Maintenance and Installation Manual

IMPORTANT
PLEASE DO NOT ATTEMPT TO START OR OPERATE
THE SCREEN UNTIL YOU HAVE THOROUGHLY READ
THIS MANUAL. VIBRAMECH WILL ACCEPT NO
LIABILITY, NOR WILL THE EQUIPMENT GUARANTEE BE
HONOURED SHOULD ANY DAMAGE BE INCURRED AS
A RESULT OF INCORRECT SCREEN USE.

Vibramech (Pty) Ltd

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Maintenance and Installation Manual

CONTENTS

1.
1.1
1.2
1.3

Introduction
Technical Specification Data
Vibrator Motor Technical data Sheet
Screen Overview

3
4
5
6

2.
2.1

Mechanical Installation
Installation Procedure

10
10

3.
1.2

11

1.4
1.5

Electrical Installation
Two-Motor Drive - Electrical Supply and
Vibrator Motor Rotation Direction Testing
Four-Motor Drive - Electrical Supply and
Vibrator Motor Rotation Direction Testing
Cabling Issues
Starters and Overloads

4.

Start-Up Procedure

16

5.

Maintenance

17

6.

Troubleshooting

19

7.

Tightening Torques

20

8.
8.1
8.2

Vibrator Motor Data

Lubrication
Vibrator Motor Drive Force Adjustment

21
22
23

9.

Recommended Spare Parts

24

10.

Certified General Arrangement Drawing

25

11.

Vibrator Motor Brochure

26

1.3

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14
15

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1.

INTRODUCTION

Thank you for your decision to purchase a Vibramech Vibrating Screen. This
maintenance and installation manual provides the purchaser/operator of the
screen with a thorough description of all aspects of the screen operation,
enabling the end user to obtain the best results from the equipment. Should there
be any aspect covered in this manual that is not clear, please do not hesitate to
contact Vibramech for further information.

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Maintenance and Installation Manual

1.1.

Technical Specification Data.

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Maintenance and Installation Manual

1.2.

Vibrator Motor Technical Data Sheet

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1.3.

Screen Overview.

Although the exact configuration of a screen may vary (installation angle, isolator
type and vibrator motor geometry), the fundamentals of operation and installation
are common.
The screen may be installed such that the deck is declined or inclined at various
angles to the horizontal ranging from horizontal to 5 degrees (incline) or 19
degrees (decline).
Some important terminology and components of the screen are denoted below
(also shown in figures 1, 2 and 3 in detail). These include :Vibrator Motors

These provide the drive force on the screen. The

force is adjustable from 0 to 100% of rated output.

Isolator

Provides screen isolation and stiffness. (May be a coil

spring, rubber or Rosta isolator).

Isolator Pad

Used (where the screen is floor mounted) to locate

the base of the isolator.

The configuration of vibrator motor mounting on the screen is dependent on the

size and inclination of the screen. Two or four vibrator motors may be mounted
on the screen. Some of the various alternatives are again shown in figures 1 ,2
and 3, namely :-

Figure 1 : Two-Motor Drive (Horizontal Screen).

Figure 2 : Two Motor Drive (Declined Screen).
Figure 3 : Four Motor Drive (Horizontal Screen).

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01

10

11
12
15

05

14

02
04

03

08
01
07

16
18

20

17

09

05

J No-01
J No-02
J No-03
J No-04
J No-05
J No-06
J No-07
J No-08
J No-09
J No-10

13

Side plates
Vibrator motor
Vibrator motor bolts
Drive harness
Cross member
Back plate
Spray pipe with nozzles
Stiffener pipe
Discharge lip
Isolator bracket

J No-11
J No-12
J No-13
J No-14
J No-15
J No-16
J No-17
J No-18
J No-19
J No-20

Isolator
Isolator pad
Panels
Ledge angle
Angle runner
Side plate liner
Feed box side liner
Feed box impact liner
Feed box back liner
Discharge lip liner

Figure 1. Two-Motor Drive (Horizontal Screen)

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01

10

11
12

17

03
01

04

06

07

02

08
18
16
15
14
09

13
05

J No-01
J No-02
J No-03
J No-04
J No-05
J No-06
J No-07
J No-08
J No-09
J No-10

Side plates
Vibrator motor
Vibrator motor bolts
Drive harness
Cross member
Back plate
Spray pipe with nozzles
Stiffener pipe
Discharge lip
Isolator bracket

