CC Turbine Service Manual
Contents
1. inches skip 1 to 2 inches and repeat until securely mounted Always stop welds Sa 1 in from ends to prevent heat concentration and bin cracking oe 5 E nting brackets see pages 35 amp 36 of the VIBCO General Catalog g NOTE fora list of alternate mo Welding Mounting Plate to Channel Iron Stitch weld the mounting plate to the channel iron If the bin plate is 3 16 in or less weld the mounting plate to the back of the channel iron see Figure 3 or 4 If the bin plate is over 3 16 in weld the mounting plate to the legs of the channel iron see Figure 1 Drill and tap holes or use studded plate see Figure 1 or 5 Make sure the mounting plate does not warp or distort If this occurs straighten it replace it or shim vibrator Note No matter what thickness of plate used plate can still warp due to welding heat if not welded per VIBCO instructions see example to right Placement For coarse materials the vibrator should be mounted approximately 1 3 of the distance from the discharge opening to the top of the sloped portion of the bin For fine materials place the vibrator approximately 1 4 of the same distance see different mounting suggestions on the following pages Note For live bottom bins mounting placement procedure is different Please call VIBCO A factory to speak with an application engineer Welding Channel Iron to Bin Where possible the mounting plate or the channel iron should be placed 12. out the damaged bearings from the turbine wheel Remove both nuts press the shaft out of the bearings and turbine Note Use Andok C or Unirex N2 by Exxon or equal type of grease When reassembling be sure the turbine wheel is put back so that the incoming air will hit the pocket of the tooth not the back of the tooth When new the turbine vibrator might be slow in starting due to A The bearings being packed with grease Excess grease will be thrown out of the bearing after a short operating time B Temperature might be low causing the grease to be stiff After a short operating time the grease will warm and begin to loosen C Bearing seals are stiff when new or cold A brief run time will wear them in sudden loss of vibration A Loss of vibration could be caused by a cracked weld or a crack in the bin Vibration will not travel through a crack Follow the instructions below on how to fix the problem Cracked Bin Shell Cracked bins are usually due to improper welding or improper mounting of the vibrator to the bin If you notice that cracks have developed on your bin follow the procedure detailed below to repair the cracks and eliminate any further cracking REPAIRING BIN CRACKS 1 Remove the vibrator from the mounting plate removing one bolt at a time PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 13 2 Locate where cracks stop Take note of any places where the cracks may have bra
3. should Short bursts of vibration are usually more effective than operating continuously Experience has shown that for most applications short bursts of 10 to 30 seconds for every 1 to 5 minutes of discharge are more effective and efficient Life of the Unit The life of the vibrator will be determined by the length of operation and the cleanliness of the air supply Guaranteed Success of the Application The vibrator can only furnish material to the discharge area If more is furnished than conveyed the remaining material will pack inside the bin We suggest the vibrators only run when the bin gates or doors are open or when material flow is needed MAINTENANCE VIBCO turbine vibrators function without maintenance They require no lubrication in the air line lt is advisable to put an air cleaner the line to prevent dust and dirt from going through the unit and clogging the muffler All models are easily repairable Remove both nuts press the shaft out of the bearings and turbine Use Andok C or Unirex N2 by Exxon or equal type of grease When reassembling be sure the turbine wheel is put back so that the incoming air will hit the pocket of the tooth not the back of the tooth PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 12 TROUBLESHOOTING If required all models are easily repairable The ball bearings can easily be changed by any maintenance mechanic by removing the two end covers and pressing
