Page 3 - Sterling Warranty Information
Page iii of 53 Sterling Warranty Information Thank you for your purchase of your new BP1000 Series Granulator. We are confident that you will have excellent results and trouble-free operation with this machine. When the machine arrives at your plant, inspect it carefully for shipping damage before u...
Page 5 - Table of Contents; Safety Considerations
Page v of 53 Table of Contents 1 Safety Considerations 9 1-1 Safety Guidelines 9 1-2 Safety Procedures 11 1-2-1 Guidelines for Moving the Granulator 11 1-2-2 Clearing a Jammed Cutting Chamber 11 1-3 Safety Features 12 1-3-1 Safety Features Fitted On the Granulator 12 1-3-2 Opening the Granulator 13 ...
Page 7 - Table of Figures
Page vii of 53 Table of Figures 1. Safety Switch 13 2. Control Panel 14 3. Noise Test Specifications 15 4. Average Sound Levels 15 5. Noise Test Method 16 6. Main Components of Standard Granulators 19 7. Overall Dimensions and Weights 20 8. Lifting the Granulator 23 9. Inserting the Bin 25 10. Elect...
Page 9 - Safety Considerations; Safety Guidelines
Page 9 of 53 1 Safety Considerations 1-1 Safety Guidelines 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, o...
Page 11 - Safety Procedures
Page 11 of 53 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. Sterling has long recognize...
Page 12 - Safety Features
Page 12 of 53 !! CAUTION !! NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING HANDS ON ROTOR, ROTOR KNIVES, OR WITHIN THE CUTTING CHAMBER. HANDS MUST BE KEPT CLEAR OF THE ROTATIONAL PATH OF THE ROTOR KNIVES. A block of wood should be used to exert force on the rotor, usually in the direction opposit...
Page 17 - General Information; Introduction
Page 17 of 53 2 General Information 2-1 Introduction This family of granulators has been designed to granulate plastic material such as sprues, runners, and small reject parts. The granulator is comprised of an infeed hopper into which the material to be granulated is fed, mounted on a cutting chamb...
Page 18 - Safety Symbols Used in This Manual; Description
Page 18 of 53 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 Troubleshooti...
Page 21 - Shipping Information; Unpacking and Inspection; If the Shipment is Not Complete
Page 21 of 53 3 Shipping Information 3-1 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...
Page 22 - If the Shipment is Not Correct; Returns; Uncrating Your Granulator
Page 22 of 53 Operating and Installation packet Detailed recommended spare parts list Electrical schematic and panel layout drawings Component instruction manuals Re-inspect the container and packing material to see if you missed any smaller items during unpacking. 3-4 If the Shipment is Not Correct...
Page 24 - Installation; Lifting; Positioning the Granulator
Page 24 of 53 4 Installation 4-1 Lifting Important! Before lifting or moving the granulator, check the relative weight shown on the shipping papers and in Figure 7. To facilitate the lifting operation using forklift trucks, the drop box has been removed from the granulator and is packed with any spa...
Page 25 - Electrical Connection
Page 25 of 53 water. The granulator should be installed in an inside covered, weather-proof environment and away from any areas where water collects on the floor. Once the granulator is in position, the front panel must be opened in order to insert the bin as illustrated in Figure 9. Figure 9: Inser...
Page 30 - Start Up and Operation; Pre-Operational Checklist
Page 30 of 53 5 Start Up and Operation 5-1 Pre-Operational Checklist To ensure the granulator is ready for operation, perform the tasks listed on the following pre-operational checklist. Make sure that all electrical and mechanical machine elements are inspected and any defects corrected first. Have...
Page 31 - Operation
Page 31 of 53 5-2 Operation The granulator can be operated in a vertical top feed position or in a horizontal front feed position. Before starting the granulator, always check for and remove tools or any other objects placed on the granulator. Turn the Power disconnect switch to “ON”, pull the Start...
