Page 3 - Safety Considerations
BP1620, BP1628 & BP1640 Granulators Page 3 BP1600 Safety Considerations Sterling 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 dam...
Page 5 - SAFETY IS NO ACCIDENT
BP1620, BP1628 & BP1640 Granulators Page 5 BP1600 ALWAYS DISCONNECT AND LOCKOUT THE MAIN ELECTRICAL POWER TO THE GRANULATOR BEFORE PERFORMING ANY SERVICE. SAFETY INTERLOCKS MUST NOT BE BYPASSED . The mechanical and electrical safety interlocks ensure the safety of personnel. They should never be...
Page 6 - Table of Contents
BP1620, BP1628 & BP1640 Granulators Page 6 BP1600 Table of Contents 1 General Information 9 1-1 Introduction 9 1-2 General Description 10 1-3 Granulator Specifications 11 2 Shipping Information 12 2-1 Unpacking and Inspection 12 2-2 In the Event of Shipping Damages 12 2-3 If the Shipment is Not ...
Page 7 - Startup Checklist
BP1620, BP1628 & BP1640 Granulators Page 7 BP1600 Table of Contents 7 Startup Checklist 24 7-1 Introduction 24 7-2 Fan Evacuation 24 7-3 Granulator Startup Checklist 24 8 Operation 26 8-1 Operation Instructions 26 8-2 Temporary Machine Stops 26 8-3 Final Machine Stops 26 8-4 Emergency Stops 27 9...
Page 8 - Charts and Figures
BP1620, BP1628 & BP1640 Granulators Page 8 BP1600 Charts and Figures 1 Granulator Specifications Table Granulator Dimensions 11-12 2 Belt Span and Deflection Belt Deflection Force Table 33-34 3 Rotor Knife Drawings 36 4 Recommended Knife Replacement Blades 37 5 Bed Knife Drawings 39 6 Recommende...
Page 9 - General Information
BP1620, BP1628 & BP1640 Granulators Page 9 BP1600 1 General Information 1-1 Introduction This manual is intended to be used as a guide and reference for personnel who will be installing, operating, and maintaining the Sterling BP1600 Series Granulator. The purpose is to aid these individuals in ...
Page 10 - -2 General Description
BP1620, BP1628 & BP1640 Granulators Page 10 BP1600 1-2 General Description Sterling granulators are designed to uniformly and consistently size reduce your scrap. They have been engineered to consistently deliver clean granulate with a minimum of “fines”. The rotor, on which the cutting knives a...
Page 11 - -3 Granulator Specifications
BP1620, BP1628 & BP1640 Granulators Page 11 BP1600 1-3 Granulator Specifications Figure 1 Granulator Dimensions Model BP1620 BP1628 “A” Dimension 51.25” (1301.8 mm) 59.25” (1505 mm) Weight 3025 lbs (1372 kg) 3400 lbs (1542.3 kg) Est. Throughput 900 lbs/hr (408 kg/hr) 1500 lbs/hr (680 kg/hr)
Page 12 - Shipping Information; -1 Unpacking and Inspection; -2 In the Event of Shipping Damages
BP1620, BP1628 & BP1640 Granulators Page 12 BP1600 2 Shipping Information 2-1 Unpacking and Inspection You should inspect your Sterling BP1600 Series granulator for possible shipping damage. If the container and packing materials are in re-usable condition, save them for reshipment if necessary....
Page 13 - -3 If the Shipment is Not Complete; -4 If the Shipment is Not Correct
BP1620, BP1628 & BP1640 Granulators Page 13 BP1600 2-3 If the Shipment is Not Complete Check the packing list. You should have: Sterling BP 1600 Series granulator Bill of lading for equipment shipped Operating and Installation packet Electrical schematic and panel layout drawings Re-inspect the ...
Page 15 - Installation
BP1620, BP1628 & BP1640 Granulators Page 15 BP1600 3 Installation 3-1 Scope This section contains all instructions required for experienced installation personnel to install the Sterling granulator and prepare it for production. It is essential to follow all instructions carefully and in the seq...
Page 17 - -4 Electrical Service Connections
BP1620, BP1628 & BP1640 Granulators Page 17 BP1600 CAUTION! The knives mounted on the rotor and also located at the front and rear of the cutting chamber are extremely sharp. Always wear heavy gloves and exercise care when working in the cutting chamber. Wipe out the inside of the hopper and upp...
Page 18 - -5 High Amperage Readings
BP1620, BP1628 & BP1640 Granulators Page 18 BP1600 interlocks have been verified for proper functioning before shipment. It is only necessary to connect the electrical power source to the machine at the control enclosure. WARNING! All equipment must be grounded in compliance with Article 250 of ...
Page 19 - Accessing Cutting Chamber; -1 Opening Cutting Chamber; -2 Closing Cutting Chamber
BP1620, BP1628 & BP1640 Granulators Page 19 BP1600 4 Accessing Cutting Chamber 4-1 Opening Cutting Chamber 1. Allow material to run out of the cutting chamber. 2. Shut OFF and LOCKOUT all power, including the main disconnect switch. 3. Release latch that holds (2) front doors closed. Loosen the ...
Page 20 - Accessing Screen Chamber; -1 Opening Screen Chamber
BP1620, BP1628 & BP1640 Granulators Page 20 BP1600 5 Accessing Screen Chamber 5-1 Opening Screen Chamber 1. Allow all material to run out of the cutting chamber and screen chamber. 2. Shut OFF and LOCKOUT all power including the main disconnect switch. 3. Remove discharge chute located below the...