4. 3 of the distance from the discharge opening to the top of the sloped portion of the bin for fine grain materials place 1 4 of the same distance Tack weld channel iron in place then weld intermittent welds 3 in to 6 in long with 3 in between them along the entire length of the channel Stop weld a minimum of 1 in from the ends It is important that you do not weld the ends of the channel iron The heat concentration when welding the ends could cause premature fatigue cracks Installing Safety Chain or Cable a It is important to install a safety chain or wire to prevent the vibrator from falling and causing injury if it comes loose from its mount Attach chain to stationary object not to mounting plate or channel iron PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 4 MOUNTING SUGGESTIONS Two Vibrators On Conical Bin 1 2 Rectangular Bin Rectangular Bin A Single Bin PS f5 N N T Angle Iron Stiffeners Bin With Stiffeners Instead of Channel HI ORBI iron Corner Mount FAX 401 539 2584 VIBRATORSQVIBCO COM PHONE ORDER 800 633 0032 WWW VIBCO COM Sheet Metal Bin Belt Conveyors Bolt To Bin W 1 S3N Drill Holes To Match Bolt Pattern On Bin Weld Both Sides d Of Angle Iron Angle Iron Feet 24 3 8 in Mounting Plate t d Belt Conveyors Long Bin Belt conveyor feeds from th
5. 8 in longer than vibrator 8 to 12 longer than vibrator 3 16 to 3 8 in 1 to 2 ft longer than vibrator 1 2 to 5 8 in 8 to 12 in longer than vibrator Mounting Plate Use 1 4 in thick mounting plate L or Thru Hole Studded 1 4 to 3 16 in 1 1 2 to 3 ft longer than vibrator Mounting Channel Never place the vibrator directly onto the skin of the bin t should be mounted to either a mounting plate or a piece of channel iron that has been stitch welded to the bin The proper mounting method is to use 2 in X 1 in X 1 8 in thick channel iron This will help to stiffen the structure to be vibrated as well as spread the vibration over a larger surface increasing the overall efficiency and diminishing the possibilities of fatigue cracks in the bin material The channel iron should reach within 6 to 12 in from top and bottom of the sloped section of the bin and should never be shorter than 6 in longer than the vibrator mounting foot Different Suggestions for Mounting the Channel 1 Mounting plate welded to legs of channel iron see pictures below 2 2 in channel with holes drilled thru and nuts welded on back or just holes drilled thru Mounting channel with mounting plate and holes drilled or tapped thru Notch the channel for access to mounting bolts Weld studs to back of channel PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 3 3 4 5 Stitch weld channel weld 2 w2 to 3
6. CC Series Heavy Duty Pneumatic Turbine Mounting Instructions 7 Operating Instructions 7 Technical Data Parts List Maintenance 7 Troubleshooting Corporate HQ amp Factory Canada 75 Stilson Road Wyoming RI 02898 215 Dunwin Drive Phone 800 633 0032 401 539 2392 MISSisse 9NT L5L 1X1 A Fax 401 539 2584 Phone 800 465 9709 905 828 4191 j E mail vibrators vibco com Fax 905 828 5015 Website www vibco com i Western US Southeastern US D TM TheWibrator Guys Phoenix AZ 85254 Charlotte NC 28277 Phone 800 633 0032 480 596 1809 Phone 800 633 0032 401 539 2392 Fax 480 596 1614 Fax 401 539 2584 Thank you for choosing VIBCO Inc for your vibration needs You are now the owner of the finest silent pneumatic vibrator available today backed by complete manufacturer confidence in its quality and dependability For reference please complete the information below about your new VIBCO vibrator Model Number Date of Purchase TABLE OF CONTENTS Safety Instructions skart 2 Mounting Instructions Checklist 3 Mounting Procedures pp 3 4 Mounting To Bin Walls Or Chutes nnn 5 8 Bolting Specifications Pneumatic 9 11 Operating Instructions Matenence nenne 12 MOTO VS OO T Um 13 Bin Crack 13 14 Technical Data amp Dimensions 15 Explo
7. FM Flow Valve A simple flow control valve is recommended to allow tuning the vibrator to the desired force necessary for solving your material flow problem The air flow determines the force and frequency of the vibrator By throttling the air flow you can find the desired material discharge rate You should watch for and avoid speeds frequencv at which the bin wall and the vibrator shake violentiv An increase or decrease of air flow assuming the mount is rigid usuallv stops the excessive movement and will smooth out the operation Quick Opening Valves These are recommended between the air regulator and the vibrator so that the air enters the vibrator at full starting force even at low regulator valve settings The only requirement is that you install the air regulator at least 12 inches away from the quick opening valve so that the air pressure between the two valves will build up enough to vield the necessarv starting force Solenoid quick opening valves are suggested for automatic operations Automatic Timed Cycling is programmed with the timer usually directly connected to the bin or hopper gate switch When the gate is opened the timed cvcling svstem is activated Solenoid Air Air Flow Valve Regulator Fil Valve EEK E Fe NENNEN To Gate To Control Switch IK Timer NOT LUBRICATE tA 22 Air Filter It is recommended that you use an air filter in the line Clean air will prolong the life of an
