Rapid Granulator Manual
October 31, 2021 | Author: Anonymous | Category: N/A
Short Description
Download Rapid Granulator Manual...
Description
INSTRUCTION MANUAL 8045-U ENGELSK/ENGLISH/ENGLISCH
© Copyright Applicable to all texts and illustrations in this manual, completely and in part. MASKIN AB RAPID
IB 11400 02 C03 96-11-05
8045-U
Contents 1. Introduction ........................................................................................................................ 1:1 2. Technical Specification ................................................................................................... 2:1 2.1 Dimensions ................................................................................................................. 2:1 2.2 Data .............................................................................................................................. 2:1
3. Function description ........................................................................................................ 3:1 3.1 General ........................................................................................................................ 3:1 3.2 Safety systems ........................................................................................................... 3:2
4. Safety Rules ...................................................................................................................... 4:1 5. Installation .......................................................................................................................... 5:1 5.1 Pre-start checks .......................................................................................................... 5:1 – Two hours after first start ...................................................................................... 5:1 5.2 Electrical connection .................................................................................................. 5:1 5.3 Air connection .............................................................................................................. 5:2 5.4 Opening the hopper, screen box and changing the screen ................................. 5:2 – Opening the hopper ............................................................................................... 5:2 – Opening the screen box ........................................................................................ 5:3 – Change the screen ................................................................................................. 5:3 5.5 Closing the screen box, granule bin and hopper ................................................... 5:4 – Closing the screen box and install the granule bin ........................................... 5:4 – Closing the hopper ................................................................................................. 5:4
6. Operation and daily maintenance ............................................................................... 6:1 6.1 Starting and stopping ................................................................................................. 6:1 6.2 Inspection .................................................................................................................... 6:1 – Daily inspection ...................................................................................................... 6:1 – Weekly inspection .................................................................................................. 6:1 – Monthly inspection .................................................................................................. 6:2 – 1000 running hours (6 month) ............................................................................... 6:2 6.3 Stoppage and overloading of granulator ................................................................ 6:2 – Stoppage in cutter housing ................................................................................... 6:2
7.
96-11-05
Stoppage from lumps ............................................................................................... Overfilling in cutter housing ...................................................................................... Hardened lumps in the cutter housing, screen box and granule bin ........................ – Stoppage in blower ................................................................................................ – Stoppage in hopper ............................................................................................... – Stoppage in material conveyance system ......................................................... Smell of melted plastic and smoke formation ........................................................... 6.4 Cleaning ...................................................................................................................... – Opening and cleaning ........................................................................................... Cleaning the screen box cylinders ............................................................................ – Re-install after cleaning ........................................................................................ 6.5 Fault-finding ................................................................................................................ The granulator does not start ................................................................................... The hopper and screen box can not be opened ....................................................... The granulator stops for some unaccountable reason ............................................. Service ................................................................................................................................. 7.1 Changing knives ........................................................................................................... – Removing the knives ............................................................................................. – Installing the knives ............................................................................................... 7.2 Sharpening the knives ............................................................................................... – Sharpening fixed knives ........................................................................................ – Sharpening rotating knives ...................................................................................
8045-U
6:2 6:3 6:3 6:4 6:4 6:4 6:4 6:5 6:5 6:6 6:6 6:7 6:7 6.8 6:8 7:1 7:1 7:1 7:2 7:5 7:5 7:6
7.3 Transmission ............................................................................................................... 7:7
8. 9.
10. 11.
12.
V-belt inspection and adjustment of drive belts ............................................................ 7:7 V-belt adjustment .......................................................................................................... 7:7 7.4 Lubrication ................................................................................................................... 7:8 – Pneumatic system ................................................................................................. 7:8 7.5 Cutter pulley, removing and installing ..................................................................... 7:9 – Removing the cutter pulley ................................................................................... 7:9 – Installing the cutter pulley ..................................................................................... 7:9 7.6 Motor pulley, removing and installing .................................................................... 7:10 – Removing the motor pulley ................................................................................. 7:10 – Installing the motor pulley ................................................................................... 7:10 Spare parts list, overview ................................................................................................ 8:1 Wiring diagram .................................................................................................................. 9:1 9.1 Current sensing relay ................................................................................................ 9:2 – Connection .............................................................................................................. 9:2 – Example .................................................................................................................. 9:3 Layout ................................................................................................................................ 10:1 Accessories, overview ................................................................................................... 11:1 11.1 Pre-setting of knives ................................................................................................ 11:2 – Knife setting ........................................................................................................... 11:2 – Installation of pre-set knives ................................................................................ 11:2 11.2 Third fixed knife, changing the knife, sharpening ................................................ 11:3 11.3 Fourth fixed knife, changing the knife, sharpening .............................................. 11:4 11.4 5-blade rotor ............................................................................................................. 11:6 – Knife change .......................................................................................................... 11:6 – Sharpening knives ................................................................................................ 11:8 11.5 Flywheel ................................................................................................................... 11:11 11.6 Band conveyor belt ................................................................................................ 11:12 – Spare parts for the band conveyor ................................................................... 11:14 11.7 Roll feed RF800 – single drive ............................................................................ 11:15 11.8 Autoflap .................................................................................................................... 11:18 Transport and storage .................................................................................................. 12:1
8045-U
96-11-05
1. Introduction This Manual applies to the RAPID granulator, model 8045-U. Read the Manual before installing and using the machine. Be careful when the knives are accessible, they are sharp, and can cause personal injury! These RAPID granulators are designed for granulating injection moulded, blow moulded and extruded plastic waste. The size and performance of the granulators are designed to suit the type of waste material. Approval must be obtained from the head office for granulating other products and materials for the warranty regulations to apply. The granulators are designed so that maintenance and cleaning can be done quickly and easily, both routine maintenance and material changes. All service must be done by trained service personnel. This Manual contains instruction for both operation and service. Chapter 7 contains instructions directed towards service personnel. Chapter 11 contains accessory equipment for the machine. Other chapters contain instructions for the operator. The granulators are delivered with an Instruction Manual, tool kit and touch-up paint. Any modifications or conversions of the machines must be approved by RAPID. This is to prevent injuries. The machine warranty and product assurance would otherwise be rendered void. Please address any queries to the RAPID local distributor or the RAPID head office. Head Office: Maskin AB Rapid Box 9 S-330 10 BREDARYD Sweden. Phone. +46 (0) 370 865 00 Facsimile. +46 (0) 370 802 51
We reserve the right to change technical specifications without prior notice. MASKIN AB RAPID
96-11-05
8045-U
1:1
2. Technical specification 2.1 Dimensions Overall size of the machine 8045-U (l x w x h) ........................................................ 1960 x 1580 x 2040 mm
2.2 Data Figures in bold refer to standard versions. Motor power .......................................................................... 30; 37; 45; 55 kW V-belts
......................................................................................... 6, 7, 9 pcs
Cutter speed ............................................................................................ 420 rpm Blower type ........................................................................ F............ / ............kW Cutter housing opening ................................................................. 800 x 450 mm Rotating knives ........................................................................................... 6 pcs Fixed knives ................................................................................................ 2 pcs Screen Ø
................................................................. 4; 6; 8; 10; 12; 17; 25 mm
Weight
................................................................................ approx. 2200 kg
Sound level Sound level when idling ........................................................ -U approx. 90 dBA
96-11-05
8045-U
2:1
3. Function description 3.1 General The granulator is designed for grinding plastic waste to granulate for recycling. The plastic waste should be free from metal parts and dirt before granulating. The granulators are controlled by start/stop controls on the control panel.
