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Italvibras USA Industrial Electric Vibrators For Use In Hazardous Locations
Model CDX, IMX, VMX
Operator’s Manual
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Table of Contents Section Title
Page
Tables and Figures Index Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Below Introduction Introducti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Installation Design Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Eccentric Weight Weight Adjustment Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Lubrication Lubricatio n requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Electric Vibrator Repair & Maintenance . . . . . . . . . . . . . . . . . . . . . . . .15
Appendix Electric Vibrator Vibrator Item Numbers Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1 Electric Vibrator Torque Torque Requirements Requir ements . . . . . . . . . . . . . . . . . . . . . . . .A2 Electric Vibrator Vibrator Parts List List Diagrams . . . . . . . . . . . . . . . . . . . . . . . .A3-5
Figures Figure # 1 2 3 4 5 6 7 8 9 10 11
Page
Electric Vibrator Mounting Examples . . . . . . . . . . . . . . . . . . . . . . .3 Safety Safet y Cable Cable Instal Installati lation on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Mounting Moun ting Bolt Torqu orquee Sequenc Sequencee . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Explosion-Proof ExplosionProof Wir Wiring ing Kit for Haxardous Locations . . . . . . . . .7 Wirin iring g Diagram Diagramss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Proper Prop er Wirin Wiring g Arrang Arrangement ement/Posi /Position tioning ing . . . . . . . . . . . . . . . . . . . .8 Termin erminal al Block Block Hard Hardware ware Inst Installat allation ion . . . . . . . . . . . . . . . . . . . . . .9 Wirin iring g Block Block Assembl Assembly y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Manual Manu al Reset Reset Conn Connecti ections ons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Ground Bonding Bonding Screw Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Eccentric Weight Weight Adjust Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
12 Setting Sets of Eccentric Weights to Mirror Mirror Images Images . . . . . . . . . .12
Tables Table I II III IV V
Page
Mounting Bolt & Torque Torque Requirements . . . . . . . . . . . . . . . . . . . . .4 Wiring Wir ing Kits Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Lubrication Schedule for Each Bearing . . . . . . . . . . . . . . . . . . . .14 Vibrator Item Item Number By Frame . . . . . . . . . . . . . . . . . . . . . . . . .A1 Vibrator Nut & Screw Torque Torque Requirements Requirements . . . . . . . . . . . . . . .A2
© 2011 Italvibras USA
All rights reserved. reserved.
All materials subject subject to change. change.
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Introduction Italvibras USA expl Italvibras explosio osion-pr n-proof oof and dust dust-igni -ignition tion-pro -proof of indu industria striall elec electric tric vibra vibrators tors have been designed and manufactured in accordance with the most exacting international industrial standards and requirements. requirements. Italvibras USA industrial electric vibrators are designed for long life at continuous duty and maximum force output. The electric vibrators are suitable for operation in ambient from -25°C to 40°C for Class I and Class II electric vibrators and for operation in ambient from -25°C to 55°C for Class I electric vibrators. Italvibras USA industrial electric vibrators have been evaluated for installation throughout the world. Standard ratings include Underwriter’s Laboratories, Inc. (UL) listing, CSA (Canadian Standards Association) Approval, the CE (European Directive) Mark, EX Approval for Zone 21 (ATEX Ex d IIB tD A21 IP66), Russian GOST Mark for Ex d explosion-proof rating and IECEx Approval (Ex d IIB and tD A21 IP66). Check the electric vibrator nameplate for the exact ratings and Approvals for the specific Model. Model. The electric vibrator can be referred to by its Model or Type Type designation or by its Item number. The vibrator Model or Type designations referred to in this manual are as follows: CDX - Continuous duty explosion-proof industrial electric vibrator, single or three
phase. IMX - Continuous duty explosion-proof explosion-proof industrial electric vibrator having a mounting bolt hole pattern the same as Invicta vibrators. VMX - Continuous duty explosion-proof industrial electric vibrator having a mounting bolt hole pattern the same as VIMARC® vibrators.
