Great Western OM manual (2).pdf

8/15/2019 Great Western OM manual (2).pdf

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Tru-Balance Box-Type Sifter

Installation and Operations Manual

Great Western Manufacturing Company, Inc.2017 South 4 th Street

PO Box 149Leavenworth, KS 66048-0149

USAPhone: (913) 682-2291 • Toll-Free Phone: (800) 682-3121 • Facsimile: (913) 682-1431

World Wide Web: http://www.gwmfg.com

http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/http://www.gwmfg.com/


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Table of ContentsTOC

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Model: TBB- 221 Shop Number(s): 4 500

Purpose PSafety Alert Symbols SASProduct Description PDFlow Scheme Description FSDFlow Schematic(s) FSMInstallation Drawing(s) IDGeneral Safety Instructions GSIGeneral Operation and Maintenance Instructions GOMILifting the Sifter LSUncrating and Installing the Sifter UISInlet and Discharge Socks and Clamps IDSCElectrical Connections ECVibration-Sensing Switch (Optional) VSSLow Pressure Switch (Optional) LPSMicroswitches for Lift-Off Shields (Optional) MPneumatic Connections (Optional) PNCSafety Decal Placement Guide SDPGPre-Operation Checks POC

Sieve Removal SRMSieve Replacement SRPPneumatic Clamping (Optional) PCRack and Pinion Clamping (Optional) RPCInspection Checklist ICScreen Replacement SRLubrication Schedule LBSRemoving, Installing, Adjusting, and Maintaining the Tie-Bar MTBTru-Balance Box-Type Guards JTGSifter Balance SBTroubleshooting TVibration Troubleshooting VTTechnical Data TDParts List PL


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PurposeP

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This manual is part of the Tru-Balance Box-Type Sifter and should be kept near the Sifter for users to read.

This manual provides the reader with:

• Installation instructions

• Operation guidelines

• Safety information

• Maintenance instructions

• Parts information

Copyright© 2005Great Western Manufacturing Company, Inc.


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Safety Alert SymbolsSAS

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Safety alert symbols are used in this manual to indicate potential personal injury hazards. All personnel mustobserve these potential personal injury hazards and take appropriate preventative action where applicable.

Indicates an imminently hazardous situation that, if not avoided, will result in seriousinjury or death. This symbol is observed for the most extreme of situations.

Indicates a potentially hazardous situation that, if not avoided, could result in seriousinjury or death.

Indicates a potentially hazardous situation that, if not avoided, may result in minor ormoderate injury. It may also be used to alert against unsafe practices.

Indicates useful information gained through industry experience that, if not followed, mayresult in a caution, warning or danger situation.


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Product Descript ionPD

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The Tru-Balance Box-Type Sifter is custom designed and built for screening dry, free-flowing products ranging insize from 0.25 to 0.0025 inches. The gentle gyratory sifting action provides accurate separation and sizing of aproduct. It is usually floor mounted, but can be attached to the ceiling.

The Sifter’s dust-tight gyrating housing is mounted in a sanitary tubular steel drive frame. The Sifter opens easilyfor inspection, cleaning and maintenance. Sieve frames are nested one on top of the other in the gyratinghousing.

Each sieve frame may hold a removable tray with sieve screening material. The screens are attached to theframes in one of two methods: mechanical (stapled) attachment or glued-on attachment. Screen cleaners unplugproduct from the screen openings. Gaskets seal the sieves and trays.

The Sifter is operated by a motor(s) mounted on the frame, V-belts, and counter-balancing weights on eccentricshafts synchronized by a tie-bar. The clamping system ensures constant compression of the sieve stack whilethe Sifter is in operation.

The Sifter has been assembled, operated and balanced at the factory prior to shipping. The Sifter may be cleanedthrough dry brushing and/or vacuuming.


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Flow Scheme DescriptionFSD

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The Tru-Balance Box-Type Sifter is a multi-sieve gravity flow screening machine. The product is gently sievedthrough vertically nested sieve frames without being forced through the screens.

When the product enters the Sifter, it is cascaded along the sieve screens by a horizontal gyratory motion. Thisgyratory sifting action accurately separates product particles and reduces the risk of fracturing oversize impuritiesand forcing them through the sieve screens.


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Flow Schematic(s)FSM

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See Attached Sheet(s)


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Installation Drawing(s)ID

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See Attached Sheet(s)


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General Safety InstructionsGSI

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For your protection, please read these instructions completely before installing,operating, or maintaining the Tru-Balance Bo x-Type Sifter.

• Follow your employer’s plant safety guidelines.

• The Sifter should be operated only from the type of power source indicated on the motor(s) labels.

• Appropriate safety measures should be exercised during installation, operation, and maintenance of theSifter. Work should be compliant with all appropriate local and national codes.

• To ensure proper operation of equipment, periodic maintenance must be performed in accordance with themanufacturer’s instructions.

• Only trained and authorized personnel must be allowed to operate and perform maintenance on the Sifter.

• Use caution, especially regarding hands and arms, when installing and operating the Sifter. Operate withguards in place.

• When performing maintenance on the Sifter, all power sources must be locked out to prevent injury topersonnel and potential damage to the equipment.

• Use hearing and eye protection in accordance with plant safety guidelines when installing, operating, and

maintaining the Sifter.

