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ACS Marathon MV1012, Operation And Installation Manual

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ACS Marathon MV1012 Operation And Installation Manual Download Page 45

ACS GROUP Marathon Series Beside-the-Press Granulators 

Page 45 

 

Problem 

Possible cause 

Solution 

Granulate builds up in the 
transition or tubing. 

Fan is too small. 

Replace with larger unit or 
larger fan wheel. 

Transition or cyclonic air 
separator tubing is clogged. 

Clean as required. 

Return air vents are covered 
or too small. 

Ensure that vents are open. 

Fan is not evacuating 
properly. 

Check for loose fan wheel on 
shaft, worn fan wheel, or 
loose fan drive belts. 

Feedstock hangs up in the 
hopper or cutting chamber. 

Material being placed into the 
machine for processing is too 
large for the hopper, cutting 
chamber, or rotor diameter. 

Reduce the initial size of the 
feedstock. 

Knives are dull. 

Sharpen or replace knives 
and re-install. 

Overloading of the machine. 

Regulate the in-feed of scrap 
to uniformly feed the machine 
over an extended time 
period. 

 
 

6-2  Troubleshooting Fan and Evacuation Systems 

Optional 

Problem 

Possible cause 

Solution 

No granulate. 

Fan is too small. 

Replace with larger unit or 
larger fan wheel. 

Fan wheel is damaged or 
worn. 

Replace or repair as needed. 

Fan tubing is not connected 
properly. 

Connect as needed. 

Fan stalls. 

Fan has loose belts. 

Inspect, and if acceptable for 
use, re-install and tighten per 
maintenance instructions. 

Fan wheel is loose on shaft. 

Tighten set screws as 
needed. 

Bearings sound noisy or are 
hot. 

Lack of lubrication. 

Lubricate per maintenance 
instructions. 

Bearings have exceeded 
their rated life. 

Consult with the ACS Service 
Department 262-641-3950 for 
replacement instructions. 

Summary of Contents for Marathon MV1012

Page 1: ...Installation Manual Marathon Series Beside the Press Granulators 8 x 10 8 x 14 8 x 18 10 x 12 10 x 16 Cutting Chambers Important Read Carefully Before Attempting to Install or Operate Equipment Part No 20050 0002 00 ...

Page 2: ...____ 2 _____________ _______________ _______________ _______________ 3 _____________ _______________ _______________ _______________ ACS Group is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright ACS Group 2021 All rights reserved Effective 8 29 2019 Part No 20050 0002 00 Revisio...

Page 3: ...ACS GROUP Marathon Series Beside the Press Granulators Page 3 Notes ...

Page 4: ...ND LIABILITIES ON OUR PART This warranty shall not apply to any goods or product manufactured by us which has been subject to accident negligence alteration of any kind abuse or misuse We further make no warranty whatsoever in respect to accessories or parts not supplied by us Any warranty of any nature shall apply only to an original purchaser which shall be deemed to mean that person or entity f...

Page 5: ...tion any manufactured item on your Marathon Series granulator without charge FOB factory within two 2 years after date of original purchase which is proved to be defective when shipped Claims for labor or consequential damages is not allowed Excluded from the above are knives screens and V belts Purchased items including electrical components motors etc shall carry the warranty of the supplier and...

Page 6: ...ghts and dimensions Granulator location Provide adequate area for routine maintenance for opening the machine for knife screen or cleanout service Proper service area clearances also allow people who are working on the machine to be clearly visible to others thereby reducing potential safety hazards Safe housekeeping Keep the work area clean and uncluttered to allow personnel safe movement around ...

Page 7: ...e Never stand on the granulator when it is in operation Rotation of motors All rotating items in the granulator are clearly marked on the machine Always check for proper rotation of motors Electrical grounding All electrical equipment on the granulator must be grounded in accordance to all local codes and Article 250 of the National Electric Code ALWAYS DISCONNECT AND LOCK OUT THE MAIN ELECTRICAL ...

Page 8: ...ptions 2 Shipping Information 17 2 1 Unpacking and Inspection 2 2 In the Event of Shipping Damages 2 3 If the Shipment is Not Complete 2 4 If the Shipment is Not Correct 2 5 Returns 2 6 Uncrating Your Granulator 3 Installation 19 3 1 Placing and Installing Your Granulator 3 2 Inspecting and Cleaning Granulator Components 3 3 Completing the Installation of Your Granulator 3 4 Electrical Considerati...

