PPM Ultra User manual

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Ultra and Ultra Direct Conveyors
Installation
Operation and
Maintenance
Manual

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PPM Contact information:
AMERICAS EUROPE|MIDDLE EAST|AFRICA ASIA
PPM TECHNOLOGIES PPM TECHNOLOGIES EMEA PPM TECHNOLOGIES
500 E. Illinois St. Axis 40 Oxford Rd 3/F Taiseido Bldg
Newberg, OR 97132 | USA Stockenchurch 2-4-7 Hongo
[phone] toll free in the US NR High Wycombe Bunkyo-ku | Tokyo 113-0033
[phone] fax Buckinghamshire HP14 3SX | UK JAPAN
[phone] [phone]
[phone] fax [phone] fax
Webpage: www.ppmtech.com
Email: [e-mail]
Drawing P/N SM1082 Printed in the USA
Manual Revision Log
REV #
DATE
CHANGE DESCRIPTION
PG # MODIFIED
BY
0
10/27/03
Updated manual revision log
2
NJD
1
4/2/04
Added P/N & date to header
All
NJD
2
9/3/04
Safety Sling Information
All
NJD
3
2/8/08
Updated to PPM Technologies
All
SS
4
12/13/10
Updated office locations
2
DER
PPM Technologies reserves the right to alter at any time, without notice and without liability or other
obligations on its part, materials, equipment specifications, and models. PPM Technologies also reserves
the right to discontinue the manufacture of models, parts, and components thereof.

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SECTION
1 INTRODUCTION
1.1 Safety Instructions.................................................................................................................4
1.2 Special Considerations..........................................................................................................5
1.3 Description............................................................................................................................5
2 INSTALLATION
2.1 Long Term Storage................................................................................................................7
2.2 Site Preparation.....................................................................................................................7
2.3 Equipment Installation ..........................................................................................................8
2.3.1 Installation Equipment and Tools.............................................................................9
2.3.2 Support Erection.......................................................................................................10
2.3.3 Isolators and Isolator Support Brackets....................................................................12
2.3.4 Conveyor Installation and Isolator Adjustment........................................................17
2.4 Electrical................................................................................................................................17
2.4.1 Conduit strain relief orientation ...............................................................................18
2.4.2 Polarity/Motor Rotation ...........................................................................................19
2.4.3 Variable Frequency Drive........................................................................................19
2.5 Safety Sling Information .......................................................................................................19-20
3 OPERATION
3.1 Operational Limits.................................................................................................................21
3.2 Unusual Motion.....................................................................................................................22
3.3 Tuning ...................................................................................................................................23
3.3.1 Measuring the Stroke................................................................................................24
3.3.2 Checking the Speed..................................................................................................25
3.4 Accessories............................................................................................................................26
3.4.1 Covers.......................................................................................................................26
3.4.2 Pneumatic Gates.......................................................................................................26
3.4.3 Screen Cloth.............................................................................................................26
3.4.4 Adjustable Diverters, Clamped-in Screen Panels, etc..............................................26
4 MAINTENANCE
4.1 Preventative Maintenance .....................................................................................................27
4.1.1 Recommended Tools................................................................................................27
4.1.2 Maintenance Schedule..............................................................................................28
4.1.3 Leaf Springs .............................................................................................................29
Table 1 Spring Usage on Cast Spring Brackets........................................................30
4.2 Troubleshooting –Ultra Conveyor: (Units with fiberglass leaf springs).............................31
4.3 Troubleshooting –Ultra Direct Conveyor: (Units with no leaf springs)..............................32
4.4 Mechanical Disassembly/Assembly......................................................................................33
4.4.1 Removal and Replacement of the Drive...................................................................34
4.5 Electrical Disassembly/Assembly.........................................................................................35
4.6 Recommended Spare Parts....................................................................................................36
Table 2 Spare parts list..........................................................................................................36
Table 3 Torque Specifications............................................................................................................36
TABLE OF CONTENTS