• Dispose of any hazardous waste in accordance with established laws and regulations. Recycle asappropriate.

• Modifications, extensions, additional welding, and rebuilding of the Sifter are not permitted without priorapproval of Great Western .


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General Operations and MaintenanceInstructions

GOMI(TBB)1 of 1

For your protection, please read these instructions completely before installing,operating, or maintaining the Tru-Balance Bo x-Type Sifter.

• Before starting the Sifter, make sure the sieve stack is clamped tightly in the box. The appropriate section(Pneumatic Clamping or Rack and Pinion Press-Top Clamping ) of this manual has detailed instructionson this procedure.

• The Sifter has a 2-5/8”, 3-1/2”, or 4” diameter circle of gyration. The 2-5/8” Sifter should be driven between230 and 263 rpm. The 3-1/2” Sifter should be driven between 200 and 230 rpm. The 4” Sifter should be

driven between 185 and 210 rpm. Do not vary the speed of the Sifter without consulting a Great Western representative.

• Do not allow product to build up inside the Sifter; it will become unbalanced, which may possibly damage thedrive mechanism.

• Lubricating the Sifter is essential for efficient operation, and helps to maximize the life of the Sifter. See theLubric ation Schedule section of this manual for the recommended lubrication schedule of the Sifter.

• The tie-bar below the Sifter must be properly adjusted. For more information on the tie-bar, see theRemoving, Installing, Adjusti ng, and Maintaining the Tie-Bar section of this manual.

• For advice on installation or operation of the Sifter not covered in this manual, contact a Great Western

representative. When calling Great Western , it is helpful to have available the Shop Number and ModelNumber of the Sifter on which you are working. These numbers help Great Western identify characteristicsand special construction features of the Sifter.


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Lifting the SifterLS

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For your protection, please read these instructions completely before lifting theTru-Balance Box-Type Sifter.

When Lifting th e Sifter:

Using a Crane:• When lifting the Sifter, use extreme care.• Use only hoists that are in good working condition.• Perform a suspension test.• Never work or stand below lifted loads.

Using a Forklift: • Check the weight of the sifter in the Technical Data section of this manual to verify needed carrying capacity.• When lifting the Sifter, lift carefully to avoid damaging the tie-bar and discharge fittings.• Perform a suspension test.• The machine can be top heavy. Lower carefully.• Since the shipping case also contains accessories, an out-of-balance situation could occur.


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Uncrating and Installing the SifterUIS

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The Tru-Balance Box-Type Sifter will arrive in a heavy wooden crate, bolted to a skid. The Sifter may be suppliedwith an inlet spout support stand.

□ Inspect the Sifter for shipping damage. Immediately notify the carrier, in writing, as well as Great Western ifany damages are discovered.

□ Remove the crating, except for the skid to which the Sifter is bolted.

□ Position the skidded Sifter as close as possible to its final location.

□ Unbolt the Sifter from the skid. Lift and place the Sifter in position if using a forklift. Ensure forks go underframe members at front and back of the frame to protect the tie-bar.

When lifting the Sifter, do not attach chains or straps to the top dome or bearingarms. Use the top or bottom f rame members at the front and back for liftin g.

Photo 1: Proper Sifter Lifti ngPoints, Option 1


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□ Prior to final positioning of the Sifter,ensure that the inlet(s) and outlet(s) areproperly situated for product lineconnections. They must be centrallylocated to allow for proper rotation of theSifter. Also ensure that there is adequatespace around the Sifter for proper safety,operation, and maintenance.

Prior to fastening the Sifter frame, ensure that the foot pads of th e frame sit flat andthat all four corners of the frame are level. If the Sifter frame is not level, placeshims under the footpads. When the Sifter is installed, the frame must be levelfront-to-back and side-to-side.

Do not pull the legs down to meet the floor. Shim from the floor up to the legs .

Photo 2: Proper Sifter LiftingPoints, Option 2

Photo 3: Inlet Support Stand


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□ If the Sifter is equipped with an inlet support stand, install it at this time. See the instructions for connectingthe Inlet and Discharge Socks and Clamps .

□ Connect the motor(s) and any other electrical devices in accordance with the Electrical Connections sectionof this manual.

□ If necessary, connect the pneumatics in accordance with the Pneumatic Connections section of thismanual.

Do not weld or attach anything to the tubular frame or either the top or bottomdomes. Do not use the frame to support other machinery. These actions willdestroy the pr ecise dimensions of the Sifter.


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Inlet and DischargeSocks and Clamps

IDSC(TBB)1 of 1

Flexible connecting socks are provided for the inlet and discharge points of the Tru-Balance Box-Type Sifter. Twoclamps per sock are also provided; use the clamps to secure all of the socks to the Sifter.

□ When installing socks on the Sifter, connect the socks at both ends. Securely clamp the sock to one end.Manually collapse the sock and then securely clamp the sock to the other end.

□ The socks should be loose enough to freely rotate with the Sifter. Check this by manually rotating the Sifter.

Standard socks furnished are twelve (12) inches long. These are intended toconnect th e gyrating Sifter to a fixed spo ut seven (7) inches apart.

Do not attempt to change the socks or adjust the sock clamps while the Sifter isrunning.

Photo 1: Flexible Sock and Clamp


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Electrical ConnectionsEC

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For your protection, please read these instructions completely before performingelectrical work on the Tru-Balance Box-Type Sifter.

