ay wy PMT INDUSTRIES SDN. BHD. eros AMember ot "8 Wah Seong Corporation Berhad OPERATION MANUAL Cea ae ROO WEIGH ' The use of manufacturers nas and part numbers where quoted, are provided jor reference purposes only. his no intended to imply that PMT Replacement Parts are supplied by the original equipment manufacturer nar indeed (s this the case Lot 1929, Jalan Buket Kemuning, Seksyen $2, 40460 Shah Alam, Selangor Darul Ehsan, Malaysia. Tol: 603-5122 6522 (Hunting Line), 5122 5577 Fax: 603-5122 6533, E-mal: pmt@ pmiindusties.com Website: wwrw.omtindustries.comOPERATION MANUAL APPENDIX 1. INTRODUCTION 2, THE BASIC MODELS 3. INSTALLATION 4. OPERATION 5. MAINTENANCE 6. RECOMMENDED SPARE PARTS 7, MOTOR DETAILS $S/niey/08/2008OPERATION MANUAL INTRODUCTION The basic components of the ciroular vibrating screen separator are a single or numeral number of sieves/mesh-screens supported on a base table frame which is mounted on coil or air suspension system. In direct drive unit, the table frame carries the vibrating motor with two eccentric weights mounted at both shaft ends. In indirect drive unit, the table frame carries the main bearing housing assembly with two eccentric weights mounted at both shaft ends. The main shaft of the ‘main bearing housing assembly is driven by a standard foot mounted motor via a belt-pulley system, fixed intermediate shaft and flexible bellow coupling, Vibrating generator with two eccentric weights when running, produces the gytatory action, a combination of circular and reciprocating motion in a horizontal plane with a small vertical movement. ‘These circular vibrating screen separators are extensively used throughout the industries : Food Pharmaceutical Chemical Agrochemical Paint Oil and Petrochemical Foundary Ceramic Brewery tt is gonorally accepted that gyratory screen separators provide the most efficient separations at high feed rates operating over screen opening from 12 mm hole to 325 mesh. These machines are applicable to a very wide variety of products, There are different models and sizes available, ranging from 600 mm @ to 1800 mm @ and up to five decks. Generally there are three types of screening for these separators: © Scalping Removal of small amount (say 5% or less) of oversized from a large volume (at least 50%) of undersize (e.g. plastic pellet manufacturer). * Sizing of grading Single or multiple sizing used to gather and retain patticles into groups of various size (e.g. finished product, food, pharmaceutical). * Dewatering Dewatering removes solid particles from a liquid stream (e.g.) waste water clean-up, laundry, brewering etc) SS/riey/08/2008THE BASIC MODELS D.D. CS. DIRECT DRIVE COIL SPRING. LD. CS. INDIRECT DRIVE COIL SPRINGS. LD AS. INDIRECT DRIVE AIR SPRINGS.OPERATION MANUAL INSTALLATION CAUTION: — LIFT SEPARATOR FROM THE LOWER BASE UNIT ONLY REMOVE SHIPPING BLOCKS BEFORE START UP A. Set the separator on a firm foundation or platform. B. Remove shipping angle bracing between the underside of lower table assembly and the top of base assembly. C. Level the separator using shims between the anchor bolt positions and the foundation. D, Check the motor overload protection devices i.e. circuit breaker, overload relay etc. comply with the motor current rating, Standard WG separator of direct drive type are furnished with one of the following totally enclosed, non-ventilated motor: > 385v or 415v, 50Hz, 3ph, 1460 rpm Ratings are as follows: - For 900 mm (36") separator, 1.5 kW ~ For 1200 mm (48") separator, 2.0 kW > For 1500 mm (60") separator, 2.0 kW + For 1700 mm (67") separator, 4.0 kW S5/hiey/08/2008| OPERATION MANUAL | affected. INSTALLATION (cont'd) i | | i D. cont'd i | Motors of other voltage, cycle and phase motion are available on special i H request. i E. Connect the motor power supply. | F. Check the motor rotation. Lower eccentric weight should be moving | from left to right when viewed through lower base door. If motor L direction is incorrect