The Italvibras USA explosion-proof electric vibrator is intended for the following hazardous locations: In are areas as tha thatt hav havee exp explo losiv sivee or fla flamm mmabl ablee gas gases es,, vap vapors ors and and/or /or du dusts sts whe where re the exp explo losio sion n hazard is referred to as Division 1 or Zone 1, the electric vibrator is marked for Class I, Groups C and D and Class II, Groups E, F and G hazardous locations and Ex d IIB 120°C tD A21 IP66 T120°C T120°C.. In ar area eass th that at hav havee ex expl plos osiv ivee or fl flam amma mabl blee gas gases es and and/o /orr va vapo pors rs wh wher eree the exp explo losi sion on haz hazar ard d is referred to as Division 1 or Zone 1, the electric vibrator is marked for Class I, Groups C and D hazardous locations and Ex d IIB 160°C. Italvibras Italvib ras USA USACDX CDX,, IMX and VMX exp explos losion ion-pr -proof oof ele electri ctricc vib vibrato rators rs com comply ply wit with h the Ess Essent ential ial Health and Safety Requirements: EN 60079-0:2006, EN 60079-1:2007, EN 61241-0:2006, EN 61241-1:2004, IEC 60079-0:2004, IEC 60079-1:2007, IEC 61241-0:2004 and IEC 61241-1:2004.
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General Safety requirements Read this entire manual before proceeding. Compliance with all company, local and OSHA regulations is essential. Any electrical work must be done in accordance with all applicable local and national codes and must be performed only by qualified, licensed and authorized personnel. Always follow lockout and tag out procedures procedures and requirements and always wear ear protection when in close proximity to operating vibratory equipment. Comprehensive adherence toI z244 these documents a minimum is d required – The National Electri Ele ctrical cal Cod Codee NFP NFPA A 70, ANS ANSI z244.1 .1 the America Ame rican natNati National onal Stan Standar dard for Per Person sonnel nel Pro Protect tection ion – Lockout/Tag out of Energy Sources – Minimum Safety Requirements, CFR 29 Part 1910 – Control of Hazardous Energy Sources (Lockout/Tag (Lockout/Tag out) Final Rule and CFR 29 Part 1910.15 Occupational Noise Exposure. Dimensions of flame-proof flame-proof joints are other than the relevant minimum or maximum specified in Table Table 2 of EN 60079-1:2007. Vibrators are marked with an “X” and manufacturer’s Drawing Nos. 601297, 601296, 601294, 601293, 601332, 601292, COMPL-94-40-IMX/VMX, COMPL-9440-EX-1, 40-E X-1, COM COMPL-0 PL-02-352-35-EXEX-4, 4, 88.80 88.80/0-E /0-EX, X, 88.7 88.70IV/ 0IV/01-E 01-EX, X, 88.6 88.60/010/01-EX, EX, 88.5 88.50/01 0/01-EX -EX,, 88.40/0-EX and 88.30/0-EX detail the dimensions of the flame-proof joints.
Storage Storage of the electric vibrator should be in an ambient not less than 5°C with a relative humidity humid ity not more than 60%. If the vibrator has been stored for longer than two years, the vibrator should be evaluated by authorized and trained personnel to ensure that the grease is intact, that there is no bearing damage such as brinelling and that the ground insulation insulation is sound and not damaged from condensation.
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Installation Before installing the vibrator, vibrator, make sure that you have everything that you will need and that there is no shipping damage. Any product damage should be reported to the delivery service immed im mediat iately ely.. Sta Standa ndard rd me metri tricc han hand d too tools ls wil willl be nee neede ded. d. Car Carefu efully lly han handle dle the ele electr ctric ic vib vibrat rator or.. Dropping or impacting the electric vibrator may damage the bearings. Welding – Never weld on a bin, hopper or machine with the electric vibrator mounted to it since the welding may damage the vibrator bearings or electrical circuits. When you do weld, especially in an enclosed area, make sure that the area is known to be nonhazardous and that there are no flammable or explosive levels of gases, vapors or dusts. Mounti Moun ting ng Su Surf rfac acee – Th Thee ob obje ject ct of vi vibr brat atio ion n on bi bins ns an and d ho hopp pper erss is to tr tran ansm smit it vi vibr brat atio ion n en ener ergy gy throu thr ough gh the st struc ructur turee to the ma mater teria iall wit within hin.. Th Thee mo moun untin ting g su surfa rface ce mu must st be rig rigid id and str stron ong g fo forr this transfer of energy to take place. The mounting surface must also be clean, flat (0.010 in. across mounting mounting feet maximum), free of paint and have a minimum thickness equal to the major diameter of the mounting bolt. Also make sure that the electric vibrator feet are clean and free of debris.
Mounting Plate The mounting plate should be at least the overall size of the electric vibrator feet. It should be located on the bin and hopper wall at a height of ¼ to 1/3 of the sloped wall height. The mounting plate or bracket should extend at least ¾ the length of the sloped wall. Reference Figure 1. If a second electric vibrator is to be installed to the bin or hopper hopper,, install it at a height of ½ of the sloped wall height and 180° from the first vibrator. Weld the mounting plate or bracket to the structure wall with skip welds that are 3 in. long then skip 2 in. then 3 in. long weld, etc. Do not weld at corners of mounting plate within 1 in. of the corner.