8. Ibs Of bin content at 80 PSI CCF Max Ibs Material in Bin W MODEL DIMENSIONAL DATA C L D Inch mm Inch mm Inch mm 6 162 541 16 129 ICCL 2000 amp 4000 Te 7 178 8 116 205 741 4184 51 16 129 8 203 34 19 6 116 154 CCL 5000 amp 7000 L 9 e 238 8 y8 X 219 8 58 219 6 1 16 154 M Inch mm CCF 2000 amp 4000 1 34 19 5 38 137 1 34 44 S34NPT 2 51 6 162 CCF 5000 amp 7000 1 1 8 29 f 6 1 4 159 2 78 3 73 A tNPT 31 8 79 8 203 NPT Pipe tap size Bolt size PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 15 Model CCF 2000 CCL 2000 CCW 2000 CCF 5000 CCL 5000 PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM Model CCF 2000 CCL 2000 CCF 5000 CCF 5000T CCL 5000 CCF CCL CCW 2000 CCF CCL 5000 Description Number Part Numbers Part Numbers Required 5 16 24X1 1 4SH 5 16 24X1 1 4SH Screw Socket Head Cap 5 16DL 5 16DL Disc Lock 20CC10 1 Exhaust Cover 20CC01 1 Muffler Pad 5 8 11SN Stover Nut Inside Cover With Keyway Washer Kit Foot Housing CCF Lug Housing CCL Foot Housing No Handle 6303LLB C3 Bea
9. OM MOUNTING APPLICATIONS For custom mounting applications Call 1 800 633 0032 E mail vibrators vibco com Or 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 8 VIBRATOR INSTALLATION It is now time to put the VIBCO vibrator in place Make sure that it is secured tightly Retighten the bolts after the first 10 to 15 minutes of operation and check them periodically to maintain proper tightness NOTE Damage to the bin and the vibrator can occur if A not mounted securely No matter how thick the mounting plate can still warp during welding if you do not follow these instructions Angle Iron Channel Iron Note Joo loose a mount will cause feedback or bounce back amplitude causing vibrator to burn out Mount must be rigid Remember Check those GRADE 5 MAX BOLT TORQUE SIZE ft lbs V4 9 160 160 Eum PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 9 Air Line To Vibrator The hose to the inlet port of the vibrator should have the same or larger hose I D as the inlet I D pipe size of the vibrator so that the pressure loss from the compressor to the vibrator is minimized TO DETERMINE CORRECT AIR HOSE SIZE CC TURBINE MIN FR MODEL MIN AIR THREAD NUMBER HOSE DIA F filter R regulator these specs for installation of single unit for multiple units adjust to maintain C
10. al ring CR seal Bearings Turbine wheels Woodruff key and Shaft PHONE ORDER 800 633 0032 WWW VIBCO COM Number Required a a naa MN PR BR NNa NNN 2584 VIBRATORS VIBCO COM 19 WARRANTY AND GENERAL INFORMATION Warranty All warranty claims must be submitted to VIBCO for approval prior to any repairs being done Failure to do so will void any and all warranty coverage Errors Shortages and Complaints Complaints concerning goods received or errors should be made at once Claims must be made within five days after receipt of goods Clerical errors are subject to correction Returning Parts Parts should not be returned to VIBCO without prior authorization Call VIBCO customer service department at 1 800 633 0032 1 800 465 9709 in Canada for a Return Goods Authorization RGA number A return authorization will be faxed to you Return shipping must be prepaid Material returned may be subject to a 10 rehandling charge All returned shipments should clearly display your name and address In order to assure proper credit our invoice number against which parts were returned must be supplied Orders for equipment built to specifications which vary from VIBCO s standard units are not subject to cancellation Responsibility VIBCO cannot be responsible for delays due to strikes accidents negligence of carriers or other causes beyond our control Freight Claims Should you receive a shipment fro
11. ators The portable CCL 2000 uses the LC 2 lug bracket Its light weight makes it ideal for all small concrete precast forms Model CCL 5000 is ideal for tables casting concrete panels window frames or replacing large piston vibrators on large bins Thank you for choosing VIBCO Vibrators CCF PERMANENT FOOT MOUNTED TWO HOLE MOUNT CCL REMOVABLE LUG TYPE BRACKET MOUNT Lug Bracket PORTABLE INCONJUNCTION PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 2 MOUNTING INSTRUCTIONS CHECKLIST The warranty is void if vibrator is not properly installed During installation follow and check off the following steps and your vibrator should provide you with years of trouble free service r1 Determine style of mounting plate r1 Determine length of channel iron 1 Select method of mounting channel iron r1 STITCH weld mounting plate to channel iron O Determine vibrator placement on bin O STITCH weld channel iron to bin r1 Place vibrator on mounting plate r1 Check the mounting plate for warping Secure firmly O Install safety chain or cable Connect pneumatics FILL OUT WARRANTY CARDI NOTES ABOUT INSTALLATION If you have any questions consult the Mounting Instructions section of this manual or call VIBCO Technical Support at 800 633 0032 Force lbs Bin Thickness Channel Iron Length 1 4 to 3 16 in 3 to 4 in longer than vibrator 100 500 6 to