interchange the motor connection. | | i | H. Check v-clamp tings. They must be securely fastened to prevent mesh G. _ Install spout connectors. Connectors between all inlet and outlet spouts and conveyors must be flexible so that the action of separator will not be frames rotate and damage to gaskets.OPERATION MANUAL OPERATION FEEDING THE PRODUCT TO THE SEPARATOR ‘The material to be screened must be fed to the separator perpendicular to the screen surface at a controlled and even feed rate, The velocity of the feed must be kept to a minimum to prevent premature screen wear. A. WET SCREENING A baffled device as shown in figure 1 recommended when screening wet products to reduce velocity and evenly distribute product to the sere n. ‘ The feed pipe must be maximum 150 mm away from the screen surface. B. DRY SCREENING When sereening dry materials the feed pipe must be 100 mm away from the screen as shown in figure 2. Normal methods of feeding dry materials to the separators use belt conveyors, bucket elevators and feeders.SCREEN SURFACE CENTER TIE DOWN ASSEMBLY SCREEN SURFACE CENTER TIE DOWN ASSEMBLY FEED (WET PRODUCTS) ¥ 150mm MAX. BETWEEN BOTTOM rT OF FEED BUCKET & SCREEN SURFACE 100mm FROM FEED TO SCREENOPERATION MANUAL OPERATION (cont'd) PRODUCT PATTERN OF TRAVEL ACROSS THE SCREEN A, The product to be screened must form a pattern of travel over the mesh surface that will attain the efficiency and final product quality desired. The screening pattem will vary with wet and dry products, their specific gravity, moisture content, size, mesh aperture opening, analysis of feed and overall feed rate. The product screening pattern is regulated by the degree of lead of the bottom weight with respect to the position of the top eccentric weight (Note: Top eccentric weight is always in a fixed position and not adjustable.) The lead setting will read from 0° to 360° on the i located on a steel collar directly below the bottom weight. Examples of average screening patterns are shown in Figure 3. if after starting your WG separator and feeding the product, you do not have the desired screen pattem, adjust the lead angle of the bottom weight shown in Figure 4 as follows: S5/niey/08/2008PATTERN OF TRAVEL ACROSS SCREEN 0° Lead - Ory material may be 15* Lead - Dry material may thrown straight and may give begin to spiral insufficiant separation tS SS 38" Lead - Hay give dry 60° Lead - May give wet Maximum lead may keep oversize palerial maximum efficient nnalerial maxinum efficient material from being discharged screening pattern screening pattern, and assist in receiving maximum throughput of ninus material which tends to “ball” FIG. 3‘LEN SCREW — AMP BOLT TAD INDICAT O ‘201TED NUT =} BOTTOM WEIGHT ADDER WEIGHT LOCKNUT ADDER WEIGHT BOTTOM WEIGHT ASSEMBLY TP WEIGHT RETAINING WASHER ~ AEN CAP SCREW ha O uevstter —| Ler wee MAIN SHAFT TOP WEIGHT ASSEMBLY Fig.5| ! ' i i OPERATION MANUAL. OPERATION (cont'd) PRODUCT PATTERN OF TRAVEL ACROSS THE SCREEN (cont'd) E cont'd 1. Shut off the power supply and lock the circuit breaker il. When all vibration has stopped, open the inspection door in the lower base. MM. Loosen the allen screws with allen wrench. IV. Loosen adjusting nut M12 with a %" wrench. V. Rotate the weight around the main shaft until the open slot at the rear of the lower weight is aligned with the degree of lead desired on the indicator. VI. Tighten adjusting nut with °%” wrench. Vil. Tighten alien screw with alien wrench. Vill, Close the inspection door. IX. Start the separator motor and check the pattern. X. Repeat the procedure, making only 5° changes in lead setting, until the desired pattern is developed. F, If the product to be screened is sticky or viscous and does not move easily on the screen, then it may be necessary to add additional top weight plates (See Figure 5). Altern ively the lead angle can be adjusted lower to increase the horizontal motion. $Siniey/08/2008OPERATION MANUAL, OPERATION (cont'd) PRODUCT