Figure 1. Mounting Examples
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Safety Cable Always install a safety cable metal rope from the electric vibrator to a reliable support should the vibrator become free from its mount and fall more than 6 in. The metal rope should be taut and positioned above the electric vibrator vibrator.. Reference Figure 2.
6”
Figure 2. Safety Cable Installation
Mounting Kits Mounting kits are Italvibras framemounting sizes 00, 01, 10, 20, 30, 40 and 50. The mounting kits available include afrom channel mountUSA withfor integral plate, mounting screws and washers and safety cable cable kit. Contact Italvibras USA by phone at 815-872-1350.
Mounting Hardware & Torque Always use new bolts, nuts and compression washers. The bolts should be Grade 5 or 8 (equivalent international designation designation is 8.8 and 12.9, respectively). respectively). Grade 5 bolts are suitable for a majority of applications. Do not use split lock washers. Use only compression washers. Tabl ablee I of offe fers rs su sugge ggeste sted d mo mount unting ing bo bolt lt tor torqu quee val values ues.. Al Alway wayss che check ck wit with h the bol boltt ma manuf nufact actur urer er for recommended torque values. Torque the mounting bolts in the proper sequence as shown in Figure 3 so as not to damage casting. After operating vibrator for 15 minutes, disconnect, locko lo ckout/ ut/tag tag out out,, and to torq rque ue the mo mount untin ing g bo bolts lts a se secon cond d tim time. e. Pe Perio riodi dical cally ly che check ck the mo mount unting ing bolt torque thereafter thereafter..
Table I. Mounting Bolts & Torque Requirements British CDX CDX CDX
Metric
Fram Fr ame e Si Size ze
Bol oltt Si Size ze
Dry Tor orqu que e, Gr Gra ade 5
Bol oltt Si Size ze
Dry Torque ue,, Grade 8.8
10, 20
1/2 in-13 NC
58
M12
8
3 0, 35, 40 30
5/8 in-11 NC
137
M16
19
50, 60
3/4 in -10 NC
288
M20
38
CDX
70
7/8 in -9 NC
430
M24
71
CDX
80
1 in-8 NC
645
M24
71
IMX
50, 60
5/8 in-11 NC
137
M16
19
IMX
70, 80
1 in-8 NC
645
M24
71
VMX
60, 70
3/4 in -10 NC
288
M20
38
80
1 in-8 NC
645
M24
71
VMX
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3
2
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6
1
2
5
4
4 Bolts
6 Bolts
5
8
3
2
1
4
7
6
8 Bolts
Figure 3. Torque Sequence
Vibrator Nameplates
Stainless Name Plate
Stainless Name Plate For Explosion Proof Vibrators, Item #519003
Alternate Stainless Name Plate
Stainless Warning Name Plate For Explosion Proof Vibrators Item #518497
Alternate Stainless Name Plate
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Wiring Kits The wiring kits outlined in the table below are for hazardous locations classified classified by Divisions only onl y. Haz Hazard ardous ous loc locati ations ons clas classif sified ied by Zon Zones es sha shall ll uti utilize lize Ex d fla flameme-pro proof of wiri wiring ng com compon ponents ents.. Wiring Kit Item No. 18105 is for use with frame sizes 10, 20 and 30. Wiring Kit 18100 is for use with frame sizes 35, 40 and 50. Wiring Kit 18101 is for use with frame sizes 60, 70, 80 and 110.
Table II. Wiring Kits Wiring Kit Item No. 18105 Frame Sizes 10, 20, 30 No.
Quantity
Item Description
Item No.
1
7 feet
18/6 cord
11007
2
1
1/2 in. NPT elbow
18106
3
1
1/2 in. NPT cord connector
18107
4
1
packing fiber
18108
5
1
sealing compound
18104
6
4
wire connectors
12001
Wiring Kit Item No. 18100 Frame Sizes 35, 40, 50 No.
Quantity
Item Description
Item No.
1
7 feet
12/6 cord
11008
2
1
3/4 in. NPT elbow
18102
3
1
3/4 in. NPT cord connector
18103
4
1
packing fiber
18108
5
1
sealing compound
18104
6
1
wire connectors
12002
7
3
wire connectors
12001
Wiring Kit Item No. 18101 Frame Sizes 60, 70, 80, 110 No.
