GSi InterSystems TP User manual
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1
Table of Contents
I. GENERAL SAFETY INFORMATION............................................................................................................3
II. GENERAL INFORMATION.............................................................................................................................5
2.1 System Description...................................................................................................................................................5
2.2 Optional Features.....................................................................................................................................................6
2.3 Material Sampled......................................................................................................................................................6
2.4 Truck Probe Construction........................................................................................................................................6
III. GENERAL INSTALLATION REQUIREMENTS.......................................................................................7
3.1 Receiving Inspection................................................................................................................................................7
3.2 Pre-Installation Preparation.....................................................................................................................................7
3.3 Location......................................................................................................................................................................8
3.4 General Installation Guidelines...............................................................................................................................8
3.5 Initial Startup............................................................................................................................................................10
3.6 Controller Location..................................................................................................................................................11
3.7 System Wiring.........................................................................................................................................................11
3.7.1 Electrical Power Requirements, System..........................................................................................................11
3.7.1.1 Controller...........................................................................................................................................................12
3.7.1.2 Solenoid Valve Coils........................................................................................................................................12
3.7.1.3 Hydraulic Tank Heater (Optional)..................................................................................................................12
3.7.1.4Hydraulic Pump Motor...................................................................................................................................12
3.8 System Plumbing....................................................................................................................................................13
IV. OPERATIONS AND ADJUSTMENTS.....................................................................................................14
4.1 Operators Control Components And Their Functions.......................................................................................14
4.1.1 POWER OFF/ON Switch S-1 & Light...............................................................................................................15
4.1.2 VACUUM MOTOR OFF/ON Switch S-2..........................................................................................................15
4.1.3 PROBE MOVEMENT Push-button Switches S-3 thru S-10 (Old Style Control)........................................15
4.1.4 PROBE MOVEMENT Joy-stick Switches S-3 & S-4 (Standard JS Control)..............................................15
4.1.5 Main Fuse.............................................................................................................................................................15
4.1.6 Terminal Strip.......................................................................................................................................................15
4.1.7 Vacuum Motor(s) Relay......................................................................................................................................15
4.2 Electrical Components...........................................................................................................................................16
4.2.1 Hydraulic Pump Motor........................................................................................................................................16
4.2.2 Pump Motor Starter & Thermal Overload........................................................................................................16
4.2.3 Hydraulic Oil Heater............................................................................................................................................16
4.2.4 Vacuum Motor......................................................................................................................................................16
4.3 Hydraulic Components...........................................................................................................................................17
4.3.1 Solenoid Valves V-1, V-2, V-3, & V-4...............................................................................................................17
4.3.1.1 Boom UP/DOWN Valve V-1...........................................................................................................................17
4.3.1.2 Counter Balance Valve V-12..........................................................................................................................17
4.3.1.2.1CounterBalanceValveadjustment:...................................................................................................................17
4.3.1.3 Boom LEFT/RIGHT Valve V-2.......................................................................................................................18
4.3.1.4 Boom IN/OUT Valve V-3.................................................................................................................................18
4.3.1.5 Sample Ports OPEN/CLOSE Valve V-4 (Compartmentalized Probe Only)............................................18
4.3.2 Relief Valve V-5...................................................................................................................................................18
4.3.3 Boom Left/Right Flow Control Valves V-6, V-7...............................................................................................19
4.3.4 Hydraulic Cylinders.............................................................................................................................................19