Page 32 - Maintenance; General Recommendations
Page 32 of 53 6 Maintenance 6-1 General Recommendations Before carrying out any work on the granulator, carefully read the instructions contained in this manual. NOTE: Only specialist and competent personnel should carry out this operation. All maintenance work must be carried out with the granulato...
Page 33 - Monthly Maintenance Operations
Page 33 of 53 6-2 Monthly Maintenance Operations 6-2-1 Drive Belt Tension NOTE: This operation should be carried out by an operator / mechanical maintenance engineer. For the granulator to function correctly, it is extremely important that the drive belt is always tight. Correct tension reduces the ...
Page 34 - Removal and Replacement of the Screen
Page 34 of 53 Figure 14: Belt Tension Chart Belt Cross Section Small O.D. Range ∗∗∗∗ Deflection Force Lbs/V-belt Run-In Normal Running 3VX 3.7 7.0 4.7 For best performance, the force measured on the gauge should be between the minimum and maximum values shown on the chart. If there is not enough def...
Page 35 - Inspection and Adjustment of Knives
Page 35 of 53 4. Remove the screw knob that holds the hopper on top of the cutting chamber. Carefully lower the screen cradle assembly, resting it on the base. 5. Remove the screen, keeping it in a horizontal position. (See Figure 15.) 6. Replace the screen with a new one, tighten the screw knob, re...
Page 37 - Removing and Replacing Bed Knives
Page 37 of 53 Figure 16: Inspection of Knives 6-5 Removing and Replacing Bed Knives NOTE: This procedure should be performed by a qualified operator / maintenance mechanic. Protective gloves must be worn to avoid injury when handling the cutting knives. To remove and replace bed knives, complete the...
Page 38 - Removal and Replacement of Rotating Blades
Page 38 of 53 8. Install new or sharpened bed knives on each knife seat, making sure that the rotor is blocked to prevent it from rotating while installing each knife. Be sure to place the bed knives in the correct positions the rear (down stroke) bed knife must be placed with the extended cutting...
Page 39 - Specifications for Re-sharpening Bed Knives
Page 39 of 53 5. Loosen and remove the knife bolts and lift the knife off the knife seat removing it from the cutting chamber. 6. Perform the above steps until all the rotor knives are removed. NOTE: Before replacing the rotor knife with new or sharpened knives, wipe the knife seats on the rotor, be...
Page 40 - Specifications for Re-sharpening Rotor Knives
Page 40 of 53 Figure 17: Bed Knife Specifications 6-8 Specifications for Re-sharpening Rotor Knives All the rotor knives must be re-sharpened in sets. Each knife within a set must have a tolerance within 0.003” (0.05 mm) for the total height, heel to cutting edge. Greater variations within a set wil...
Page 41 - Troubleshooting; General Problems
Page 41 of 53 7 Troubleshooting The following tables list problems that could occur when using the granulator. This general information may help to locate the cause of the problem and allow it to be resolved promptly. When a problem arises, it is advisable to perform the simplest checks before proce...
Page 43 - Electrical Problems
Page 43 of 53 7-2 Electrical Problems Problem Possible Causes Possible Remedies Machine stops for no apparent reason Safety switch has stopped power Check that the knobs that operate the safety switch are tightened Electric motor does not start No power Overload failure Safety switch not working Cut...
Page 44 - Spare Parts; Table 1: Recommended Spare Parts List
Page 44 of 53 8 Spare Parts When requesting spare parts, always quote the granulator model and serial number (from the granulator label), as well as the table number and reference number (from the spare parts tables) and the quantity required. 8-1 Table 1: Recommended Spare Parts List Item 1012 Quan...
Page 49 - Typical Wiring Diagram
Page 50 - Contact Information; Parts Department; Service Department; Sales Department
Page 50 of 53 10 Contact Information Parts Department Call Spare Parts Express toll-free 8am – 8PM EST (800) 229-2919. Sterling 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 Cust...
Page 51 - Service Notes
Page 51 of 53 Service Notes ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ___________________________________...
Page 52 - Warranty
Warranty Sterling warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions. The Company’s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment t...