Page 21 - -2 Closing Screen Chamber
BP1620, BP1628 & BP1640 Granulators Page 21 BP1600 WARNING! DO NOT LET THE SCREEN CHAMBER DROP!! Guide cradle to it’s resting position. 6. Remove the screen(s) and place them upright on their side. CAUTION! The knives mounted on the rotor, and the bed knives located at the edges of the cutting c...
Page 22 - Sequence of Operation
BP1620, BP1628 & BP1640 Granulators Page 22 BP1600 6 Sequence of Operation 6-1 Scope This section contains the information required to carry out pre- operational procedures, and the checklist of items, which should always be reviewed prior to a production run. DANGER! Before undertaking any mach...
Page 23 - Alternate Procedure for testing interlock switch operation
BP1620, BP1628 & BP1640 Granulators Page 23 BP1600 • For granulators equipped with conveyors, fans, etc., test their operation also by pressing the appropriate pushbutton. Check fan outlets for proper airflow. • For granulators with emergency stop pushbuttons, test the buttons to insure all moti...
Page 24 - Startup Checklist; -3 Granulator Startup Checklist
BP1620, BP1628 & BP1640 Granulators Page 24 BP1600 7 Startup Checklist 7-1 Introduction After all electrical and mechanical machine elements have been inspected and any defects corrected, the machine can be put into production once the start-up checklist has been referred to. 7-2 Fan Evacuation ...
Page 26 - Operation; -1 Operation Instructions; -2 Temporary Machine Stops; -3 Final Machine Stops
BP1620, BP1628 & BP1640 Granulators Page 26 BP1600 8 Operation 8-1 Operation Instructions 1. Prior to machine startup -- All doors, covers, guards, and interlock switches must be in place, securely fastened, and functional. All accessory components must be properly connected. If the granulator h...
Page 28 - Routine Maintenance; -1 Lubrication Specifications; Recommended Grease Product Names
BP1620, BP1628 & BP1640 Granulators Page 28 BP1600 9 Routine Maintenance 9-1 Lubrication Specifications 9-1-1 Description All Sterling BP1600 Series machines are equipped with rotor bearings that are pre-lubricated & sealed from the factory. Mounting of the bearings on the Sterling BP1600 Se...
Page 29 - Motor & Belts Servicing
BP1620, BP1628 & BP1640 Granulators Page 29 BP1600 9-1-2 Screw Jack Lubrication Instructions Lifting screws should be checked periodically to ensure that they are adequately lubricated. It is recommended that the screw jack be lubricated at monthly intervals, unless experience indicates that re-...
Page 33 - -4 Rotor Knife Removal
BP1620, BP1628 & BP1640 Granulators Page 33 BP1600 DANGER! Before undertaking any machine repairs or maintenance, always make certain that the machine disconnect switch is turned to the OFF position or that the control enclosure is disconnected from the main power source. Either place a sign ind...
Page 34 - -5 Rotor Knife Sharpening
BP1620, BP1628 & BP1640 Granulators Page 34 BP1600 9-5 Rotor Knife Sharpening The rotor knives must be sharpened to within .003” (0.076 mm) of each other. Greater dimensional variations prevent the proper setting of the knife gap and may create other serious complications. Grinding the cutting e...
Page 35 - -6 Rotor Knife Installation; -7 Bed Knife Sharpening
BP1620, BP1628 & BP1640 Granulators Page 35 BP1600 9-6 Rotor Knife Installation 1. Carefully lock the rotor with the locking pin to prevent it from turning. 2. Re-install the rotor knives onto the rotor. Do not torque the hex head rotor knife bolts fully at this point -- snug them down only. CAU...
Page 38 - -9 Preventative Maintenance Service; -10 Recommended Torque For Knife Bolts
BP1620, BP1628 & BP1640 Granulators Page 38 BP1600 7. After the clearance setting of both the primary and secondary bed knives is complete and checked, turn the rotor by hand to ensure that none of the rotor knives hit the bed knives. 8. Double check inside the machine to make sure no tools or o...
Page 39 - Troubleshooting
BP1620, BP1628 & BP1640 Granulators Page 39 BP1600 10 Troubleshooting Problem Possible Cause Solution No power. Verify that the correct pushbuttons are being depressed and that the main disconnect switch is in the ON position. Try to locate grounds, a locked rotor or other reasons. Fuses are blo...
Page 42 - Spare Parts; 2-1 Recommended Spare Parts
BP1620, BP1628 & BP1640 Granulators Page 42 BP1600 Problem Possible Cause Solution Knives are dull. Sharpen knives (refer to Section 9) and re-install. Plastic is clogging the screens or transition, preventing proper fan evacuation. Shut the machine down and clean. Rotor speed is too fast. Chang...
Page 43 - 2-2 Additional Parts; Appendix: General Drawings
BP1620, BP1628 & BP1640 Granulators Page 43 BP1600 (1) set of rotor knives and bolts (1) set of bed knives and bolts (1) screen or set of screens, (depending if your model requires multiple screens) (1) set of belts (1) set of fuses (1) set of motor starter heaters (1) cyclone filter bag (option...
Page 47 - Service Notes
BP1620, BP1628 & BP1640 Granulators Page 47 BP1600 Service Notes