4.3.5 Rotary Actuator (Compartmentalized Probe Only).........................................................................................19
4.3.6 Rotational Motor...................................................................................................................................................20
4.3.7 Hydraulic Pump....................................................................................................................................................20
2
V. MAINTENANCE AND REPAIR...................................................................................................................21
5.1 General Maintenance.............................................................................................................................................21
5.2 Periodic Inspection.................................................................................................................................................21
5.3 Lubrication................................................................................................................................................................22
5.3.1 Boom Pivoting And Sliding Joints, Monthly.....................................................................................................22
5.3.2 Boom Rotation Drive Chain & Sprockets, Every 6 Months...........................................................................22
5.4 Hydraulic Power Unit Service................................................................................................................................22
5.4.1 Hydraulic Oil Inspection, Daily...........................................................................................................................22
5.4.2 Breather Cap Cleaning, Every 3 Months.........................................................................................................23
5.4.3 Hydraulic Filter Replacement, Every 3 Months...............................................................................................23
5.4.4 Hydraulic Oil & Filter Replacement, Annually..................................................................................................23
5.5 Compartmentized Probe Tip Inspection..............................................................................................................24
5.6 Core Probe Vacuum Pressure Equalization.......................................................................................................24
VI. TROUBLESHOOTING..................................................................................................................................25
6.1 General Truck Probe Troubleshooting.................................................................................................................25
6.2 Directional Solenoid Valve Troubleshooting.......................................................................................................26
6.3 Hydraulic Components Troubleshooting.............................................................................................................26
6.3.1 Cylinder Leaking..................................................................................................................................................26
VII. REPLACEMENT PARTS............................................................................................................................27
7.1 Scope........................................................................................................................................................................27
7.2 Ordering Parts.........................................................................................................................................................27
7.3 Replacement Parts.................................................................................................................................................27
7.4 Repair Kits................................................................................................................................................................27
7.4.1 Truck Probe Parts Listing...................................................................................................................................28
VIII. WARRANTY..................................................................................................................................................39
List of Illustrations & Drawings
FIGURE 1-1, TRUCK PROBE SAFETY LABEL LOCATIONS ..………………………………………………………….. 4
FIGURE 2-1, TYPICAL INSTALLATION, TRUCK PROBE SYSTEM ……………………………………………….…… 5
FIGURE 3-1, HOSE & REUSABLE FITTING ASSEMBLY INSTRUCTIONS ………………………………………….... 9
FIGURE 3-2, HYDRAULIC SCHEMATIC ……………………………………………………………………………...…... 13
FIGURE 4-1, STANDARD NEMA 12 OPERATORS CONTROL PANEL DETAIL …………………………………….. 14
FIGURE 4-2, RELIEF VALVE ……………………………………………………………………………………………….. 19
FIGURE 4-3, ROTATIONAL MOTOR & DRIVE CHAIN ………………………………………………………………….. 20
FIGURE 7-1, MAIN STAND ASSEMBLY …………………………………………………………………………………... 31
FIGURE 7-2, TELESCOPING BOOM ASSEMBLY ……………………………………………………………………….. 32
FIGURE 7-3, COMPARTMENTIZED & CORE PROBES ………………………………………………………………… 32
FIGURE 7-4, SAMPLE CABINETS …………………………………………………………………………………………. 33
FIGURE 7-5, VACUUM MOTOR UNITS …………………………………………………………………………………… 34
FIGURE 7-6, HYDRAULIC POWER UNIT ASSEMBLY …………………………………………………………….……. 35
FIGURE 7-7, HYDRAULIC POWER UNIT FITTINGS& HOSES …………………………………………………….….. 36
FIGURE 7-8, HYDRAULIC HOSES & FITTINGS …………………………………………………………………….…… 37
3
I. GENERAL SAFETY INFORMATION
SAFETY FIRST! The symbols shown identify
examples of the safety labels and signs to be
found on InterSystems equipment. They are
affixed to the equipment to warn of danger to
persons and of possible equipment damage.
These signs must never be removed, tampered
with, painted over or obscured in any way.
(See Page 4 for label locations.) If labels are
damaged or become unreadable, replacement
labels are available from InterSystems. The
user must institute a continuing program to
instruct all personnel in safe operating and maintenance procedures, and to insure that all safety devices, guards,
and covers are intact and operable, and that all safety signs are legible.
Consult InterSystems before making any changes to the Truck Probe or its operating environment. Careless
changes could result in death or serious injury to people, and reduce the performance and service life of the
equipment.
Never perform any service on this equipment or any other powered equipment until all power has been shut off and
locked out so that it cannot be restored without the consent and knowledge of the person who interrupted power.
Power includes electrical, fluid, mechanical, or pneumatic energy.
Never perform any service on this equipment without utilizing the required PPE (personal protective equipment).
Refer to the MSDS(s), material safety data sheet(s), on all the products to which this equipment is in contact with to
determine what PPE is required.
DANGER
THIS EQUIPMENT IS TO BE OPERATED ONLY ON THE VOLTAGE DESIGNATED ON THE
CERTIFIED ELECTRICAL DRAWING(S)! FIRE OR EXPLOSION MAY RESULT, WHICH CAN
CAUSE DEATH, SERIOUS INJURY, AND EXTENSIVE DAMAGE TO EQUIPMENT. DO NOT
CONNECT TO VOLTAGES OTHER THAN DESIGNATED.