A
B C B D E F
The plastic waste is feed into the hopper (A) and falls down into the cutter housing, where rotating knives (B) cut the plastic waste against the fixed knives (C) to granulate. The size of holes in the screen (D) determines the size of the granulate. The screen in the bottom part of the cutter housing can easily be changed. screens are available with different hole sizes, to achieve the required granulate size. The granulate passes the screen and continues down through the outlet funnel (E) to the outlet pipe (F), for transport. The granulator with supplementary designation U is fitted with a suction blower, which transports the granulate to a cyclone, where the granulate and air are separated. After this the granulate can be recycled in production, or transported to a container for later use. The granulator is designed for quick and simple cleaning. The hopper can be opened to ensure good accessibility for cleaning and maintenance. On the granulator with supplementary designation B, the hopper is equipped with a conveyor. The conveyor can be equipped with a metal detector. The knives can be sharpened. Sharpening is most easily done with a special jig. (Not included with the machine when delivered, but is a very practical accessory.) 96-11-05
8045-U
3:1
3.2 Safety system The granulator has a safety system for to prevent access to dangerous components during operation. The granulator has knives which rotate at high speed. The granulator is therefore equipped with a safety system to avoid personal injury. Emergency stop The granulator has an emergency stop on the control panel. It can also be equipped with extra emergency stops. The emergency stop is activated by pressing the button. Resetting is effected by turning the button in the direction of the arrow (anti-clockwise). Safety switch The granulator has two types of safety switches position switch. alt. safety switch with knob or breaking screw. The position safety switch: If an safety position of a component is changed, the switch breaks the current and the granulator stops.
The safety switch screw has a fine-pitch thread: When a knob or breaking screw is unscrewed, it will break the current and the granulator stops.
Time delayed operating
The granulator must have stopped before the function can be opened or operated. It should not be possible to open or operate the function for about 4 - 5 minutes.
This granulator have 4 safety switches: 1 at the screen box clasps (safety switch with knob). 1 at the granulators right-hand side, granule bin (safety switch with breaking screw). 1 in front of the hoppers lifting cylinders stand attachment (the hopper position switch). 1 behind the granule bin (position switch with breaking key). The hopper operating has a time delay. Safety switch with knob
Safety switch with breaking screw
3:2
8045-U
96-11-05
Position switch (screen box)
Position switch (hopper)
Check the wiring diagram (chapter 9), to see the number of safety switches the granulator is equipped with. Before you start the granulator: The hopper and screen box must be properly closed and locked. The knob at the screen box locking, must be fold up and fully screwed in. The granule bin must be properly installed and the breaking screw must be fully screwed in.
96-11-05
8045-U
3:3
4. Safety Rules RAPID granulators are designed for granulating injection moulded, blow moulded and extruded plastic waste. The specific technical data for this machine, concerning power and performance etc. is described in detail in chapter 2. The granulator is equipped with safety switches, which are described in chapter 3.2. The following safety measures must always be observed when handling the granulator.
Electrical installation must only be carried out by a competent electrician!
When the granulator has been opened for servicing and maintenance. Always disconnect the power with both the main switch and the switch on the granulator.
Never put any part of your body through the openings in the granulator, unless both the main switch and the switch on the granulator are in the OFF (0) position.
Be careful with knives, they are sharp and can cause personal injury.
If the rotor must be turned manually do this with great care!
Be careful when you open or close the hopper, screen box and granule bin. Do not trap any part of your body inside.
The granulator cannot be started before the hopper and screen box are properly closed.
Never remove protective screen or pipes in from the outlet/granule bin.
Granulators equipped with a conveyor. When a conveyor with dogs is used, be careful. Ensure that none of the dogs catches a foot, arm or clothing. During maintenance, pull out the plug on the distribution box.
= DANGER! High voltage! This sign is on the door to the distribution box and the junction boxes. = DANGER! Cutting or pinch risk! This sign is placed where there is a risk of being cut or pinched, e.g. by the feed chute and screen box. Follow the instructions in this manual to avoid personal injury and damage to machine components.
96-11-05
8045-U
4:1
5. Installation Read through the whole of chapter 5 before installing the machine! All instructions must be followed in the given order to avoid injury or damage. Be careful with the knives, they are sharp and cause personal injury. The granulator must only be connected to the mains by a competent electrician.
5.1 Pre-start checks Place the granulator in position and adjust the feet of the machine until the granulator stands hrizontally. Note! The hopper and screen box can not be opened before electricity and air have been connected. The unpainted parts of the machine are protected with oil prior to delivery and transport. Clean the granulator from rust protection agent before it is used. Check the knife clearance and tightening torque on the attachment bolts for the knives. To check the knife clearance and tightening torque, please refer to knife installation in chapter 7. Two hours after first start Check the knife clearance again and tightening torque of the attachment screws for knives; check the attachment screws for both the fixed and rotating knives.
5.2 Electrical connection. The mill should be connected by a competent electrician.
Connect the granulator to the mains. The wiring diagram indicates the fuse sizes, see chapter 9.
The granulator is delivered with the electrical equipment connected for clockwise phase rotation. Check with a phase sequence indicator and connect the granulator with clockwise phase rotation.
Check the direction of rotation of the granulator motor:
96-11-05
Make sure that the main switch is On.
Check that the emergency stop is not activated.
Check that the hopper and screen box are closed, and that the knob to the safety circuit breaker at the screen box clasps are fully tightened.
Check that the granule bin are properly installed and that the breaking screw at the granulators right hand side are fully tightened.
Press Start.
Check that the granulator motor rotates in the direction indicated by the arrow on the housing. 8045-U
5:1
8045-U: check that the direction of rotation of the blower corresponds with the arrow on the cover. NOTE! The fan blows even if the direction of rotation is wrong.
If the motor or fan rotate incorrectly:
Press the stop button.
Switch off the main switch.
Switch two incoming phases.
5.3 Air connection Connect the machine to filtered compressed air .... 0.6 - 0.8 MPa / 6 - 8 kg/cm2. Connection a hose located downwards on the stand right hand side.
5.4 Opening the hopper and screen box The control buttons are on the distribution box. A relay delays the opening operation enough for the granulator to stop, before the hopper can be opened. The hopper and screen box is opened by pneumatic cylinders. Be careful when you open the hopper and screen box. Do not trap any part of your body inside. When the hopper, screen box and granule bin has been opened, switch Off both the main switch and the switch on the granulator. Be careful when the knives are accessible, they are sharp and can cause personal injury. A
Opening the hopper 1. Check that the hopper is empty, stop thereafter the granulator. 2. Unscrew and and fold down the knob to the safety switch, at the screen box clasps.
H
E
3. Undo the clasps to the hopper (A). 4. Put the knob (B) to Hopper. 5. Put the knob (C) to Open. 6. Wait until the lamp in left Start-button goes on.
F
G
D
J
7. The opening is a two-hand operation for safety reasons. Press both the Start (D) buttons at the same time and the hopper will be opened. Keep the buttons pressed, until the hopper is completely open and the cylinder stops. 5:2
8045-U
C
B
96-11-05
Opening the screen box 1. Undo the fan connection, and pull out the outlet pipe stub (E). 2. Unscrew the breaking screw to the safety switch at the granulators right hand side. 3. Remove, pull out the granule bin (F). 4. Put the knob (B) to Screen.
