VIBRATING Be un dembonamds OperatiACKNOWLEDGEMENT We wish to acknowledge the contributions of members of the CIMA, Vibrating Screen Manufacturers Association (VSMA), for the preparation of this manual. Notice of Copyright Protection Copyright 1998 - Construction Industry Manufacturers Association (CIMA) ‘A mechanical vibrating screen properly installed, operated and maintained, will normally provide relatively long life and safe, trouble-free operation. Like any heavy power-driven machine, the vibrating screen must be properly operated to insure safety of personnel. The CIMA Vibrating Screen Manufacturers Association offers suggestions in this booklet for proper installation, operating and maintenance procedures. These suggestions cover all types of mechanical vibrating screens and feeders. The Operating and Maintenance personnel represent the keys to safety. These persons should be thoroughly familiar with the Screen Manuals provided by the manufacturer, but there will never be any substitute for common sense and alertness by an operator. The following suggestions are basic procedures for establishing a safe and economical operating program. PROPER INSTALLATION IS IMPORTANT Although a relatively simple machine, the vibrating screen can perform numerous and varied functions. Generally individ- Lials familiar with vibrating screens are employed for the design of structural supports and chutework attendant to the screen. They must see that the structure is adequate and free from vibratory response to the screening motion, that chutes are large enough, are sloped correctly, and are sufficiently clear of the moving screen parts. They must see that clearances and work platforms are adequate, and provide access to all portions of the machine normally inspected or maintained. They should insure tht there is adequate space provided for handling and renewing wire cloth or other screening media. For good installation procedure: READ THE MANUFACTURER'S INSTRUCTION BOOK FIRST. Be safe instead of sorry, Select crane or hoist and ting tackle based on manufacturer's weights for screen Provide means for hoisting and handling largest usual repair par. Provide adequate clearance and headroom for making repairs, Provide means for handling wire cloth, or other screening surfaces, Provide “Remote Start Waring" device and "Emergency Stop" control at the screen. Provide safety lockout at the Control Panel Provide an adequate electrical equipment ground. Screens mounted on rubber isolators will require a static electricity ground. Check angle of inclination with manufacturer's recommendation. If inclination is variable, allow for + five degrees variation from manufacturer's average specified slope.Provide adequate clearance between screen and stationary parts in accordance with manufacturer's specifications. Drain any preservative oil from vibrating unit and refill to correct level with specified lubricant. Do not weld any attachments onto screen body or base without consuiting the manufacturer. Run screen motor without V-belts. Check motor rotation. Take ammeter reading of motor at "No Load for future reference. Check complete installation for compliance with OSHA * standards and local, State and Federal regulations for ladders, walkways, rails and platforms, color coding, hazard wamings, guards enclosing drives and rotating parts. * MSHA SAFE OPERATION IS A MUST Vibrating screens are designed to operate within specific limits such as stroke, speed, inctination, screening media type, and. openings. The manufacturers prints and operating manuals for a particular machine will specify these quite clearly. Refer to this data before operating your screen or before making any major change in the screen's original intended function. For safe and efficient operation: READ THE INSTRUCTION MANUAL BEFORE STARTING THE SCREEN. Consult manufacturer's instructions for critical bolts and retorque to manufac- turer's specifications, Be sure all guards for the rotating screen parts, V-belt drives, etc, are in place and properly secured. Check the screen speed and rotation. Compare to manufacturer's for your machine. Do not exceed manufacturer's recommendations. Operate the screen empty. Look and listen for any indication of loose parts or impacting of the screen parts on chutes or the structures. Check the supporting structure for vibration. Stiffen or secure members ted speed resonating with screen ‘Check and record the amperage on the screen motor with the screen running empty, then with the material lowing, Check the material flow to the screen. Check for even spread of material ‘over the screening surfaces. Avoid surge loads. Check for material bouncing out of screen. If necessary provide spillage guards independent of screen. Alter a short operating period re-tension wire cloth. Provide closed storage for small parts and tools specifically provided for the screen. Keep spare wire cloth or other screening surfaces out of the immediate operating area. Review manufacturer's instructions for intial startup.PROPER MAINTENANCE AND REPAIRS PAY OFF A vibrating screen, as any machine, will operate longer and more satisfactorily when attended to and serviced according to a prearranged Maintonance Schedule and Checklist. Repairs can be minimized by good maintenance, but abrasion and metal fatigue will take their tol, Plan ahead for repairs so that parts and tools necessary to insure a First Class and Sate repair job will be available. For maintenance: Establish a Maintenance Schedule based upon manufacturer's recommendation. Set a daily time period and routine for lubrication, inspecting cloth for condition and tension, inspecting butter strips. Do not inspect or lubricate a soreen that is running. Wipe all tings before lubrication. Check all bolted connections for proper torque on a routine basis, Use checkof lists to ald in insuring completion of maintenance duties. Keep good main- tenance records. Lubricants, oil cans and grease guns must be stored in a dust-resistant room. Use care to avoid putting contaminants in vibrator bearing with the oil or grease. I welding is necessary, property ground the vibrating body to avoid arcing the bearings. Keep the screen area clean, spillage shoveled away; clear away spilled lubricants and discarded screening surfaces. Check to be sure all guards are replaced. Refer to OSHA Lockout/Tagout Standard. For repairs: READ THE INSTRUCTION BOOK FIRST. Pian for safe repairs. If screen can be fed by truck or loader, barricade access. Cut off and padiock (OSHA Lockout/Tagout) all power to the screening station except for repair equipment and tools. Anatd hat, safety glasses, gloves, hard-toed shoes and cutting goggles are a must Close off area below screen being repaired to avoid injury from falling objects. Provide adequate hoisting capacity and tackle. Stock spare parts and bolts recommended by the manufacturer. Don't count on re-using gaskets, seals or O-rings. Only use hand tools that fit, and manufacturer's special tools when provided. Cover conveyor belts, wood or rubber linings, before cutting or welding, and have a fire extinguisher on hand, Leave bearings wrapped until ready to install. Clean up work area, destroy olly rags or other waste before restarting the screen. Keep a written repair record ‘This manual is an industry related Vibrating Screen Manufacturers Publication. For additional copies conta: Construction Industry Manufacturers Association (CIMA) 111 E, Wisconsin Ave., Suite 1000 Milwaukee, WI 53202 Phone: 414-272-0943 * Fax: 414-272-1170 Email: [email protected] + Web site: www.cimanet.comVIBRATING SCREENS Application and Technical Data Standards a bureau of the Construction industry Fe\\\as Manutacturers AssociationACKNOWLEDGEMENT We wish to acknowledge the contributions of members of the CIMA Vibrating Screen Manufacturers Association (VSMA), for the preparation of this manual. Notice of Copyright Protection Copyright 1998 - Construction Industry Manufacturers Association (CIMA) APPLICATION DATA STANDARDS Preface Many diverse factors affect the selection of proper screening equipment for any particular application. The following information is helpful for a manufacturer to evaluate a screen application and to recommend properly the type, size and number of screens required |. What is the material to be screened: A. Sieve analysis of feed material — give gradation to feed including maximum size piece. If screen is used in closed circuit operations, give combined sieve analysis. B. Physical characteristics. Weight in pounds per cubic foot. (Indicate loose or bulk weight) Shape of particles. (Cubical, slabby, flaky or round) Is material abrasive or corrosive? |. Is material dry, damp (percent surface moisture) or slurried (percent of solids)? Does material contain clay or other adhesive matter? (What is i? Give percent.) . Has material been washed or wet processed? is material hot? What degrees F. at feed point? Has material any special properties affecting screening such as being electrostatic, deliquescent, or having a tendency to plug or blind? Il, 1s added water required in screening for washing or rinsing or for some other purpose? Ill, Feed rate. ‘A. Maximum feed rate in tons per hour including any recirculating load during surge periods. (in 2,000 Ib. tons) B. Average feed rate in tons per hour. (2,000 Ib. tons) C. Is feed continuous or intermittent? Describe, IV. Method of feeding screens — hopper, conveyor belt, feeder, slurried, other. V. Purpose of screening such as scalping, sizing, rinsing, washing, rescreening, desanding, dewatering, closed circuiting, etc., and products required. ‘A. Describe each product desired from screen by size range and state any allowable deviation B. If washing, rinsing, or dewatering, ist moisture limits acceptable in products.VI. Operating conditions — describe specific conditions affecting application such as: A. If operation is continuous, how many hours per 24 hour day? B. If operation is intermittent, what is length of average run and total hours per 24 hours? C. If operation is seasonal, how many months per year? D. List temperature range in area sereen will operate. E. Are there any specific climatic conditions that could atfect operation such as extreme temperatures, high alttude, excessive rainfall, high winds, etc? F. Describe any corrosive conditions that may be present. Vil. Installation requirements-include information applicable to the following conditions: A. Any restrictions on installation space — height, width and length — or with feed discharge. B. Are there any structural conditions that would affect installation or operation? C. Type of mounting required. (Base mounted or suspended) D. Power supply available. 1. Electric. a. line power or generated power? b. voltage, phase, cycle. 2, Mechanical or other. Describe. E, Hand of drive. F, Ifyou have specific screen surface preferences, please list by deck including specification of surface material and shape and size of openings. Vill. Auxiliary equipment. Is any of the following required? A. Dust enclosures — 1. Vibrating or stationary. 2. Provision for dust exhaust. 