INSTRUCTIONS MANUAL

FOR
OPERATION & MAINTENA
MAINTENAN
NANCE
OF
VIBRATING EQUIPMENT

Tega McNally Minerals Limited

Office Space No.1606 B, 16th Floor, Godrej Waterside, Tower-II, Block DP-5, Salt Lake,
Sector V, Bidhannagar, Kolkata- 700091
 Storage at site prior to erection (up to 12 months)
a) Store large cases containing structures unopened in an enclosed
room, or cover with canvas, if stored outdoors.
b) If stored outdoors, place cases on square timbers, planks or boards,
with 80 mm ground clearance.
c) Check canvas covers monthly. Remedy damages, if any.
d) Mend any transit damages detected.
e) Store cases containing machine components, such as drive shafts,
springs, bolts, etc., unopened in an enclosed, dry room.
f) Vibrators are internally preserved and packed in cases. Store in
accordance with item 1.5 above. If stored for extended periods,
corrosion protection requires to be renewed. See relevant
suggestions as part of operating instructions.
g) For storage beyond 18 months, open cases, and remove foils, to
enable moisture which has penetrated to escape.
b) Storage of components upon completed erection.
a) Remove vibrators and drive shafts and store in an enclosed, dry
room, placed on wooden supports.
b) Preserve vibrators inside, in accordance with suggestions given in
operating instructions.
c) Paint or spray bright surfaces on vibrators and drive shafts with a
preservative. Protect bright connecting areas for vibrators in the same
manner.
d) Store vibrator and drive shaft bolts in enclosed cartons or wooden
boxes, after spraying them lightly with oil.
e) Check assembled machine components for damaged paint spots,
and retouch.
f) Release tension of compression springs, proceeding as follows :
Measure distances between spring pads above and below. Cut two
steel channels per spring location 30 mm longer than the distance
measured and let down machine on these channels.
g) A monthly check is recommended to mend any unexpected damage.

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a) Use auxiliary transport eyes or traverses resp. provided.
Knocking on construction parts and welding of auxiliary transport
devices is not permitted.
Remove transport traverses before commissioning.
b) Mount supporting brackets, cable suspensions of spring plates resp.,
and insert springs. Maintain dimensions of TMML arrangement
drawing.
Bolt all suspension brackets tightly to their supports. Weld or bolt
spring support plates to supporting structure only after final alignment
of the equipment.
c) Fill isolation frame (if applicable) with concrete as per arrangement
drawing. Place isolation frame on springs. Align lengthwise and
across by means of leveling instrument (water or hose balance).
d) Bolt spring consoles and splash plates (if removed for transport) to
equipment.
All bolts on vibrated parts are strength grade 8.8. See table for
tightening torque.

Required
Dimensions Tightening
Torque
in Nm
M 12 84
M 16 210
M 20 410
M 24 710
M 30 1450

e) Place equipment on springs

f) Mount Exciter (if removed for transport). (See “Vibration Exciter”)
g) Mount intermediate and cardan shafts. (See “Vibration Exciter”)
h) Mount guards.
i) Commissioning and lubrication of exciters as per operating
instructions “Vibration Exciter”.
j) Align equipment lengthwise and across in accordance with the
arrangement drawing.
Make sure that spring discs are horizontal and that springs have same
compression on right and left hand side; if not, adjust by using shims
(tolerance ±2 mm).

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 Fasten spring support plates.
In case of cable suspension tightens cables evenly.
k) Provide safety catches (ropes, brackets, cross bars, etc.) for
equipment suspended by cables, chains or bars.

Be sure that cables are not bent at tensioning points nor chafe at any
point.

l) Suspension parts (chains, cables) must not have excessive natural

oscillations, otherwise an extra mass of 1-2 kg per cable must be
added. Find best point by trials. Suspension parts must be calm so
that no perceptible heat develops at tensioning points.

m) Before the equipment is switched on, exciters must be checked for

free movement by turning swing segments by hand.

n) Check equipment for free movement. No vibrated part is to knock

against stationary parts with particular regard to the wider vibrations
during startup and stoppage.
See arrangement drawing for minimum clearance.