Quantity
Item Description
Item No.
1
7 feet
12/6 cord
11008
2
1
3/4 in. NPT elbow
18102
3
1
3/4 in. NPT cord connector
18103
4
1
packing fiber
18108
5
1
sealing compound
18104
6
1
wire connectors
12002
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Figure 4. Explosion-Proof Wiring Kit for Hazardous Haza rdous Locations
Wiring Electric Vibrator It is mandatory to comply with the National Electrical Code, NFPA 70, and all applicable local codes. Remove the screws with washers securing the wiring box cover along with the foam rubber block and set aside. Identify the wiring diagram by referencing the wiring diagram found within the wiring box or by referring to the diagrams shown in Figure 5.
CDX Model, 1-phase
2 P 1 P
W2
U2
2 P 1 P
V2
W2
U2
U1
V1
V2
K W1 U1 V1 W1
G
G
K
Rotati Rot ation on in One Dir Direct ection ion
Rotation Rotat ion in Oppos Opposite ite Direction
Diagram 1 CDX Model, 6-lead, 3-phase
2 P 1 P
W 2 U2
2 P 1 P
V2
W2
U2
U1
V1
W1
G
U1
CDX Model, 9-lead, 3-phase
2 P 1 P
4 75 8 6 9 1 2 3
V2 W1
V1
G
2 P 1 P
U V
1 72 8 3 9 4 5 6
G
W
G
Cable Entry Y - High Volta Voltage ge
V
U
W
Cable Entry Y (S (S) - High Voltage
S - Low Volt Voltage age
Diagram A
Diagram B
Figure 5. Wiring Diagrams
7
YY - Low Voltage
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Wiring Electric Vibrator Cont. Select a 4-conductor cord for Class I only electric vibrators. Select a 6-conductor cord for Class I an and d Cl Clas asss II vi vibr brat ator ors. s. Th Thee co cord rd ty type pe sh shal alll ha have ve a vo volt ltag agee ra rati ting ng no nott le less ss th than an th thee po powe werr su supp pply ly voltage and a minimum temperature temperature rating of 105°C. We We recommend Coleman black cord SEOOW Seoprene Seoprene cable rated 600 V and 105°C. Coleman Cable Inc. can be reached by phone at 847-672-2300 or at www.colemancable.com. Italvibras USA also stocks the Coleman Coleman cable. When wiring the electric vibrator vibrator, , leave enough in the so that best the cord doesn not become taut during operation operatio n causing stress on theslack connections. connectio ns.cord It is always to positio position the cord down so that should there be any moisture present present the moisture would tend to run down instead of into the vibrator wiring box. Trim the cord by removing the jacket exposing the conductors and ground wire for approx. 6 in. Be careful not to cut the conductor or ground wire insulation. Insert the cord through the conduit fittings and then through the opening in the side wall of the wiring compartment. Position the jacket of the cord approx. ½ in beyond the inside wall of the wiring box wall. Assem As semble ble all con condu duit it fit fittin tings gs mak making ing sur suree tha thatt the there re is alw always ays mi minim nimum um thr thread ead eng engage agemen mentt of 5 full threads. Install the conduit seal following all instructions being certain to comply with Articles 501 and 502 of the NEC. Trim the conductors wiring leaving of slack. Next, insulation for ¼ in. towithin 3/8 in.the Crimp onbox closed loopplenty wire connectors. Usestrip onlythe theconductor intended crimping tool as designated by the wire connector manufacturer. The conductors should be neatly arranged on the floor of the wiring box. The wires should not cross over each other. See Figure 6.
Figure 6. Proper Wirin Wiring g Arrangement/Positioning Secure the wire connectors and the shorting bars to the terminal block in the positions shown on the wiring diagram using the hardware hardware provided. provided. It is essential that the hardware hardware be positioned as shown in Figure 7.
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Wiring Electric Vibrator Cont.
