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Under-The-Press applications
Use this manual as a guide and reference for installing, operating and maintaining your granulator.
The purpose is to assist you in applying efficient, proven techniques that enhance equipment
productivity.
This manual covers only light corrective maintenance.
No other maintenance should be undertaken without first contacting a Wittmann service engineer.
The functional description section outlines models covered, standard features and safety features.
Additional sections within the manual provide instructions for installation, pre-operational procedures,
operation, preventive and corrective maintenance.
The installation chapter includes required data for receiving, unpacking, inspecting and setup of the
granulator.
We can also provide the assistance of a factory-trained technician to help train your operator(s) for a
nominal charge.
This section includes instructions, checks and adjustments that should be followed before
commencing with operation of the granulator.
The operation chapter includes a description of electrical and mechanical controls, in addition to
information for operating the granulator safely and efficiently.
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 section is included to ensure that you granulator provides excellent, long
service.
The troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
A spare parts list with part numbers specific to granulator is provided with your shipping paperwork
package.
Refer to this section for a listing of spare parts for purchase. Have your serial number and model
number ready when ordering.
The appendix contains technical specifications, drawings, schematics, parts list and available options.
Please record your model of granulator model and serial number and the date you received it in the
spreadsheet below.
Our service department uses this information along with the manual number to provide help for the specific
granulator you installed.
IMPORTANT
1.1 Introduction
These operating instructions enable safe and efficient handling of the granulator.
The operating instructions are a component of the granulator and must be kept accessible to the personnel at
all times in the immediate vicinity of the granulator.
The user must have carefully read and understood these operating instructions before starting any work.
The present operating instructions were carefully prepared.
Nevertheless, no liability is assumed for possible errors or for direct or indirect damage occurring in connection
with any errors in these operating instructions.
DANGER
Imminently hazardous situation resulting in fatal or serious injuries.
WARNING
Possible hazardous situation which can result in fatal or serious injuries.
CAUTION
Possible hazardous situation which can result in minor injuries.
IMPORTANT
Possible situation which can damage the granulator.
NOTE
Points out useful hints, suggestions and information.
Warnings indicated at the start of a section apply for the entire section and all of its subsections.
Warnings referring to a subsection or the subsequent operating step are integrated in the relevant
procedure.
Pay strict attention to all warnings and notes.
1.5 Copyright
All rights reserved.
Any reproduction, editing, distribution or other exploitation is prohibited.
This also includes excerpts.
NOTE
Information about telephone numbers, email addresses, homepage and subsidiaries can be found at
the end of these operating instructions.
1.7 Definitions
These operating instructions use recurring terminology.
User
The user is the person who operates the device on his/her own responsibility or according to instructions.
Operator
The operator of a device is the person responsible for all of its processes (e.g. production supervisor, hall
manager, etc.) The operator instructs the users to perform a task.
Qualified personnel
Specialists include persons whose training or education qualifies them to perform work professionally and to
recognise possible hazards.
IMPORTANT
Any kind of improper usage of the granulator shall void the warranty claim.
Every other usage of the granulator is prohibited.
Strictly follow all instructions referring to safety, operation, servicing and maintenance.
These operating instructions must be used by every person assigned to work on or with the granulator.
DANGER
The plastic sprues / parts must before grinding be free from contamination and metal.
DANGER
Misuse can lead to serious injury or death.
Ensure that the cause of the emergency stop has been eliminated and all safety devices installed are
functional before restarting the granulator.
Do not restart the granulator until the danger and its source have been eliminated.
Safety shoes
Non-slip
Protection against falling parts
Gloves
Protection against sharp-edged, hot or moving parts
Hearing protection
Protection against loud noises
Safety glasses
Protective eyewear
Beware of crushing
Particular caution in the affected area
NOTE
The corresponding item numbers for the adhesive labels are provided in the "Spare and wear parts"
section.
IMPORTANT
Emergency stop shall always be within reach of the operator.
DANGER
The plastic sprues / parts must before grinding be free from contamination and metal.
3.4 Returns
Do not return damaged or incorrect items until you receive shipping instructions from the shipping
department.
WARNING
Possible injury due to heavy device/component.
Always use suitable equipment (forklift, hoisting crane, etc.) for moving the granulator and accessories.
Only appropriately qualified personnel may operate transport and lifting equipment.
