This document is an instruction manual for the Conair NCR and NC Series granulation mills. It covers installation, operation, and service for models 69, 614, and 617.
Function Description
The Conair granulation mills are designed for grinding injection-molded, blow-molded, or extruded plastic waste. The plastic waste must be free from contaminants such as metals and substances that are poisonous, flammable, explosive, or otherwise hazardous. Grinding wood products, household and garden waste, pharmaceuticals, or hazardous substances is not permitted unless approved in writing by the machine supplier.
The granulator is started and stopped by pressing buttons on the control panel. Plastic waste is fed into the hopper funnel and falls through the hopper into the cutter housing. Here, rotating knives cut the plastic material against fixed knives to create granulate. A perforated screen, installed in the screen box, determines the size of the granulate. The standard screen has Ø 5.0 mm holes, but options for Ø 3, 4, 6, or 8 mm are available and can be easily changed. The granulate then passes through the screen into the granule bin.
The granule bin can be emptied continuously by air suction through an outlet pipe, controlled by a pulse relay that manages compressed air pulses and pause times. The finished granulate can be reused immediately in production machinery or transported to a collection bin for later use. The standard cutter housing features a multi-stage cutter with rotating knives and two fixed knives. Both types of knives are disposable and should be changed as necessary, as blunt knives cause abnormal wear and damage to the granulator.
Important Technical Specifications
Cutter Housing:
- Cutter housing opening:
- NC(R)-69(S): 150 x 205 mm
- NC(R)-614(S): 150 x 345 mm
- NC(R)-617(S): 150 x 415 mm
Knives:
- Rotating knives, disposable:
- NC(R)-69(S): 9 pcs. (3 x 3)
- NC(R)-614(S): 15 pcs. (5 x 3)
- NC(R)-617(S): 18 pcs. (6 x 3)
- Fixed knives, disposable:
- NC(R)-69(S), 614(S), and 617(S): 2 pcs. (2 x 1)
- Knife clearance: 0.15 – 0.20 mm
- Tightening torque:
- Rotating knives: 38 Nm
- Fixed knives: 38 Nm
Screen:
- Hole diameter:
- Standard: Ø 5 mm
- Options: Ø 3, 4, 6, or 8 mm
Motor:
- NCR Motor power / Cutter rpm:
- 2.2 kW: 195 rpm
- 4.0 kW: 290 rpm
- NC(S) Motor power / Cutter rpm:
Noise Level:
- NC(R)-69(S): approx. 77* dBA
- NC(R)-614(S), 617(S): approx. 78* dBA
- *Depending on material, capacity, temperature, etc.
Weight:
- NCR:
- NCR-69: 175 kg (2.2 kW) / 190 kg (4.0 kW)
- NCR-614: 205 kg (2.2 kW) / 220 kg (4.0 kW)
- NCR-617: 220 kg (2.2 kW) / 235 kg (4.0 kW)
- NC-69S, 614S, and 617S:
- NC-69S: 160 kg (2.2 kW)
- NC-614S: 200 kg (2.2 kW)
- NC-617S: 220 kg (2.2 kW)
Dimensions (for NC-69S, NC-614S, NC-617S):
- Overall height: 1350 mm
- Width: 630 mm
- Depth: 480 mm
- Inlet A: Varies by model (e.g., 8.1 x 5.9" for NCR-69, 13.6 x 5.9" for NCR-614, 16.3 x 5.9" for NCR-617)
- B: Varies by model (e.g., 19.7" for NCR-69, 25.2" for NCR-614, 28.0" for NCR-617)
- C: Varies by model (e.g., 10.6" for NCR-69, 13.4" for NCR-614, 14.8" for NCR-617)
- D: Varies by model (e.g., 19.3" for NCR-69, 24.8" for NCR-614, 27.6" for NCR-617)
Usage Features
Safety Rules:
- Always read the instruction manual before installation and use.
- Risk of cutting or pinch injuries: Be aware of rotating knives and pinch points when opening/closing the granulator.
