OPERATING INSTRUCTIONS Superpave Gyratory Compactor 45

Superpave Gyratory Compactor
45-6750
OPERATING INSTRUCTIONS
Superpave Gyratory Compactor
45-6750
ELE International
Chartmoor Road, Chartwell Business Park
Leighton Buzzard, Bedfordshire, LU7 4WG
England
phone: +44 (0) 1525 249200
fax: +44 (0) 1525 249249
email: ele@eleint.co.uk
http://www.ele.com
Distributor:
ELE International
Soiltest Product Division
PO Box 389, Loveland, CO 80539
USA
phone: +1 (800) 323 1242
fax: +1 (970) 663 9781
email: soiltest@eleusa.com
http://www.eleusa.com
ELE International, a division of Hach Lange Ltd.
In the interests of improving and updating its equipment, ELE reserves the right to alter specifications to equipment at any time.
ELE International 2016 
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Contents
Section
Page
1
Document Overview
3
2
Product Overview
4
3
Installation
6
4
Software Installation
7
5
Operation
8
6
Maintenance
21
7
CALANG (External Angle Gauge)
24
8
WEEE Directive
29
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1.
Document Overview
This manual contains comprehensive information about the operation and maintenance of
the Superpave Gyratory Compactor EN.
Please take the time to read this manual as it contains information on the installation,
maintenance and use of the Gyratory Compactor.
This manual is aimed at general users of the Gyratory Compactor, including Laboratory
Technicians, Maintenance Technicians and Technical Users.
i
This manual should be strictly observed. ELE International accepts no liability for
damage caused by disregarding the information contained in this manual or other
related documents.
Glossary of Terms, Abbreviations and Definitions
Abbreviations
EN
kPa
cfm
mm
Hmin(mm)
mPa
Description
European Norm
Kilo Pascal
Cubic Feet/Min.
Millimetres
Defined in the Standard
Mega Pascal
Typographical Conventions
Icon
!
Description
This icon denotes a caution, which advises you of precautions to take
to avoid injury to equipment or loss of data.
i
This icon denotes a note, which alerts you to important information,
further information in this document or other sources such as
manuals, data sheets, literature etc.
Bold
Bold text indicates a reference to a physical or software control, or a
user interface screen.
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2.
Product Overview
This section provides an overview of the Superpave Gyratory Compactor.
2.1 General Description
The Superpave Gyratory Compactor is specifically designed to meet the EN and AASHTO
requirements (see section 5.3), be high quality and user friendly.
The Gyratory Compactor motion is generated with a precise eccentric which is factory
calibrated to 0.82o+/-0.02o (note: the Gyratory Compactor can be set to achieve angles
outside of this range). Speed of the Gyratory Compactor is accurately controlled with an
inverter and is accurate to greater than 0.5 rpm.
Load is applied with a 160mm diameter pneumatic cylinder and each compaction load
controlled with a pressure regulator. The pneumatics has a switchable pressure so that
600kPa can be achieved for both 100mm and 150mm specimens. The specimen height is
measured with a 250mm stroke linear transducer.
Test software allows the user to select compaction methods based on achieving a target
density, or specified number of gyrations. The number of gyrations, compaction depth and
density are logged to disc and displayed on screen. Percentage void content is calculated
and displayed on screen.
The desktop PC is connected to the gyro through a high speed Ethernet connection.
Emulsion mixtures can be compacted using perforated moulds.
2.2 Machine Elements
1
3
4
2
5
6
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9
7
8
Part No.
1
2
3
4
5
6
7
8
9
Part Description
Main Actuator
Mould Extruder
Front Control Panel
Top Safety Door
Bottom Safety Door
Air Inlet Regulator
Mould Retaining Bar Locking Pin
Mould Retaining Bar
Main Ram
Quantity
1
1
1
1
1
1
1
1
1
2.3 Controls
Front Panel
Mould Extractor
4
2
1
3
Right hand side
Right hand side
6
Back panel
7
5
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Part No.
1
2
3
4
5
6
7
Part Description
Air pressure gauge
Safety reset button
Power on/off button
Mould extractor raise/lower switch
EMERGENCY STOP push button
Pressure regulator switch
Main isolator
2.4 Unit Specification
Specification
Voltage
Current
Power
Operational temperature
Transport and storage
Humidity
Size
Weight
3.