Figure 7. Termin Terminal al Block Hardware Installation Note that the closed loop wire connectors provided on the power supply cord are positioned between betwee n the two flat washers washers.. A drop or two of thread sealan sealantt such as Lockti Locktite te is recom recommende mended. d. Do not use permanent thread sealant because the terminal block will be damaged should you wish wi sh to re remo move ve an and d re repl plac acee th thee po powe werr su supp pply ly co cord rd.. Th Thee te term rmin inal al bl bloc ock k nu nuts ts sh shou ould ld no nott be ov over er tightened since the possibility of damaging the plastic insulating body is high. Reference table IV in the Appendix for torque values. Make the connections hand-tight followed by a ¼ turn but never put a ratchet on these nuts. nuts. For constructions that do not incorporate terminal blocks, make the wire-to-wir wire-to-wiree connections using wire nuts. The nuts should be taped with electrical insulation. Electric vibrators for use in Class I and Class II hazardous locations will include a small 2-pole terminal block in the wiring box. This is the thermostat circuit. Proceed to Thermostat Wiring. Class I electric vibrators do not include this circuit. For Class I electric vibrators, reinstall the rubber block over the power supply conductors and install the wiring box cover being careful not to pinch the O-ring. Screw torque is specified specified in the Appendix. Reference Reference Figure 8.
Figure 8. Wir Wiring ing Block Assem Assembly bly 9
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Thermostat Wiring Class I and Class II electric vibrators have thermostat circuits installed in the winding. The thermostat terminals are identified as P1 and P2. These devices are intended to limit surface temperatures to no more than the marked operating temperature (code). Connect the thermostats to the motor starter as shown in Figure 9. The thermostat circuit is rated 600 V ac maximum and 720 VA. Use a manual momentary start switch.
Disconnect Phase Pha se C Phase Pha se B Phase Pha se A Fuse F5
Fuse F4
Fuse F1
Fuse F2
Fuse F3
Primary Transformer Secondary X1
MS1 X2
Fuse F5 1 Primary
Start
Stop 1
2
3
2
MS1 Coil
2
MS1
P1
OL
OL
P2
OL
3
Figure 9. Manual Reset Connections Reinstall Reinsta ll the rubber block over the power supply and thermost thermostat at circuit conductors and install the wiring box cover being careful not to pinch the O-ring. Screw torque is specified in the Appendix. See Figure 8.
Grounding & Bonding The electric vibrator must be grounded using the ground wire provided in the cord. The ground wire shall be connected to a closed loop wire connector which is then connected to the ground terminal located within the wiring box (See Figure F igure 6). The ground terminal is identified by the international symbol.
GROUND
It may be necessary to bond the electric vibrator to ground using the external ground screw as shown in Figure 10. The external ground terminal is identified by the international symbol. Use a wire size no smaller than the internal ground wire.
10
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Grounding & Bonding Cont.
Figure 10. Ground Bonding Screw
Overload, Short-Circuit & Ground-Fault Protection In th thee US USA, A, Th Thee Na Nati tion onal al El Elec ectr tric ical al Co Code de,, NF NFP PA 70 70,, an and d al alll ap appl plic icab able le lo loca call co code des, s, go gove vern rn ho how w to properly size, select and install overload protection (sometimes called heaters) and shortcircuit cir cuit and grou ground-f nd-fault ault pro protecti tection on (fus (fuses es or circ circuit uit brea breakers) kers).. Pro Proper per sel selectio ection n and inst installat allation ion of th thes esee de devi vice cess is re requ quir ired ed an and d es esse sent ntia iall fo forr no nott on only ly pr prot otec ecti tion on of th thee el elec ectr tric ic vi vibr brat ator or an and d th thee power supply circuit but also for protection of personnel. If the overload or short-circuit and ground fault protection operate, have qualified personnel locate and fix the problem before resetting. When operating two electric vibrators, the vibrators should be controlled with a single motor starter that has overload protection dedicated to each electric vibrator vibrator.. The overloads shall be electr ele ctrica ically lly int interl erlock ocked ed suc such h tha thatt sho should uld the there re be a fau fault lt wit with h one ele electr ctric ic vib vibrat rator or,, bot both h ele electr ctric ic vibrators will be de-energized de-energized..
Variable Frequency Inverter The electric vibrators may be supplied with a variable frequency inverter. Never operate the vibrators above the maximum frequency noted on the nameplate. If operating two vibrators, use one variable frequency inverter along with overload protection dedicated to each electric vibrator.. The overloads shall be electrically interlocked such that should there be a fault with vibrator one electric vibrator, both electric vibrators will be de-energize de-energized. d. The nameplate current should never be exceeded throughout the entire frequency range.