Page 9: ...he Cutting Chamber 4 5 Restarting Considerations 5 Maintenance 31 5 1 Maintaining Belts 5 2 Replacing Chains 5 3 Lubrication Specifications and Considerations 5 4 Knife Recommendations and Adjustments 5 5 Removing and Replacing Screens 5 6 Adjusting Bin Level Monitor Sensitivity 5 7 Recommended Spare Parts List 6 Troubleshooting 41 6 1 Troubleshooting Marathon Granulators 6 2 Troubleshooting Fan a...

Page 10: ...imensions 15 2 Typical Marathon Series Electrical Wiring Diagram 24 3 Typical Marathon Series Electrical Subpanel 25 4 Belt Deflection Forces 32 5 Recommended Grease Product Names 33 6 Correct Feeler Gauge Usage 35 7 Recommended Torque for Knife Bolts in Foot Pounds and Newton Meters 38 8 Customer Recommended Spare Parts List 41 ...

Page 11: ... granulator operating controls The control enclosure is built to meet NEC regulations 1 2 Necessary Documents Use this manual as a guide and reference for installing operating and maintaining your Marathon Series granulator The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This introduction includes a brief functional description a physical de...

Page 12: ...sted along with possible causes and related solutions Safety Symbols Used in This Manual The following are safety alert symbols They are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided directly results in death or serious injury DANGER ...

Page 13: ...Corten drilled screens 1 4 5 16 3 8 1 2 and 5 8 available Two 2 locking two 2 swivel casters 1 5 Available Options Available standard options for Marathon Series granulators include Alternative rotor speeds 590 rpm 250 rpm 150 rpm 125 rpm Alternative rotors Staggered rotor 2 blade open 3 or 5 blade solid Alternate feed chutes front robot conveyor rear robot long part or long part Alternative volta...

Page 14: ...coating for CortenTM drilled screens Front manual feed hinged door for noise reduction Regal sound enclosure Zero speed switch with alarm light senses rotation of granulator rotor If the rotor slows the switch shuts off the motor to prevent belt burnout Hardfaced welding of cutting chamber and rotor AR400 screen chamber plates ...

Page 15: ...2 10 x 12 N A 3 2 10 50 65 257 lbs 1 40 0 40 1 120 lbs MV1016 10 x 16 3 2 10 50 87 340 lbs 1 90 0 50 1 300 lbs Per SPI testing specifications E F C B A G D Dimensions in inches Long Machine Robot Floor mount Marathon part height with Manual conveyor Total Total Total Width Machine fan hole hgt model infeed out chutes infeed infeed depth width height door open from floor numbers A B C D E F G open ...

Page 16: ...Page 16 ACS GROUP Marathon Series Beside the Press Granulators Notes ...

Page 17: ...mes full responsibility of the shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to ACS Group before the transportation company inspection and authorization File a claim against the transportation company Substantiate the claim by referring to the agent s report A ...

Page 18: ...ve a floor rated to adequately support the weight of the machine A concrete floor of 4 10 2 cm minimum thickness is recommended Your Marathon Series granulator is mounted on wooden skids then blocked and banded to secure it for shipment All non painted items subject to corrosion are coated with a quality rust preventative and the machine is covered with heavy duty polyethylene to protect it from m...

Page 19: ... the bolt holding the cutting chamber closed loosens The actuator of the red time delay safety switch must be loosened to open the cutting chamber Note that the time delay safety switch is positioned behind the cutting chamber at the back of the machine Apply lifting pressure to the hopper to swing the machine up and back into the fully open position 4 Open the door to the front of the base Pull o...

Page 20: ...in open without the use of the safety latch you may find the cutting chamber resting on the safety latch While applying lifting pressure to the hopper swing the cutting chamber to its fully open position The safety latch pull lever is located on the right side of the machine and should be pulled to disengage the safety latch The cutting chamber can now be easily lowered to close the machine 2 Secu...

Page 21: ...rical service conforms before making any electrical connections Total running amps for Marathon Series granulators are listed on the nameplate Make sure that all three phases are wired correctly If not wired properly the unit will run backwards Again check the unit nameplate for correct voltage and amperage Bring properly sized power leads and ground from a fused disconnect installed by your elect...

Page 22: ...all sources of power including the main disconnect switch and follow all of your plant lockout procedures Electrical Service Connections Carefully check the diagrams packed with the machine All internal wiring has been done at the factory All safety interlocks have been verified to be functional before shipment It is only necessary to connect the electrical power source to the machine at the contr...