3, Provision for inspection por. 4, Is bottom enclosure required? B. Carrying pan. C. Feed box. D. Discharge spouts or lips. E. Special deck construction such as trough, split, ball, heated, tray, step deck, ete. F. Motors. G. Spray bars — vibrating or stationary. H. Belt or other safety guards. |. List other special items. IX. Include flow sheets or sketches that would be helpful in determining proper screen for application and installation. X. Ifyou are currently screening this or similar materials, list make and size of screen used, products, capacities, and other experience with this unit. Describe any application problems with present unit.TECHNICAL DATA STANDARDS Preface A variety of information is available to purchasers of vibrating screens. The following is information buyers, consultants engineering companies, or contractors may reasonably expect to receive from a vibrating screen manufacturer in bids or quotations, Number of Vibrating Screens Size of Vibrating Screens Number of Decks General Dimension Drawings Name or Mode! Number Nominal Stroke and Speed, Slope Description of Screening Surface Horsepower Requirements In addition, information on auxiliaries, or modifications, is available, such at ‘Type of Drive ‘Type of Mounting Shipping Weight of Vibrating Screen Price and Terms FOB. Point Export Packing, if Applicable ‘Approximate Shipping Date Warranty Backplates Liners Ball Decks Motor and Controls. Enclosures Motor Base Dust Hood Safety Devices Stationary Sprouts or Lips Vibrating Spray Bars and Nozzles Feed Box Sub-base Hoppers This manual is an industry related Vibrating Screen Manufacturers Publication. For additional copies contact: Construction Industry Manufacturers Association (CIMA) 111 E. Wisconsin Ave., Suite 1000 Milwaukee, Wi 83202 Phone: 414-272-0943 * Fax: 414-272-1170 Email: [email protected] * Web site: www.cimanet.comVIBRATING eo Bete mBACKNOWLEDGEMENT We wish to acknowledge the contributions of members of the CIMA Vibrating Screen Manufacturers Association (VSMA), for the preparation of this manual. Notice of Copyright Protection Copyright 1998 - Construction industry Manufacturers Association (CIMA)VIBRATING SCREENS Amplitude (See Related Term: Stroke) ‘The distance from the meen position to the point of maxi mum displacement. In the case of @ vibrating sereen with film limiting dimensions: 5. Feed rate (including circulating load Regn enc ee enon ee it applicable} Maximum — 202 TPH Average OO _ TPH (Ton 2,000 Ibs.) If feed is slurry. %Solids: % by 6. Feed analysis: Maximum size particle 10. Preterred type of screen: inclined 2&_Horizontal___ Other. Open Enclosed ___ gpm wt % by volume Opening 11. Type of Installation: — —— Tyler. ‘Square X Round Cumulative’ Passin 2 Stationary Plant x 106 &o Portable Plant —____ 12. Type of Mounting Preferred: Floor Suspension (Cie eeome 13, Desired Screen Efficiency: Top Deck: X 95% 90% 85% _80% 2nd Deck: X 95% 90% 85% _80% ‘3rd Deck: 95% X 90% 85% 80% _— Other.COMMON VIBRATING SCREEN APPLICATIONS SCALPING SCREEN A vibrating screen used to remove a small amount of oversize from a feed which is predominantly finer without regard for finished product sizes. SIZING SCREEN (Dry or Wet) A vibrating screen used to produce material sizes that meet specifications in a particular range of sizes. Usually expected to perform at a high and constant rate of efficiency. WASHING SCREEN A vibrating screen equipped so that watercan be sprayed on the material. Normally water's used to clean material and/or assist in the sizing. DEWATERING SCREEN A vibrating screen used to remove liquid from material RESCREEN SCREEN (Dry or Wet) A vibrating screen used dry or wet to remove fines or contaminants from previously screened material. Often called dedusting screen (dry) desliming screen (wet) or a polishing screen. EXAMPLE CALCULATING SCREEN AREA Application Details from Screen Questionnaire Material Crushed Limestone Weight. 100 Ibs. f.? Feed Rate. 300 STPH, Separations Required V2", a" Type of Screen inclined Triple Deck Sieve Analysis of Feed to Screen Opening Cumulative Passing STPH Passing 2 100% 300 STPH 11a" 91% 273 STPH v 85% 255 STPH 3a" 70% 210 STPH V2" 60% 180 STH 3/8" 45% 135 STPH Wa" 30% 90 STPH anne 22% 66 STPH 18" 15% 45 STPH no 6% 18 STPH Feed Distribution per Sieve Analysis Formula: i AxBXCxDXEXFXGXHX)EXAMPLE CALCULATIONS FOR TOP DECK Sieve Analysis of Feed to Top Deck Cumulative Opening Passing STPH Passing. Conditions for Top Deck 2” 100% 300 STPH Feed to Ist Deck = 300 STPH 144" 1% 273 STPH Factor “A” (for 1") = 3.36 1" 85% 255 STPH Factor "8" (for +") = 1.08 3a" 70% 210 STPH Factor °C" (for-1/2") = 1.40 2" 60% 180 STPH 180 STPH = 60% 3/8” 135 STPH Factor “D” for Top Deck wa" 90 STPH Factor “E” (Dry Screening) = 1.00 ane" 66 STPH Factor “F” (100 Ibs. cu. ft) = 1.00 18" 45 STPH Factor “G” (64% Surface O.A} = 1.00 no 18 STPH Factor “H" (Square Opening) = 1.00 ‘Area 1” Separation = 255 = 48 Sq Fe saa Foran Carr aly Saas ay a OEY EXAMPLE CALCULATIONS FOR SECOND DECK Theoretical Analysis of Feed to 2nd Deck Curative Opening Passing STPH Passing Conditions for Second Deck vw 100% 255 STPH Feed to 2nd Deck = 255 STPH 3/8 82% 210 STPH Factor "A" (for 1/2" = 2.47 2" m1% 180 STPH Factor “B” (for +1/2") = 968 75 STPH = 29% 3/8" 53% 135 STPH Factor "C” (for 1/4") = 90 va" 35% 90sTPH 90 STPH = 35% 3/16" 26% 66 STPH —Factor“D” for 2nd Deck = .9 8 18% 45 SPH Factor “E" (Dry Screening) = 1.00 fo 7% 18 STPH Factor “P” (100 Ibs. cu. ft) = 7.00 Factor "G" (54% Surface O.A) = 1.00 Factor"H” (Square Opening) = 1.00 Factor "J" (95% Efficiency) = 1.00 Feed Distribution per Sieve Analysis ‘Area/2" Separation =180 = 93 Sq. Ft 2.7 x.968 x90 x90 x 1.00 x1.00 x1.00x1.00x1.00 7.94 aera ae cde oeEXAMPLE CALCULATIONS FOR THIRD DECK Theoretical Sieve Analysis of Feed to 3rd Deck Cumulative Opening ‘Passing STPH Passing Conditions for Thied Deck v2" 100% ‘wo sTPH Feed to 3rd Deck = 180 STPH 3/8” 75% 135 STPH Factor “A” (lor 1/4") = 1.60 va" 50% 90 sTPH Factor“ Wor + 1/4") = 79 ‘90 STPH = 50% ane" 37% 66 STPH Factor “C’ for ~ 1/8") = 70 145 STPH = 25% us" 25% 45 STPH #0 10% 18 sTPH Factor “0” for 3rd Deck 8 Factor “E" (Dry Screening) 1.00 Factor” (100 Ibs, cu. ft) = 1.00 Factor "G" (46% Surface OA) 00 Factor “H" (Square Opening) = 1.00 Factor “J” (90% Eficiency) =1.15 Feed Distribution per Sieve Analysis ‘Area 1/4" Separation = _ 90 90 = 1115q. Fe TOXIN IOX BOXT00xT0OXTOOXTOORTIS gy icy areata: EXAMPLE, COMPOSITE CALCULATIONS ALL DECKS Area 1" Separation = _ 255 _ 3,56 x 1.08 x 1.40 x 1,00 x 1.00 x 1.00 x 1.00 x 1.00 x 7.00 UAT ng Heep opp Ga aye‘Area 1/2" Separation = 180 80 = 93 Sq. Ft 2.47 x.968 x 90 x 90x 1.00%1,00x1.00%1.00x1.00 194 a ore ‘Area 1/4” Separation ope Hy : oO meee — = 90 = 111SqFt X7OxBOxT00xTOONTOONTOORTAIS gy ce ONO Bh HCE UDP BEB Gi mgr nye EXAMPLE CALCULATING BED DEPTH DISCHARGE END DBD = _Oxc = SxTxw Top Deck = 45x20 = 900 5x75x6 2200 Second Deck 75 x 20 1500 5x75x6 2200 Third Deck 90x20 = 1800 Simi7 sino). 2200 A logical choice from the above calculations is to select a 6" x 20’ triple-deck screen. This completes the exercise of calculating theoretical screening area. The experienced screen application specialist will proceed from here and devote some time in reviewing some of the variables that govern screen- ing performance but cannot be included in a formula. These variables can contribute to a more favorable or unfavorable screening condition. It is the presence of unfavorable conditions that requires attention after calculated screen area is established. Moisture can affect a separation as it presents problems with blinding of the screen surface. The manufacturer may have an accessory available that will alleviate this condition, Inches of Bed Depth = 7/16” Depth to 1” Separation = 11/16" Depth to 1/2” Separation = 13/16” Depth to 1/4” Separation Peculiar particle shapes, such as wedges, slivers and flats, are often difficult to separate. This can have an adverse effect on screen capacity and efficiency. If the feed to the deck contains a large amount of nnearsize, there is also the danger of plugging. The screen surface specifications become very important in making an efficient separation when this condition exists Obviously, the screen area calculations deal with a mathematical formula but there are several factors unaccounted for in this formula. It is impossible and impractical to assign a numerical value to all of the uncontrollable variables present in separating materials. Experience and common sense must be applied after completing capacity calculations. That is why it is important that the formula be considered as only a guide,Orla) Speed . Stroke and Stope 1S) Nene AldSPEED STROKE AND SLOPE ‘After selecting the proper size and type (inclined or horizontal) of screen, tis essential that tbe operated to produce optimum results. This means that it must be ‘operated at the best combination of speed, stroke and in the case of inclined screens, slope. To prevent any misunderstanding. we define these operating variables as follows: SPEED The frequency at which a vibrating screen operates, usually expressed in revolutions per minute or cycles per minute. STROKE ‘The distance between extremities of traverse: viz; the diameter of a circular motion, SLOPE The angle with the horizontal made by the first or top deck screen section. Each of these variables has its own effect on the screen performance. For example; The speed at which the screen is operated should be enough to produce a bed depth that allows stratification to occur before the material is discharged, This gives the fines an opportun- ity to pass through the screening media. The speed, however, should not be so high that the bearing life is reduced to an uneconomical level. The stroke must be large enough to throw the near size particles out of the ‘opening and keep the screen from plugging The stroke however, cannot be so great that it interferes with stratification and tends to throw near size particles out of the aperture before they have a chance to adjust themselves and pass through. Too much stroke will tend to increase the distance a particle is thrown and, as a result, reduce the effective life ofthe screen, Too laige a stroke also has a tendency to affect the life of the screening surfaces as well as the screen body parts and mechanism. The slope of inclined screens must be sufficient to keep the material moving across the deck, and yet not so steep that it foreshortens the opening too much and interferes with the passage of the material through the deck. In most instances, the slope of the screen should be steeper for counter-flow rotation than for with-flow rotation In general, a lesser slope will increase the depth of the bed of material on a deck. This increase in load on a deck will increase screening meda wear and also produce more plugging. In extreme cases the load can become so great the screen will bog down: Conversely, a steeper siope will have the same affect as too large a stroke. Itwill increase the distance between impacts on a screen for a given particle and reduce the effective length of the screen. This will require a longer screen for a given efficiency. All these variables are inter-related and dependent on each other. Each screen manufacturer has its own standards of combinations of speed, stroke and slope which should be used for given situations. While these combinations vary to some extent, they can be grouped into ranges as shown in Figures‘. and 1.2 for inclined and horizontal screen, respectively. As one can see from these tables, all Screen manufacturers agree that small strokes and high speeds are more acceptable for, small openings, whereas large openings require large strokes and relatively slow speeds for optimum oper ation. The ranges of stroke, speed and, in the case of inclined screens, the slope as shown on these tables, are to be used as a guide and are adequate for most conditions. There are, however, special conditions such as clay or other sticky substance materials which reduce its screenability. This requires a change in throw and speed to increase the intensity of vibration and, hopefully, obtain good screening. Screens normally operated horizontally can be put on a slope of up to 10 degrees to help in overcoming plugging problems. This may allow them to be operated at smaller strokes than shown in Figure 1.2 ‘These tables give a basis for operation of screens under average conditions. They can however be modified to suit particular conditions. The screen manufacturer should be consulted before changing either the stroke or the speed of an existing screen to be sure no ‘mechanical problems will occur because of the change.Fig. 1.1 INCLINED SCREENS STROKE, SPEED AND SLOPE SELECTION FOR DRY 100 LB. PER CUBIC FOOT MATERIAL & FLOW MECHANISM ROTATION TOP DECK OPENING nomunat [asm] 20m [rom [am Paar [ove [ae [ae [ae To 7 on store stroke | “sreeo | ‘to.| ‘to | to | to | ‘to | to | to | to | to | To | To |asove| RANGE ‘in (mem) | som | 35m | 20m | som | am [ava | ove | oa | ae | a | or |" er | Cdegree) 03 | 3500 24-30 05 | 2600 24-30 2100 PREFERRED RRR accerraste AMMFig. 1.2 HORIZONTAL SCREENS Stroke & Speed Selection For Dry 100 Ib. per Cubic Foot Material a a | NOMINAL Tess stroKe Seere aK fnvaee Seeman eet | Eeeesisat 3/8 950 = 3 fo - oe. 76 900 & = oe 7 < V2 850 & _ | _| $ 5/8 800 ia 2 of 8 L234 750e Chapter 7 ENGINEERING DATA QUALITY / INTEGRITYENGINEERING DATA SECTION 1 - BEARING LIFE Bearing manufacturers have long known that vibrating screen applications are among the most severe bearing, environments encountered in machinery construction. ‘The bearings used on vibrating screens are exposed to all of the adversities which make their job difficult. These adversities include: 1, Heavy impact loads. 