4
FIGURE 1-1, TRUCK PROBE SAFETY LABEL LOCATIONS
5
II. GENERAL INFORMATION
2.1 System Description
The Truck Probe is designed to collect a representative sample of granular, pellet, chip, flake or other materials from
an open top hopper truck. Figure 2-1 illustrates a typical Truck Probe installation.
Sample collection is initiated in response to the operator's manual command generated by controller logic. A sample
cycle begins when the operator positions the probe tip for insertion into the truck by rotating the boom and stroking it
in or out to the desired sampling position. The vacuum system is turned on and then the probe tip is inserted down
into the hopper truck with the sampling ports closed. The sampling ports are opened to receive a sample and then
closed to dump the sample in the vacuum conveying chamber of the probe tip. The probe tip is raised and re-inserted
into the material in a different location. This is repeated as required by the FGIS or other regulating guidelines.
Once the truck has been properly sampled and sufficient time has elapsed for the sample to be thoroughly conveyed
to the collection cabinet the operator will shut off the vacuum system. The sample can now be emptied from the
collection cabinet to be analyzed.
FIGURE 2-1, TYPICAL INSTALLATION, TRUCK PROBE SYSTEM
6
2.2 Optional Features
The certified drawings indicate which, if any, optional features are included with a Truck Probe System. Some of the
more frequently specified optional features are briefly described in the following list.
Additional optional items that may be furnished if described in the Equipment Quotation and if specifically ordered,
may include some or all of the following items:
A. Traffic control lights
B. Intercom system
C. Aluminum sample conveying tubing
2.3 Material Sampled
Most material from light to heavy density powders, granules, flakes and pellets.
2.4 Truck Probe Construction
Standard Truck Probe construction is of painted carbon steel, this includes the base, stand, booms, probe, etc.
Other materials and/or finishes appropriate to the operating environment and the material or product being sampled
may be used. Refer to the certified drawing(s) for any optional or special components installed on the Truck Probe.
7
III. GENERAL INSTALLATION REQUIREMENTS
3.1 Receiving Inspection
Carefully inspect the equipment for damage as soon as it is received. Also, verify that the quantity of parts or
packages actually received corresponds to the quantity shown on the packing slip. Report any damage or shortage
to the delivering carrier as soon as possible. InterSystems' responsibility for the equipment ended with acceptance
by the delivering carrier. Refer to the bill of lading.
A typical shipment of a Standard Truck Probe, without any of the optional items described in Section 2.3, has five
major units:
A. Hydraulic Power Unit
B. Main Stand and Boom Pivot
C. Probe Boom
D. Probe Tip
E. Bulkhead Bracket, Operators Control Panel, Vacuum Power Unit, Vacuum Hose, Sample Collection Cabinet,
Hydraulic Hoses & Fittings Kit, Hydraulic Fluid, Hydraulic Power Unit Motor, Starter & Heaters and Hardware
Package.
NOTE: ANCHORING DEVICES & FASTENERS ARE NOT PROVIDED.
3.2 Pre-Installation Preparation
Note, before starting Truck Probe System installation, study this manual, the certified drawing(s) furnished with the
system, and other applicable documents (including, but not limited to OSHA Regulations; the National Electrical
Code; and all other applicable federal, state, and local codes and regulations).
InterSystems Truck Probes are designed to be self-supporting when securely anchored to a reinforced concrete base
constructed as specified by the certified drawing(s). The Truck Probe requires no bracing but it was not designed to
support other equipment. Separate support must be provided for any accessory equipment. The user or installer is
advised to retain a civil or architectural engineer to plan the overall installation and more specifically, the reinforced
concrete bases for the probe itself and the hydraulic power unit.
InterSystems does not assume turnkey responsibility for the installation. Therefore, the factors presented hereafter
for consideration are just that and only that.
A. Before initiating the actual installation process, determine where the probe, sample cabinet, vacuum unit,
control panel, and hydraulic power unit will be situated.
B. As shown on the General Data Drawing, plan to locate the control panel so that the probe operator has a
clear, unobstructed view of the loads to be sampled, so that the operator's signals to drivers of the loaded
vehicles will be seen and understood.
C. The Truck Probe may be set up for either 180 degree rotation single lane or 300 degree rotation dual lane
operation.
D. Plan the routing of the vacuum sampling hose for a minimum distance, number of bends and changes in
elevation.
E. The air exhausted from the vacuum power unit may include dust or other fines from the material being
sampled. Plan to exhaust the air to a roof or another location away from pedestrian traffic where the
occasional discharge will not be objectionable.
