Instruction/ maintenance manual of the product BP1640 Sterling
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Operation and Installation Manual Model BP1620, BP1628, & BP1640 Granulators Important! Read Carefully Before Attempting to In stall or Operate Equ ipment $30.
BP1620, BP1628 & BP1640 Granulators Page 2 BP1600 Write down your gran ulator ________________ ________________ serial numbers h ere ________________ ________________ for futu re referenc e ______.
BP1620, BP1628 & BP1640 Granulators Page 3 BP1600 Safety Consider ations Sterling granulators are designed to provide safe a nd reliable operation when installed and operated within design specifications, following national and local safety codes.
BP1620, BP1628 & BP1640 Granulators Page 4 BP1600 to internal cutting chamber and screen chamber components. SAFETY GLASSES OR A FACE SH IELD MUST ALWAYS BE W ORN when servicing or operating the machine.
BP1620, BP1628 & BP1640 Granulators Page 5 BP1600 AL WAYS DISCONNECT AND LOCKOUT THE MAIN ELECTRICAL POWER TO THE GRANULATOR BEF ORE PER FORMI NG ANY SERVICE. SAFETY INTERLOCKS MUST NOT BE BYPASSED . The mechanical and electrical safety interlocks ensure the safety of personnel.
BP1620, BP1628 & BP1640 Granulators Page 6 BP1600 Table of Contents 1 General Info rmation 9 1-1 In troduction 9 1-2 Ge neral Descript ion 10 1-3 Gra nulator S pecifica tions 11 2 Shipp ing In for.
BP1620, BP1628 & BP1640 Granulators Page 7 BP1600 Table of Contents 7 Startup Checklist 24 7-1 In troduction 24 7-2 Fan Evacuation 24 7-3 Gra nulator S tartup Ch ecklist 24 8 Operation 26 8-1 Op e.
BP1620, BP1628 & BP1640 Granulators Page 8 BP1600 Charts and Fi gures 1 Granulator Specificat ions Table Granulator Dimen sions 11-12 2 Belt Span and Def lection Belt Deflection F orce Table 33-34.
BP1620, BP1628 & BP1640 Granulators Page 9 BP1600 1 General Informati on 1-1 Introdu ction 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.
BP1620, BP1628 & BP1640 Granulators Page 10 BP1600 1-2 General Description Sterling granulators are designed to uniformly and consistently size reduce y our scrap. They have bee n engineered to consistently deliver clean granulate with a minimum of “fines”.
BP1620, BP1628 & BP1640 Granulators Page 11 BP1600 1-3 Granulator Specifications Figure 1 Granulator Dimension s Model BP1620 BP1628 “A” Dim ension 51.
BP1620, BP1628 & BP1640 Granulators Page 12 BP1600 2 Shipping Inf ormation 2-1 Unp acking an d Inspectio n You should inspect your Sterling BP1600 Series granulator for possible shipping damage. I f the container and packing materials are in re-usable condition, save them for reshipment if necessary .
BP1620, BP1628 & BP1640 Granulators Page 13 BP1600 2-3 If the Shipment i s Not Complete Check the packing list. You should have: Sterling BP 1600 Series granulator Bill of lading for equip.
BP1620, BP1628 & BP1640 Granulators Page 14 BP1600 2-6 Uncrating BP1600 Series Granulator BP1600 Series granulators are shipped mounted on a wooden skid then blocked and banded to prevent movement.
BP1620, BP1628 & BP1640 Granulators Page 15 BP1600 3 Install ation 3-1 Scope This section contains all inst ructions required for experienced installation personnel to ins tall the Sterling granulator and prepar e it for production. It is essential to follow all instructions carefully and in the sequence presented.
BP1620, BP1628 & BP1640 Granulators Page 16 BP1600 Loosen the fa stener in the right side front door. Note that this fastener does not need to be completely removed from the front access door, as it is designed to be captive for convenience. NOTE: DO NOT USE ANY OTHER MEANS T O CRANK OPEN THE MACHINE OT HER THAN TH E HAND CRANK PROVIDED .