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Eccentric Weight Adjustment The eccentric weights may be adjusted to produce the desired centrifugal force output. It is alwa al ways ys be best st to op oper erate ate th thee el elec ectri tricc vi vibra brato torr at the lo lowe west st we weig ight ht se setti tting ng tha thatt pr prod oduc uces es the de desi sire red d result. This will result in lower energy expense and extend the bearing life. The factory setting is 50% which would result in 50% of the centrifugal force noted on the nameplate. To adjust the forc fo rcee out outpu put, t, lo locko ckout/ ut/tag tag ou outt the el elec ectri tricc vi vibra brator tor.. Re Remo move ve ea each ch we weigh ightt co cover ver and se sett it and the scre sc rews ws,, wa wash shers ers and OO-rin rings gs as asid ide. e. The ou oute terr ad adjus justab table le we weigh ightt cla clamp mpin ing g sc scre rew w or the sha shaft ft nut may be loosened and then the adjustable weights may be rotated to the desired position. Reference Figure 11.
Figure 11. Eccent Eccentric ric Weight Weight Adjust. The eccentric weights must be adjusted to mirror images of each other at the same setting number as shown in Figure 12.
Figure 12. Setting Sets of Eccentric Weights Weights to Mirror Images Properl Prop erly y to torq rque ue the cl clam ampi ping ng sc scre rew w or sh shaf aftt nu nutt to se secu cure re the we weig ights hts in po posi siti tion on.. Tor orqu quee va valu lues es aree ou ar outli tlined ned in the Ap Appen pendix dix.. Rei Reinst nstall all the wei weight ght cov covers ers mak making ing sur suree not to pin pinch ch the OO-rin rings. gs.
12
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Eccentric Weight Adjustment Cont. Check shaft rotation before replacing weight covers. Start vibrator for 1 second, stop and lockout/tag out. Observe direction of rotation. If desired to reverse the direction of rotation, swit sw itch ch tw two o of th thee th thre reee po powe werr su supp pply ly le lead adss in th thee wi wiri ring ng bo boxx or at th thee mo moto torr st star arte terr fo forr 33-ph phas asee electric vibrators. For 1-phase electric vibrators, refer to the wiring diagram for changing the direction of shaft rotation. Replace weight covers using screws and washers being careful not to pinch the O-rings. The screw torque is outlined in the Appendix. Never operate the electric vibrator without weight cove co vers rs in pl place ace.. Th They ey pr prov ovid idee a de degr gree ee of pr prot otec ecti tion on fo forr the be beari arings ngs an and d a sh shie ield ld fo forr th thee ro rota tatin ting g eccentric weights. Always replace broken weight covers immediately immediately.. Do not operate electric vibrator with weight covers removed or with damaged weight covers.
Starting Up Afterr ma Afte maki king ng su sure re tha thatt the po powe werr su supp pply ly vo volta ltage ge ma match tches es th thee vo volt ltage age ma marke rked d on the nam namep epla late te,, that the mounting bolts are properly secured, that all covers are in place and secured, and that the motor starter is properly installed and adjusted, turn the electric vibrator on. Excessive noise would indicate a problem but slight bearing noise is normal due to the type of bearing used. After a few hours of operation, check each line current and verify that it does not exceed nameplate current. If the line current exceeds the nameplate current, then the mount needs to stiffened,, the vibrator weights need to be reduced or the vibrator needs to be moved to a more stiffened rigid location. Never operate the vibrator above nameplate current. After the first 8 hours of operation, check the line current to make sure that it does not exceed nameplate and check mounting bolt torque. See MOUNTING HARDWARE HARDWARE AND TORQUE.
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Electric Vibrator Lubrication All electric vibrators are lubricated at the factory. factory. If there are no external grease fittings, then the vibrator construction is lubricated for life. No grease ever need be added to these electric vibrators. If external grease fittings are provided, then it is intended that the bearings be periodically lubricated. The lubrication schedule is outlined in Table III.
Table III. Lubrication Schedule For Each Bearing
Frame Size
Grease Quantity, g
Lubrication Frequency, hrs.
10
life
life
20
life
life
30
life
life
35
life
life
40
12
2000
50
16
2000
60
25
3000
70
40
2000
80
50
2000
110
220
1000
The lubrication frequency is every 2000 hours of operation unless specified otherwise in the table. There is an exception - 3600 rpm electric vibrators operating continuously or for long periods of time should be lubricated in ½ the time specified using ½ the grease volume specified. For all other vibrators, follow the table except when the operating temperature exceed exc eedss 90° 90°C. C. If the ope operat rating ing tem temper peratu ature re exc exceed eedss 90° 90°C, C, re reduc ducee the lub lubric ricati ation on fre freque quency ncy and lubrication volume by 50% for every 10°C increment above 90°C. If the electric vibrator operating temperature exceeds 100°C, contact Italvibras USA by phone at 815-872-1350. The electric vibrator should never operate above 120°C. When adding grease through the grease fitting, make sure to clean the fitting so as not to introduce dirt into the bearing. Add the specified amount of grease. Experiment with your grease gun to determine how many grams are introduced with each pump. Never over-grease a bearing since this will damage the bearing and cause high operating temperature. Always use the correct grease. Never mix greases. Use Kluber ISOFLEX TOPAS NB 52 grease. Kluber grease may be purchased direct from Kluber Lubrication by calling 800-447-2238. Italvibras USA also stocks the Kluber Kluber grease.
