Instructions For Operation As Delivered En-1

Instructions for operation
Pelletising Plant
INTAREMA® 1714 T
P-20170149
Machine manufacturer and copyright owner
EREMA
Engineering Recycling Maschinen und Anlagen Ges.m.b.H.
Freindorf - Unterfeldstraße 3 - P.O.B 38
A-4052 Ansfelden/Linz, AUSTRIA
Phone: (43)732/3190-0, Fax: (43)732/3190-23
e-mail: erema@erema.at
As per 2018-03
General The subject operating instructions help you familiarize with the machine/plant and its
range of applications according to its intended use.
The operating instructions include important information about the reliable, proper and
economic operation of the machine/plant. If you strictly observe these instructions, you
can preclude possible hazards, reduce the repair cost and downtimes and increase the
operational reliability and lifetime of the machine/plant.
Ensure that the subject operating instructions are supplemented with the applicable
national regulations for the prevention of accidents and environmental protection
regulations.
The subject operating instructions must be carefully read and observed by all personnel
entrusted with any operations to be carried out at the machine/plant, such as:
operation, including fitting, failure elimination during operation, waste disposal,
maintenance, disposal of utilities and auxiliaries and maintenance (corrective
maintenance, inspection and repair).
Note that also the general technical provisions for workmanlike operation must be
complied with in addition to the subject operating instructions and the mandatory
national regulations for the prevention of accidents applicable in the country of
destination and at the place of installation.
Signs
and symbols In this operating manual the following graphical symbols are used:
resp. .....describes a functions of an operating and control element.
001 ..... reference to a maintenance instruction.
.... reference to operating and maintenance manuals for purchased parts. (motors,
gears, aggregates, controllers,....)
Trademarks Any company- and product names mentioned in this manual are registered trademarks of
the respective companies.
Use This manual is intended for your own use only.

The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event
of the grant of a patent, utility model or design. (DIN ISO 16016).
Reservation The mentioned data are intended to describe the product and shall not be understood as
properties warranted in the legal sense. Any claims for indemnity made against EREMA
are excluded, irrespective of the legal ground, unless intention or gross negligence apply.
Manual EREMA documentation (Instructions for operation)

I contents page
Chapter 1 Safety instructions and warning signs ............................ 7

Danger classification ............................................................................................ 8
General ..................................................................................................................... 9
Organisational measures .................................................................................... 9
Selection of personnel, qualification, basic duties .......................................... 10
Personal protective equipment ........................................................................ 10
Transport and installation of the machine/plant ............................................ 10
Proper use.......................................................................................................... 11
System limits ..................................................................................................... 12
Safety-relevant components ............................................................................ 12
The following hints must be observed when using the product (residual
risks) .................................................................................................................. 13
Safety regulations regarding specific operating phases ........................... 15
Normal operation .............................................................................................. 15
Special operations within the range of application of the machine/plant .... 16
Special risks .......................................................................................................... 18
Electrical energy ................................................................................................ 18
Hydraulics, pneumatics..................................................................................... 18
Noise .................................................................................................................. 19
Oil, grease and other chemicals....................................................................... 19
Environmental protection ................................................................................. 19
Gas, dust, vapours, smoke .............................................................................. 20
Excess pressure, explosion .............................................................................. 20
Chapter 2 Transport, installation and mounting ............................ 21

General ................................................................................................................... 22
During transport ................................................................................................ 22
Storage .............................................................................................................. 22
Accessories included in the scope of supply ................................................... 22
During installation ............................................................................................. 23
Flatness tolerances ...................................................................................... 23
INTAREMA Process Combination I_1714_T ................................................ 24
Powered Exhaust System SAS_2500 ............................................................ 28
EREMA Backflush Filter SW_4_170_RTF ...................................................... 29
Screen changer hydraulic unit ......................................................................... 30
Automatic Strand Pelletizer ASP_200_SERIE ............................................. 31
Pellet Dewatering Screen GS_2010_1000 ................................................... 34
Water Pump Station WPS_300 ....................................................................... 36
Pellet Drying Centrifuge GZ_1000_M11 ....................................................... 37
Pellet Transport System FG_40 ...................................................................... 38
Pipe routing for pellets conveying ................................................................... 39
Control cabinet..................................................................................................... 40
Chapter 3 Startup and shutdown ...................................................... 41

II contents page
Overview of utilities and filling quantities.................................................... 42

Start-up .................................................................................................................. 43
Shutdown .............................................................................................................. 45
Preparing for transportation ............................................................................ 46
Putting into operation after long shutdown ................................................. 46
Chapter 4 Description of operating and control elements ............ 47

Control panel ........................................................................................................ 48
General control and operating elements ....................................................... 49
Feeding .................................................................................................................. 50
Process Combination .......................................................................................... 51
Backflush Filter .................................................................................................... 52
Pelletizing system ............................................................................................... 53
Simatic panel ........................................................................................................ 54
Entry of actual value and setpoint value ................................................... 54
feeding ............................................................................................................... 55
feeding selection .......................................................................................... 57
extruder ............................................................................................................. 58
melt filter ........................................................................................................... 61
piston 1 ........................................................................................................ 62
downstream equipment .................................................................................... 63
screen saver ...................................................................................................... 65
archive ............................................................................................................... 66
alarms ................................................................................................................ 67
more functions ............................................................................................. 68
recipes ................................................................................................................ 69
SERVICE CONFIGURATION ............................................................................... 75
Log on........................................................................................................... 75
SERVICE FEEDING ....................................................................................... 77
SERVICE CUTTER COMPACTOR .................................................................. 78
SERVICE MELT FILTER ................................................................................ 79
SERVICE DOWNSTREAM EQUIPMENT ........................................................ 81
SERVICE GENERAL ...................................................................................... 82
Log on........................................................................................................... 82
Chapter 5 Description of function and control sequences ............ 85

Flow sheet ............................................................................................................. 86
Process Combination .......................................................................................... 87
Feeding material into the cutter compactor in auto mode ............................ 88
Setting................................................................................................................ 89
Setting the intake slide at the cutter compactor ............................................ 90
Setting the slide bar at the grooved bushing of the extruder ....................... 91
Extruder liquid cooling system ......................................................................... 92
Automatic tracking control of extruder screw ................................................. 93
Backflush Filter .................................................................................................... 94
Flow sheet - schematic of melt filtration ......................................................... 94
III contents page
Logic diagram - schematic of piston movement ............................................. 95

Correlation between backflush pressure, backflush rate and lifetime of a
screen pack........................................................................................................ 96
Selecting the proper backflush nozzle for backflushing ................................. 97
Determining the optimum backflush melt flow for screen flushing .............. 98
When to change the screen pack ..................................................................... 99
Selecting the proper screen packs ................................................................... 99
Safety solenoid interlock .................................................................................101
Limit switch .................................................................................................102
Strand pelletizing system.................................................................................103
Flow sheet - schematic of material flow .........................................................104
Chapter 6 Operation .......................................................................... 105

Starting the plant ...............................................................................................106
Shutting down the plant ...................................................................................109
Feeding .................................................................................................................110
Feeding customer .............................................................................................111
Process Combination .........................................................................................112
Start-up ............................................................................................................112
Restarting the machine after a shut down under full load ...........................113
Shutdown ..........................................................................................................114
Backflush Filter ...................................................................................................115
Start-up ............................................................................................................115
Changing the screen and the backflush nozzle .............................................117
Pelletizing system ..............................................................................................120
Prior to start-up................................................................................................120
Switching on .....................................................................................................120
Switching-off ....................................................................................................120
Chapter 7 Maintenance and Repair ................................................. 123

Overview of maintenance work ......................................................................124
Work to be carried out (daily – every 1000 hours).......................................124
Work to be carried out (every 2000 hours - after 25000 hours) .................126
Overview of lubricants ......................................................................................128
General drawing - maintenance work...........................................................130
Process Combination .........................................................................................131
Dismounting and mounting the rotor knives .................................................131
Regrinding the rotor knives .............................................................................132
Rotor knife holders ...........................................................................................132
Maintenance of the cutter compactor bearing ...............................................133
Maintenance of electrical intake slide .............................................................134
Oil change ...................................................................................................134
Maintenance of the powered exhaust system ...............................................135
Maintenance of the extruder drive .................................................................136
Rotex-coupling .................................................................................................137
Lubricating the main drive motors .................................................................138
Extruder screw .................................................................................................139
Dismounting ................................................................................................139
IV contents page
Mounting .....................................................................................................140
Extruder cooling system ..................................................................................141
Criteria for changing the thermal oil .........................................................141
Thermal oil change .....................................................................................142
Measures taken to increase the lifetime of the thermal oil .....................142
Maintenance of pump .................................................................................143
Cleaning the filter .......................................................................................143
Maintenance of tube heat exchanger ........................................................143
Backflush Filter ...................................................................................................144
Cleaning the screen changer pistons ..............................................................144
If the piston gets seized ..................................................................................145
Checking the automatic positioning of the piston in venting position .........146
Maintenance the backflush breaker plate and the support breaker plate ...147
Cleaning the backflush breaker plate and the support breaker plate ..........147
Cleaning light sensor .......................................................................................147
Replacing the proximity switches ...................................................................148
Maintenance of the hydraulic system ...........................................................149
Hydraulic cylinders ...........................................................................................149
Changing the sealings ................................................................................149
Hydraulic unit ...................................................................................................150
Hydraulic hoses and piping .............................................................................150
Pelletizing system ..............................................................................................151
Automatic Strand Pelletizer .............................................................................151
Strand nozzle ..............................................................................................151
Strand pelletizer .........................................................................................151
Cleaning the filter candle ...........................................................................151
Pellet Dewatering Screen ................................................................................152
Vibrating motors .........................................................................................152
Maintenance of the vibrating screen .........................................................152
Screen insert ...............................................................................................153
Filter drum ..................................................................................................153
Water Pump Station .........................................................................................154
Maintenance of the water pump................................................................154
Cleaning the water basin and the heat exchanger ..................................154
Pellet Drying Centrifuge...................................................................................155
Cleaning the centrifuge ..............................................................................155
Removing the screen .................................................................................156
Maintenance of centrifugal dryer bearing .................................................157
Pellet Transport System ...................................................................................158
Belt drives ............................................................................................................159
General..............................................................................................................159
Maintenance .....................................................................................................160
Preventive maintenance ............................................................................160
Inspection intervals ....................................................................................160
Careful inspection/service..........................................................................161
Checking and adjusting the belt tension ........................................................162
Checking the tension of V-belt or synchronous belt .....................................163
By means of the Sonic tension tester .......................................................163
Mounting or replacing a synchronous belt (toothed belt) .............................164
Checking the belt tension with Sonic tension tester ...............................165
Mounting and dismounting the pulleys ..........................................................166
Dismounting ................................................................................................166
Mounting .....................................................................................................167
Maintenance of the electrical equipment .....................................................168
V contents page
Test EMERGENCY STOP switch and safety devices .......................................168

Mechanical inspection ................................................................................168
Electrical inspection ....................................................................................168
Maintenance of the pneumatic system .........................................................168
Chapter 8 Checking malfunction ..................................................... 169
Chapter 9 Technical data .................................................................. 181

Chapter 1
Safety instructions
and
warning signs
Before starting work on the machine, staff

must read the operating manual and in
particular the chapters relating to safety and
hazard warnings. This applies in particular to
staff who only work occasionally with the
machine, e.g. tooling, maintenance. The
owner/operator is responsible for observing
safety instructions!
8 EREMA Instructions for operation Chapter 1
Danger classification
The designations/signs listed below, which are included in the operating instructions or are
attached to the machine/plant, convey very important information:
NOTE is an important information about the product or the

respective part of the operating instructions which is
particularly referred to.
This also includes information regarding the economic use
of the plant/machine.
CAUTION special information/orders regarding loss

prevention/prevention of injuries,
special information regarding the prevention of personal
injuries.
ATTENTION special information/mandatory and prohibitory signs in

order to prevent machine damage
DANGER means that death, severe injuries or considerable damage

may be caused if the respective safety measures are not
taken.
electrical equipment!
Safety instructions and warning signs 9
General
Organisational measures
§ Make sure that the operating instructions are always available at the place of installation
of the machine/plant.
§ Take care that the general legal regulations or other mandatory provisions for the
prevention of accidents and for environmental protection are observed in addition to the
operating instructions.
§ Complete the operational instructions with such instructions including obligations to

supervise and report as take into account any operational particularities, e.g., regarding
the work organisation, work sequences, personnel employed, etc.
§ Before starting to work, the operating personnel at the machine must be familiar with the
operating instructions, in particular with the safety regulations and warning signs. When
already working at the machine it is too late to get acquainted with the respective
provisions. This applies particularly to personnel working temporarily at the machine, e.g.
for fitting operations, maintenance etc.
§ Check the personnel for working in accordance with the safety regulations and operating
instructions.
§ Use personal protective equipment if required or provided by regulations.
§ Observe all safety regulations and warning signs attached to the machine/plant.
§ In case of changes that are relevant with respect to the safety of the machine/plant or if
the operational performance has been changed, shut down the machine/plant immediately
and report to the department/person in charge.
§ Any modifications, supplements or reconstruction of the machine/plant that might impair

its safety must not be carried out without the approval of the supplier. This also applies to
the installation and setting of safety equipment and safety valves as well as to the welding
of bearing components.
§ Any spare parts must be in accordance with the manufacturer´s technical requirements.
This is always warranted in case of original spares.
§ Do not carry out any program modifications (software) to programmable control systems.
§ Make sure that mandatory periods or such intervals as are specified in the operating
instructions for periodical checks/inspections are observed.
(see also chapter 7 Maintenance and Repair, page 123 et seq.)
§ Note that the performance of any maintenance work requires an appropriate workshop
equipment.
§ For all activities on or with the machine, the owner/operator or the operating company
must ensure sufficient illumination in line with national occupational health and safety
regulations and/or in accordance with EN 12464-1.
§ Suitable fire extinguishing equipment, and alarm and escape plans in line with national
regulations, must be provided in the machine area; the operating staff must be instructed
in their use on an on-going basis.
Selection of personnel, qualification, basic duties
§ Note that any work to be carried out at the machine may only be performed by reliable
personnel. Observe the legal minimum age.
§ Employ only trained and sufficiently instructed personnel. Define personnel

responsibilities installation, regarding operation, fitting, maintenance and repair.
§ Make sure that only such personnel works at the machine as has been authorized.
§ Define responsibilities of machine operator and authorize him to refuse any third parties´
instructions that are not in compliance with the safety regulations.
§ Personnel to be trained or instructed may only work at the machine/plant under the
permanent supervision of an experienced person.
§ Any work at the electrical equipment of the machine/plant may only be carried out by
electrical engineers or persons that have been instructed accordingly. All such work must
be performed under the supervision of an electrical engineering specialist according to the
respective electrotechnical regulations.
§ Hydraulic equipment may only be handled by persons having special knowledge and
hydraulic experience.
Personal protective equipment
If required or provided by regulations and/or by instruction manuals, use personal

protective equipment such as work clothes, work boots, work gloves, ear protection, face
screen and helmet!
Transport and installation of the machine/plant
§ Use only but lifting equipment and load suspension devices that are designed for a sufficient
carrying capacity. Note that the facilities may only be operated by authorized personnel.
§ Appoint competent operators to give instructions during the lifting operation.
§ Make sure that the machines are lifted as described in the operating instructions (lifting
points for load suspension devices, etc.). Use appropriate hoisting gear for workmanlike
lifting.
§ Ensure all parts that have been dismounted for transport, are carefully mounted and
fastened before start-up.
§ The installation location must be well lit, on enclosed premises equipped with lightning
protection in order to be able to perform all work with the required degree of precision.
§ The owner/operator is responsible for sufficient ventilation and for safe and stumbling
hazard-free routing of the connecting cables (see space assignment plan).
Proper use
The INTAREMA® 1714 T Pelletising Plant comprises:
§ INTAREMA Process Combination I_1714_T:

cutter compactor, cutter compactor hood, optional water injection, cylinder with single
screw extruder, cylinder cooling, optional degassing with vacuum unit, optional dosing
systems, control cabinet, control desk with control panel.
§ Powered Exhaust System SAS_2500:

dedusting unit with suction fan.
§ EREMA Backflush Filter SW_4_170_RTF:

screen changer with hydraulic unit,
§ Strand pelletizing system (downstream)

comprising strand die SD_200_ASP, automatic strand pelletizer ASP_200_SERIE, pellet
dewatering screen GS_2010_1000, water pump station WPS_300, pellet drying centrifuge
GZ_1000_ M11.
§ Pellet Transport System FG_40:

transport blower, piping.
Workflow:
§ Feeding of plastic materials (scrap foil, fibers, foil, edgings, bottle flakes, etc.) via the
feed system to the cutter compactor in automatic operations or under manual control.
§ Cutting, mixing, heating, drying and pre-compacting of material in the cutter compactor.
Tangential feeding of feedstock through the cutter compactor rotor disk to the extruder.
§ Plasticizing and homogenization of material in the extruder.Onward feeding of the melt to

the filtering process in the melt filter.
§ Extraction of moisture and other additives from melt in the degassing unit (optional).
§ The melt is converted to regular, clean cylindric or nugget shaped pellets in the pelletizing
system. Subsequent cooling and drying of pellets in the downstream pellet cooling and
drying unit.
§ Optional feeding of pellets through conveyor blower through pipes to cyclone system or
cyclon-silo-combination.
§ Single-operator controls and/or automatic process with monitoring.
§ Perform maintenance and repair work in line with the "Overview of maintenance work"
(see Chapter 7 Maintenance and Repair page 123 ff.).
Operative range:
ATTENTION: For due application the prescribed operative range must be observed.
. . . operative range
Fig.1
NOTE: Special provisions must be made by the owner/operator for installation,

assembly, commissioning, operation and maintenance (platforms) in line with
EN ISO 14122 and national regulations. Safety distances to danger areas
must be observed as per EN ISO 13857.
System limits
§ The plant is suitable for processing the following materials: PET as well as
thermoplastics, provided that the user takes the necessary measures, depending on the
material.
If other material is used, dangerous operating states and/or emissions might be generated.
§ Ambient temperature: 5-40°C at max.