8
F. Plan the location of the Sample Collection Cabinet. Most often the desired site is at the beginning of the
sample grading process in the grain inspection area. If the material other than grain is being sampled, other
criteria may apply.
G. Plan the location of the concrete base for the hydraulic power unit. Preferably, it should be located within
four feet of the concrete probe base. If the Probe is separated from the power unit by more than four feet, the
user or installer may have to purchase additional hydraulic hose. Maximum separation between the Probe
and power unit should be held to ten feet or less.
H. Excessively long hydraulic hoses can result in pressure loss, which in turn results in slow, erratic probe
operation. Excessive vacuum hose length can produce low vacuum at the probe tip. The Sample Collection
System may not function properly.
I. It is recommended that guard posts and/or rails be placed around the Probe and hydraulic power unit for
protection from vehicular traffic.
J. Review all installation plans once more. Double-check to be sure that the probe will not interfere with any
power and communications lines, and that no conveyors or spouting are routed through the area where the
Probe is to operate.
3.3 Location
The Truck Probe is typically installed near the receiving truck scale and sample lab, as in Figure 2-1. Locate the
Truck Probe and associated equipment for ease of access and maintenance. The Truck Probe operator should have
an unobstructed view of the entire area of boom movement.
The Truck Probe is to be installed only as shown on the certified drawing(s). If an alternate mounting arrangement is
desired, contact InterSystems, prior to installation for proper guidance. The Truck Probe is of a general design with
modifications specifically for your application. It may be necessary to rework the Truck Probe in order for it to
function properly if you alter the application.
3.4 General Installation Guidelines
The Truck Probe assembly is designed to support ONLY its own weight. As shown on the certified drawing, the
Truck Probe must be installed on a special concrete foundation. The main stand base has eight clearance holes for
securing to the foundation. Refer to the certified drawing(s) of the Truck Probe for the dimensioned locations of
these holes.
DANGER
TRUCK PROBE CANNOT SUPPORT ANY OTHER EQUIPMENT! COLLAPSE OF THE WHOLE
SYSTEM CAN CAUSE DEATH, SERIOUS INJURY, AND EXTENSIVE DAMAGE TO EQUIPMENT.
PROPERLY SUPPORT ALL ELECTRICAL CONDUITS, AND CONVEYING LINES.
A. Verify that the concrete probe and power unit bases have cured to develop adequate strength.
B. Position the main stand assembly on the concrete foundation as shown on the certified drawing(s). Install a
washer and two (2) nuts on each of the anchor bolts. Verify that the main stand is plumb and tighten the
anchor nuts.
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S MUST
10
I. Compartmentized Probe only: Cut & install one 5’-0” length of vacuum hose between the probe tip & the
inner telescoping vacuum tube. Clamp in place using the worm screw clamps provided in the hardware
package.
J. Core Probe only: Install the core vacuum tube kit provided. Refer to the kit installation drawing and the
already installed vacuum tube assembly for proper placement. Cut & install two 5’-0” lengths of vacuum
hose between the core probe vacuum ports & the inner telescoping vacuum tubes. Clamp in place using the
worm screw clamps provided in the hardware package.
K. Route the vacuum hose from the outer telescoping vacuum tube(s) to the Sample Collection Cabinet and the
vacuum power unit. Route the sample hose along the most direct and shortest path. Avoid tight bends and
joints that may become locations that plug. Make all connections airtight and make sure all interior surfaces
of joints are smooth and flush. Any ragged or raised tube ends will collect dust and debris as well as retard
material flow. Escaping sample material can contaminate surrounding atmosphere and equipment. Clamp
in place using the worm screw clamps provided in the hardware package.
L. Install the 1” x 1.5” x 1.5” rotational stops. The two stops must be field-welded to the 1” thick top plate of the
probe stand beneath the driven sprocket of the pivot tube. These stops limit clockwise and counter-
clockwise (right and left) probe rotation. The probe rotation must be limited to 180 degrees for single lane or
300 degrees for dual lane operation. This will prevent the probe from being swung around and hitting the
hydraulic hoses. Reduce the amount of rotation if other obstructions such as buildings, poles, etc. are
nearby. First lightly tack weld the stops to the plate on top of the probe stand. Then swing the Probe
through the entire range of travel to verify that it does not hit any obstruction. When proper stop placement is
determined, weld the stops in their permanent position.
NOTE: WHEN WELDING THE STOPS, CAREFULLY SHIELD THE DRIVE SPROCKET AND OTHER DRIVE
COMPONENTS FROM WELD SPATTER.
M. Remove the pump shipping bracket from the hydraulic power unit. Install the drive coupling & spider from
the hardware kit on the motor provided, but do not tighten yet. Place the motor in the cabinet, slide the pump
mount onto the motor shaft and fasten the motor to the cabinet & the pump mount. Access the coupling
through the hole in the pump mount. Make sure the motor coupling is almost fully engaged, (there should be
about 0.03” to 0.06” end clearance within the coupling, so that no force is pushing on the pump shaft).
Tighten the coupling set screw and replace the pump mount cover.
N. The hydraulic power unit is furnished with the valves pre-wired to an electrical junction box. Have a qualified
electrician complete the probe field wiring. This includes bringing the required power supplies to the
hydraulic unit electrical junction box, motor starter, motor, tank heater, vacuum motor(s), and the operators
control panel. Refer to the certified electrical drawings.
3.5 Initial Startup
A. On the operators control panel, turn the POWER switch on. The hydraulic power unit motor should start,
building system pressure. Verify proper hydraulic pump motor rotation. Correct wiring if necessary.
B. Use the push-buttons or joy-sticks to move the probe around. Make sure the air is removed from all
hydraulic lines. It may be necessary to loosen a hose where it connects to a cylinder, motor, or actuator to
bleed off trapped air.
11
WARNING
HYDRAULIC LINES UNDER HIGH PRESSURE, FLUID CAN ESCAPE WITH GREAT VELOCITY!
EYE AND SKIN INJURY MAY RESULT. USE EYE & HAND PROTECTION WHEN BLEEDING
HYDRAULIC LINES.
C. While operating the Probe, make sure that the hydraulic and vacuum hoses do not become pinched and are
not pulled tight.
D. Adjust the relief valve pressure setting. Refer to section 4.3.2.
E. Adjust the flow control valves which determine the rotational speed (left and right) of the boom. Turn a valve
knob counter-clockwise to increase fluid flow from a motor port; turn a knob clockwise to reduce flow and
slow the motor.
F. After the Probe has operated and air has been purged from the system, add hydraulic oil and raise the level
up to the top line on the level gauge.
G. Turn the vacuum motor on and verify proper operation.
3.6 Controller Location
A. Use vibration isolation pads when mounting the control enclosure or mount the controller in a vibration-free
location.
B. Unless ordered for severe duty, locate controller so it is protected from water and dust.
C. Unless an explosion-proof rated controller was specifically ordered, DO NOT locate the controller in a
hazardous area.
D. Most applications require that the Truck Probe be in easy view of the controller.
3.7 System Wiring
Refer to the certified electrical drawing(s) for specific wiring requirements.
The electrical installation must comply with OSHA Regulations; the National Electrical Code; and all other applicable
federal, state, and local codes and regulations.
If wiring between the controller and the Truck Probe unit is run through rigid conduit, use a short length of flexible
conduit to connect wiring to the Truck Probe. This will isolate the rigid conduit from any vibration originating at the
Truck Probe hydraulic unit.
3.7.1 Electrical Power Requirements, System
Refer to the certified electrical drawing(s) for specific wiring requirements.
12
3.7.1.1 Controller
Refer to the certified electrical drawing(s) for specific wiring requirements.
3.7.1.2 Solenoid Valve Coils
110/120 VAC, 50/60 Hz, Single Phase, 50 Watts.
Optional - 220/240 VAC, 50/60 Hz, Single Phase, 90 Watts.
3.7.1.3 Hydraulic Tank Heater (Optional)
120 VAC, 50/60 Hz, Single Phase, 500 Watts.
3.7.1.4 Hydraulic Pump Motor
Hydraulic Power Unit
Horsepower Voltage & Phase
60 HZ Amps
3 HP TP Comp & Core 230 1PH 14.0
3 HP TP Comp & Core 230/460 3PH 8.29/4.14
3 HP TP Comp & Core 575 3PH 3.32
5 HP STP Comp & Core 230 1PH 21.5
5 HP STP Comp & Core 230/460 3PH 13.2/6.6
5 HP STP Comp & Core 575 3PH 5.28
NOTE: THE MOTOR CHART AMPERAGES SHOWN ARE FOR REFERENCE ONLY. VERIFY BY CHECKING
MOTOR NAMEPLATE.
3.
T
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S
As
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e
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&
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e hydraulic
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factory.