BP1620, BP1628 & BP1640 Granulators Page 17 BP1600 CA UTION! The knives mounted on the rotor and a lso locate d at the front and re ar of the cutting chambe r are e xtremely sharp. Always we ar heavy glov es a nd exerc ise care w he n w orking in the c utting chamber .
BP1620, BP1628 & BP1640 Granulators Page 18 BP1600 interlocks have been verified for proper functioning bef ore shipment. It is only necessary to connect the electrical power source to the machine at the control enclosure. WA RNING! A ll equipm ent must be grounde d in compli ance w ith Article 250 of the National Electric Code.
BP1620, BP1628 & BP1640 Granulators Page 19 BP1600 4 Accessing Cutti ng Chamber 4-1 Openin g Cuttin g Chamber 1. Allow material to run out of the cuttin g chamber. 2. Shut OFF and LOCKOUT all power, including the main disconnect switch. 3. Release latch that holds (2) front doors closed.
BP1620, BP1628 & BP1640 Granulators Page 20 BP1600 5 Accessing Screen Cham ber 5-1 Openin g Screen Chamber 1. Allow all material to run out of the cutti ng chamber and screen chamber. 2. Shut OFF and LOCKOUT all power including the main disconnect switch.
BP1620, BP1628 & BP1640 Granulators Page 21 BP1600 WA RNING! DO NOT LET THE SCREEN CHAM BER DRO P!! Gu ide cradle to it’s restin g position. 6. Remove the screen(s) and place them upright on their side. CA UTION! The knives mounted on the rotor, and the bed knives loca ted at the ed ges of the cutting chambe r, are e xtremely sharp.
BP1620, BP1628 & BP1640 Granulators Page 22 BP1600 6 Sequence of O peration 6-1 Scope This section contains the information required to carry out pre- operational procedures, and the checklist of items, which should alway s be reviewed prior to a production run.
BP1620, BP1628 & BP1640 Granulators Page 23 BP1600 • For granulators equipped with convey ors, fans, etc., test their operation also by pressing the appropriate pushbutton. Check fan outlets for proper airflow. • For granulators with em ergency stop pushbutt ons, test the buttons to ins ure all motion stops.
BP1620, BP1628 & BP1640 Granulators Page 24 BP1600 7 Startup Checkl ist 7-1 Introdu ction After all electrical and mechanical machine ele ments have been inspected and any defects corrected, the machine can be put into production once the start-up checklist has been referred to.
BP1620, BP1628 & BP1640 Granulators Page 25 BP1600 Are all accessory components electrically and mechanically connected with proper support and with all fasteners tight? Are cy clonic air .
BP1620, BP1628 & BP1640 Granulators Page 26 BP1600 8 Oper ation 8-1 Operation Instruction s 1. Prior to m achin e startup -- All doors, covers, guards, and interlock switches must be in place, securely fastened, and functional. All accessory components must b e properly connected.
BP1620, BP1628 & BP1640 Granulators Page 27 BP1600 8-4 Emergency S top s Feedstock must be cleaned out of the hopper and cutting chamber prior to restarting the machine. NOTE : The Sterling BP1600 Series granulators are not designed for small purging, chunks of solid plastic or other heavy wall cross- sectional pieces.
BP1620, BP1628 & BP1640 Granulators Page 28 BP1600 9 Routine Maintenance 9-1 Lubricatio n S pecifi cations 9-1-1 Descripti on All Sterling BP1600 Series machines are equipped with rotor bearings that are pre- lubricated & sealed from the factory .
BP1620, BP1628 & BP1640 Granulators Page 29 BP1600 9-1-2 Screw Jack Lubricati on Instructions Lifting screws should be checked periodically to ensure that they are adequately lubricated.
BP1620, BP1628 & BP1640 Granulators Page 30 BP1600 1. Verify that the alignment of the pulley s is correct. Utilizing a straightedge of sufficient length to span from one pulley to the other, place it along the sides of both pulley s. The entire edge of each pulley should fully contact the straightedge.