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Electric Vibrator Repair If the ele electri ctricc vib vibrato ratorr need needss rep repair air,, cont contact act Ital Italvibr vibras as USA USAat at 815815-872872-1350 1350 for inst instruct ruction ions. s. Mos Mostt electric motor repair shops are not trained to repair our industrial electric vibrators. We recommend that they be returned returned to the service center located in Princeton, Princeton, IL. Attempting to repair the electric vibrator or replace the bearings will void the warranty warranty..
Electric Vibrator Maintenance Every quarter, quarter, we recommend a thorough inspection of the electric vibrator. After lockout/tag out, do the following: 1.) Inspect the cord for any visible damage or wear. wear. Replace the cord if there are any signs of damage or wear. This holds true for both the power supply cord and the thermostat circuit cord. 2.) Remove the wiring box cover and inspect for any foreign matter or liquid. Vacuum any foreign matter. If wet, remove electric vibrator from service and have the ground insulation tested by a trained, qualified and licensed technician. 3.) Before replacing the wiring box cover, make sure the electrical connections are tight (do not over-tighten) and inspect the cover O-ring and rubber compression block. If the O-ring O-ring or rubber compressio compression n block is damaged damaged or if they have lost their compression set, replace them. 4.) Remove each weight cover and inspect for foreign matter. Vacuum if necessary. Replace O-rings if they are damaged or if they have lost their compression set. 5.) Check the mounting bolt torque. 6.) Replace any broken parts.
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Appendix Electric Vibrator Item Numbers
The table below outlines a list of electric vibrator Model/Type designations next to their respective Item The information is sorted by frame size.orPlease reference the Model/Type designation andNo. Item No. when ordering electric vibrators their parts.
Table IV. Vibrator Item Numbers By Frame 10 Frame Model
20 Frame
Item No.
30 Frame
I tem No.
Model
35 Frame
Item No.
Model
40 Frame
Item No.
Model
Model
Item No.
CDX 600384 36-650
CDX 600385 36-1040
CDX 600387 36-1660
CDX 600387 36-1660
CDX 600437 36-3530
CDX 601409 18-470
CDX 601410 18-910
CDX 601412 18-1670
CDX 601413 18-2150
CDX 601424 18-3190
CDX 602315 12-110
CDX 601411 18-1300
CDX 602318 12-750
CDX 602320 12-1630
CDX 602325 12-1990
CDX 602316 12-220
CDX 602317 12-575
CDX 9-570
CDX 602581 9-1440
CDX 9-330
50 Frame Model
Model
602577
CDX 9-910
602578
602317
60 Frame
Item No.
70 Frame
Item No.
Model
80 Frame
Item No.
Model
110 Frame
I tem No.
Model
Item No.
CDX 600317 36-4400
CDX 600320 36-5060
CDX 600323 36-7040
CDX 600486 36-10500
CDX 602201 12-45000
CDX 601328 18-3850
CDX 601329 18-5380
CDX 601330 18-8300
CDX 601487 18-10900
CDX 602513 9-49000
CDX 601358 18-4400
CDX 602277 12-3410
CDX 602280 12-6050
CDX 602365 12-8450
CDX 602274 12-2530
CDX 602555 9-2920
CDX 602558 9-4640
CDX 602602 9-6830
CDX 602552 9-2020
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Electric Vibrator Torque Requirements Table V. Vibrator Nut & Screw Torque Requirements Cap Screws
ft/lb (kgm)
Shaft Nuts
ft/lb (kgm)
Terminal Block Nuts
ft/lb (kgm)
M6
7 (1)
M13x1
22 (3)
M4
0.87 (0.12)
M8
16.5 (2.3)
M15x1
36 (5)
M5
1.45 (0.20)
M10
35 (4.8)
M20x1
72 (10)
M6
2.17 (0.30)
M12
58 (8)
M25x1.5
123 (17)
M8
4.70 (0.65)
M14
95 (13)
M30x1.5
246 (34)
M10
9.80 (1.35)
M16
137 (19)
M45x1.5
360 (50)
M18
195 (27)
M20
275 (38)
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1 1
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7 3
2 5
3 3 4 3
9 2 0 5
8 3
1
1 5
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6 3 , 5 3
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8 2 , 7 2
6 2
9 3
9
0 1
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6 4
4 1 6 1 5 1
3
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0 2
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7 3
4 3
2 5 9 0 4 5
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1
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3
0 4 4 1
5 1 5 4
9 1
2 2
3 2
7 1 6 1
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0 2
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Order Information When ordering, please specify the following: Vibratorr Model______________________________________________ Vibrato Model ______________________________________________ Series ______________________________________________________ Serial number_______________________________________________ Voltage, frequency & number of of phases ________________________ Par t #/Description 1 2 3 4 5 6 7 8 9