A
H
The screen box is opened and closed by two pneumatic cylinders. 5. Set the cylinders up, so that the arms of the cylinders engage the screen box. Put the knob (C) to Close. Wait until the lamp in left Start-button (D) goes on.
E
Press both the buttons Start (D) at the same time so that the arms of the cylinders engage the screen box.
F
G
D
J
6. Undo, pull out, and fold the wheels down (G). Lock the wheels down. 7. Undo and fold out the clasps for the screen box (H). 8. Put the knob (C) to Open. 9. The opening is a two-hand operation for safety reasons.
C
B
Press both the buttons Start (D) at the same time and the screen box will be opened. Keep the buttons pressed, until the screen box is completely open and the cylinders stops. 10. Switch Off both the main switch and the switch on the granulator. 11. Install the handle (J), make sure that the lock button engages. The wheel beneath the handle should be adjusted so that it does not touch the floor. 12. Press the handle down so that the rear edge of the screen box is lifted up, and the guide dowels can pass the stop blocks on the track. 13. Pull and roll the screen box out. Change the screen Remove the granule bin, open and remove the screen box.
96-11-05
J
Undo the front lock moulding in the screen box, 5 screws.
Change the screen. NOTE! The sides of the screen are not the same. 8045-U
5:3
5.5 Closing the screen box, granule bin and hopper The control buttons are on the distribution box. The hopper and screen box is closed by pneumatic cylinders. NOTE! Before closing make sure that the mating surfaces are clean! Note! If the granule bin and screen box safety switches not sense the Closed position the granulator will not start. Be careful at closing! Do not trap any part of your body inside. Closing the screen box and install the granule bin 1. Check that the screen is correctly installed in the screen box. 2. Press the handle down so that the rear edge of the screen box is lifted up and the guide dowels can pass the stop blocks on the track. 3. Roll the screen box in, so that the lifting arms on the cylinders are centred in front of the lifting handles. 4. Remove handle (J). 5. Switch On the main switch. 6. When the lamp in the left Start-button goes on, put the knob (B) to Screen. 7. Put the knob (C) to Close. 8. Closing is a two-hand operation for safety reasons.
J
Press both the buttons Start (D) at the same time, so that the cylinders lift up and close A the screen box. Keep the buttons pressed, until the screen box is completely closed and the cylinders stops.
H
9. Lock the screen box with the clasps (H). 10. Undo, pull out and fold the wheels up (G). Lock the wheels up. 11. Install the granule bin (F).
E
12. Screw in the breaking screw for the granule bins safety switch to stop. 13. Install the outlet pipe stub and connect the fan.
F
G
D
J
Closing the hopper 1. Check and make sure that no granules are left on mating surfaces or flanges. 2. Switch On the main switch. 3. When the lamp in the left Start-button goes on, put the knob (B) to Hopper. 5:4
8045-U
C
B
96-11-05
4. Put the knob (C) to Close. 5. The closing is a two-hand operation for safety reasons. Press both the buttons Start (D) at the same time, and the hopper will be closed. Keep the buttons pressed, until the hopper is completely closed. 6. Lock the hopper with the clasps (A). 7. Fold up and screw in the knob for the safety switch, at the screen box clasps. 8. Start the granulator.
96-11-05
8045-U
5:5
6. Operation and daily maintenance
Start Stop
6.1 Starting and stopping The main switch is located on the distribution box. Starting and stopping is controlled by push buttons on the start panel.
Emergency stop
NOTE! Never stop the granulator before all material in the hopper and cutter housing is completely granulated. Residual material will clog the rotor in the granulator during re-start. The motor will be overloaded and the overloading protection will trigger.
6.2 Inspection There must be no plastic material left in the granulator when inspection is carried out. NOTE! All servicing must be done by trained personnel in order to avoid personal injury and damage to the machine. Daily inspection Flaps in the hopper. Check that the flaps are undamaged. Replace damaged flaps at once. Damaged flaps can drop down into the cutter housing and damage the knives. Damaged flaps also entail the risk of material ejection. Emergency stop. Check the emergency stop function. Start the granulator and stop it with the emergency stop(s). Reset. Turn the stop button in the direction of the arrow (anticlockwise). Weekly inspection Cables. Check the electric cables of the machine for wear or other damage. Replace damaged cables at once. Safety switches. Check the safety switch functions. The granulator has 4 safety switches: 1 at the screen box clasps (safety switch with knob). 1 at the stands right-hand side, granule bin (safety switch with breaking screw). 1 in front of the hoppers lift cylinders stand attachment (the hoppers position switch). 1 behind the granule bin (position switch). Check the screen box safety switch, at the clasps. Check the granule bins position, the switch in the rear and the breaking screw. Check the hoppers time delay at opening. Check thereafter the hoppers position switch, by manually manipulate and press the safety switch breaking roll.
99-03-29
8045-U
6:1
Check the wiring diagram (chapter 9), to see the number of safety switches the granulator is equipped with. The granulator should not be able to start, unless all the safety switches are in their correct positions. Monthly inspection V-belt: Check that the V-belt are undamaged. Pneumatic system mist lubrication: Check the oil level and empty the water separator. The hoppers lift cylinder. Check that the cylinder stays at its end positions, Open and Close. Screen box cylinders. Check that the cylinders stays at their end positions, Open and Close. 1000 running hours (6 month) Check the V-belt tension every 6 months, see chapter 7.3 Transmission. Lubricate all the granulator lubrication points, see chapter 7.4 Lubrication.
6.3 Stoppage and overloading of granulator NOTE! Before trouble-shooting, attending to mechanical faults and maintenance work, switch Off the granulators main switch and
Break the power supply to the granulator and the granulators optional fittings.
If power supply is needed during opening and closing of hopper or screen box, then only connect up the granulator for the short period needed for opening or closing. There is a risk of serious personal injury. Stoppage in cutter housing Stoppage from lumps If lumps or stiffened/hardened plastic are fed into the granulator, this can result in overloading. Open the hopper carefully, then undo and remove the granule bin and screen box. Opening see chapter 5. If the cutter has jammed, use a wooden pole and carefully try to release the cutter in reverse rotational direction. NOTE! Never use metal objects to try and release a jammed cutter. This can damage the cutter, knives, knife positions, support rules, cutter housing and screen. Clean the hopper, cutter housing, screen box, granule bin and screen. Reset the granulator motors overload protection in the distribution box see chapter 6 Fault-finding.
6:2
8045-U
99-03-29
Overfilling in the cutter house Look for and attend to the cause of overfilling in the granulator.
Check hopper and outfeed (blower, transport pipe, cyclone filter etc.)
Check the knives and knife tolerance. If the granulator knives are blunt and unsharpened, or if the knife clearance is incorrect, this can cause overfilling in the cutter housing. Check the knives. Sharpen or replace the knives, or adjust the knife clearance, see chapter 7 Sharpening of knives.
Check the drive belts. If the tension of drive belts is too low the transmission will slip and the cutters rotational speed will drop too low this can cause overfilling in the cutter housing.
Clean the hopper, cutter housing, screen box, granule bin and screen. Reset the granulator motors overload protector in the distribution box see chapter 6 Fault-finding.
Check the granulators screen. The dimensions of the holes in the granulators screen must be appropriate to the material to be granulated, and if the size of the holes is wrong this can lead to overfilling in the cutter house. Contact RAPIDs local distributor or RAPIDs head office.