J No-11
J No-12
J No-13
J No-14
J No-15
J No-16
J No-17
J No-18

Isolator
Isolator pad
Panels
Side plate liner
Feed box side liner
Feed box impact liner
Feed box back liner
Discharge lip liner

Figure 2. Two-Motor Drive (Declined Screen)

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21

01

10

11
12
15

05

14

02
04
03
01

08

07

16

20

17

18

19

09

20
09
05
13

J No-01
J No-02
J No-03
J No-04
J No-05
J No-06
J No-07
J No-08
J No-09
J No-10
J No-11

Side plates
Vibrator motor
Vibrator motor bolts
Drive harness
Cross member
Back plate
Spray pipe with nozzles
Stiffener pipe
Discharge lip
Isolator bracket
Isolator

J No-12
J No-13
J No-14
J No-15
J No-16
J No-17
J No-18
J No-19
J No-20
J No-21
J No-22

Isolator pad
Panels
Ledge angle
Angle runner
Side plate liner
Feed box side liner
Feed box impact liner
Feed box back liner
Discharge lip liner
Coupling assembly

Figure 3. Four Motor Drive (Horizontal Screen)

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2.

MECHANICAL INSTALLATION

Prior to any installation, please check that all the necessary components are
present (i.e. isolators, isolator pads or pedestals etc.).
Check that there has been no damage to the screen during transportation and
off-loading. If there is any damage to the screen, please contact Vibramech
immediately.
2.1.

Installation Procedure

The recommended installation procedure for screens is detailed. Where there is

any doubt as to any aspect of the installation, please contact Vibramech
immediately for further explanation.
IMPORTANT

No welding or gas cutting may be carried out on any structural

component of the screen, or on the motors.

No additional components (chutes, lips etc.) are to be attached to

the machine.
If the above is not complied with, the warranty on the equipment will be
invalid.

1. Position and loosely bolt the isolator pedestals onto the support structure.
Ensuring that their positions correspond the general arrangement drawing of
the screen.
2. Place the isolators (springs, rubbers) over the central guides on the isolator
pedestals.
3. Lower the screen onto the isolators. Check that all isolators are correctly
located between the pedestals and the screen.
4. Tighten all pedestal bolts.
5. Check that all isolators are vertical (i.e. no inclination), and that the screen inlet
and outlet align with the feed and discharge chutes.
6. The installation should ensure that there is a recommended clearance
(normally 75 mm) between the screen and all surrounding steelwork. Should
this not be adhered to, the screen may impact on the surrounding steelwork
during operation (particularly during shutdown) which will result in structural
damage. If this condition is not adhered to, the screen warranty is invalid.

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3.

ELECTRICAL INSTALLATION

3.1

Two-Motor Drive - Electrical Supply and Vibrator Motor Rotation

Direction Testing

The two motors must be connected in parallel and wired to counter-rotate

(i.e. one motor rotates clockwise and the other anticlockwise).
In the case where the motors are mounted in the conventional horizontal
configuration, the specific rotational direction of each motor is irrelevant provided
that they rotate in opposite directions.
The easiest method of achieving the correct rotation directions of the motors is as
follows :1. Ensure that both vibrator motors are correctly electrically connected.
2. Start both vibrator motors and observe the motion of the screen.
3. If the motion of the screen in linear (straight line stroke) then the
motors are counter-rotating and the directions are correct.
4. If the motion of the screen is elliptical, then the motors are running in
the same direction. In this case, swap two electrical supply wires
(phases) on any one motor and counter-rotating motors will be
achieved.
5. Please note that no damage to the screen will result if the motors run in
the same directions for a short period of time, however this method
of direction testing may not be adopted with a four-motor drive.
6. It may be preferred to remove one weight cover from each motor and
observe the direction of each motor. Electrical cables may then be
changed as required.

3.2

Four-Motor Drive Electrical Supply and Vibrator Motor Rotation

Direction Testing

All four motors must be connected in parallel and wired such that one adjacent
pair of coupled motors rotate in the same direction, and the other two coupled
motors rotate in the opposite direction. This is illustrated in figure 4. Once again
the specific direction of the coupled motors is irrelevant provided that each pair of
coupled motors rotate in opposite directions.