Page 23: ...n viewed from the shaft end If the motor turns in the opposite direction reverse any two incoming power leads Testing Remaining Electrical Controls Once the rotation direction is correct the remaining electrical controls need to be tested as follows 1 Press the granulator Stop push button and allow the machine to stop 2 For granulators equipped with conveyors fans etc test their operation by press...

Page 24: ...R CLEANOUT 2LS 6 7 8 EG 3500 L1 L2 L3 1M 1OL T1 T2 T3 1 MTR WARNING GROUND NATIONAL ELECTRIC CODE LOCAL CODES ALL EQUIPMENT MUST BE GROUNDED IN COMPLIANCE WITH THE 1 2 FUSE 3 FUSE 1 X1 120 VAC 1T CONNECT FOR PROPER VOLTAGE X2 W W LT OPTIONAL LITE 1OL 1M WARNING NATIONAL ELECTRIC CODE CUSTOMER S DISCONNECTING MEANS AND BRANCH CIRCUIT PROTECTION MUST BE IN COMPLIANCE WITH LT LT STARTER CUTTING CHAMB...

Page 25: ...NAL PROXIMITY LEVEL SENSOR HOPPER CLEANOUT 2LS 8 3PB 5 5 3 4 2 1 5 5 6 6 7 TB 1 2 3 4 4 3 2 1 5 6 7 8 9 10 11 12 13 4 RED MTW 16AWG 39 1 WHT MTW 16AWG 39 1 RED JUMPER 3 1 RED JUMPER 3 1 WHT MTW 16AWG 39 4 RED MTW 16AWG 39 1 2 2 3 4 4 5 5 6 7 8 EG 3515 1PB STOP W LT START CUTTING CHAMBER 1LS 4PB 5 5 3 4 2 1 2PB STOP W LT START ...

Page 26: ...Page 26 ACS GROUP Marathon Series Beside the Press Granulators Notes ...

Page 27: ...on machine operation and all machine safety mechanisms Have sufficient location clearances been allowed Has the equipment been grounded as required by local codes and or Article 250 of the National Electric Code Have all motors been checked for rotation Have all machine controls push buttons and limit switch safeties been checked for proper functioning Have the cutting and screen chambers been che...

Page 28: ...ave the drive belts been checked for alignment and tension Are all accessory components electrically and mechanically connected with proper support and with all fasteners tight Are optional separator and filter units empty Are all electrical enclosure boxes tightly closed and clamped shut Are all personnel clear of the fan Have all auxiliary components been checked for any foreign matter 4 3 Granu...

Page 29: ... limit switch or the machine will not start 4 5 Restarting Considerations Emergency Stops Feedstock must be cleaned out of the hopper and cutting chamber prior to restarting Temporary Machine Stops To temporarily stop the machine allow all material to run out of the cutting chamber first Never try to restart the machine with material remaining inside the cutting chamber Final Machine Stops To shut...

Page 30: ...o position and tightening the ratcheting tool Turn the time delay safety switch actuation knob located at the rear of the machine counterclockwise to return the actuator into the full closed position Note This model series of granulator are not designed to grind purgings large chunks of solid plastic or other heavy cross sectional pieces ...

Page 31: ...belts at the mid point of the span 4 Measure the force in pounds lbs Kg required to deflect any one of the belts one sixty fourth of an inch for every inch 1 64 per 1 or 1 mm per 64 mm of span For example the deflection for a 32 inch about 812 mm span would be one sixty fourth of an inch 1 64 times 32 or half an inch 1 2 or about 13 mm The force required to deflect the belt is listed in Figure 4 o...

Page 32: ... to 559 42 30 19 20 28 80 13 08 E 20 0 to 32 0 508 to 813 51 80 23 52 37 50 17 03 For V Band belts multiply the force shown in the table by the number of belts in the band 5 2 Replacing Chains 1 Remove the sprocket guard cover 2 Loosen the gear motor hold down screws and move the motor towards the granulator rotor to allow more slack in the chain 3 Split the chain at the master link and remove the...

Page 33: ...ads It also contains rust inhibitors has high temperature stability and exhibits good water resistance Figure 5 Recommended Grease Product Names Brand Product name Brand Product name Amoco Amolith EP2 Mobil Mobilith AW 2 Castrol EP2 Shell Alvania EP LF 2 Exxon Ronex MP Sunoco Sunaplex 2 Gulf Crown 2 Texaco Multifak EP2 Pillow block bearings should be lubricated with care Too much grease applied to...

Page 34: ...dertaking any machine repairs or maintenance always make certain that the machine disconnect switches are turned to the OFF position or that the control enclosure is disconnected from the main power source Lock out all sources of power including the main disconnect switch and follow all of your plant lock out procedures Removing Replacing and Adjusting Granulator Knives Removing Rotor Knives 1 Shu...