Single phase 220-240VAC 50/60Hz
Fuse at 13A
3KVA
5oC to 40oC
-40oC to 70oC
10% to 90% (with no condensation)
Assumes dry air supply
780 x 1000 x 1920mm
508kg
Installation
This section describes the basic tasks that must be carried out when the machine is first
installed, moved to a new location or if the software needs to be installed.
3.1 Location
The machine should be located in a dry and adequately ventilated room. To ensure efficient
operation, it must not be placed in direct sunlight or against heat-emitting surfaces. The
machine should be conveniently located to allow access all around.
!
Warning: be aware that cables may be stretched across the path when moving items
around. To avoid hazards of this type, place a mat or a cable cover over the wire and
tubing.
3.2 Electrical Supply
!
Warning: the following operations should only be carried out by suitable qualified
staff.
The machine requires a 220-240V A.C. 50/60Hz supply, protected at 13A.
The detachable cord supplied with this appliance has 3 cores for use with single phase
supply with neutral and earth.
Note: it is not recommended that the Gyratory Compactor is powered from a supply that
contains an RCD. Use of an RCD might result in the supply tripping when the machine is
switched on.
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The wire in the mains lead are coloured in accordance with the following code:
Wire colour
Green/Yellow
Blue
Brown
Function
Earth
Neutral
Live
Note: the colours of the wires in the mains lead of this appliance might not
correspond with the colours in the wall socket.
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3.3 Pneumatic Supply
Warning: the following operations should only be carried out by suitably qualified
staff.
!
The machine requires a pneumatic supply with a minimum pressure of 6bar, maximum
10bar. 7bar is required to achieve test load on 150mm diameter specimen, 10cfm. The
machine is supplied with 8mm tubing for connection to the compressed air supply. The
supply should be attached to the Air Inlet Regulator.
4.
Software Installation
It is important to ensure the software is installed before the NI software.
Contact ELE International for assistance.
Connect the USB from the PC to the machine, if the PC pops up with a window asking to
install new hardware then insert the disc provided which is labelled ‘BELKIN Gigabit USB 2.0
Network adapter’ and follow these steps:
-
Follow the steps in the install wizard, once complete a new local area network
connection will be available.
-
Open ‘network connections’ which can be accessed through the settings part of the
windows start menu.
-
Locate the new connection and right click, and select properties. The window below
should appear, ensure ‘Belkin F5D5055’ is in the text box in ‘Connect using:’
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5.
-
Highlight ‘Internet Protocol (TCP/IP)’ and click the properties button.
Select ‘use the following IP address’ and enter the values shown below:
-
Click ‘OK’ once the values have been entered to confirm.
Operation
This section describes how to use the Gyratory Compactor and its software to perform a
compaction.
5.1 Start up the Compactor
The Gyratory Compactor is controlled by the PC which should be positioned to the right hand
side of the machine. To turn on the machine and start the software follow this procedure:
1. Ensure the machine is connected to the electrical and pneumatic supplies, and the
Gyratory Compactor Ethernet cable is connected to the PC.
2. Turn the isolator switch on the rear panel to the “I” position.
3. Turn the red valve on the air inlet to the “SUP/ON” position. Ensure the pressure
gauge reads 0.6mpa minimum. If the pressure is reading less than this pull the centre
black adjuster up and ensure it is fully open.
4. Press the power button on the front panel.
5. Wait until the Red power light on the front panel of the machine lights before running
the software.
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5.2 Start the Software
Open the Gyratory Compactor software via the icon situated on the desktop or Windows
Start menu. The following screen will appear.
5.3 Performing a Compaction
To perform a compaction click Compaction. The following screen will appear.
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Note: you can return at any point by clicking Previous.
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The software offers 3 different compaction options as follows:
EN 12697-31 Specimen preparation – this option is designed to compact specimens for
use in further testing (i.e. for Marshall testing).
The normal method of operation would be to set a target number of cycles, but a target
density or target height can also be entered.
The machine will end compaction whichever end criteria is met first.
EN 12697-31 Void content analysis – This option will run for a set number of cycles and
calculate/record void content according to EN 12697-31.
AASHTO T312-09 – This method will run for a set number of cycles and calculate density
and void content in accordance with AASHTO T312-09
Data file path: In all cases a data file can be selected into which test data is recorded. The
format is Windows tab-delimited so data can easily be imported into Excel for further
analysis.
Specimen reference: A mixture reference/name can be entered here.
Mould diameter: The correct mould diameter for the desired mould size should be selected
here.
Target number of gyrations: Sets the number of gyrations to run after which compaction
will end.
Target Height: If a value is entered here then the compaction will end if the target height is
reached (even if the set number of gyrations is not reached).
