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Theory of Operation
Concrete and mold
combinations each have unique vibratory characteristics. Each has an
optimum amplitude 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 finish.
Limits have been preset for both
low and high speed of the motors to prevent operation outside optimum
parameters. Amplitude is adjustable from 0 to 100% of 9000, 11,000, 13,000
or 15,000 lbs. depending on the model of concrete products machine and which
shaft assemblies are used. Amplitude should not be set below 30% as
vibration will not synchronize and will be erratic.
Installation of the system can
be made on machines with mold locks or pin guidance. Make mechanical and
electrical changes according to print and check that all parts are aligned
properly. Attach correct length shafts to the mold you want to run. Make
sure the right hand shaft is on right side and the left one is on left side.
Disconnect lower hoses from
"V" fitting on dump valve assemblies and fill with ATF fluid. Make
sure all air is removed from the hoses. Fill control unit tank with ATF
fluid. Keep tank 3/4 full during setup and operation. Connect 80 psi 5 cfm
air supply to control unit. Set air pressure for rod end of cylinder to 60
psi and cap end of cylinder to 30 psi. Install mold with SmartPac vibrator
shafts. Thoroughly clean both ends of the quick disconnects and attach hoses
to the dump valve assemblies. Operate the air valve to extend the rod of the
air cylinder. Retract the air cylinder, wait 2 seconds, then extend the rod
again. Repeat process until both vibrators shift 90 degrees when rod is
extended. If vibrators don't shift fully, refill bottom hoses on the dump
valves. When rod is extended both weights return to the balanced position.
DO NOT run system if vibrators or control unit are not functioning properly.
To set AFC frequency of
vibrator: stop machine with feed drawer over the mold. Start vibrator motors
with vibration off. Check that the top belts are both going towards the
center of the machine. Bring up the SmartPac screen on the monitor and set
the speed of shafts to 2900 rpm. Check the speed with a strobe light (Besser
Part # 02-115212) or photo tachometer (Besser Part # 02-112910), then adjust
one motor so it runs exactly the same speed as the other. On non AFC units
adjust frequency drive to match shaft speeds.
AFC amplitude adjustments are
made with vibrator motors stopped and large cylinder rod fully extended.
Adjust the transducer to read zero by monitoring register #467 if your
machine uses a PLC® 2, or monitor register #N10:21 if your system uses a
SLC™-500.
To adjust transducer, loosen
mounting screws, move transducer to get zero in register, then retighten
screws. Retract rod on air cylinder by manually activating valve, the
reading should go to between 800 and 1000 and both weights should be shifted
90 degrees. Extend rod and recheck zero. Set amplitude to 500 and with
vibrator motors off, turn on vibration. Check register reading and subtract
500, enter this into register #543 on PLC2 or #N10:26 on SLC500™. This is
your Offset to compensate for delays in the system.
Smartpac Maintenance and Care
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Store in clean dry area.
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Lubricate bearings before
storing.
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Prevent concrete spillage
from accumulating on shafts.
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Keep quick disconnects clean
and capped.
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For extended storage, spray
rust preventive in tube hole & on seals.
Note: Spray lubrication (Besser Part # 02-114044) in tube hole
periodically in order to reduce drag on interior parts.
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Handle units with care, DO
NOT hit or pry the weights.
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Mount to good mold side bars
and make sure bearing housings are seated directly to bar and the
vibrator bolts are properly torqued.
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Inspect vibrator bearings at
least every 500,000 cycles by removing the old seals and replacing with
new ones. Look for contamination and excessive movement or signs of
wear.
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Lift unit by the shaft not
Bearing Housing as this can damage the seals.
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Use Mobil 210, or an
equivalent automatic transmission fluid. Mark sure there are no
contaminants in the fluid. Change oil filter every 3 months. Note: Make
sure the oil filter is full of hydraulic fluid, before putting filter
back on. Otherwise excessive air will be in the system.
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Thoroughly clean both ends
of the quick disconnects before attaching the hoses to the dump valves.
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Replace "O" ring
in quick disconnects at least every month or immediately when they
become worn or damaged.
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Never operate system
pressure above 80 psi.
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Use only new clean fluid
when filling the system. Contamination will cause erratic operation.
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Shaft speeds in excess of
2900 RPM may result in premature vibrator shaft bearing failure.
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Do not disassemble unit.
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Tighten sheave to the
recommended torque of 18 ft. lbs. Over tightening will cause rotary
union to bind, or reduce its life.
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Never put undue pressure on
rotary union fittings or connection hose.
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Lubricate vibrator bearing
every 8 hours with 1 fluid oz. of clean high temperature synthetic
grease (Besser Part # 02-114135) per housing.
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Always have guards in place
when operating vibrator motors.
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Keep system in top condition
by replacing any worn belts, sheaves, and/or hoses.
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Use of a Photo Tachometer to
synchronize vibrators is necessary to maintain smooth operation.
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Use high temperature
synthetic grease (Besser Part # 02-114135) to:
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Extend bearing life.
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Lower the operating
temperature by up to 20 degrees Fahrenheit.
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Reduce grease
consumption.
SAFETY
BULLETIN
This notice is issued to advise you that some previously
accepted shop practices may not be keeping up with changing Federal and State
Safety and Health Standards. Your
current shop practices may not emphasize the need for proper precautions to
insure safe operation and use of machines, tools, automatic loaders and
allied equipment and/or warn against the use of certain solvents or other
cleaning substances that are now considered unsafe or prohibited by law. Since many shop practices may not reflect
current safety practice and procedures, particularly with regard to the safe
operation of equipment, it is important that you review your practices to
ensure compliance with Federal and State Safety and Health Standards.
IMPORTANT
The operation of any
machine or power-operated device can be extremely hazardous unless proper
safety precautions are strictly observed. Observe the following safety precautions:
Always be sure proper guarding is in place for all
pinch, catch, shear, crush and nip points.
Always be sure that all personnel are clear of the
equipment before starting it.
Always be sure the equipment is properly grounded.
Always turn the main electrical panel off and lock
it out in accordance with published lockout/tagout procedures prior to making adjustments, repairs,
and maintenance.
Always wear appropriate protective equipment such
as safety glasses, safety shoes, hearing protection and hard hats.
Always keep chemical and flammable material away
from electrical or operating equipment.
Always maintain a safe work area that is free from
slipping and tripping hazards.
Always be sure appropriate safety devices are used
when providing maintenance and repairs to all equipment.
Never exceed the rated capacity of a machine or
tool.
Never modify machinery in any way without prior
written approval of the Besser Engineering Department.
Never operate equipment unless proper maintenance
has been regularly performed.
Never operate any equipment if unusual or
excessive noise or vibration occurs.
Never operate any equipment while any part of the
body is in the proximity of potentially hazardous areas.
Never use any toxic flammable substance as a
solvent cleaner.
Never allow the operation or repair of equipment
by untrained personnel.
Never climb or stand on equipment when it is in
operation.
It is important
that you review Federal and State Safety and Health Standards on a continual
basis. All shop supervisors, maintenance
personnel, machine operators, tool operators, and any other person involved
in the setup, operation, maintenance, repair or adjustment of Besser-built
equipment should read and understand this bulletin and Federal and State
Safety and Health Standards on which this bulletin is based.
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