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INTRODUCTION
1 PPM TECHNOLOGIES ULTRA FEEDER CONVEYORS
Thank you for buying your equipment from PPM Technologies. This service instruction manual will help
you to understand how your equipment operates and what is required to maintain peak performance.
Please read it thoroughly and keep it on file for reference. Your satisfaction is very important to us.
Please direct any comments, questions or concerns to our Service Department.
Date Purchased:
Serial No.:
Factory Order No.:
General Arrangement Drawing No.:
1.1 SAFETY INSTRUCTIONS
WARNING: PPM Technologies is not liable for any damage or reduced
performance that may occur as a result of improper equipment assembly
and installation, or due to unauthorized alterations. Such actions will
void any and all warranties.
WARNING: These instructions and safety precautions must be followed.
There is danger of electrical shock to the operator.
WARNING: The unit must be properly grounded and verified at
installation.
WARNING: The electrical power supply connection to the PPM-supplied
unit must be made through a customer-supplied safety disconnect
switch. Incorporation of an emergency stop may also be required,
according to local codes.
Product safety labels must be highly visible on the equipment. Check
visibility regularly. If safety labels need replaced, contact PPM
Technologies for an additional supply free of charge.
Supporting information that may be attached (e.g., drawings) takes
precedence over corresponding information printed in this manual.
CAUTION: Local safety codes and regulations must be considered when
installing and/or operating this equipment.

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INTRODUCTION
Safety is a basic factor in the maintenance and operation of Ultra and Ultra Direct Vibrating Conveyors.
Proper clothing, tools and methods of handling can prevent serious injury to you or a fellow worker. A
number of safety precautions are listed throughout this manual. Please study and follow the precautions
and insist that your coworkers to the same.
1.2 SPECIAL CONSIDERATIONS
Each conveyor by design has components or properties that may require special consideration. These
items are noted here to avoid potential problems when operating or servicing Ultra and Ultra Direct
conveyors.
Ultra and Ultra Direct conveyors are dynamically balanced machines; it is imperative that no
weight be attached in any way as it may negatively affect performance and void the warranty. A
one-inch (25 mm) clearance must be maintained at all points so that there is no contact while the conveyor
is operating.
Do not lubricate the drive bearings with food grade grease. Please refer to the VIBRATOR
MANUAL (M3286FMC) section for further information.
1.3 DESCRIPTION
PPM Technologies Ultra and Ultra Direct are dynamically balanced, vibrating conveyors. Material is
conveyed along the trough in a rapid succession of short hops by the vibratory action of the conveyor.
The vibration is generated by a pair of counter-rotating electric motors with unbalanced shafts. The
motors (vibrators) synchronize as they come up to speed to produce straight-line motion in the trough.
The trough on an Ultra conveyor is supported and guided by a tuned fiberglass leaf spring system that is
mounted on a base (see Figure 1.) The two vibrators are also mounted on the base. The base is supported
on a set of isolation springs. During normal operation, there is minimal motion of the base, and therefore,
negligible forces transmitted to the support structure. Because it is a tuned system, the trough stroke of
Ultra conveyors varies with speed. The higher the speed, the larger the stroke will be. The base stroke
also varies with speed, and will be approximately zero at the design speed of the unit.
Ultra Direct conveyors (see Figure 2) are direct drive type units and do not have fiberglass leaf springs.
The vibrators are mounted directly to the trough. The stroke of the Ultra Direct conveyor does not vary
with speed. The trough is mounted on a set of isolation springs to minimize the dynamic loads to the
support structure.

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INSTALLATION
Trough
Leaf Spring
Base
Isolation System
Direction
of Vibration
Vibrator
Flow
Figure 1: PPM Technologies Ultra Conveyor
Trough
Base
Vibrator
Springs
Figure 2: PPM Technologies Ultra Direct Conveyor

