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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
Granulators MAS2A 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 MAS Series granulators are rugged, rotary-cutting machines specifically designed to cut, chip and
granulate plastic materials with a minimum expenditure of horsepower.
Granulators MAS2A is equipped with a 3-blade open rotor design which gives an efficient scissor
cutting action and optimize the cooling effect.
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 auger, conveyed along the screw and falls down into the cutting
chamber, where rotating knives cut the material against fixed knives to granulate.
A perforated screen determines the size of the granulate.
The screen is located in the lower section of the cutter housing and can easily be changed to give the
desired granulate size.
The granulate passes the screen 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.
Fixed blades 2
Rotating blades 3
Drawing MAS2873
6.5.1 Auger
The cutting chamber is a rectangular enclosure comprising the main frame, the fixed knives, a
balanced rotor and a screen.
The screen is supported in position below the rotor and acts as a separating barrier to the granulated
material, retaining the material in the cutting chamber until the particle size is such that it will pass
through the screen holes.
The screen is pulled out from the side for quick access into the cutting chamber.
Different screen holes sizes are available as options.
The rotor carries the rotor knives. The rotation of the rotor produces a cutting action between the rotor
knives and the stationary knives, thus reducing the material size.
Cutting chamber
MAS2A
The granulated material that falls through the screen is collected by the collection bin located beneath
the cutting chamber.
The regrind collection bin is equipped with an swivel 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
*Serial number is also inscribed on topside of cutting chamber and behind the trap door.
NOTE
Please specify the serial and item numbers in the case of questions, complaints, spare parts
orders, etc.
Knife gap pre-adjustment fixture to pre-set the knife gap outside the granulator.
Capacitive detector for regrind bin level (probe is located underneath cutting chamber) with sound and
visual alarm.
High level detection sending of a signal to Wittmann Feedmax hopper loader with connector and 6
metre cable, adjustable timer before to stop the granulator.
Hour counter to schedule preventing maintenance on granulator.
Auto reverse system (ARS) on auger rotor.
Water cooling jacket on auger tube.
Water cooling circuit with internal water channel on attack side of cutting chamber.
Metal detector on the auger type METALSTOP.
Polycarbonate transparent hopper on auger for robot feeding.
Remote control box.
Lower frame.
Extended auger tube (+200 mm / 7.87 in).
Symmetrical execution for MAS2A with opening reversed.
Inertia fly wheel for more inertial energy for thicker cross-section parts
Lever tool for easier screen removal.
Selection of screens ranging to 4 and 8 mm.
- Standard screens with straight.
- Conical holes best suited for very soft materials as PU.
-Slanted holes best suited for sprues/runners with longs with smaller diameter compare to the
screen.
Kits of wearing parts.
Custom painting.
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
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 accidents.
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.
9.1 Lubricant
9.1.1 Bearings
Sharpening or
Round cutting parts
replacement
Blades / knife Clearance between fixed According to usage
Knife retaining screws for
and rotated knife 0.25 mm
tightness
Screen According to usage
Clean and check the
Checking of the thread
thread of the anti-dust If dirty or obstructed Annually
on anti-dust part
rings
Check, tightening and
Safety switch Malfunction
change if necessary
Clean the holes with
Cleaning of bearings If dirty or obstructed Weekly
airgun
Check and change if Gap between fixed and
Anti-wrapping blade Round cutting parts
necessary rotated knife 0.25 mm
Blade / knife, screen
Screws for tightness
auger, cutting chamber
Unbrako screws
Thread Factor of rubbing 8.8 10.9 12.9
12.9
NOTE
All knife positions must be properly cleaned and free from oil, grease and dust.
Use a plastic or rubber mallet and knock/hammer the knives down and in against the rear of the knife
position.
CAUTION
Before connecting the granulator, manually turn the rotor to check the gap between moving and fixed
blades ( to be sure they dont hit each other)
Recommended gap between 0.15 to 0.25 mm
MODEL_V00_MAS2A_Eng. 10.23.2015 Operation and Installation Manual
Page 38
10.3 Sharpening the knives
Under normal operating use, the cutting edge of the knives will eventually become dull, resulting in
reduced cutting efficiency.
The blunt knives may either be re-sharpened to restore the cutting edge or replaced with new knives
when resharpening is not possible.
When sharpening it is not harmful to allow a few small nicks to remain in the cutting edge.
Sharpening the cutting edge until perfectly clean can sometimes be wasteful.
All knives must be sharpened precisely to give the correct cutting and relief angles otherwise the
granulator loses its efficiency.
Pre-setting fixture to rotating and fixed knives (Optional).
The pre-setting fixture makes the knife installation simple and quick.
Both fixed and rotating knives should be pre-set before installing.
Moving blades:
Fixed blades:
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 screen and push it in the screen guides firmly to stop.
Install the regrind collection bin, slide the regrind bin in on the guides on the screen box and push it
firmly to stop.
Clean the outside of the granulator.
Close the auger.
CAUTION
Hold the auger carefully while closing.
Open clamp and tilt on the side the auger Use a vacuum cleaner
Remove regrind from holes with air gun or Finish cleaning with vacuum cleaner and rag
screw driver
Slide the clean bin and close the clamps Connect and start to check operation
All troubleshooting must be accomplished with the power off, line fuses removed, and with the machine 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 qualified staff.
A qualified 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
Blades are dull Resharpen or replace and re-install
Blades gap is too large Adjust to proper gap specification
Reduce amount / size of feedstock put into
Overloading
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 knife 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 knives
crushed and not cut
Blades are dull Replace or sharpen knives
Long granulate Blades gap is too big Adjust to proper gap specification
Rotor turns in the wrong Check the rotor direction with the arrow
direction Change the wiring inside the electrical plug
Knives 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