Mass of material (kg): Enter the mass of the mixture in kg here.
Mould spacer height (mm): If extra spacers are used (for compacting to smaller sample
heights for example) then enter the thickness of those spacers here.
Note: It is not necessary to enter the top and bottom platen thickness here – the thickness of
those is taken into account by the height calibration.
Target mixture density (kg/m^3): You can enter a target density here after which the
compaction will stop if reached.
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If compaction type EN 12697-31 Void content analysis is selected then further data
entry parameters are shown:
hmin (mm): For Void content analysis, the Void content % is calculated in accordance with
EN 12697-31.
hmin should be entered by the user to ensure the calculated void content is correct, a value
of 115mm is often used.
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If compaction type AASHTO T-312 is selected then further data entry parameters are
shown:
Gmm (Theoretical maximum specific gravity): this should be calculated and entered in
accordance with AASHTO-T312 as defined –
Gmb (Bulk specific gravity): this should be calculated and entered in accordance with
AASHTO-T312 as defined –
Binder percentage %: AASHTO-T312 requires that the Binder percentage to the nearest
0.1% is recorded.
Click ‘NEXT’ when the desired test parameters have been set.
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1. Place the bottom platen into the bottom of mould. We recommend paper disks are
placed between platens and material. Note: the 100mm bottom platen should be
inserted such that the smaller diameter is towards the bottom.
2. Place a known mass of material into the mould.
3. Position top platen on top of the material.
Note: The 100mm bottom platen has a different profile to the top platen, the 150mm top and
bottom platens are identical.
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Mould layout:
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4. Open the bottom safety door by pulling the door towards you.
5. Open the top safety door by lifting up until the magnets hold the door in place.
6. Open the mould retaining bar by lifting the retaining pin up and pulling the bar
towards you.
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Select the correct pressure for size of mould by turning the pressure regulator on the
right hand side of machine to either Low for 100mm moulds or High for 150mm
moulds.
100mm Moulds
i
150mm Moulds
Follow the on screen instructions:
1. Insert mould into machine – ensure the mould faces the correct direction as indicated
in the mould layout diagram above.
2. Close mould retaining bar and ensure locking pin is pushed fully down.
3. Close the safety doors. Top door first then bottom door.
4. Press begin compaction on-screen when ready to start compaction.
Note: you can return to the test setup screen by clicking back to setup.
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Press the safety reset switch on the front panel. The switch light turns from red to green and
compaction begins.
Press
The machine will now automatically begin compaction with the following sequence:
1.
2.
3.
4.
Motor begins to turn
Mould is lowered down and locked in place
The main piston comes down and applies the 600kPa compaction pressure
The software starts counting gyrations
Note: To stop the test in an emergency, press the Emergency stop switch or open the
machine door.
The machine will stop immediately in this case and inform the user to exit the software.
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When compaction is finished (or if END COMPACTION is pressed) the software will indicate
this with a COMPACTION FINISHED message:
The main piston will lift removing the load, the mould will lift and the motor will stop.
Open the safety doors, lift the mould retaining pin and open the mould retaining bar then
slide the mould out of the machine.
5.4 Specimen Extraction
1. Slide the mould over the mould extraction ram. Ensure it seats under the retaining
rim.
2. Turn the green mould extraction switch to the RAISE position. The mould will be
extracted.
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3. After the mould has been extracted turn the green switch back to the LOWER
position allowing the mould to be removed.
5.5 Main menu options
System Check Panel:
This allows access to manual control of the compactor for diagnostic and calibration
purposes. Each function of the machine can be operated independently from here:
Configuration settings (Password protected):
The configuration settings screen is password protected and
contains access to the calibration factors associated with the
machine and also allow the machine to be configured for
various factory options:
Temperature option – This allows for a PT-100 temperature to
be fitted and placed inside holes drilled in the front of the
moulds and records the mould temperature during a
compaction.
Shear option – This is when factory set allows a measure of
the shear effort (in % of maximum motor current to be
measured during compaction and can be used for comparative
purposes, i.e. one mixture against another).
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Add/Delete Operator:
This menu selection allows different users to be created with two levels (Engineer or
Technician).
Only Engineer level has access to the calibration and configuration parameters.
User passwords can be changed in this screen also.
Language:
The Gyratory Compactor software is translatable via a translation file, the Language option
from the main menu allows pre-defined language options to be selected.
Print report:
The print report option allows the user to select a previous compaction and produce a report
of the compaction data, example shown below.