PATTERN OF TRAVEL ACROSS THE SCREEN (cont'd) VERTICAL MOVEMENT For efficient screening or separation, the product must have vertical movement as it travels horizontally across the screen cloth. Heavy, coarse or viscous materials will requit more bottom weight to increase the vertical action on the screen cloth. Light and fine materials may require less vertical action on the screen cloth hence fewer additional ‘weight plates would be required on the bottom weight. If the vertical movement is required to be adjusted, add or remove one or more of the additional lower weight plates: |, shut off the power supply and lock the circuit breaker. I. When all vibration has stopped, open the inspection door on the lower base. I. Using %" wrench to remove the nut and lockwasher holding the weight plates, Insert or remove the required number of weight plates off or on the stud. IV, Replace the lockwasher and nut. V. Close the inspection door and start the separator motor. SS/niey/08/2008OPERATION MANUAL, OPERATION (cont'd) PRODUCT PATTERN OF TRAVEL ACROSS THE SCREEN (cont'd) H. cont'd vi. CAUTION: Repeat the procedure until the required vertical movement is accomplished. 00 NOT EXCEED FIVE ADDITIONAL WEIGHT PLATES ON THE BOTTOM WEIGHT. MORE PLATES WILL OVERLOAD THE BEARINGS AND MAY CAUSE PREMATURE BEARING FAILURE. ‘SS/niey/08/2008OPERATION MANUAL OPERATION (cont'd) PRODUCT PATTERN OF TRAVEL ACROSS THE SCREEN (cont'd) If adjustment of bottom weight have not achieved the required condition and additional throw is required to discharge the material, top weight should be added or removed: A. Shut off the power supply and lock the circuit breaker. B. After all vibration has stopped, remove the lower clamp ring or remove the tightening bolts and nuts between the table frame and lower table, The table frame then can be removed from the lower table assembly. ©. Using a %” wrench remove the nut and lockwasher holding the weight plates in position. Insert the required number of weight plates on or off the stud. D, Replace the lockwasher and nut. E. Replace table frame. F. Replace the clamp ring or tightening bolts and nuts. G. Repeat the procedure until the required throw is obtained. CAUTION: DO NOT EXCEED FIVE ADDITIONAL WEIGHT PLATES ON THE TOP WEIGHT. MORE PLATES WILL OVERLOAD THE BEARINGS AND MAY CAUSE PREMATURE BEARING FAILURE, SS/niey/08/2008OPERATION MANUAL, MAINTENANCE GENERAL The maintenance of the followin, rating screen separator is basically restricted to the Mesh Screen Periodic inspection must be carried out. Proper screen tension ensures long screen life and efficient screening. Clamp ring Periodic tightening of clamp ring must be carried out. Loose clamp ring will cause damage to the gasket, spacing frame, distribution frame and screen. Motor Upper and lower bearing of motor require frequent lubrication. Use high quality grease with Lithium base. Type of grease used as follows: (i) Texaco Premium RB (i) SKFLGEP 2 (ili) Lubot LB 328 Please refer to motor operating and maintenance manual for more details. SS/riey/08/2008OPERATION MANUAL MAINTENANCE (cont'd) GENERAL (cont'd) Channel gasket. It must be of the correct length and shape and is made of Neoprene rubber. Spring assembly The supporting springs must be of equal and correct compression, Excessive worn spool and distorted springs must be replaced. Frames Cracks must not be developed on the table frame, distribution frame and spacing frame, Over-tightening of clamp ring causing frames distortion must be avoi xd. For cracks repair, employ only qualified welder to carry out good quality welding, Lower table assembly Cracks must not be developed on the lower table assembly. SS/niey/08/2008OPERATION MANUAL. MAINTENANCE (cont'd) MOTOR REPLACEMENT 1. Shut off power and lock out the circuit breaker. 2. Disconnect the power leads at the junction box and loosen the cord grips on the base and the center column. 