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The only method of achieving the correct rotation directions of the motors is as
follows (to be read in conjunction with figure 4).
1. Consider a four-motor driven screen with vibrator motors A, B, C and
D.
2. Remove both centre weight covers to reveal the coupling assembly.
3. Connect the electrical supply cables to motor A only and disconnect
the other three motors. Start (and immediately stop) motor A. For
simplicity it is assumed that motor A is rotating clockwise.
4. Disconnect motor A, and connect motor B only. Start (and immediately
stop) motor B. If motor B rotates in the same direction as motor A (ie
clockwise) then the electrical connections for motors A and B are
correct make a note of them. If motor B rotates in the opposite
direction to motor A, swap any two electrical wires (phases) on motor B
and remember the connections.
5. Disconnect motor B and connect motor C only. Start (and immediately
stop) motor C. Motor C should rotate in the opposite direction to both
motors A and B, and wires should be adjusted as required.
6. The same procedure should be adopted for motor D.
7. In short, each motor is connected in turn (with the remaining three
motors not connected) and the wire connections adjusted such that
motors A and B rotate in one direction, with motors C and D rotating in
the opposite direction.
8. Two coupled motors must never be started at once. Should the
directions be opposite, the rubber coupling between the motors
will be damaged and/or a vibrator motor may be damaged.

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Motor A

Motor B

Motor C

Motor D

Direction of motors
A and B
Direction of motors
C and D

Motor A (farthest),
Motor B (nearest)

Motor C (farthest),
Motor D (nearest)

Figure 4. Four-Motor Drive Schematic

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3.3

Cabling Issues

The flexible multi-strand (non armoured) trailing cables supplied with the vibratory
motors must not be removed. These trailing cables must be terminated in a
waterproof junction box located on a fixed structure suitably located near the
motors. The cables should be clamped to the structure, by means of the short
piece of rubber hose and U-bolt. This is illustrated in figure 5. The cable length
between the motor and the clamp should be in the region of 450 mm to 900 mm
with sufficient slack to prevent pull or jerking on the cable glands during machine
start-up and shutdown. The cable should not come into

JUNCTION BOX
MAX 50 mm
U-CLAMP

RUBBER
HOSE

TRAILING
CABLE TO
MOTOR

Figure 5. Vibrator motor terminal box location.

contact with any component that will cause cable wear and possible shorting to
earth.
The terminal box on each motor is completely packed with a non-hardening
electrical putty. This prevents the ingress of moisture and secures the cable
within the terminal box against vibration damage.

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3.4

Starters and Overloads

Individual starters may be used but they should be wired so as to all motors
simultaneously. Overload protection should be such that all motors are
shutdown in the event of a fault occurring on any motor.

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4.

START-UP PROCEDURE

Upon completion of the installation procedure and the electrical connection,

several safety checks must be made prior to starting the machine :1. Due to the vibratory stresses that the machine is subjected to, it is essential
that all bolts are tightened adequately. In this vein, all bolts, particularly bolts
securing the vibrator motors, liners and any load bearing bolts should be
checked.
2. The vibrator motors are packed with the correct amount of grease upon
delivery. However if the time between delivery and commissioning is greater
than 6 months, it is recommended that the motors be re-lubricated with the
correct amount of grease and indicated in section 8. The motors should then
be rotated by hand a number of times (until smooth rotation is achieved)
before starting the screen.
3. Check that the eccentric vibrator motor weights are set identically. This is
highlighted in section 6.3.
4. Check that the vibrator motors are running in the correct direction (i.e.
highlighted in section 3).
5. Once again, ensure that there is adequate clearance between the screen and
the surrounding chute work and steelwork.

If all of the above has been checked, start the screen.

Should any abnormal noise be heard, stop the machine immediately and repeat
the above checks. Should all item checks be adequate and the noise persists,
contact Vibramech immediately.
During the initial running period, check the current being drawn from the motors
and allow the screen to run for four hours before putting material over the screen.
During the initial running period monitor the motor current drawn. Should this
value exceed that on the motor nameplate (listed in this manual), stop the screen
immediately and again check above items 2,3 and 4. Should the item checks be
adequate, contact Vibramech immediately.
After 24 hours of operation, the screen should be stopped and all bolts should be
checked again. This includes motor studs and (should the screen deck be woven
wire mesh) the mesh tensioning bolts should be re-tightened.

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5.