• Only properly licensed electricians should perform electrical work on the Sifter.• All work must be performed in compliance with the technical specifications and regulations for local and

national electrical codes.• Electrical connections should only be made after electrical personnel have read and understood this section

of the manual.• Maintenance on electrically active parts should only be performed in the presence of a second person that

can turn off the electrical power.• The working area should be properly identified for the safety of workers.• Use only insulated tools.• The voltage ratings in the wiring diagram must coincide with the supply voltage.• Assure the Sifter is securely grounded before work begins.

Connecting the Motor

Connect the motor(s) in accordance with existing electrical codes. Refer to the diagram on the motor nameplate.

The rotation of the drive do es not matter. Machines equipped with two motors should have two properly sizedstarters. The two starters can be connected to start and stop from a single control device. Both motors, however,must rotate in the same direction.

Connecting Other Electrical Devices

Connect other optional electrical devices in accordance with existing electrical codes.

Optional devices include:• Vibration-sensing switch.• Low pressure switch. • Microswitches for lift-off shields.


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Vibration-Sensing SwitchVSS

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The vibration-sensing switch is an added safety feature of some models of the Tru-Balance Box-Type Sifter.When properly adjusted, the switch detects out-of-balance conditions, minimizing damage to the Sifter. Thisdevice contains an internal switch that activates when there is vibration or shock above a pre-set level.

Connecting the Switch

□ Carefully read the included instructions before installing the vibration-sensing switch. The switch must beconnected to the motor controller in accordance with existing electrical codes.

□ The switch should be connected to stop the Sifter immediately upon activation.

Adjust ing the Switch

□ The vibration-sensing switch arrives pre-set. Under normal operating conditions, it should not need adjusting.However, should adjustment be needed, Great Western recommends adjusting the switch so that the Sifteris just able to start without tripping the switch.

□ Turn the set point adjustment screw clockwise 1/4-turn to further decrease the sensitivity of the unit.

Turning the set point adjust ment screw clockwis e decreases the sensitivity t ovibrations, while a counter-clockwise turn i ncreases the sensitivity.


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Low Pressure Switc hLPS

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Tru-Balance Box-Type Sifters equipped with pneumatic clamping systems have a low pressure switch. Theswitch arrives pre-set in the pneumatic control box. It is intended to function with a programmable logic controller.The switch provides both normally open and normally closed contacts limited to the current rating specified in thePneumatic Connectio ns section of this manual, and must be wired in accordance with existing electrical codes.

Normal operating pressure for the Sifter is between 100 and 120 psi. Some systems may require a booster tomaintain adequate air pressure. If pressure falls below 80 psi, the switch will cause the Sifter to shut off or soundan alarm.

If the Sifter suddenly shuts off due to inadequate air supply:

□ Check air supply and air line.

□ Re-establish adequate air pressure.

□ Initiate start-up procedure and continue operation.


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Microswitches for Lift-Off ShieldsM

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Lift-off shields equipped with microswitches are optional components of the Tru-Balance Box-Type Sifter. Thesecomponents are an added safety feature.

These microswitches must be connected to the motor controller in accordance with existing electrical codes.

The microswitches prevent the Sifter from running when the lift-off shields are not installed. They also may bewired to shut off the Sifter and/or sound an alarm when the lift-off shields are removed or become improperlyaligned during operation.

If the Sifter will not run, or the microswitches shut off the Sifter and/or sound an alarm:

□ Ensure the lift-off shields are properly installed.

□ Initiate start-up procedure and continue operation.


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Pneumatic ConnectionsPNC

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Supply Pressure:

• Minimum = 100 psi

• Maximum = 120 psi

Connection:

• Connect the air supply line directly to the pneumatic control box.

• In the pneumatic control box, the supply line is equipped with a checkvalve.

• Use clean, dry air.

• The low-pressure switch (optional) is intended to function with aprogrammable logic controller.

During periods of scheduled maintenance, check the condition of the pneumaticconnection s and lines to assure they are not worn and no leakage is occurrin g. Ifleaks or w orn areas are discovered, repair immediately.


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Safety Decal Placement GuideSDPG(TBB)1 of 1

Decal Placement Decal

A(End Guards)

B

(Motor Side End Guard)

C(Front and Back Shields)


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Pre-Operation ChecksPOC(TBB)1 of 1

Always lock out the electr ical power before working on the Tru-Balance Box-TypeSifter.

□ Before starting the Sifter, open it. Remove the sieves and completely clean the Sifter and sieves. This willensure that foreign matter has not contaminated the Sifter during shipping or installation. See the SieveRemoval section of this manual for instructions on how to perform this procedure.

□ Reassemble the Sifter. Make sure the trays are properly installed in the sieve frames. The SieveReplacement section of this manual includes instructions on how to perform this procedure.

□ Manually rotate the Sifter and ensure that the Sifter turns freely and that there are no obstructions. TheRemoving, A djustin g, and Maintaining t he Tie-Bar section of this manual includes instructions on how toperform and troubleshoot this procedure.


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Sieve RemovalSRM(TBB)1 of 3

The nested sieves are stacked on top of each other in the Tru-Balance Box-Type Sifter box. The sieves arenumbered in order, with the number “1” at the top of the stack. The highest numbered sieve is called the bottomsieve. The bottom sieve is tailored to fit the outlets of the Sifter.

