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BESSER DYNAPAC 3 AT A TIME (466361F9710US). OPERATION / MAINTENANCE MANUAL - page 6

SECTION 11

MAINTENANCE

11.7.3.6

VARIATOR TROUBLESHOOTING

This is a list of problems that can occur on the variator and their possible solutions.

TEMPERATURE IS RISING

Temperature on the casing is exceeding 105⁰F (40⁰C) over ambient temperature. This may indicate:

- Heat generation due to a shortage of oil or deterioration. Replenish or change oil.

- Over-slippage due to overload. Measure input power of motor at the lowest speed and remove the causes for

overload.

- Wear of disc. Resistance can be felt in manual speed change operation. Replace worn discs.

- Broken component or faulty assembly. Usually attended by abnormal sound. Disassemble and inspect the drive.

- Other than the above, lack of oil on the lip(s) of oil seal causes temperature rise on the oil seal. Lubricate lip of oil

seal.

ABNORMAL SOUND

The variator is making strange and unusual noises:

- If it is a rolling noise, that may indicate broken discs or bearings. Replace discs or bearings.

- If it is a high cyclic metallic sound, that may indicate damage to the gears. Correct or replace gears according to

the extent of damage.

- If it is a grinding noise, that may indicate a rotating component in contact with unrelated parts due to faulty

assembly.

- If it is a rattling noise, that may indicate loose fit of coupling, fan, etc. due to worn key. Inspect the keys and

replace if required.

- If it is a squeaking noise, that may indicate poor lubrication on the lip of oil seal. Lubricate seal.

- If it is a sliding noise, that may indicate excessive corrosion on discs and bearings. Corrosion tends to occur

when oil deteriorates during long periods of no operation without appropriate care. Overhaul is required.

- If it is a sound difference at certain speeds during speed change operation, that may indicate excessive wear on

a certain range of cone disc due to operation at one set speed. Occurs with resistance for speed change opera-

tion. Operate drive at other speeds or replace discs.

- If it is a sound difference according to load condition, there is usually no trouble. Meshing sound of gears varies

subject to load intensity. Care should be taken that no overload is applied to the drive.

INCREASE OF INPUT POWER

If you notice an increase of input power, that may indicate:

- Sudden increase at certain speed during speed change due to excessive wear at a certain range of cone discs.

Select other speed for operation or replace discs.

- Higher viscosity of oil or more oil than required. Replace oil or reduce oil to the proper level.

- Rotating component in contact with unrelated parts. Occurs with noise. Reassemble properly.

- Overload. Disengage with load and measure the no load input power.

VIBRATION

Abnormal vibration of the variator may indicate:

- Weak foundation or loose mounting. Reinforce the foundation and tighten the bolts.

- Misalignment. Correct misalignment.

- Loose fitting or broken coupling, sheave or fan. Replace key or coupling, sheave or fan itself.

- Pulsation of belt or chain. Determine the cause of pulsation.

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SECTION 11

MAINTENANCE

- Resonance caused by the vibration of other element. Reduce or isolate the vibration of other element.

FLUCTUATION OF SPEED

A fluctuation of speed of the variator may indicate:

- Overload or lack of capacity. Detect the cause for overload.

- Wear of rim on flange disc. Replace disc.

- Movement of shifting screw by vibration. Lock the handwheel.

OIL LEAKAGE

If you notice oil leaking from the variator, that may indicate:

- Fatigue or wear of oil seal. Replace oil seal.

- Oil is overfilled. Reduce oil to appropriate level.

- Improper fitting or housing, cover, etc. Check fit and fasteners.

- Oil return hole clogged. Clear the hole.

INABILITY OR DIFFICULTY OF SPEED CHANGE OPERATION

An inability or difficulty for speed change operation on the variator may indicate:

- Broken disc (impossible to keep running). Replace discs.

- Fatigue of splined shaft or input shaft, where cone disc slides. Correct or replace subject to the extent of fatigue.

- Disengagement of disc meshing. This tends to occur when severe peak load is applied under extreme high

speed running. Reassembly is required.

- Shifting nut is locked at extreme low or high speed. Release shifting nut.

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SECTION 11

MAINTENANCE

FLUID TEMPERATURE

11.8

HYDRAULIC POWER UNIT

FLUID TYPE

(pump inlet)

MAINTENANCE

Petroleum

Recommended max.: 130⁰F (59⁰C)

Oil in hydraulic systems performs the dual function of

Water-based

Recommended max.: 120⁰F (55⁰C)

lubrication and transmission of power. It constitutes a

vital factor in a hydraulic system and its careful selec-

tion should be made with the assistance of a reputable

Synthetic

Recommended max.: 130⁰F (59⁰C)

supplier. The proper selection of oil assures satisfacto-

ry life and operation of the system components - with

Table 11.19

Fluid temperatures

particular emphasis on hydraulic pumps and motors.