Relative humidity: 70% at max.
Max. altitude above sea level: 1000 m
No explosive atmospheres
Max. hydraulic pressure: 200 bar
Min. processing temperature: depending on the material
Max. processing temperature: as per polymer processing sheet.
Materials like duroplasics, rock, metal, etc. must not be used.
§ On the basis of EN ISO 11201 noise is measured at a distance of 1m and a height of

1.60m of points to be measured.
Safety-relevant components
§ The service life of the safety-relevant components is 20 years (please refer to the
electrical drawing for details of the safety-relevant components).
The following hints must be observed when using the product (residual risks)
§ The user may apply only input material as specified in the plant specification (see also
Chapter 9, Technical Data, page 182). If other material shall be used the manufacturer
must be consulted.
For input material like HDPE, LDPE, LLDPE, PP, PS and PA no dangers are known,
provided that the machine is duely applied.
If PVC is processed, chlorine, dioxine or hydrochloric acid might develop.
If POM is processed at a temperature of more than 220°C, formaldehyde might develop.
Typical soiling such as wood, paper, printing ink generate gases during processing. The
line operator must thus ensure extraction and safe disposal as a function of the risk.
§ Only material specified in the operating manual may be used. On no account duroplastics,
rock, metal, etc. shall be used.
§ In particular, the line operator must check the material for decomposition processes,
gasification, toxicity, fire behavior, and risk of explosion. The operator must take suitable
safety precautions as a function of the risk.
§ Lift the control cabinet exclusively with a suitable lifting crane.
§ During maintenance and repair work the master switch must be switched off and secured
against reclosing.
§ Prior to grinding and welding work at the machine it must be cleaned from combustible
matter and dust to avoid danger of fire and explosion.
§ Granulate residues must be removed from the floor. Þ Danger of skidding.
§ The cooling cirucit must always be drained-off unpressurized. This spot must be chosen in
such a way that no persons are injured by hot water or vapour.
§ During work at the cutter-compactor ensure sufficient ventilation, the master switch must
be switched off and secured against reclosing.
§ When exchanging knives in the cutter-compactor use recessed knives only! Check tight
seat of knife prior to start-up.
§ Every day all hydraulic conduits and connections must be visually checked for leakage. If
some damage is detected, it must be repaired immediately.
§ During work in the hydraulic circuit the hydraulic motor must be switched off and secured
against restarting.
§ Danger of burning when cleaning and exchanging the screen exchanger

screens and/or pistons. Þ Make sure to wear safety gloves!
§ Danger of splashing out of liquid melt when the screen exchanger piston is
extended. Therefore close the protection hood when the piston is moved.
§ The water at the pellet dewatering screen must be regularly checked for bacteria or other
hazardous substances.
In the case of a contamination, drain off the water and dispose of properly.
§ The water in the pellet dewatering screen can be acidic/alkaline or toxic

depending on the material to be processed. It is the owner/operator's responsibility
to ensure that the water is safely processed and disposed of to reflect their potential
hazardousness.
§ Danger of burning upon dismantling of heating strip and heating strip

connection elements. Switch off heating before and let it cool down.
Danger of burning when retightening screwed connections at the heating
plate and the heating strip. Þ Make sure to wear safety gloves!
Safety regulations regarding specific operating phases
Normal operation
§ Refrain from any working methods that are precarious from the safety point of view.
§ Take all measures so that the machine/plant is operated under reliable and safe conditions
only.
Note that the machine may only be operated if all safety equipment and protective devices
are available and in proper working condition, e.g., protective equipment to trigger,
EMERGENCY STOP devices, safety limit switches, sound absorbing equipment, suction
devices, etc.!
§ Check machine/plant once per shift for externally visible damage and deficiencies. Any
changes (including changes in the operational performance) must be immediately reported
to the department/person in charge. If required shut down and lock machine immediately.
§ In case of malfunctions the machine/plant must be shut down and locked without delay.
See to that the malfunctions are immediately eliminated.
§ Observe the switch-on/off procedures, control indications according to the operating

instructions as well as the warning signs attached to the machine/plant.
(see also chapter 6, Operation, page 105 et seq.)
§ Before putting the machine/plant into operation make sure that no persons are jeopardized
by the start-up of the machine/plant.
§ Do not switch off or remove suction devices and ventilation equipment with the machine
running.
§ Do not reach or lean into the operating cutter/compactor for visual inspection. Use
the sight glass provided on the side.
§ When changing the cutter/compactor knives insufficiently cleaned clamping

surfaces or improperly tightened clamping screws may endanger man and machine as
knives parts may be tossed about upon start-up of the cutter compactor.
§ When changing the screen changer screens observe the following:

- Use protective gloves ð DANGER OF BURNS.
- Wear SAFETY CLOTHING. In the case of highly liquid melts hot melt particles may
be tossed about due to the sudden pressure drop when the flow channel is opened for
the first time on extending the piston. Keep the cover plates closed when extending the
piston.
- Use insert tool when retracting the piston. Otherwise the screen changer may be
damaged by metal parts that might be chipped off and tossed about may endanger the
operating personnel.
Special operations within the range of application of the machine/plant
§ All activities and terms regarding setting, maintenance and inspection as well as exchange
of components/partial equipment that are specified in the operating instructions must be
strictly adhered to. Note that these activities may only be carried out by specialists.
(see also chapter 7, Maintenance and Repair, page 123 et seq.)
§ Inform the operating personnel before any special work or maintenance is commenced.
Appoint supervisor.
§ Observe all switch-on/off procedures specified in chapter 6, Operation (see page 105 et
seq.), as well as all maintenance instructions specified in chapter 7, Maintenance and
Repair (see page 123 et seq.), when performing any work regarding the operation,
production adaptation, retrofitting or setting of the machine/plant, its safety equipment as
well as the inspection, maintenance and repair.
§ Provide ample securing of the maintenance area if necessary.
§ For maintenance and repair switch off machine/plant completely and lock against
unexpected switching-on:
- lock master switch, remove key and
- attach warning sign at the master switch.
§ On exchanging individual components or large subassemblies fasten carefully and secure

at lifting equipment so as to preclude any danger. Use only proper and reliable hoisting
gear and load suspension devices with sufficient carrying capacity. Do not stand or work
under suspended loads.
§ Appoint only experienced personnel for slinging loads and instructing crane operators.
Note that the operator giving instructions must be within range of sight of and have voice
communication with the crane operator.
§ When performing overhead mounting work use appropriate working platforms and
climbing devices according to the respective safety regulations. Do not use machinery
components for climbing up. Use safety equipment to protect you from falling when
working at greater height (see applicable safety regulations).
Make sure that all handles, steps, landings, platforms and catwalks are clean.
Observe national occupational health and safety regulations!
§ Before commencing maintenance/repair work clean machine and particularly all

connections, bolts, nuts, and fasteners from oil and dirt. Do not use offensive detergents.
Use non-fibrous cleaning rags.
§ Make sure that any screwed connections which might have got loose during
maintenance/repair work are retightened.
§ Fixing screws with a load-bearing function must be checked at regular

intervals for tightness, and replaced with new screws if required!
§ Partial heating up of the machine can cause pressure peaks. Always start the heat-up
sequence beginning with the melt discharge to avoid excess pressure in the system and
ensure that the melt discharge is not under pressure.
§ If safety equipment must be dismounted for fitting, maintenance and repair, remount and
check immediately after completion of the maintenance and repair work.
§ Ensure that utilities, auxiliaries and exchanged parts are disposed in accordance with the
safety- and environmental regulations.
§ Use protective gloves when cleaning the screen changer pistons

ð DANGER OF BURNS.
§ Use protective gloves when retightening heating plates and strip heater bolts
and/or bolt/nut connections of flanges ð DANGER OF BURNS.
§ Make sure the heating zone is switched off before dismounting the strip heater.
Otherwise, damage to strip heater and risk of fire.
§ Insulating sleeves contaminated with heat transfer oil, or other flammable substances, must
not be remounted and must be replaced! ð DANGER OF FIRE AND EXPLOSION!
Operation of the barrel heating is not permitted when the insulating sleeves
are removed.
Special risks
Electrical energy
§ Use only original fuses having the required ratings. In case of failures of the power supply
shut down machine/plant immediately.
§ Any work at the electrical systems or equipment may only be carried out by electrical
engineering specialists or persons that have been instructed accordingly. All such work
must be performed under the supervision of an electrical engineering specialist according
to the respective electrotechnical regulations.
§ Mechanical components and plant parts that are subject to inspection, maintenance and
repair must be isolated. Check dead parts for isolation, then ground and short-circuit and
isolate adjacent live parts.
§ Inspect/check electrical equipment of a machine/plant periodically. Any deficiencies such

as loose connections or scorched cables must be repaired/replaced without delay.
§ If any work must be carried out at live parts be sure to be accompanied by a second person
to switch off the EMERGENCY STOP- or the master switch respectively in case of
emergency. Close off working area with a red-white safety chain and provide a warning
sign. Do not use but isolated tools.
§ Silo, cyclone and piping must be earthed by the owner/operator throughout, in order to
prevent electrostatic charge.
Hydraulics, pneumatics
§ Hydraulic equipment may only be handled by persons having special knowledge and
hydraulic experience.
§ Check all lines, hoses and screwed unions periodically for leakages and visible damage.
Repair immediately. Note that splashing oil may cause injuries and fire.
§ Prior to any repair depressurize system sections and pressure lines (hydraulic fluids,
compressed air) according to the respective descriptions of subassemblies.
§ Lay and mount hydraulic and compressed air lines correctly! Do not mix up the
connections - note existing identification marks! Fittings, length and quality of the hose
lines must meet the requirements.
§ Exchange hydraulic hose pipes at specified or reasonable intervals, even if no deficiencies

that might adversely affect the safety are discovered.
Noise
§ All sound absorbing equipment at the machine/plant must be used during operation.
§ Use personal ear protection according to regulations and instructions.
Oil, grease and other chemicals
§ Observe the respective safety regulations when handling oil, grease and other chemicals.
NOTE: See also "Data sheets of special oils and greases"!
§ Be careful when handling hot utilities and auxiliaries (danger of burns or scalds).
Environmental protection
For all work on and with the machine you must observe legal waste avoidance and
recycling/disposal requirements!
In case of installation, repair and maintenance work you must avoid substances harmful to
waters such as:
§ greases and oils
§ hydraulic oils
§ coolants
§ solvent-based cleaning agents
contaminating the soil or entering drains!

These materials must be stored, transported, collected and disposed of in suitable con tainers!
Gas, dust, vapours, smoke
§ Welding and grinding at the machine/plant may only be carried out upon express approval
supervisor. Fire or explosion hazard.
§ Before welding and grinding clean machine/plant and the surrounding area from dust and
remove combustibles. Ensure sufficient ventilation (explosion hazard).
§ To fulfil the safety precaution, local laws and terms, to get nitrogen or other operating
materials in the plant, is in the responsibility of the user of the plant.
§ Gases and vapors can occur during processing depending on the material to be processed.
It is the owner/operator's responsibility to ensure that the gases and vapors are safely
extracted and disposed of as a function of the risk.
Excess pressure, explosion
§ In particular, the line operator must check the material to be processed for decomposition
processes, gasification, toxicity, fire behavior, and risk of explosion.
The max. processing temperature as per the polymer processing sheet must not be
exceeded under any circumstances.
§ Thermoplastic materials which change to a gaseous state during processing are not
covered by intended use.
Chapter 2
Transport, installation
and
mounting
This chapter shows you how to transport,

install and mount equipment/machine
components and which supply lines and
connections are to be made.
When choosing an installation site, make sure
that you have sufficient space for assembly,
disassembly and maintenance work.
General
During transport
§ Ensure that lifting equipment and load suspension devices with appropriate carrying
capacity are used only. Note that the facilities may only be operated by authorized
personnel.
§ Observe the graphical symbols shown on the packing.
top center of sling here
§ Make sure that the machine/plant components is/are lifted at the lifting points only. Use
appropriate hoisting gear for workmanlike lifting. Follow lifting instructions shown on
machine.
§ Appoint competent operators to give instructions during lifting!
Storage
Truck carriage, air freight:

To prevent corrosion store individual plant components in a covered place or a confined space
respectively prior to installation.
Sea freight:
You can store the packed machine/plant up to 5 months in a covered place or a confined space
respectively and no corrosion will occur.
Make sure package may not be damaged by third objects. Unless otherwise stipulated, the
packing is in accordance with the HPE packing guidelines.
Accessories included in the scope of supply
§ Standard accessory package (see also: „Mechanical drawings, parts list“)

§ Screw pressure device (see also: „Mechanical drawings, parts list“)
§ Package including auxiliary tools
§ Kit of spares
NOTE: Please note that the kit of spares may only be opened in the presence of
an EREMA representative. Otherwise EREMA shall not warrant for
defective or missing components.
Transport, installation and mounting 23
During installation
§ Deploy only authorized staff with technical training and appropriate knowledge.
§ When choosing the place of installation, make sure there is enough clearance for
mounting, dismounting- and maintenance work. (see space assignment plan)
§ Make sure that the place of installation is accessible for hoisting gear so that individual
components may be removed easily and safely.
§ The installation location must be well lit and sufficiently ventilated on enclosed premises
equipped with lightning protection in order to be able to perform all work with the
required degree of precision.
§ Make sure that the foundation at the place of installation is level and compact so that no
deformation occurs. Check floor load prior to installation. Also check for possible
vibrations. (see foundation plan)
Make sure that supporting surface is made of cement, quality class C 25/30, according to
DIN 1045.
Flatness tolerances
Excerpt from DIN 18202:
Industrial floors
Distance (in m) between measuring

Maximum deviation in mm:
points of or below:
0.1 5
1 8
4 12
10 15
15 20
Table I
NOTE: For arranging the plant components, see also the "space assignment
plan" included in chapter mechanical drawings, parts list.
NOTE: Place the plant align levelly and horizontally.

Level out uneven surface (flatness tolerances ±1mm)!
M8 M10 M12 M16 M20

L L .... anchor length 75 90 100 140 170
hef h1 h 1 . . min. depth of drill 65 70 95 115 130
hole
h ef .. embedment depth 48 50 70 84 103
Fig.2 Anchor bolt
§ Use anchor bolts to fasten the plant parts.

NOTE: The anchor bolt diameters must match the drill holes in the fastening lugs.
INTAREMA Process Combination I_1714_T
ATTENTION: Use 2 hoisting cranes for lifting the process combination!

First lift the process combination slightly with crane 2.
crane 1 crane 2
2 1 4 2 2 4 1
2 2 3
2
2
2 5
2 3
Fig.3 Transport I_1714_T - weight approx. 14600 kg
1. Use for the transport over ground heavy-duty rollers (1).

ATTENTION: Take care of proper positioning of the heavy-duty rollers.
Place the rollers below the frame and not underneath the control
cabinet. ð Danger of damage to control cabinet!
2. Remove the rope ears at the marked lifting points (3) and insert the hexagon head bolts (2).
2 6
Fig.4 Mounting process combination
3. Align the process combination with a spirit level (5),by screwing in the hexagon head
bolts (2), beginning on the transmission side, at the red-marked measuring points (4)
levelly and horizontally. (flatness tolerances ±1mm).
4. Place shims (6) of at least 150x150mm to level the aligned process unit at a maximum
distance of approx.1m to the supporting base frame profiles (not underneath the switch
cabinet platform).
NOTE: Especially in the area of the extruder, cutter compactor drive, and in the
degassing area and at the barrel end, ensure a clean supporting surface
on the shop floor or foundation. The main static load and the dynamic
forces of the main drives in the process unit are dissipated into the shop
floor at this point.
5. Use anchor bolt to fasten the process combination to the floor at the site of installation.
NOTE: The anchor bolt diameters must match the drill holes in the fastening lugs .
Fig.5 Mounting cutter compactor hood - weight approx. 300 kg
6. Lift and place cutter compactor hood (7) onto cutter compactor tank (8) and fasten with
clamping jaw and screws.
7. Provide supply connections. (see figure below)
Fig.6 Central connection for compressed air (7 bar)
cooling
water outlet
cooling
water inlet
thermal oil outlet
leckage oil outlet
Fig.7 Extruder cooling

Powered Exhaust System SAS_2500
4 5
4
3
2
3285
1
Fig.8 Mounting dedusting unit - weight approx. 174 kg
1. Fasten the cyclone support (2) with the half shell (3) at the cyclone (1).
2. Set up the suction fan (5).

CAUTION: Use only screw-type clamps do not use quick couplings that can
be applied or released without tools.
3. Adjustment of height with the screws (4).
4. Lay pipe (6).
5. Filter housing and filter bag install.
ATTENTION: Silo, cyclone and piping must be earthed by the owner/operator

throughout, in order to prevent electrostatic charge.
EREMA Backflush Filter SW_4_170_RTF
ATTENTION: Do not use the cleaning rope (accessories) for lifting the screen
changer.
1
Fig.9 Transport and mounting of SW_4_170_RTF - weight approx. 1680 kg
1. When installing the screen changer align towards the melt outlet flange of the extruder.
ATTENTION: After finishing setup, remove the rope ears (2)!
2. Use screws (1) to adjust height (h) so that the extruder melt outlet flange and the screen
changer melt inlet flange are aligned and the sealing surfaces are parallel to each other.
3. Tighten flange screws at extruder side and at the tool and/or pelletizing head side.
NOTE: Use intermediate flanges for different flange sizes or if required for
reasons of construction.
Screen changer hydraulic unit
See to that the hydraulic unit is accessible for maintenance at any time.
Primarily, the following periodical maintenance is carried out:
n checking the oil level
n refilling oil
n changing the filter
Make sure that the unit is clean and free from splash water. Ensure proper ventilation. If the
unit is subjected to considerable air pollution or high temperatures, provide special protective
equipment.
Use hydraulic hoses to provide connections between screen changer and hydraulic unit (see
Fig.10)
Note that the connecting points (A1, A2, B1, B2) and the hydraulic hoses have been marked at
the workshop in order to prevent wrong connections.
ATTENTION: All pipes and hoses used for the hydraulic unit must be free from
corrosion and dirt.
Positively no welding or soldering of pipes after installation.
screen changer
A2 B2
piston 2
forward backward
piston 1
A1 B1
A1 B1 A2 B2
a b a b
hydraulic unit
Fig.10
Check connection and function of pressure measuring device at the melt inlet of the melt
filter.
ATTENTION: It is absolutely necessary to equip the melt inlet with a pressure
measuring device with PL=c which indicates the maximum operating
pressure and puts the extruder out of operation or releases a discharge
opening, respectively, in case of maximum pressure.
Automatic Strand Pelletizer ASP_200_SERIE
Fig.11 Installation strand pelletizing system
For transport and installation, see operating instructions for " Strand pelletizing system;
Typ ips-SGU 220/2 HS ".
strand die
±3
50
ASP 200
±3
11
Fig.12 Installation strand die - strand pelletizer
from double filter unit
Fig.13 Installation strand pelletizer

from dewatering screen strand pelletizer
Fig.14 Installation of double filter unit - weight appr. 51 kg
to double filter unit
Fig.15 Installation heat exchanger and water pump - double filter unit
Pellet Dewatering Screen GS_2010_1000
Fig.16 Transport of pellet dewatering screen - weight approx. 361 kg
4
3
Fig.17 Mounting of GS 2010_1000
1. Arrange pellet dewatering screen (1) such that it faces the strand pelletizer (2).
2. Fix pellet transport hose (3) at strand pelletizer (2) and at dewatering screen (1).
ATTENTION: Make sure the hose crown is never at a level higher than the
pelletizing house bottom! è Check hose supports! (4)
connection
pellet transport hose
water overflow
fresh water inlet
connection water outlet

water pump
Fig.18 Provide supply connections
NOTE: Do not use but fresh water of drinking water quality for the pellets
dewatering screen.
CAUTION: The water in the pellet dewatering screen can be acidic/alkaline

or toxic depending on the material to be processed. It is the
owner/operator's responsibility to ensure that the water is safely
processed and disposed of to reflect their potential
hazardousness.
Water Pump Station WPS_300
cooling water inlet
cooling water outlet
connection
water hose
Fig.19 Mounting of heat exchanger and water pump - weight appr. 240 kg
ATTENTION: Note thresholds for chloride level!

At a water temperature of 30°C, the chloride level must not exceed a
value of 20mg/liter, as there is danger of corrosion at higher levels!
ð Pitting!
Pellet Drying Centrifuge GZ_1000_M11
Fig.20 Transport of pellet drying centrifuge - weight appr. 674 kg
pellet dewatering screen
pellet drying centrifuge
Fig.21 Mounting of pellet drying centrifuge
1. Take care to position properly.
2. Place sound absorbing cover (1).

Pellet Transport System FG_40
Fig.22 Transport of conveyor blower - weight appr. 54 kg
Fig.23 Mounting of silencer - weight appr. 69 kg
1. Use coupling to fasten the spiral hose (1) at the conveyor blower (2).
2. Lift and place silencer (3) above the conveyor blower.
CAUTION: Use only screw-type clamps (4), do not use quick couplings that
can be applied or released without tools. Do not remove the
existing cover grilles (5) on the intake side.
Pipe routing for pellets conveying
Ensure that the pipeline is as short as possible. Use only the minimum required number of
bends and branches. This allows you to obtain maximum blower output.
Make sure that the pipeline is as tight as possible, as leakages are liable to reduce the blower
output. Not that any leakage occurring within the first section of the pipeline downstream of
the blower causes the greatest reduction in blower output. Therefore, you should provide older
pipes and couplings at the end of the pipeline.
Use only pipes of the same size over the entire pipeline as even a small pipe having a
different diameter reduces the blower output to a considerable extent.
In the case of horizontal pipe routing, mount the pipes such that the seams show upwards or
sidewards. This allows to reduce the wear.
Make sure that the pipes are laid vertically or horizontally only. An inclined pipe routing
reduces the blower output more than a vertical run.
Fig.24
Close the pipeline with a cyclone or blow-off head.
ATTENTION: Silo, cyclone and piping must be earthed by the owner/operator

throughout, in order to prevent electrostatic charge.
Control cabinet
Fig.25 Transport - weight approx. 1050 kg
ATTENTION: Counterbalance by an adjustable lifting traverse!