The Sifter box door and box ribs (located at the interior corners of the box) properly align the sieves. A press-topframe (located above sieve number “1”) is used to compress the sieve stack and prevent the product from leakingduring operation.

□ Remove the front and back machine guards as shown in the Tru-Balance Guards section of this manual.

Pneumatic Clamping System

The press-top is raised and lowered through the use of pneumatic cylinders.

□ Remove the door rod (if applicable).

□ Turn the pneumatic control key to the unclamped position as shown in Photo 1.

Photo 1: Initial Pneumatic ClampingSystem Sieve Removal Proc edure


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□ Loosen the door tail nuts until the door bar clamps can be turned parallel to the edge of the door frame.

□ Remove the Sifter door.

Pull the door out evenly side-to-side and from the top. The door wedge can bedamaged if the door is pulled fro m one side only.

□ Remove the sieves from the Sifter box beginning with the sieve at the top (number “1”) of the sieve stack asshown in Photo 2.

Rack and Pinion Clamping System

The press-top is raised and lowered through the use of hold-down posts or shafts.

□ Remove the door rod (if applicable).

□ Turn the press-top shafts clockwise to raise the rack and pinion press-top assembly and loosen the sievestack.

Do not loosen one side of the rack and pinion press-top system all of the way;

loosen one side part way and then the other side, or both sides simultaneously.This action prevents the rack and pinion p ress-top assembly from bi nding.

Use a 1/2” female, press-top ratchet wrench to operate the mechanisms. Do notuse slip join t pliers or an adjustable wrench.

□ Loosen the door tail nuts until the door bar clamps can be turned parallel to the edge of the door frame.

□ Remove the Sifter door.

Pull the door out evenly side-to-side and from the top. The door wedge can bedamaged if the door is pulled fro m one side only.


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□ Remove the sieves from the Sifter box beginning with the sieve at the top (number “1”) of the sieve stack asshown in Photo 2.

When removing sieve frames, minimize the tendency to drag the sieve frame on

the screen below. This action will help to prolong t he life of the screens.

Photo 2: Intermediate Sieve Removal Procedure


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Sieve ReplacementSRP

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□ Install the Tru-Balance Box-Type Sifter door bottom-first and push the top into position.

□ Turn the door bar clamps at a right angle to the door andhand-tighten the door tail nuts to help snug the door intoposition. Go around the door several times hand-tightening the door tail nuts evenly.

Pneumatic Clamping System

□ Turn the pneumatic control key to the clamped position.

□ Replace the door rod (if applicable).

Only tighten the door rod nut ti ght enough to begin cl osing the gaps between thedoor frames and openings. Do not overtighten as this will distor t the frame andpotentially damage the frame posts.

Rack and Pinion Clamping System

□ Turn the press-top shafts counterclockwise to lower the rack and pinion press-top assembly and compressthe sieve stack. It is recommended that the press-top assembly be tightened to 25 ft-lb f and/or until the sievestack is securely compressed.

Do not tighten one side of the rack and pinion press-top system all of the way;tighten one side part way and then the other side, or both sides simultaneously.This action prevents the rack and pinion p ress-top assembly from bi nding.

Photo 2: Door Bar Clamp and Door Tail Nut


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Sieve ReplacementSRP

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Use a 1/2” female, press-top ratchet wrench to operate the mechanisms. Do notuse slip join t pliers or an adjustable wrench.

□ Replace the door rod (if applicable).

Only tighten the door rod nut tig ht enough to begin clo sing the gaps between thedoor frames and openings. Do not overtighten as this will distor t the frame andpotentially damage the frame posts.

If clamping issues exist, see the appropriate ( Pneumatic Clamping or Rack and Pinion Clamping ) section ofthis manual for detailed instructions.


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Pneumatic ClampingPC

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The sieve stack is clamped by a pneumatic clamping system. The system keeps constant pressure on the sievestack and prevents product leakage through proper gasket compression.

The configuration and number of assemblies differs slightly in Tru-Balance Box-Type Series Sifters; however, thefunction is identical for all Sifters.

The Tru-Balance Box-Type 100 Series Sifter has two assembliesthat extend through the top carrier. The isometric view of thisassembly is depicted in Figure 1.

Figure Number Great Western Item Number Descript ion

N/A 000-005-300 Pneumatic Press-Top Assembly (TBB-100)1 000-001-007 Cylinder Mounting Plate

2 000-001-084 Take-Down Shaft3 000-001-797 Press-Top Bracket4 000-001-787 Washer Plate5 See Pneumatic Connections Cylinder6 400-141-210 Flat Head Machine Screw7 400-071-000 Flat Washer8 400-022-003 Lock Nut

Figure 1: Tru-Balance Box-Type 100 SeriesSifter Pneumatic Press-Top Assembly


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The Tru-Balance Box-Type 200 Series Sifter has twoassemblies that extend through the top carrier. The isometricview of this assembly is depicted in Figure 2.