MAINTENANCE

Part of the design philosophy behind the screen is that maintenance activities are
reduced to a minimum. Naturally, however, there are mandatory maintenance
activities required.
5.1 Vibrator Motors
Detailed instructions are highlighted in the appended vibrator motor catalogue,
however a few basic maintenance items are mentioned here.
In the case of a 60 Hz electricity supplies, the motors eccentric weights may
have been pinned to limit the maximum drive force on the screen. Under no
circumstances should these be removed.
When a vibrator motor is replaced or when routine maintenance is carried out, it
is imperative that the motors eccentric weight are set identically on all motors. In
other words the percentage of maximum force available must be set to the same
value on both sides of all motors (i.e. all pairs of weights). If this is not the
case, severe structural damage will be caused to the screen.
The exact manner of adjusting the eccentric weights on the motors is highlighted
in section 10 of this manual.
5.2 Bolt Torque
Periodically check that all bolts are correctly tightened. Should any bolts be
loose, re-tighten, or replace them.
Particular attention should be paid to vibrator motor bolts. After the initial running
period of 24 hours, remove the locknuts from the motor bolts and check the main
nuts for adequate torque (these values are listed in the motor manual and on the
technical specification section of this manual). After this, replace the locknut and
tighten to 25% torque of the main nut. In cases where torque wrenches are not
available, flogging spanners may be used. The main nut should then be hand
tightened, and then flogged a further half turn. In the case of a lock nut, a further
quarter turn is adequate.
5.3 Isolators
Check that springs are not fatigued, broken or severely corroded. Ensure that
there is no accumulation of material in the coils of the springs, since this would
render them ineffective. Also ensure that under no circumstances should the
springs become coil bound (i.e. fully compressed) during screen operation.
Replace broken springs immediately.

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In the case of rubber isolators, check that they do not become permanently set or
deformed. Should this occur, replace immediately.
5.4 Suspension Equipment
Check all suspension equipment (shackles, steel ropes, hanger brackets etc.) for
wear, fretting and corrosion periodically. Replace any deteriorated
components.
5.5 Liners
The liners should be checked for wear periodically.
5.6 Vibrator Motor Coupling Spider
The adjacent pairs of vibrator motors are coupled with a rubber spider (cog).
Without this spider, the vibrator motors will not synchronise and damage will
result to the screen structure. Similarly, if the rubber spider is worn or damaged,
the vibrator motor coupling (synchronisation) will be hindered.
It is advised that the rubber spider is inspected every 12 months for signs of
damage/wear, although one would expect a five year life from the spider. The
spider is designed such that the vibrator motors can rotate relative to each other
through a 5 mm circumferential distance on the coupling edge. Should this
rotation be higher, replace the coupling.
Damage/wear to the rubber spider is rare, however one cause of spider wear is
mis-setting of vibrator weights. If weights are mis-set on adjacent motors, the
coupling is subjected to an uneven torque from each coupled motor and the
rubber will fret.

5.7 Electrical Supply Cables

Periodically check all electrical supply cables for signs of rubbing against other
components. Should this be the case, the cable must be repositioned to avoid
this. Any signs of fretting or wear on the cables should be repaired. It a cable is in
a poor condition, it should be replaced.
5.8 Vibrator Motor Greasing
The vibrator motors should be greased in accordance to the schedule shown in
section 9.1.
5.9 Huck Bolts

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Huck bolts must be periodically checked to ensure a tight connection. Any loose
huck bolts should be removed as soon as possible to eliminate the loose huck
bolt from causing the locating hole becoming oval. The huck bolt should be
replaced with another huck bolt, however as a temporary solution, a normal HT
bolt can be used.
5.10 Liner Bolts
Liner bolts should be checked periodically to ensure a tight connection. Any loose
line bolts should be replaced or re-torqued to prevent locating bolts becoming
oval.

6.

TROUBLESHOOTING

Problem

Possible Cause

The screen has an excessive

sideways motion.

1. Check that the motors are not running in the

same direction.
2. Check that both Motors eccentric weights are
set identically.
3. Check that both motors are operating.
4. Check that all isolators are in good condition.
5. Check that the vibrator motor coupling (in the
case of a four-motor drive) is in an acceptable
condition.

Vibrator motors constantly trip.

1. Check the trip-out rating on the motors.

2. Check that the motors are running in the correct
directions (in the case of a four-motor drive).

Unusual vibratory noise heard from

the screen.

1. Check that all bolts are tight (including isolator

pedestal bolts and motor bolts)
2. Check that the screen is not impacting on
surrounding steelwork.
3. Check that no foreign material/item is lodged in
the screen.

Screen has an excessive

(uncontrolled) motion.

1. Check that a frequency controller is not being

used with a low frequency setting causing the
screen to run with a speed of less than 300 rpm.
(The use of a frequency controller is not
recommended with a screen).
2. Ensure that the support steelwork is sufficiently
stiff.