Hardened lumps in the cutter housing, screen box and granule bin If the cutter housing, screen box, screen and granule bin are filled with compacted stiffened/hardened plastic. Contact RAPIDs local distributor or RAPIDs head office. By heat-treating the cutter housing and screen box the plastic can be melted away. In order to be able to apply heat treatment, the cutter housing and screen box must be removed from stand, hopper and enclosure. This is work which can be carried out by RAPIDs service department at the head office. A change of bearings is always necessary after heat treatment. The granule bin must be changed. To dismantle the cutter housing and screen box, the granule bin must be removed. A granule bin filled with stiffened/hardened plastic can in most cases only be removed by means of cutting treatment. A granule bin filled with stiffened/hardened plastic cannot be heat-treated without the fit changing. A granule bin with a poor or altered fit will leak out granules from the granulator, both internally and externally. An alternative way of removing hardened plastic is by means of mechanical treatment. Removing hardened/stiffened plastic mechanically is very timeconsuming. Furthermore, there is a big risk of damaging the rotor, knives, knife positions, support rules, cutter housing and screen. 99-03-29
8045-U
6:3
Stoppage in blower Look for and attend to the cause of the stoppage in the blower.
Check there is no stoppage in the transport pipes, cyclone, dust filter and collecting container. Clean and empty transport pipes, cyclone, dust filter and collecting container.
Check the blowers rotational direction is in accordance with the arrow on the blower hood. NOTE! The blower blows even if the rotational direction is wrong, but the capacity will be less than 25%.
Stoppage in hopper Look for and attend to the cause of the stoppage in the hopper.
The hopper´s feed speed too high or pieces too large. Clean the hopper and lower the feed speed.
Change the direction or mechanically break up the pieces fed into the hopper.
The cutter housing is overfilled. Look for and attend to the cause of the overfilling in the cutter housing see previous chapter.
Stoppage in material conveyance system Look for and attend to the cause of the stoppage in the material conveyance system.
Overfilling or stoppage in transport pipes, cyclone, dust filter or collecting container. Clean and empty transport pipes, cyclone, dust filter and collecting container.
Check that the blowers rotational direction is in accordance with the arrow on the blower hood. NOTE! The blower blows even if the rotational direction is wrong, but the capacity will be less than 25%.
Smell of melted plastic and smoke formation
Overfilling or stoppage in transport pipes, cyclone, dust filter or collecting container. The blower functions easily and the granulator grinds plastic into powder and subsequently into a hot mass. WARNING! If the granulator is turned off, the result will be hardened lumps in the cutter house. Read the section on hardened lumps in the cutter housing. WARNING! Risk of fire in the cutter house.
6:4
8045-U
99-03-29
NOTE! Do NOT turn off the granulator. Try to attend to, release and evacuate the stoppage in transport pipes, cyclone, dust filter or collecting container. Then clean and empty transport pipes, cyclone, dust filter and collecting container.
6.4 Cleaning Clean monthly or at least once every 300 hours. NOTE! When the hopper and screen box have been opened, for cleaning. Put both the main switch and the switch on the granulator in the Off position. Be careful when the knives are accessible, they are sharp, and can cause personal injury. Opening and cleaning 1. Stop the granulator. 2. Switch off both the switch on the granulator and the main switch. 3. Clean the flaps in the hopper. Remove the top part of the hopper (air inlet), 4 screws, lift then the flaps straight up. 4. Switch On the granulators main switch. 5. Undo the hoppers clasps. 6. Open the hopper with the push buttons on the control panel (opening see chapter 5). 7. Undo the fan connection and pull out the outlet pipe stub from the side. 8. Screw out the breaking screw on the granulators right-hand side and remove the granule bin. 9. Unscrew the knob for the safety switch at the clasps to the screen box. 10. Set the cylinders up, so that the arms of the jacks, engage the screen box. 11. Undo the clasps for the screen box. 12. Fold down, open the screen box, with the push buttons on the control panel (opening see chapter 5). 13. NOTE! Switch Off both the switch on the granulator and the main switch. 14. Clean the inside of the hopper. 15. Clean the screen and screen box. If the screen needs to be removed from the screen box unscrew the screws in the front lock moulding, and lift out the screen. 16. Clean the inside of the cutter housing, granule bin and outlet pipe stub. 17. Clean the outside of the cutter housing and the frame. 18. Clean if necessary the transport conduits, fan and cyclone.
99-03-29
8045-U
6:5
DANGER! Never try to simplify cleaning between the knives by changing or increasing the clearance between the pair of knives on the rotor.
The knives are centred in pairs to the middle of cutter housing. The maximum clearance between the pair of knives is 0.50 mm. If the knife setting is changed the granulator can be seriously damaged! Cleaning the screen box cylinders. It can be necessary to clean the air cylinder used to open/close the screen box. Particles of dirt can accumulate between the inner seal and the mating surface of the cylinder tube. These particles cause leakage and must be removed. NOTE: Use protective goggles 1. Remove condensate. 2. Connect compressed air to the cylinder. 3. Undo the inner and outer strap locking screws and pull the strap out from one of the end pieces. 4. Localise any leakage. 5. Lower the air pressure to 1 bar. 6. Lower the cleaning tool into the slit and press against the seal. The compressed air will blow out any particles of dirt. 7. Lock the seal after cleaning. Re-install after cleaning 1. Install the screen in the screen box and tighten the front lock moulding. NOTE! The sides of the screen are not the same. 2. Install and push in the screen box. 3. Switch On the main switch. 4. Close the screen box with the buttons on the control panel (closing see chapter 5). 5. Lock the screen box with the clasps. 6. Install the granule bin, the outlet pipe stub and connect the fan. 7. Close the hopper with the buttons on the control panel (closing see chapter 5). 8. Lock the hopper with the clasps. 9. Switch Off both the main switch. 10. Install the flaps and the top of the hopper (air inlet).
6:6
8045-U
99-03-29
11. Fold up and screw in the knob to the safety switch, at the screen box clasps. 12. Screw in the breaking screw to the granule bins safety switch, on the stands right-hand side. 13. Switch On the main switch. 14. Start the granulator.
6.5 Fault-finding The granulator does not start
Check that the emergency stop is not activated. Reset by turning the button(s) in the direction of the arrow (anti-clockwise).
Check that the hopper is properly closed. The granulator will not start, if the hopper not is properly closed. The safety switch breaks the current. Close the hopper see chapter 5.
Check that the screen box is properly closed, and that the knobs to the safety switch are fully tightened to stop. The granulator will not start, if the screen box not is properly closed. The safety switch breaks the current. Close and lock the screen box. Fold up and screw in the safety switch knob to stop see chapter 5.
Check that the granule bin is properly installed and that the breaking screw are fully tightened to stop. The granulator will not start, if the granule bin not is properly installed. Any of the safety switches breaks the current. Install the granule bin properly and screw in the breaking screw to stop.
Stoppage in the cutter housing and overloading of granulator motor. Open the hopper, granule bin, screen box, and lift out the screen. Clean the hopper, cutter housing, screen box, granule bin and screen. Reset the granulator motor´s overload circuit breaker F1 in the distribution box.
A B
The overload circuit breaker trips if you jam or overload the granulator motor. The overload circuit breaker indicated 0 in the window (X). Reset, press the Reset button (X).
Check the fan motor protection switch. The granulator will not start unless the fan starts. Check the motor protection switch Q2 in the distribution box.