3. Remove the clamp rings, spacing frames, center tie-down assemblies and frame mesh. 4, The motor can be removed with the base remaining secured to the foundation or platform. 5. Remove bolts and lock washers from wedges. 6. Remove wedges. 7. Disconnect the top lube line from the motor only. Disconnect the bottom. lube line at the motor. 8. Cover the open ends of the Jube lines to prevent contamination, SS/niey/08/2008OPERATION MANUAL, MAINTENANCE (cont'd) MOTOR REPLACEMENT (cont'd) 9. Insert an eyebolt at the top end of the shaft and lift the motor up, at the same time feed the cord through the coupling in the center column. 10. Ensure that the motor mounting ring contact surface and wedges are clean and rust free. 11, After positioning motor in the center column, place wedges and tighten wedge bolts to a maximum torque of 24 kg.m. Apply even pressure to all wedges to ensure centering of the motor. Repeat several times before reaching the maximum torque. 12, Install the table frame, lube lines, power leads, and cord grips and run the motor for 10 minutes. Then, remove the table frame, retighten the wedges, 13, Use socket wrench with an extension to tighten the wedges. CAUTION: NEVER RUN MOTOR WITH ECCENTRIC WEIGHTS EXPOSED. ‘$5 /niey/08/2008OPERATION MANUAL MAINTENANCE (cont'd) RECTIFYING FAULTS ‘cHeck porn | Weeks | TYPE OF cHEcK ACTION 1. | Mesh Periodic | Tension Tighten jam nut on center tie~ sereen down bolt. Binding Soft brush or high pressure water spray to clean, Tear Replace 2. | Clamp ring | Periedic | Tightening Tighten the tight-bolt Distortion Replace 3. | Motor 300 Greasing Ensure correct and sufficient hours greasing - refer motor greasing running instructions Rotating noise | Check for bearing failure. 4. | Channel| Periodic | Correct length | Replace gasket | and shape i 5. [Frames | 2weeks | Crack Repair with qualified welder or { consult factory Deform Consult factory 6. | Lower ‘Abnormal | Crack Consult Factory table noise assembly | developed 7. | Support | Monthly | Unequal Replace spring ‘compression. Distorted Replace | Abnormal Replace | vibration 8. | Spool ‘Monthly | Wear Replace SS /hiey/08/2008OPERATION MANUAL MAINTENANCE (cont'd) CAUTIONS 1! 1, Do not start separator before removing shipping brackets. 2, Do not over tension fine mesh screen. 3. 10. nN Do not use wrong type of grease. Do not operate with abnormal noise or abnormal vibration. Do not operate without anchor the separator on firm foundation/platform. Da not place tools and parts on screen. Do not tighten center tie down jam nut before tightening the clamp ting. Do not over tighten the clamp ring. Do not add to the bottom weight with more than 5 plate Do not add to the top weight with more than 5 plates. Do not change the lead, remove or add the plates or service the motor without locking out the circuit break ‘SS/hiey/08/2008OPERATION MANUAL RECO! SPARE PARTS (MODI SERIES) To ensure continuous service of separator, we recommend the following spare parts for each unit: 1, One unit each of every mesh screen mesh used. 2. One unit v-clamp ring assembly. 3. One unit v-channel gasket. 4. Six units springs. 5. Three units top spring spools 6. Three units bottom spring spools. 7. One unit center tie-down stud c/w jam nuts, 8. One unit spare motor (For operation with three or more separators) $S/niey/08/2008OPERATION MANUAL PARTS LIST. TEM NO. PART NO. DESCRIPTION, 1 6 60010200 si ‘Spacing frame (S.S.) 6 e9020000 st Mesh frame c/w mesh $5304 + 6b 60020100 st + Mesh frane c/w 104mg mesh $5304 + 6 60020200 $1 + Mash frame e/w 20#ng mesh $5304 = 6D 60020300 st + Mesh frame c/w 203mg mesh $5304 + 60 60020400 st + Mesh frame c/w 40i#mg mesh $5304 + 6 60020600 $1 + Mesh frame c/w 608g mesh $5304 + 6D eocateco st + Mesh frome c/w 100%4ng meshS304 6 60030000 53 V-elamp ring + eb 60030001 $3 + Holf ring + 6b 60030902 st + Te bolt fw rut +6 60030001 53 Half ring = 4. 