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2 INSTALLATION
2.1 LONG TERM STORAGE
Ultra and Ultra Direct Conveyors should be stored indoors. If stored off-site, place on cribbing, cover
with plastic, and remove motor to an inside storage area. Rotate the shafts periodically.
2.2 SITE PREPARATION
The Ultra and Ultra Direct Conveyors’ isolation system is designed to prevent transmission of dynamic
loads to the support structure. However, the natural frequency of the support structure must not be too
close to the operating speed of the conveyor. This condition results in large support structure
displacements and stresses that may cause failure of the support structure. The natural frequency of the
support structure must be greater than or equal to 1.5 times the operating speed of the unit. Also,
the support structure design should limit the calculated dynamic deflections to 0.004 inches (0.1
mm) in all directions. Static and dynamic forces for each conveyor can be obtained from the general
arrangement of the unit.
Regardless of whether this equipment is installed at grade level, elevated, or on upper floors, the mounting
surfaces at the location of the coil spring isolators must be level or at a uniform slope, within 1/16
inches (1.6 mm). Grade 5 bolts (minimum) are recommended for connections to elevated steel work.
When designing the site layout for the conveyor system, it is important that a one-inch (25 mm) clearance
be maintained at all points. It is also important to provide clearance in the layout for drive (and drive
guard) removal and accessing the drive for maintenance. Avoid severe inclines that reduce the capacity of
the conveyor.
Ultra and Ultra Direct Conveyors are designed to operate in wet or dry environments. The ambient
temperature should be between 0F (-18C) and 110F (43C). NOTE: Ambient and product
temperatures must be specified when ordering a conveyor.
The air supply (if required) must be clean, dry or slightly oily, and regulated. Normally 80 psi is more
than adequate for accessory operation. (For additional information, see ACCESSORIES.) Refer to the
drawings supplied with each order for specific air pressure recommendations.
WARNING: PPM Technologies is not responsible for damage or personal
injury resulting from improperly designed or constructed supports.
Installation of the conveyor on improperly designed or constructed
supports will void any and all warranties.

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INSTALLATION
2.3 EQUIPMENT INSTALLATION
INSTALLATION
NOTE: The natural frequency of the support structure must be greater than or equal to 1.5
times the operating speed of the unit. The support structure design should limit the
calculated dynamic deflection to 0.004 inches (0.1 mm) in all directions. Isolation
forces for each model can be obtained from the factory.
WARNING: PPM Technologies is not responsible for damage or personal
injury resulting from improperly designed or constructed supports.
Installation of the conveyor upon improperly designed or constructed
supports will avoid any and all warranties.
CAUTION: Do not make any alterations to the conveyor without first
contacting PPM Technologies. PPM Technologies will not assume any
responsibility for poor conveyor performance or mechanical failure as a
result of unauthorized alterations to the equipment. Such actions will void
any and all warranties.
CAUTION: Local safety codes and regulations must be considered when
installing and/or operating this equipment.

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INSTALLATION
If rubber seals are installed between the pans of in-line conveyor units, contact should not restrict the
motion of the machines. Freedom of motion should be checked in both the loaded and unloaded
conditions.
NOTE: Due to the short burst of high inrush current that occurs when starting Ultra and
Ultra Direct Conveyors, it is recommended that slow-blow type fuses be used to avoid
nuisance tripping.
2.3.1 INSTALLATION EQUIPMENT AND TOOLS
The following equipment and tools are required or recommended for conveyor installation:
•Transit
•Crane or forklift and come-along
•Lifting straps
•Digital level
•Tape measure
•Plumb bob
•Chalk line
•Heavy duty drill and masonry bits
CAUTION: Isolation cables must not come into contact with the isolation
bracket or any surrounding structures. Do not exceed inclines or declines
shown on the General Arrangement drawing provided with the conveyor.
CAUTION: The conveyor must not come into contact with any rigid object
or adjacent surface that could hamper its vibrating action. A one-inch (25
mm) clearance must be maintained.
CAUTION: The rubber components of the conveyor must not be exposed to
oil or to an oil intense atmosphere.