Reset
If the motor protection switch has switched Off the switch will be in position 0. Reset - set the switch button to position 1. 99-03-29
8045-U
6:7
Check the conveyor motor protection switch (8045-UB). The granulator will not start unless the conveyor starts. Check the motor protection switch Q3 in the distribution box.
Reset
If the motor protection switch has switched Off the switch will be in position 0. Reset - set the switch button in position 1.
Check the granulator knives and knife tolerance. If the granulator knives are blunt, or if the knife clearance is incorrect, this can result in stoppage. The granulator motor overloading protection will trigger. Check the knives. Sharpen or replace the knives, or adjust the knife clearance, see next chapter.
Check also the wiring display in chapter 9; supplements and deviations may be applicable.
The hopper and screen box can not be opened
Check the granulator motor overloading protection. If the motor overloading protection (F1 in the distribution box) has tripped because of stoppage or overload. The hopper can not be operated from the control panel until the relay has been reset.
Check the fan motor protection switch. If the fan motor protection switch has switched Off (Q2 in the distribution box) because of stoppage or overload. The hopper can not be operated from the control panel until the motor protection switch has been reset.
Options.
Check the conveyor motor protection switch (8045-UB). If the conveyor motor protection switch has switched Off (Q3 in the distribution box) because of stoppage or overload. The hopper can not be operated from the control panel until the motor protection switch has been reset.
The granulator stops for some unaccountable reason
If the drive belts tension not is enough, the transmission slips and the granulator motor´s overload protection trips. Check and adjust the drive belt tension, see chapter 7 Transmission.
If the machine is equipped with a friction clutch (option). Check that the friction clutch not slips. Check and adjust the tightening torque of the friction clutch. If the clutch slips during normal granulating, even if the tightening torque is correct, the clutch discs may need to be degreased or replaced. See chapter 7 Cutter pulley, changing of friction clutch.
6:8
8045-U
99-03-29
NOTE! The tightening torque for the friction clutch must never be increased. When the machine is delivered, the friction clutch is set to transmit torque for normal granulating.
If the machine is equipped with a speed monitor (option). If the cutter does not reach correct speed after start, or if the speed drops to a level too low at grinding. The granulator stops. The speed monitor is set at the factory and does not normally require readjustment. Check the cutter housing is empty at start. Empty and clean the cutter housing. Check and adjust the drive belt´s tension see chapter 7 Transmission. Check and adjust the cutter pulley´s friction clutch (option). The speed monitor has no reset restart the granulator.
At a bad or loose contact in connection to a limit switch/safety switch,the granulator will stop. Call for an qualified electrician for fault-finding and appropriate measures. NOTE! Never connect past a limit switch or safety switch.
If the machine is equipped with a speed monitor (option). The granulator stops straight after start, on transition to Delta-mode. Check the speed monitor´s function.
99-03-29
8045-U
6:9
7. Service All servicing should be carried out by trained personnel in order to avoid personal injury or damage to the machine.
7.1 Changing knives (Removing/installing of knives to granulator with 5-blade rotor, see chapter 11, accessories.)
OBSERVE! The granulators cutter is balanced, therefore auto-rotates the cutter at removing or installing of rotating knives.
The cutter auto-rotates when the centre of gravity becomes unstable. Therefore be wery careful when changing knives, so as not to injure fingers or hands.
OBSERVE! Never resort to help when removing or
installing rotating knives. Always carry out knife changing alone, so as to minimise the risk of injury to fingers or hands. Lock the cutter to the cutter housing with a thick block of wood to avoid auto-rotation. Be careful when handling the knives, they are sharp and can cause personal injury. Use protective gloves! Each time the set of knives is changed, the screws and washers which hold the knives must be replaced by new ones. Check the screen for wear when the knives are changed. Change the screen when the holes begin to be pear shaped.
C
A, B
Removing the knives Removing the rotating knives 1. Open the hopper, undo the outlet pipe, remove the granule bin and open the screen box. (Opening see chapter 5.) 2. Remove the screws (A) and washers (B). The knife pairs (C) are now loose. Removing the fixed knives 3. Undo the adjustment screws (D) 3 stop screws per knife. The screws are undone from the outside of the cutter housing. NOTE! Don´t confuse the rear fixed knife´s adjustment screws with the screen box´s adjustment screws. If the setting of the screen box is changed the rotating knives and the screen will be damaged. 99-03-29
8045-U
D
The screen box adjustment screw
7:1
E, F
4. Undo and remove the screws (E) and washers (F). NOTE! Hold the knife before removing the last screw the knife is heavy. 5. Lift out the fixed knives. 6. Clean the knife seats. Installing the knives Install first the front fixed knife (Installation of third and fourth fixed knives, see chapter 11, accessories.)
D
The screen box adjustment screw
1. Check that the knife seats are properly cleaned. 2. Install the front fixed knife, with screws (E) and washers (F) loosely. 3. Adjust the knife to the forward position with the adjustment screws (D), so that the knife reach its fixed setting position. The knife has a fixed position in the sides of the cutter housing. Check that the knife is straight. 4. Tighten the screws (E) alternately and increase the torque to 300 Nm. Installation of rotating knives
OBSERVE! The granulators cutter is balanced, therefore
auto-rotates the cutter at installing of rotating knives.
The cutter auto-rotates when the centre of gravity becomes unstable. Therefore be wery careful when changing knives, so as not to injure fingers or hands.
OBSERVE! Never resort to help at installing of rotating knives. Always carry out knife changing alone, so as to minimise the risk of injury to fingers or hands.
Lock the cutter to the cutter housing with a thick block of wood to avoid auto-rotation. Be careful when handling the knives, they are sharp and can cause personal injury. Use protective gloves! Each time the set of knives are changed, the fastening screws and washers must be replaced by new ones. OBSERVE! Install all the rotating knives on the cutter, so that the cutter is balanced. Then set the knife clearance.
7:2
8045-U
99-03-29
E, F
Tips for knife installation: Mark each knife, with a felt-tip pen when each task is carried out: = The knife clearance is correctly set. = The knife´s screws are torqued to the correct torque. = The knife´s adjustment screws are ocked with the lock nuts.
Install all pairs of rotating knives
C H G
A, B
5. Clean the knife seats properly. 6. Install all pair of rotating knives on the cutter, so that the cutter will be balanced. Use two screws with washers (A, B) for each knife, and install loosely. 7. Set the knives. Undo the lock nuts (G). Screw in the knife pair adjustment screws (H) into the cutter a few turns, so that the knife pair freely can pass the front fixed knife. Check that the rear of the knives butt up against the adjustment screws. Set the knife clearance to 0.30 - 0.50 mm, against the front fixed knife (foil 0.15 - 0.30 mm). Put the feeler gauge between the rotating and fixed knife edges. Unscrew the adjustment screws against the rear of the knife, until the feeler gauge begins to bind. The setting is now ready. Install the remaining screws with washers (A, B) for the knife pair. Centre the knife pair in the cutter housing. NOTE! The knives should be centered in pairs in the middle of the cutter housing. Max. clearance between the knives is 0.50 mm. 8. Tighten the screws alternately and increase the tightening torque to 600 Nm. 9. Check that the rear of the knives are in contact with the adjustment screws. 10. Lock the adjustment screws (H) settings with the lock nuts (G). Install the rear fixed knife 11. Check that the knife seats are properly cleaned. 12. Install the rear fixed knife, with screws (E) and washers (F) loosely. 13. Adjust the knife to the forward position with the adjustment screws (D), so that the knife reach its fixed setting position. The knife has a fixed position in the sides of the cutter housing. 99-03-29
8045-U
D
E, F
7:3
14. Check the knife clearance with a feeler gauge against the rotating knives. The clearance should be 0.30 - 0.50 mm (foil 0.15 - 0.30 mm). Adjust if necessary. 15. Check that the knife is straight. 16. Tighten the screws (E) alternately and increase the torque to 300 Nm. NOTE! Re-check the knife clearance and centering. 17. Re-check the knife clearance. Check the clearance for all the rotating knives, against both the front and the rear fixed knives. 18. Re-check the centering of the rotating knives, in the centre of the cutter housing. The clearance between the pairs of knives should be max. 0.50 mm.