Use dowels to fasten control cabinet to the floor at the site of
installation.
Chapter 3
Startup
and
shutdown
Do not commission the machine until you

have fitted all safeguards and have
demonstrated the effectiveness of all safety
equipment.
Work platforms needed e.g. for feeding the
machine must be firmly attached and must
not impede or nullify the effectiveness of
safeguards.
Overview of utilities and filling quantities
filling point filling quantity utilities 1)

grams litres
sealing appr. 35 sealing grease

cutter compactor
bearing, upper and lower appr. 55 lubricating grease
helical worm gearbox gear oil synlub

intake slide cutter compactor 0.8
Lenze; GSS04-2M HBR 063C12 CLP PG VG 460
gear drive gear oil synlub

93
Köllmann; EKG 120-315/EO CLP HC VG 320
extruder
sealing - flange globe appr. 25 sealing grease
sealing - groove bush appr. 38 sealing grease
main drive motors bearing 2) 3)
tank
extruder cooling system appr. 30 thermal oil
Hainzl; 10260024 A
EREMA Backflush Filter hydraulic unit appr. hydraulic oil

SW_4_170_RTF Rexroth; AKAG032 B411-0-AC 39.6 HVLP VG 46
Pellet Drying Centrifuge

bearing appr. 5 lubricating grease
GZ_1000_M11
Table II
ATTENTION: Mixing oil of different manufacturers or different oil grades of one

manufacturer may cause mud accumulation and sedimentation, which in
turn may result in malfunctions of and damage to the equipment.
Note that if oil of different manufacturers is mixed or additives are
added to the oil, the issue of liability cannot be settled any more in case
of damage. However, if required, the lubricant supplier can check the
miscibility of different oils and give the operator a guarantee in this
respect.
1) Fore recommended utilities, see page 128 of chapter 7, Maintenance and Repair
2) Note that the lubrication should be carried out with the motor running. If the entire grease
quantity is applied at a time, part of the grease might penetrate into the motor through the
internal bearing sealing. (for grease type and quantity see type plate)
An additional lubrication after "break-in" time increases the lifetime of new bearings.
3) See also " Siemens- Low-voltage motor; 1LE1" and "ABB - low voltage motor; M3BP
315LKA" given in the annex.
Start-up and shutdown 43
Start-up
1. Check installation and mounting.
2. Remove transport protection
3. Disassemble the rope ears on the screen changer.
4. Ensure that the technical data for voltage and current intensity that are specified on the
electrical parts and on the electric motor are in accordance with the actual power supply.
5. Provide electrical connections.
6. Provide compressed air connection.
7. Check oil level when the gear is out of operation.
8. Check oil level of hydraulic unit.
9. Check hydraulic hoses for proper connection and tight fit.
10. Check supply lines for proper connection and tight fit.
ATTENTION: All inlets of operating and cooling liquids have to be equipped with
flexible hoses or compensators between the connections at the
machine and customer supplied main. Otherwise damages at the
water circuits can arise!
11. Check liquid circuits for leakages.
12. Ensure there is no oil leakage.
13. Switch on machine/plant and set to operating temperature,

i.e. to ±10°C of the melt processing temperature, depending on the polymer to be
processed.
14. When the operating temperature is reached retighten fastening bolts of strip heaters and
screws of connecting flanges.
CAUTION: Use protective gloves when retightening the fastening screws -
DANGER OF BURNS.
15. Heat up and check control response.

ATTENTION: Make sure that thermocouples are not mixed and installed correctly
- ensure constant heating up.
16. Check cutter compactor for emptiness. Check proper torque of hexagon nuts of rotor disc
(1) and screws of knife holders (2).
Fig.26
item fastening torque
hexagon nuts of rotor disc .................................. 1 ............................................... 820 Nm

screws of knife holders ...................................... 2 ................................................. 95 Nm
Table III
CAUTION: Insufficiently tightened or loose screws at the rotor disc and at

the knife holders may cause hazards to man and machine as knife
parts may be tossed about.
17. Check direction of rotation of extruder screw and electric motors

ð Observe direction arrows.
18. Check connection and function of pressure measuring device at the melt inlet of the melt
filter.
ATTENTION: It is absolutely necessary to equip the melt inlet with a pressure
measuring device with PL=c which indicates the maximum operating
pressure and puts the extruder out of operation or releases a
discharge opening, respectively, in case of maximum pressure.
19. Preset backflush period to approx. 10 seconds at the button backflushtime screen
changer [BF-time SC] for melt backflushing at the screen changer.
ATTENTION: Positively no movement of screen changer pistons in cold condition
and/or at a screen changer temperature that deviates by more than
±10°C from the melt temperature. Make sure that the maximum
operating temperature of 300°C is not exceeded.
20. Fill basin of pelletizing system with water.

Allow some water to run over the overflow so that any impurities that may have
accumulated in the basin during transport are removed.
Start-up and shutdown 45
Shutdown
If you need to store the machine/system for an extended period of time, you must perform the
following tasks to avoid damage:
1. Isolate the machine electrically (switch off the main switch and secure against
reactivation). Remove the fuses on the main power lines.
2. Remove residual material and pellets from the machine/system.
3. Coat non-coated, blank parts with preservative.
4. Coat the cutter disk with preservative.
5. Loosen the belt on the cutter compactor drive.
6. Clean the extruder screw and coat with preservative.
7. Fill the transmission with recommended preserving oil and seal air -tight.
8. Preserve the screen changer piston and screen changer block.
9. Coat the adapter flange and pelletizing die with preservative.
10. Drain parts filled with water and fill with antifreeze.
Control cubicle heat exchanger:
· Inner circuit drained via water pump.
· Drain outer circuit via drain screw or solenoid valve control (fill with antifreeze).
Heat exchanger on cylinder and/or transmission cooling:

· Blow out the heat exchanger with compressed air (blow in antifreeze).
Other pipes:
· Open and blow clean machine supply lines (cooling lines, water infeed lines,..).
· Depressurize pneumatic components.
Pelletizing system ASP:

· Drain the plate heat exchanger at the process water tank (fill with antifreeze).
· Drain the backflush tank and the water pump (fill with antifreeze).
· Fill the bearing ring seating on the lower bearing on the centrifuge/dryer with
antifreeze.
Water pumps:
· Open drain screws and completely blow out water (fill with antifreeze).
Pellet dewatering:
· Drain water from basin of pelletizing system.
Preparing for transportation
1. Fit the transportation locks.
2. Attach the transportation lock to the extruder drive motor.
3. Set the cutting gap on the ASP strand pelletizing system to approx. 1 mm for
transportation.
4. If the system is completely encased, use desiccant to absorb moisture and replace every
6 months.
Putting into operation after long shutdown
1. Clean all parts coated with preservative.
2. Drain all fluids and replace with fresh fluids.
3. Remove desiccant.
4. Perform a general check for corrosion and remove flash rust.
5. In case of storage in rooms with a high humidity level, Check the insulating resistance of
the motors in line with the manufacturer's recommendations.
6. For further procedure, see "Start-up," page 43.

Chapter 4
Description of
operating
and
control elements
This chapter describes the individual controls

and the corresponding control units.
Read this chapter carefully before operating
the machine.
Control panel
A
04 SW
01
SW
03
A A BE SV EX
03 01 01 04 02
Fig.27 Control panel at the control desk
Fig.28 Control cabinet

Description of operating and control elements 49
General control and operating elements
Selector switch main switch

Position 0
The facility is currentless, only isolates the components supplied with electricity.
Position 1
The facility is connected to a power supply unit.
Key switch control voltage off - on

For switching on/off the machine/plant.
0 = control voltage off
I = control voltage on
Pushbutton EMERGENCY STOP

when operating the EMERGENCY STOP pushbutton the machine or the entire plant is shut
down respectively.
Turn red knob to the left to unlock.
NOTE: The EMERGENCY STOP must not be used to switch off the machine in normal
operations.
SIMATIC Panel PC 477C 15" Touch

see "Simatic panel," page 54.
NOTE: To prevent soiling and damage a touch pen must be used.
ATTENTION: No network settings may be changed without consultation with EREMA.

The EREMA system may only be connected to the customer network via a
firewall and only according to the agreement of the Internet connection!
Feeding
Selector switch feeding off – automatic-operation – manual-operation
NOTE: The feeding selector switch overrides the feeding selector touch screen.
The setting carried out at the selector switch is the base setting for the feeding
selector touch screen.
0 = feeding off
I = feeding automatic-operation
à = feeding manual-operation
Position off
The complete feeding system is switched off. The settings on the feeding selector touch screen
are not active.
Position automatic-operation
The selected feeding method of the feeding selector touch screen (cf. page 57) is accepted.
Position manual-operation
The feeding system only runs while the switch is held down.
NOTE: When the feeding is in operation the selector switch feeding lights.
Process Combination
Luminous pushbutton cutter compactor on - off

Actuate. Rotor disc of cutter compactor starts running, which is signalled by the light of the
luminous pushbutton.
NOTE: The back pressure blower / air flushing only runs when the cutter compactor is
started.
Luminous pushbutton extruder on - off

Actuate. Extruder and the entire pelletising system starts running, which is signalled by the light
of the luminous pushbutton.
NOTE: The pelletising system is in operation when the pelletising housing is closed.
Button unlock service door
The button lights up and the service door can be unlocked only in the following situation: the
rotary disc has come to a standstill and the cutting compactor and extruder have been switched
off.
Pushing the button will switch the solenoid limit switch, thus unlocking the
cutter/compactor service door.
Backflush Filter
Selector switch screen changer manual-operation – automatic-operation –

auto-start
0 = manual-operation
I = automatic-operation
à = auto-start
Position manual-operation
No automatic pressure-dependent backflushing is carried out.
The selection switch is illuminated in this position. The selection switch flashes when the
hydraulics are operational.
Position automatic-operation
Backflushing is carried out fully automatic and as a function of the pressure. The selection
switch flashes when the hydraulics are operational.
Position auto-start
to trigger backflushing voluntarily during auto mode of operation. The pushbutton flashes when
the backflushing process is running.
Switch piston backward - 0 - forward

á = piston backward
â = piston forward
activate to retract or extend piston 1/2

NOTE: The requested piston is to be selected in the window “melt filter“ on the touch
screen.
If the switch is lit ð the piston can only be extended (the piston can only be retracted after
fitting the sliding sleeve)
If the switch flashes ð the piston can be forward or backward
If the switch flashes quickly ð the pistion is in the venting position and the preset venting time
is running, or the piston is in the front backflush position after changing screens.
Pelletizing system
Fig.29 Operating and control panel of the strand pelletizing system
Pushbutton EMERGENCY STOP

when operating the EMERGENCY STOP pushbutton the machine or the entire plant is shut
down respectively.
Turn red knob to the left to unlock.
NOTE: The EMERGENCY STOP must not be used to switch off the machine in normal
operations.
Switch granulator speed (–) - (+)

– = reduce granulator speed
+ = increase granulator speed
The length of the pellets can be manually changed by readjusting the pelletizing motor speed.
The granulator speed changes only as long as you press and hold the button. For the display of
the granulator speed, see touch screen pelletizing downstream equipment, page 63.
Simatic panel
Fig.30 Touch screen
SIMATIC Panel PC 477C 15" Touch
NOTE: In order to prevent soiling and damage, touch pens and protective foils are
available.
USB interface
For further product information, see "SIEMENS Visualization Software".
Entry of actual value and setpoint value

NOTE: If a current actual value display is pressed, a window will open permitting the
setting of the setpoint value. The setpoint value input is pressed, a window
will open permitting the setting of the setpoint value. The setpoint value input.
1
2
Fig.31 Display of actual value and setpoint value

feeding
5
2
8
3 1
9
11
Fig.32 Feeding touch screen
Actual value and setpoint value display of cutter compactor – power [kW]:
The feeding of the cutter compactor is automatically controlled as a function of the cutter
compactor power. Adjustment of the basic load value for an optimal feeding and thus optimal
production.
Please also refer to "Feeding material into the cutter compactor in auto mode" on page 88.
Actual value display of cutter compactor – load [%]:

Indicates the instantaneous load consumption of the drive motor.
Actual value and setpoint value display of cutter compactor – temperature [°C]:
Display of the current temperature in the cutter compactor and of the temperature setpoint value
for water injection.
Button manuel waterinjection:

To actuate water injection in the cutter compactor.
If the water injection is active, the touch screen will display blue water drops.
Actual value and setpoint value display of slider[%]

Intake slide regulation on
Indication of the position (0-100%) of intake slide.
The intake slide ensures a precisely dosed material transfer from the cutter compactor to the
extruder.
Intake slide regulation off
By setting the value [%], the intake slide in the cutter compactor is lowered or raised.
NOTE: The intake slide is functional only when the service door is closed.
Actual value display of extruder – load [%]:

Actual value and setpoint value display of extruder speed [rpm]:

Indication and setting of extruder speed.
The extruder speed can be manually changed at the button.
Actual value and setpoint value of temperature for barrel zones EZ-1, ZZ-1 [°C]:
Changing the value will lower or lift the temperatures.
feeding selection
14
15
16
17
Fig.33 Feeding selection touch screen
NOTE: The settings on the feeding selection touch screen are active only, if the feeding
selector switch has been set to automatic-operation .
Actual value and setpoint value display of the feeding speed [%]:
to set the feeding speed.
feeding customer manual:

The feeding starts to run continuously.
feeding customer off:

Feeding is out of operation.
feeding customer auto:

The feeding is automatically switched on/off as a function of the power of the cutter compactor
motor.
extruder
10
6
7 12
2 13
3
5 1
8
9
11
Fig.34 Extruder touch screen
Actual value and setpoint value display of cutter compactor – power [kW]:
The feeding of the cutter compactor is automatically controlled as a function of the cutter
compactor power. Adjustment of the basic load value for an optimal feeding and thus optimal
production.
Please also refer to "Feeding material into the cutter compactor in auto mode" on page 88.
Actual value display of cutter compactor – load [%]:

Actual value and setpoint value display of cutter compactor – temperature [°C]:
Indicates the temperature in the cutter compactor.
Actual value and setpoint value display of slider[%]

Intake slide regulation on
Indication of the position (0-100%) of intake slide.
The intake slide ensures a precisely dosed material transfer from the cutter compactor to the
extruder.
Intake slide regulation off

By setting the value [%], the intake slide in the cutter compactor is lowered or raised.
NOTE: The intake slide is functional only when the service door is closed.
intake slide regulation:

Position on
The intake slide of the cutter compactor is controlled as a function of extruder – load [%].
Position off
The intake slide regulation is not active.
The intake slide is not controlled automatically.
Actual value and setpoint value display of suction 1 [%]:

The dedusting unit speed can be manually changed at the button.
NOTE: After the cutter compactor has been started and a minimum temperature of 85°C
or a temperature difference of 10°C less than the set temperature has been
reached, the suction fan is started.
Actual value display of extruder – load [%]:

Actual value and setpoint value display of the extruder speed [rpm]:
tracking control extruder on
Indication of extruder speed.
tracking control extruder off
The extruder speed can be manually changed at the button.
tracking control extruder:

Position off
The extruder is operated in normal or manual mode.
The extruder speed can be manually changed at the button extruder [rpm].
Position on
The speed of the extruder screw is controlled as a function of cutter compactor power and/or cutter
compactor temperature.
See also "Automatic tracking control of extruder screw" on page 93.
Actual value and setpoint value of temperature for barrel zones EZ-1 - AZ-1 [°C]:
Changing the value will lower or lift the temperatures.
Actual value display of melt temperature before melt filter [°C]:

Indicates the melt temperature.
Actual value display of melt pressure before melt filter [bar]:

Shows current melt pressure upstream of melt filter.
melt filter
1 2
Fig.35 Melt filter touch screen
Display the number of backflush counter at the screen changer:

Counts the number of backflushings since the screen was last changed and must be reset to 0
following each screen change.
ATTENTION: Change the screens regularly (on average every 25 to 50 backflushings,
depending on the screen quality) to preclude the danger of screen rupture
as the fatigue strength for completely reversed bending stress of the wire
cloth is limited and therefore the downstream components could become
damaged.
Setpoint value display of backflushtime screen changer [sec]:

Allows to set period of time the pistons are to remain in the front or rear backflush position during
backflushing. (see also chapter 5, "Logic diagram", page 95)
The period is dependent on the viscosity and the degree of contamination of the material to be
filtered, as well as on the screen pack used, and must be determined empirically. It should at least
be preselected such that:
n approximately twice the quantity of the processing melt accumulating in the screen basket
upstream of the filter screen is backflushed and separated;
n a sufficient cleaning rate of the filter screen is obtained.
NOTE: If the period is too short the dirt accumulating upstream of the filter screen is
removed from the screen by the backflush current. However, the period of time is
not sufficient to separate the dirt laterally. It remains in the melt duct and deposits
again at the filter screen after backflushing.
As a result, the cleaning rate is poor or even zero ð no pressure drop
(see also chapter 5, Fig.62 page 96)
This automatically causes a new backflushing cycle to be started repeatedly.
These frequent backflushing cycles affect the screen packs which must then be
frequently changed which is uneconomic! Lower lifetime – higher costs!
Actual value and setpoint value display of melt pressure before melt filter [bar]:
Shows current melt pressure upstream of melt filter.
Allows to set release pressure (bar) for automatic backflushing at melt filter in automatic mode.
Actual value and setpoint value display of master temperature screen changer zone
SWZ-1 [°C]:
Changing the value of zone SWZ-1 (master temperature) will increase or reduce all temperature
zones at the screen changer.
Actual value display of temperature screen changer zone SWZ-2 - SWZ-3 [°C]:
Indication of temperature zones at the screen changer.
With the zone SWZ-1 (master temperature) one regulates.
piston 1
Fig.36 Indicates the piston position of piston 1.

downstream equipment
4 6
7 8
Fig.37 Downstream equipment touch screen
Actual value and setpoint value of temperature at the strand zones STZ-1, STZ-2 [°C]:
Changing the value will lower or lift the temperature.
Actual value and setpoint value display of infeed roll [rpm]:

Indication and setting of infeed roll speed.
granulat length [mm]

Used for preselecting the pellet length (2.0 - 5.0mm).
Button incremental factor [%]:

The incremental factor is a percentage value [%] which determines whether the speed of the
infeed roll is to increase or decrease considerably or weakly in dependence of the extruder speed.
synchronisation granulator:
Position off
The length of the agglomerat can be manually changed by adjusting the pelletizing motor speed at
the potentiometer infeed roll [rpm].
Position on
In order to maintain a agglomerat quality as uniform as possible (length of the agglomerat), the
speed of the pelletizing motor is automatically increased or reduced as a function of the extruder
speed.
strand cut control

Position off
Breakage of the strands the plant/machine will not go off.
Position on
Breakage of the strands the cutter compactor, extruder and downstream equipment will go off after
a while. A alarm will be indicated on the touch panel and a acoustic signal sounds.
Actual value and setpoint value of the temperature water bath [°C]:
Indication and setting the water bath temperature in the pellet dewatering screen (GS_2010_1000).
Actual value and setpoint value display of centrifuge speed [rpm]:

Indication and setting of centrifuge speed.
The centrifuge speed can be manually changed at the button.
screen saver
If no input occurs in the main menus (feeding, extruder, melt filter, downstream equipment) for
15 minutes, the screen saver is automatically enabled.
Fig.38 Screen saver touch screen

archive
The Archive stores all data of the last 168 hours.
Storing data in the Archive allows you to find out the reason for a malfunction, poor pellet quality
or the like at a later time.
Fig.39 Archive touch screen

alarms
The “Alarms” touch screen lists all alarms that have occurred. The list allows to check which
alarm occurred at what time.
In case an alarm occurs, a message in red color appears in the alarm window and the red flashing
beacon at the plant is activated.
This menu also allows the acknowledgement of error messages .
The following times are logged: Alarm appeared – Alarm disappeared – Alarm acknowledged.
When the fault has been removed and the alarm message has been acknowledged, the alarm
message in the “Current alarms” touch screen goes off and is saved to the “Historic alarms "
touch screen.
When necessary, any alarms occurred in the past 500 days can be viewed here.
2 1
Fig.40 Alarms touch screen
Alarm no.:
If an alarm occurs and the EREMA service is required for the removal of the alarm, the alarm
number has to be forwarded.
NOTE: Please also refer to Chapter 8 "Malfunctions", page 169.
more functions
Fig.41 More functions touch screen
clean screen:
After having pressed the “clean screen” button, the image shown below will appear. Now all
screen functions are deactivated for 30 seconds and the touch panel can be cleaned.
The cleaning instructions are rendered in the “SIEMENS documents” supplied.

recipes
A user-friendly system certainly offers the possibility of storing recipes and a so-called Teach-In
function:
„Teach-in“ means that the actual value of all process variables, i.e. the present condition of the
plant, can be stored as a recipe by simply pressing a button. The plant can revert to this condition
anytime by simply loading the respective recipe.
This allows for a simple reproduction of operating states, facilitating the adaptation of the plant to
varying conditions. (e.g.: change of material)
Furthermore all setpoints and limit values are stored in the recipes, allowing to adapts the plant to
a certain material (polymer to be processed) by pressing a button.
NOTE: Modification of a recipe requires a password to ensure only authorized personnel

may change these values, see service setup on page 75.
3
4
1
2
5
Fig.42 Recipe managment touch screen

login:
If you press the "login" button the touch screen "log on" will appear (see page 75). After logging
in, press the "login" button again to unlock the remaining buttons .
Login to recipe screen:
Press "login" and log in with a user.
After logging in press "login" once again.

new recipe:
Pressing the "new recipe" button creates an empty recipe. Enter the recipe name along with
the required values using the keyboard. After having completed the modification, the recipe is to
be saved! See item .
Create new recipe:
Press „new recipe“.
5
write recipe:
The selected recipe is accepted in the control unit by selecting and then "write recipe"!
Load recipe values into system:
Select recipe and press "write recipe".
3
7
read recipe:
By pressing the “read recipe“button, the current production values are taken over into the recipe
called.
The individual values, however, can also be modified “manually“ and separately!
After having completed the modification, the recipe is to be saved! See item .
save recipe:
If new recipes are created or if the values in existing recipes are modified, it is required to save
these recipes.
Read in recipe values from system:
Select recipe and press "read recipe", then "save recipe".
5
delete recipe:
To delete the selected recipe, press the "delete recipe" button. The deletion must be confirmed in
the next window in order to finalize this.
Delete recipe from the system:
Select recipe, click on "delete recipe", confirm with "Yes".
6
SERVICE CONFIGURATION
Pressing the service configuration button will open the log on-window:
NOTE: Access to this mode requires a password to ensure only authorized personnel
may change these values.
The system is configured in service mode. Configuration is completed by EREMA before the
system is delivered.
Log on
Fig.43 Service setup - log on touch screen
Password: 0000
After entering the user [CUSTOMER] and the password [0000], press [OK] to acknowledge, and
the press the service configuration button again.
NOTE: The registration in the service configuration is active for five minutes!
Fig.44 Touch screen service configuration
service EREMA:
EREMA internal use only.
SERVICE FEEDING
Fig.45 Touch screen service configuration - feeding
feeding by auto- load detector:

Position off:
Feeding of the cutter compactor is handled via the cutter compactor – power.
Position on:
Feeding of the cutter compactor is handled exclusively via the load detector.
The feedstock quantity is controlled automatically in automatic mode (cutter compactor –
power) depending on the cutter compactor – temperature.
NOTE: If the preset cutter compactor power is exceeded, feeding stops .
Minimum power cutter compactor [kW]:

If the preset cutter compactor power is fallen below, the plant stops.
SERVICE CUTTER COMPACTOR
5 6
Fig.46 Touch screen service configuration - cutter compactor
cutter compactor configuration:

If the cutter compactor has been refitted from single disc (SD) to double disc (DD) or vice versa,
the respective specification has to be set.
shut off mode with cutter compactor:

Position on:
The cutter compactor is automatically switched off if there is an extruder or pelletizing system
malfunction.
Position off:
The cutter compactor is not switched off if there is a malfunction.
suction 1 manual:
The suction will start operating at the speed suction 1 [%].
suction 1 off:
The suction is out of operation.
suction 1 automatic:
After the cutter compactor has been started and a minimum temperature of 85°C or a temperature
difference of 10°C less than the set temperature has been reached, the suction fan is started.
SERVICE MELT FILTER
10 11 12 13
16
14 15
Fig.47 Touch screen service configuration - melt filter
Setpoint value display of backflushtime front [sec]:

For selecting the period of time the pistons must remain in the front backflush position during
backflushing.
The time set here is added to the set backflushtime screen changer [bf-time sc] and results
in a total backflush time for the backflushing position!
Setpoint value display of backflushtime rear [sec]:

For selecting the period of time the pistons must remain in the rear backflush position during
backflushing. (otherwise, see position )
interval time piston move [h]:

To set the interval time for automatic piston movement.
interval time auto backflushing [h]:

To set the interval time for automatic backflushing.
Setpoint value display of degassing time after screen changing [sec]:

For setting the degassing time at the piston (venting the screen baskets).
If the piston is in the degassing position, it remains stationary until the degassing time set at the
timing element elapses.
NOTE: The degassing time should be selected so that no visible air escapes any longer
in the degassing position.
After the piston returns from the degassing position to the production position,
there should be no more bubble formation after the screen changer or
downstream equipment. – If, however, this is the case, the degassing time or the
flushing time after screen change must be increased! These times are dependent
on the material / screen pack / throughput / MFI and IV, and must therefore be
determined empirically
Setpoint value display of flushing time after screen changing [sec]:

For selecting the period of time the piston must remain in the front backflush position after screen
change and after expiry of the degassing time.
NOTE: The flushing time after screen change effects the subsequent removal of any air
bubbles that did not escape in the degassing position.
tact time screen changer [ms]:

The cycle impulse setting is used for venting the new screens after a screen change.
NOTE: A shorter cycle time means that the newly inserted screen pack is flushed for
longer so that the enclosed air can be conveyed out. This means it is possible to
entirely avoid air bubbles being present in the melt flow after a screen change.
SERVICE DOWNSTREAM EQUIPMENT
17
20
18
19 21
Fig.48 Touch screen service configuration - downstream equipment
downstream manual:
Collective start of pelletizing system.
If you press the button the entire pelletizing system starts to operate.
downstream off:
The entire pelletizing system is out of operation.
downstream auto:
The entire pelletizing system starts to work when the extruder on illuminated pushbutton
is pressed.
downstream GS interval time [min]

Adjustment of flush intervals in the pellets dewatering screen (GS_2010_1000).
lowering granulation during backflush [%]:

The factor is a percentage value [%] which determines by how much the speed of the granulator is
reduced during the backflushing operation of the screen changer.
SERVICE GENERAL
NOTE: Modification of a service configuration – general requires a password to ensure

only authorized personnel may change these values.
Log on
Fig.49 Service setup - log on touch screen
Password: 4052
After entering the user [EREMA] and the password [4052], press [OK] to acknowledge, and the
press the service configuration button again.
NOTE: The registration in the service configuration is active for five minutes!
22 23
26 24
25
Fig.50 Touch screen service configuration- general
Setting of language
close runtime
Close the visualization.
Explorer IPC - 477

Open the windows-explorer.
operating hours
Display of the operating hours.
NOTE: Has to be observed when completing certain maintenance jobs (Chapter 7)!
Screen settings calibrate touch:

If the screen calibration does not perfectly match operations, you will need to recalibrate the
screen:
For this purpose, press the calibration points (by finger or using a touch pen) after each other.
Fig.51 Calibrate touch

Chapter 5
Description of
function
and
control sequences
This chapter describes the production

workflow in the order in which the material
passes through the machine.
It also describes control processes relevant to
controlling and operating the machine.
Flow sheet
In order to ensure a correct production process, the material feed should be constant to the
granulate output.
The material is fed by means of the feeding equipment, such as belt conveyor, feeding screw,
livetrim receiver, reel feeder, et cetera.
The process combination consists of a cutter compactor and an extruder.

The cutter compactor is used to cut up, mix, dry, heat and pre-compact the material fed.
The extruder is used to plastify, homogenize and degas (option) the material.
The melt filters are used to remove impurities from the contaminated plastic melt by
filtration.
The pelletizing system is used to produce dry, clean and pourable granulate.
1 M
M
4
material
2
feeding
EZ-1 ZZ-1 ZZ-2 ZZ-3 AZ-1 STZ-1 STZ-2

pellets
M outlet
3 5
M
M
1 reel feeder / livetrim receiver (option)

2 belt conveyor / feeding screw (option)
3 Process Combination
4 extruder liquid cooling system
EZ-1... cooling and he ating zone
ZZ-1 - ZZ-3...cooling and he ating zone
AZ-1... heating zone
5 pelletizing system
STZ-1 - STZ-2... heating zone
Fig.52 Schematic of material flow

Description of function and control sequences 87
Process Combination
The Process Combination consists of a cutter compactor with tangentially attached single
screw extruder. It is required to produce a uniform melt from plastic waste.
The material is fed to the cutter compactor by one or several feeding units. There it is cut,
mixed, heated, dried and precompressed in one process step.
Furthermore, the rotating cutting tools are so powerful as to provide a proper and continuous
filling of the connected single screw extruder ð stuffing effect.
In the extruder screw the material is plasticized and homogenicized.
cutter-compactor
drive motor
extruder liquid rotary knife
cooling system
stationary knife
melt
outlet
extruder cutter-compactor
drive motor
single screw extruder
Fig.53
Feeding material into the cutter compactor in auto mode
The charging device (e.g. belt conveyor, reel feeder) of the cutter-compactor is controlled
automatically via the power of the cutter-compactor drive motor. Control is realized via the
button cutter compactor – power.
The more the cutter compactor is filled the more energy input is required to heat the material.
The load of the drive motor increases.
Together with a load increase the actual value of the kW display is increased, too. As soon as
a value set is reached, the charging device is switched off and material supply is stopped (to
avoid overfilling of the cutter-compactor and overheating of the charged material).
Neither the feed system is reactivated nor the cutter compactor filled with new material before
the material in the cutter compactor has been processed or passed on to the extruder so that
the load is slightly reduced.
In general it can be said that over an extended period a balance is obtained between small
quantities of cold material which is dosed into the cutter compactor by the feed system, and
large equal quantities of cut, heated material which leaves the cutter compactor via the
extruder. The cutter compactor level remains about the same.
As a reference value for the filling level a charged quantity of up to 10cm below the upper
edge of the inspection window can be assumed. The filling level is determined by several
factors:
§ kW setting at the touch screen - cutter compactor – power
§ temperature (= degree of pre-compacting = piled density)
§ equipment in the cutter-compactor (number of knives, height of base)
§ sharpness of the knives
NOTE: high level ð high cutter compactor temperature
low level ð low cutter compactor temperature
The proper temperature in the cutter compactor depends on the material to be processed and
should be chosen such as to ensure a proper precompression (softening point of the polymer to
be processed) which is required for an appropriate extruder filling (high output rate).
However, take into account a safety margin to ensure that the plastic is not melted in the
cutter compactor (normally approx. 10-15°C below the melting point of the plastic to be
processed).
optimum material circulation excessively filled cutter compactor

Fig.54 Fig.55
Note that particularly under "cold" start-up conditions the cutter compactor is excessively
filled already before the requested motor load is reached (see Fig.55) as the material is not yet
precompressed.
Setting
1. Make a rough preliminary calculation of the necessary motor load of the cutter-compactor,
depending on output and type of plastics, on the basis of the below diagram.
2. Set kW value button cutter compactor – power controller such that desired output is
obtained.
3. Adjustment is to be optimized during operation, so that the empirically established

optimum temperature of the cutter-compactor is achieved.
cutter compactor
power
[kW]
200
190
180
170
160
150
140
130
120
110
100
90
80 BOPET
70
60
50
40
30
20
10
0
300 400 500 600 700 800
output rate [kg/h]
Fig.56 Power of cutter compactor as a function of output rate and material (polymer) to
be processed.
NOTE: The values shown in the diagram are intended as reference values for dry
feed material.
To obtain the precise output performance, the kW setting must be adapted
to the feed material and the local conditions.
Setting the intake slide at the cutter compactor
The quantity of material fed into the extruder varies according to the feed material (pellets,
foil, etc.). You can set the intake rates by raising and lowering the intake slide.
Fig.57 Intake slide setting – outside of the cutter/compactor bin.
intake slide ê Material intake reduce:

Intake slide -
lowering!
screw é Material intake raise:
Intake slide - lifting!
Fig.58 Intake slide view inside of the cutter/compactor bin.
Setting procedure
1. Screw standstil
2. Intake slide is almost closed
3. Start up the plant (see also chapter 6 „Operation“ – Start up.)
4. Open the Intake slide so that the extruder load indicator shows an aproximate value
between70 and 90 %.
5. The intake slide can also set at operation.
NOTE: When start up the plant with granulate or bottle flakes the intake slide
schould be almost closed. è To avoidance a overcharge of the screw.
Setting the slide bar at the grooved bushing of the extruder
The quantity of material fed into the extruder varies according to the feed material (pellets,
foil, etc.). The feed rates can be adapted to the extruder capacity by raising or lowering the
slide bar.
Fig.59
Reduce the material feed rate ð raise the slide bar

Increase the material feed rate ð lower the slide bar
NOTE: Please do not modify the the slide bar without consultance with EREMA
Service department!
ATTENTION: The slide and screw could be damaged on improber setting!

Extruder liquid cooling system
The EREMA extruder cooling system is a closed oil cooling circulation comprising a coolant
pump, heat exchanger, line filter, collecting tank and equalizing reservoir.
The collecting tank and the equalizing reservoir are connected via a capillary. The equalizing
reservoir is filled with hot oil. The oil level is kept constant which allows to prevent air-
oxygen from penetrating the system.
The thermal oil is pumped by the coolant pump from the collecting tank in the flow collecting
pipe. The barrel zones are cooled via the solenoid valves and the heated thermal oil is
returned through the return collecting pipe and the line filter into the heat exchanger.
The temperature of each zone is determined by a temperature sensor and is evaluated by the
regulator at the control cabinet. An excessive temperature causes the solenoid valve to open
and the respective barrel zone is cooled down to the value set on the regulator by the thermal
oil.
EZ-1 ZZ-1 ZZ-2 ZZ-3 AZ-1

4
3 7
PI
LI M
8 9 5
1 6
1 collecting tank 5 solenoid valvel

2 heat exchanger 6 line filter
3 oil pump 7 pressure gauge
4 extruder 8 level indicator
9 equalizing reservoir
Fig.60 Schematic of extruder cooling system
Automatic tracking control of extruder screw
NOTE: The speed of the extruder screw is controlled as a function of cutter

compactor power and/or cutter compactor temperature.
Adjusting sequence (cutter compactor temperature)
A sword-shaped feeler installed in the cutter-compactor container continuously measures the

temperature of the material to be processed and transmits these values to the temperature
controller.
If the actual temperature differs from the preset target temperature, the extruder speed is
automatically controlled.
1. Adjust a set temperature value depending on the material to be processed at the button
cutter compactor – temperature.
For standard values cf. below table.
Material to be processed Setting value
PET ............................................................................................................. approx. 80°C

Table IV
Adjusting sequence (cutter compactor power)
If the target value set using the cutter compactor – power button is exceeded, or
undershot, the extruder speed is automatically controlled.
2. Set desired value for cutter-compactor load at button cutter compactor – power
(see page 89)
NOTE: A new recipe must be written in case of a material change (see page 69).
3. Switch on tracking control extruder.
4. Optimize adjustment during operation.

Backflush Filter
The screen changer separates solid impurities from the contaminated plastic melt. The
filtration is carried out by four screen packs, with two packs each arranged opposite to each
other in one piston.
With increasing contamination of the filter screens and when the backflush pressure is
reached (see Fig.62 on page 96) the filter screens are put into backflush position fully
automatically (selector switch backflush filter in position automatic-
operation ) one after the other. One screen pack each is supplied with clean melt from
the backside via the other three screen packs which remain in active filtering position.
The impurities that come off upstream of the screen are separated by the backflush melt flow.
Note that 75% of the total screen surface remains in active filtering position during
backflushing.
Flow sheet - schematic of melt filtration
pistons 1 and 2 in production position,

all 4 screen packs in active filtering position
melt inlet melt outlet

main melt flow
II I
cleaning screen pack I

in piston 1
piston 1 in backflush position 1
melt inlet main melt flow
backflush melt flow
cleaning screen pack II

in piston 1
piston 1 in backflush position 2
melt inlet main melt flow

backflush melt flow
Fig.61
Logic diagram - schematic of piston movement
screen changer position

Legend
sliding sleeve remove position
A backflush time 1 - piston 1
venting position (option) B backflush time 2 - piston 1
backflush position 1 C backflush time 1 - piston 2
D backflush time 2 - piston 2
production position
E backflush cycle
backflush position 2
piston 2
piston 1
time t manually controlled sequence

SW
Operating piston backward - 0 - forward 03
position allows to move the piston to the

required levels.
piston
path s
time t
programm-controlled backflush sequence
The screen changer piston is fully automatically
moved to the individual backflush levels one after
the other. Triggering via pressure indication or
D SW
piston 2 auto-start 01 selector switch.
C Set backflush times of piston at the time button
E backflushtimes front and backflushtimes rear
B or at button backflushtime screen changer.
piston 1
A
path s
Correlation between backflush pressure, backflush rate and lifetime of a screen

pack
Depending on the applied screen pack, the output rate and the melt index (viscosity) of the
material to be processed, an INITIAL PRESSURE p 0 is obtained upstream of the clean screen.
Normally, the BACKFLUSH PRESSURE p1 should be set to approximately 15 to 35% above
the INITIAL PRESSURE p 0 .
If the BACKFLUSH PRESSURE p1 is too high, the impurities are pressed between the screen
mesh at a very high pressure, so that they cannot come off the screen by the backflush melt
flow.
This results in poor cleaning, insufficient pressure drop after backflushing as well as in
shorter screen change intervals.
If the BACKFLUSH PRESSURE p1 is set at too low a value, frequent backflushing is

required. In addition, taking into account the limited fatigue strength for completely reversed
bending stress of the screen cloth, the screens must be changed after a short time.
This results in high screen cost and a considerable melt loss.
In practical operation, you should empirically balance the aforementioned extreme conditions
so as to find a compromise allowing for the longest screen lifetime.
Depending on the type of screen packs and the filtered impurities, the cleaning effect
(pressure drop resulting from backflushing) of the screens tends to be reduced by each
backflush sequence as not all impurities can be flushed off during backflushing.
pressure p
p0 initial pressure in the case of new screens

p1 backflush pressure
p2 (on an average, 1.15 to 1.35 x p0)
p2 overpressure (extruder EMERGENCY STOP)

backflushing at excessively high screen pressure
p1
pressure drop
p0 pressure after backflushing
time t
backflush interval
screen change interval
(lifetime of a screen pack)
Fig.62 Melt pressure course upstream of screens
Selecting the proper backflush nozzle for backflushing
Each piston of the screen changer is equipped with a backflush nozzle that is installed
between the two screen packs. The nozzle opening width determines the backflush melt flow
rate during backflushing.
screen changer piston
backflush nozzle
Fig.63
The selection of the proper nozzle depends on the viscosity of the material to be processed or
the respective case of application respectively.
Basically, the opening width should be chosen as large as possible, so that
n the reduction in the main melt flow by the volume of the backflush melt flow, which takes
place during backflushing, does not adversely influence the downstream equipment such
as pelletizing, film blowing die head, spinning nozzle, etc.
n the greatest possible backflush cleaning effect is obtained.
nozzle opening width too large

A sudden pressure drop downstream of the screen changer is caused by the sudden high
backflush melt loss. This may cause malfunctions during pelletizing, film blowing or the
downstream equipment respectively.
nozzle opening width too small

The flow rate and/or the volume by time unit of the backflush melt flow which passes the
screen to be flushed, is reduced such that instead of the entire screen only part of the
screen surface is actively cleaned by the backflush melt.
This results in a poor cleaning effect of the screen.
The screen changer is equipped with standard backflush nozzles which have a hole diameter
of 5mm, which is a compromise between a proper cleaning effect and a low flow rate of the
backflush melt of most of the commercial polymers.
In addition, each screen changer is supplied with two appropriate backflush nozzles that are
not provided with bores. If required these nozzles can be provided with bores of a
different, optimized diameter and are then screwed into the piston.
For nozzle change, see chapter 6 on page 117.
Please contact our technical experts which are ready to advise you on the selection of the
proper backflush nozzles to suit your specific requirements.
Determining the optimum backflush melt flow for screen flushing
The backflush melt flow is set at the buttons backflushtimes front and backflushtimes
back and/or the button backflushtime screen changer by preselecting the period the
pistons should remain in the respective backflush positions during backflushing (see also
Logic diagram on page 95).
Select the period so that

n an efficient operation of the screen changer is ensured, ie the melt loss should be as low as
possible during backflushing;
n the filtering screen is sufficiently cleaned.
If the period is too short, then the dirt accumulating upstream of the filtering screen is
removed from the screen by the backflush flow, but is not laterally separated. The dirt
remains in the melt duct and deposits again at the filtering screen after backflushing.
This results in a poor or no cleaning efficiency at all. ð no pressure drop (see also Fig.62
on page 96)
The below formula allows to determine the optimum backflush melt flow per screen pack.
Compare the weight of the backflush cake with the calculated weight and reset the time
function elements accordingly.
GRS = VSP x S FS x r KS
GRS ..... weight of the backflush cake per screen pack [kg]
VSP ...... screen pack volume per piston side (SW_4_170_RTF = 0,69 [dm 3 ])
S FS ...... safety factor (1.2 to 1.5)

r KS ........ density of the plastic material to be processed [kg/dm 3 ]
When to change the screen pack
If after a certain number of backflushing sequences the cleaning rate is not sufficient (low or
no pressure drop at all after backflushing, see also Fig.62), the screens must be changed.
For screen changing, see chapter 6 on page 117.
Changing the screens is also necessary in view of the limited fatigue strength for completely
reversed bending stress (on an average, approximately 25 to 50 backflush cycles).
The number of backflush sequences per screen pack is counted by the backflush counter
(see also chapter 4)
Selecting the proper screen packs
A screen pack consists of the following:

internal support screen - fine screens - external support screen.
The selection of the fineness should be based on the application of the pellets/final product.
support breaker plate
screen pack
internal support screen
fine screens
backflush breaker plate external support screen
Fig.64
Table V indicates the recommended fine screens as a function of the final product. The values
are based on experience EREMA has gained in this field.
Note that the melt pressure upstream of the screen changer will be the higher the finer the
screens are. An increased melt pressure requires a higher extruder performance, which results
in that the melt temperature increases. Thus, you should not select the screens finer than is
necessary.
In case of strongly contaminated material or melts that are viscous, a very fine screen is liable
to cause a high melt pressure.
In order to preclude any breaking of the screen the fine screen must be properly supported.
The support screens recommended by EREMA are given in table VI and should be chosen in
relation to the fine screen.
use of pellets mesh size wire thickness fineness

final product mesh / inch mm mm
Injection molding of thick-walled components,
profile extrusion .................................................. 16 ....................... 600 / 600 ............. 1000
Injection molding of thin walled components ....... 12 / 64 ................. 400 / 600 ............... 300
Blow molding/blown films thicker than 75 µm ..... 80 ....................... 125 / 125 ............... 200
PE washed film for blown film............................. 14 / 88 ................. 480 / 281 ............... 200
Blow molding/blown films thinner than 75 µm ..... 24 / 110 ............... 250 / 350 ............... 125
PP fibres and non-woven ..................................... 150 ........................ 63 / 63 ................ 100
PP fibres and non-woven ..................................... 30 / 150 ............... 180 / 230 ............... 100
BOPP, BOPET .................................................... 50 / 250 ............... 110 / 140 ................. 50
PET bottle to bottle ............................................. 80 / 300 ............... 90 / 120................. 40
PET fibers and non woven ................................... 200 / 600 ............... 46 / 58 .................. 25
Table V fine screens
fine screen fineness int.l support screen 1) ext.l support screen 2) pressure resistance
mesh / inch mm mesh / inch mesh / inch bar
16 ...................... 1000 ....................... - ................................. - ............................... 400

12 / 64 ................ 300 ........................ - ................................. - ............................... 400
80 ....................... 200 .......................16 ............................... 16 ............................. 300
80 ....................... 200 ................... 12 / 64 ........................... 16 ............................. 400
14 / 88 ................ 200 .......................16 ............................... 16 ............................. 400
24 / 110 .............. 125 .......................16 ............................... 16 ............................. 400
24 / 110 .............. 125 ................... 12 / 64 ........................... 16 ............................. 400
150 ..................... 100 ................... 16 + 80 ........................... 16 ............................. 300
150 ..................... 100 ............... 12 / 64 + 80 ........................ 16 ............................. 400
30 / 150 .............. 100 .......................16 ............................... 16 ............................. 300
30 / 150 .............. 100 ................... 12 / 64 ........................... 16 ............................. 300
50 / 250 ............... 50 .................... 16 + 80 ........................... 16 ............................. 300
50 / 250 ............... 50 ................ 12 / 64 + 80 ........................ 16 ............................. 400
80 / 300 ............... 40 .................... 16 + 80 ........................... 16 ............................. 300
200 / 600 .............. 25 .................... 16 + 80 ........................... 16 ............................. 300
200 / 600 .............. 25 ................ 12 / 64 + 80 ........................ 16 ............................. 400
Table VI support screens
1) screen between support breaker plate and fine screen.