Always use the sling points provided/labelled for moving the granulator and accessories.
Ensure that no metal parts or packing materials are located in the granulator.
Perform a general cleaning.
CAUTION
In case of damages, immediately notify the carrier.
Wittmann will not be responsible for the damages, if carrier is not immediately notified.
Be certain that the area to be occupied by the granulator is clean, level, and free of obstructions.
Make sure the floor is rated to adequately support the weight of the granulator.
The granulator should be set on a concrete floor, and care must be taken when moving the granulator
across a hollow timber floor, so that the point loading of the casters does not cause damage.
Place the granulator so you can access electrical components, cutting chamber and auger.
Maintenance personnel should have unobstructed access to the granulator.
To avoid squeezing people working near the granulator, there should be adequate clearance
maintained between machines, walls etc.
Hinged hopper, door, covers should have full swing.
IMPORTANT
Inspect the granulator for visible transport damage.
Please note that various devices can be disassembled for transport.
Do not use any sharp or pointed objects - they can damage the surfaces and the granulator itself.
4.3 Handling
The granulator is fitted with casters (2 swivelling with brake and 2 fixed).
Do not move the granulator on uneven ground. In such a case, use a handling machine with brake
and securely tie the granulator with a rope.
Brake the front castors when the granulator is unmovable.
IMPORTANT
Possible damage to downstream devices.
Take care to ensure that no small parts (screws, nuts, etc.) fall into the downstream devices.
Tighten all of the parts by hand.
DANGER
Risk to life due to electrical voltage.
NOTE
Wittmann local agency can provide you with its own technicians for start-up and commissioning.
WARNING
Granulator MINOR2A is not made to granulate: heavy or hard pieces, flush, metal part, glass, paper,
wood, toxic or flammable parts or to work inside an explosive area.
The screenless granulators MINOR2A feature a massively built, low rpm rotor to granulate glass filled
plastic materials with a minimum expenditure of horsepower and assure less wear on cutting tools due
to low speed.
Sound level may vary and is dependent on the type of granulated plastics, the shape of granulated
items, granulator feed equipment and the general surroundings (premises).
The plastic waste is fed into the hopper and falls down into the cutting chamber, where rollers and
breaker knife cut the plastics against combs to granulate.
The tooth height determines the size of the granulate.
The granulate passes combs and falls down through the granule bin towards the outlet pipe for further
transport.
Extraction device (optional) ejects the granulate which is then ready for reuse in the production
machine or for transportation to a container for later use.
Simple cleaning, access to all the places that need cleaning when changing colour or type of plastics
is quick and easy.
DANGER
The plastic sprues / parts must before grinding be free from contamination and metal.
Quantity of cutters 2
Drawing MI2524905
Measured level value of the acoustic pressure pondered: Sample A=77 dBA
LAeq=Db(A) of measurement: 2 dBA
6.5.1 Auger
The goal of auger is conveying the material into the cutting chamber
The screw is directly driven by the motor through a gearbox.
The auger is equipped with an anti twisting blade to avoid material stoppers.
The cutting chamber is a rectangular enclosure comprising the main frame, the rollers, combs and
breaker knife.
The breaker knife pre-cut sprues / parts until small enough to be grabbed by the small roller cutters.
Material is then cut between the roller cutters and the stationary or comb cutters for final size
reduction.
The regrind size is dependent on the cutter size and shape and is very uniform compared to
conventional type granulators with a screen.
Since it is impossible for long pieces to pass through the cutting chamber, there is no chance for longs
to end up in the regrind.
Pre-sized plastic is re-introduced into the cutting chamber.
Final size is achieved via the toothed rollers without screening.
Because the rotor turns slowly (27 rpm at 50hz / 30 rpm at 60hz), screenless granulators generate
less noise and dust than traditional screen-type granulators.
Different tooth rollers sizes are available as options.
1 Knife 4 Roller
2 Central comb 5 Scraper
3 Lateral comb
The granulated material that falls is collected by the collection bin located beneath the cutting
chamber.
The regrind collection bin is equipped with an outlet pipe for vacuum unloading (vacuum system is an
option).
6.5.7 Nameplate
Year of manufacturing
Name/Model
Electrical power
Weight
Current
Connected load
NOTE
Please specify the serial and item numbers in the case of questions, complaints, spare parts
orders, etc.