7:4
8045-U
99-03-29
7.2 Sharpening knives Be careful when handling the knives, they are sharp, and can cause personal injury. NOTE! The knives should be sharpened by skilled personnel. Only sharpen the marked areas! The knives must be sharpened exactly, so that the correct cutting and relief angles are achieved. Otherwise the efficiency of the granulator will be impaired. The RAPID grinding jig SF 8045 (accessory) and a surface grinder with magnetic bed are recommended for sharpening work. The knives must be cooled during sharpening. The knives must not be burned or blued under any circumstances, otherwise they will loose their hardness and durability. If the knives are burned or blued, they cannot be repaired by grinding down the blued or burned area. The hardened knives will already have lost their hardness and temper, and are completely ruined. Sharpening fixed knives The fixed knives are reversible: grind 2 cutting edges when re-sharpening. NOTE! Only grind the marked areas and respect the given dimensions!
Grind both knives equally.
Grind two knife edges on each knife.
Grind
The knives can then be turned round, and two edges can be used before the next sharpening.
Grind the worst knife edge first.
Fix the knife in the left-hand position of the jig, see illustration.
Use a surface grinder to make the cutting angle exactly 90o.
Grind until all the irregularities on the knifes both edges have disappeared.
Retain the surface grinder setting, and grind two edges of the other knife.
The knives can be sharpened up to the limits shown in the diagram. After this the knives are used up and must be replaced by new ones.
99-03-29
8045-U
Grind
Min. 60 mm
7:5
Sharpening the rotating knives Keep the complete knife set well ordered. NOTE! To avoid imbalance, all the knives belonging to the cutter must be sharpened exactly the same. Only grind the marked surfaces and respect the given dimensions! The RAPID grinding jig SF 8045 (accessory) and a surface grinder with magnetic bed are recommended for sharpening work. The jig gives the knives the exact cutting and relief angles. Grind the relief angle of the worst knife first. Grind until all the irregularities on the knife edge have disappeared. Retain the surface grinder setting and grind all the knives equally.
First grind the relief angle of the knives to 40o.
Grind the worst knife first.
Fix the knife in right-hand position of the jig, with spacer A beneath the knife (see illustration).
Grind
Spherical washers should be used when tightening the knife.
Grind until all the irregularities on the knife edge have disappeared.
Retain the surface grinder setting and grind all knives equally.
A
Using the surface grinder and jig makes the relief angle exactly 40o.
Grind the cutting angle of the knives to 35o.
Remove spacer A beneath the knife.
Fix the knife and grind until the cutting edge is 3 mm wide.
Grind
Using the surface grinder makes the cutting angle of the knife exactly 35o.
Retain the surface grinder setting and grind all rotating knives equally. Grind
The knives can be sharpened up to the limits shown in the display. After this the knives are used up and must be replaced by new ones.
3 Min. 70 mm 350 400
7:6
8045-U
99-03-29
7.3 Transmission The machine is driven by 6 V-belts. V-belt inspection The tension and condition of the V-belts should be checked after 20 - 30 hours.
Release the screws and remove the belt guard.
Rotate the V-belts a few turns and check that the belts are complete and undamaged, and that they are not cracked.
DANGER! Pinch risk between pulleys and V-belts.
Check the belts tension and adjust if necessary.
Apply a load of about 75 N to each of the V-belts between the cutter and motor pulleys, in the centre between the cutter and motor pulleys. It should not be possible to deflect the V-belts more than about 12 mm. L = 12 mm F = 75 N
Then check the V-belts every 6 months. V-belt adjustment
Release the motor attachment screws (A) slightly, 4 items.
Adjust the belt tension by increasing/reducing the distance of the motor pulley to the cutter pulley, using the motor adjustment screws (B) 2 items (square screw head).
Tighten the motor attachment screws (torque 220 Nm).
If the V-belt tension is adjusted, the belts needs be re-checked after 20 - 30 hours.
A B A
99-03-29
8045-U
7:7
7.4 Lubrication The granulator is lubricated on delivery. RAPID recommends the following lubrications intervals and maintenance of the granulator. NOTE! Never mix synthetic and mineral-oil based lubricants! Plummer blocks:
SKF SH 522TG
Bearings:
SKF 23222 CCK
Grease quantity:
850 g grease for bearing change. 100 g grease per bearing/grease nipple for subsequent greasing. NOTE! Wipe off excess grease.
Lubricants:
Suitable lubricants:
Grease interval:
1000 hours of operation or annually.
Lubrication points:
Cutter housing: 2 grease nipples, 1 grease nipple to each plummer block
SKF; SKF Grease LGEP 2 BP; BP Grease XRB2-DP Chevron; Dura-Lith Grease EP2 Chevron; Alexol HMP 1 EP, Alexol HMP 2 EP ESSO; Beacon EP1, Beacon EP2 FINA; Marson HFF 2 EP Gulf; Synthetic Grease Gulflex MP Mobil; Mobilux EP2 Nynäs; L62 EP OK; Oktosol Grease EP2 Shell; Shell Alvania EP2 Texaco; Multifak EP2, Novotex Grease EP2
Electric motor: Depending on motor size and manufacture, 2 grease nipples (front and rear motor bearing). Pneumatic system The pneumatic system has oil mist lubrication. Metering is set by RAPID. At the lower right on the granulate box, there is a compressed air valve with two containers. The inner one is the oil container for oil mist lubrication (the outer one is the water separator).
7:8
Check:
Oil level monthly. The level should be at least 80% of the volume of the container.
Lubricant:
Atlas Copco 9721 400-283.
Filling:
Stop the granulator. Shut off and evacuate the compressed air. Unscrew and fill the container up to the screwed flange. Check the gasket. Put the container back again.
8045-U
99-03-29
7.5 Cutter pulley, removing and installing Remove the belt guard over the transmission. Removing the cutter pulley 1. Open the hopper and lock the cutter with a block of wood between the knives and the cutter housing. 2. Release the 4 motor attachment screws (A). 3. Release the two V-belt tension adjustment screws (B). 4. Remove the V-belts. 5. Bend the lock tab flat, undo and remove the centre screw (M36, spanner size 55 mm).