2) High accelerations. 3. High speeds 4. Wide temperature ranges. 5. Contamination hazards. 6. Misalignment, 7. Inaccessability Design and material improvements developed from actual field experience, combined with modem man- ufacturing equipment and techniques, have produced bearings that withstand these severe conditions. There are two types of bearings used in vibrating screens, cylindrical and spherical roller bearings. The cylindrical roller bearing has a higher radial load car- rying capacity. It also is separable, thatis the outer race and rollers can be separated from the inner race or vice versa. This featuresimplifies mounting and dism— ounting, The cylindrical roller bearing is more sensitive to misalignment than the spherical roller bearing, The spherical roller bearingis the most widely used bearing for vibrating screens, Bearing manufacturers have, therefore, spent the most effortin refining this bearing. Consequently, they have devel oped a bearing that provides reliability and long life for extremely diff icult vibrating screen applications. They are continuing their development and now offer races made of vacuun-degassed or vacuum remelted steel, Under ideal conditions, bearings made with this steel have five times the fatigue life of standard screen bearings. This may or may not be true under actual operating conditions because most bearings on screens fail primarily because of contamination rather than fatigue Bearing manufacturers express the life of a bearing in the number of hours the bearing will operate ata given speed and load beforeany evidence of fatigue develops Life may vary from one bearing to another but stabilizes into a predictable pattem when considering a large group of the same size and type. The rated life of a ‘group of such bearings is defined as the number of hours at a constant speed and load that 90% of the tested bearings will exceed before the first evidence of fatigue develops. This i‘ is called B-10, |-10 or Minimum Expected Life. Bearing manufacturers have also deter- mined that the average life of a group of bearings is approximately five tirres the Minimum Expected Life. The formula for figuring B-10, L-10 or Minimum Expected life can be expressed as follows: 10 3 (16,667) ce Rated life = P ) P wast f 35200 (N Basic dynamic capacity of bearing (lbs. Eccentric weight of screen ibs) Radius of eccentricity inches. RPM of screen, Application factor. Number of eccentric bearings in mechanism W, R 5 and N factors in the above formula are The c constant fora screen operating with a given stroke and speed The f or application factor varies with different screen manufacturers. Most VSMA members use 1.2 for this factor, but there are two that use 1.0. Those who use 1.0 as the application factor, compensate for this by estab- lishing a higher required minimum B-10 or L-10 bearing life for their screens, The range for VSMA members is from 8,000 to over 100,000 hours. AAs can be seen from the preceding formula, the three factors that are under the control of the vibrating screen manufacturer are the speed, stroke end weight of the screen. The weight of the screen is, more or less, controiled by the application so that leaves the speed and stroke as the factors that affect the load on the bearings. Since in the formula the speed is squared, a relatively small increase in speed will greatly affect the 8-10 or L- 10 life of a screen. Screen operators are, therefore, cautioned to checkwith the screen manufacturerbefore changing the speed at which their screen is operated. A relatively small increase of, say, 100 8PM could cut in half the 8-10 or L-10 life of a screen ‘The screen manufacturer should also be consulted before making changes in the stroke of a screen. Changes in the stroke can also reduce the B-10 or L-10 life. SECTION 2 - LUBRICATION Successful operation of a vibrating screen depends on adequate bearing life. The high speeds and high specific loads of the bearing impose special requirements on the lubricants used. Many screen bearings do not reach their potential design life because of severe lubrication problems and abrasive wear. The primary need for a lubricant is to support the rotating eccentric load while keeping the surfaces of the bearing races and rollers from touching each other. Secondary requirements are to prevent corrosion and flush out or shield against contaminants.‘The two types of lubrication of vibrating screen bearings are grease and oil. We will examine each of these separately. GREASE LUBRICATION Grease is a manufactured product consisting of an oil plus a thickener and various additives. There are innu- merable combinations of these ingredients used to make different greases, however, the more important considerations are the following: The base oil should be a good grade of oxidation resistant mineral oil, Various synthetic oils are unnecessary and are more expensive. Of the many available thickeners, the usual ones used are soaps of calcium, sodium or lithium Calcium soap greases can be used if they contain anti-corrosive additives, Sodium or lithium soap ‘greases are better for use where moisture conden- sation may be a problem. Complexing agents are frequently added to the metallic salt thickeners. These will raise the upper operating temperature limit. Additives are materials introduced in small amounts toa grease to improve one or more ofits properties. In general, the additives needed for screen bearings use are anti-corrosive and extreme pressure agents. Without attempting to get into a highly technical discussion, grease lubrication is used because it is relatively inexpensive and because it forms an easily replaceable shield against contaminants, The primary function of the grease in supporting the rotating load is directly affected by the temperature at the load cartying surfaces. This temperature is a com- bination of the ambient temperature plus increases due to operating speed, screen load, and shearing and churning of the grease, The National Lubricating Grease Institute (NLGI) class number gives a comparison of a grease’s ability to support the bearing load. Class 2 is specified for use at ambient temperatures occurring during the summer. At the much lower ambient temperature occurring for outdoor operation in the winter, Class and sometimes Class 0 grease must be used. These greases have the softness or fluidness at very low temperatures which is equivalent to that of Class 2 grease at summertempera- tures. When the grease is too stiff there is increased frictional resistance to movement which results in an increased load on the motor. In addition, the grease does not flow to the load-carrying surfaces to supply them with sufficient lubricant. Asa secondaty function, in some oil lube mechanisms, grease is used to fill the space in the labyrinth seal to help seal against the entry of contaminants. In this application there is no load-carrying requirement. The grease recommended for use in labyrinth seals is heavier NLGI Class 3 grease with calcium soap thickener ‘with anti-corrosive agents. IfClass 3 grease is unavailable, Class 2 grease is generally acceptable. The difference in sealing ability is usually slight. Vibrating screen bearings should be lubricated fre- quently with relatively small amounts of grease. Screens operating in extremely dusty and hot atmospheres will require more frequent greasing than those used in wet screening applications where dust contamination and overheating are not factors. Grease addition can be accomplished in either of two ways, manual or automatic. The most common is manual greasing, When machines are greased manually, care must be taken to be sure all points are greased, and inaccessible ‘ones are not missed Also, the proper amount must be added each time to ‘each fitting, It does no good to under grease one time and over grease the next time. The lubricant quantity has only to be inadequate during one portion ofits life to permanently damage the bearing. Additionally, the grease fittings must be clean and free from dust, dirt, sand, etc., to avoid introducing contaminants, ‘An automatic grease system will insure adequate grease additions at fixed intervals to all bearings and seals. Care must be taken to inspect the flexible connections between the screen and the stationary parts of the system to insure breaks and leaks do not occur. ‘OIL LUBRICATION The primary advantage of oil lubrication is the ability to operate at higher speeds and temperatures. Viscosity is one of the key considerations in selecting the proper oil. Bearing manufacturers have generally recommended a viscosity of 100 to 105 SSU minimum at the bearing operating temperature. This temperature cannot be measured in practice, therefore, asa practical guide, viscosity ranges are given on the basis of a temperature of 70° 090° F. above the ambient temper- ature, or approximately 30°F. above the bearing housing temperature and/or the oil temperature. A number of additives or combinations of additives have been developed to modify various properties of the oil. Among these are viscosity index improvers pour point depressants, wear preventatives, anti- foaming, anti-oxidants and extreme pressure agents Generally all of these additives are helpful and are used in the high grade lubricants. Apourpoint depressant will keep an oil from solidifying downto a temperature that may be 50” F. lower than its usual pour point value, Anti-foaming agents can reduce the formation of foam and/or help the air to escape from the oil if it does become entrained. In a mechanism the oil is splashed about and air may be entrained easily. Foam does not flow easily so oil flow is restricted and the bearing surfaces may receive insufficient oil Wear preventative agents are divided into several groups. Fatty oils, organic compounds and phosphateesters act to reduce the coefficient of friction between surfaces and are called medium-duty anti-wear agents. Extreme pressure additives are used where the spot pressure may be expected to rise above 100,000 PSI. These additives, which now are compounds of sulfur and phosphorus and, sometimes, chlorine instead of lead, act to prevent metal to metal contact by forming antiweld lubricating films by a reaction between the extreme pressure agent and the metal surface. These films take effect when the normal oil film is broken by chemically forming a new film to separate the metal surfaces, Viscosity index shows the degree of change in viscosity. or fluidity of the oil as its temperature changes. A high viscosity index shows less change and is, therefore, more desirable. Viscosity index improversthus make an oil usable over a wider temperature range. All of these additives, in general terms, are helpful and desirable but there can be drawbacks. Occasionally an oil with pour point depressant may revert to a higher temperature pour point. All mechanisms should be regularly checked for proper amount of oil. Atthe same time the oil should be examined to be sure that it has not deteriorated. Deterioration or degradation usually occurs through oxidation of the oil. Deterioration is indicated by changes in fluidity, color and/or smell Extreme pressure agents are chemically active and may contribute to the deterioration of the oil. Corrosive wear will occur from deteriorated oil. The most common method of oil lubrication is splash lubrication. It is a convenient way if there are gears involved such as on a horizontal screen. ‘Another type of oil lubrication is the circulating oil system. Here oil is pumped through the bearings and filtered. Circulating oil is generally used to remove heat and to filter out abrasive particles, rather than merely lubricate the bearings. The screen bearing load zone temperature may be 20-25° F. above the outlet temper- ature. Oil circulating systems lend themselves to the addition of oil cooling devices (air, water or refrigerants) and safeguards such as flow indicators, oil level indicators, etc A third type of lubrication is the drip method where ‘measured amounts of oil are introduced to the bearings at prescribed intervals. A fourth type is oil mist