11.8.3 OIL LEVEL

Two very important factors to be remembered in the

selection of hydraulic fluids are:

Oil level should be checked at every start-up and after

8 hours of continuous operation. You may have to

The oil must have rust and oxidation inhibition

increase checks frequency if there are some leaks. The

for satisfactory system operation, and

oil level gauge is on side of unit (see figure 11.21 on

next page).

The oil must have proper viscosity to maintain

adequate sealing and lubricating quality at the

11.8.4 OIL CHANGE

expected operating temperatures.

Oil change intervals are variable, and depend on the

11.8.1 RECOMMENDED FLUIDS FOR

kind and brand of oil being used. Consult with your oil

HYDRAULIC POWER UNITS

manufacturer for exact oil change intervals.

Petroleum base and most phosphate ester fluids, water

11.8.5 OIL FILTRATION

glycols and emulsions with water content not exceeding

40%.

Of major importance to long and trouble-free compo-

nent and fluid life is fluid cleanliness. Fluids filtered at

11.8.2 FLUID OPERATING

nominal 10 micron filtration is the most inexpensive

TEMPERATURE & VISCOSITY

insurance possible for continuous trouble-free opera-

tion. Look at table 11.20 for more details.

Fluid temperatures up to 160⁰F (71⁰C) will not apprecia-

bly affect pump performance. However, from a safety

standpoint, temperatures above 130⁰F (65⁰C) are not

FILTRATION

TYPE OF FILTER

recommended. The oil temperature indicator is on side

of unit (see figure 11.21 on next page). Specified oper-

Petroleum fluids

100 mesh screen

ating viscosities (see table 11.18) must be allowed for

Suction

Water-based fluids

60 mesh screen

optimum life and performance. For continuous operat-

Phosphate esters

60 mesh screen

ing temperatures above 140⁰F (60⁰C), consult fluid

manufacturer for correct fluid at elevated temperatures.

Look at table 11.19 for appropriate fluid temperatures.

ISO 18/15 (25 micron) to 1000 PSI

Return

ISO 16/13 (10 micron) to 2000 PSI

CONDITION

VISCOSITY

Table 11.20

OIL FILTRATION.

At start-up

Maximum : 1000 SUS

At operating

Acceptable : 80-400 SUS

temperature

Recommended : 100-250 SUS

Nominal

ISO Grade 46 or 32

Table 11.18

OIL VISCOSITIES.

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SECTION 11

MAINTENANCE

FILL

OIL LEVEL &

TEMPERATURE

DRAIN

Figure 11.21

THE HYDRAULIC POWER UNIT.

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SECTION 11

MAINTENANCE

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SECTION 12

VIBRATION

SECTION 12

VIBRATION SYSTEMS

Figure 12.1 SMARTPAC.

12.1

SMARTPAC

12.1.2 SYSTEM INSTALLATION

12.1.2.1

Make mechanical and electrical changes

This section will show you Smartpac vibration sys-

according to drawing supplied by BESSER

tem. With this option, an electric motor (see figure

and check that all parts are aligned properly.

12.1) is turning all the time and a cam activated by

air change position to start and stop vibration.

12.1.2.2

Attach correct length shafts to the mold you

want to run.

THEORY OF OPERATION

12.1.2.3

Make sure the right hand shaft is on right side

Concrete and mold combinations each have unique

and the left one is on left side.

vibratory characteristics. Each has an optimum ampli-

tude and frequency for filling and consolidating.

Concrete units can be made to the highest quality in

the shortest time by matching the optimum frequency

and amplitude for feed and for finish.

12.1.1

AMPLITUDE

Limits have been preset for both low and high speed of

the motors to prevent operation outside optimum para-

meters. Amplitude is adjustable from 0 to 100% of 6500

or 9000 lb. Amplitude should not be set below 30% as

vibration will not synchronize and will be erratic.

466361F9710US F1 29OC99

12-1

SECTION 12

VIBRATION

12.1.2.5

Disconnect lower hoses from “V” fitting on

match shaft speeds.

dump valve assemblies and fill with ATF fluid.

12.1.4 AMPLITUDE ADJUSTMENTS

12.1.2.6

Make sure all air is removed from the hoses.

Amplitude adjustments are made with vibrator motors

stopped and large cylinder rod fully extended. Adjust

12.1.2.7

Fill control unit tank with ATF fluid. Keep tank

the transducer to read zero by monitoring register

3/4 full during setup and operation.

#N10:21 (see section 9.9.6).

