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User Operating Guide

Machine Type/Designation
ACS-HTM Compacting and Pelletizing System

ACERETECH MACHINERY CO.,LTD


Address: No. 18 Yuefeng Road, Nanfeng Town, Zhangjiagang City, Jiangsu, China
Tel: +86-512-58622012
Fax:+86-512-58622013
E-mail: info@aceretech.com
Web: www.aceretech.com
ACS-HTM Compacting and Pelletizing System Operation Manual

Introduction

Thanks for choosing the equipment from ACERETECH Machinery company, in


order to operate the machine more convenient and to assure the best
performance the machines present, please seriously read this operation
manual before you operate the machine. The incorrect operation may cause
the danger or trouble and reduce the machine’s using-life.

The operation manual not content related electrical spares and mechanism
spares, and neither fully mentioned every accident or risk which may be
happened during the period of machine installation and maintenance. Please
contact with ACERETECH Machinery, if you want to get more information or if
more problem happens to the machine.

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ACS-HTM Compacting and Pelletizing System Operation Manual

Safety Attentions

Dangers
 Incorrect operation will cause death, serious damage to life, or property
loss;

 Please make sure that it is under the premise of full power down, when
open the electrical cabinet. Any live operation can cause personal injury
accident.

 Please make sure that do not stand in front of machine head, when
machine running with materials;

 Please make sure that do not touch the electrical heater, when machine
starts to heat, otherwise, may cause the scalding.

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ACS-HTM Compacting and Pelletizing System Operation Manual

Cautions
 Incorrect operation will cause regular life damage or equipment damage;

 Incorrect rotating direction of main motor will cause the machine damage;

 The machine shall avoid running without raw materials, otherwise it may
damage the machine;

 Please make sure seriously that avoids rigid materials, such as metal,
stone etc., entering into the feeding throat, otherwise it may damage the
machine;

 The connections among the barrels, flanges, die sections, shall choose the
qualified fasteners which hardness grade is higher or equal to 12.9;

 The installation job shall follow the operation instruction;

 Detailed electrical programming, please reference to equipment electrical


drawing;

 The electrical maintenance must be done by the qualified electrical


engineer;

 Please use the right lifting instruments and follow the lifting guidance
during transporting the machines, to avoid machine damage;

 When equipment maintenance, please take preventive measures,


suspension warning signs, or it may cause dangerous accidents.

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ACS-HTM Compacting and Pelletizing System Operation Manual

 01. Application………………………………………………………………………06

 02. Main technic parameters………………………………………………………07

 03. Structure explanation and working principle …………………………………


09

 04. Lifting and installation of extruder ……………………………………………12

 05. Commissioning ………………………………………………………………13

 06. Maintenance …………………………………………………………………15

 07. Schematic diagram of gearbox structure………………………………………


19

 08. Schematic diagram of screw disassembly ……………………………………


20

 09. Equipment outline drawing ……………………………………………………21

 10. Equipment lifting drawing………………………………………………………22

 11. Safety precautions mark ………………………………………………………23

 12. Other related documents


Electric principle diagram
Touch screen operation manual
Quality certificate
Packing list

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ACS-HTM Compacting and Pelletizing System Operation Manual

 01. Application

ACS-HTM series compacting and pelletizing system mainly applied for plastic
scrap recycling and pelletizing, especially suitable to the low-bulk density
materials, such as film, foams, woven bag, ribbon type filaments, etc, can
handle the above mentioned materials of PE, PP, EPS, PA, PET, etc., by the
steps of material conveying, compacting, plasticizing, extruding, filtering and
final making the granules. To expand the machine’s usage, additional feeding
throat for rigid plastics equips, to handle the rigid plastic scrap re-pelletizing
job.

For different materials, ACS-HTM can combine with various pelletizing system,
such as strand cutting, water-ring, air-cooling hot face cutting and under-water
pelletizing system.

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ACS-HTM Compacting and Pelletizing System Operation Manual

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ACS-HTM Compacting and Pelletizing System Operation Manual

 02. Main technic parameter

Compactor

Model: AC800
Compactor room volume: 800L
Motor power: 90KW
Stationary blades quan.: 5 (includes
one blades with temperature sensor)
Rotating blades 1 quan.: 3 blades*4
Rotating blades 2 quan.: 3 blades*4

Single screw extruder

Model: ASE100/36
Screw diameter: Φ100mm
Screw L/D: 36:1
Maximum screw RPM: 120r/min;
Main motor power: 110kw
Heating zones and power: 5 zones of
barrels, 7kw*5
Barrels’ cooling method: 5 fans,
0.55kw*5
Cooling fan of inlet barrel: 0.55kw
Center height: 1180mm

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ACS-HTM Compacting and Pelletizing System Operation Manual

 03. Structure explanation and working principle

ACS-HTM series compacting and pelletizing system consists of belt conveyor,


compactor, single screw extruder, vacuum degassing, filtration and water ring
pelletizing unit, electric cabinet, etc.
Single screw extruder, as the main machine, composed of main motor,
gearbox, extrusion section (screw, barrel, feeding seat, heating and cooling
unit), machine frame, die section flanges.