where atomized oil isintroduced tothe bearing under pressure. This approach eliminates entry of contaminants and promotes cooling SEALS Grease lubricated mechanisms are generally only pro- tected bya labyrinth seal. This seal can be independently lubricated orcan be lubricated by spent grease from the bearing. Itisimportant the seal be kept full of grease to keep out contaminants. Oil lubricated mechanisms generally incorporate a combination of seals. A labyrinth grease seal can be used to keep out contaminants anda lip type oil seal to retain the oil. Another approach is the use of flinger rings instead of labyrinth grease seals. Itis extremely important to maintain the oil seal as even a small leak will eventually drain the oil and cause bearing failure. The seals are the first thing to check at the sign of an oil leak. The bearing lubricant reservoir should be vented to atmosphere to prevent seal failure. Your screen manufacturer, along with the bearing and lubrication manufacturers have spent considerable effort developing the proper components and lubricants for the extreme duty of vibrating screens, These lubricants and the recommended schedules are outlined in the screen manufacturers’ instruction books. SECTION 3 - TYPES OF DRIVES There is a wide variety of power sources for driving vibrating equipment. The most popular methods used for vibrating screens are electric motors, hydraulic motors and combustion engines. The electric motoris the most commonly used vibrating screen power source. The reasons are that the electric ‘motors easy to install and to maintain, and iscommer- Cially available in most locations. It is also the most dependable and cost efficient. The motor can be either AC or DC, depending on the application. AC is normally used for constant speed operation. When variable speed operation is desired, ‘AC motors will normally be used for 10 horsepower and below while DC motors will frequently be used for above 10 horsepower. The reason for this difference is primarily the present initial higher cost of the AC motor control, The AC motor is typically an induction motor with synchronous speed of either 1800 RPM or 1200 RPM. Depending upon the application, the motoris generally of the totally enclosed, fan cooled, ball bearing type Open drip proof motors are occasionally used, When hydraulic power is used on other related equip- ment, a hydraulic motor might be considered instead of an electric motor. One advantage of the hydraulic motor is its variable speed capability. Combustion enginesare available in both gasoline and diesel types. They are often used in remote locations where electric power is not readily available, and on portable screening plants where a completely self contained plant is desired or required. Often under these circumstances, the engine is used to powereither an electric generator or a hydraulic pump, and the screen is driven by either an electric or hydraulic motor, The primary reason for this latter approach is that itis difficult to locate the engine close to the screen, The smaller motor can also be mounted either on a pivoted motor base or on the screen itself, resulting in a less complicated drive.Afterselecting the power source, the next consideration is the method of transferring the drive force to the vibrating screen mechanism, The most common drive Consists of V-belts and sheaves. Other types of drives include flexible couplings, timing belts, fiexible shat, gear reducer, and a jack shaft arrangement. ‘The V-belts and sheaves method is the most economical means of operating the screen at a speed different from that of the power source. It is easy to maintain and, if necessary, to change. Some screen manufacturers counterweight the ends of the motor shaft and use the motor as the vibrator eliminating the use of separate drives. Flexible couplings are the least expensive drive but do not permit speed change. A flexible shaft may be used in the same manner but, likewise, does not permit speed change. Timing belts are normally used only where phasing of the exciter shafts is desired, Gear reducers permit operating the screen at a speed different from the power source but are expensive, take up more space than a V-belt drive and still require an attachment to the exciter shaft, For these reasons they are infrequently used. A jack shaft arrangement permits either operating the screen ata speed different from the power source, or of decreasing or eliminating transfer of vibration from the screen to the power source. The jack shaft must be connected through a drive to both the screen and the power source. This is normally accomplished by a V- belt drive or a flexible connection/V-belt drive com- bination, The method of mounting the power source is another, consideration. When a motor is used as the power source, it can be mounted on the screen with a sliding motor base for belt take-up, orseparate from the screen with provision for belt tensioning. On the single shaft four-bearing screen, the motor can be mounted on the stationary base (main frame) of the screen in which case a sliding motor base is used, Motors are frequently mounted directly on horizontal screens with a sliding type base. When mounted ex- ternal to the horizontal screen, the motor is normally mounted ona pivoted base. When the stroke is small or the V-belt drive is perpendicular to the screen action, the motor may be mounted ona sliding base. On two- bearing screens, motors are mounted separate from the screen, generally on a pivoted base. A slide rail base may be used if the stroke is 5/16” or less. Location of the motoris important to minimize loading the motor shaft and the V-belt drive. The angle of the drive for horizontal screens should preferably be per- pendicularto the line of action of the screen. On afour- bearing inclined screen, the motor may be located anywhere around the 360° circumference. On a two- bearing screen, the motor is generally located below the shaft center line at an angle of 15-45° When either flexible couplings or flexible shafts are Used, the motor shaft must be in line with the exciter shaft. SECTION 4- ISOLATING VIBRATION PRODUCED BY VIBRATING SCREENS. All vibrating screens have a tendency to transmit some of the vibration they produce into their supporting structures. Some types transmit a great deal more than others. This will be discussed at length later in the chapter. It should be noted that any vibration transmitted from the screen into the supporting structures (defined as Dynamic Loading) creates potential problems, such as (1) fatigue in building structural members, (2) innacurate scale readings, (3) electrical shorts in starters, wiring, etc. All screen manufacturers equip their units with an isolation system utilizing some type of elastic component with the exception of four-bearing screens as indicated below. Some go so faras to produce screensthat can be so finely balanced that there isno perceptible escaping vibration. However, this ideal balancing systems delicate and easily upset by fluctuations in screen loadings, changes in screen decking, etc. It should be noted that asa GENERAL RULE, four-bearing positive stroke screens, when properly balanced, do not need a supplementary isolating system, Because this ideal cannot always be realized, units of this type may come equipped with a supplementary system of springs or elastic elements to minimize transmitting vibration. Conversely, some screens, which produce all their motion from rotating unbalanced weights, can never have their motion totally isolated although somewhere between 90% and 98% can usually be isolated by the use of: Compression Type Coil Springs Leaf or Formed Flat Springs Air Bags, sometimes called Air Rides Rubber-in-Shear Rubber-in-Compression Beehive Type Tension Springs An example of each of the six typesis shownin Photos 1 through 6, respectively. This subject of vibration isolation, or lack of it, is of serious concem, or should be, to the designer of the screening station. Therefore, the selected screen man- ufacturer should be consulted as to what static and dynamic loads can be expected at each spring cluster location, usually at each of the four comers of the screen. The static load at each corners of interest only so that the structure is adequate for supporting the dead load of the screen when itis not vibrating, To this static load, the structural designer must add the reversal ‘ordynamic loads produced as the screen moves up and down on its springs. This dynamic load is usually stated as plus or minus a given number of pounds, depending on the spring rate of the isolating device or medium ‘Methods for calculating the loads that the screen will impose on the structure and procedures for designing the structures are given in Section 11 of this chapter.SECTION 5 - SCREEN BALANCE CONSIDERATIONS. DEFINITION OF BALANCE Screen balance is a subject frequently misunderstood, Balance, as related to vibrating screens, is the equating of the machine moment and the balance moment. This balancing can only be accomplished on four-bearing, single shaft screens. All vibrating screens consist of a body to which are aitached screen decks and one or more shafts with unbalanced weight. This unbalanced weight produces the exciting force when it revolves resulting in screen vibration, (On four-bearing screens, the unbalanced weight is a counter weight or balance weight which offsets the machine imbalance. Vibration is accomplished (multiple shaft) through a machined shaft offset. On two-bearing and horizontal multiple shaft screens, vibration is pro- duced by unbalanced weight on a rotating shaft, there- fore, these types of screens work on an unbalanced principle. FOUR-BEARING SCREENS The four-bearing screen is a positive displacement screen. The eccenttic shaft setves as a crank arm. The balance weight is incorporated in or attached to this eccentric shaft. The offset crank shaft design produces vibration when it rotates. The balancing moment (at- tached to the shaft) is equivalent to the eccentric moment of the body of the screen and is 180° opposed to it resulting in little, if any, vibration transfer to the screen supporting frame. Balance is achieved by adjusting the balancing moment to assure that it equals that of the screen ‘TWO-BEARING AND HORIZONTAL SCREENS, The rotating unbalanced weight produces the exciting force. The screen reacts to this force by vibrating at the frequency of the rotating unbalanced weight with the vibration amplitude or stroke seeking a point of equil- ibrium. Ifthe stroke is incorrect, unbalance weight must be added to increase the stroke or conversely taken away to decrease the stroke. Support springs are used to isolate the supporting structure from the screen vibration, METHOD OF ACHIEVING BALANCE ON FOUR-BEARING SINGLE SHAFT SCREENS As previously described, the shaft balance weight is designed to equal the screen weight times the desired eccentricity (1/2 stroke) This design can be achieved in numerous ways. Referto Fig. 5.1) (1) The total balance weight is machined integral with the shaft. (2) The shaftis symmetrical, either round orsquare, and balance weights are bolted alongits length. (3) Flywheels orsegments are attached to each end of the shaft and balance weights added. (4) Any combination of two or three of the above. ‘CONFIGURATIONS OF ECCENTRIC SHAFTS WITH BALANCE WEIGHTS FOR FOUR BEARING SINGLE SHAFT SCREENS [ MACHINED BALANCE WEIGHT | a SHAFT WITH FLAT BOLT ON BALANCE WEIGHTS SECTION 6 - DETERMINATION OF CRITICAL FREQUENCY Critical frequency is the natural frequency of an object. When applied to screening, critical frequency evidences itself by one ormore of the screen components vibrating at different stroke and frequency from the screen. In other words, the vibration of one or more of the components is not in unison with the screen. Another type of critical frequency experienced with screens is that of the spring mass system. Critical frequencycan be both detrimental to screen performance and reduce the expected life of the screen components and in the case of spring/mass critical frequency cause excessive star/stop bounce. Determination of critical frequency can be achieved either empirically or theoretically. Empirical determin- ation is the easier and more commonly used approach. EMPIRICAL DETERMINATION