- Dangerous voltage: Electrical cabinet and junction boxes contain high voltage.
- The granule bin, hopper, and hopper funnel are safety components and must be securely installed for operation.
- The electrical cabinet and transmission doors must be securely closed and locked during operation. The key is a safety component and should be kept by the responsible person.
- Never start the granulator without the hopper funnel installed, as the cutter would be accessible.
- Use ear protection and protective goggles during all granulation work.
- Never work alone when opening/closing the granulator.
- Stop the granulator, move the main switch to "Off," and remove the mains plug before any service or maintenance.
- Never insert any body part into openings unless the main switch is "Off" and the mains plug is removed.
- The machine contains sharp rotating knives; handle with care even when not rotating.
- If the rotor needs to be turned manually, do so with extreme care.
- Electrical installation and maintenance must be done by a qualified electrician.
- During knife changes, use protective gloves and lock the cutter to the cutter housing with a piece of wood to prevent rotation.
- The granulator must never be regularly stopped using the safety system.
Starting and Stopping:
- Preparations before starting: Ensure the screen box, granule bin, and hopper are installed and closed. The star knob between the hopper and granule bin must be fully screwed down. Electrical cabinet and transmission doors must be installed, closed, and locked. The granulator must be firmly installed against the plastic machine, and wheels locked.
- Starting: Connect the mains plug, move the main switch to "On," ensure the emergency stop button is not depressed, and press the start button. The granulator cannot start if material is left in the hopper or cutter housing; it must be cleaned first.
- Stopping: Stop feeding material and wait until all material is granulated. Stop the granulator with the stop button, move the main switch to "Off," press the emergency stop button, and pull the mains plug.
Opening the Granulator:
- Stop the granulator, move the main switch to "Off," press the emergency stop button, and pull the mains plug.
- Unscrew the star knob until the circuit-breaking key is released.
- Opening the hopper: Release the tip catch (if present), fold the hopper backward, and it will remain open against a stop heel.
- Opening the granule bin: Pull out the granule bin catch, move the front edge forward, slide it backward to unhook, then down and toward you.
- Opening the screen box: Undo the star knob, fold the screen box down, remove the screen, and pull the screen box out of the grooves.
Closing the Granulator:
- Installing the screen box: Move the screen box along the grooves to the upper position, pull it towards you to hook it on, place the screen in the milled grooves, fold the screen box up, and screw the star knob in firmly.
- Installing the granule bin: Hold the bin with one hand underneath and the other on the handle, insert it into the grooves, lift the rear to hook it in place, and angle the front up until the catch engages.
- Closing the hopper: Fold the hopper forwards, check that the tip catches engage (if present), and lock the hopper.
- Locking the safety system: Pull the circuit-breaking key upwards and hold it in place. Screw the star knob in until you feel the circuit-breaking key engages, then continue screwing until it stops.
Air Veyor (Optional):
- Allows continuous emptying of the granule bin with compressed air pulses.
- A pulse relay controls the air pulse and pause time.
- Settings for "Working Time" (Ton) and "Pause Time" (Toff) can be adjusted via white and blue knobs for time interval and time factor, respectively, to suit the volume of plastic material, granulator size, and screen hole dimension.
Level Indicator (Optional):
- A capacitative level indicator can be installed in the granule bin to sense non-electrically conductive material.
- If the material level is too high, the granulator stops.
- Sensitivity can be adjusted between 2 and 16 mm using a screwdriver on the left-hand screw (Distance). The right-hand screw (Output) is pre-set and should not be changed.
Hours Counter (Optional):
- Installed in the electrical cabinet, it counts the time the granulator cutters are moving. It does not have a reset function.
Maintenance Features
Inspection Schedule:
- Daily (Operator): Emergency stop, flap, granule bin.
- Once/week (Trained personnel): Electrical components, safety switch.
- Once/month (Operator): Knife sharpness and knife clearance, screen in screen box, roll out time, tipping catch (if installed).