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e Truck Pro
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actuators.
ntaminants f
r
HYDR
A
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OTE: DO
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Plumbing
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ons and all o
t
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e certified d
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When conn
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IV. OPERATIONS AND ADJUSTMENTS
DANGER
FAILURE TO OBSERVE ALL SAFETY RULES, WRITTEN AND IMPLIED, AND THOSE
SUGGESTED BY COMMON SENSE, CAN RESULT IN DEATH, SERIOUS INJURY, AND /OR
EQUIPMENT DAMAGE. LOCKOUT POWER BEFORE PERFORMING ANY MAINTENANCE.
4.1 Operators Control Components And Their Functions
FIGURE 4-1, STANDARD NEMA 12 OPERATORS CONTROL PANEL DETAIL
Refer to the certified electrical drawing(s) for dimensions on control panels with optional features.
15
4.1.1 POWER OFF/ON Switch S-1 & Light
This illuminated selector switch controls electrical power to the controller, valve solenoid coils, vacuum motor relay
coil and the hydraulic motor starter coil. The light is illuminated as long as power is available to the controller and the
POWER switch is set to ON.
4.1.2 VACUUM MOTOR OFF/ON Switch S-2
This switch permits the operator to turn on the vacuum motor when sampling. The motor will need to be turned off
before opening the collection cabinet door.
4.1.3 PROBE MOVEMENT Push-button Switches S-3 thru S-10 (Old Style Control)
The push-button control panel is wired so that only one of the eight valve solenoids can be energized at any given
time. This prevents probe operators from initiating contradictory actions.
4.1.4 PROBE MOVEMENT Joy-stick Switches S-3 & S-4 (Standard JS Control)
Due to the physical arrangement of the switches on the joy-sticks, only one of the four valve solenoids controlled by
each joy-stick can be energized at a given time. As a consequence, two boom/probe motions can be initiated
simultaneously. However, if two boom motions are initiated simultaneously, both will occur at a slower rate because
of the limited pump capacity. It is much harder to accurately control two boom motions simultaneously.
4.1.5 Main Fuse
This fuse, located in a fuse block within the controller enclosure, protects the controller and probe components
against overloads and short circuits.
For 110/120 VAC, 1PH operation use ONLY a Buss Type FNM, 4 Amp, 250 Volt Slo-Blo fuse or equal.
For 220/240 VAC, 1PH operation use ONLY a Buss Type FNM, 2 Amp, 250 Volt Slo-Blo fuse or equal.
4.1.6 Terminal Strip
This 17-position barrier terminal strip is fastened to the sub-plate within the operators control enclosure. It serves as
the controller's interface with and connection point for all external circuits and for the components mounted on the
enclosure's front panel. Refer to the Certified Electrical Drawing(s).
4.1.7 Vacuum Motor(s) Relay
This 25 amp control relay makes and breaks the power to the vacuum motor(s).
16
4.2 Electrical Components
4.2.1 Hydraulic Pump Motor
This motor is coupled to the hydraulic pump via flexible shaft coupling and a pump adapter that bolts to the motor.
The motor runs at fixed speed of ~1800 RPM. A label is located on the pump mount designating the correct direction
of rotation (reference Figure 1-1). Verify that the motor is turning the proper direction of rotation when wiring the
system.
NOTE: DO NOT RUN THE MOTOR THE WRONG DIRECTION. DAMAGE TO THE HYDRAULIC PUMP WILL
RESULT.
4.2.2 Pump Motor Starter & Thermal Overload
The motor starter makes and breaks the power to the hydraulic pump motor. The motor is protected with a set of
overload heaters, that sense the motor current and trip if and overload occurs. If the overload trips, it will be
necessary to determine the cause and manually reset the overload module inside the starter enclosure.
4.2.3 Hydraulic Oil Heater
The immersion heater is mounted in the side of the oil reservoir to heat the oil to a suitable operating temperature.
The heater is rated at 500 watts and has in internal thermostat to shut it off at when the oil has been heated. The
thermostat should be set at 90 degrees F.
4.2.4 Vacuum Motor
The vacuum motor(s) are used to create suction at the probe tip to convey the sample to the collection cabinet. The
vacuum motor(s) are turned on during the probing of a truck and must be turned off to retrieve the sample from the
collection cabinet.
NOTE: SHUT THE VACUUM SYSTEM OFF WHEN EMPTYING THE COLLECTION CABINET. FAILURE TO
DO SO MAY RESULT MECHANICAL DAMAGE TO THE VACUUM MOTOR(S) AND WILL LIKELY PROVIDE A
BIASED SAMPLE.