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2.3.2 SUPPORT ERECTION
Before starting, review all equipment drawings for specific installation instructions, support loads, and
dimensions. Lay out conveyor centerlines first, and then lay out support centerlines with a chalk line.
Position supports on centerlines and transfer hole locations from supports to the floor. Drill holes for
anchor bolts based on recommendations by the anchor bolt manufacturer. Insert the anchor bolts in the
holes, and place supports into position. Using a transit, place steel shims at each anchor bolt location to
raise supports to the proper elevation, making sure to allow one inch for installation of grout. (See Figure
3a.) Plumb the supports with shims, using a plumb bob or digital level. Tighten anchor bolts and recheck
plumbness and hole centers at the top of the supports. After all bolts are tightened, install non-shrinking
grout between floor and bottom of support.
Isolation System
Direction of
Vibration
Flow
See Fig. 3b for
Mounting Details
Figure 3a: Typical Floor-Mounted Installation

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Figure 3b: Floor Mounting options

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2.3.3 ISOLATORS AND ISOLATOR SUPPORT BRACKETS
The isolation system can be either floor-mounted or suspension-mounted. The base isolator bracket that is
furnished for a floor-mounted isolation system is different from the suspension-mounted isolation system
bracket. Therefore, the type of isolation system (floor-mounted or suspension-mounted) must be specified
when the conveyor is ordered from PPM Technologies.
Isolation system
Suspension cable
(Do not use rods!)
Direction of
Vibration
Flow
Figure 4: Typical Suspension-Mounted Installation

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INSTALLATION
Figures 5 and 6 on the following pages illustrate typical cable isolation assemblies. If the cable isolation
assembly is not as shown, contact PPM Technologies. The isolators are shipped loose and must be
assembled. The coil springs and rubber springs must be seated in the spring retainers.
For suspended units, the top isolator bracket must be attached to a rigid structure. Clamp the top isolator
bracket tight using a Grade 5 bolt (minimum).
Base-mounted conveyors may use rubber springs for the isolation system. Figure 7 shows side-mounted
isolators. In this configuration, it is critical that the springs be installed with the word “TOP” on the side
face and the arrow pointing upwards. Figure 8 shows bottom-mounted isolators. In this configuration, it
is critical that the springs be installed with the lean of the isolators opposing each other.
On most units, isolator stiffness corresponds to a specific location. The coil spring isolators have a color-
coded stripe on them and the rubber isolators have the stiffness designation, K1 through K8, molded into
the side of the rubber. Refer to the General Arrangement drawing supplied with the conveyor to
determine the proper location of each pair of isolators.
CAUTION: After the isolator is assembled, at least one full thread on the
cable fitting must protrude through the locknut.
For both floor-mounted and suspended isolation systems, conveyor
installation must include a final adjustment to ensure that the isolators are
loaded equally on the left and right sides of the conveyor.
CAUTION –Safety cables should be installed on all units that are in areas
where person can walk under suspended units. Failure to do so could result in
severe injury.

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INSTALLATION
Coil spring
Coil spring cap
and locknut assy
Snubber
Suspension
cable
Hex head
cap screw
Locknut
Isolator
bracket
Locknut
Adjusting nut
Rubber element
Neoprene-backed
washer
Figure 5: Typical Floor-Mounted Isolation Assembly

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INSTALLATION
Coil spring cap
and locknut assy
Snubber
Thimble
Neoprene-
backed washer
Rubber element
Adjusting nut
Locknut
Isolator bracket
Spring retainer, ref
Wire rope clip
(Install saddle on live end)
Suspension cable
Coil spring
Top isolator bracket
Figure 6: Typical Suspension-Mounted Isolation Assembly

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INSTALLATION
Flow
Vibration direction
Rubber
Isolation
Figure 7: Side-mounted Isolators
Flow
Vibration direction
Rubber
Isolation
Figure 8: Bottom-mounted Isolators