A
B A
6. Remove the lock screw, lock tab and cover washer. 7. Put a drop of oil into the extractor hole for the puller and fit the puller with M16 screws. Use screws of at least strength class 10,9. 8. Tighten the screws, with an alternated increased torque to 120 Nm. 9. Release the pulley with a sharp blow to the centre of the puller. If the pulley don´t release increase the tightening torque on the puller screws and give the puller centre another sharp blow. Max. tightening torque on the screws to the puller, M16 strength class 10,9 = 180 Nm. 10. Lift off the cutter pulley by means of a lifting device. Installing the cutter pulley 1. Fit the crosskey in the groove on the cutter shaft. 2. Lift the cutter pulley into position by means of a lifting device. 3. Fit the cover washer, lock tab, center screw and lock screw. 4. Tighten the centre screw, increase the torque by stages to 800 Nm. 5. Lock the centre screw, bend the lock tab towards both the centre screw and the lock screw. 6. Install the V-belts, and adjust the V-belt tension, see chapter 7.3. 7. Install the belt guard. 8. Remove the block of wood, from the cutter housing and close the hopper.
99-03-29
8045-U
7:9
7.6 Motor pulley, removing and installing Remove the belt guard over the transmission to remove or install the motor pulley.
Open the hopper and lock the cutter with a block of wood between the knives and the cutter housing.
Release the 4 motor attachment screws (A).
Release the two V-belt tension adjustment screws (B) and remove the V-belts. A
Removing the motor pulley
B A
The motor pulley is fitted with a compression bush. 1. Undo and remove the two screws (C).
2. Put a drop of oil into the extractor hole (D) (the hole with a half thread in the bush). Insert a screw and tighten so the compression bush release. 3. Lift off the compression bush and pulley from the shaft by hand, without tools, blows etc. D
D
C
Installing the motor pulley 1. Clean and degrease the motor pulley. 2. Oil the screws, and fit the compression bush lightly on the pulley. 3. Fit the crosskey in the groove on the motor shaft. 4. Lift the pulley on to the motor shaft. Make sure that the key fits into the compression bush. 5. Check and make sure that the pulleys line up. 6. Tighten the screws in the compression bush. Tighten alternate screws progressively, and increase the torque to 45 Nm. 7. Tap the compression bush between the shaft and the screws. Use a block of wood or plastic. 8. Tighten the pulley. Tighten the screws in the compression bush alternately, in stages and increase the torque to 90 Nm. 9. Install the V-belts, and adjust the V-belt tension, see chapter 7.3. 10. Install the belt guard. 11. Remove the block of wood from the cutter housing and close the hopper. 7:10
8045-U
99-03-29
8. Spare parts list Overview The spare parts list is divided into modules. Each module illustrates a particular part of the granulator. The granulator is divided into the following modules: Page 8.1 3-blade rotor, exploded view .................................................... 8:2 8.2 Knives, 3-blade rotor, fixed & rotating .................................... 8:3 8.3 Clasps, screen box, feed chute .................................................. 8:3 8.4 Fan F-25/AX-16 ........................................................................ 8:4 8.5 Pneumatics ................................................................................ 8:5 Ordering spare parts Only use original RAPID spare parts when you replace machine components. Orders should go to the representative in the country where the granulator was purchased. When ordering, the following should be specified:
96-11-05
machine designation, as specified on the machine plate
serial number, as specified on the machine plate
part number, as specified in the spare parts list
quantity, as specified in this spare parts list.
8045-U
8:1
8.1 3-blade rotor, exploded view
58
1
3
44 40 45 43 45
4
57
7
6 5
29
2
59 62
9 10 8
57
54
60 61 47 53
15
49 38 39
18
34 46
42 41
55
48
27 12 28
16 17
13
52 24
11
25
19 50
31
37 26 63 64 65 14
35
32
33
30
36
22 21
23
20
51 56
Pos Qty. Part. no. 1 1 9-20712 2 1 3-17927 3 2 4-13236 4 1 4-14969 5 6 3-07434 6 1 1-16967 7 2 9-50078 8 1 1-11113 9 1 4-05740 1 4-05741 10 1 2-05750 1 2-05004 11 2 3-07433 12 1 2-05013 13 1 2-05044 14 1 1-05009 15 1 2-11115 16 1 9-50290 17 1 4-11116 18 1 9-50071 19 1 3-05713 1 3-07380 20 2 4-05042 21 1 3-05041 1 3-05742 22 2 4-08313 23 2 9-50144
8:2
Description Cylinder Plummer block Bracket Locking bolt Rotating knife Cutter Key Cutter housing Spacer left Spacer right Gable inserts left Gable inserts right Fixed knife Lock moulding, screen Screen Screen box Handle, screen box Spring Catch Hjul handtag Lift arm, right Lift arm, left Wheel Bracket, wheel right Bracket, wheel left Spacer, wheel bracket Star knob
Pos Qty. Part. no. 24 1 4-05710 1 4-05735 25 2 9-20235 26 1 4-05711 1 4-05734 27 2 3-05020 28 1 2-05005 29 1 9-10935 30 1 1-16080 31 1 3-05081 32 1 4-11103 33 1 3-13000 34 2 4-05024 35 1 1-23463 36 4 4-08342 37 1 9-10133 38 2 4-05736 39 2 3-18033 40 1 9-30099 41 1 4-05045 42 1 4-05046 43 1 9-30100 44 6 9-30097 45 1 3-015819 46 1 3-08288 1 3-07429 47 2 9-60053
Description Pos Qty. Part. no. Bracket, upper right 48 2 9-60052 Bracket, upper left 49 1 9-60054 Cylinder 50 2 9-60056 Bracket, lower right 51 2 4-05724 Bracket, lower left 52 2 3-08333 Hinge unit, cutter housing 53 8 9-60109 Hinge, cutter h/screen box 54 1 3-20942 Distribution box 55 1 9-90161 Granule bin 56 1 2-12366 Sheet, granule bin 57 1 3-16538 Cover, granule bin 58 1 9-90782 Bracket, cover granule bin 59 1 4-15584 Stop 60 1 4-15583 Stand 61 1 4-15585 Machine shoe 62 1 9-10779 Motor 63 1 9-91255 Adjusting screw 64 1 4-07530 Belt tensioner 65 1 3-04305 Cutter pulley - 1 End washer cutter - 1 9-10570 Locking washer cutter - 1 9-10697 Motor pulley - 1 3-16081 V-belt - 1 9-10573 Belt protection, complete - 1 3-14654 Bearing housing, drive side Bearing housing, flywheel side Bearing
8045-U
Description Bushing Guide Sliding sleeve, lift arm Stop, screen box Protection Sealing, plummer block Bracket Push button box Bracket outlet pipe Protection Bracket, ball joint Bracket, switch Bracket, switch Hinge, switch Switch Switch Breaking screw Bracket, switch Luftskåp Brytare luftskåp Nyckelbrytare Fäste nyckelbrytare Brytare m rulle Fäste brytare m r