12. de mounting channel FAX 401 539 2584 CHUTES In order to successfully move material in a chute the angle of repose of the material has to be Known It can be found in most handbooks or can easily be measured by pouring a cup of the material on a table The angle between the table and the cone the material makes is the angle of repose To move the material in the chute it should be inclined no less than 1 2 of the angle of repose If this cannot be obtained a feeder is necessary to move the material A Chutes up to 6 ft are generally handled by one vibrator mounted approximately 1 3 from the discharge B On chutes over 6 ft long two vibrators are needed one should be placed 18 24 from the discharge The other approximately in the middle Since chutes are very sensitive to vibration provision should be made to move the lower vibrator 6 inches in either direction This could mean the difference between moving the material or not moving it C The direction of rotation of the vibrator shaft should be in the direction of material flow D Force impact needed on vibrator is equal to weight of chute vibrator max material in chute Chutes must have an inclination of at least 10 for vibrators to be able to move the material If inclination is less the chute has to be made into a feeder Contact VIBCO for selecting the proper size vibrator or ask for the bulletin covering chutes L Up to 6 FT CUST
13. ded Views amp Parts List ss 16 19 Warranty amp General Information pp 20 CAUTION A These mounting instructions MUST be followed Use of another manufacturers procedures may void warranty PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 1 SAFETY INSTRUCTIONS WARNING Failure to read and follow these installation instructions and safety precautions could result in personal injury equipment damage shortened service life _ or unsatisfactory equipment performance All information in this document is vital to EN the proper installation and operation of the equipment It is important that all personnel who will be coming in contact with this product thoroughly read and understand this manual HOW IT WORKS VIBCO turbine air vibrators are designed to keep noise pollution at a minimum Compressed air turns a specially designed turbine wheel allowing the air to be channeled through the unit then exhausting through muffler pads making them virtually noiseless Theses units require no lubrication and its oversized bearings give it years of trouble free service General Features CCF models are the quiet solution for large bins hoppers and chutes Ideal for packing tables and screen applications The lightweight and high force output CCF 2000 and CCF 5000 replace noisy 3 in and 4 in piston vibrators The CCF 7000 Is ideal for precast and prestressed concrete and replaces loud roller vibr
14. e front Vibrator should be placed 1 3 from the front If 2 vibrators are used place 2nd one directly opposite 1 3 from the back Do not operate back vibrator until bin is empty in front and the front vibrator has turned off For more details consult Vibco M LA As Close As Possible Screw Convevors Feeds from back Vibrator should be placed 1 3 from the back 1f 2 vibrators are used place 2nd one directly opposite 1 3 from the front Do not operate front vibrator until bin is emptv in back and the back vibrator has turned off For more details consult Vibco PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSOVIBCO COM 6 Heat Mounts for Insulated Bins Containing High Temperature Materials When materials in the bin have a temperature over 150 F it is advisable to use a heat mount to prevent excessive heat from reaching the vibrator causing overload or bearing failure Also ask for high temperature grease in vibrator bearing Consult VIBCO for vibrator size Mount steel plate on inside of bin so that the vibrator sits 1 3 up bin side Isolate the plate from the concrete by using vibration shock absorbers Consult VIBCO for detailed drawings PHONE ORDER 800 633 0032 WWW VIBCO COM VIBRATORS VIBCO COM 500 F 8 IN CHANNEL 300 F 6 IN CHANNEL 4 IN CHANNEL Gusset 3 Or 4 Channel Iron Use steel plate on inside and bolt to outsi