17
4.3 Hydraulic Components
4.3.1 Solenoid Valves V-1, V-2, V-3, & V-4
These valves are 4-way, 3-position, double-solenoid operated, spring-centered directional control valves. When both
solenoids of a valve are de-energized, the valve spool is spring-centered and hydraulic fluid is routed directly into the
manifold's return passage.
Each solenoid valve also has a manual operator that can be used to physically shift the valve spool. If a valve does
not operate when the associated control switch is actuated, depressing the manual operator with a ball-point pen or a
screwdriver will cause the valve to shift. If the valve shifts, it can be determined that the problem is in electrical circuit
or solenoid.
The electrical connections to the solenoids are accessible by removing the cover of the terminal box on each valve.
The valves are pre-wired to the electrical junction box inside the hydraulic power unit.
Refer to the certified drawings for additional valve information.
4.3.1.1 Boom UP/DOWN Valve V-1
This solenoid-operated directional control valve alternately pressurizes the piston end and rod end of the double-
acting cylinder to raise and lower the boom. When the valve's "A" solenoid is energized, the valve spool shifts,
pressurizing the piston end of the cylinder, thus raising the boom. When the "B" solenoid is energized, the valve
spool shifts, pressurizing the rod end of the cylinder, thus lowering the boom. Note, when neither "A" nor "B"
solenoid is energized the valve is spring centered so that all ports are blocked and movement is inhibited.
4.3.1.2 Counter Balance Valve V-12
Whenatrest,theprobe’sweightcausesstatichydraulicpressure.ThepurposeoftheCounterBalanceValveisto
preventtheprobefromfree‐fallingslightlywhentheprobeisinitiallypowereddown.Thecounterbalancevalve
alsopreventstheprobefromdriftingdown.Iftheprobedriftsdown,thecounterbalancevalvewillneedtobe
adjustedasfollows:
NOTE:PriortoperformingtheCounterBalanceValveadjustment,firstverifythattheUPport,asshownonthe
powerunitdecal,isactuallytheuphose.Ifnot,theUPandDOWNhosesandthecontrolwiresmustbe
reversed.
4.3.1.2.1 Counter Balance Valve adjustment:
A.TurnONthepumpandraisetheboomhalfwayup(horizontal),extendtheboomallthewayout.TurnOFF
thePump.
B.PushINontheDOWNOVERRIDESPOOL,ontheUP/DOWNDirectionalControlValve.Thisisthevalve’s
bottomoverrideaslookinginsidetheHydraulicPowerUnit.
C.WhilepressinginontheDOWNoverride,turntheCounterbalanceValve’sadjustingscrewClockWise(CW),
tolowerthepressure,untiltheboomjustbeginstodrop.SlowlyturnthescrewCCWuntiltheboomstops
lowering.Turntheadjustmentscrewanadditional¼turnCCW.
D.TheCounterbalanceisadjusted.Ifthereisaproblemprobingdownintothematerial,thesystempressure
mayneedtobeincreasedinsmallincrementsuntiltheprobeoperatesnormally.Aftereachsmallincrease
inpressure,monitorthesystempressurebydeadheadingtheprobeinthedownposition.DONOTEXCEED
THERECCOMENDEDSYSTEMPRESSURE.Ifthepressurewasincreased,theLEFT/RIGHTflowcontrolsmay
needtobereadjusted.
18
4.3.1.3 Boom LEFT/RIGHT Valve V-2
This solenoid-operated directional control valve alternately pressurizes opposing ports of the rotational motor to
swing the boom left and right. When the valve's "A" solenoid is energized, the valve spool shifts, pressurizing the
port that swings the boom to the left. When the "B" solenoid is energized, the valve spool shifts, pressurizing the port
that swings the boom to the right. Note, when neither "A" nor "B" solenoid is energized the valve is spring centered
so that all ports are blocked and movement is inhibited.
4.3.1.4 Boom IN/OUT Valve V-3
This solenoid-operated directional control valve alternately pressurizes the piston end and rod end of the double-
acting cylinder to extend and retract the boom. When the valve's "A" solenoid is energized, the valve spool shifts,
pressurizing the rod end of the cylinder, thus retracting the boom. When the "B" solenoid is energized, the valve
spool shifts, pressurizing the piston end of the cylinder, thus extending the boom. Note, when neither "A" nor "B"
solenoid is energized the valve is spring centered so that all ports are blocked and movement is inhibited.
4.3.1.5 Sample Ports OPEN/CLOSE Valve V-4 (Compartmentalized Probe Only)
This solenoid-operated directional control valve alternately pressurizes opposing ports of the rotary actuator to rotate
the sample ports to collect and dump samples. When the valve's "A" solenoid is energized, the valve spool shifts,
pressurizing the port of the actuator that opens the sample ports. When the "B" solenoid is energized, the valve
spool shifts, pressurizing the port of the actuator that closes the sample ports. Note, when neither "A" nor "B"
solenoid is energized the valve is spring centered so that all ports are blocked and movement is inhibited.
4.3.2 Relief Valve V-5
DANGER
EXCESSIVE SYSTEM PRESSURE MAY CAUSE HOSE OR COMPONENT BREAKAGE
RESULTING IN PROPERTY DAMAGE, BODILY INJURY AND/OR EVEN DEATH. SET RELIEF
VALVE TO PROPER SETTING.
The relief valve limits the hydraulic pressure produced by the
pump. Adjust the pressure to the recommended setting.
Check the hydraulic pressure. First open the gauge shut-off
valve. If the pump motor is running and the probe operates at
all, then the gauge should register some pressure. If it does
not, then the gauge may be defective. It is normal for the gauge needle to vibrate slightly. In order to view the relief
valve pressure setting on the gauge, a function must be dead headed momentarily to build pressure. Retract the
boom all the way in. Now activate the probes down function until the cylinder bottoms out. Continue activating the
solenoid momentarily while observing the pressure setting at which the relief valve is set on the pressure gauge.
Adjust the relief valve as necessary.
Hydraulic Power Unit
Horsepower Relief Valve
Pressure Setting
3 HP TP Comp & Core 750
5 HP STP Comp & Core 1250
19
To adjust the relief valve setting, remove the protective cap-
nut and loosen the lock-nut on the valve stem. Use a 1/8" hex
key to turn the valve stem clockwise to increase pressure or
counter-clockwise to reduce pressure. Make valve
adjustments in small increments and observe the gauge while
doing so. When adjustment is complete, tighten the lock-nut
to maintain valve adjustment, then tightly rethread the cap-nut
onto the valve stem.
If no change in pressure is noted when making adjustments,
the relief valve may be sticking or the gauge may be
defective. If the gauge and relief valve have been eliminated
as the source of the problem, then the pump may be worn,
particularly if the problem is low pressure.
NOTE: THE GAUGE WILL LAST LONGER IF IT IS NOT CONTINUOUSLY SUBJECTED TO PUMP
PRESSURE PULSATIONS. CLOSE GAUGE SHUT-OFF VALVE AFTER CHECKING & SETTING PRESSURE.
4.3.3 Boom Left/Right Flow Control Valves V-6, V-7
A pair of in-line flow control valves mounted at the rotational motor, meters the flow of hydraulic fluid out of the
rotational motor ports (reference figure 4-3). V-6 controls the speed of the boom swing to the left. V-7 controls the
speed of the boom swing to the right. The flow controls will need to be adjusted upon initial start-up. To adjust, first
loosen the small set screw on the metering screw. Turn clockwise to decrease boom swing speed and counter-
clockwise to increase boom swing speed. After desired speed is achieved, re-tighten the set screw to lock setting.
NOTE: AVOID EXCESSIVE BOOM SWING SPEED, WHICH WILL RESULT IN UNCONTROLLABLE BOOM
POSITIONING, AND INCREASED WEAR AND TEAR ON THE TRUCK PROBE.
4.3.4 Hydraulic Cylinders
These double-acting, non-cushioned rod cylinders raise or lower, and extend or retract the boom. The up/down
cylinder is 3.00 bore x 24 stroke. The in/out cylinder is 1.50 bore x 48 stroke. The cylinders are attached at each
end to the boom with a pivot pin. Solenoid valve V-1 controls the up/down movement. Solenoid valve V-3 controls
the in/out movement.
4.3.5 Rotary Actuator (Compartmentalized Probe Only)
The actuator is essentially a double acting hydraulic cylinder that drives a rack and pinion unit, thus converting linear
motion into rotary motion. The actuator is coupled directly to the inner tube of the compartmentalized probe. The
rotary actuator opens the sampling ports to receive a sample. When the sampling ports are closed, the sample
dumps into the vacuum conveying chamber of the probe. Solenoid valve V-4 controls rotary actuator motions.
FIGURE 4-2, RELIEF VALVE
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