Alternative voltages.
Customized design.
Install the granulator solely in closed and dry area which can be ventilated.
Prevent drafts and abrupt deviations in temperature and humidity.
Consider the stability of the installation site, particularly when installing the granulator on platforms.
Floors must be level, non-slip, dry and easy-to-clean.
Please ensure that all parts of the granulator remain accessible for servicing and repair work.
7.1 Degreasing
Degrease the granulator to take off the rust protection.
Clean inside the cutting chamber, auger and bin.
You may use a soft cleaner, or degreaser.
Apply with a brush or an atomizer and immediately dry it.
Be careful not to touch the seals, the plastic components and the painted parts.
Ensure that nothing has been left inside the granulator.
Carefully inspect the interior of the cutting chamber, evacuation area, regrind collection bin for foreign
material or debris.
IMPORTANT
Do not initially use the new granulator with clear material, because of possible contamination.
Grind raw materials which will not be re-used for degreasing the granulator during its first run.
NOTE
Sign the executed inspection in the granulator maintenance schedule.
CAUTION
Check the direction of rotation of the granulator motor in relation to the arrow on the rotor.
If the rotor rotation is incorrect, turn off the granulator, turn the main disconnect to Off, unplug the
granulator and reverse phases.
Check all other accessories are correctly turned on (evacuating system, high level sensor).
Check the safety systems of the auger and the bin.
In case of any problem do not use the granulator until Wittmann service has been contacted.
CAUTION
If the safety systems are modified, Wittmann will not be responsible for any damage and/or accident
7 Start button
NOTE
The key for the electrical cabinet door is a safety component
The key must be kept by the person who is responsible for granulator safety, service, and
maintenance
Detection cycle:
Upon detection of a metallic part, the screw will stop and the alarm will sound
Turn the selection switch #5 to the position to reverse the screw direction until the metallic part(s)
can be seen; remove all metal parts found
Turn the selection switch #6 to the position R to reset the METALSTOP system
Turn the selection switch #5 to the position to choose the normal direction of the screw
Turn the selection switch #6 to the position to restart the screw
CAUTION
Hold the auger carefully while opening
DANGER
Under no circumstances should the operator attempt to reach into the auger to dislodge any bridged or
jammed material while the granulator is in operation
To clear the auger of jammed material, the granulator main power must be turned off and the
granulator isolated
MODEL_V00_M2A_Eng. 10.23.2015 Operation and Installation Manual
Page 31
8.6 Overfilling and stoppage of the granulator
If the granulator is overloaded so that the cutting chamber is jammed, engage the Emergency stop
button and turn the main disconnect to Off, then unplug the granulator from the electrical supply
Open the auger carefully
If the cutting chamber has jammed, use a wooden pole and carefully try to release the rotor in reverse
rotation direction.
Clean the auger, cutting chamber, and regrind collection bin
Reset the granulator motors overload protector in the electrical cabinet
Determine the cause that resulted in the overfilling of the granulator:
- Check the auger, regrind collection bin, and outfeed (blower or vacuum tube)
- replace, or adjust the combs and breaker knives, refer to the chapter 10.
Determine for the cause of the stoppage in the auger. The auger feed speed (metering rate) may be
too high or the pieces too large
Clean the auger and lower the metering rate
The cutting chamber is overfilled: determine for the cause of the overfilling in the cutting chamber (see
previous section)
NOTE
Before troubleshooting, attending to mechanical faults, and maintenance work, switch Off
the granulator main switch and break the power supply to the granulator and disconnect the
power plug
WARNING
IMPORTANT
Working clothes are necessary to avoid any risks of injury.
For each spare parts order, please contact the after sales service, Wittmann agency, or subsidiaries.
Do not forget to mention: Type of granulator, serial number, item code of the parts required and
quantity needed.
All parts which are not from Wittmann are forbidden.
NOTE
When the cutting chamber door and the auger have been removed for service or maintenance, we
recommend that the cutting chamber is covered to avoid injury.
For each maintenance on the gear motor, refer to the chapters 17.2.
Unbrako screws
Thread Factor of rubbing 8.8 10.9 12.9
12.9
WARNING
Shut Off and Lock out all power, including the main disconnect switch
All service must be carried out by trained personnel in order to avoid personal injury or damage to the
granulator.