N/A 000-005-299 Pneumatic Press-Top Assembly (TBB-200)

1 000-001-816 Cylinder Mounting Plate2 000-003-059 Cylinder Spacer3 000-001-084 Take-Down Shaft4 000-001-797 Press-Top Bracket5 000-005-286 Washer Plate6 See Pneumatic Connections Cylinder7 400-141-210 Flat Head Machine Screw8 400-071-000 Flat Washer9 400-022-003 Lock Nut

Figure 2: Tru-Balance Box-Type 200 SeriesSifter Pneumatic Press-Top Assembly


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Tru-Balance Box-Type 300/400 Series Sifters have four assemblies that extend through the top of the woodenbox. The isometric view of this assembly is depicted in Figure 3.


N/A 000-005-302 Pneumatic Press-Top Assembly (TBB-300/400)

1 000-003-106 Cylinder Mounting Plate2 000-001-534 Take-Down Shaft3 000-001-797 Press-Top Bracket4 000-001-787 Washer Plate5 See Pneumatic Connections Cylinder6 400-141-210 Flat Head Machine Screw7 400-071-000 Flat Washer8 400-022-003 Lock Nut

Figure 3: Tru-Balance Box-Type 300/400Series Sifter Pneumatic Press-Top Assembly


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Though rarely built, the Tru-Balance Box-Type X21 Series Sifter with 28-3/4”x28-3/4” sieves has two assembliesthat extend through the top carrier. The isometric view of this assembly is depicted in Figure 4.


N/A 000-005-303 Pneumatic Press-Top Assembly (TBB-X21, 28-3/4”)

1 000-005-274 Cylinder Mounting Plate2 000-005-355 Take-Down Shaft3 000-001-797 Press-Top Bracket4 000-005-286 Washer Plate5 See Pneumatic Connections Cylinder6 400-141-210 Flat Head Machine Screw7 400-071-000 Flat Washer8 400-022-003 Lock Nut

Figure 4: Tru-Balance Box-Type X21, 28-3/4”Series Sifter Pneumatic Press-Top Assembly


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Ensure 100 to 120 psi of dry, oil-free compressed air is available at the Sifter.

Once the pneumatic clamping is complete, the Sifter is ready for operation.

The pneumatic control key should be removed to prevent operation of thepneumatics while the machine is i n operation.


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Rack and Pinion Clamping RPC

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This mechanical (rack and pinion) press-top assembly is used in Great Western’ s wooden box Sifters to

compress and seal the sieve stack.

The configuration and number of assemblies differs slightly in Tru-Balance Box-Type 100/200 and 300/400 SeriesSifters; however, the function is identical in both.

Tru-Balance Box-Type 100/200 Series Sifters have two assemblies that extend through the top carrier. Tru-Balance Box-Type 300/400 Series Sifters have four assemblies that extend through the top of the wooden box.The isometric view of this assembly is depicted in Figure 1.

It should also be noted that the pinion assemblies (Figure 1, Item 4) are of differing lengths for the Tru-BalanceBox-Type 100/200 and 300/400 Series Sifters.

Figure 1: Tru-Balance Box-Type SifterRack and Pinion Press-Top A ssembly


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Inspection ChecklistIC

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The Tru-Balance Box-Type Sifter is intended to serve as a quality assurance tool. Inspect the entire Sifterregularly in accordance with your maintenance and quality control program.

Disconnect and lock o ut Sifter motor.

Inspection

□ Check for evidence of leaks or dusting out.

□ Check condition of inlet and discharge socks.

□ Check condition of all gaskets (sieve to sieve and sieve to tray) in accordance with plant policy.

□ Check screen condition for wear and/or holes on all trays in accordance with plant policy.

□ Check screens for blinding (plugging) of product in accordance with plant policy.

□ Ensure screen cleaners are in good condition (must be ≥ Ø3/8”).

□ Check sieve pans (they should be free of product accumulation).

□ Lubricate in accordance with the Lubrication Schedule section of this manual.


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Screen ReplacementSR

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The trays used in the Tru-Balance Box-Type Sifter have screens that are attached using one of three methods.The stapled-on attachment method stretches and bonds the sieving media to the sieve frame through the use ofstaples or tacks. The glued-on attachment method stretches and bonds the sieving media to the sieve framethrough the use of an adhesive. A third method of attachment is comprised of a system of looped edges sewn inthe perimeter of the sieving media and secured by rods, clamps, and set screws.

When it is necessary to replace the screen cleaners or the screen itself due to wear or damage, two alternativesexist:

• Return the sieves and/or trays to Great Western for replacement. Great Western will remove the oldscreens and cleaners, clean and inspect the tray frame, and replace the screens and cleaners, if necessary.

• Replace the screens and c leaners in your facility. With respect to the stapled-on and looped-edge screenattachment methods, this consists of either purchasing the screen and cleaners from Great Western oranother provider of these materials. On-site glued-on attachment requires the purchase of a pneumatic ormechanical screen stretcher. Provided that you own the proper equipment to perform glued-on screenattachments, the procedure is quick and simple. Great Western can provide the equipment and supplies forthis option.

Instructions for stapled-on and looped-edge screen attachmentmethods are provided in this manual section.

When ordering replacement screen for the Sifter, give the supplierthe frame size, number of side channels, the throat width, thetype of screen fabric, and the mesh size of the screen. Thesupplier will make allowances for the proper amount of stretch inthe screen.

Stapled-On At tachment Instructio ns

Tools and Materials Required:• Light-Duty Hammer• Awl/Staple Remover• Duckbill Jaw Screen Stretching Pliers• Staple Gun• Diagonal-Cutting Pliers

Photo 1: Screen Replacement Using the Stapled-On Attachment Method

Read all instructio ns beforebeginning this process.