12.1.2.8

Connect 80 PSI - 5 SCFM air supply to con-

trol unit.

12.1.5 TRANSDUCER ADJUSTMENT

12.1.2.9

Set air pressure for rod end of cylinder to 60

To adjust transducer (see figure 12.2):

PSI and Cap End of cylinder to 30 PSI (see

figure 12.2).

12.1.5.1

Loosen mounting (A) then move transducer

(B) to get zero in register. Retighten screw.

12.1.2.10 Operate air valve to extend rod of air cylinder.

Install mold with SmartPac vibrator shafts and

12.1.5.2

Retract rod on air cylinder (C) by manually

attach hoses to dump valve assemblies.

activating valve. The reading should go to

between 900 and 1000 and both weights

12.1.2.11 Retract air cylinder, wait 2 seconds, then

should be shifted 90 degrees.

extend rod, repeat process until both vibra-

tors shift 90 degrees

12.1.5.3

Extend rod and recheck zero.

Note: when rod is retracted. If vibrators don’t shift

12..1.5.4

Enter 0 into register #N10:26.

fully, refill bottom hoses on dump valves.

12..1.5.5

Set amplitude on the SmartPac screen to 500

12.1.2.12 When rod is extended, both weights return to

and with vibrator motors off, turn vibrator

balanced position.

switch to “hand”.

Note: DO NOT run system if vibrators or control unit

12..1.5.6

Check register #N10:21 reading and subtract

are not functioning properly.

500, enter this into register #N l0:26 on

SLC500. This is your Offset to compensate

for delays in the system. This will have to be

12.1.3 VIBRATOR FREQUENCY

updated from time to time.

To set frequency of vibrator:

12..1.5.7

Operate vibration "hand" and check register

N10:21 reading, it should be close to 500.

12.1.3.1

stop machine with feed drawer over the mold.

The weights should be shifting about half

way.

12.1.3.2. Start vibrator motors with vibration off.

Note: Check that the top belts are both going towards

the center of the machine.

12.1.3.3

Bring up the SmartPac screen on the monitor

and set the speed of shafts to 2900 RPM.

Note: Check the speed with a strobe light or

photo tachometer.

12.1.3.4

Adjust one motor so it runs exactly the same

speed as the other. Registers N10:30 and

N10:31 may be used to adjust motor speeds.

Note: On non AFC units, adjust frequency drive to

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SECTION 12

VIBRATION

Figure 12.2

SMARTPAC PANEL

466361F9710US F1 29OC99

12-3

SECTION 12

VIBRATION

12.2

FREQUENCY DRIVE OPTION

Enter

12.2.1 DISPLAY PANEL KEY DESCRIPTIONS

When pressed, a group or parameter will be selected

or a parameter value will be entered into memory. After

a parameter has been entered into memory, the top

line of the display will automatically become active,

allowing another parameter (or group) to be chosen.

Escape

When pressed, the ESCape key will cause the pro-

gramming system to go back one level in the menu

tree.

12.2.2 OPERATION

EX: To change a preset input mode value on the

main drive or Smartpac, follow the steps

below:

Select

Pressing the SELect key alternately causes the top or

The status display must read “Stopped + 0.00 Hz”

bottom line of the display to become active. The flash-

(see figure 17.1).

ing first character indicates which line is active.

Press the

key.

Status display reads “Choose Mode”.

Increment/Decrement

Press the

key.

These keys are used to increment and decrement a

value or scroll through different groups or parameters.

Keep pressing until you reach “Program”.

Press the

key.

Press the

key.

Keep pressing until you reach “Setup”.

Press the

key.

Press the

key.

Keep pressing until you reach “Input Mode 2”.

Press the

key.

You can now change the numerical value with

the help of the

keys. Select the desired

value.

Press

The change is recorded. To come back to step 1

(initial position), press

until "Stopped + 0.00 Hz" appears on display.

Figure 12.3 DISPLAY PANEL.

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SECTION 12

VIBRATION

Note: Other parameters that can be changed in the

Setup menu includes “Freq Select”, “Accel

Time”, “Decel Time” and “Minimum Freq”. When

in “Setup” mode, press increment/decrement

keys to choose another one of these parameters.

Also, if you choose “Frequency Set” instead of

“Setup” in step 5, you can establish preset fre-

quencies: “Preset Freq 1” and “Preset Freq 2”.

Follow the same steps to change preset frequen-

cies.

12.2.3 LIST OF FREQUENCY PRESET VALUES

FOR SMARTPAC

SET-UP

Input mode:

Freq. Select:

4-20 mA

Accel time 1:

Decel time 1:

Minimum Freq.:

Maximum Freq:

Stop Select 1:

COAST

Motor NP RPM: