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Installation
Guidelines
Install and maintain
correctly sized thermal overload protection.
Vibrators last longer
and are more effective when bolted to a rigid mount.
Mounting plate must
be totally flat. Warped surfaces can cause housing stress and possible cracks.
Take an amp reading
to make sure that unit is not drawing more that the specified amps.
In situations of high
amp draw, reinforce area of mount and relocate until rated amp draw is achieved.
Mounted Vibrators should
be attached to a safety cable.
Use grade 5 bolts and
nuts or better at all times.
Use compression washer(s)
together with locking nut.
Retighten bolts after
the initial two hours of operation.
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Bearings
Add new grease every
1200 working hours (1000 hours for every 3600 VPM)
Replace old grease every
5000 working hours.
Overgreasing can cause
bearing damage.
For optimal performance,
use only VIBRATEK specified grease: STABURAGS NBU 8 EP.
Vibrators use long life
bearings with a unique code specifying:
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 1.
Bearing type
2. Cage
3. Fit
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Example NJ-2310-E-TVP2-C4.
Substituting originals with improper bearings (not matching the exact code)
will cause the vibrator to fail.
Bearing fit is C4.
Protect electric vibrators
from excessive moisture. This series is not designed to operate submerged.
External temperature
range is -40° to +110° F.
Vibrator's housing surface
temperature should not exceed 210° F
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Weight
Settings
When adjusting the force
output, set weights at a lower force setting and then gradually increase the
weight settings until the unit produces enough vibration to do the job. This
will allow the longest possible life of the motor.
Make sure weight adjustments
are the same at both ends of the rotorshaft.
Never run the vibrator
with end caps off.
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External
Factors Affecting the Vibrator |
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Incorrect
Voltage
Besides a thorough maintenance
and testing program, one of the best ways to guarantee economical performance
and long motor life is to make sure your motors operate at nameplate voltage.
Applying too high a voltage may reduce the motor's efficiency and increase
core losses. This, in turn, shortens motor life by overheating the insulation
system. Under voltage can also shorten motor life. Operating on too low a voltage
reduces the motor's effective horsepower. For example, a 5-hp motor operated
at 10% below rated voltage becomes a 4-hp motor. The motor tries to drive the
load it was intended to drive, becomes overloaded, draws more current and overheats.
The result- premature failure. |
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Unbalanced
Voltage
Operating a three-phase
motor with unbalanced voltage can also cause serious overheating that will
shorten the vibrator's life dramatically. Voltage unbalanced should not exceed
2%. |
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Moisture
Moisture is detrimental
to long motor life because it can deteriorate the insulation. To prevent condensation,
one of two common methods is usually effective. One is to install electric
heaters in the motor. The other is to apply a low dc voltage to one phase of
the motor windings whenever the motor is at rest. With either method, the objective
is to keep the temperature of the windings 10° F to 20° F above the
ambient temperature. |
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Mounting
Guidelines
When mounting a Rotary
Vibrator, the objective is to vibrate the material in the bin - not the bin
wall.
Maximum vibration transfer
efficiency occurs when the vibrator rigidly mounted, and the force and frequency
are transmitted over a large reinforced surface area.
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A mounting channel or
W-beam (better!) should be as long as is practical to install (2/3 the length
of the slope - minimum), and as wide as the vibrator base. It should be stitch
welded to the hopper, bin, or chute to be vibrated. Weld 3", skip 11/2"
- never weld closer than 1" from the end or corners of the W-beam. If
using channel, it can be notched to provide access to mounting bolts.
When mounting the vibrator,
make sure mounting surfaces are free of dirt, rust, scale, paint, grease,
oil, etc., and dry.
Install the vibrator
on the lowest 1/3 of the slope cone section.
Regularly examine the
mounting vibrator for loose bolts, nuts, structural cracks, gussets, legs,
W-beam (or channel), etc. to ensure performance of unit. Correcting those
problems will reduce structural damage, reduce noise levels, and increase
vibration transfer
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Sizing
Guidelines
In order to determine
the force to be applied, only the weight of the product in the cone should
be considered. Vibrator force output (lbs) should be approx. 10% of material
weight (lbs).
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| VIBRATOR
SELECTION FOR BINS AND HOPPERS |
| WEIGHT OF MATERIAL
ON SLOPE PORTION |
VIBRATOR MODEL |
MINIMUM WALL THICKNESS |
W-BEAM OR CHANNEL
SIZE |
MOUNTING PLATE THICKNESS |
| LBS |
LBS |
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| 1000 |
100 |
12 GAUGE |
3" |
1/4" |
| 2000 |
200 |
12 GAUGE |
3" |
3/8" |
| 3000 |
300 |
11 GAUGE |
4" |
1/2" |
| 5000 |
500 |
10 GAUGE |
4" |
1/2" |
| 10000 |
1000 |
3/16" |
4" |
5/8" |
| 20000 |
2000 |
1/4" |
5" |
3/4" |
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Boxcar Bully
Repairs