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Figure 1: Stapled-On Attachment Diagram

Although tacks can be used fo r sc reen attach ment, Great Western recommendsusing a good pneumatic or mechanical staple gun. Staples should have a 1/2” -wide crown with a 3/8” leg length. Staples shou ld be installed at a 45° angle.

□ When removing or replacing screens, use a clean, flat, stable work surface.

□ Remove all old screen and staples, using an awl or staple remover, from the tacking frame. Ensure that thebackwire is tightly stapled to the frame and cross pieces. Also, check the sieve compartment liners for areasthat are missing or loose. All cleaners that are badly worn should be replaced.

□ Place the screen on the tacking frame so it is square against the head-end and the right-side. Staple that

corner with 2 or 3 staples, 1/2” to 1” apart. See Figure 1, Position A.

Great Western recommends using a crossed staple pattern on the corners of thescreen.

□ Using screen pliers, pull the screenacross the right-side as tightly aspossible and staple at the right-side,throat-end corner. See Figure 1,Position B. Staples are then installedacross the right side, 1/2” to 1” apart, andat a 45° angle. See Figure 1, Position C.

□ The head-end of the screen is stretchedto the left-side using the pliers until tight,and then stapled at the left-side, head-end corner. See Figure 1, Position D.Staple the head-end with staples 1/2” to1” apart and at a 45° angle. See Figure1, Position E.

□ Using the pliers, stretch the left-handside of the screen to the throat, placingstaples at the left-side, throat-end corner.See Figure 1, Position F. Pull with theawl or pliers ( Great Western recommends the use of an awl with wirescreen, and the pliers with syntheticscreen) to stretch the screen toward theleft-side. Begin at the head working to the throat, stapling at 1/2” to 1” intervals and at a 45° angle. SeeFigure 1, Position G.


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If the screen pu ckers at t he end, remove the staple(s) and restretch the end.

□ With the awl or pliers ( Great Western recommends the use of an awl with wire screen, and the pliers withsynthetic screen), tightly stretch the throat side of the screen. Work from the left-side to the right-side with thestaples 1/2” to 1” apart and at a 45° angle. See Figure 1, Position H.

The screen, when pressed down firmly with one finger, should depress no more

than 1/2” .

Looped-Edge Attachment Instruction s

Read all instructions before beginning this process.

Tools and Materials Required:• Smooth, Flat, Clean Plywood (or equivalent)• Large Slotted Screwdriver (blade should have rounded edges)• Large Pair of Slip-Joint Pliers (teeth ground to match contour of rods)• 1/8” Allen Wrench• Light-Duty Hammer

□ When removing or replacing screens, use a clean, flat work surface. Place a piece of plywood on the worksurface. The plywood must be cut to the size of the tray or up to 1” greater than the sides of the tray.

□ When removing screens, place the tray, with backwire side up, on the plywood. Loosen all set screws.Remove loops (containing rods) from the grooves of the tray. Lift tray off of screen. Remove cleaners andremove rods from loops.


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□ When replacing screens, put the screen, looped edge up, on the plywood. Slide the appropriate size rod intoeach loop.

□ Place cleaners on the screen, ensuring all are in compartment areas, and not on wear strips. With set screwspartially tightened, place tray over cleaners, backwire side up and centered on the screen (centering both therods and tray is extremely important).

□ Beginning with the corner of sides AD, bring rods of sides A and D up and over the edge of the tray untilseated in the groove of the tray. Tighten only the corner set screws, just enough to hold rod in groove. Do nottighten securely. Repeat this procedure in this order: Corners AB, BC, and CD (Note: If you cannot tighten theremaining corners by hand, use the rounded-tip screwdriver. Place tip of screwdriver between rod and edgeof tray. Using the tray edge as a leverage point, pry out and up on the rod).

□ While prying, keep pressure against the rod with the thumb of opposite hand. Bring the loop out and up farenough to clear the edge of the tray. Be careful not to pry too hard: this may cause damage to the screen.

□ Push the rod into the groove of the tray, tapping lightly with a hammer, if needed. While partially tightening setscrews, use slip-joint pliers to squeeze and hold the rod into the groove of the tray. (Ensure pliers are grippingthe plywood, not the screen.)

□ After partially tightening all corner set screws, partially tighten side set screws. Finally, securely tighten allcorner and side set screws. Return the tray to the Sifter.

Figure 2: Looped-Edge Tray Diagram


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Photo 2: Screen Replacement Using the Looped-Edge Attachment Method


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Lubrication ScheduleLBS

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Always lock out the electr ical power before lubricat ing the Tru-Balance Box-TypeSifter.

Under Normal Operating Conditi ons

The following should be lubricated with Mobilux® EP2 grade grease or a proven, compatible equivalent every 60days:

• 8 Pillow-Block Bearings• 2 Tie-Bar Bearings

Photo 1: Pillow-Block Bearing

Photo 2: Tie-Bar Bearing


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Lubrication ScheduleLBS

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The following should be lubricated with an anti-seize lubricant ( Great Western recommends the use of LoctiteFood Grade Anti-Seize, Part Number 51168) or a proven, compatible equivalent every 60 days:

• 2 Shafts of Pinion Assembly (Rack and Pinion Clamping System)• 2 Upper Eccentrics (Pneumatic Clamping System)

Under Severe Condition s

When operating in an extremely dusty environment, lubricate all bearings and lube points more frequently.