For instance, 12 / 64 + 80 means the following: 12 / 64 internal, followed by 80; then
followed by the filter screens
2) screen between fine screen and backflush breaker plate
NOTE: In the event of problems with the pressure resistance has to be supported
with a second support screen 1) !
When new screens will be ordered, it is absolutely necessary to keep following tolerances:
Screen shanger Support screen Filtration screen max.

type Ø-tolerance Ø-tolerance thickness of
(mm) (mm) screen package
SW_4_170_RTF 170,1 –0,4/+0,0 170,3 –0,0/+0,4 3 (mm)
Table VII
Safety solenoid interlock
On the screen changer cover is a solenoid interlock for safety mounted.
1 2
2
Fig.65 Safety solenoid interlock – safety hatch
The solenoid interlock (1) permits retracts and extends the piston only during closed cover (2).
The cover can be opened only if the piston is in a safe position.
NOTE: As safe position is the position where no melt can come out. If the green LED
(3) is on a safe position is reached.
Fig.66 Safety switch for the piston cover
If the piston cover (4) is opened and the piston is to be extended or retracted, this error
message will appear: “Nr.:2141: piston cover screen changer open”.
Limit switch
limit switch
venting position
limit switch
safe position
Fig.67 Limit switch - screen changer

Strand pelletizing system
The strand pelletzing system is installed downstream of the extruder and the melt filters
(depending on the system version used) and is used for the production of dry and free-flowing
pellets made from screened polymer melt.
The melt, which is continuously fed by the extruder, is discharged through the strand nozzle.
The produced strands slide on to the “ASP_200_SERIE “ (Strand pelletizing system; Typ ips-
SGU 220/2 HS) to cool down and solidify.
The strands are then cut to pellets in the downstream pelletizer and then transported with the
transport water through a cooling piping to the dewatering screen. The water and the residual
moisture are removed from the pellets in the downstream centrifuge.
The pellets are finally transported by a conveyor blower to an intermediate storage.
stran d d ie
str and p ell e tizer
pe lle t tran sp or t h ose
wa te r h ose
Fig.68 Strand pelletzing system
wate r pu mp
vibratin g motor
heat exchanger
pellet transport hose
dewatering scr een c entri fugal drye r
convey or bl ower*
Fig.69 Downstream equipment

* depending of design and type of the plant
Flow sheet - schematic of material flow
1
melt
inlet
exhaust air
2
M 7
M
oversize
5
3 8
M
4
M
M pellets outlet
cooling water outlet
6
cooling water supply
fresh water supply
water outlet
1 strand die 5 pellet drying centrifuge

2 automatic strand pelletizer 6 conveyor blower
3 pellet dewatering screen 7 cyclone system
4 water pump station 8 silo*
* depending on the type and design of the plant
Fig.70
Chapter 6
Operation
Do not operate the machine until

commissioning has been completed, and staff
working on the machine have read the
operating manual and in particular the
chapters relating to safety and hazard
warnings.
This chapter describes the processes for

switching the individual components of the
machine on and off.
Starting the plant
.... connect compressed air ....
.... Open supply connections (cooling water, fresh water).....
main switch 1
control voltage on
....Load the "recipe" by material to be processed ....
.... close material intake slide ....
.... Check temperature of individual heating zones approx. 1.5 hours ....
feeding customer automatic
feeding manual-operation
.... Fill cutter compactor slightly (to avoid dust collection upon cutter-compactor start) ....
cutter compactor on
.... Turn the button cutter compactor power to MIN....
feeding automatic-operation
.... Turn up button cutter compactor power step by step to maintain

tank filling level automatically and to increase the material temperature ....
.... When the material-specific temperature is reached in the cutter compactor ....
extruder on
Operation 107
.... Wait until extruder drive has reached full capacity ....
.... Open material intake slide stepwise according to bulk pressure and extruder drive load ....
flushing of extruder (option)
.... After short time flush extruder ....
.... close material intake slide ....
.... Empty the extruder – wait until the melt pressure drops to 20 – 30 bar
and/or the load on the extruder drive has dropped to approx. 30%......
extruder off
.... Remove any melt that has escaped ....
.... Spray pelletizing knifes with silicone spray and close pelletizing housing ....
extruder on
.... Wait until extruder drive has reached full capacity ....
.... Open material intake slide stepwise according to bulk pressure and extruder drive load ....
.... Set pelletizing speed ....
backflush filter automatic-operation
.... providing that the melt comes out uniformly and continuously from all extrusion die holes ....
.... check compressed air....
.... open sound insulation cover of pelletizer....
.... adjust length of pellets ....

.... set infeed roll speed (increase speed slightly for start-up) ....
....set water flowrate of pelletizer (increase slightly for start-up) ....
....separate rapidly the strands coming out from the extrusion die by means of a spatula. ....
....tilt strand chute to extrusion die....
....observe whether strands are inserted correctly in the pelletizer ....
.... set water flowrate and drawing speed ....
.... Check feeding; if necessary readjust the button cutter compactor power
to maintain desired temperature in cutter-compactor ......
.... set optimum tank temperature at button cutter compactor temperature;

if necessary redjust during material change ...
Operation 109
Shutting down the plant
.... Turn the button cutter compactor power stepwise to MIN. The dosed feeding of material
slowly emties the cutter-compactor ......
- Note that sudden shutdown of feeding may cause excessive temperature in the cutter-compactor!
.... If the load of the cutter-compactor drive (cutter-compactor tool has free run) and the material
temperature in the cutter-compactor have decreased ......
.
feeding off
cutter compactor off
.... Empty the extruder – wait until the melt pressure drops to 20 – 30 bar
and/or the load on the extruder drive has dropped to approx. 30%......
extruder off
.... Open pelletizing housing and clean pelletizing head from sticking plastic residues and time deposits ...
… Check temperature of material remaining in the cutter-compactor ....
control voltage off
main switch 0
.... Close supply connections (cooling water, fresh water, compressed air).....
NOTE: The aforementioned procedures, i.e. “Starting the plant, shutting down the plant”
shall be regarded as short instructions only. For detailed information regarding
starting- and shutting-down sequences of the individual plant components, see
the following pages of this chapter.
Explanations:
… Comments, working instructions ....
PRESS RESPECTIVE KEY OR OPERATE SWITCH

Feeding
The feeding (feeding customer) can be operated either manually or automatically.

The operating mode is selected by means of the feeding and selector switch and the
feeding selection touch screen.
Fig.71 Touch screen feeding selection
NOTE: If a fault causes the complete plant to be switched off, the feeding system is
switched off as well, and the selector switch will start flashing.
After the fault has been acknowledged and the plant is switched on again, the
feeding system will return to the previously selected mode of operation.
The feeding system can also be set manually by using the "on and off" setting
of the selector switch in the mode of operation selected.
Operation 111
Feeding customer
The feeding can be operated either manually or automatically.

The mode of operation is selected in the feeding selection touch screen (see page 57) using
the feeding customer manual off auto button.
manual mode - for manual operation and start-up of the plant
1. Press the button feeding customer manual.
2. Set feeding selection switch to automatic-operation or manual-

operation position.
The feeding will start operating continuously at the speed [%] set.
When the feeding runs the selector switch lights up.
3. Set the speed [%].
4. Switch off by pressing the button feeding customer off.
auto mode - for normal production
1. Press the button feeding customer automatic.
2. Set feeding selection switch to automatic-operation position.

The feeding is automatically set according to the power on the cutter compactor –
power and the speed set [%].
When the feeding runs the selector switch lights up.
NOTE: Feeding the "cold" cutter compactor cannot be performed automatically.
This is only possible when a specific material-dependent operating
temperature has been reached.
NOTE: The feeding is in manual-operation when the button is held down.
3. Set the speed [%].
4. Switch off by pressing the button feeding selection off, or by setting the feeding
selector switch to off operating mode.
NOTE: If the feeding selector switch is set to off , the entire feeding system
is switched off.
Process Combination
Start-up
1. Open supply connections (cooling water, fresh water, compressed air).
2. Switch on main switch .
3. Switch on key-operated switch control voltage off - on .
4. Load the "recipe" by material to be processed (see page 69).
5. Close material intake slide.
6. Heat up unit. After approx. 1.5 hours heating time check temperature of individual heating
zones.
7. Operate cutter compactor on pushbutton to switch on cutter-compactor. Fill

with material manually.
NOTE: When the cutter-compactor tank is empty upon start, we recommend to
feed material when the cutter-compactor is still off (manual feeding) so
that the rotor disk is covered and excessive dust collection is avoided.
8. Turn button cutter compactor power to MIN and readjust feeding to auto mode.
Check cutter-compactor filling and cutter-compactor motor power consumption.
See also "cutter compactor power" on page 55 in chapter 4.
Turn up cutter compactor power stepwise.
9. As soon as the cutter-compactor has nearly reached working load and the material-specific
temperature:
n switch on extruder drive by pressing the extruder on pushbutton when the

pelletising housing is open, the strand cooling bath pushed back.
NOTE: If the pelletiser housing is not opened till engage, the malfunction
“safety device granulation – HG” occurs.
When the load increases check extruder ampere, extruder load and melt pressure.
Excessive screw load

The causes could be as follows:
§ Insufficient temperatures
§ Material in the cutter compactor is too cold
§ Excessively compacted material
§ Intake slide open too wide
Excessive pressure
May be caused by wrong or displaced screens or too low process temperatures in the melt
filter or by a frozen palletizing die.
Operation 113
10. Wait until the extruder drive is at full speed, and open material intake slide stepwise
according to melt pressure and extruder drive load.
11. After short flushing of extruder close material intake slide.

This is necessary in order to remove the plastic residues which remain in the extruder
during heating-up. Without cutter-compactor the extruder is not filled, so that after some
seconds the extruder drive load is decreased to 50 % of the standard value. Now put the
extruder out of operation. Press pushbutton extruder off .
ATTENTION: Never let the extruder screw turn for longer than 30 seconds without
material to avoid metal abrasion between the extruder screw and the
barrel.
12. Remove any melt that might have penetrated at the strand die of the strand pelletizing
system respectively. .
13. Press pushbutton extruder on to switch on the extruder and the entire pelletiser
system.
14. Wait until the extruder drive is at full speed, and open material intake slide stepwise
according to melt pressure and extruder drive load.
15. Check whether the requested temperature in the cutter-compactor can be reached and
maintained respectively by means of the values set at button cutter compactor -
power. Readjust if necessary.
Restarting the machine after a shut down under full load
If the Process Combination has been shut down under full load make sure that it is restarted
within 5 minutes.
If this is not possible the material is liable to bake together ("freeze"). The cutter compactor
and the screw feed must be emptied completely before starting anew.
Shutdown
1. Empty cutter-compactor tank slowly by reduced dosing of material (reduce load at button
cutter compactor - power step by step by appr. 10-15% at intervals of some minutes).
NOTE: The frictional heat caused in the cutter-compactor during operation
increases upon emptying as only reduced quantities of cold material are
fed (which cools the hot precompressed material).
Too rapid an emptying procedure (or reduction of feeding) may cause
"freezing" of the material in the tank.
2. If the cutter-compactor tank is nearly empty, which can be checked by the following:
n reduced cutter compactor motor load
n reduced extruder motor load
n reduced material temperature
n reduced melt pressure
Press pushbutton cutter compactor off to switch off the cutter-compactor.
NOTE: During the shutdown process, do not leave the plant unattended.
3. Empty extruder (lower the speed), which can be checked by the following:
n reduced extruder motor load (extruder motor load appr. 30%)
n reduced melt pressure (melt pressure between 20-30bar)
Press pushbutton extruder off to switch off the extruder and the entire pelletiser
system.
CAUTION: There is a risk of injury during maintenance work due to high
melt pressure!
ATTENTION: At a melt pressure of more than 30 bar a return flow can occur in
the extruder intake area where the melt solidifies and makes it
difficult to restart the plant.
At a melt pressure of less than 20 bar, never let the extruder screw
turn for longer than 30 seconds without material to avoid metal
abrasion between the extruder screw and the barrel.
4. Check whether the material remaining in the cutter-compactor is loose or sticks to the hot
cutter-compactor elements.
If necessary empty tank completely.
5. Switch off key-operated switch control voltage on - off .
6. Switch off main switch .
7. Close supply connections (cooling water, fresh water, compressed air).

Operation 115
Backflush Filter
Start-up
The screen changer can be operated either manually or automatically (program-controlled).

See also chapter 5, "Logic diagram", page 95.
CAUTION: Never extend the pistons with the splash cover open. Danger of
splashing hot melt - DANGER OF INJURIES.
NOTE: Positively no piston movement in cold condition. - Operating temperature

±10°C of the melt temperature to be processed.
In order to ensure a uniform heating, wait for approximately 15 minutes when
the operating temperature is reached, before moving the pistons.
manual mode - for hand operation and plant-start up
Set screen changer selection switch to manual-operation position.

The selection switch is illuminated in this position. The selection switch flashes when the
hydraulics are operational.
Now the piston can be extended and retracted by operating the switch piston forward-0-
backward . (see also position on page 52, chapter 4)
Repeat the entire procedure using piston 2.
screen.
NOTE: The piston does not move except when the switch is operated and the other
piston is in production position.
If the backflush position or the screen change position is reached the piston
stops even if the switch has been operated. Operate the switch once again to
move the piston
If a piston is moving, the hydraulics are operational and the switches
flash.
NOTE: In order to avoid that the backflush breaker plates get jammed when the
piston retracts from the screen change position into the production position,
push the provided sliding sleeve over the plates or the piston respectively. If
the sliding sleeve has been properly attached the switch is flashes and the
piston can be retracted by operating the respective switch (correct
position of sliding sleeve ð see chapter 6, "Changing the screens", page 117)
Only if the switch is flashes then the extended piston can be retracted.
auto mode - for normal production
Set screen changer selection switch to automatic-operation position.

If the backflush pressure p 1 is reached at the pressure measuring device (see also Fig.62 on
page 96), a signal is given to the screen change control, thus releasing automatic
backflushing.
Note that the backflushing sequence can also be released manually.

Set selector switch to position auto-start . For further sequence, see pressure
controlled release. The pushbutton flashes when the backflushing process is running.
For program sequence of backflushing, see page 95, chapter 5.
If the screen changer is in automatic mode and if backflushing is not enabled, holding down
the switch piston forward for 2 seconds automatically moves the piston to the
screen changer position. The selection switch flashes when the hydraulics are operational.
Repeat the entire procedure using piston 2.
screen.
Operation 117
Changing the screen and the backflush nozzle
ATTENTION: Durning procedure of screen change and backflush nozzle change

selector switch screen changer must be in automatic-
operation position all the time.
Fig.72
1. Cover must be closed.
2. Wait until both pistons are in production position. (switches without light)
3 Set selection switch to automatic-operation position.

Hold the piston forward switch down for 2 seconds to automatically move the
piston (1) to the screen changer position. The LED on the solenoid interlock becomes
green.
NOTE: The selection switch flashes when the hydraulics are operational.
4. Open cover (2).

CAUTION: Use protective gloves. - DANGER OF BURNS.
11 1
12 10
9
4 3
5
7 6
8
Fig.73
5. Use spatula to clean backflush breaker plates (7) lightly from melt and dirt. Use tool (8),
which is supplied together with the screen changer, to pull off.
6. After the screen basket (12) has been cleaned, lift and remove dirty screens (5).
7. Clean support breaker plate (4) and screen basket (12).
8. Only upon changing the backflush nozzle (3):

8.1 remove support breaker plate (4)
8.2 replace backflush nozzle
NOTE: Set 2 center punch in the outer range of the backflush nozzle (3) with
a peening tool.
8.3 clean corners of screen holder of piston
8.4 insert support breaker plate again
9. Clean venting slots (11) and corners of screen holder of piston.
10. Insert new screen pack which normally consists of coarse screen, fine screen, coarse
screen. Press against the support breaker plate.
Be aware of the maximum thickness of the screen pack, see page 100, chapter 5.
ATTENTION: Providing screen packs of greater thicknesses may cause damage
to the screen changer.
Operation 119
11. Insert backflush breaker plate (7).

In order to preclude any distortion during operation, make sure that the protruding locking
pin (6) of the backflush breaker plate is placed into the groove of the screen holder of the
piston.
12. Push sliding sleeve (9) onto the piston.

Let reflector (10) coincide with light sensor.
The correct position is indicated by the light of the selector switch piston forward-0-
backward at the switch cabinet. Note that the piston can be retracted only when
the switch light.
ATTENTION: Positively no piston retracting when the sliding sleeve has not been
pushed on.
Danger of damage to the screen changer.
13. Close cover.
14. Press switch piston backward . The piston (1) moves to the sliding sleeve
position and stops.
14.1 Open lid
14.2 Remove sliding sleeve
14.3 Close lid.
15. Press switch piston backward , the piston moves to the front backflush position,
then automatically moves to production position and stops. Change the setting of the cycle
impulse with the tact time button.
The time that the piston must remain in the front backflush position can be set with the
flushing time button. The time that the piston must remain in the venting position can be
set with the degassing time button.
16. Repeat the entire procedure using piston 2.

NOTE: The requested piston is to be selected in the window “melt filter“ on the
touch screen.
17. Acknowledge the button backflush counter(reset to 0)!