This report can be printed or saved as a jpeg for future retrieval.
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6.
Maintenance
This section contains details on general and routine maintenance of the Gyratory Compactor.
!
Warning: the following operations are to be carried out by skilled staff only.
6.1 Maintenance Schedule
i
Note: the following maintenance should be carried out by skilled staff. For further
information regarding maintenance contact ELE International.
ID
1
Interval
Daily
2
3
Daily
Weekly
4
Weekly
5
5
6
7
Weekly
3 months
3 months
Yearly
Description
Ensure any foreign objects that may have fallen into the tray,
crevices etc. are removed.
Check control panel warning lights.
Visually check the hydraulic oil reservoir, if low top up and
check for leaks.
All tubing and fittings on the pneumatic circuits to be checked
for leaks and rectified accordingly.
Lubricate the main ram using a light oil eg. WD40.
Service the motor
service the gearbox
change air inlet filters
Ref
MP1
MP2
6.2 MP1 - Service the Motor
!
Before any intervention, the motor, auxiliary circuits and/or accessories must be
disconnected from the mains.
In particular:
 Check disconnection from the electrical mains.
 Provide suitable protection from exposed live parts.
 Double check that accidental restarts are not possible under any circumstances.
It is recommended that periodical checks of motor operating conditions are scheduled as a
routine maintenance practice.
Check particularly on the following:
1. Check that operation is smooth and absorbed current within rated value.
2. Keep motor clean and fan cowl unobstructed by accumulation of dust or foreign
particles.
3. Check that seal rings are in good condition.
4. Check that lead-in wires and all wirings are safely and tightly secured.
5. If condensate draining holes are provided, remove periodically the screws that close
the holes and allow the condensate to drain.
6. Standard bearings are grease packed for life and in general no periodical
maintenance is required; it is good practice however to check their condition and
eventually replace them after approx. 3 years.
The motor does not have to be removed for normal inspections unless the bearings need to
be replaced. In this case, the operations should be performed by specialised personnel and
with appropriate tools.
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6.3 MP2 – Service the Gearbox
!






Warning: before doing any work on the unit, the operator must first switch off the
power to the gear unit and ensure that it is out of service, as well as taking all
necessary precautions against it being accidentally switched on again or its parts
moving without warning (due to suspended loads or similar external factors).
Furthermore all additional environmental safety precautions must be taken (e.g.
elimination of residual gas or dust, etc).
Before doing any maintenance work, activate all safety equipment and if necessary,
inform persons working in the vicinity. In particular, mark off the area around the unit
and prevent access to any equipment which, if activated, might be the cause of
unexpected health and safety hazards.
Replace worn components with original spare parts only.
Use the lubricants (oil and grease) recommended by the manufacturer.
When working on the gear unit always replace gaskets and seals with new original
ones.
If a bearing requires replacement, it is good practice to also replace the other bearing
supporting the same shaft.
We recommend replacing the lubricating oil after all maintenance work.
i
Note: the above instructions are aimed at ensuring efficient and safe operation of the
gear unit. The manufacturer declines all liability for injury and damage to components
due to the use of non-original spare parts and non-routine work, which modifies the
safety requirements without the express prior authorisation of the manufacturer. Refer
to ELE International to order spare parts for the gear unit.
!
Warning: do not dump polluting liquids, worn parts and maintenance waste into the
environment. Dispose of all such materials as stipulated by applicable legislation.


Observe the routine inspection and maintenance schedule.
Before servicing or repairing internal components, allow the gear unit to cool down
completely before opening the casing so as to avoid burns from parts which are still
hot.
Make sure, on completion of maintenance work, that all vent, filler and level plugs are
tightened to their specified torque.
On completion of any maintenance work, all seals must be refitted and sealed as
prescribed. On gear units with double seal rings, the cavity between the two rings
must be packed with synthetic grease (fluorocarbon gel 880 ITP or equivalent product
with similar properties and application range) before assembly.
Regardless of the type of gear unit, whenever a seal ring is replaced its lips should be
smeared with a thin layer of grease (fluorocarbon gel 880 ITP or equivalent product
with similar properties and application range) before assembly.
Use only original spare parts for repairs.




6.4 Routine Maintenance
Keep the gear unit at its maximum efficiency by following the routine maintenance schedule
specified by the manufacturer.
Good maintenance enables the unit to operate at its maximum performance over a long
service life in compliance with safety regulations.