Quantity Required
Part #/Description
Quantity Required
CASE _______________________ ________________________________ _________ STATOR ST ATOR _________________________ ______________________________ _____ BEARING FLANGE ______________________ ______________________ SCREW ______________________________ ______________________________ SCHNORR WASHER _____________ ____________________ _______ O-RING ______________________________ ______________________________ SHAFT SHAF T _____ _________ _________ _________ _________ _________ _______ ___ FLANGE ADAPTER _____________ ______________________ _________ SHAFT WASHER_______________ WASHER________________________ _________
32 RUBBER COMPRESSION BLOCK __________ 33 O-RING O-RING ______________ ___________________________ ________________ ___ 34 WIRING BOX COVER _____________ ____________________ _______ 35 SCREW SCREW ______________ ___________________________ ________________ ___ 36 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 37 CORD GRIP ____________ _________________________ ________________ ___ 38 GREASE FITTING/PLUG _____________ __________________ _____ 39 LEAD PROTECTOR _____________ ______________________ _________ 40 INTERNAL SNAP RING _____________ __________________ _____
10 BEARING ______________ ____________________________ ______________ 11 BEARING COVER _____________ ______________________ _________ 12 SHAFT SEAL ____________ __________________________ ______________ 13 SHFT SHFT KEY ______________ ____________________________ ______________ 14 FIXED FIXED WEIGHT ____________ ________________________ ____________ 15 ADJUSTABLE ADJUSTABLE WEIGHT WEIGHT _____________ __________________ _____ 16 SCREW SCREW ______________ ___________________________ ________________ ___ 17 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 18 BRASS WASHER _____________ ______________________ _________ 19 WEIGHT WEIGHT ADJUS ADJUSTMENT TMENT DISC _____ _________ _______ ___ 20 EXTERNAL SNAP RING _____________ __________________ _____ 21 SHAFT NUT ____________ __________________________ ______________ 22 O-RING O-RING ______________ ___________________________ ________________ ___ 23 WEIGHT COVER ____________ ________________________ ____________
41 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 42 SHAFT SEAL ____________ __________________________ ______________ 45 FAN_________ FAN______________________ _________________________ ____________ 46 BEARING COVER _____________ ______________________ _________ 47 SCREW SCREW ______________ ___________________________ ________________ ___ 48 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 49 THERMISTOR TERMINAL BLOCK __________ 50 SCREW SCREW ______________ ___________________________ ________________ ___ 51 ADAPTER SCREW SCREW _____________ ______________________ _________ 52 PLUG ______________ ___________________________ __________________ _____ 53 SCREW SCREW ______________ ___________________________ ________________ ___ 54 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 55 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 59 SPACER ______________ ___________________________ ________________ ___
24 SCREW SCREW ______________ ___________________________ ________________ ___ 25 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 26 TERMINAL BLOCK _____________ ______________________ _________ 27 SCREW SCREW ______________ ___________________________ ________________ ___ 28 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 29 GROUND GROUND SCREW _____________ ______________________ _________ 30 SCHNORR SCHNORR WASHER _____________ ____________________ _______ 31 GROUND LABEL ________________________
60 SCREW SCREW ______________ ___________________________ ________________ ___ 61 WIRING BOX COVER _____________ ____________________ _______ 64 SCREW SCREW ______________ ___________________________ ________________ ___ 66 GREASE SEAL RING _____________ ____________________ _______ 67 SPLIT SPLIT WEIGHT COVER _____________ __________________ _____ 71 SHAFT SEAL ____________ __________________________ ______________ 75 WEIGHT WEIGHT SPAC SPACER ER _____________ ______________________ _________
Fax, Phone or E-Mail to: Italvibras USA 1940 Vans Way Princeton, IL 61356 p.815-872-1350 f. 866-337-2693
[email protected] www.italvibrasusa.com
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