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7.

TIGHTENING TORQUES

The following table summarises the recommended tightening torques for

Vibramech equipment. Where a lock-nut is used, a value of 25 % of the main nut
should be used.
Bolt Size
M10
M12
M16
M20
M22
M24
M30
M36
M42

Tightening Torque (Nm)

50
80
200
380
500
640
760
980
2600

Please note that these values supersede those quoted in the Vibrator Motor
Brochure due to varying material specifications of the bolts.

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8.

VIBRATOR MOTOR DATA

8.1.

Lubrication.

ITALVIBRAS VIBRATOR MOTORS

Use only KLUEBER grease type STABURAGS NBU 8 EP
Motor Type
MVSI 15/80
MVSI 15/200
MVSI 15/400
MVSI 15/550
MVSI 15/700
MVSI 15/1400
MVSI 15/1700
MVSI 15/2400
MVSI 15/3800
MVSI 15/5000
MVSI 10/1100
MVSI 10/1600
MVSI 10/2600
MVSI 10/3800
MVSI 10/5200
MVSI 10/6600
MVSI 10/10000
MVSI 10/12000
MVSI 10/15000
MVSI 10/17500
MVSI 075/10000
MVSI 075/12000
MVSI 075/14000
MVSI 075/17000
MVSI 075/22000

Amount of Grease (per bearing)

Not required
Not required
Not required
Not required
Not required
9 grams every 1000 hours
16 grams every 1000 hours
19 grams every 1000 hours
26 grams every 1000 hours
80 grams every 5000 hours
16 grams every 1000 hours
14 grams every 1000 hours
18 grams every 1000 hours
60 grams every 5000 hours
100 grams every 5000 hours
60 grams every 1000 hours
90 grams every 1000 hours
130 grams every 1000 hours
150 grams every 1000 hours
180 grams every 1000 hours
180 grams every 5000 hours
130 grams every 1000 hours
150 grams every 1000 hours
180 grams every 1000 hours
220 grams every 750 hours

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YASKAWA (URAS) VIBRATOR MOTORS

Use Shell Alvania R3 Grease
Motor Type
KEE 3-4
KEE 6-4
KEE 9-4
KEE 12-4
KEE 17-4
KEE 24-4
KEE 34-4
KEE 52-4
KEE 3-6
KEE 5-6
KEE 9-6
KEE 18-6
KEE 24-6
KEE 34-6
KEE 45-6
KEE 60-6
KEE 80-6
KEE 110-6
KEE 140-6
KEE 165-6
KEE 54-8
KEE 85-8
KEE 110-8
KEE 135-8
KEE 170-8

Lubrication Requirements
(per bearing)
Not required
Not required
Not required
Not required
10 grams every 1600 hours
12 grams every 1400 hours
15 grams every 1200 hours
30 grams every 1100 hours
Not required
Not required
Not required
Not required
Not required
15 grams every 2000 hours
20 grams every 1800 hours
30 grams every 1500 hours
50 grams every 1400 hours
65 grams every 1200 hours (roller)
25 grams every 1200 hours (thrust)
80 grams every 1100 hours (roller)
30 grams every 1100 hours (thrust)
90 grams every 900 hours (roller)
35 grams every 900 hours (thrust)
30 grams every 2200 hours
65 grams every 1900 hours (roller)
25 grams every 1900 hours (thrust)
80 grams every 1600 hours (roller)
30 grams every 1600 hours (thrust)
90 grams every 1500 hours (roller)
35 grams every 1500 hours (thrust)
105 grams every 1400 hours (roller)
40 grams every 1400 hours (thrust)

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8.2.

Vibrator Motor Drive Force Adjustment.

The exact method of adjusting the vibrational force of each motor is highlighted in
the attached motor catalogue. It must again be stressed that the correct setting of
the vibrator weights is imperative to the structural integrity of the screen.

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9.

RECOMMENDED SPARE PARTS

Item

Qty

Vibrator Motor

(see section 1.1)

Rubber Coupling Spider

Motor Studs

1 set

(see section 1.1)

Isolators

1 set

(see section 1.1)

Liners

1 set

When ordering spare parts, please quote the Vibramech reference number (Jnumber), which is found in this manual and on the nameplate on the side of the
screen.

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10.

CERTIFIED GENERAL ARRANGEMENT DRAWINGS

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11. VIBRATOR MOTOR BROCHURE

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