Photo 4: Upper Eccentric(Pneumatic Clamping System)

Photo 3: Pinion Assembly(Rack and Pinion System)


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Removing, Installing, Ad justing , andMaintaining the Tie-Bar

MTB(TBB)1 of 3

The Tru-Balance Box-Type Sifter is provided with a tie-bar assembly to synchronize the Sifter’s two

counterweights.

Do not attempt to operate the Sifter with the tie-bar assembly loose ordisconnected.

□ When removing, installing, or adjusting the tie-bar,begin by positioning the Sifter’s counterweights so thatboth are parallel and facing the rear of the machine asshown in Photo 1. Both throw blocks should be

positioned in the same direction, facing to the right ofthe Sifter.

Removing the Tie-Bar

□ Loosen the throw block clamping bolts with a 9/16”wrench as shown in Photo 2.

□ Remove the tie-bar and throw blocks as one unit.

Photo 2: Throw Bloc k ClampingBolt

Photo 1: Counterweight Placement


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The original tie-bar equipped on a new Sifter will arrive from the factory pre-adjusted; h owever, replacement tie-bars w ill need adjustment.

Installing the Tie-Bar

□ Loosen the set collar.

□ Position the tie-bar (with the throw blocks attached) under the Sifter and lift towards the Sifter from both ends.

□ Slide the throw blocks on to their respective shafts; ensuring that the key slot located in the throw block aligns

with the key located in the shaft.

□ Continue to slide the throw blocks up the shafts until the bottom of each shaft and the bottom of each throwblock are flush.

□ Securely tighten both throw block clamping bolts as shown in Photo 2.

Adjust ing the Tie-Bar

The preferred method for adjusting the tie-bar consists of aligning and adjusting the length of the tie-bar.

□ Adjust the tie-bar using the counterweights to rotate the Sifter to top dead center position, allowing the tie-bar

to adjust itself to the proper length.Tighten the set collar and rotatethe Sifter by hand. The machineshould freely rotate.

□ If tight spots in the rotation aredetected, first inspect the tie-barassembly for possible problems. Ifno apparent physical problemsexist, perform the followingalternate tie-bar adjustmentprocedure:

□

With the counterweights properlypositioned parallel towards the rearof the Sifter and the throw blockspointing to the right, place astraight edge that is long enough tospan the width of the Sifter acrossboth of the throw blocks. Thisstraight edge placement isdepicted in Photo 3.

Photo 3: Straight Edge Placement


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MTB(TBB)3 of 3

The tie-bar is properly adjusted when the straight edge is flat against both throwblock edges.

□ Adjustment of the length of the tie-bar may be necessary to align the tie-bar. One end of the tie-bar isequipped with a split set collar. This is the side from which the length adjustment takes place.

□ Loosen the socket head screw located in the set collar with a socket wrench. This will adjust the length of thetie-bar.

□ After performing the tie-bar length adjustment, check the alignment with a straight edge as described above.

□ When the alignment is correct, retighten the socket head screw located in the set collar with a socket wrench.

□ Check for freedom of rotation.

Maintenance

Great Western recommends lubricating the bearings on the ends of the tie-bar a minimum of every 60 daysand/or per plant maintenance schedule.


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Tru-Balance Box-Type GuardsJTG

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The guard package on the Tru-Balance Box-Type Sifter has been designed to allow for easy access to itscomponents.

The Sifter’s guard package consists of front/back shields and end guards.

Proper installation of the guard package is necessary for safe operation. Do notattempt to run the Sifter when any component of the guard package is removed.

Proper lock-out, tag-out procedures must be followed when any component of the

guard p ackage is removed.

Removing the Front/Back Shields

□ Lift the shield using the providedhandles as shown in Photo 1. It isonly necessary to lift the shield to theextent that it clears the bottombrackets.

□ Angle the bottom of the shield awayfrom the Sifter.

□ Slide the shield down and out fromthe Sifter.

Photo 1: Removing theFront/Back Shields


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Removing the End Guards

□ Loosen the top set of screws from the guard. Thetop screws are identified by the keyhole slot asshown in Photo 2.

□ Remove the bottom set of screws from the guard.

□ Lift and slide the guard up through the keyholeslot.

□ Angle the top of the guard out and away from theSifter and remove as shown in Photo 3.

Photo 3: Removing t he Side Guards

Photo 2: Top Screw and Keyhole Slot


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Replacing the Guards

□ Reverse the guard removal procedure for replacement.

The motor guard can be removed individually or kept attached to the larger endguard.

Smaller Sifters have two (2) end guards , one (1) on each end. Larger Sifters mayhave four (4) end guards , two (2) on each end. Regardless, the procedure forremoving all end g uards is th e same.

Do not attach or weld items to the guards. These actions interfere with the properuse of th e guards.


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Sifter BalanceSB

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The Tru-Balance Box-Type Sifter was assembled and tested at the factory before shipping. It has been balancedto minimize vibration or movement. If after installation the Sifter does not run smoothly, review the VibrationTroubleshooting section of this manual for a listing of the most common causes.

Some of the typical problems that occur during installation and initial start up are:

• The mounting platform could be too weak for the Sifter and its load.

