manual in english car shaker

Produzido com TECNOLOGIA

M.V.L - Máquinas Vibratórias Ltda. ® “ Tecnologia em Vibração “

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Av. Marginal Direita do Rio Jundiaí, 1265 – Dist. Industrial

Várzea Pta. – SP – CEP : 13.221-800 Fone / Fax : (11) 4595-8212

Site: www.mvl-maq.com.br e-mail: [email protected]

MANUAL

OF

OVERHEAD

RAILROAD

CAR SHAKER



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Foto meramente ilustrativo



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INDEX 1. INTRODUCTION 2. OPERATION 3. CARACTERISTICS 4. INSTALLATION 5. OPERATION 6. MAINTENANCE 7. LIST OF SPARE PARTS 8. TECHNICAL ASSISTANCE 9. WARRANTY 10. ATTACHMENTS



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1. INTRODUCTION ----------------------- The mechanical vibrator of railroad cars is a robust and specially designed equipment to perform the task of collaborating in unloading and compression products or railroad car. It consists of special steel structure, an electric motor, a set of pulleys that drive a shaft designed to vibrate through inertial mass eccentric Principal Components --------------------------------

The main components of the vibrator are: • Body of vibrator with the lower clamps plugin on the sides of the Railroad car • Electric Motor • Transmission system with pulleys and belts with protection grid • Roller sleeves with special bearings • central axis with eccentric weights • System Superior of anti-rotation • Set of suspension with wire ropes and shackles

• See also dimensional drawings attached



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2. OPERATION

----------------------

The vibrator car should be properly seated in the wagon.

The transportation of the motor pulley and back to the rotational shaft eccentric

drive that contains inertial mass properly sized, causing the formation of mechanical

waves in the longitudinal direction, in favor of the movement of the load inside the

wagon, providing her flow and or compaction.

Note:

DO NOT START THE EQUIPMENT WITHOUT BEING DULY

SNAPPED IN THE WAGON



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3.CHARACTERISTICS ------------------------------- Drive Type: Rotor Cage Specification Totally enclosed with external ventilation (TFVE) Quantity 01 Power : 20 CV Dimension and mounting shaft (NBR - 5432) Amperage : 28A Frequency :60 Hz Rotation :1150 RPM Voltage 220/380/440 V, three phase Protection: IP 55 (NBR - 6146) Isol. Cl : F (NBR - 7094) Housing: WEG 160 L Noise Limits: (NBR - 7565) Vibration Limits: (NBR - 7094) Housing ----------- Of robust construction, cast iron, corrosion resistant, with external fins to provide maximum cooling. Are provided with lifting lugs to facilitate their transportation, housing relative power X is normalized according to ABNT, NBR-8441, allowing interchangeability.



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Winding ----------- In copper wire reinforced insulation, varnish, suitably bound and encapsulated to support long periods of work.

Axis ------ In SAE 1045 carbon steel carefully dimensioned to withstand the harsh regime of work common to this type of equipment. Stator Core -------------- Silica plate. Rotor -------- The cage in short circuit, injected aluminum purity 99.9% ensures perfect performance. Insulation - Class "F" - for up to 155 ° C temperature. Degree of Protection IP - 55 (According to ABNT) - Closed, well protected, to work outside and in agressive ambients. Construction type TFVE - (Totally closed w / external ventilation). • Please also consult the manual attached of WEG Electric Motor



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Set of Pulleys ------------------------ Dimensioned to transmit the motion of the engine to the eccentric weights, installed at the bottom of the equipment Eccentric masses ------------------------- Made up of steel weights, conveniently sized to provide the necessary vibration impact to each type of task. Vibrators can be operated by manual or automatic operation and support of continuous or intermittent regimes of work. Thus, the vibrators are carefully assembled with enviable performance and able to offer their services for an unlimited time, with minimal maintenance and proven efficiency.



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4. INSTALLATION ------------------------- - The installation of vibrators meets the same criteria used for the installation of any conventional electric motor under the electrical point of view, but the care required in dealing with equipment subjected to intense vibration. - Remember that the vibrators are manufactured to 220/380/440 V and 60 Hz Thus, from the point of view of frequency (Hz) , the vibrator is able to work around the country - It is recommended that the connections of the vibrators and any other electrical equipment industry, is made categorized by electricians, skilled in dealing with connections to three-phase electric motors. - The use of automatic protection switches is recommended. You should protect the vibrator against phase failure, overload, overvoltage and undervoltage. Protected, the vibrator will be fully guaranteed and offer unlimited good service, if this protection is combined with careful preventive maintenance.

4.1 ELECTRICAL CONNECTIONS ---------------------------------------------- - For the connection of the motor must be selected gauges conductors compatible with the distance, the capacity of each unit and amperage



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The connections between the net and cables from the motor cables must be made with great accuracy. They must be very firm (preferably welded), taking into account that the set will be subjected to intense vibration. Should be given to these certain tolerance in length, that is, the cables should never stay straight for the same reason mentioned above.

