VIBCO AUSTRALIA PTY LTD
For details contact Ken Gower
Phone 02 9983 9397 or mobile 0409 842 262
EMail :- firstname.lastname@example.org
MOUNTING AND SERVICE INSTRUCTIONS FOR VIBCO PNEUMATIC "Silent" TURBINE, BALL AND ROTARY VIBRATORS
1. Placement of Vibrator:
Further to the details provided in our applications section the important point is to place the vibrator onto the cone of the bin were material flow is least.
(a) for coarse materials mount vibrator 1/3 up the bin side from the discharge.
(b) for fine materials, 1/4 up bin side.
2. Mounting Channel:
Never place the vibrator directly on the skin of the bin. It is either mounted to a plate or a channel iron, or both which is welded to the bin. The plate should be at least 1/4" (6mm) thick and extend (75-100mm) 3-4' outside the vibrator for the smaller vibrators with impacts up to (50kgs) 100 lbs.
For vibrators up to (250kgs) 500 lbs force, use a (10-12mm) 3/8 to 1/2" thick plate (150-200mm) 6-8" larger than the vibrator.
For vibrators with a force over (250Kgs) 500 lbs, use a (12-19mm) 1/2 to 5/8" thick plate (200-300mm) 8-12" larger than the vibrator.
The preferable mounting is to use a (75-100mm) 3 or 4" channel iron, which will not only help to stiffen up the structure to be vibrated but also spread the vibration over a larger surface, increasing the overall efficiency and dimishing the possibilities of fatigue cracks in the bin material.
The length of the channel iron is determined by the thickness of the bin plate, for under (4mm) 3/16", (300-450mm) 1-1/2-3'Iong, for (4-10mm) 3/16" - 3/8" plate, the channel iron should be (300-600mm) 1-2'Iong, over (10mm) 3/8" it needs to be only be (200-300mm) 8-12". The above for vibrators with a force up to (250kgs) 500 lbs. For vibrators with forces from (250-500kgs) 500-1000 lbs, add (300-450mm) 1-1-1/2' to the channel iron.
3. Welding Mounting Plate to Channel Iron:
Weld the mounting plate to the middle of the channel iron. If bin plate is less than (4mm) 3/16" or less, weld the mounting plate to the back of the channel iron, if bin plate is over (4mm) 3/16" weld mounting bracket to the legs of the channel iron. Make sure bracket does not warp. If warped, straighten it out or replace it.
4. Different Suggestions for Vibrator Mounting Channel:
Note: Always stop welds 1" (25mm) from ends, to prevent heat concentration and bin crack, skip weld channel, weld 2-3" (50-75mm), skip 1-2' (300-600mm).
(a) 3 or 4" (57-100mm) channel with holes or nuts welded on back side;
(b) add mounting plate and tap 2 holes;
(c) notch the channel for access to mounting bolts;
(d) weld studs to back of channel.
5. Welding Vibrator Mounting Plate and Channel to the Bin:
Where possible the mounting plate on the channel iron should be placed 1/3 to 1/4 of the distance L on the bin. Tack weld channel iron in place, then weld intermittent welds 3-6' (75-150mm) long with 3' (700mm) between them. Note: Stop welds at least (25mm) 1' from the ends of the channel iron--do not weld the ends. The heat concentration when welding the ends could cause crystallization of the metal and the start of fatigue cracks.
6. Installation of Vibrator:
The VIBCO vibrator is now put in place. Make sure it is secured tightly. Retighten the bolts after the first 10-1 5 minutes of running, then check them periodically for tightness.
Note: A loose vibrator can cause damage to the bin and to the vibrator. It is also advisable to install a safety chain or wire in case the vibrator works itself loose.
B. OPERATING INSTRUCTIONS
1. To Obtain Maximum Performance:
It is not necessary to operate the vibrators at their maximum capability to obtain maximum performance, (the same as you do not drive your car at maximum speed just because it has that capability).
Air regulators, timers, etc., should be used to tune the vibrator for optimum performance and to save wasting money whilst increasing equipment life.
Operating pressure of Ball or Turbine vibrators should be no higher that 80-90psi and no lower that 60psi. Check with VIBCO, or the Service instructions supplied with the vibrator, for the recommended operating pressure (Max & Min) for your vibrator.
2. Continuous Versus Intermittent Operation of the Vibrator:
For bulk material handling applications, the vibrator should be used to reduce the material friction not as a feeder. Once the friction of the particles has been reduced gravity flow occurs, and the vibrator has performed its function, it should then be turned off for several reasons:
Power is a cost of production and is increasing every year. Most vibrators are run between 60-80% of the time longer than they should. They run for the full time the bin is being activated. If the vibrator has performed its function, why leave it on? A great amount of energy is wasted. Rotary vibrators produce enough force that short bursts of vibration are usually more effective than operating continuously. Experience has shown that for most applications, short bursts of only 10-30 seconds for each 1 to 5 minutes of discharge are more effective and efficient.
(b) Life of the Unit.
The life of the vibrator will be extended to the same degree that the power is conserved.
(c) Guarantee Success of the Application.
The vibrator can only furnish material to the discharge area. If more material is furnished than conveyed, the remaining material will pack in the bin. We suggest the vibrators only run when the gates or doors are open on the bin, or when material flow is desired.
3. Air Line to Vibrator:
The hose to the vibrator should have the same or larger hose ID as the inlet ID (pipe size) of the vibrator, so that the pressure loss from the compressor to the vibrator is minimized.
4. Flow Valve:
A simple flow control valve is recommended to allow 'tuning" the vibrator to the desired force necessary for solving your material flow problem. The flow volume determines the force and frequency of the vibrator. By throttling the flow, you can 'find' the desired material discharge rate and avoid the natural frequency of the bin or hopper. You should watch for and avoid speeds (frequency) at which the bin wall and vibrator shake violently. A simple increase or decrease of the speed will (assuming the mount is rigid) usually cause them to smooth out and run with a minimum of movement.
5. Quick Opening Valves.
These are recommended between the air regulator and the vibrator so that the air enters the vibrator with full starting force even at low regulator valve settings. The only requirement is that you install the air regulator at some distance from the quick opening valve so that the air pressure between the two valves will build up enough to yield the necessary starting force. Solenoid (quick opening) valves are recommended for filter automatic operations. Automatic Timed to Cycling is diagrammed with the timer usually directly connected to the bin or hopper gate switch. When the gate is opened the timed cycling system is activated.
6. Air Lubricator:
Lubrication is only to be used for rotary and ball vibrators, not for turbines (they have pre-lubricated bearings). Adjust lubricator to 5 drops of oil per minute.
7. Air Filter:
Use an air cleaner in the line. Clean air will prolong the life of any pneumatic vibrator. Dirty or moist air will harm the unit and impair it from operating at maximum efficiency and lowest energy consumption.
VIBCO turbine vibrators function without maintenance. They require no lubrication in the airline. It is advisable to put an air-cleaner in the line to keep dust and dirt from going through the unit and clogging the muffler. All models are easily repairable. Remove both nuts, press shaft out of bearings and from turbine wheel. Use Andok C or Unirex N2 (by Exxon) or equal type grease. When reassembling be sure the wheel is put back so the incoming air will hit the pocket of the tooth, not the back of the tooth.