6 60040200 51 Distribution frame (S.5) B 60 60050300 s1 ‘Toble frame ($.5) 6. ‘6 60060000 £0 Lower table assembly (M.S) x. {60 60070000 50 Bose assembly (M.S) a ‘6 60080000 00 ‘Spring assembly + 6D 60081201 60 Lower supporting bolt c/w mt + 6D 60080002 60 = Lower spool + 6b 60087003 00 + Spring + 60 60080002 00 + Upper spool +6 60081201 00, + Upper supporting belt e/w nut 2. {60 60090000 50. Channel gasket 10, {8b 60100000 Si Center tie-down assembly 6b 60100001 $1 Tension spring (SS) Gb 60101602 $1 em nut (2 nos) (55) 46 60100003 $1 Tie down washer (2 nos) ($8) 460 60100004 00 6D 60101605 $1 Cushion washer (2 nes) (neoprene) Tie down stud (16) (SS) 60 60100006 51 ‘Spring retainer (2 nos) 60 69101602 1 Hola-down mut (2 nos) (85) i. 60 60110000 st Slotted nut 12, 46> 60120000 00 Bolance spring assembly 8 6b 60130000 20 Vibro-motor For spore parts, refer motor manual 4. | 60 eos40000 so Bottom eccentric weight 45. 60 60180000 50 Top eccentric weight 6, {60 60160000 00 Tuneton box 7, {60 60170000 00 Lube hase cfm iting SSiniey/08/2008(S'HI 393M OLOH "92 JAN SMLSAFOY ‘¢z Fig): 22 XOgNOHONAL 12 INoILdo} ATSWaSS¥ ONIYES 39NVIVA "OZ ‘BOLOW OIA MH 7 (S'S) LON 8 1709:71H 3H00:318 ONINIEO/NOLLI3SNI ‘1NOdS SDY¥HSIO INOLLdO} ATEHISSY NMOG-3N3BENID ATANASSY: ONDGS (Sih) ATH3SSW aSWa (S'W) ATHASSY FAG UEAOT Bais 21ev1 BHU NOLLABIALSIO ATHASSY'DNA-dAVAD-A, (S'S) HS3W MVD NVUSHSSH 7 HVS SNDYES ESE} YOLVEVdIS OM WWHZSt 2/09 S300 * 13G0WSPACING FRAME, oO RE ERR FRY SERRE vesumnave c/w MESH ISS @ SQNES TRIN BRI SERRE ~ SSE SSS V-CLAMP RING @ DISTRIBUTION FRAMETOP TENSION'RING ELASTOMER SEAL, MESH SCREEN UPPER SPACING FRAME V" CLAMP RING ELASTOMER SEAL (JUST BE KEPT TIGHT } BOTTOM TENSION RING ‘CHANNEL GASKET LOWER SPACING FRAME SERRE SERRE SEER SRO MESH FRAME c/w REN MESHIS.S.) OS NW Sess V-CLAMP RING TABLE FRAMEpiserenimeniaions rte 2 ESAT LETS. PR RERANCH HE INSPECTION DOOR LOWER TABLE ASEMB.LY UPPER SPOOL. ‘SPRING LOWER SPOOL BASE ASSEMBLY (M.S.)LOWER SUPPORTING C/W NUT Mi2 x 95L SPRING ASSEMBLY CENTRE TIE-DOWN ASSEMBLY (@)OPERATION MANUAL. PARTS LIST EER NO. PART NO. DESCRIPTION 4 6 60010200 St Spacing frame (S.S.) 2 ‘60 60020000 st Mesh frame c/w mesh 58304 + 6D 60020100 Si + @D 60020200 Si + 6b 60020300 St + Mesh frame c/w 10%#mg mesh $304 Mesh frame c/w 20#mg mesh $$304 Mesh frame e/w 30#mg mesh S304 6p 60020400 $1 Mesh frame c/w 40ffmng mesh SS304 ‘8b 60020600 st ‘Mesh frame c/w 6G#mg mesh SS304 5b 60021000 st ‘Mesh frame c/w 100%ng meshsS304 3 80 60030000 $3 Veelomp ring + 6D 60030001 $3 + Half ving | + 6b 60030902 St + Tle bolt c/w nut + 6b 60030001 $3 + Hal ring | 4, eb 60040200 St Distribution frame (S.S) 5. 6b 60050300 st Table frame (8.5) 6 ‘60 60080000 $0 Lower teble assembly (M.S) 1 ‘5p 60070000 $0 Base essenbly (M.S) 8 ‘6 60080000 00, Spring essembly + GD 60081201.00 + Lower supporting bolt c/w nut + 6D 0080002.00 + Lower speol + 6p 60087003 00 + Spring + 6b 60080002,00 + Upper spect + 6b 60081201 00 + Upper supporting bolt c/w nut 6 60030000 $0 Charnel gasket 10. 0 60100900 st Center tie-down assembly + 6b 60100001 $1 + Tension spring (SS) + 6b 60101602 St + Tom nut (2 nos) (SS) + 6D 60100003 $1 + Te down washer (2 nos) (SS) + 6D 60100004 00 + Cushion washer (2 nos) (neoprene) + 6D 60101605 Si + Tle down stud (116) (SS) + 6D 60100006 51 + Spring retainer (2 ros) + 6p 0101602 $1 + _Hold-down nut (2 nos) (SS) i 8b 60110000 St Slotted nut 32. ____| 6p 60120000 00 Balance spring assembly 143, > 60130000 20 \Vibra-moter For spare parts, refer motor manuel. 14, 2 60140000 $0 Bottom eccentric weight 15, 6 60150000 $0 Top eccentric weight 16 | 6p 0140000 09 Tunetion box, 17, ‘6 60170000 00. Lube hose c/w fitting $9/nley/2008VB SERIES VIBROMOTOR e i casing 1 cable connector 9 upper flange 2 terminal box cover 2 bottom flange 3 foam rubber block 23 complete shaft 4 screw 2A winded stator 5 schnor 25 oring 6‘ orgasket 26 roll beating 7 foom rubber block 7 plug 8 roll bearing B i oF gasket n beating cap a screw E 2 beating cap 30 4 schnor 13 stop ting 31 : cable grip 4 stop ting 32 ground connection plate 16 cable % screw 7 dowel uM schnor 8