4.2 MECHANICAL CONNECTIONS ----------------------------------------------- Installation of the anti-rotation system of the vibrator -------------------------------------------------- ------------------------- Check first if the equipment is supplied with antirotation system of the vibrator wagon. To install the antirotation system, the hoist shall be equipped with two cables descending to the bar of the antirotation system. Fix the two steel cables at the bar and hoist cable connection with their steel shackles for the body of the vibrator wagon. Adjusting the intensity of vibration of the vibrator -------------------------------------------------- -------------------- The intensity of vibration of the equipment can be adjusted by counterweights mounted on the main shaft of the vibrator. To increase the intensity of vibration, adding a steel bar supplied with the equipment. To reduce vibration, take a steel bar.



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OPERATION ------------------ - Vibrators must be operated manually and is actuated using a electric panel with protection key with push-button "start - stop" and protection systems, This panel will contain the usual gauges (volts and amps) if necessary.

The vibrators are built for continuous operation (24 hours / day) or intermittent work. When used in intermittent work, should take care in observing the working regime (x working time rest time) and, consequently, the number of starts per unit time. The standards for these operations are the same as provided for conventional electric motors. It should be noted the temperature behavior of the motor in the first minutes of service. Note that the motors are isolated in class "F", ie, to 155 ° C. at most. Thus, in surroundings of 40 ° C, it is permissible for an increase to 90 ° C. This value (T) clearly decreases with increasing temperature. These values are measured in the head coil. Although condemned to measure the temperature evaluation with a simple hand touch on the motor, a qualified electrician can "assess", with this touching , if the heating is excessive or not. (Remember the motor is TFVE, ie, three-phase, closed, with no external ventilation).

Remember ::

DO NOT START THE EQUIPMENT WITHOUT BEING DULY

SNAPPED IN THE WAGON



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It is recommended the installation of a sensor in the equipment, electrically connected with the panel to switch on and off the vibrator. The purpose of this sensor is to `` liberate `` the electrical panel , only when the vibrator is seated to the sides of the wagon and ready for the operation and working.



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MAINTENANCE ----------------------- 6.1 Electrical Maintenance - The maintenance of electric vibrators wagon is not very different from the usual maintenance devoted to conventional electrical drives. - Any electrical problems that can occur are due, invariably, the winding, the rotor, the connections, or even the keys to the net power. - Because it is a piece of equipment subject to vibration, must be constantly inspected the connections of the link. Bad contact between cables or network key and the drive can cause burning due to lack of phase. Oxidation can also cause the same problem. - Similarly, network interruptions and blown fuses, defective switches, etc. ., even cause damage. So it is always advised to preview a protection system, that involves the possible lack of phase.

- The abnormal warming should be detected immediatelythat means , that there is a problem in the electrical system of the equipment or the net. The accumulation of debris on the finned of the motor housing also causes overheating. - In this case such debris must be removed immediately, the most convenient way.



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Remember that overheating significantly decreases the quality of insulating materials that make up the vibrator. As with any electrical equipment, a vibrator constantly subjected to overheating has seriously reduced their useful life. Always check if the heater is compatible with the limits for a Class "F" or preferably below them. - When submitted, for long periods of bad weather or when installed in an environment of excessive drive or vibrators TFVE even though the type and degree of protection IP - 55, can absorb, accidentally, of the moisture. Should submit them, when such facilities to the usual testing and moisture resistance, like a conventional electric motor. The abnormality being noticed, disassemble the drive and provide a drying in an oven. - After long periods of work, continuously subjected to vibration, it is advisable to dismantle the engine to check the general condition of the winding, and its firmness in the "package". Encapsulation, the moorings, the position of "spaghetes" insulation and even the most critical part of the insulation should be inspected carefully. Correct any abnormalities before they can take more severe to the point of burning the motor.



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6.2 Mechanical Maintenance ---------------------------------------- - Never forget that the equipment is being subjected to severe vibration system of work, the vibrator should be given some extra care. - Check periodically: tension of belts, rubber cushions, wear plates in contact with the car. - A periodic visual inspection of fixation is mandatory due to the type of work the vibrator. Must be constantly examined bolts and nuts (or weld, as appropriate); eventually placed the shims, the motor feet and the wall or base mounting, always checking if we do not have cracks or cracks caused by nature or put failures after the installation.