Remove the bolts holding in the bearings (reference 2) and pull out the entire cutter assembly.
Remove the toothed rollers and knives one at a time from the splined shaft.
Clean thoroughly the inside of the bearings and the anti-dust fillets reference 3 and 4 and lubricate the
shaft with high temperature resistant grease.
The cutting edges of rollers must be placed in direction to the cutters (reference 6A and 6B).
Mount the shaft on the granulator and tighten the screws of the bearings.
Make sure the assembly moves freely by slowly turning the rotor back and forth (reference 7).
Put back the gear motor and the shaft end screw.
Tighten the fastening screws (reference 1).
Unlock the cutting chamber, swing back the feed hopper and clean the granulator thoroughly with
vacuum and compressed air.
Take the new scrapers and fix them in the middle of their support, push back until they stop (reference
3) and lock fastening screws.
Take the new combs, place them in their support and fix with their screws (reference 2).
Do not tighten the screws too much in order to allow a margin / gap.
Close the cutting chamber (reference 8) and check whether the rotor turns without interference and
noise. You can use a wrench on the end-shaft to rotate.
Turn the rotor through 360 in both rotation directions to ensure clearance with combs (reference 9).
Toothed rollers, and knives are made of core treated steel. This enables the customer to sharpen
them several times.
You should not wait until their maximum wear.
Their lifetime increase by sharpening them regularly (the sharpening frequency hereby depends on
use and wear).
Scrapers have to be replaced when both sides are worn off.
Properly sharpened cutting tools improve performance of the granulator by providing higher
quality regrind.
Use fine-grained grinding wheels (CORADIN type).
It has to be carried out by surface grinding only of the two large faces of combs.
The thickness should never be less than 13 mm
For perfect cutting, the teeth angles must not show visible rounded edges.
Minimum thickness = 13 m
Sharpening the toothed rollers must be accomplished on a grinding machine with grinding wheels by a
specialist, to who this sheet is to be handed out.
Helix angle = 8
WJ5 WJ7 CJ4 CJ5 CM4 CM5
e 0.4 0.4 0.6 0.6 0.6 0.6
WARNING
The outside diameter as well as the lower halves of the teeth profiles may not be changed.
Surfaces to be
sharpened
Surfaces to be
sharpened
Surfaces to be
sharpened
Unbrako screws
Thread Factor of rubbing 8.8 10.9 12.9
12.9
WARNING
There is a pinch risk during closing, be careful
Install the regrind collection bin, slide the regrind bin on the guides and push it firmly to stop.
Clean the outside of the granulator.
Close the auger.
CAUTION
Hold the auger carefully while closing.
All troubleshooting must be accomplished with the power Off, line fuses removed, and with the granulator
tagged as out of service.
The utmost in safety precautions should be observed at all times when working on or around the granulator
and the electrical components.
WARNING
The operations of checking of alarms and the breakdowns must be carried out by specialized staff.
A specialized employee is a person, who, thanks to his preparation, experience, and specific
knowledge is authorized to carry out a work of control and prevention.
Motor is connected on 2
Review electrical installation
phases
Reduce amount / size of material put into
Excessive power
the granulator
required: thermal relay Overloading of the granulator
activation or blown Granulator capacity does not correspond to
fuses the required job
Rollers are dull Resharpen or replace and re-install
Roller/comb gap is too large Adjust to proper gap specification
Reduce amount / size of jammed material
Overloading
put into the granulator
Clear the jammed material then visually
Granulator stalls
Parts jammed in the rotor inspect the rotor to ensure it is not damaged
and that the comb gap is correct
Screw is blocked Turn backward to release the material
Rotor is turning in the wrong Check the rotor direction with the arrow
direction Change the wiring inside the electrical plug
Material is mashed / Replace or sharpen rollers/combs
crushed and not cut
Rollers/combs are dull Replace or sharpen rollers/combs
Rotor turns in the wrong Check the rotor direction with the arrow
direction Change the wiring inside the electrical plug
Rollers/combs are dull Resharpen or replace and re-install
IMPORTANT
Possible damage to the granulator due to non-original spare and wear parts
Always use original spare and wear parts from Wittmann
NOTE
The item numbers for electrical components can be found in the "Designation list in the circuit
diagrams