Empirical analysis is normally conducted by the screen manufacturer during testing following completion of screen assembly and prior to shipment. Visual observa- tion by trained personnel will detect most instances of critical frequency. Evidence is erratic vibration of a particular atea or component of the screen, The most common areas which exhibit these problems are the side plates and the deck cross members. Most manufacturers attach a stroke card to the four comers of the side plates (feed end and discharge end of both side plates) and record the stroke configuration, angle and amplitude at each comer. The strokes at each comer are then compared. Differences indicate the possibility of critical frequency problems and corrective action should be taken, The stroke cards are often retained on file in the event problems subsequently develop in the field. Similar empirical analysis can be conducted in the field. Normallyitis only required when the operating speeds changed or items added to or removed from the screen (eg. addition of liners, side extensions, or discharge lipsand deletion of stiffeners or braces). These changes alter the critical frequencies of the specific components involved. ‘THEORETICAL DETERMINATION Prior to the current widespread usage of the computer in equipment design, theoretical determination of critical frequency was not possible because of the extensive time required. Use of the computer has made theoretical frequency determination possible, though impractical because of the complexity of the screens, variations in the fabrication techniques, and computer programs required In computer analysis, the normal approach is to use finite element analysis. This approach consists of dividing each component into extremely small (finite) sections (elements) and analyzing the stresses acting upon each of these finite elements. The computer program must be validated by measuring vibration and deflection at various points and comparing the results with the theoretical indications. Because of the wide variety of types and sizes of screens and the frequency of minor design changes, computer analysis is seldom used. CORRECTIVE ACTION When critical frequency is encountered, there are several approaches to correcting the problem including changing operating speeds, adding stiffeners, adding weight, reducing stiffness and reducing weight. Changing operating speed is the most common and easiest approach and usually achieves the desired result. Changing speed often takes the screen away from the critical frequency of the component and hence eliminates the erratic motion of the component. Caution must be exercised to assure that performance is not adversely affected. When speed incteases are made, the new speed must not exceed that recom- mended by the screen manufacturer for minimum. bearing life and maximum “G" loading, Adding stifeners increases critical frequency and is the second most frequently used approach for eliminating critical frequency in side plates. Adding weight also, increases critical fequency but may resultin additional stress in the weight added area Deletion of stiffeners and/or weight reduces critical frequency and while possibly eliminating the critical frequency problem, may also weaken the screen to the point where failure occurs. When a critical frequency problem is suspected,it is best to contact the screen manufacturer for assistance. SECTION 7- ATTACHMENT OF SCREENING MEDIA To assure maximum life of screening media, proper attachment is important. The two basic ways of attach- ment are tensioning over a crowned support frame or bolting to a flat frame. Tensioning can be done either from the sides of the screen (side tensioning) or from the ends of the screen (end tensioning). In either method a hookis formed on opposite edges of the screening media (Fig. 7.1) The media is then stretched over the support bars of a support frame by tension members and pulled so it is not only taut but also fits snugly against the support bars. ig. 71 Pressure to pull the screening media tautis supplied by the tension bolt. This bolt can be furnished with or without a spring. Springs may be used with bolts for smalier wire diameters (normally 120" or less) to maintain tension on the screen cloth as the wires stretch, Springs are also useful for hot applications. The tension bolt can also be a wedge bolt. In this instance, the bolt is slotted and the tension on the screen media is supplied by a wedge in the slot. The advantage of this type of bolts that its easy to loosen and can be tightened by a hammer while the screen is operating. Illustrations of tension bolts with springsand wedge bolts are shown in (Fig.7.2) and (Fig, 7.3) < Tension Member Screening Medi Compression Spring Support Frame {| Fig. 72Tension Member Slotted Bolt ‘Screening Media Fig 73 In some instances, the screening media is so heavy or ‘igid, it cannot be tensioned but stilineeds to be installed on a crowned support frame. In these cases a tension plate(Fig.7.4)or wood clamp bars with wedges, (Fig,7.Slare used to clamp the screening media in place. Some screening media such as cast and perforated plate decks are so thick that they cannot be bent over a crowned support frame. These heavy screen surfaces ate either (1) bolted directly to a flat support frame with countersunk bolts or (2) held in place with clamp plates Fig. 7.6These types of hold-downs are used for grizzly bars, profile rod decks, louvered plate decks and semitigid polymer decks. _-Tension Plate “y" Bolt Screening Media Support Frame Fig. 7.4 Clip For Cross Dam Screening Le Fig. 7.5 Side 1) Pate j-— Clamp Block SV 374"-10 anco nut Torque to 350 ft. Ibs. Regardless of how the screening media i attached, the mostimportant consideration should be to keep ittight, against the support. Any movement between the Screening media and its support will lead to wear and fatigue, shortening the life ofthe media and/orthe deck support frame. SECTION 8 - TEMPERATURE CONSIDERATIONS, (ENVIRONMENT & MATERIALS) A. GENERAL COMMENTS The standard vibrating screen produced by most manufacturers is designed for ambient temperatures ranging from minus 20° F. through 110° F. and for material temperatures through. 200° F.B. MATERIAL TEMPERATURES. Deck Considerations When material temperatures exceed 200° F. early failure of common rubber buffer strips (provided to cushion the screen cloth) can be expected. When material temperatures be- tween 200° F, and 300° F. are contemplated, special rubber compounds such as those listed below or other heat resistant elastomers should be specified for the buffer strips: a Butyl — 115° F, Max. b. BunaN — 250° F. Max. c Nordel — 350°F. Max. d. Neoprene — 250° F. Max. e. Silicone — 450°F. Max. f. Viton — 400° F. Max. When material temperatures range between 300° F. and 400° F., such as when screening hot asphalt stone, itis generally appropriate to cap the support bars with half rounds of “soft” mild steel such as AISA C-1010. When the temperature of the material screened exceeds 40°F, conventional woven wire screen cloth, supported as above, usually must be replaced by stainless steel or flat decks made from cast steel or special alloy perforated plates, Itshould be noted that at these higher temperatures it is necessary to Use special compensating springs on the cloth tension bolts because of expansion and contraction These lattertwo deck preparations should be so designed that they are largely self-supporting and can be clamped in place rather than side ‘orend tensioned as in the case of woven wire. Conventional deck materials and special clamping methods are usually successful when temperature does not exceed 600" F When material temperature exceeds 600° F., the deck and deck clamping components must be a special design that allows for expansion without the loss of the clamping effect of the deck components. It follows that the deck clamping members, the deck supporting members and the deck itself should be machined in the clamping areas to permit expansion of the deck as the temper- ature increases beyond 600° F. A typical clamping arrangement allowing forexpansion is shown in (Fig, 8.1). For materials substantially hotter than 600° F, itis often necessary to select special metals for the deck and its components which have a low coefficient of expansion such as stainless plate, high chrome iron, or stainless castings. Properiy designed decks can accommodate material temperatures in the 1700 to 2000 F. range. Deck clamping arrgt 4 3/4"-10 anco nut Torque to 350 ft. Ibs. Fig. 8.1 There are many other considerations that must go into the manufacture of screens to bbe used in these extremely high temperature applications such as live frame and vibrator designs, These are discussed in the paragraphs that follow. Vibrator Considerations When the temperature of material handled ranges from 200° F. to 400° F,, and the vibratoris directly exposed to these materials, the machine will withstand these tempera- tures better if the vibrator is continuously oil lubricated. Greases can also withstand these conditions, but most greases break down and need frequent replenishment which is sometimes difficult unless an automatic greasing system is provided. At temperatures exceeding 400° F,, it is normally mandatory to provide a water jacket on the vibrator through which ambient water (50° to 70° F) can be circulated Suprisingly little water is required to carry away the vibrator heat, often in the range of only 5 t0 10 gpm. in some designs it may be advisable to use refrigerated water. Live Frame Considerations At temperatures from—30" F. through 400° F. most live frames made from conventional A36 grade steel will survive without special considerations. With the use of special steels and using water-cooled cross_ members, material with temperatures up to 1700-2000" F. can be handled. Designs for temperature above 600° F. require very careful consideration of each component, especially deck tension- ing orclamping devices. Since the side plates are at least partially “insulated” from the material by side deck clamping devices, they usually do not get as hot as those live frame ‘components in the direct low of the materialhardness of 321 or 360 Brinnel, in which case all other specification prop- erties are waived. i) Yoloy—A Youngstown Sheet and Tube product for use in certain corrosive atmospheres, @ R-100—Republic Steel's equivalent of 7-1. Minimum is 360 Brinnel. ( Jalloy—Jones and Laughlin’s product for abrasion resisting applications, Ayailable in a variety of hardnesses, Low Temperature Steels (Cryogenic Steels) These steels are normally selected for appli- cations where low ambient temperatures are anticipated. They provide increased ductility and toughness and are best selected in the low carbon range because their impact value increases when moving from the high carbon into the low carbon ranges. Sometimes castings are specified with 2-1/2% nickel Content to increse their ductility at low temperatures. High Temperature Steels These steels provide exceptional creep strength. T-1, or its equivalent, is good to about 600° F. Cast stainless ‘steel alloys provide the ultimate in creep strength. Abrasion Resistant Steels The variety is almost limitless. The common quality apparent in each designation is hardness, usually specified by a “Brinnell” number or a “Rockwell C”" designation, Generally speaking, the higher the carbon content the more abrasion resistance provided. Specifically, Abrasion Resisting Steel is a carbon-manganese-silicon steel which con- tains hardening elements that provide maxi- mum ductility consistant with hardness, permitting certain machining, forming, and welding operations, following prescribed practice. This steel has from 2 to 10 times the life of ordinary carbon steels and is suited for applications such as liners for side plates, feed boxes, discharge lips and cross members where severe abrasion is encountered. The typical chemical analysis is as follows: Element Per Cent Carbon 35/.50 ‘Manganese 1.40/2.00 Phosphorus 05 max Sulphur 05 max Silicon 15/.30 Manganese Steels (Hadfield Formula) Most manganese steels, rolled orcast, havea very low resistance to abrasion but are reasonably tough. Placed in an application where the managanese component can be work-hardened by impact, they can develop 2 hardness difficult to match or surpass Cast Hi-Chrome Iron This material, almost exclusively used in deck materials where extreme abrasion is encoun- tered, comes in several grades. It can be cast with openings as small as 1/4” slots with thicknesses that range up to 1” and in large 3” or 4” openings with thicknesses up to several inches. Some grades are identified below: 532-67 Type Ill 24-28% Chrome, 5 Nickel 470,000-95,000 Tensile Strength. 