LUBRICATION: -------------------- - In preventive maintenance, lubrication is the main point in dealing with vibrators. Because the characteristics of the bearing and used mainly by the nature of the service, it is recommended bearing lubrication every 500 hours. - Recommended - also that at least every 3000 hours of work, the bearings are removed, and the old grease is completely removed and replaced. - For removal of grease used, uses gasoline or kerosene or diesel oil (in that order), using a brush with soft bristles. Never use in drying the air jet, tow, etc.. Drying must be spontaneous and under dust or other impurities (why gasoline is the best cleaning measure chosen, due to evaporation)



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IMPORTANT When you perform to re-lubrication should be careful not to over load the bearings with grease. Likewise, when replacing the bearing grease, you should put just enough to fill the space between the rollers and between them and the side walls of the track. REMEMBER THAT THE EXCESS GREASE is as bad as MISS. The excess or lack of grease in the bearings causes overheating. - Always use good quality, preferably the lithium soap base, insoluble in water, drop point around 200°C. - Never use grease "Stauffer" or based on graphite

When disassembling the bearings ,be careful not to damage the coil winding. - When serving the bearings for any inspections or replacements, always use proper tools (drawers, presses, pulls, pulleys, etc..) avoiding improvisations that usually damage them. Likewise, by placing the bearings, try to act as the technical recommendations, avoiding strikes or assaults to rotating parts and the outer ring. - Always use proper devices. Lubricate the shaft with a little grease for better sliding. If necessary, heat the bearing in oil bath, at 90-100 ° C



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- Take care to avoid the inclination of the bearing to the shaft or bearing. - Seek always the perfect parallelism between the inner ring and shaft shoulder that serves as a seat for the bearing.

SPECIAL CARE IN OPERATION OR RE-LUBRICATING BEARINGS OR REPLACEMENT OF GREASE. - Never leave uncovered a can of grease to avoid contamination by impurities - When applying the grease, make sure it contains no impurities. - Use just enough, removing the can with a spatula and applying it with your finger or with the proper pump. - When replacing a bearing, do not remove the new packaging at the time of inserting it into the shaft. Do not leave out of packaging bearings for long. - Clean the bench, the tools and the surrounding area, to prevent penetration of foreign material bearing or grease. - Avoid keeping the bearing contact with the hands for long. Oxidation is the enemy of accuracy. - Try to keep the bearings in airy places, too little moisture, dust free and away from sunlight. - Do not store bearing directly on the floor. Use a shelf that is at least 30 cm from the floor. Do not stack or inordinately large amount, about each other.



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7. SPARE PARTS =============== See the attached drawing set. 8. TECHNICAL ASSISTANCE ======================== All considerations must be forwarded to the technical department: M.V.L. MAQUINAS VIBRATÓRIAS LTDA ( supplier of the equipment). by fone/fax: (55) – 11 - 4595-8212 or by e-mail: [email protected]



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WARRANTY ========== The equipment and products subject of this delivery will be guaranteed to operate for a period of 12 months from date of issue of invoice, against defects in workmanship and design errors. This warranty is subject to monitoring by a qualified MVL at the beginning of the operation (expenses paid by the customer), and full compliance with the conditions and maintenance records provided in the Instruction Manual, as well as the guidelines contained in the Inspection Reports. The MVL disclaims any and all liability, if alterations or repairs are carried out without prior authorization in writing. Defective equipment not be operated, especially when shown that their continued operation could result in damage to it and / or endanger the system. The MVL is not responsible for reimbursement of expenses due to problems arising, for loss or damage, direct or indirect, to persons or property, or loss of business profits and losses of production coming from natural wear, corrosion, improper operation, construction civil or faulty foundations, overload operation or any other thing, whose cause can not be imputed to the manufacturer. We accept responsibility for material defects in products / services provided by us (except wear parts) for a period of 12 months, confirming that the MVL is responsible for the failure and that it was caused before the end of warranty (exceptionally as a result of failure of design, materials or manufacturing). We can correct these failures, in our sole discretion, through repair or replacement. Noting to the merits of a manufacturing defect within the warranty period, parts and technical staff hours worked will not be charged. However, the costs of technical assistance such as accommodation, transport parts, meals, travel expenses and hours of coach travel, usually running on the buyer. Wherever possible, because existing manufacturing facilities, preferably recommend sending the equipment to repair the "MVL"



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MAKE NO PART OF THIS WARRANTY - Parts considered normal wear and tear. - Spare parts and electronics (and will be considered when the same assurance of sub-supplier). - Equipment supplied by third parties that have their own warranty provided by their supplier .. In this case we undertake to forward any complaints that may occur to their subcontractors. WARRANTY vanishes occurring any of the following conditions: - Misuse or overloading the equipment; - Improper maintenance; - Use original parts M.V.L - Accident with our equipment; - Repairs not authorized by M.V.L



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10. ATTACHMENTS ------------------------------ 10.1 GENERAL DRAWING OF THE OVERHEAD CAR SHAKER 10.2 MANUAL OF THE ELECTRIC MOTOR ( WEG ) 10.3 CONNECTION SCHEDULE OF WEG ELECTRIC MOTOR 10.4 CONNECTION SCHEDULE OF THE INTERMEDIATE JUNCTION BOX

manual in english car shaker

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