 Compactor
Mainly to compact and change raw material’s bulk density, to improve the
efficiency on materials feeding into the single screw extruder. Its working
principle is: through the high speed rotation of rotating blades, which
assembled on the rotating-blade disc, the material will act the circular motion;
thanks to the strong shear between the rotating blades and stationary blades,
the materials will be continuous crushed and compacted. The strong shear
also brings high shearing hot, which will make the materials shrinking and
enlarge material’s bulk density. By the circular motion and guidance plate
which assembled aside of compactor’s room inner, the compacted and
shrinking materials will be enforcing feed into the inlet throat of extruder.

 Single screw extruder

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ACS-HTM Compacting and Pelletizing System Operation Manual
 Screw
It is the key part to realize the plastic material conveying and plasticization; By
screw’s rotation, the plastic material goes forward, to finish the processing of
compacting, melting, homogenization. The screw composes of different
functional sections, to realize better performance of conveying, compacting,
homogenization and plasticization. Material of screw adopts qualified nitride
steel(38CrMoAlA), process of CNC, with nitride treatment, has the ability of
corrosion resistance and wear-resisting. With the specialized design of screw,
even running with high speed, the material of polyolefin can be well melted
under lower temperature and lower melting pressure, which can assure the
final pellets’ quality and present higher capacity output.

 Barrel
It is part of screw pair, made of nitride steel, inner surface with nitriding
treatment, to present higher surface hardness and better wear-resisting. 5
zones electric heaters will be assembled outside of barrel. The hot energy
generated by heaters transmits through the barrel to the inside plastic
materials, makes the plastic melting; with the temperature sensors and cooling
fans which assembled on each heating zone, the heating temperature is
automatically controlled according to the process requirement.

 Feeding seat
It set between the gearbox and barrel, to realize the connection with outlet of
compactor, to let compacted materials enter into screw; cooling groove set on
outline surface of feeding seat, to avoid the passed materials over-heating and
let materials enter into screw channel smoothly; Internal spiral groove structure
set in feeding seat inner room, to guarantee higher output requirement.

 Drive system
It is set under certain processing condition, to let screw rotate at necessary
RPM with enough torque output, to realize the plasticization and conveying
performance of plastics; The screw maximum RPM may vary to fit different
kinds of plastics processing requirement. ACS-HTM system adopts AC motor
drive, to connect with gearbox by coupling; speed of motor controlled through
inverter, to realize screw RPM adjusting smoothly and stepless; RPM of screw
shown on touch screen.

 Gearbox
ACS-HTM adopts high strength hardened reducer; Due to the compact
structure and small center distance, the gearbox cannot be configured larger
models of bearings, therefore, it is necessary to ensure that concentrate both
coupling of motor drive and gearbox, to reduce effect of additional
bending-motion to the bearings, which may affect the bearing using-life.

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ACS-HTM Compacting and Pelletizing System Operation Manual
Ensure that the gearbox have sufficient lubricating oil during machine
running, and make sure that, to inspect the oil level regularly.

The lubricating oil is the 150# middle load industrial gear oil or other high
quality lubricating oil with similar viscosity.
During the machine running, if noise of oil pump increased, the general
situation is because that oil is too dirty, needs to change the oil filter and other
related auxiliary.

 Heating/cooling system
With the change of screw speed, extrusion pressure, heating and extruder’s
surround medium temperature, the temperature of the material in barrel will
change accordingly; to ensure the plastic raw materials extruding under certain
required processing temperature, heating and cooling system configured.
ACS-HTM adopts electric ceramic heaters, transfer the heat energy through the
barrel to the plastic raw material; barrel cooled by air fans; both heating and
cooling actions automatically controlled.

 Die flange
It is to connect the screen changer with barrel outlet, equip with heating ring, to
avoid the inside melting plastic cooling.

 Vacuum degassing
Its function is to remove the low molecule and remain moisture from the melts
which happened during the plastic raw material melting.
The vacuum degassing system consists of vacuum pump, vacuum room,
filtering tank, pressure guage and pipelines. Vacuum pump is water ring type,
forms the high negative pressure by the water sealing, suitable to waste gas
and water enforcingly separate.