Equipment or Cardan shafts are not to knock against any other part
during start-upand stoppage.

o) Adjust rubber buffers (if applicable) to allow a 10 mm clearance under

load. Buffers limit vibration deflections during stoppage of the
equipment (passage through the resonance zone).
If rubber strips are used as amplitude limiters they have to be
adjusted at idling in such a way that the equipment can vibrate freely
upwards for about 30 mm while passing through the resonance zone.

p) When mounting stationary parts, such as chutes, hoods, jackets, etc.,

made sure that wear parts of equipment remain easily accessible.

q) Observe all statutory regulations and codes when fitting electrician. It

isessential to have a safeguard against tampering.

r) Follow other directions of operating instructions.

s) We recommend that our TMML service engineer assists with
mounting and
In this connection kindly ask for our standard offer for supervision
charges.

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 MAINTENANCE OF VIBRATING EQUIPMENT’S

a) The vibrated structure and all connected movable parts (springs,

cardan shafts) must be able to oscillate freely. They must not fouling
with static parts (feed and discharge chutes, platform, etc. or
material, nor work in the material).gap between equipment and
static parts must be as per GA drawing. The swing segments of the
exciters must rotate freely, i.e. no material is to accumulate below the
exciter.

b) Check all bolts and tighten loose bolt after the first 50 hours of
operation, then after 200 hours of operation later after 500 hours of
operation. Check fasteners subjected to heat above 200°C daily.

Tighten loose bolts or keys, especially fasteners for exciters and

decks. Secure all bolts of the vibrated structure against loosening.

c) Repair or replace worn deck plates in time.

Always have spare parts in stock. In the case of powdery material

seal the joints with suitable cementing agent. Keep deck clean,
remove any adherent material.

d) If springs are subjected to extreme moisture or other agents, protect

them against premature wear with proper cleaning regularly.
(Normally, springs have long life).

Replace broken springs immediately.

e) Maintenance of exciters as per sheet “Vibration Exciter”.

f) Clean or repair equipment only at standstill and after precautions

have been taken that accident.

To cool off equipment handling hot material does not spray with water!

g) TMML cannot be held responsible for damage due to non-

observance oftheir operating instructions.

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1. No change of vibrated weight, by adding e.g. screen plates, chutes,
wear plates, etc., or by increasing the plate thickness, except after
consultation with TMML.

2. If the temperature of the feed material is higher than indicated in the

order acknowledgement, difficulties might arise.

3. If side walls are protected by skirt plates, the height of bed must not
exceed these plates so as to protect the walls. (Adjustment of the
bed by gates at the hopper outlet). Make sure that the material is
continuously fed across the entire width of the screen/feeder.
Height of fall limited to 300mm to 400mm.

4. The equipment can be switched on under load but only at standstill

in order to prevent troublesome oscillations during passage of
resonance zone.

5. For technical reasons the motors are selected so as to reach the

nominal speed in about 3-4 seconds. The starting torque for over
critical equipment is ~2.5 time of rated torque.
Times the normal torque is a speed range of 0-300 rpm. Motor starter
is to bedesigned for direct and heavy duty start-up.
6. The delivery rate Q depends on the width of the equipment (b=cm),
the height of bed (h=cm), and the conveying speed (v=m/min):

Height of bed and conveying speed are influenced by the material

properties. Crystalline and lumpy bulk materials having a dust
content (0.3mm) of less than 10% are easily handled. Powdery or
sticky products are more difficult to handle.

7. The conveying speed (v) can be adjusted by changing the

amplitude(s), the angle of throw (a), the inclination of the equipment,
or the number of oscillations.

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 Normal stroke 2s (double amplitude s) :
at 1500 oscillations/min-1 = 2.5 - 4.5 mm,
at 1000 oscillations/min-1 = 6 - 10 mm
at 750 oscillations / min-1 = 10 - 12 mm.

Normal angle of throw (α):

At Vibro Feeders (for conveying only) = 20 - 35°
at Vibro Screen Feeders = 30 - 55°
at Knock-out Feeders for Foundries = up to 75°
The angle of throw depends on the material to be handled, the
inclination of the deck, the screen perforation (larger openings
require a steeper angle of throw), the screening effect (gentle smaller
angle, sharp-large angle.)