550 Mini- ‘mum Brinnell Hardness in Hardened Condition AS32-67 Type II—14-18% Chrome, .5 Nickel 70,000-95,000 Tensile Strength. 600 Minimum Brinnell Hardness in Hardened Conditioned, Cast ACL-HF (Stainless) Steels ACHE is employed for deck and deck components where extreme heat and good wear resistance are simultaneously needed. This type material has a very low coefficient of expansion. Some available grades are: ACIHF & AZ97-67 (Type 320-8)—19% Chrome, 9% Nickel, 70,000 Ibs. Tensile Strength. Maximum use temperature 1600° F. Good corrosion resistance in the range of 1200-1600" F. ACI-HK—25% Chrome, 20% Nickel. Tensile Strength 65,00 Ibs. Maximum use tempera- ture 2100° F. VIBRATING SCREEN PROTECTIVE MATERIALS. ‘Many materials are available to protect major screen components from abrasion and corrosion. ‘The primary ones are: Structural Component Liners To extend their useful life, such portions of a screen as side plates, cross members, deck holddown, etc. may be provided with one or more of the following liner materials: 1. Rubber Liners—These come in various types and grades such as (a) Natural Rubber—excellent abrasion resistance when used to cover decks, tension plates, cross members and vibrator tubes.In some cases it may be necessary to spring load the side clamping devices as previously indicated, For temperatures below —30° F, itis desire able to use special low temperature steels. Supporting Spring Considerations Since the springs should neverbe exposed to the flow of material and are only exposed to the heat conducted through the side plates, no special design would be required in this area. However, when temperatures exceed- ing 400° F. are experienced in the spring area, special spring steels such as nickel Chrome alloys are available and can be pro- vided by your screen manufacturer. Environmental Considers ions When the ambient temperature surrounding the total screen unit, including the springs, is above 400° F., every component of the screen needs to be evaluated to determine its suitability to perform under the expected temperature. In these cases it may be necessary to coo! the vibrator and live frame members with circulating water. The side plates and other appurtenances such as feed boxes may need to be jacketed with air or water cooling devices such as comugated vanes through which water or refrigerated air is passed SECTION 9 - SPECIAL CONSTRUCTION MATERIALS. INTRODUCTION Most manufacturers build their vibrating screen live frames vibratin high re stength from medium tensile strength steels. When screen components are required to withstand versal stresses, (5.0G to 7.0G) special high steels may be used. Screens may also be subjected to abrasive, corrosive and/or extreme hot or cold temperature conditions. For these reasons, this, chapter specific will be devoted to discussing some of the construction materials employed by the various screen manufacturers, namely: A VIBRATING MACHINE CONSTRUCTION MATERIALS. Stainless Steels There are many types of stainless steels. The types most commonly used in the construction of vibrating machines and their specific benefits are’ Type 302—General purpose stainless with good mechanical properties and excellent resistance to atmospheric corrosion and a large number of corrosive media. 17-19% Chrome. 8-10% Nickel Type 304—Low carbon variation of 1-302. Minimizes carbide precipitation during ‘welding, Like T-302, it offers excellent resis- tance to a wide fange of corrosive and atmospheric exposures. 18-20% Chrome, 8 10% Nickel. Type 316—Best corrosion resistance of the standard stainless steels. Resists pitting and most chemicals used in paper, textile and photographic industries. High temperature strength. 16-18% Chrome. 10-14% Nickel. Type 410—Low Cost general purpose heat treatable stainless steel, Used widely where corrosion is notas severe and greater abrasion resistance is desired. 410A, with lowercarbon, offers improved weldability but lower hard enablity. 11.5-13.5% Chrome. High Strength Alloy Steels There are many varieties of high strength steels. Every majorsteel company hasits own family of these steels. Some of the better known and more commonly used are identi- fied by trade name. The names used are not intended to be restrictive or limiting. a Cor-Ten—These steels are a group of premier, atmospheric corrosion-resistant high-strength low-alloy steels intended principally for applications requirin durability, reduced weight and main, tenance. Cor-Ten Steels are often used in the bare condition to provide eithera desired appearance after weathering or to provide savingsin maintenance. Cor- Ten A Steel has 5 to 8 times the atmos- pheric corrosion resistance of structural carbon steel. Paint and protective coat- ings will last twice as long on Cor-Ten A. Steels as on carbon steel, o) T-1 Steel is a high strength steel. Its higher initial cost is offset by weight reduction in structures of all kinds. Its toughness has enabled vibrating equip- ment to last longer without breakage even in cold weather. It also offers increased impact and abrasion resist- ance. Its weldability has opened new avenues of design at high working- stress levels, T-1 Constructional Alloy Steel is furnished in the quenched and tempered condition with a minimum yield strength of 100,000 psi and a tensile strength in the range of 115,000 t0135,000 psi. These minimum strength levels apply to T-1 Steel plates from 3/16" to 2-1/2" thick. Plates over 2 1/2” to6”, havea minimum yield strengt of 90,000 psi and a tensile strength from 105,000 to 135,000 psi. For maxi- mum resistance to impact abrasion, -1 Steel may be ordered to a minimum(b) Synthetic Rubber—can be compounded to give good results in many high abrasion areas. (6) Butyl Rubber—particularly adapted to higher than average temperature appli- cations (up to 300° F) (@ Hypalon—Although it does not have ideal abrasion resistance, it can with- stand temperatures to 800° F. 2, Metal Liners—Many Abrasion Resistance (AR) steels are readily formed and fabricated to prevent wear on screen components such as side plates, tension plates and cross members. Most construction mater- ials discussed at the outset of this chapter lend themselves to use as liners orprotective materials. Polyurethane Liners—This material, although similar to rubber, is available in many grades and compounds. Polyure- thanes are available in (a) sheets varying from 1/8” to several inches thick, (b) in cast form having about the same thick- nesses as the sheets and (c) also as a spray coating up to 1/4” or thicker. 4. Polyethelene Liners—Available in many grades and compounds. They offer good abrasion and stick-resistance 5. Ceramic Liners—An excellent solution where sliding abrasionisa prime consider- ation and there is an absence of impact. Ceramics can be purchased in several grades with some approaching the hard- ness of industrial diamonds. Ceramics can be attached by several methods, the more popular attach to extreme wear areas with special cements. They also attach to back- ing plates by welding inserts supplied as part of the ceramic block and referred toas "Weld-a-lets.” 8B. Coatings 1. Paints and Enamels—This broad category encompasses all the corrosion and abrasion resistant materials that can be brushed, dipped or baked onto vibrating screen components. These include sophisticated epoxys, rubber-based materials and fired enamels that may be used when extreme hygienic and anti-corrosion conditions must be observed. SECTION 10 - FASTENERS Fasteners are devices used to hold screen components together in one complete assembly. Any conventional fastener can be used in screen assemblies provided stress within an acceptable range is maintained. The more common screen fasteners include conventional bolts, Huck bolts and wedges (for tensioning screen cloth) Conventional bolts are used in all grades with flat washers, lock washers, plain nuts and lock nuts. The more popular types of conventional bolts used are fitted bolts in reamed holes and grade 5 high strength bolts. They must be torqued properly at assembly. Scteen vibration frequently causes nuts to loosen or members to nest more closely producing the same effect as aloose bolt and nut, Because of this loosening, the nuts and bolts should be periodically checked and retorqued as required, Huck bolts are a more positive fastening system and do not require torquing, checking or retightening. When replacement of a screen component is required, the Huck bolts are normally burned off and replaced with new Huck bolts or conventional bolts and nuts. A disadvantage of Huck bolts is the requirement for special tooling for fastening Wedges are used only for screen cloth tensioning or fastening of deck coverings as described in Section 7 of this chapter. They represent a quick means of fastening. They are not normally used for fastening other screen components except attaching certain types of dust enclosure panels. In addition to fasteners, screen components can also be welded together. Welding eliminates the need for checking and retorquing as does Huck bolting. Normally the welded components are not designed for disas- sembly, but rather consist of complete sub-assemblies which can be replaced in their entirety when they wear out or fal SECTION 11 - VIBRATING SCREEN INSTALLATION INTRODUCTION: ‘A mechanical Vibrating Screen properly installed, operated and maintained will provide relatively long life and safe, trouble-free operation. As with any heavy, power-driven machine, the vibrating screen must be properly operated to insure personnel safety. Generally, individuals familiar with vibrating screens are employed for the design of structural supports and chutework attendant to the screen. They ascertain that the structure is adequate and free from vibratory response to the screening motion, that chutes are large enough and correctly sloped and are sufficiently clear of moving screen pats. They make certain that clear ances and work platforms are adequate and provide access to alll portions of the machine normally inspected and maintained. They should insure that adequate space is provided for handling and renewing wire cloth or other screening media CHUTES AND HOPPERS The vibrating screen will function if itis properly fed. Provision must be made for proper distribution of the material to the deck of the vibrating screen. This can beaccomplished either by vibrating feed hoppersupplied {as part of the screen by the manufacturer orastationary feed hopper designed by the plant engineer or purchaser. In any event, care must be taken to assure that the hopper properly distributes the material across the entire width of the vibrating screen, If the vibrating screen is not equipped with a vibrating feed hopper, under no circumstances should the user attempt to design and attach a feed hopper to the vibrating screen. Vibrating screens are designed to meet specific operat- ing conditions. Normally these operating conditions are primarily centered around the separation of the ‘material. Ifit is necessary to collect material, either from the discharge end or beneath the vibrating screen, this should be done with chutes. No chutes, hoppers or additions should be welded onto the vibrating screen ‘without first consulting the manufacturer. Care should be taken in designing stationary hoppers, feed and discharge spouts to assure that adequate clearance is provided between the non-vibrating and vibrating machinery in accordance with the manufac- turer’srecommendations. Eitherthe manufacturer oran engineering company should be consulted on the proper clearances and design of these chutes, SUPPORTING STEEL Some manufacturers offer formulas to help the user design the supporting steel for the vibrating screens. It is strongly recommended that the user consult an engi- ‘neering company or the vibrating screen manufacturer to be certain all conditions