Pelletizing system
Prior to start-up
1. Open supply connections for downstream equipment (fresh water, cooling water).
2. Fill water into basin up to shortly below the overflow.
3. Open cooling water cock at the heat exchanger of the dewatering screen.
Switching on
1. Switch on the extruder and charge with material. (see also extruder instructions of
operation)
2. Check the compressed air on the pelletizer and open sound insulation cover.
3. Adjust requested pellet length.
4. Set infeed roll speed (increase slightly for starting up the plant).
5. Set water flowrate of the pelletizer (increase slightly for starting up the plant).
6. Remove strands coming out from the extrusion die by means of a spatula and tilt strand
chute to the strand die.
7. Observe whether the strands are inserted correctly in the pelletizer.
8. Re-adjust and set water flowrate and transport speed.
9. Switch on synchronisation granulator.
Switching-off
1. Switch off extruder (see also Extruder)
2. Press pushbutton extruder off to switch off the extruder the vacuum pump and
the entire pelletizing system.
Operation 121
Pellets cooling and drying
The cooling time and/or the cooling intensity must be optimized so as to ensure the following:
n The pellets do not stick together in the pellet transport hose or at the
vibrating screen respectively. Pellets sticking together are particularly caused by
insufficient cooling through short retention times in the water current (choked heat
exchanger or use of insufficient water circulation pump).
n The pellets are not wet at the bagging facility. Wet pellets results from insufficient
drying in the upstream facilities.
n The pellets do not form bubbles due to strong cooling. Basically, bubbles are
formed when the pellets surface is cooled to rapidly. The shrinkage which results when
the pellet core cools off, can only take place inside, which simultaneously causes a
bubble.
Methods to avoid the aforementioned effects:

n Change knife head speed to change the pellets. Short pellets cool off more rapidly than
longer ones.
n Change cooling water temperature by means of the water temperature control valve at the
heat exchanger.
Chapter 7
Maintenance
and
Repair
Before performing maintenance or repair work

on the machine you must depressurize the
machine/plant and switch off the power supply
at the main switch. Secure the main switch
against re-enabling and display a warning
sign!
Before starting work on the machine, staff

must read the operating manual and in
particular the chapters relating to safety and
hazard warnings. This applies in particular to
staff who only work occasionally with the
machine, e.g. tooling, maintenance. The
owner/operator is responsible for observing
safety instructions!
Overview of maintenance work
Work to be carried out

(daily – every 1000 hours)
daily drain air system
clean blower grid
check cutter compactor knives for jagging and sharpness
check oil level of gear and refill if necessary (SYNTH. GEAR OIL CLP HC VG320)
clean and remove plastic residuals from sliding sleeve
clean screen insert
weekly lubricate seals of cutter compacter and extruder (SEALING GREASE)
check oil level of cooling liquid reservoir (THERMAL OIL)
clean the space between suction funnel and cutter compactor hood
clean the filter candle at the filter unit
clean screen changer piston with cleaning rope
check backflush breaker plates for impurities and burn out if necessary
clean lens of light sensor
dismantle and clean filter drum
clean screen round of centrifuge
every 500 hours test alarm signalling and shock sensor
check filters in coolant system and clean if necessary
check sliding sleeve for accurate fit
clean filter of hydraulic unit
every 500 hours clean screen of vibrating frame
after 500 to 700 hours 1st oil change at gear (SYNTH. GEAR OIL CLP HC VG320)
monthly check belt tension
check oil level at hydraulic unit (HYDRAULIC OIL VG46)
lubricate bearing centrifuge (LUBRICATING GREASE)
every 1000 to 8000 hours dismantle and clean extruder screw
Clean the housing of intakeslide and lubricate the spindle
Table VIII; For lubricants, see overview of lubricants on page 128.

Maintenance and repair 125
Process Backflush Pelletizing

Combination Filter system
001
002 002
004
011
012
016
038
040
045
046
048
049
050
055
056
070
072
078
079
086
090
104
109
112
122
124
For hatched fields, see general drawing on page 130.

Work to be carried out

(every 2000 hours - after 25000 hours)
every 2000 hours lubricate bearings (LUBRICATING GREASE)
clean the water pump
every 3 months Check electric screwed connections (terminals) and retighten if necessary.
every 3000 to 4000 hours

check knife holders in the cutter compactor for wear
min 1 x per year
dismantle and clean support breaker plates of filter changer
oil change at hydraulic unit (HYDRAULIC OIL VG46)
every 6 months test EMERGENCY STOP switch and safety devices
check tooth belt for wear and damage and replace if necessary
every 6000 to 7000 hours oil change at gear (SYNTH. GEAR OIL CLP HC VG320)
every 12 months check the extruder screw wear on the extruder “normal” use
exchange coolant (THERMAL OIL)
check backlash of jaw-type coupling
after 25000 hours,

oil change at gear (SYNTH. GEAR OIL CLP PG VG460)
no longer than 3 years
If needed clean or replace the filter bag and empty the dust collecting bin
Table IX; For lubricants, see overview of lubricants on page 128.

Process Backflush Pelletizing

Combination Filter system
130
139
145
157
161
162
169 169
170
175
196
197
200
220
230
For hatched fields, see general drawing on page 130.

Overview of lubricants
Utilities hydraulic oil HVLP synth. gear oil synth. gear oil
ambient temp.: DIN 51524 CLP HC CLP PG
+5 to +35°C part 3 DIN 51517 / part 3 DIN 51517 / part 3
ISO Classification viscosity class viscosity class viscosity class
VG 46 VG 320 VG 460
Hydrauliköl ECO Gear Poly Gear

HVLP 46 320 S 460 S
Vitam Degol Degol

HF-46 PAS 320 GS 460
Bartran Enersyn Enersyn

HV 46 EP-XF 320 SG-XP 460
w Alphsyn EP 320
w Hyspin AWH-M 46 w Alphsyn PG 460
w Optigear sy. A 320
w Hyspin HVI 46 w Tribol 800/460
w Tribol 1510/320
w Arnica 46 Blasia
w Autol Hys 46 SX 320
Univis
N 46
w Renolin MR 46 MC Gearmaster SYN 320

w Renolin
w Renolin B 46 HVI w Renolin Unisyn
PG 460
w Renolin ZAF 46MC CLP 320
Klübersynth Klübersynth
GEM 4-320N GEM 6-460N
w DTE 15 M Mobilgear
w DTE 10 Excel 46 w SHC Gear 320 Glygoyle 460
w Excel 46 w SHC 632
Tellus Omala
Omala S4 WE 460
S2 VX 46 S4 GX 320
Rando
HDZ 46
Equivis Carter
ZS 46 SH 320

Utilities thermal oil lubricating grease sealing grease

ambient temp.:
+5 to +35°C - DIN 51502/51825 DIN 51502/51825
ISO Classification viscosity class NLGI-class NLGI-class
2/3 2/3
Addinol
XW 15
Aralub Aralub
MKL3 MKL3
Energrease Energrease
LS-EP 3 LS-EP 3
Marlotherm N
Gadus Gadus
S3 V220C 2 S3 V220C 2

General drawing - maintenance work
112 056 112
016
002
086
055 139
046
169
079 109 162
161 078 050 049 012 048
122 196
169
170 104
157 130 045 038 004

124 220
001 011 038 090 175
002
200
230
145 070
197 072 040
145
Fig.74
For work to be carried out, see overview of maintenance work on page 124.
Process Combination
CAUTION: During work on the cutter compactor, ensure sufficient ventilation,

switch off the main switch and secure against reactivation.
Dismounting and mounting the rotor knives

004
CAUTION: Make sure that knives with a depression are used only. When
inserting into the knife holder make sure that the ball engages in the
depression. Otherwise, knife parts may be tossed about and cause
personal injuries or damage to the machine.
rotor knife or
rotary knife substitute
depression
ball knife holder lower part
Fig.75
Before dismounting the knives clean screws and knife holders from plastic residues. Clamping
surfaces must also be cleaned before mounting the knives.
CAUTION: Clamping surfaces that are not sufficiently cleaned and/or

insufficient tightening of clamping screws may result in that knife
heads are tossed about, causing personal injuries and damage to the
machine respectively.
The knife holders (1) are designed as clamps. Loosen clamping screws (3) to remove (change)
the knives (2).
3 fastening torque : 95 Nm
Fig.76 rotor knife
If any of the rotor knives has been broken the cutter compactor - also below the rotor disk -
and the screw must be carefully checked for metal parts.
Unbroken knives must be dismounted and checked for damage such as fissures and cracks.
Regrinding the rotor knives
Note that the sharpness of the rotor knifes influences the cutting capacity input into the
material, which is still increased the less cut material is fed.
The sharper the rotor knives the smaller the material is cut, but the smaller the cutting
capacity input into the material.
If the requested preheating temperature (working temperature) is not reached in the cutter
compactor, break the cutting edges carefully using a whetstone.
High motor load of the cutter compactor at low dosing quantities indicates dull knives.
Note that the rotor knives can be reground several times. The cutting edge need not be free
from notches.
Knife material Grinding wheel acc. to DIN 69100

HSS 89A = white alumina
Tungsten carbide C = silicon carbide, green
Surface quality required for regrinding: N6 as per DIN ISO 1302
Make sure that the cutting forms are observed for rotor knives made of HSS and tungsten
carbide metal. - Otherwise, danger of knife fracture.
Rotor knife
R 2,5
5 mm
L min = 26 mm
Fig.77 (drg. no. 10103600, 10104509)
Rotor knife holders

157
ATTENTION: Depending on the material to be processed it is often necessary to

remove individual knife holders. The so open taps of the rotor disc must
be closed with countersunk bolts. Otherwise, when mounting the knife
holders the contamination may cause a deformation of the squares
mounted at the lower side.
Maintenance of the cutter compactor bearing

038 130
The cutter compactor bearing must be periodically lubricated and sealed.

An additional lubrication increases the life of the bearings after "break-in" time.
Lubricate the cutter compactor bearing when the machine is running.
Material penetrating in the form of dust indicates that the cutter compactor must be sealed
with sealing grease.
D
D
S
Fig.78 bearing
lubricating point S sealing point D
Lubricant 1) .................. lubricating grease .................................................. sealing grease

Quantity ....................... appr. 55 grams ...................................................... appr. 35 grams
Interval ........................ 2000 hours .................................................................... weekly 2)
Table X
1) See also "overview of lubricants" on page 128.

2) Carry out more often in the case of dust penetrating.
Maintenance of electrical intake slide

124 220
Open the lid of the intake slide ca. 1000 till 8000 hours.
Clean the compartment and lubricate the spindle (2).
The intervall depends oft he processed material as well as oft he amount of contamination.
NOTE: In case of unusefull amount of residuals, check the sealings (3) or replace
them.
NOTE: to preserve its smooth function move the intake slide at each shut down of
the machine but at least once a month (0-100%).
Oil change
The helical worm gearbox (1) mechanical power train is maintenance free.
The gear has been filled with synlub at the manufacturer´s workshop.
(see synth. gear oil CLP PG VG460 included in the list of lubricants on page 128)
Require oil change after 25000 operating hours or after 3 years latest.
See also “Lenze-helical worm gearbox, GSS04-2M HBR 063C12” given in the annex.
3
2
Fig.79 Intake slide setting – outside of the cutter/compactor bin.

Maintenance of the powered exhaust system
5 6
7
4
2 3
Fig.80 powered exhaust system
1) bin top complete 5) centrifugal blower

2) maintenance opening 6) filter housing
3) suction funnel 7) filter bag*
4) cyclone 8) dust collecting bin
* depending on the type and design of the plant
045
.... Open maintenance doors (2) and clean the space (pointer) between suction funnel (3)
and cutter compactor hood (1) periodically (weekly).
230
.... Clean or replace the filter bags (7) and empty dust collecting bin (8) if needed.
Maintenance of the extruder drive

011 038 090 175
In the interest of a long working life, it is recommended to drain the lubricant at the intervals
specified in the following table XI and to refill with fresh lubricant after careful cleaning of
the transmission.
Refilling of inadequate lubricating agents might cause damage. Do not mix different
lubricating agents.
ATTENTION: Do not mix synlub and mineral oil.
sealing-filling hole
flange globe
filling opening
groove bush
sealing-filling hole groove bush
flange globe
oil inspection glass
oil drain
Fig.81
sealing point
gear flange globe groove bush
Lubricant 1) ............ synth. gear oil CLP HC VG320 ......... sealing grease ........... sealing grease
Quantity ................. approx. 93 litres 2) ............................ appr. 25 grams ......... appr. 38 grams
Interval .................. 3) ...................................................... weekly ................................ weekly
Table XI

2) See oil level gauge
3) The first oil change is to be carried out after 500-700 hours of operation.
Any further oil changes: after a further 6000 – 7000 hours of operation or after 2 years at
the latest.
An oil change takes place by draining the gearing oil, which should be at operating
temperature, using the oil drain plug.
See also "Köllmann-gear drive; EKG 120-315/EO" given in the annex.
Rotex-coupling
200
Check the backlash of the Rotex-coupling every year.
feeler gauge
spider
Fig.82 Inspection oft he limit of wear
In case of a backlash > Xmax. the flexible spider must be replaced.
Limit of wear
ROTEX size
Xmax.
75 6 mm
90 8 mm
100 9 mm
Tab.XII
See also "KTR Kupplungstechnik-jaw-type coupling; ROTEX" given in annex.

Lubricating the main drive motors
Note that the electric motors must be lubricated at regular intervals.

NOTE: For grease type and quantity see type plate.
An additional lubrication increases the life of the bearings after "break-in" time.
Lubricate the electric motors when running. If the entire quantity of grease is put in at once
with the motor at a standstill, part of the grease might penetrate into the motor through the
internal bearing seal.
Fig.83 cutter compactor motor
Fig.84 extruder motor
See also " Siemens- Low-voltage motor; 1LE1" and "ABB - low voltage motor; M3BP
315LKA" given in the annex.
Extruder screw
122 196
In order to ensure a long service life it is useful to dismantle the screw after approxiamtely
1000 to 8000 operating hours and to clean it thoroughly.
The interval of the screw dismantling largely depends on the material processed as well as on
the type and degree of impurities.
Wear and tear on the extruder screw must be checked (see screw measuring protocol). For
abrasive applications or special applications like PA 6, the screw must be checked every 6
months and for normal applications once a year. Extreme wear can lead to screw failure!
Refurbishment of the standard armor is possible without extra effort and expense till wear is
no more than 2mm on the diameter of the screw.
CAUTION: Use protective gloves and clothing for dismounting and mounting -
DANGER OF BURNS!
Dismounting
Empty extruder as far as possible before dismounting the screw.
saf ety screw

tie rod
dism ounting
direc t ion
screw
spindle gear
t hreaded spin dle pull-off flange
hand drill
Fig.85
1. Remove tools such as melt filter, die etc. which are flange-mounted to the extruder.
2. Remove extruder- and cutter compactor motor fuses.
3. Heat cylinder to processing temperature + 20°C (max 320°C).
4. Remove safety screws of tie rod.
5. Unscrew and remove tie rod from screw.
6. Use screws to fasten double flange to gear.
7. Screw spindle gear down to double flange.
8. Screw threaded spindle into the screw.
9. Use hand drill for driving the spindle gear. Pull off screw.
10. Remove screw completely from the cylinder. Use wire brush for cleaning the hot screw
carefully.
Mounting
hand dril l
sp indle gea r
dou ble flange
mou nting
dir ection
sc rew
toot hed whee l
thre ade d spi ndle
Fig.86
1. Heat cylinder to processing temperature + 20°C (max 320°C).
2. Make sure the clean screw is thoroughly lubricated in the area of the driving toothed
wheel work (high-temperature grease up to 1000°C) in order to prevent that hot plast melt
remaining in the cylinder gets stuck to the screw.
3. Push screw into the cylinder manually as far as possible.
4. Screw threaded spindle into the screw.
5. Use hand drilling machine to drift the spindle gear and to pull in screw up to the guard
window (hexagonal socket screw).
6. Rotate screw until the screw rear end is locked into place.
7. Pull in screw until the stop is reached.
8. Remove threaded spindle and spindle gear.
9. Screw tie rod into the screw.

Screw in until the stop is reached, then turn back to the left until the screws can be
mounted.
10. Secure tension rod disk with screw.

ATTENTION: Secure safety screw with „Loctite 243“!
11. Set normal working temperatures at the heating zones.
12. Provide extruder- and cutter compactor motor fuses.
13. Use sealing grease to seal off extruder bearing.

See also "Maintenance of the extruder drive" on page 136.
Extruder cooling system

040 072 197
filling opening
oil inspection glas
tube heat exchanger
thermal oil pump

line filter
thermal oil outlet
Fig.87 Oil-cooled system
ATTENTION: Retighten the oil plugs after six months.
Criteria for changing the thermal oil
n To prevent the thermal oil from loosing its cooling effect, the oil should be changed if its
viscosity is too high.
Adding fresh oil reduces the viscosity, allowing the drain interval to be extended.
thermal oil
intrinsic viscosity .................................................................................. 40 to 50 [mPas]

max. admissible viscosity at 20°C ...................................................... 250 to 300 [mPas]
Table XIII
ATTENTION: Do not mix oil different manufacturers.
n Also, the oil should be changed whenever there are traces of residues in the filter. The
filter must be cleaned every 500 hours. An increase in the cleaning frequency
(approximately every one to two days) is a sign of an increase in the thermal oil viscosity,
requiring the oil to be changed and the oil tank to be cleaned.
n The oil sould be changed once a year with the cleaning procedure. Only residue free
cleaning agents should be use.
NOTE: The black colour of the thermal oil is no criterium for changing the oil.
Thermal oil change
1. Machine/system is switched on.
2. Set temperature controller to 100°C ð Solenoid valves are open.
3. Open filling opening.
4. Open thermal oil outlet and drain oil.
5. When oil has finished exiting the system, close the oil outlet and fill up with thermal oil to
¾ of filling level display to flush the cooling system.
6. Open thermal oil outlet and drain oil. (you may need to reduce the temperature to 80°C to
ensure that the solenoid valves are open)
NOTE: Repeat flushing step if needed.
7. When oil has finished exiting the system, close the oil outlet and fill up with thermal oil to
¾ of filling level display.
8. Vent the cooling system (heat exchanger, oil tank, pump) using the venting system.
See "Hainzl- oil coolant unit; 10260024 A", included in the annex.
9. Pump runs steadily ð Oil fill level okay.

Pump starts up and stops again ð Top up with oil and vent again.
quantity liquid change
thermal oil 1) ................................... approx. 30 litres ..................................... 1 x per year

Table XIV
Measures taken to increase the lifetime of the thermal oil
n Keep plant clean

Make sure that accumulation of foreign deposits in the cooling system is kept to a
minimum.
n Make sure the max. temperature (310°C) is not exceeded. This may deteriorate the oil.
n Do not shut down the plant when it is hot.
Allow the heating/cooling zones to cool down under 100°C before shutdown.
n Check the equalizing reservoir level at regular intervals.
A low level may cause strong turbulences at the oil surface, allowing a high amount of
atmospheric oxygen to blend into the oil. This will have a detrimental effect on the oil.
n A safety device is integrated into the plant, in order to allow oil to be exchanged in all
heating/cooling zones, independently of the controller setpoint. This prevents oil from
stagnating over a prolonged period.
Maintenance of pump
Bearing is in the plain bearings or ball bearings of the drive motors which are permanently
greased. Therefore they are maintenance-free.
Check bearing continually for low-noise and vibration-free run.
Remove dirt from the surface of the driving motor periodically.
In case the conveying performance decreases, check for contaminations or damaged pump
unit.
Cleaning the filter
The filter should be cleaned at regular intervals (every 500 hours) to remove any traces of dirt
and contamination.
Overheating of heating zones may be a sign of dirt in the filter!
To remove the filter cartridge, shut off the filter inlet and outlet by means of the ball valves.
Remove the oil drain plug from the lower side and drain the oil. Bleed filter on the upper side.
Clean the filter cartridge with a cleaning liquid (e.g. spirit) and blow through compressed air
from the inside to the outside. Be cautious to prevent dirt from getting into the filter cartridge
(clean oil side).
Maintenance of tube heat exchanger
Clean heat exchanger periodically and remove any dirt or accumulations consisting of lime,
suspended matter, plastic residues, etc.
Backflush Filter
012 048 049 050 078 161
Cleaning the screen changer pistons

048
Plastic residues that stick to the parts protruding from the screen changer block get charred
and hard due to heat influence.
This results in jammed pistons or friction. In order to preclude this, the pistons must be
periodically cleaned with the cleaning rope (supplied together with the screen changer)
(Fig.88).
Make sure that the extended zone of the piston surface is also cleaned periodically during
screen change.
Fig.88
CAUTION: Use protective gloves - DANGER OF BURNS!
NOTE: Extend and retract either piston at least 1-2 times a day, even if no
backflushing or screen change is necessary.
This measure increases the operational reliability and reduces the probability
of jammed pistons.
If the piston gets seized
1. Clean free piston surface with cleaning rope (or with the scraper if necessary).
2. Check solenoid valves and proximity switches for proper function.
3. Set selector switch screen changer manual - auto - auto-start to position

manual . Open pressure relief valve to 250 bar at the hydraulic unit. Check piston for
movement. Otherwise ð proceed as indicated under item 4.
4. Heat screen changer to 300°C. Then repeat procedure described under item 3.
ATTENTION: The drive motor of the hydraulic unit is designed for a 10% duty
cycle only. Consequently, continual extending and retracting of the
piston is liable to damage the pump motor.
5. Clean free piston surfaces.

Repeat procedure until the piston allows free extending and retracting again.
ATTENTION: Turn back pressure relief valve to 200 bar!
6. Clean piston surfaces periodically.

Checking the automatic positioning of the piston in venting position
piston switch rod

block edge limit switch
Fig.89
Procedure
1. Set selection switch screen changer manual - auto - auto-start to manual .
2. Piston 1 must be in production position. Open cover and check if block edge and
piston are aligned. Ascertain value of measurement X.
Close cover.
CAUTION: Wear PROTECTIVE CLOTHING!
3. Move piston 1 to venting position, see "Changing the screen" page 117 in Chapter
6.
4. The value ascertained for X - 112.5±2.5 mm = preset dimension A
5. If necessary, correct preset dimension A by changing the positions of the end position
delimiter switches.
NOTE: The set measure should be taken as a reference value. Depending on the
material to be processed the optimum venting position may sughtly vary
from the set measure and should therefor be empirically determined during
operation.
Depending on the production conditions, we recommend to keep the piston
in the venting level as long as possible in order to ensure proper venting.
6. Move piston 1 to production position, see "Changing the screen" page 117 in
Chapter 6.
7. Repeat the entire procedure using piston 2.