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ACS-HTM Compacting and Pelletizing System Operation Manual

 04. Lifting and installation of extruder

 Lifting
The base frame of extruder opens rectangular holes to lift/move the extruder;
forklift is recommended to lift/move the machine; if need crane lifting, choose
the rugged steel, insert the steel into the rectangular holes of extruder (avoid
the rugged steel moving on length direction), lift the machine following the
lifting drawing guidance.
Due to the unbalance weight of extruder causes the center of gravity shift
during the lifting/moving job, the rope winding on the hook shall be more than 2
circles, to avoid the hoisting rope sliding on the hook.

 Installation
 Check all necessary accessories and instruments before the
installation

 According to ground condition, position the machine with ground foot


bolt expansion bolt.

 For better managing installation location, in addition to consider the


factors of the process flow and convenience of stacking/transport, but
also the factors of coordination among the installation and disassembly
of various parts of the machine and water, electricity, gas
configuration.

 Concrete foundation basis, the foot bolt of machine embedded in the


pit bottom.

 After the basis dried, the machine is to be installed, the basic


installation needs to find the level ahead, which required data as:
horizontal straightness: 1/1000, left and right symmetry degree: 1/1000;
foundation should pay attention to the level of the ground, after the
level regulated to the requirements, fasten the ground foot bolts and fix
the machines.

 Connect the cables, water pipelines, air pipelines;

 Fuel the lubricating oil or grease to all required places.

 Final check after machine accomplish the installation and connection


according to the drawing.

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ACS-HTM Compacting and Pelletizing System Operation Manual

 05. Commissioning

 Preparation of commissioning
 Trial testing shall launch after the machine completed installed, check
the reliability of installation, such as fasten condition of connection,
sealing performance of pipelines, lubricating oil fueling level of
transmission parts, etc.

 The lubricating oil shall be fueled to reach the required level of oil
meter.

 Check the motors’ rotating direction, stop the machine immediately in


case main motor rotates in wrong direction.

Caution: avoid the machine running without plastic raw materials in long
time, which may cause the damage or accident on screw and barrel. In
case to check the rotating direction, ensure the machine running under
low rotating speed and control the running not more than 3 minutes.

 Set up temperature for compactor and heating zones according to the


raw plastic materials.

 Check all heating zones whether reaching setup temperature.

 Check the cooling water is ready or not.

 Check the interlock setup between the compactor and belt conveyor.

 Check the compressed air on the water ring bottom.

 Commissioning
 According to the process requirement, check each heating zone
temperature, after temperature reach the set value and kept among 45
minutes to 2 hours, then, machine can be started.

 At first time of machine trial, push the button of “one-button start”, the
machine will automatically start in a sequence; during the trial testing,
pay attention to motor’s current, temperature situation, noise which
may from compactor or extruder. Based on quality of final pellets,
adjust the machine online, till the machine presents the pellets meeting
the required shape and size.

 After trial testing finished, press the button of “one button stop”, the

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ACS-HTM Compacting and Pelletizing System Operation Manual
machine will automatically stop in a setup sequence; during the
machine stopping period, pay attention to the compactor, make sure
the materials in the compactor consumed mostly. When next time
machine running, ensure the temperature keeping more than 45
minutes after the set value of temperature reached.

 Interrupt operation
 Extruder interrupt in short time
In case that short time stop (including emergency stop), the heating system
can be continuous on, ensure the cooling of compactor and gearbox still
working, after trouble fixed, start the machine again.

 Extruder stop in long time


If the time of extruder stop needs more than the short time stop (e.g. the
materials in the compactor start to melt or the materials in the screw start to
degrade), long time stop process is necessary.

For long time stop, suggest pressing the button of “one button stop”, all parts
stopped in a setup sequence; after the machine fully stopped, open the
compactor’s door to check whether materials remain in the compactor room,
do necessary cleaning in the compactor room and remove the remain
materials from the compactor.

Caution: cooling system for compactor and gearbox can not stop until
the machine stopped more than 30 minutes.

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ACS-HTM Compacting and Pelletizing System Operation Manual

 06. Maintenance

 Empty the extruder


Before the maintenance start, shift the control system into manual model, start
the main motor to empty the extruder, then, shut down the power of whole
system.

 Disassembly the screw


During disassembling the screw, first remove the protective cover, which
installed on output shaft of gearbox back side, then, insert the screw mandrel
into the hole of gearbox back side at output shaft position, feed the screw
mandrel to push the extruder’s screw moving forward till the extruder’s screw
separates from the gearbox. Drawing shown as below:

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ACS-HTM Compacting and Pelletizing System Operation Manual

In case the extruder in cooling condition, start the heating ahead till the
temperature reach set value, then shut down the power and push the screw
out.
Coordinating with lifting instrument when disassembling the screw.