In the case of horizontal deck, medium strokes, and easily handled

material, a conveying speed of 10-12 m/min. can be obtained.

8. Stroke (2s) and angle of throw (a) can be ascertained by pencil

diagram. Determine direction of oscillation by observing e.g. surface
pits, then hold pencil as much as possible in this direction so at to
obtain a straight line, after that move lead pencil at right angle to this
line and obtain the actual stroke. It is advisable to repeat the
procedure. As a result, a rectangle is obtained from while the stroke
and the angle of throw can be determined.

α = Angle of throw
2s = Stroke

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9. Step-by-step adjustment of the conveying speed can be made by
changing the stroke. To that end, unbalance weights are added or
removed (see “Vibration Exciter”). There is an inter-relation between
the so-called static moment (Kg-cm) of the exciter, the weight W(kg)
of the vibrated structure, and the amplitude s (cm), due to the fact
that in a speed range above approx. 400 rpm the amplitude is
almost independent of the speed and therefore, constant.

Static moment
S= (cm)
Weight

The diagram shows the relationship between feed rate Q and amplitude 2s.

Note: Set amplitude to no larger than required to obtain the desired

feed rate, otherwise exciter and vibrated structure are subjected
to unnecessary stresses.

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 10. The conveying capacity increases if the deck has a downward slope
and decreases in the case of an upward slope. If inclination is too
steep (above 15°) and particularly if the equipment is short, the feed
material might slide beyond the trough after equipment is stopped.
(This is especially true if feed tends to flush. In that case, only a slight
slope is permissible and the feeder must not be too short).

11. In order to keep trickle feed to a minimum after stopping the

equipment, it is advisable to break the drive motor (by motors with
electromagnetic, reverse or direct current brake). In addition, the
drive should be braked in the following cases :

Note: Do not go below a minimum speed of 400rpm

Supporting structures sensitive to vibrations (reducing vibrations in the

foundation during stoppage);
_ Arrangement of vibrating equipment in series with troughs
connected by gaskets (reducing wear of gaskets).

The brake torque should be about equal to the starting torque of the
drive motor (approx. 2.5 times the rated torque).

Time delay approx. 2 sec. before commencement of braking action.

See also “Vibration Exciter”.

12. For screens the vertical acceleration component must be too small,
since otherwise material might get stuck in the openings. Therefore,
speed control of screens is not recommended.

13. For maximum screening efficiency feed material evenly across the
entire width of the deck.

14. Make sure that screen mats are correctly tensioned.

When using vibrating machinery, vibrating parts will always be located in

close proximity to stationary parts, and it is at these points that there is the
possibility of danger to operating personnel, etc.

Therefore, affix to our machines, a clearly visible sign to this effect.

In order to achieve a maximum degree of safety, a blocking chain or

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 similar type of restriction should be placed about an individual machine at
a distance of approx. I’m, with chain, etc., but be capable of being easily
removed when work on the shutdown machine is to be carried out.

CAUTION: - KEEP SAFE DISTANCE WHEN EQUIPMENT IS IN OPERATION

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a) General Remarks
Feed the material evenly across the entire width of the Screen at the
least possible height of drop.

b) Assembly
Tension the screen mat so tight that it rests firmly on the supports and
does not lift off due to the vibrations of the Screen. (Avoid over
tensioning).

Carefully remove any material adhering to the contact surfaces before

mounting a new screen mat. Cover the protruding supports with
rubber or the like.

Tensioning bolts or bars have to rest firmly and fully in the tensioning
folds.

In the case of longitudinal tensioning, install the wedges on the long

sides of the Screen only after the mat is properly tensioned.

c) Maintenance
Retention a newly installed screen mats after 3 hours of operation
check and tightened fasteners if required. Check after another 10
hours of operation check and tightened fasteners if required, do the
same exercise after every week after operation.
If applicable, loosen the lateral wedges and tighten them again after
tensioning. Check wear of screen mats frequently. Repair smaller
damaged areasat once, for instance by inserting new wires or
attaching screen mat remnants. Never weld spring steel wires!
If only small areas are worn, turn screen mat or exchange individual
sections

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THANK YOU!

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