NOTE: The requested piston is to be selected in the window “melt filter“ on the
touch screen.
Maintenance the backflush breaker plate and the support breaker plate
049 161
Check breaker plates for impurities and clean if necessary.
backflush breaker plate support breaker plate
Interval 1) weekly every 3000 hours
Table XV
1) Carry out more often, if extremely printed material is processed.
Cleaning the backflush breaker plate and the support breaker plate
For dismounting the breaker plates, see "Changing the screen", chapter 6, page 117.
Pre-clean the breaker plates with a plastic scraper. Burn off any leftover impurities.
Only use a temperature-controlled furnace at a maximum temperature of 400°C.
After firing the plates cool them slowly (DO NOT accelerate the cooling process with water).
ATTENTION: Only use a temperature-controlled furnace. Never use hand torches or
similar, since a maximum temperature of 400°C must not be exceeded!
Cleaning light sensor

050
Fig.90 Light sensor
Clean light sensor at regular intervals (weekly) using a soft cloth.

Replacing the proximity switches
CAUTION: Before replacing the proximity switches (1) and hydraulichoses (2)
make sure the hydraulic power unit is non-pessurized.
2 2
1 1
Fig.91 Proximity switches
Fig.92 Pressure compensation system
Mount pressure relief hose (3) for relieving the excess pressure.
NOTE: Before the hydraulic power unit is pressurized again, dismantle pressure
relief hose and check hydraulic oil level.
Maintenance of the hydraulic system
Hydraulic cylinders
The hydraulic cylinders are virtually maintenance-free.

The lifetime of the sealings is dependent on the operating temperature and the cleanliness of
the operating medium.
Should the cylinder be leaky use original sealings.
Changing the sealings
1 2 3 4
Fig.93
1. Screw cylinder head (1) from cylinder tube (2).
2. Pull piston rod (3) including piston (4) off the cylinder tube.
3. Change sealings.
4. Reassemble cylinders carefully. Make sure seals do not get into contact with sharp-edged
objects.
5. Vent cylinders. The cylinder is vented when the operating medium is discharged without
bubbles and no foam formation occurs.
Hydraulic unit
079 109 162
See also “Rexroth-hydraulic power unit; AKAG032 B411-0-AC", included in the annex.
n Check oil filter.

During start-up at intervals of 2 - 3 hours (clean if necessary). During the following week
check daily. After completion of one week the filters should be cleaned according to
requirements (every 500 hours).
n Check oil level.

Check liquid level of unit at regular intervals (once a month).
n Changing the hydraulic oil.

Drain oil at operating temperature and fill in new hydraulic oil (every 3000 to 4000
hours).
For hydraulic oils, see overview of lubricants on page 128.
ATTENTION: Considerably old or contaminated system fluid cannot be upgraded
by adding fresh fluid.
Hydraulic hoses and piping
n Check all lines, hoses and screwed connections periodically for leakage and visible
damage. Repair immediately. Splashing oil may cause injuries and fire.
n Replace hydraulic hose pipes at the specified or at reasonable intervals respectively, even
if no defects are perceptible that are relevant from the safety point of view.
Pelletizing system
Automatic Strand Pelletizer
Strand nozzle
The strand nozzle requires to be cleaned at regular intervals.
Strand pelletizer
For maintenance work please refer to documentation of

See also " Strand pelletizing system; Typ IPS-SGU 220/2 HS "
Cleaning the filter candle

046
See also "WFS-fluidized bed filter; 501 6/4“, included in the annex.
Pellet Dewatering Screen
Vibrating motors
Check fastening screws of vibrating motors periodically.

If the pellets are conveyed too slowly or too rapidly on the vibrating screen, change
conveying speed by readjusting the weights of the vibrating motors.
The vibrating motors are adjusted to 70% at the manufacturer´s workshop.
0
50
100%
marking
adjustable weight
fastening screws
rigidly mounted weight
vibrating screen
Fig.94
See also "Oli-motor vibrator; MVE 400/15", included in the annex.
Maintenance of the vibrating screen

086
Use dissolving agent or wire brush to remove any furring occurring at the screen.
If the conveyance of the pellets cannot be ensured, retighten adjusting nuts.
adjusting nuts vibrating screen
Fig.95
Screen insert
016
Clean screen insert of water overflow reducer daily.
Fig.96
Filter drum
055
Dismantle and clean filter drum periodically (weekly)
Fig.97
Water Pump Station
Maintenance of the water pump

139
Bearing is in the antifriction bearings of the drive motors which are permanently greased.
Therefore they are maintenance-free.
In case of extended shutdown, the bearings must be changed after 4 years as the grease gets
old and loses its lubricity.
Check bearing continually for low-noise and vibration-free run. Furthermore, check bearing
temperature periodically. The bearing temperature should be max. 50°C above room
temperature and should not exceed 90°C.
See also "Tuma-water circulation pump; CM 40-200B ", included in the annex.
Cleaning the water basin and the heat exchanger
Clean water basin and heat exchanger periodically and remove any dirt or accumulations
consisting of lime, suspended matter, plastic residues, etc.
Open drain cock to empty the basin completely. Clean basin.
If the cooling capacity of the heat exchanger is not sufficient any more to keep the pellets
cooling water at a constant temperature, clean the cooling tubes.
See also " CS Impex -heat exchanger; SCP 806-W-2-Weg ", included in the annex.
Pellet Drying Centrifuge
Cleaning the centrifuge

056
CAUTION: Use only screw-type clamps (1), do not use quick couplings that can
2 2
1
3
4 5
Fig.98
1. Centrifugal dryer open.

NOTE: Centrifuge continues running (follow-up). You can only open the machine
when it is at a standstill. (Green lamp is lit.)
2. Release the tension latches (2) to lift open the centrifuge housing.
CAUTION: Before performing any work that requires you to open the
centrifuge, turn off the main switch and secure against
reactivation.
3. Spray the screen (3) clean with water and rinse.
4. Open the cover (4) and clean the blower stage (5).
CAUTION: DANGER OF CRUSHING!
Removing the screen

(necessary when replacing wings or performing a complete cleaning)
CAUTION: Use only screw-type clamps (1), do not use quick couplings that can
detail
11
10 9
Fig.99
1. Centrifugal dryer open.

NOTE: Centrifuge continues running (follow-up). You can only open the machine
when it is at a standstill. (Green lamp is lit.)
2. Release the tension latches (2) to lift open the centrifuge housing.
CAUTION: Before performing any work that requires you to open the
centrifuge, turn off the main switch and secure against
reactivation.
3. Remove the top (6) of the screen by loosening the hexagonal nuts (7) and opening the eye
screws (8).
4. Remove the base (9) of the screen.

Loosen the hexagonal nuts (10) and detach the front portion of the base.
After the base is detached from the rear mount (11) hook, the screen portion can be
removed toward the front of the centrifuge housing.
Maintenance of centrifugal dryer bearing

112
Fig.100 Fig.101
lubricating point S
lubricant 1) ................... lubricating grease

quantity ........................ 5 grams
interval ......................... monthly
Table XVI
1) See also the list of lubricants on page 128.

Pellet Transport System
Clean blower grid (daily).

002
Fig.102 Conveyor blower
See also "Kongskilde-high-pressure blower, TRL 40", included in the annex.
CAUTION: Use only screw-type clamps (1), do not use quick couplings that
can be applied or released without tools. Do not remove the
existing cover grilles on the intake side.
Belt drives
104 170
General
Belt drives allow power to be transmitted in a most economical and reliable way. However, to
ensure a reliable operation, the belts and drives require proper maintenance.
Each belt has the potential for a long service life. Regular maintenance work ensures trouble-
free operation of your drive belts and drives for an extended period of time and precludes any
machine down-time as well as expensive nonproductive time.
NOTE: Only allow trained service staff to work on the belt drives.
CAUTION: Prior to starting maintenance work, disconnect drive from power

supply, even in the case of a short inspection. Lock control cubicle
and attach a note saying “Off because of maintenance work. Do not
restore power.” Take key with you and remove fuses, if possible.
NOTE: Keep area around the drive clean and free of dirt or other foreign objects.
Make sure the floor is clean and free of oil and waste.
ATTENTION: Shield drives properly. Make sure each belt drive is completely shielded
during operation. Proper shielding not only reduces maintenance work
but also protects the drive from harmful surroundings.
Maintenance
Preventive maintenance
Regular drive inspections are the first stage of preventive maintenance.
· Watching and listening:

Watch and listen for any noise or vibrations generated during drive operation. Any properly
dimensioned and serviced drive runs smoothly and silently.
· Inspecting shielding:
Check shielding for looseness and defects. Keep free of waste and dirt. Any material
accumulating on the shielding has an insulating effect and may cause the drive to run hot.
· Oil and grease:

Check for oil or grease dropping out of the shielding. This may be due to excessive greasing
of the bearings. Oil or fat may affect the belt material and cause the belt to swell and get out
of shape, thus reducing its service life.
· Locating devices:
Finally check motor locating devices for tight fit. Check slide grooves or rails and clean or
slightly grease if necessary.
Inspection intervals
The intervals for inspection of the drives depend on the following:

· drive speed
· drive service cycle
· minimum and maximum ambient temperature
· surrounding
NOTE: High speed, heavy loads, frequent starts/stops and extreme temperatures
require shorter inspection intervals.
In most cases a quick visual and auditory inspection once per month is
recommended.
A complete standstill of the drive for a careful inspection of belts, pulleys or

crown gears and of all other drive components once every three to six months is
recommended.
Careful inspection/service
Once the drive is disconnected from the power supply and a note is attached, detach shielding
and start inspection.
· Inspecting shielding:
Check shielding for possible defects. Remove any dirt to preclude thermal insulation and
ensure sufficient ventilation. Remove any grease or oil accumulated as a result of excessive
greasing of the bearings.
· Inspecting belt:
Mark the belt, or in the case of a multiple belt drive one of the belts, with a point. Check belt
drives for fissures, chafe marks, cuts or irregular wear.
Check belt for excessive warming. It is normal that belts get hot during operation, however,
certain limit values must not be exceeded. In case belts are so hot that you cannot touch them
action must be taken. The maximum temperature that may occur during operation of a
properly maintained drive belt is 60°C.
Belts showing clear signs of fissures, chafe marks, irregular wear or any synchronous belt
with incomplete toothing should be replaced.
· Inspecting pulleys:
Once you have removed belts from the drive, check pulleys or crown gears for irregular wear
or visible defects. Sometimes wear is difficult to detect; use a pulley gage to check for wear
that is invisible with the naked eye.
Be sure to check pulleys and crown gears for correct alignment and mounting. Non-aligned
pulleys or crown gears may reduce the service life of the belt. Non-alignment is mainly due
to:
§ pulleys not being correctly mounted on the shaft;
§ motor shafts and driven primary shafts not being parallel;
§ pulleys being tilted due to incorrect mounting.
To check correct alignment, you need a ruler or, in the case of drives with a great center
distance, a steel tape. You can also use a thick string. Put ruler or tape on top of the pulleys.
In the case of non-alignment, there is a gap between pulley surface and ruler, tape or string.
However, make sure that the distance between groove center and outer surface of the two
pulleys is the same.
· Checking alignment tolernace:

As a general rule, the pulley alignment of belt drives should not deviate by more than ½° or
5mm per 500mm center distance. The alignment deviation of synchronous belt drives should
not exceed ¼° or 2.5mm per 500mm center distance.
The greater the alignment deviation, the higher the risk of an unstable belt, which increases
belt wear and facilites distortion of the V-belt.
· Checking other drive components:

Check motor locating devices for tight fit. Make sure that slide rails are free of waste,
obstacles, dirt or rust.
· Checking belt tension:

Finally check the belt tension and re-tense, if required. Then make a final alignment check.
In case the tension is too low, the V-belts may slip. Too high a tension reduces the service life
of V-belt and rolling bearings and may cause the shafts to break.
The optimum tension is such a tension, where the V-belt is under full load and does not slip.
Experienced mechanics may be tempted to check the tension with their thumb; EREMA,
however, recommend the use of a tension tester, enabling a simple and precise tension
measurement.
Checking and adjusting the belt tension
Note that an appropriate belt tension is required for optimum operation. Inadmissible tension
causes malfunctions and accelerates the wear of the belt.
Once it is adjusted make sure the center distance does not vary during operat ion. Otherwise,
the belt tension would be reduced. In the case of the synchronous belt this might cause a
skipping of teeth.
A straight parallel run requires that the shafts and pulleys are carefully aligned in parallel.
Any excessive error of parallelism will result in diverging edge stress, causing the belt to run
off to the side with higher edge stress or to run against a flanged wheel. This would cause
excessive running noise and excessive belt wear. Make sure that the synchronous belt does not
protrude from the crown gear. If required relocate the driven pulley slightly.
Fig.103 Angle error Fig.104 Error of parallelism
NOTE: Note that proper handling is of utmost importance when mounting the belt.
Make sure that the belt is not distorted or buckled and that no angles
occur.
Positively no forced belt mounting.
Checking the tension of V-belt or synchronous belt
CAUTION: Check belt tension with master switch in OFF position only!
NOTE: Usually a higher tension is required during the running-in period. Therefore,
when tensing belts of new drives, make sure the deflection force is about 1/3
higher than the respective maximum value given in below table. Check the
belt tension after the running-in period.
By means of the Sonic tension tester
Unlike conventional tension testers,

which display the deflection force, the
Sonic Tension Tester analyses the
sound waves emitted by the drive belt
when being tapped. The vibration
frequency of a drive belt depends on
belt tension and mass and span length.
The tension tester calculates the
tension from the frequency.
Fig.105 e.g. Sonic tension tester
1. Enter unit weight (see Sonic operating manual), width and span length. This data is stored
even if you switch of the Sonic tension tester.
2. Bring the small sensor close to the belt and tap the drive belt so that it starts vibrating.
3. Press the Measure key. The computer processes the sound waves emitted by the belt. The
tension is displayed in Newton or in Hz.
Mounting or replacing a synchronous belt (toothed belt)
1. Switch off master switch.
2. Remove belt cover.
3. Loosen motor plate clamping screws.
4. Move motor until belt gets slack so that you can remove it without the use of levers.
ATTENTION: Never use lever to remove drive belt!
5. Remove old belts. Check for irregular wear.

ATTENTION: Always replace full set of belts! Never mix old and new belts!
6. Choose correct belt for replacement. è see EREMA parts lists.
7. If required, clean belt and crown gears using a cloth soaked with a non-volatile solvent.
We warn against applying the solvent to the belt or allowing it to soak. Never use a sharp-
edged object to remove fat or dirt. Make sure the belts are dry before using them on a
drive.
8. Check crown gears for irregular or excessive wear.

Make sure the pulleys are in true alignment. Synchronous belts absolutely require true
alignment.
9. Check other drive components, such as bearings, shafts, etc., for alignment, wear,
lubrication, etc.
10. Mount new synchronous belt on crown gears.

ATTENTION: Never use levers or apply force!
11. Readjust drive center distance until correct tension is displayed on the tension tester used.
Manually rotate drive and retest tension.
12. Tighten motor plate clamping screws.

Make sure all components are locked as any change in center distance will affect the
driving power.
13. Mount belt cover and check for completeness of all fasteners.
ATTENTION: Positively no operation when the belt cover is dismounted.
14. Allow belts to run in for a while. To do so, operate drive under full load, stop and readjust
according to below table.
15. Pay attention to any unusual noise or vibrations after start. We recommend you to stop
and inspect the machine after a while. In case the bearings get hot, the belt tension may be
excessive or the bearings are not in true alignment or improperly lubricated.
Checking the belt tension with Sonic tension tester
Check belt tension monthly.
Z1 Z2
Dw1 Dw2
Fig.106
P n T G fmin fmax
Synchronous
Z1 Z2 selected belt
belt drive
kW rpm mm kg Hz Hz
Poly Chain GT2 7.90 41.7 43.6

centrifugal dryer 200 1490 48 192 1287
14MGT-4410-90 (0.79) (35.6) (37.8)
P ....... drive power G ........ unit weight input value

n ....... drive speed for Sonic 505C/507C (305)
Z1 ..... grooves-DriveR fmin ... minimum frequency
Z2 ..... grooves-DriveN new belt (used belt)
T ...... span length fmax ... maximum frequency
new belt (used belt)
Table XVII Recommended deflection forces of synchronous/toothed belts.
Mounting and dismounting the pulleys
It is very important that the pulleys are correctly mounted and in true alignment. The bolts
and locking screws must be tightened using the correct torque.
The pulleys are mounted on the shafts with TAPER-LOCK ® spring collets.
1 5 2 3 4 2 5 1 3 4
Fig.107 Pulleys mounted with 2 screws Fig.108 Pulleys mounted with 3 screws
Dismounting
1. Loosen screws (1) and screw into the pulling-off bores (2) (bores with half thread in bush
(3) ). Before doing so, lubricate bores.
2. Tighten screws uniformly until the TAPER-LOCK-bush (3) has got loose from the hub (4)
and allows to be moved freely.
3. Remove parts from shaft (5).

Mounting
1. Clean and grease all blank surfaces such as bores, external taper of TAPER-LOCK spring
collet and taper hole of the hub. Then place bush into the hub and allow bore halves to
coincide.
2. Lubricate thread and tip of setscrew (in the case of pan head cap screws also the lower
side of the cap) and screw in manually.
3. Clean shaft and push hub including TAPER-LOCK spring collet onto the shaft until the
requested position is reached.
4. Use Allen key to uniformly tighten the locking screws (cap screws).
size of spring collet fastening torque No. of screws

1610, 1615 ..................................... 18 Nm ............................................ 2
2012, 2017 ..................................... 27 Nm ............................................ 2
2517, 2525 ..................................... 45 Nm ............................................ 2
3020, 3030 ..................................... 81 Nm ............................................ 2
3525, 3535 .................................... 105 Nm ........................................... 3
4030, 4040 .................................... 150 Nm ........................................... 3
4535, 4545 .................................... 170 Nm ........................................... 3
5040, 5050 .................................... 245 Nm ........................................... 3
Table XVIII
NOTE: Use appropriate sleeve or a wooden block to drive home the TAPER-
LOCK spring collet by slightly stroking with a hammer. Then retighten the
screws. Repeat this procedure once or twice.
NOTE: When using a key, first put the key into the hub´s keyway.
Without the key the optimum balance is obtained when the hubs of the
shaft and the TAPER-LOCK spring collet are offset to one another at an
angle of 180°.
5. Let drive run under load for a short time before checking the screws for tight fit.
6. Fill the empty bores with grease to avoid the penetration of foreign matter.
Maintenance of the electrical equipment

070 145
§ Test alarm signalling and shock sensor (every 500 hours).

See also "Hiquel-shock sensor evaluator; ICBP01" given in annex.
§ Check electric screwed connections (terminals) every 3 months and retighten if necessary.
Test EMERGENCY STOP switch and safety devices

169
The emergency stop button and the safety devices are used in case of danger, or in order to
prevent a danger, to quickly return the system and system parts to a safe condition, and/or to
ensure safety.
The service life of the safety-relevant components is 20 years (please refer to the electrical
drawing for details of the safety-relevant components).
Check emergency stop buttons and safety devices for correct function every 6 months.
Mechanical inspection
n The safety devices must not be manipulated or damaged.
n Make sure that the safety devices are safely attached.
n Ensuring free accessibility. Do not block routes.

The emergency stop button must not be covered or manipulated.
n The emergency stop button must latch when actuated.

Release by turning the red button anti-clockwise
Electrical inspection
n The system must be brought to a standstill when the emergency stop button is actuated.
n The emergency stop button and/or the emergency stop circuit must not be
manipulated.
n Depending on the application, safety devices must stop, switch off, or prevent access to or
opening of, the system.
n Make sure that connections are firmly attached.
Maintenance of the pneumatic system

001
§ Drain condensate daily.