• The Sifter is not securely fastened and leveled to the floor or ceiling.

• The tie-bar is out of adjustment.

• The screen frames (trays) are not in the Sifter.

• The Sifter has become overloaded.


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TroubleshootingT

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Always lock out motor.

Never run the Tru-Balance Box-Type Sifter without guards.

Never run the Sifter without sieve frames and trays.

Don’t start the Sifter without notice.

Problems and Possible Causes:

Leaking or Dusting-Out: Sieve frames not tightened. Connecting socks damaged or improperly installed. Improper sieve alignment. Sieve frame damaged.

No Overs: Broken or damaged screen. Sieves turned wrong or improperly installed.


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TroubleshootingT

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Excessive Overs (Overs Contain Too Much Product):

Load to sifter or product changed. Screens blinded. Screens too loose. Sieves turned wrong or improperly installed.

Sifter Backs Up and Chokes the System: Sieves turned wrong or improperly installed. Screens blinded. Cleaners worn out. Change in sifter load. Failing system after the sifter.

Pneumatic Clamping System Not Functionin g (If Installed): Inadequate air pressure. Ruptured air line. Faulty cylinder.

Rack and Pinion Clamping System Not Functioning (If Installed): Excessive pinion slippage (often makes a popping noise). Can be caused by either a deformation of the

wooden press-top or a worn rack and/or pinion. Collar digs into chrome plate. Spring and/or ball may need to be replaced.

Machine Will Not Run: Front/back shields not properly seated in the brackets.

Excessive Vibration: See the Vibration Troubleshooting section of this manual.

For further questions concerning troubleshooting the Sifter, contact a Great Western representative.


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Vibration TroubleshootingVT

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• Broken Drive Component. If the upper or lower carrier drive frames or any of the four bearing frame supportarms have broken, a mechanical punch or vibration will result when operating the Sifter. Due to the precisionto which these Sifters are manufactured, it is not possible to weld the broken components; they must bereplaced. Also verify that the knuckle has not broken loose from the weight bucket. If it has, the entire bucketassembly should be replaced.

• Out of Balance. Verify that the lead weights and wooden spacers are in the bucket in the number andsequence shown by checking the weight chart on the weight buckets. Generally, if the housing, sieves, andweights in the weight bucket have not changed, then the originally balanced Sifter will remain in balance.


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Technical DataTD

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TBB-100 Series TBB-200 Series TBB-300 Series TBB-400 Series

Dimensions:(W x D x H)

Inch

Centimeter

67 x 39 x(43 to 75)

170 x 100 x(109 to 191)

75 x 53 x(43 to 75)

191 x 135 x(109 to 191)

78 x 63 x(43 to 75)

199 x 160 x(109 to 191)

82 x 56 x(43 to 75)

208 x 142 x(109 to 191)

SpaceDemand:

(W x D x H)

Inch*

Centimeter*

103 x 100 x(79 to 111)

262 x 254 x(201 to 282)

111 x 120 x(79 to 111)

282 x 305 x(201 to 282)

114x 143 x(79 to 111)

290 x 364(201 to 282)

118 x 133 x(79 to 111)

300 x 338 x(201 to 282)

Total Weight: (with Crating)

Pound

Kilogram

≈ 1900

≈ 862

≈ 2150

≈ 975

≈ 2600

≈ 1180

≈ 3200

≈ 1452

ElectricalData:

Voltage

Horsepower

230/460

1.5

230/460

1.5

230/460

1.5

230/460

1.5 (2 Count)

Space Demand: Ensure adequate space is in fr ont o f, behind, and on each sid e ofthe Tru-Balance Box-Type Sifter for proper safety, operation and maintenance.These dimensions reflect the space needed to remove the sieves plus anadditional 18” all around the Sifter.


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Technical DataTD

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TBB-100 Series TBB-200 Series TBB-300 Series TBB-400 Series

NoiseEmission: < 85 dB(A) < 85 dB(A) < 85 dB(A) < 85 dB(A)

PneumaticData:

MinimumPressure

MaximumPressure

Quality

100 psi5.5 bar

120 psi8.3 bar

Dry, Oil Free

100 psi5.5 bar

120 psi8.3 bar

Dry, Oil Free

100 psi5.5 bar

120 psi8.3 bar

Dry, Oil Free

100 psi5.5 bar

120 psi8.3 bar

Dry, Oil Free

SieveDimension:

Inch

Centimeter

24-11/16 x 24-11/16

63 x 63

30-7/8 x 30-7/8

78 x 78

30-7/8 x 40-7/8

78 x 104

40-7/8 x 40-7/8

104 x 104

SpoutingDiameter:

Inch

Centimeter

4 to 6

10 to 15

4 to 6

10 to 15

4 to 6

10 to 15

4 to 6

10 to 15


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Technical DataTD

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Ambient Condi tion s:(For All Models) Transport and Storage Operation

Operating Temperature:

Humidity:

Installation Location:

Normal Room Temperature

Dry, Roof Over

Read Transport Instructions onPacking

Normal Room Temperature

Dry, Roof Over

Horizontal, Solid Foundation


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Parts L istPL

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42 Microswitch43 Microswitch Mounting Bracket44 Motor Guard


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Parts L istPL

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Parts L istPL

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Parts L istPL

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Parts L istPL

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