rpm 3 60 230 460 Feed Roll Motor Drive Parts AA o Components 12 Labels Safety caution operation French Spanish Accessories 6 Blower 5 HP Machine or Floor Mounted 8 Separator 8 Stand Machine Sound Enclosure 30 of 41 WHITAKER 800 243 9226 W Dimensions DC DRIV EED ENING p fF RE 22 3 4 l PRO US MUFFLER l l l l OPTIONAL MACHINE BLOWER MOUNTED No OPTIONAL BLOWER SOUND ENCLOSURE 21 7 8 W 36 model 56 model SINCE 1945 WHITAKER BROTHERS A 36 914 4 mm 56 1422 4 mm 23 3 4 3 3
36. s and related solutions The Appendix contains technical specifications drawings schematics parts lists and available options 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 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 DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation or practice that if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice that i p y p not avoided may result in minor or moderate injury or in property damage WHITAKER 800 243 9226 UU W 1 2 General Safety Regulations This machine uses knives for the performance of its intended use Consequently it can be a dangerous machine to operate and maintain unless these safety regulations are followed These regulations should be read understood and periodically reviewed by all personnel involved in any way with this machine Never operate or remove any machine components that are secured by wrench type fast
37. the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Becoming familiar with materials inspection speed limitations screens and guard maintenance and total user responsibility will assist you in learning potential areas in need of observation for danger Each individual must take responsibility for observing the prescribed safety rules as outlined All caution warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor 6 of 41 WRITAKER 800 243 9226 W 1 4 Warnings and Precautions Our granulators are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this granulator use good judgment and follow these safe practices M LEARN AND OBEY your company s safety policy regarding granulating equipment I 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 W
38. ual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional Description section outlines models covered standard features and safety features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the granulator We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the granulator These instructions are intended to supplement 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 granulator provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible cause
39. unt End Bearing FR 26 E Pressurer Spring Op pass 32 E Bed Knife Twin Shear s p Co SSCS 34 M Block Knife Downstroke ER E on 36 Sprocket SIN 19th 1 4 Bore H us Bracket chain Tensioner 3 M Washer Threaded HT 1 00 ID x 2500 OD x 25 ERR puasa C 40 D Screw Min 1 5 x 25 mm 41 E Lock Washer Mi 42 fas Chain roller 405L 1 2 Pitch 43 E Screw Hex Hd Cap MS F Thd M16 2 x 70mm 44 Cover Bearing L H 45 24 Screw Hex Hd Cap HT M16 2 x 50 Ig 46 H End Plate Out Board 32 of 41 800 243 9226 WHITAKER ee Qs Model 56 B TO gz D HA ul ao An ci til Waua sWde pHxeH Merzel cu A wuesse tan WA z oS TA las Alsa Woyo tapag m ng acgpi MBI HIS eyed e axpasumog Juy sora d a wwgz wwa proqual d sti 47 dond mol a HY fond veta d a amy syonsumag peYS zi en uucexa SA ea Le malag d e aaa 77377 EL ES uu D x Lon 1H des pu sett maras zi vw aog YGE NIS Toude z o 180b pupa ol eg aaa r ee z sJ TT EE EZ T ac es A m z AE E o az N Faena ng A E cz ocios pl az alog pay duro py Eug pug j ETT sl sz apig anu pag sa d cs Pag npe ME S F ez SOSES wo Sal H zz AO ww q poo Buusng m F uu es Z 918 SA de bt ven maosi cul oz A A d ei AA d su A if en sde ze pp ws ar ga do e vue m3 Tuy eure Jeu A E eu eetceUez ss Bwe gea dc ake psdl zi ou Ha ke 7 oH E E
40. uug x epa Yea puxeH Merzel A al er yy Song an ul TTT amus Hu eu um i 3 ey Hi I lt E O ti syoned aguy vota d imam RRE en i IE x C canis e on 33 of 41 800 243 9226 BROTHERS WHITAKER o 7 4 Vertical Cross Section 36 Model 7 c9 Ce as lt BAN ILIE ma TE MI 35 KAN A RB u C Q o A KA i A TH N WA Ls S K INR 21 E a E Kr 31 A S eE KS RE A VE ur jr d a SUN CH 7 TVA 30 D ROUX C X IS ERE XOU SU XI SEES AA 38 24 6 37 N WHITAKER 800 243 9226 W 56 Model 7 8 2 45 Til 11 SN d Far Side 41 AA Near Side 4 pa A 14 1 i T 16 IN AA 6 WR met gt 17 AY 1 L 61 WA 18 1 S f a bs y 20 TES ey k 21 48 za AR 479 E E 32 46 ti F 1 62 Wes 22 E M 1 f 0 Y f 14 da 24 2 37 38 W WHITAKER 800 243 9226 na 7 5 Longitudinal Cross Section 36 Model eg A eme A A A E NI ee A RR CC YO Ce 25 GA YA VA YA ES SSD YA EN AW 25 SS SSS NI SS AV E s A t NGA ww NN koy ae MW Ref Only LI W HITAKER 800 243 9226 ao 56 Model o St 52 Wm LO LO LO TH LO N Fab an gt SI AN Ed Ser ES SIN tO N jJ 37 of 41 WAER 800 243 9226 7 6 Spare Parts List Specifications 1 Set Spe
41. www WhitakerBrothers com Thermoforming Granulator 36 and 56 Models INS CUMBERLAND Part Number D 20691 50 Bulletin Number CG5 605 3 Effective 11 10 03 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2004 All rights reserved Y HITAKER 800 243 9226 Shipping Info Unpacking and Inspection You should inspect your 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 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 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
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