BP1620, BP1628 & BP1640 Granulators Page 31 BP1600 6. There will normally be a drop in belt tensi on during the first 24 to 48 hours of operation due to st retch and the belts seating themselves in the sheave grooves. 7. After this initial “RUN IN” period, the machine should be stopped and the belts should be re-checked for tension.
BP1620, BP1628 & BP1640 Granulators Page 32 BP1600 Table 2 Belt Deflection Force BELT DEFLECTION FORC E (in lbs.) BELT SMALL SHEAVE DIAMETER (INCHES) A RUN IN B RUNNING 2.65 to 4. 0 6.00 4.00 3V 4.12 to 7. 0 8.25 6.75 7.10 to 10.9 21.00 14.25 5V* 11.
BP1620, BP1628 & BP1640 Granulators Page 33 BP1600 DA NGER! Bef ore und ertaking any ma chine rep airs or ma intenan ce, always make certain th at the m achine d isconnec t switch is turned to the OFF positio n or tha t the co ntrol enclosure is disconn ected f rom t he ma in power source .
BP1620, BP1628 & BP1640 Granulators Page 34 BP1600 9-5 Rotor Kni fe 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 ga p and may cre ate other serious complications.
BP1620, BP1628 & BP1640 Granulators Page 35 BP1600 9-6 Rotor Kni fe Inst allation 1. Carefully lock the rotor with the lockin g 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.
BP1620, BP1628 & BP1640 Granulators Page 36 BP1600 I t is i mportant to note that the mini mum dimensions given for the rotor knife and bed knife cannot be combined simultaneously to produce a cutting combination. NOTE: Replacement knife sets and knife resharpening services are available from Sterling .
BP1620, BP1628 & BP1640 Granulators Page 37 BP1600 2. Align a rotor knife with the primary bed knife, in the front of the granulator. With a .006” feeler ga uge between the rotor and bed knife, start to adjust the bed knife into the rotor knife using the adjusting screw.
BP1620, BP1628 & BP1640 Granulators Page 38 BP1600 7. After the clearance settin g 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.
BP1620, BP1628 & BP1640 Granulators Page 39 BP1600 10 Troubleshooti ng Problem Possible Caus e Solution No power. Verify tha t the co rrect pushb uttons a re being depressed and t hat the main d isconnect switch is in the ON position . Try to loca te grounds, a locked rot or or oth er reasons.
BP1620, BP1628 & BP1640 Granulators Page 40 BP1600 Machine h as loose or thrown belts. Inspect , and if accepta ble f or use, reinstall an d tighten per instruction s. Machine s talls/(option al) fan stalls (Optiona l) Fan wheel is loose o n shaf t.
BP1620, BP1628 & BP1640 Granulators Page 41 BP1600 Problem Pos sible Caus e Solution Fan wheel is lo ose on shaf t. Tighte n set screws as required. Transitio n or cyclonic air separat or tubing is clogged. Clean as required. Granulat e builds u p in the tran sition or tu bing Fan is no t evacuatin g properly.
BP1620, BP1628 & BP1640 Granulators Page 42 BP1600 Problem Pos sible Caus e Solution Knives are d ull. Sharpe n knives (ref er to Section 9) and re-install. Plastic is clogging the screens o r transition, preventing prop er fa n evacuation . Shut t he ma chine do wn and clean.
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 scree ns, (depending if y our model requires multiple scre.
BP1620, BP1628 & BP1640 Granulators Page 44 BP1600.
BP1620, BP1628 & BP1640 Granulators Page 45 BP1600.
BP1620, BP1628 & BP1640 Granulators Page 46 BP1600.
BP1620, BP1628 & BP1640 Granulators Page 47 BP1600 Service Notes.
BP1620, BP1628 & BP1640 Granulators Page 48 BP1600 Service Notes.
An important point after buying a device Sterling BP1640 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling BP1640 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling BP1640 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling BP1640 you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling BP1640 will certainly help you make a decision on the purchase.
If you already are a holder of Sterling BP1640, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling BP1640.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling BP1640. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling BP1640 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