- Every 6 months or after 1000 hours of operation (Trained personnel): Drive belt, belt tension.
General Maintenance:
- Always make a note of maintenance performed.
- All maintenance and service must be done by trained personnel.
- Never modify basic electrical settings without consulting Conair's service department.
Cleaning:
- Ensure the hopper is empty.
- Open the cutter housing (refer to chapter 5.4).
- Clean the hopper, granule bin, screen box, and screen with compressed air, both inside and outside.
- Clean bearing housings by undoing and removing the two blue-painted screws, then blowing through with compressed air and rotating the cutter one full rotation.
- Re-install all components in reverse order (refer to chapter 5.5).
- Use protective goggles and gloves when cleaning.
- Granulate and plastic residue on the floor can be slippery.
Knife Change:
- Only trained personnel should change knives.
- Use protective gloves and be careful as knives are very sharp.
- Lock the cutter to the cutter housing with a piece of wood to prevent rotation during knife changes.
- Check screen wear; change if holes assume a teardrop shape.
- Disassembling rotating knives: Ensure hopper and cutter housing are empty. Open cutter housing. Undo screw A, remove rotating knives B.
- Disassembling fixed knives: Undo and remove screws C1 and C2. Use a socket extension to undo C1. Remove support rules D and knives E.
- Installing fixed knives: Clean knives E and knife seats. Press fixed knives in towards stop screws F (do not change stop screw settings). Install support rules D. Tighten screws C1 and C2 to 38 Nm.
- Installing rotating knives: Clean rotating knives B and knife seats. Install one rotating knife B at a time, pressing it securely against the bottom of the knife seat. Install screws A and fix loosely. Check knife clearance (0.15 - 0.20 mm) with a feeler gauge against both fixed knives E. Fix the rotating knife with screws A to 38 Nm. Install remaining knives. Re-check knife clearance.
- Every second time fixed or rotating knives are changed, new screws should be installed.
- Mark knives with a marker pen to indicate correct clearance and torque.
Transmission (Drive Belt):
- NCR models use one vee-belt; NC(S) models use three vee-belts (always checked/changed together).
- Belt type depends on motor size (kW) and frequency (Hz).
- Check drive belt tension and condition after 4 hours of operation at full load, then every 1000 hours or 6 months.
- Preparations: Ensure hopper is empty. Stop granulator. Open transmission door (key in tool bag).
- Check condition: Rotate pulley a few turns. Check for cracks; change if necessary.
- Check tension: Two methods:
- Method 1 Optikrik gauge: Load drive belts with Optikrik I (NC(S)) or II (NCR) gauge. Position centrally between pulleys, press indicator arm until "Click" is heard, read tension from scale.
- Method 2 Deflection with a pre-load gauge: Load belt centrally between pulleys with a specific force, read deflection. For NC(S), deflect one belt at a time. Refer to the belt tension table for specific values based on motor size, frequency, and belt condition (new or re-adjustment).
- Adjusting tension: Remove granule bin. Undo 4 screws A holding motor to locking bars. Turn screws on motor bars B and C to increase/reduce tension. Ensure pulleys are in line (tolerance 0.5 mm) and parallel. Fix screws A to 40 Nm. Re-check pulley alignment. Install granule bin. Close transmission door.
- Installing a new drive belt: Stop granulator. Open transmission door. Remove granule bin. Undo 4 screws A. Undo two screws for motor bars B and C. Remove old belt, install new one. Adjust belt tension.
Lubrication:
- All bearings in the granulator are lubricated for life and cannot be re-greased.
Troubleshooting:
- Granulator does not start: Check for activated emergency stop, mains connection, main switch position (Off), loose star knob (safety switch cut current), or tripped overloading protection (F1).
- Granulator stops unexpectedly: Hopper or granule bin position changed (safety switch cut current).
- Granulator with level monitor stops unexpectedly: Granulate level too high, or level monitor plug not inserted correctly.
- Cutter still rotates when hopper is opened: Faulty belt tension or worn drive belts.
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