15. m VIBCO which was damaged in transit your claim is to be filed immediately with the carrier All parts sold by VIBCO are on the basis of F O B Wyoming Hhode Island Product Changes The right is reserved by VIBCO to make changes in pattern design or materials when deemed necessary without prior notice or obligation to make corresponding changes in previous models Price Changes Prices are subject to change without notice Ordering Spare Parts Parts can be ordered through authorized distributors or direct from VIBCO The following data should be provided when ordering From foot of housing Model of unit From spare parts list Reference number part number description and quantity required Shipping instructions opecify shipping point and method of shipping PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 20 Corporate HQ amp 4 actory 0c o com
16. nched off It is very important that you located all the branches of the crack 3 Drill holes at the end of every crack on every branch For average size cracks use a 1 4 drill For larger cracks use your best judgement to determine the appropriate drill size What is important is that the drill size is larger than the width of the crack The improper welding of bin stiffeners to which the vibrator is attached often results in fatigue cracks in the bin This can be prevented by properly welding stiffeners to the bin side A stiff ener should be skip welded to the bin leaving 3 to 4 inches between welds STOP WELDS 1 IN FROM THE ENDS OF THE STIFFENER This will prevent fatigue cracks that occur due to crys tallization of the material This crystallization is caused by the heat concentration that develops when the ends of the channel iron are welded To stop the cracks drill a hole at the end of each crack and weld on a piece of angle iron as shown above When welding on the angle iron STOP WELDS 1 IN FROM THE ENDS PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 14 MODEL CC TECHNICAL DATA 60 PSI 4 Bar 80 PSI 5 Bar Weight Ibs kg Speed VPM CFM Speed VPM CFM Data obtained on laboratory test block Frequency and force will decrease on less rigid mount Data subject to design changes Decible from A scale at 1 meter and 80 PSI Rule of thumb for sizing One Ib vibratory force for each 10
17. ring 20CC11 Sawtooth Gear 3 8 16X1SH 3 8 16X1SH Screw Socket Head Cap 33VM23 56VM38 2 Gasket 404 61 Woodruff Key 20CC26 50CC37 Shaft With Key Cut 20CC09 1 50CC16 1 Inside Cover O N NA 2 Nea NNN RK 2000 RK 5000 Repair Kit Washer Kits include Retaining rings Wave washers Felt washers Bearing spacers Nylon shields and Snap rings Repair Kits include Washer Kit Bearings Turbine wheels Shaft Gasket Cover with keyway and woodruff key PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 17 Were The Vi Model CCF 4000 CCL 4000 CCW 4000 brator Guys PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 18 Model Part Numbers 5 16 24X1 1 2SH ON O O amp W CCF 4000 CCL 4000 5 16DL 20CC10 1 20CC01 1 7 8 9SN 20CC29 2 20CC30 20CC24 6305LLB C3 1 32X2 7 16 RR244 20CC16 20CC27 404 20CC07 20CC12 33VM23 1 4 20X3 4SH 20CC18 20CC29 1 RK 4000 Repair Kits Includes Description Screw Socket Head Cap Washer Disc Lock Exhaust Cover Muffler Pad Stover Nut Inside Cover With Keyway Seal Ring CR Seal Bearing Bearing Spacer Snap Ring Turbine Wheel Left Shaft Woodruff Key Housing Foot CCF Housing Lug CCL Gasket Screw Socket Head Cap Turbine Wheel Right Inside Cover Repair Kit Stover nut Inside cover with keyway Se
18. y pneumatic vibrator Dirty or moist air will harm the unit and impair it from operating at maximum efficiency and lowest air consumption PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSQVIBCO COM 10 MAXIMUM AIR PRESSURE The CONTINUOUS DUTY operating pressure of the CC Series Turbine vibrator should not exceed 80 psi Safe Operation for Continuous Duty Not Recommended The INTERMITTENT DUTY operating pressure of the CC Series Turbine vibrator should not exceed 100 psi Safe Operation for Intermittent Duty IM Not Recommended Maximum Temperature The operating temperature of the vibrator should not exceed 200 F 93 C High temperature units are available Figure 4 PHONE ORDER 800 633 0032 FAX 401 539 2584 WWW VIBCO COM VIBRATORSOVIBCO COM 11 OPERATING INSTRUCTIONS To Obtain Maximum Performance Itis not necessary to operate the vibrator at its maximum capacity to obtain maximum performance Air regulators timers etc should be used to tune the vibrator for optimum performance and ensure longer life Continuous vs Intermittent Operation For bulk material bin applications the vibrator should be used to reduce the material friction and increase flow not as a feeder Once the friction of the particles is reduced gravity flow takes over and the vibrator should then be turned off for several reasons Economy Most vibrators are run 60 to 80 longer than they
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