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ACS-HTM Compacting and Pelletizing System Operation Manual

 Clean the screw


Use the brass wire brush, brass scraper or aluminum scraper to clean the
screw, avoid scratching the screw surface.

 Screw installation
Installation steps: Push the screw to connect with gearbox’s output shaft
through the two keys on the bottom of screw shaft (key) and key-seats inside
of gearbox’s output shaft (key seat).
Method to let the keys aim to key-seat: rotate the coupling manually and slowly
till the key insert into the key seat, then, push again the screw to the direction
of output shaft till the keys fully enter into the key seats.

Caution: during the installation, do not use force so as not to damage the
keys and keyways. In case installation has problem, pull the screw out
and install the screw after problem found (see detailed schematic
diagram), soft hoisting rope suggested to lift the screw (the rope need
special treatment in case of the screw with high temperature), cannot use
iron, steel rope to lift, to avoid damaging the head or bottom of the screw.

 Clean the barrel


In regular situation, no necessary to clean the barrel inner surface; in case that
cleaning the barrel inner, shall clean the barrel after the barrel well heated; use
the semi-round shovel to clean the remain melt inside of the barrel till the
remain melt removed clearly.

 The machine operation needs full time operator, dress qualified safety
clothes during the machine operation.

 Lubricating oil
 Extruder’s gearbox
Fill the lubricating oil of no. 150 medium duty industrial gear oil.
Recommend to change the oil every year at least one time; oil changing
circle based on the oil temperature within 70℃ at the gearbox running.
When gearbox running, the oil temperature higher than 70 degrees,
means the oil needs to be changed.

During the machine running, discharge the oil from the gearbox in a small
amount, then, fill the fresh lubricating oil, repeat the actions till the
discharged oil from gearbox looks cleaning with light color.

When the extruder stopped, discharge the oil from the gearbox at the
normal temperature, after all oil discharged, refill the cleaning oil till the oil
reach the level of the oil meter; regularly operation as: change the oil after

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ACS-HTM Compacting and Pelletizing System Operation Manual
first 400 hours running, then, change the oil after every 3000 hours
running.

 Motors and other reducers


Rated 1500 RPM motor, grease shall 1/3 full of bearing room;
Rated 3000 RPM motor, grease shall 1/2 full of bearing room;
In general situation, all motors already filled with grease, after every 5000
hours running, need to change or refill the grease.
Warm gear reduce needs to be checked and refilled the grease before it
unning, fill level shall reach the center of oil meter, and change or refill the
grease after every 2500 hours running.

 Heating component
During install the heating components (such as die-flange, die-connection,
etc.), put the anti-temperature grease on the surface of each screw bolt
ahead.

 Gearbox and its sealing and bearings


Schematic diagram see the detail drawing below;

 Cautions on installation/disassembly the gearbox:


 In the gearbox, the dividing gap and the bearing cover must be coated
with 515 anaerobic adhesive or similar sealing material;
 Change the related sealing materials every time, in case open the
gearbox;
 Ensure all position holes and connection surface cleaning enough
when fasten and install the components of gearbox.

 Consumption spares of gearbox


No Name Specific. Qua No. Name Specific Qua
. n. n.
1 Input shaft 1 8 Big gear 1
2 Oil sealer FB65×90×1 2 9 Output shaft 1
0
Spherical 32313(65*1 thrust 29428(140*2
3 2 10 1
Roller 40*51) self-aligning 80*85)
Bearings roller bearing
Deep groove 6230C2(150
4 Bridge shaft 1 11 1
ball bearing *270*45)
Tapered 32315(75*1 FB150*180*
5 2 12 Oil sealer 1
roller bearing 60*58) 12
6 Oil sealer FB100×125 2 13
×12
Cylindrical 22222CA/W
7 1 14
roller bearing 33(110*200*
53)

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ACS-HTM Compacting and Pelletizing System Operation Manual

 07. Schematic diagram of gearbox

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ACS-HTM Compacting and Pelletizing System Operation Manual

 08. Schematic diagram of screw disassembly

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ACS-HTM Compacting and Pelletizing System Operation Manual

 09. Equipment outline drawing

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ACS-HTM Compacting and Pelletizing System Operation Manual

 10. Equipment lifting drawing

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ACS-HTM Compacting and Pelletizing System Operation Manual

 11. Safety precautions mark

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ACS-HTM Compacting and Pelletizing System Operation Manual
A1= Warning Caution burns

A2= warning caution mechanical wounding, only can remove the safety cover
when the machine stops

B1= warning electric shock risk

B2= rotate follow the arrow directing

A3= the machine must be grounded

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