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2.3.4 CONVEYOR INSTALLATION AND ISOLATOR ADJUSTMENT
When lifting the conveyor, make sure that the lifting straps straddle the center of gravity of the conveyor
to ensure a safe lift. To ensure a safe lift on cable-isolated conveyors, the unit can be lifted by wrapping a
chain around the isolator bracket, as long as the chain angle is within 30of vertical. NOTE: Use edge
protectors around sharp edges, and a spreader bar above the trough to prevent bending the sheet
metal. Lift the conveyor into position and install the isolators in the proper locations.
On cable-isolated conveyors, check for even loading on the isolators by measuring the compressed height
of the coil springs. The height of the coil springs should be the same from one side of the conveyor to the
other within 1/8 inch (3.2 mm). For each pair of suspension cables, the left-side cable should have the
same tension as the right-side cable. This can be gauged by pushing and pulling laterally on the cables.
Also, check the side-to-side levelness of the conveyor with a level. If adjustment is required, lift the
conveyor off of the coil springs by an inch or two (25 or 50 mm), and adjust the effective length of the
cable by turning the adjusting nut at the bottom of the cable. Set the conveyor back down on the coil
springs. Re-check all isolator locations and repeat the process, if required.
IMPORTANT: For conveyors located above floor level that are suspension-mounted, PPM
Technologies requires that safety cables be installed around the conveyor.
2.4 ELECTRICAL
INSTALLATION
WARNING: Do not use rods for suspending the conveyor PPM
Technologies is not liable for any damage or reduced performance that
may occur as a result of improper equipment installation, or due to
unauthorized alterations. Such actions will void any and all warranties.
WARNING: These instructions and safety precautions must be followed.
There is danger of electrical shock to the operator. The unit must be
properly grounded and verified at installation.
WARNING: The electrical power supply connection to the PPM
Technologies-supplied unit must be made through a customer-supplied
safety disconnect switch. Incorporation of an emergency stop may also
be required, according to local codes.
WARNING: The electrical power supply must be of sufficient size to carry
the current designated on the equipment nameplate.
WARNING: Do not attach electrical conduit to the conveyor. PPM
Technologies is not responsible for poor conveyor performance as a
result of unauthorized alterations. Such actions will void any and all
warranties.

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INSTALLATION
The electrical power supply must not vary beyond the standard IEEE tolerance of +10% / -6%.
NOTE: Due to the short burst of high inrush current that occurs when starting Ultra
and Ultra Direct Conveyors, it is recommended that slow-blow type fuses be
used to avoid nuisance tripping.
Position conduit box
strain relief fitting so
it points towards the
ground
Figure 9: Conduit Box Orientation
2.4.1 ULTRA DRIVE CONDUIT BOX CABLE ORIENTATION
Extra caution must be taken to ensure that the ultra vibratory drive enclosure remains watertight. The
vibratory drive is a self-contained unit. A possible water entry point is at the strain relief fitting where the
power cable enters the conduit box. To keep this point water tight, the vibratory drive must be installed so
that the strain relief fitting is oriented so that it points towards the ground (see figure 9.)

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INSTALLATION / OPERATION
2.4.2 POLARITY/MOTOR ROTATION
The motors must be wired to rotate in opposite directions when mounted on the machine. This is
normally addressed at the motor conduit box. Therefore, the connections at the junction box will have
like-colored wires on the same terminals.
If the conveyor does not produce a smooth straight-line motion after several seconds of operation,
immediately turn off the conveyor. Lock out the power and reverse any two of the leads (except the
ground lead).
2.4.3 VARIABLE FREQUENCY DRIVES
Variable frequency drives must be of the pulse-width-modulated type. The current rating of the VFD
must be 1.25 times the sum of the current ratings on the two vibrators.
In order to avoid resonant frequency problems, the acceleration time should be set to 1 to 2 seconds and
the deceleration time should be set to 2 to 4 seconds.
WARNING: Never adjust the frequency above 60 Hz without consulting the PPM
Technologies; serious machine damage and or personal injury will result.
2.5 SAFETY SLING INFORMATION
- For Information Purposes Only -
Safety cables should be used on all PPM Technologies equipment that is either: (i) hung from the ceiling; or (ii) mounted in
any other area that could result in bodily or physical harm should the unit become dislodged from its mounting position. Below
are basic guidelines that PPM Technologies suggests for using safety cables.
1. PPM Technologies recommends installing safety cables at each conveyor support location. On short equipment
use at least two (2) safety cables spread far enough apart to equally distribute the conveyor’s weight.
2. Safety cables should be wrapped around the base, unless there is a chance that the cable could slip off under
dynamic loading, in which case it is recommended to wrap the cable between the trough and base as close to the
conveyor as possible without coming in contact with the conveyor as it vibrates.
3. On most PPM Technologies models, use at least ¼” diameter coated wire rope (5/16” O.D.) for the safety slings,
rated at a minimum breaking strength of 7000 lbs.
4. If using cable clamps, make sure that the load bearing side of the safety cable is on the nut/saddle side of the
clamps. Use a minimum of three clamps on each cable end. 5/16” diameter wire rope cable clamps should be
torqued to a minimum of 30 ft-lbs.
5. On FMC/Allen Models: BL, LBL, Dynatron, Magnatron, and Vastron use 3/8” diameter coated cables (7/16” O.
D.). 7/16” diameter wire rope cable clamps should be torqued to a minimum of 65 ft-lbs.
6. Safety cables must be secured to existing building ceiling structure. Fastening must be done in the manner
specified by the manufacturer(s) of the fastener and safety cable. Installation must be done only by a certified or
otherwise qualified person experienced in this type of installation. Structural integrity and installation shall be the
responsibility of “others” and not PPM Technologies.
WARNING: Before performing any maintenance, the electrical power
supply must be disconnected at the safety disconnect switch.