Make sure the distinctly marked "max. condensate level" is not exceeded. Non-observance
may result in that undesired condensate particles are entrained.
Chapter 8
Checking malfunction
In case of malfunctions use the below list to

check all possible sources of error. Should
after this check the difficulties not be
eliminated or if malfunctions occur other than
those described in the below list, please
contact our service department.
( +43/732/3190-530
FAX +43/732/3190-220
service@erema.at
The owner/operator is responsible for

identifying safety-relevant defects in case of
machine malfunction. If a safety-relevant
defect exists, the machine must be disabled
until the defect has been remedied.
malfunction
possible cause action
Process Combination
colour change and/or material residues of previously processed Prior to any material change
change takes too much time material remain in the machine empty machine as far as
too long and get mixed possible. Remove residues from
cutter compactor. Remove
material deposits from cutter
compactor parts. Use spatula and
wire brush to remove deposits
(e.g. printing colours, pigments)
from the screw in hot condition.
Set high temperatures at cylinder
and pelletizing system and feed
cold coarsly precut material of
new type.
In case of a change from dark to
light colours light material of
higher viscosity should be run
through the plant in order to
obtain a better cleaning
efficiency. In the meantime
change screens and remove
material residues sticking to the
screen chamber walls.
Melt cake formation in the cutter n Energy balance between cold Determine previously the
compactor tank material feed and throughput required cutter compactor motor
does not correspond with the load as a function of throughput
requirements of the feed and type of plastic
material. In practical operation the feed is
set such that the cutter
compactor temperature levels
out below the melt point of the
respective type of plastic.
For setting, see page 88.
n Excessive wear of cutter If the cutter compactor tends to

compactor knives. form cakes in spite of optimum
presetting, the rotor knives are
liable to be dull. Another
possible cause may be
overpressure and back-up of
material in the screw.
Change screens or eliminate
material clogging the screw or
the downstream equipment.
Checking malfunctions 171
malfunction
Process Combination
high peak load of cutter poor cutting, dull cutter n Insert sharp knives. In case of
compactor motor when normal compactor knives, high cutting short lifetime use tungsten
batches are fed. forces carbide knives.
Blocking.
n Change knife fitting position.
We recommend to check the

efficiency of the individual
measures according to the above
order.
overload of extruder drive motor n excessive screw filling n The feed rates can be adapted
to the extruder capacity by
n compressed material (grinding raising or lowering the slide
material, pellets) bar.
n By raising or lowering the

intake slide, the intake
opening will be appropriate
bigger and smaller.
When processing considerably

compressed material, the intake
opening must be provided with a
diaphragm in order to reduce the
opening.
If the material is considerably
compressed through cutting- and
heating, the feed quantity can be
reduced.
The use of cutters with slightly
whetted cutting edge (radius
approx. 0.1mm) results in
reduced feeding through the
coarsly cut material while the
preheating is improved.
Check temperatures and correct
if necessary.
Check pressure. If necessary use
screen pack with reduced
pressure build-up or change
screens at low pressure. In the
case of hot die face cutting use
die plate with reduced
resistance, i.e. more and bigger
holes.
malfunction
Process Combination
cutter compactor motor stop, n overload, let cool off (wait at least half an
extruder motor stop overtemperature of motor hour);
check air inlet grid. Clean if
required.
n foreign matter in the cutter remove foreign matter from

compactor. Shock sensor cutter compactor tank
releases. Cutter compactor
motor is switched off.
n Limit switch at the cutter service door at cutter compactor

compactor tank stops the is not closed and/or not locked.
motor
n overpressure alarm clean melt filter screens
n temperature alarm check strip heater temperatures
n malfunction of pelletizing check protective motor switch

system
set temperatures are not reached n insufficient heating capacity check heating current, if required
n heating element partially or change heating element

completely burnt out
n heating contactor or fuses change fuses

burnt out check cooling
check function of controller
use heating element with
increased capacity
n humid feed material use dry feed material

malfunction
Process Combination
failure of heating zones n defective strip heater check strip heater and/or cabling
(measure current again)
n defective cabling
overheating of heating zones n excessive frictional heat No problem if within the usual
through high viscosity of temperature range.
plastic Increase temperature zones that
excessive frictional heat are particularly overheated.
through high pressure
upstream of melt filter
n defective or improperly Check temperature controller,

adjusted temperature change if necessary.
controller
n screw not suitable for material Reduce screw speed, e.g. by

changing the belt pulley. Use
screw with different geometry.
n screen of line filter installed clean screen

in cooling water return line is
dirty
Extruder cooling system

malfunction:
n Heat transfer oil pump stops n Pump malfunction Check pump for contamination
"Motor protection switch and damage to pump mechanism.
coolant pump or coolant fill
n Oil fill level too low n Check the fill level display on
level"
the compensation tank and fill
up with oil if needed.
n Check oil screws.
n "Excessive coolant Oil temperature too high Check cooling system.

temperature" (>60°C, for longer than 10
minutes, after 50 minutes the
extruder and cutter compactor
are switched off)
n "Excessive cooling water Cooling water return Check tube heat exchanger for
temperature" temperature is too high calcification and clean.
(>60°C, for longer than 30 min)
malfunction
Process Combination
overpressure resistances of downstream reduce resistances by selecting

equipment (e.g. adapter, melt higher but material-specific
filter, pelletizing head) are too temperatures
high
clean clogged holes of breaker
plates (screen changer,
pelletizing die)
use pelletizing die with more
and greater holes, screen packs
with less resistance.
Select higher cylinder
temperatures. Thus unmolten
particles can be melted upstream
of the screen pack. Thaw "frozen
dies" by selecting higher head
temperatures.
If freezing is caused by splash

water, check water whirls from
nozzles. If required clean
nozzles or pump wheel (sticking
pellets).
malfunction
Backflush Filter
screen changer piston does not proximity switch mixed at eliminate faults and reset by
move ð hydraulic cylinder screen changer manual -
fault message by PLC control auto - auto-start
piston directly controlled via the selector switch.
directional control valve instead To this effect, operate switch to
of the keyboard one operational mode and vice
versa.
pistons are stepwise moved to
production level and are
therefore not exactly positioned
running time exceeded, caused by

e.g. burnt material at screen
changer piston surface caused by
insufficient maintenance.
n upon return to backflushing

level 1 or production level
n upon approach of backflush

level 1
n upon approach of backflush

level 2
n when the piston moves from

backflush level 1 to production
level
n when the piston moves from

backflush level 2 to production
level.
screen change piston does not low melt temperature increase temperature
move
burnt plastic sticks to pistons clean screen changer pistons
proximity switch check screw-in depth
screen changer hydraulic is overloaded hydraulic motor, check cooling, let cool down
stopped overtemperature
low oil level in hydraulic tank refill oil
high oil temperature let cool down

malfunction
strang pelletizing system does EMERGENCY STOP unlock pushbutton

not start pushbutton pressed
intermittent material discharge n Wrong temperature at Review set temperature

and/or torn strands extruder. program.
n irregular throughput of Balance (current consumption

extruder. In most cases caused of cutter compactor motor), that
by the filling mode of the is, uniform material feeding in
cutter compactor. small batches. Use precut
material if required.
Do not feed different material
alternately, e.g. film of
thickness of 30m and
200m, dry and wet material,
large and small batches etc.
This allows to balance density
and temperature of the material
fed into the screw.
Basically, an increased cutter
compactor feeding reduces an
intermittent discharge.
n Melt outlet bores are Clean clogged melt outlet bores

completely or partly clogged at the material supply sied.
by foreign matter, which is Positively no boring!
caused by broken melt filters
or improper screen change.
pellets have threads n cutting gap too big adjust
pellets are not dry when they drying intensity of the upstream n increase cooling water
leave the cyclone of the plant equipment is not sufficient temperature
n cut longer more voluminous

pellets with increased heating
capacity for self drying.
n pellets should be free from

porosity. They should have a
smooth surface to reduce
water adhesion.
malfunction
after leaving the plant (cyclone) insufficient cooling, check water temperature of
pellets are too hot for bagging particularly the retention time cooling. Intensify if necessary.
under air cooling (conveying Maximum retention time under
distances). conveying air conditions is
obtained by using maximum
admissible line lengths. Should
this not be sufficient under
certain circumstances, an
improvement can be achieved
by an additional transport of the
pellets into an conveying
blower cyclone unit. Such an
additional conveying system
results in a reduced moisture of
the conveying air, which helps
avoid condensation water upon
conveyance to external silos.
Low pellets output rate and low Cutter compactor feeding is too Increase material quantity in the
to varying load of main motors. low, which results in cutter compactor.
insufficient precompression. See also operating instructions
of extruder.
For adjustment see page 88.
Pellets are swollen and very Due to water, printing colours, In any cases a high preheating
light. impurities or surface treatment temperature should be achieved
gas is released during heating. up to the first extruder barrel
The gas is entrained in the zone. Thus the gas is released
screw. more rapidly and can be
separated from the plastic to be
recycled.
An other possibility to separate
gas from the melt is pelletizing
itself. The bubbles contained in
the strand can be opened and
vented by cutting very fine
lenticular pellets.
Extremely cold extrusion may
possibly result in bubble free
pellets if processing takes place
below the gas release
temperature. However, if a
higher temperature is reached
during further processing, gas
release may occur again.
malfunction
pelletizing system
Pellets are insufficiently n Insufficient water level n Clean any clogged hoses or
transported in the hose heat exchanger
…due to defective water n Replace pump

circulation pump
n Hose support too high or too n Lower or raise hose support

low
n The tube is clogged with n Remove lumps

pellet lumps
motor of centrifugal dryer, clogged check pellets flow

blower dryer or conveyor blower (underpressure)
stop empty with vacuum cleaner or
disassemble and empty
Pellets are not dry when they Drying intensity of upstream n Set cooling water to higher
leave the plant downstream of the equipment is not sufficient. temperature.
cyclone.
n Cut longer more voluminous
pellets with greater thermal
capacity for self drying.
n Pellets should be free from

porosity and have a smooth
surface in order to reduce
adhesive water.
After leaving the plant (cyclone) Insufficient cooling, in Check cooling with respect to
pellets are too hot for bagging particular the retention time water temperature, water
under air cooling, i.e. drying retention time. Intensify if
screen, centrifugal dryer and possible.
conveying section. If already optimized on the
water side, you can increase the
retention time on the vibrating
screen by retaining ribs or
reduction of vibrating intensity
(readjusting the weights at the
vibrating motors).
Longest retention time under
conveying air is achieved by
utilization of maximum
admissible line lengths. If this is
not sufficient under particular
conditions, a further
improvement can be achieved by
additionally passing on the
pellets to an injector type
conveyor blower pipeline
cyclone. Such additional
equipment also results in
reduced moisture values of the
conveying air, which helps
reduce condensate water upon
conveyance to external silos.
malfunction
pelletizing system
Pellets are swollen and very Due to water, printing colours, In any cases a high preheating
light. impurities or surface treatment temperature should be achieved
gas is released during heating. up to the first extruder barrel
The gas is entrained in the zone. Thus the gas is released
screw. more rapidly and can be
separated from the plastic to be
recycled.
An other possibility to separate
gas from the melt is pelletizing
itself. The bubbles contained in
the strand can be opened and
vented by cutting very fine
lenticular pellets.
Extremely cold extrusion may
possibly result in bubble free
pellets if processing takes place
below the gas release
temperature. However, if a
higher temperature is reached
during further processing, gas
release may occur again.
Pellets transport stops or is n overtaxed performance If maximum conveying capacity

blocked. is required, replace corrugated
hoses with smooth metal pipes.
Remove projections at
transitions of conveying
pipeline.
n high pipe resistances Make sure conveying piplelines

do not have less than 45°. Do
not use bends with small radius.
n pellets are too big and heavy Cut shorter pellets, which also
reduces the pellets temperature
and the tube wall friction.
n conveying air throughput Clean screens of centrifugal

reduced by clogged screens in dryer (externally and internally).
the centrifugal dryer.
Chapter 9
Technical data
This chapter informs about the utilities

required, such as electricity, water,
compressed air, and includes technical data
regarding the machine/plant.
General
Year of construction: ................. 2018 Equipment number: .................. P-20170149
Colour
Machine/plant .................................................................................... RAL 5011, 7037, 9003
Process data
PET ........................................................................................................... 1200 - 1550 kg/hr
The machine/plant is destined to exclusively process the above mentioned material. Any other
use exceeding this specific range of application shall not be in accordance with the intended
use.The manufacturer/supplier shall not warrant for any damage resulting from such improper
application. The risk shall be solely borne by the user.
The output rate is dependent on the material characteristics (viscosity, bulk weight, degree of
contamination, moisture content).
Electrical data
protection class: .............................. IP 54 insulation class:............................... F (B)
reted current: .................................. 694 A supply form: .................................... TN-C
mains voltage: .......... 3 x 400 V (AC) + PE ambient temperature: .................... 5-40°C
frequency: ...................................... 50 Hz humidity: ...................................... < 70%
control voltage: ......................230 V (AC) max. altitude
max. backup fuse: .................... 1000 A gG above sea level: ............................. 1000m
The electrical equipment corresponds with IEC recommendations and VDE regulations.
Sound pressure level

At a distance of 1m from the machine surface and 1.60m above floor the maximum sound
pressure level of the machine/plant amounts to =85 dB(A).
The measurement is performed acc. to EN ISO 11201 under real operating conditions in
EREMA premises. The noise level is 103.5 dB.
The measured values relate to processing of a LLDPE foil. The measured values can deviate
by +10 dB to -3 dB(A) depending on the processed material!
Temperature probe
Fe Cu Ni; bajonet catch
M14x1.5; 40mm long; probe diameter 6mm
length of line according to requirements
Heating element cable

silicone cable
Technical data 183
Cooling water
The cooling medium is industrial-, river- or lake water.
All indications refer to sea level and normal atmospheric conditions. Any deviations
therefrom may influence the quality of the pellets (cleanness) and the maintenance intervals
(calcifying and eventual corrosion) of the plant.
Cooling water specification

Effective operational pressure ....................................................... 2 bar
max. admissible pressure fluctuations ......................................+ 1,5 bar
Total hardness ................................................................ 2°dH to 12°dH
Alkalinity (pH-value) ............................................................. approx. 7
Conductivity ................................................................. 100-800 mS/cm
Chloride content ............................................................... max. 20 mg/l
Carbonate free
Suspended and settleable solids ........................................ max. 10 mg/l
Grain size ............................................................................. max. 20 m
Cooling water temperatures

External e-cabinet ................................................................ max. 25°C
Extruder gearbox ................................................................... 15 - 25°C
Extruder oil ........................................................................... 15 - 25°C
Granulation ......................................................................... max. 15 °C
Process water
Do not use but fresh water of drinking water quality for the pellets dewatering screen
(GS_2010_1000).
ATTENTION: Note thresholds for chloride level!
At a water temperature of 30°C, the chloride level must not exceed a
value of 20mg/liter, as there is danger of corrosion at higher levels!
ð Pitting!
Compressed air demand

An effective operating pressure of approximately 7 bar is required. (compressed air
consumption see supply- and utility list).
The compressed air must be free from oil, dust and condensate. The dew point is -15°C.
All data refer to sea level and normal atmospheric conditions.

Cutter compactor drive ......................................................................................... 200 kW
Intake slider ........................................................................................................ 0.12 kW
Extruder drive ...................................................................................................... 200 kW
Heating capacity of intake zone (EZ-1) .............................................................. 15.58 kW
Heating capacity of barrel zone 1 (ZZ-1) ............................................................ 15.80 kW
Heating capacity of barrel zone 2 (ZZ-2) .............................................................. 8.80 kW
Heating capacity of barrel zone 3 (ZZ-3) .............................................................. 8.80 kW
Heating capacity of adaptor zone 1 (AZ-1) ........................................................... 3.10 kW
Coolant pump ...................................................................................................... 1.10 kW
Weight complete ..................................................................................... appr. 14900 kg
Powered Exhaust System SAS_2500

Air capacity ............................................................................................... max. 3000 m 3/ h
Driving power ..................................................................................................... 1.50 kW
Weight ........................................................................................................ appr. 174 kg
EREMA Backflush Filter SW_4_170_RTF

Screen diameter .................................................................................................... 170 mm
Max. thickness of screen pack .................................................................................. 3 mm
No. of screen packs ................................................................................................. 4
Total screen surface .............................................................................................. 908 cm 2
Piston diameter .................................................................................................... 201 mm
Piston rod diameter ................................................................................................55 mm
Hydraulic cylinder diameter .................................................................................. 125 mm
Backflush stroke ................................................................................................... ±77 mm
Total stroke .......................................................................................................... 390 mm
Heating capacity screen changer zone 1 (SWZ-1) ............................................... 10.70 kW
Heating capacity screen changer zone 2 (SWZ-2) ............................................... 10.90 kW
Heating capacity screen changer zone 3 (SWZ-3) ................................................. 4.00 kW
Max. operating temperature .................................................................................. 300 °C
Max. admissible melt pressure .............................................................................. 400 bar
Weight complete ....................................................................................... appr. 1680 kg
Technical data 185
Hydraulic Rexroth; AKAG032 B411-0-AC

Pump capacity ..................................................................................................... 5.50 l/min
Operating pressure ............................................................................................... 200 bar
Tank content .......................................................................................................... 30 l
Filling quantity complete ..................................................................................... 39.6 l
Pump driving power ............................................................................................ 3.00 kW
Oil brand ...................................................... hydraulic oil HVLP DIN 51524 / VG 46
Strand Die SD_200_ASP

No. of strands ......................................................................................................... 23
Dies .................................................................................................................. Ø 6.0 mm
Heating capacity of strand zone 1 (STZ-1) ........................................................... 0.60 kW
Heating capacity of strand zone 2 (STZ-2) ........................................................... 2.30 kW
Automatic Strand Pelletizer ASP_200_SERIE

see documentation of " Strand pelletizing system; Typ IPS-SGU 220/2 HS "
Pellet Dewatering Screen GS_2010_1000

Dimensions of vibrating screen ............................................................... 1900 x 700 mm
Oversize separation .......................................................................................... < 10 mm
Tank content ..................................................................................................... 620 l
Driving power of vibrating motors ............................................................... 2 x 0.30 kW
Weight ...................................................................................................... appr. 361 kg
Water Pump Station WPS_300

Driving power of water pump ........................................................................... 5.50 kW
Weight ...................................................................................................... appr. 240 kg
Pellet Drying Centrifuge GZ_1000_M11

Driving power ................................................................................................. 11.00 kW
Weight ...................................................................................................... appr. 674 kg
Pellet Transport System FG_40

Air capacity ............................................................................................... max. 2600 m 3/ h
Driving power ..................................................................................................... 3.00 kW
Weight + sound absorbing cover .................................................................. appr. 123 kg

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Instructions for operation

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Manual EREMA documentation (Instructions for operation)

Chapter 1 Safety instructions and warning signs ............................ 7

Chapter 2 Transport, installation and mounting ............................ 21

Chapter 3 Startup and shutdown ...................................................... 41

Overview of utilities and filling quantities.................................................... 42

Chapter 4 Description of operating and control elements ............ 47

Chapter 5 Description of function and control sequences ............ 85

Logic diagram - schematic of piston movement ............................................. 95

Chapter 6 Operation .......................................................................... 105

Chapter 7 Maintenance and Repair ................................................. 123

Test EMERGENCY STOP switch and safety devices .......................................168

Chapter 8 Checking malfunction ..................................................... 169

Chapter 9 Technical data .................................................................. 181

Before starting work on the machine, staff

NOTE is an important information about the product or the

CAUTION special information/orders regarding loss

ATTENTION special information/mandatory and prohibitory signs in

DANGER means that death, severe injuries or considerable damage

§ Complete the operational instructions with such instructions including obligations to

§ Use personal protective equipment if required or provided by regulations.

§ Any modifications, supplements or reconstruction of the machine/plant that might impair

Selection of personnel, qualification, basic duties

§ Employ only trained and sufficiently instructed personnel. Define personnel

Personal protective equipment

If required or provided by regulations and/or by instruction manuals, use personal

Transport and installation of the machine/plant

§ Appoint competent operators to give instructions during the lifting operation.

The INTAREMA® 1714 T Pelletising Plant comprises:

§ INTAREMA Process Combination I_1714_T:

§ Powered Exhaust System SAS_2500:

§ EREMA Backflush Filter SW_4_170_RTF:

§ Strand pelletizing system (downstream)

§ Pellet Transport System FG_40:

§ Plasticizing and homogenization of material in the extruder.Onward feeding of the melt to

§ Single-operator controls and/or automatic process with monitoring.

NOTE: Special provisions must be made by the owner/operator for installation,

§ Ambient temperature: 5-40°C at max.

§ On the basis of EN ISO 11201 noise is measured at a distance of 1m and a height of

§ Lift the control cabinet exclusively with a suitable lifting crane.

§ Granulate residues must be removed from the floor. Þ Danger of skidding.

§ Danger of burning when cleaning and exchanging the screen exchanger

§ The water in the pellet dewatering screen can be acidic/alkaline or toxic

§ Danger of burning upon dismantling of heating strip and heating strip

Safety regulations regarding specific operating phases

§ Observe the switch-on/off procedures, control indications according to the operating

§ When changing the cutter/compactor knives insufficiently cleaned clamping

§ When changing the screen changer screens observe the following:

Special operations within the range of application of the machine/plant

§ Provide ample securing of the maintenance area if necessary.

§ On exchanging individual components or large subassemblies fasten carefully and secure

§ Before commencing maintenance/repair work clean machine and particularly all

§ Fixing screws with a load-bearing function must be checked at regular

§ Use protective gloves when cleaning the screen changer pistons

§ Inspect/check electrical equipment of a machine/plant periodically. Any deficiencies such

§ Exchange hydraulic hose pipes at specified or reasonable intervals, even if no deficiencies

§ Use personal ear protection according to regulations and instructions.

Oil, grease and other chemicals

contaminating the soil or entering drains!

Gas, dust, vapours, smoke

Excess pressure, explosion

This chapter shows you how to transport,