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Frequency
1000h
3000h
5000h
Component
External seals and
gaskets
For gear units with
torque arm
Gear unit seals and
gaskets
Type of work
Check oil level. Check for
leaks by eye
Check for cracks/ageing
Inspect carefully for
wear/ageing of external
seals
Operation
Maintain or replace
components as required
Replace if no longer fully
effective
Replace if aged or worn
Depending on the temperature reached by the lubricant, it should be replaced at the intervals
indicated in table below:
Hours
25000
15000
12500
Oil temperature t(C)
t<65
65<t<80
80<t<95
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7.
CALANG (External Angle Gauge)
(Available as an accessory item at extra cost)
Using the Gyratory Compactor external angle gauge
[1] Enter the desired angle into the Dial gauge calculation spreadsheet (Main sheet tab) as
shown below to calculate the required throw in mm:
[2] Attach the dial gauge to the Gyratory Compactor using the supplied mounting screws.
Please note there are three small phillips screws which attach the dial gauge to the
bracket (these are normally fitted before delivery), and two allen screws which attach the
dial gauge/bracket assembly to the Gyratory Compactor:
[3] Connect the dial gauge power supply cable to the mains supply:
[4] Power ON the dial gauge with the Green On/Off button, the dial gauge screen will
illuminate to indicate power is On.
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[5] If the display shows TIR and mm as shown below, the unit is ready for use (Go to Step
7) otherwise follow step 6 to set up the display:
TIR Symbol
mm Symbol
[6] If the display is locked (shown by a padlock symbol as below), press and hold the in/mm
and +/- buttons until the padlock disappears:
If ‘TIR’ is not shown on the display, press the ‘Mode’ button repeatedly until TIR shows
on the display, then press ‘PRESET’ to set TIR (Max-Min mode) as shown below:
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Ensure the display is showing mm (not ‘in’) by pressing the in/mm button until mm is
shown on the bottom right of the display:
Also ensure that the display is set to three decimal places by pressing the ‘RES’
button until three decimal places are shown.
Lock the unit to retain the settings for future use by pressing and holding the ‘in/mm’
and ‘+/-‘ buttons together until the padlock symbol is shown on the left of the display.
[7] Zero the dial gauge by pressing the ‘PRESET’ grey button, the display will show
0.000mm
[8] Run the Gyratory Compactor machine for at least 10 gyrations either in the normal
compaction mode or by running the motor in the Gyratory Compactor software check
panel.
It is not necessary to insert a mould for this.
[9] Once at least 10 gyrations are complete, the display on the dial gauge will indicate
the measured throw (Max-min) in mm:
Compare the indicated throw with the required throw calculated using the angle
spreadsheet in Step [1] above.
If the indicated throw is not within approximately +/-0.16mm of the required throw then
adjust the physical throw on the machine (instructions for this are shown below) and
then repeat steps 7-9 above to re-check the new angle.
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[10] Instructions for adjusting the internal Angle.
a) Please remove the base plate by unscrewing the two screws (circled in image below).
Please retain the screws and base plate.
Base Plate
Figure 1
b) Gently slacken (i.e. loosen the bolts, but DO NOT undo completely) the 4 bolts
circled in image (Figure 2) below to adjust the angle. This will allow bottom plate
(i.e plate to which the 4 bolts are fastened) to rotate for adjusting the angle.
c) Manually rotate the bottom plate. Clockwise rotation of the plate would allow you to
decrease the angle and anti-clockwise to increase the angle.
d) When the bottom plate is set at desired position, tighten the 4 bolts to hold the
bottom plate in position then use the CRT-CALANG device to measure the current
angle.
e) Follow the steps b-d until desired angle (ex: 1.160 degrees) is set on the machine.
f) Once the desired angle is set, put the base plate back and fasten the plate with 2
screws circled in above image (figure 1).
Figure 2
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[11]
Once the indicated throw is as close as possible to the required throw (within +/0.16mm), enter the indicated throw in the angle spreadsheet as shown below to
calculate the actual set angle in Degrees:
[12] The new physical angle can now be entered into the software configuration file as
follows:
Open the ‘c:\gyratory compactor\utils\gyro.ini’ file in Windows Notepad:
Update the value next to the ‘TARGET ANGLE =’ field with the new angle then save
and close the Gyratory Compactoro.ini file:
[13] The CRT-CALANG assembly can now be removed from the gyratory compactor.
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DIRECTIVE ON WASTE ELECTRICAL & ELECTRONIC EQUIPMENT (WEEE)
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