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REQUIREMENTS
•Safe Work Load. The safe working load of the wire rope slings must not exceed rated capacities. Installation by “others”
should follow the wire rope sling manufacture’s recommended safe working load for the specific angle of loading,
provided that you maintain a safety factor of five (5).
•Environmental Effects. Do not expose fiber core wire rope slings to temperatures above 180 ºF. Consult sling
manufacturers before using slings in chemically active environments or in temperatures above 400 ºF or below -60 ºF.
•A preventive maintenance program should be established based on all applicable manufacturers’ recommendations
and/or experience gained from use of the equipment. The program shall include procedures and a scheduling system for
normal periodic maintenance items, adjustments, replacements, and repairs. The program shall also ensure that records are
kept and unsafe test and inspection discrepancies are documented and corrected. The need to repair or replace slings shall
be determined by a certified or otherwise qualified person based on an evaluation of inspection results.
Disclaimer
PPM Technologies and its agents to ensure the accuracy and reliability of the information contained in this reference guide
have put every reasonable effort forth. However, neither PPM Technologies, its agents, nor its consultant(s) make any effort
representation, warranty, or guarantee in connection with the publication of these recommended methods and procedures. PPM
Technologies hereby disclaims any reliability for loss or damage resulting from their use; for the violation of any federal, state,
county, or municipal regulations with which these recommended methods and procedures may conflict; or for the infringement
of any patent resulting from use of these recommended methods and procedures. These handling and installation instructions
are not intended to preclude normal safety procedures, which should be followed to prevent injury to personnel. SAFE
INSTALLATION PROCEDURES SHALL BE ENTIRELY THE RESPONSIBILITY OF THE INSTALLER.
IN NO EVENT SHALL FMC/ALLEN BE LIABLE FOR CLAIMS OF PERSONAL INJURY OR FOR SPECIAL,
INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF
PROFITS OR REVENUE, LOSS OF USE OF THE CONVEYOR OR ANY ASSOCIATED EQUIPMENT, COST OF
CAPITAL, COST OF THE SUBSTITUTE EQUIPMENT, FACILITIES OR SERVICES, DOWNTIME COST, CLAIMS OF
CUSTOMERS OF THE OWNER FOR SUCH DAMAGES, OR FOR DAMAGE TO PROPERTY, WHETHER SUCH
CLAIM SHALL BE FOR BREACH OF CONTRACT, BREACH OF WARRANTY, NEGLIGENCE OR STRICT
LIABILITY, AND WHETHER SUCH CLAIM ARISES OUT OF OR RESULTS FROM THIS LIMITED WARRANTY, OR
EXPRESS OR IMPLIED WARRANTIES, OR FROM THE DESIGN, MANUFACTURE, SALE, DELIVERY, RESALE,
INSTALLATION, TECHNICAL DIRECTION OF INSTALLATION, INSPECTION, REPAIR, OPERATION OR USE OF
THE CONVEYOR OR SAFETY CABLES.
All specifications are subject to change without notice.