have been taken into consideration SPRAY PIPING Water sprays and weirboxes are used forwet screening of material. The use of water is known to improve the efficiency of separation up to 30% depending upon the application, and can increase the screen capacity by an equal amount, Itis essential for good operation that proper installation be made of spray pipes or weir boxes. ‘There are two types of spray pipe installations used with, vibrating screens. Vibrating—ie,, attached to and vibrating with the screen 2. Stationary—i.e., mounted from the stationary structure that supports the vibrating screen, and not to the screen itself VIBRATING INSTALLATION Spray pipes are fastened to the screen body by some type of clamp arrangement, such as a “U-bolt”. It is important when installing the spray pipes that the customer follow the manufacturer's recommendation to insure that pipes will not loosen during vibration and damage the vibrating screen. Proper size is important. The manufacturer's recommendation must be used to insure that the pipes will be strong enough to withstand vibration. Installation requires flexible rubber hose between the water header and the spray pipe due to the spray pipe being attached to and vibrating with the screen. Rubber hose should be a minimum length of 18”. STATIONARY INSTALLATION Spray pipes are fixed to the screen supporting structure and do not vibrate with the screen. In this type of installation, the spray pipes usually attach to the water header and either pass through 5” to9” diameterholes in the side plates or above the side plates of the screen. Good practice requires that the screen manufacturer's recommended clearances be maintained to insure that there is no interference during starting, stopping and operating the vibrating screen. ‘When spray pipes are added to an existing installation, the customer should consult with the screen manufac- turer. Many field installations of spray pipes have been made, using a cutting torch to make holes in the side plates, causing these side plates to crack and fail. All sharp comers should be ground smooth to eliminate areas of high stress which might cause cracks. In addition to these two methods of mounting spray pipes, there is the weir box method that can be used to supply water to the deck of the vibrating screen, ‘A weir box is a deep troughlike container with water running in it. The water is allowed to cascade over the weir outlet onto the bed of screen material. The weir box is used to add a large volume of water in wet screening applications. Itis able to use water with a greater amount of solids than can be used with spray pipes. Installation of weir boxes requires proper clearances between the vibrating screen and the weirboxto insure that there is no interference during starting, stopping and operating. \V-BELT DRIVE INSTALLATION Proper V-belt installation is essential to good belt life. The screen manufacturer's recommendation should be followed when installing the V-belt drive Proper installation of any V-belt drive requires that the drive and the driven sheave be in line, not staggered, to assure that the V-belts are running true in the sheave grooves. Matched sets of multiple V-belts should be used to prevent excessive slippage during starting and stopping but not overtensioned causing the vibrating screen to be pulled out of alignment on the spring supports or decreasing both motor and screen bearing life. Some manufacturers use auxiliary tension spring assemblies pulling in the opposite direction of the V-belt drive(especially on cable suspended screens) to prevent pulling the screen out of alignment on the spring support. Some manufacturers furnish screens with banded belts eliminating the need for keeping the individual belts matched. Proper drive sheave position with respect to the driven sheave is essential to good performance. Vibrating screens should be operated with the V-belt drive properly guarded to protect the operator from injury. V-belt drives for free-floating screens, positive drive screens and horizontal screens will be discussed next, INCLINED FREE-FLOATING VIBRATING SCREENS ‘The drive on 2-bearing screens without pivoted motor bases should be placed on the horizontal centerline of the driven sheave, either atthe feed or discharge end of the screen, so load variations on the screen will not tighten or loosen the V-belt When no pivoted motor base is used, the manufacturer should have the driven sheave designed so that the sheave is running true, that is, operating on the center of gyration, This type of drive on free-floating 2-bearing inclined screens is used when the stroke is 1/4” or less, with no surge loading on the screen. Pivoted motor bases are a fulcrum motor support allowing the weight of the motor to tension the V-belt; allowing the belt tension to be maintained during surge loading, and preventing belts from becoming overten- sioned during screen starting and stopping. Spring loaded motor bases are also available to accomplish the same belt tensioning. Proper tensioning of the pivoted spring-loaded motor bases is essential to its operation. The screen supplier's installation instructions should be followed; otherwise, the spring or pivoted motor base may not perform properly. INCLINED POSITIVE SCREENS The drive of an inclined 4-bearing screen may either be mounted separately or attached to the subbase frame when received from the factory. Follow the screen supplier's installation procedures for proper drive alignment. HORIZONTAL VIBRATING SCREENS Horizontal screen drive should be located at an angle perpendicular to the line of screen action when the drive motor is stationary and not vibrating on the screen. This allows the belts to pivot on the neutral axis of the line of action. When the motor is attached to and vibrating with the screen, the manufacturer has already property positioned the motor on the screen. Follow their recommendations for proper maintenance. Regardless of the type of drive used on your particular vibrating screen, proper alignment and tension with periodic inspection, per the screen manufacturer's recommendation, willinsure maximum drive performance. GUARDS Many manufacturers supply the vibrating screen with guarded counterweights and/or rotating weight wheels. These drive components must be guarded to safeguard the operating personnel. Moving weights present hazards to operating personnel if the manufacturer does not provide guards Most manufacturers offer V-belt guards either as a standard item with the vibrating screen oras an accessory item. If these guards are supplied with the vibrating screen, they must be installed prior to operating the machine. If for some reason you have elected not to purchase guards from the manufacturer, then GUARDS MUST BE INSTALLED PRIOR TO OPERATING THE MACHINERY. OSHA or MSHA regulations, whichever apply to your industry, should be consulted for proper guard design@ Chapter 8 SAFETY QUALITY / INTEGRITYSAFETY DEVICES FOR VIBRATING SCREENS FORWARD: FIRST: Carefully read the manufacturer's operating manual and review General Dimension Drawing SECOND: Review your Plant Engineer's Installation Drawings. THIRD: Select the correct hoisting and rigging equip- ment for placing the screen in operating position. A. MACHINERY PROTECTION 1. After placing screen in operating position be sure to level all mounting elements such as comer or overhead coil spring pads or structural base frame. Allow as much room for inclination angle adjust- ment as practical 2. Check motor nameplate for proper voltage and phase prior to wiring motor. Be sure motor is grounded. After driving motor is wired, check motor rotation without V-belts, making sure motor will tum vibrator in manufacturer's recommended direction. 3. Check alignment of drive and astraight edge before determir motor and screen, iven sheaves with 4, If screen is cable suspended , install and adjust inertia weights tominimize cable whip. Also, install tag lines to be certain tension produced by the driving components does not pull screen severely out of alignment. In addition, install independent safety cables to support screen in case one of the primary support cables fails. 5. Check that the slope is correct, as recommended by the manufacturer, and that there is sufficient room for installing and removing screen decks, wire cloth, perforated plate, etc,, and performing necessary maintenance. 6. At this point, determine that there is adequate clearance between vibrating screen and stationary structures such asfeed chute, discharge shutes and collecting hopper(s), as recommended by manu- facturer. DO NOT alter the vibrating screen in any way without consulting manufacturer. 7. Check all bolted connections for tightness and tighten as required to manufacturers specified torque. 8 Drain any preservative oil or grease from unit, refill and make sure that bearings are properly lubri- cated in accordance with the vibrating screen manufacturer's recommended lubricant. 9. Check actual screen speed and direction of rota- tion and compare to manufacturer's recommenda- tions. 10. Operate screen without material and check for structural interference and loose parts. nis screen supports. If structures are vibrating, request plant design engineer to add bracing or reinforcing re- 12, Make sure that the angles in hoppers and chutes are sufficient for material to flow freely and not back up or contact the screen, 13, Aftera two to four hour operatingperiod, retension screen deck and check bearing temperatures for overheating. 14, Avoid welding on your screen framework. When it can’t be avoided, be sure to properly ground the live frame to prevent arcing thre the bearings. Be certain that conveyor belt, oily rags, wood, rubber and any other combustable materials adjacent to Cutting or welding tools are removed or covered to prevent fires. B. PERSONNEL PROTECTION 1, Provide”Remote Start Warning” device and”Emer- gency Stop” control at the screen. Provide safety lockout at the Control panel. 2. Provide an adequate electrical equipment ground, Screens mounted on rubber isolators will require a static electricity ground. 3, Be sure that all rotating parts such as sheaves, flywheels, countershafts, couplings and V-belts are guarded and that guards are in place and secure. 4. Do not perform maintenance or lubricate a screen that is operating. 5. Check for material bouncing cut of screen. If necessary provide spill guards independent of screen. 6. Keep the screen area clean, spills shoveled away; remove spilled lubricants, discarded screening sur- faces, bolts, nuts and roller bearings.e Chapter 9 PROBLEMS and SOLUTIONS 1s Nee aya Re eleeOperating Problems and Solutions General Information This chapter outlines some of the most common problems that the user may encounter during the operation of a vibrating screen — Note any unusual noises, operation and trouble. Refer to the following chart to aid in determining probable cause. — Follow a procedure which insures that the most obvious causes are checked first and the easiest solution is applied to save time and trouble. Do not disassemble the vibrator assembly or components until all other possible causes and remedies for a specific problem have been examined, — It is recommended that only one step at a time be taken in correcting a problem instead of implementing changes simultaneously. This practice minimizes unnecessary corrective action. — Aftera mechanical failure has been corrected, locate and correct the cause of the trouble so the failure will not recur. — Caution: A vibrating screen is a self-destructing piece of equipment but is designed to withstand normal operating stresses, Improper or unapproved installation, use, modifications or additions to the screen body will result in premature fatigue failures. — Manufacturer should be consulted prior to making any modifications to the vibrating screen to minimize possible damage or premature failure. Trouble Probable Cause Possible Remedy Screen will not start Power failure. ‘Check power supply. Starter inoperative. Check fuses, breakers, holding coil, heatei Motor does not operate. Refer to motor section. Shaft assembly or vibrator assembly With drive belts removed check vibrator frozen or damaged. mechanism for freedom to rotate; see ——________________bearing trouble___________ ‘Material interference with screen body Clear build up from screen body or or motor base. motor base. Motor does not operate. Insufficient line voltage. Check electrical supply for sufficient —_— —__________line voltage. _ —_____ Fuse or circuit breaker blown. Replace or reset. Defective power cable. ‘Check cable for broken conductors— replace if defective. Motor hums but Defective motor Replace defective motor. _ does not start. Bearing lubricant too heavy. ‘Clean bearings and relubricate with proper lubricant. Bearing frozen or damaged. Replace damaged bearing _____ Motor too small Install correct size moter. Motor overheats. Incorrect bearing lubricant. Clean bearings and relubricate with proper lubricant. __ Motor wired incorrectly. Correct wiring—consult MFG. for Motor too small. proper size. ee “Bearing failing, Replace damaged bearing “Replace of rewind defective motor, Install power circuit with correct wire __ size Manufacturer should be consulted prior to making any modifications to the vibrating screen to minimize possible damage or premature failure.Trouble Probable Cause Possible Remedy Motor overheats. Power circuit overloaded. Install heavier circuit or reduce load on ——____________power cireuit________ Trouble with vibrator assembly. Refer to vibrator sections. ‘Overheating of Vibrator Too little lubricant. Check for leakage, damaged seals; relubricat Too much lubricant, Remove lubricant to proper level, allow lubricant to purge from system if so designed, Improper lubricant, High ambient Replace with proper lubricant, Ventilate temperature, hot material, hot area, use high temperature lubricant, environment. consult screen manufacturer. Bearing failure. Replace bearing Improper bearing clearance. Replace bearing, and check for contamination in lubricant. Material build-up on bearing housings. Remove build-up. Insufficient clearance on Labyrinth Check seal clearances. seals. Vibrator will not rotate, _ Motor inoperative, Refer to motor section. Bearing or seal components frozen _Replace damaged bearings or seals. or damaged. —__ = Lubricant too heavy. Remove lubricant, relubricate with recommended lubricant. Drive belts are loose. Tighten V-Belts. Vibrator assembled incorrectly. Review assembly procedure. Lubricant leakage Excessive operating temperature, Use high temperature lubricant. Consult screen manufacturer. Excessive lubricant. Restore lubricant to proper level. Drain plugs omitted. Install drain plugs. Damaged or wom seals. Inspect seals and replace. Noisy bearing Bearing failure. See bearing trouble. Loose in the bearing housing. Replace housing, bolts and properly torque, check bearing, insure that damage to the housing or fastener holes hasn't occurred. Make sure bearing is not turning in the housing. Improper bearing clearance, Consult screen manufacturer. Bearing failures Normal fatigue failure. Replace bearing according to manufacturer's assembly instructions. Overloading, excessive stroke or Return screen to original operating speed combination. mode and replace bearing ‘Overheating from lack of lubricant, __Restore correct lubricant level; use excessive lubricant or high ambient lubricant recommended for the ambient temperature, incorrect lubricant. temperature, replace bearing, use correct lubricant. Spalling from dirt or water entering Flush housings and lubrication system, bearing. replace bearing and replace or clean air breathers, seals. Brinnelling from storage in an area Replace bearing and correct cause. where vibration is present, loose bearing housing, or dropping screen or bearings. Improper float or allowance for Replace bearing reassemble per the expansion in vibrator assembly. manufacturer's instructions, Manufacturer should be consulted prior to making any modifications to the vibrating screen to minimize possible damage or premature failure,Trouble Probable Cause Possible Remedy Bearing failures ‘Arcing through the bearing during ‘Always ground properly. welding with improper ground. Excessive structure Support structure too weak. ‘Add structural support. vibration. Shipping blocks not removed. Remove shipping blocks. Insufficient clearance between screen Provide adequate clearance and/or and structure or material build-up. __remove build-up material. Fatigued suspension parts. Replace components and check other components for damage. Excessive screen Screen out of balance. See out-of-balance troubles. vibration, Damaged suspension. Replace damaged parts. ‘Screen operating speed too fast. Return screen to original operating Wrong stroke/speed combination. mode; Consult manufacturer. Improper or surge feeding Control feed of material, Erratic vibration. Slipping drive belts, or over tensioned Adjust belts per the manufacturers drive belts. recommendation, Replace worn, frayed or stretched belts. “Voltage drop. _ ___Check power supply. Broken suspension parts Replace suspension parts, Throwing of drive belts. Check belt alignment, check snubbers or plugging parts. Check belt lengths. Loose drive or body bolts. Replace or properly torque bolts. Screen operating near the natural Install brace on the supports. frequency of the support structure Screen operating at or near critical Change speed per manufacturer's _speed. recommendation: Excessive Screen cloth breakage. Counterweight settings changed and Match counterweights. do not match, Incorrect screen tension. Periodically check screen tension system. Corrosive material Switch to corrosion resistant cloth. Worn tension rails; insufficient to Replace tension rails. support bolting pressure. Loose screen media bolts. Properly torque or replace. Unbalanced feed condition or feed Distribute feed evenly across surface. Sot e t Worn buffer support rubber. Replace as required. Insufficient screening. __ Screen blinding, or plugging. See blinding trouble. Material feed exceeds design capacity. Decrease feed rate. Screen media open area too little. Use media with more open area Material travel rate across screen Change feed configuration. Operate too rapid. screen counterflow and decrease feed rate. Material feed analysis different than Adjust openings, feed rate, travel rate, originally defined for duty. direction of Flow. Stroke reduction due to material Remove build-up, build-up. Excessive fines in Material travel rate too rapid. Reduce screen angle or operate oversize. counterflow. Improper distribution of feed material. _ Revise feed arrangement. Excessive feed, Reduce feed. Unit operating out of balance. Restore Balance. Excessive throw for media opening __Adjust speed/throw to deck opening. Manufacturer should be consulted prior to making any modifications to the vibrating screen to minimize possible damage or premature failure,Trouble Probable Cause Possible Remedy Excessive fines in Operating speed below recommended. Restore proper speed. oversize, Moisture piggyback of fines. Dry material prior to screening. Wash material during screening Bearing failing Replace bearing. aaa ‘Opening too small Use larger opening, Insufficient open area, Use media with more open area. Screen blinding or Inclined screen too flat. Increase angle of operation. Plugging. Material moisture. Change cloth size or type. Heat cloth. ‘Wrong deck preparation. Use different screening media. Carrot shaped particles plugging Larger stroke required; consult mfg openings. Slotted openings, tapered stepped deck openings required. Screen operating speed may be slow. Increase speed at manufacturer __tecommendations. Excessive near size particles in feed. Adjust crusher openings to reduce near ____size. Use different opening. Shaft rotating in wrong direction. Reverse shaft rotation. Loose screening media, Periodically check tension or integrity of screen medi Screen out of balance Material build-up on screen, Remove build-up. Installation of heavier screen media__Rebalance screen. Consult mfg. Material travels diagonally across screen ‘Machine racking. than originally furnished. ‘Chutes, hoppers added to screen body. Remove chutework additions, Drive belts too tight Adjust drive belts “Main bearing failing Replace bearing Damaged suspension. Repair suspension. Screen out of level Unevenly balanced vibrator weights. Match vibrator weights. _ Loose body components or bolts. Retighten all body fasteners. Broken or damaged structural Replace non-conforming parts members, broken welds._ Operating at or near critical speed Consult manufacturin; Fatigue failure Field modifications by user, welding, Include design requirements in initial of screen body. cutting, etc, which concentrate specification. Replace failed abnormal stresses. components. Corrosion and wear. Replace damaged parts. Screen operating out of balance. Restore balance. Operating screen at or near critical Change speed, Consult MFG. See speed. erratic vibration section. Excessive feed rate. Reduce fee “Oversize feed materials. Reduce maximum size of feed. Interference w/structure or material Eliminate interference of build-up. build-up. Material travels in wrong Screen installed too flat. Consult manufacturer. direction. Gear driven units may be incorrectly Consult manufacturer. _timed, _ Unit running in wrong direction, Reverse motor direction, Manufacturer should be consulted prior to making any modifications to the vibrating screen to minimize possible damage or premature failure.Pee GRUSTIER CIRCUITS (57S aacCRUSHER CIRCUITS In many industries vibrating screens are used in conjunction with various types of crushers. The screens are used with the crushers to remove the material that is less than the crusher setting. This increases the efficiency of the crusher, With some types of crushers it is necessary to remove these fines to make the crusher operate properly. Screens are also used after the crushers to remove the products made by the crusher or to close circuit the crusher. Closed circuits introduce a factor known as circulating loads. This factor can drastically increase the feed rate toa vibrating screen and must. be examined carefully. Circulating load is a factor in sizing of screens to be used as part of crushing circuits where the product must be 100% minus a given product top size. A problem exists because crushing machines do not reduce all their feed toa size equal to orsmallerthan the crusher setting, In normal practice, the crusheris set at a smaller setting (opening) than the screen deck opening to obtain a good balance between net finished product (100% minus product top size) and circulating load. The amount of crusher throughput that is oversize and must be recrushed is expressed as the % of oversize in the crusher product. It continues to be recirculated through the crusher until it is reduced to a size that will pass the screen opening, This is called “closed circuiting” With each pass through the crusher an additional amount of oversize will be reduced to undersize. ‘The number of passes for any given batch of material, with no addition of new feed, before 100% reduction is achieved, is infinite, The percent of oversize remaining after each pass through the crusher and over the screen deck diminshes in a geometric progression, By definition, circulating load = total feed to the crusher minus original crusher feed, It is expressed in % of original feed to the crusher, The formula for % circulating load is: circulating load to crusher *% screen efficiency = % oversize in crusher product The following example will help to explain circulating load and the effect of screening efficiency. This example assumes 100% screen efficiency, and 30% oversize in the crusher product. 200 tph of sized feed |——_ 86 tph circulating load , 200 tph For this example the geometric progression of crusher oversize would be: Pass thea cusher TPH T* 200%30 60.00 2 dooe30x30 3.00 3 Zooe30030x30 340 4 3ooe30%30n30x30 te $ Zooe30x30030%30x30 fs 8 deocdosonsncocoae = 43 ate a6 or 86 tph by formula: R=202 = 190 — 109 4.9% ao 100 821100233 Circulating load = new feed to crusher x R 200 x .429 = 85.8 or 86 tph Look at the same example, with a change of screen efficiency. Assume 90% screen efficiency—other factors the same. 200 tph of sized feed. Tr 100 tph circulating load 200 tphWith 90% screen efficiency, the geometric progres- sion of crusher oversize would be: Pasa eu orsher tex 1 200 (20x 2 =eas7 2 200120%

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