Page 35: ...e foreign material or rust 8 Inspect the knives and replace as required refer to the following procedure CAUTION Handle new or re sharpened knives with EXTREME CARE Cover sharp cutting edges with tape to prevent damage to the knives or injury to personnel during installation Figure 6 Correct Feeler Gauge Placement FEELER GUAGE SECONDARY KNIFE PRIMARY KNIFE Installing Rotor Knives 1 Carefully block...

Page 36: ... knife 6 Once knife adjustments are completed equally and fully torque the bed knife cap screws to 40 ft lbs 54 2 N m 7 Recheck the clearance once the bolts have been fully torqued reset as needed CAUTION EXERCISE EXTREME CARE when rotating the rotor and handling knives 8 Double check inside the machine to make sure no tools or other articles are left in the cutting chamber or have fallen into the...

Page 37: ... when rotating rotors Knives are SHARP Installing Screens 1 Before installing the screen make sure all contact surfaces are clean of granulated particles 2 Insert the screen in a radial motion beginning at the rear of the chamber 3 The screen is in position when its travel is limited by the bed knife located on the front wall of the cutting chamber 4 Close the cutting chamber and insert a 015 feel...

Page 38: ...m 1 8 910 ft lbs 1 234 0 N m 1 2 20 120 ft lbs 162 7 N m 1 14 1 015 ft lbs 1 376 3 N m 5 6 Adjusting Bin Level Monitor Sensitivity Although the bin level sensor was installed and tested at the factory to ensure reliable operation variations in the physical properties of the material you run through the granulator require that you adjust the sensor to suit your particular requirements So follow the...

Page 39: ... well is misaligned with the sensor Loosen but do not remove the locking nut securing the well to the bin and re position the well so that the bin closes fully Re tighten the locking nut Step 5 Locate the sensor inside the machine base by entering at the access port below the sheave guard Using a small screwdriver locate and turn the potentiometer located on the rear face of the sensor Turning the...

Page 40: ...lation package that arrives with your new machine Look for the Recommended Spare Parts List to find the specific part numbers that pertain to the categories listed in Figure 8 below The following list reflects a general list of spare parts that you should keep on hand to keep your new granulator running at optimum performance Please keep the Recommended Spare Parts List in a place where you can ea...

Page 41: ...tomer Recommended Spare Parts List Part number Description Set of rotor knives and cap screws Set of bed knives and cap screws Screen set of screens Set of belts Set of fuses Set of motor starter heaters Optional cyclone filter bag for use in an optional fan evacuation system ...

Page 42: ...Page 42 ACS GROUP Marathon Series Beside the Press Granulators Notes ...

Page 43: ...ock Reduce the amount of feedstock put into the machine per unit of time Fines Knives are dull Sharpen knives refer to Section 5 4 on Pages 34 37 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 Change pulleys Screen size is too small Change to a screen with larger holes Excessive power required bl...

Page 44: ... their rated life Consult with ACS Group Service Department for replacement instructions Bearings are not properly installed or tightened Consult with ACS Group Service Department for installation instructions Belts slip or squeal Belts are too loose Tighten per maintenance instructions Overloading of the machine Reduce amount of feedstock put into the machine per unit of time Machine has thrown b...

Page 45: ... the feedstock Knives are dull Sharpen or replace knives and re install Overloading of the machine Regulate the in feed of scrap to uniformly feed the machine over an extended time period 6 2 Troubleshooting Fan and Evacuation Systems Optional Problem Possible cause Solution No granulate Fan is too small Replace with larger unit or larger fan wheel Fan wheel is damaged or worn Replace or repair as...

Page 46: ...ber cover plate hopper auger trough and any hopper clean out door Ensure proper actuation and replace as needed Verify that the correct push buttons are being depressed and that the main disconnect switch is in the ON position Granulate builds up in the transition or tubing Fan is too small Replace with larger unit or larger fan wheel Transition or tubing is clogged from overloading the machine Re...

Page 47: ...ACS GROUP Marathon Series Beside the Press Granulators Page 47 Service Notes ...

Page 48: ...Page 48 ACS GROUP Marathon Series Beside the Press Granulators Service Notes ...

Page 49: ...e or fax order please have the model and serial number of your unit ready when you contact us TECHNICAL ASSISTANCE If you require any technical assistance we have a qualified service department ready to help We also offer service contracts for most products SALES Our products are sold by a worldwide network of independent sales representatives Contact our Sales Department for the name of the sales...

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