96-11-05
8.2 Knives, 3-blade rotor, fixed & rotating
4 3 2 1
6
5 7
Pos Qty. 1 18 2 18 3 18 4 18 5 8 6 8 7 6
Part. no. 9-40096 4-07390 9-40228 9-40344 9-40365 4-12916 9-40361
Description Screw Washer Adjusting screw Lock nut Screw Washer Adjusting screw
8.3 Clasps, screen box, hopper 8 5 1 4 7 3
6 5 1 9 2
Pos 1
96-11-05
2 3 4 5
Qty. 4 4 2 2 2 4
6 7 8 9
4 2 4 2
8045-U
Part. no. 4-05063 3-25608 4-05065 4-05729 4-05021 9-50137 9-50512 9-40247 4-40605 9-40078 9-40476
Description Note Locking arm maskin no. – 70.649 Locking arm maskin no. 70.650 – Lock key, screen box Lock key, hopper Locking clamp, hopper Spring for lock maskin no. – 70.649 Spring for lock maskin no. 70.650 – Screw Screw Nut Screw
8:3
8.4 Fan F-25/AX-16
1 3 4
2
5
6
7
8
9
10
11 12
Pos Qty. 1 1 2 3 3 1 4 1 5 9 6 1 7 1 8 1 9 1 10 1 11 1 12 2
8:4
Part. no. 3-03037 4-00448 4-11767 4-11769 9-20107 4-11766 9-20105 2-08684 9-20210 2-08679 9-20197 4-17781
8045-U
Description Cyclone Leg cyclone Pipe OK160 L=300 Pipe bend 90o OK160 Quick coupling Pipe OK160 L=600 Telescopic pipe OK160 Outlet pipe stub F25 Fan F25 Inlet pipe stub F25 Valve Pipe bend 45o OK160
96-11-05
8.5 Pneumatics
15
1
16
2 3 4
9 10 11
5
12 13 14
6 7 8
17
Pos Qty. 1 1 2 2 3 2 4 2 5 1 6 1 7a 2 7b 2 8a 2 8b 2 9 1 10a 2 10b 2
96-11-05
Part. no. 9-20712 9-20235 9-20448 9-20703 9-20449 9-20683 9-20685 9-20690 9-20686 9-20691 9-20684 9-20685 9-20690
Description Note. Cylinder Cylinder Valve Valve, back choke Valve, alternate Valve, direction Magnetic valve 220 VAC Magnetic valve 110 VAC Cable head 220 VAC Cable head 110 VAC Valve, direction Magnetic valve 220 VAC Magnetic valve 110 VAC
8045-U
Pos Qty. 11a 2 11b 2 12 1 13a 2 13b 2 14a 2 14b 2 15 1 16 1 17a 1 17b 1 17c 1
Part. no. 9-20686 9-20691 9-20682 9-20685 9-20690 9-20686 9-20691 9-20687 9-20689 9-20242 9-20272 9-20413
Description Note. Cable head 220 VAC Cable head 110 VAC Valve, direction Magnetic valve 220 VAC Magnetic valve 110 VAC Cable head 220 VAC Cable head 110 VAC Valve, back Pressure switch Air dressing unit mini F Mist lubrication unit mini dim Mounting kit avs mini F
8:5
9. Wiring diagram Never change or modify the basic electrical settings of the granulator, without first obtaining permission from the RAPID Head Office. If the granulator settings are changed, the machine can be seriously damaged. All Warranties and Rapids Product Liability will be void, if the basic settings of the granulator are changed. All maintenance and service work must be done by trained and competent personnel! Electrical installation must only be done by a competent electrician!
96-11-05
8045-U
9:1
9.1 Current sensing relay The granulator can be equipped with an optional current sensing relay to control the feed equipment. The current sensing relay detects the mill motor current consumption and can temporarily stop accessories such as conveyors, roller feeders etc to avoid putting further material into the hopper, when the mill is running under heavy loading. The relay stops and re-starts accessory equipment automatically, without re-setting. Relay functions and normal settings: T1 Start delay, prevents the relay from breaking on connection (0.1 - 10 sec). The default start delay is 0.1 seconds.
C
T1
T2 Reaction time, prevents the relay from breaking during temporary high loading (0.1 - 3 sec). Default reaction time is 3.0 seconds. A Hysteresis, adjustable between 5 - 50% of the set limit. Default hysteresis is 20 %. B Limit value, adjustable between 0 - 100 %. A Default setting depends on the current transformer size. Check the current transformer size and then check the default setting for this granulator.
T2
B
C Relay function, N = normal; I = inverted; Connection The current sensing relay is connected in series with the mill motor via a current transformer. The transformer is connected between M and E1/E2/E3 depending on the secondary current. (For transformers with transformation to 1 A, this is connected to E2.) Default setting for this granulator: Granulator motor, rated current: ................. Current transformer:
9:2
................................
= ................ A
/1A
Start delay T1:
0,1 sec.
other value: ......................
Reaction time T2:
3,0 sec.
other value: ......................
Limit values:
% ........................... = ............................. A
Hysteresis:
% ........................... = ............................. A 8045-U
96-11-05
Example The granulator is equipped with a current sensing relay to control a conveyor. A motor of 18.5 kW has a rated current of about 35 A. When this star/delta is started, it pulls about 35 A/
i.e. about 20 A per phase.
Relay setting: Motor size 35 A/ = 20,2 A per phase T1 Start delay setting 0.1 second. T2 Reaction time setting 3.0 seconds. A Hysteresis 20 %. B Limit value 40 %. C Relay function N normal. The current transformer size is 50/1A. The current transformer is connected to E2 (1 A).
C
A
T1
T2
B
In a current transformer with a transformation ratio of 50/1, the limit value B should be set to 40 % or 20 A (50 A = 100 %). The current sensing relay detects the current consumption of the granulator motor and stops the conveyor, when the granulator motor exceeds 20 A for 3 seconds, to prevent further material from being fed into the hopper. The relay re-starts the conveyor automatically when the granulator motor consumption has fallen 20 % below 20 A, i.e. to 16 A without a time delay.
96-11-05
8045-U
9:3
9.1 Current sensing relay 7KHJUDQXODWRUFDQEHHTXLSSHGZLWKDQRSWLRQDOFXUUHQWVHQVLQJUHOD\WRFRQWUROWKH IHHGHTXLSPHQW 7KHFXUUHQWVHQVLQJUHOD\GHWHFWVWKHJUDQXODWRUPRWRUFXUUHQWFRQVXPSWLRQDQGFDQ WHPSRUDULO\VWRSDFFHVVRULHVVXFKDVFRQYH\RUVUROOHUIHHGHUVHWFWRDYRLGSXWWLQJ IXUWKHUPDWHULDOLQWRWKHKRSSHUZKHQWKHJUDQXODWRULVUXQQLQJXQGHUKHDY\ORDGLQJ 7KHUHOD\VWRSVDQGUHVWDUWVDFFHVVRU\HTXLSPHQWDXWRPDWLFDOO\ZLWKRXWUHVHWWLQJ 5HOD\IXQFWLRQVDQGQRUPDOVHWWLQJV 7 ¤ 5HDFWLRQWLPHWLPHGHOD\ZKLFKSUHYHQWVWKHUHOD\IURP RSHQLQJGXULQJDQLQWHUPLWWHQWKLJKORDGLQJ VHF 'HIDXOWUHDFWLRQWLPHLVVHFRQGV 7 ¤ 7LPHGHOD\RQVWDUWLQJZKLFKSUHYHQWVWKHUHOD\IURP RSHQLQJZKHQWKHJUDQXODWRULVVWDUWHG VHF 7KHGHIDXOWVWDUWGHOD\LVVHFRQGV $ ¤ /LPLWYDOXHDGMXVWDEOHEHWZHHQ 'HIDXOWVHWWLQJGHSHQGVRQWKHFXUUHQWWUDQVIRUPHUVL]H &KHFNWKHFXUUHQWWUDQVIRUPHUVL]HDQGWKHQFKHFNWKH GHIDXOWVHWWLQJIRUWKLVJUDQXODWRU % ¤ +\VWHUHVLVDGMXVWDEOHEHWZHHQRIWKHVHWOLPLW 'HIDXOWK\VWHUHVLVLV & ¤
View more...
Comments
