impact AG 139 User manual
User Guide
User Guide
AG139
Accelerated Polishing Machine
Impact Test Equipment Ltd
www.impact-test.co.uk & www.impact-test.com
Impact Test Equipment Ltd.
Building 21 Stevenston Ind. Est.
Stevenston
Ayrshire
KA20 3LR
T: 01294 602626
F: 01294 461168
Test Equipment Web Site
www.impact-test.co.uk
Test Sieves & Accessories Web Site
www.impact-test.com
Contents
Contents.....................................................................................................................1
SAFETY NOTICE.......................................................................................................2
GENERAL SAFEGUARDS. .......................................................................................2
ELECTRICAL SAFEGUARDS. ..................................................................................2
PERSONAL SAFEGUARDS......................................................................................3
CLEANING.................................................................................................................3
TRANSIT TY WRAPS................................................................................................3
Function .....................................................................................................................4
Machine Features ......................................................................................................5
1. INSTALLATION AND LEVELLING......................................................................6
2. ELECTRICAL INSTALLATION............................................................................7
3. PREPARING SPECIMENS.................................................................................8
4. MOUNTING SPECIMENS ON THE ROAD WHEEL...........................................8
5. WATER FEED.....................................................................................................9
6. CORN EMERY FEED.........................................................................................9
7. FLOUR EMERY FEED......................................................................................10
8. GENERAL CONDITIONS. ................................................................................11
9. ROUTINE MAINTENANCE AND ADJUSTMENT. ............................................11
10. TIMER SETTING /ADJUSTMENT
*For later models refer to appendix A......................................................13
System Diagram.......................................................................................................15
SUPPLY AND REPLACEMENTS PARTS. ..............................................................17
Factory Settings .......................................................................................................17
PSV TESTS - PRODUCT RANGE...........................................................................18
Skid Resistance Tester ............................................................................................18
AGGREGATE ABRASION MACHINE......................................................................20
EC Declaration of Conformity...................................................................................21
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Appendix A
*Controller Programming
(multi-language)..........................................................................................................24
SAFETY NOTICE
WARNING DO NOT CONNECT THE ACCELERATED
POLISHING MACHINE TO ELECTRICAL POWER UNTIL
YOU HAVE READ THESE INSTRUCTIONS
COMPLETELY. KEEP THESE INSTRUCTIONS IN A
CONVENIENT LOCATION FOR FUTURE REFERENCE.
TO GUARD AGAINST INJURY, THE FOLLOWING BASIC
SAFETY PRECAUTIONS MUST BE OBSERVED IN THE
USE OF THIS PRODUCT.
GENERAL SAFEGUARDS.
•Use the machine only for its intended purpose.
•Do not place anything on the machine other than the equipment supplied or
recommended by the manufacturer.
•All protection guards and covers must be in place and properly secured before
operating the machine.
•Do not allow untrained personnel to operate the machine without supervision
from a trained operator.
ELECTRICAL SAFEGUARDS.
WARNING
LETHAL VOLTAGES MAY BE EXPOSED IF COVERS
ARE REMOVED WHILST CONNECTED TO THE
SUPPLY.
•The machine must be connected to a supply voltage corresponding to the
electrical rating plate.
•Unplug the machine before moving it, or when it is not in use.
•Trailing leads must be covered, sign-posted, or secured to avoid trip hazards.
•Observe all Hazard Warning notices.
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PERSONAL SAFEGUARDS.
•Do not tamper with the machine whilst it is operating.
•Care must be taken when removing / replacing the Road Wheel. It is heavy.
•Loose clothing must be properly secured.
•Suitable personal protective clothing should be worn when operating or cleaning
the machine, e.g. coveralls, eye protection, safety shoes. In addition, gloves and
a breathing mask should be used when dispensing the emery flour powder.
•Local health & safety regulations must be observed.
CLEANING
•DISCONNECT FROM THE ELECTRICAL SOURCE BEFORE CLEANING THE
MACHINE.
•When cleaning the machine do not use a pressure hose directed against the
bearings or electrical components.
•Remove the feeder(s) from the machine prior to cleaning. Do not immerse the
feeders in any liquid or clean with solvents. Adequate cleaning is achievable with
an air hose and a good quality brush.
TRANSIT TY WRAPS
Remove the transit Ty wraps located on the Main Armature, Mains Lead and the
Flour Feeder.
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Function
The function of the Accelerated Polishing Machine is to produce polished stone
samples of aggregates used in road surfaces, to simulate actual road conditions.
The samples produced form an integral part of the Polished Stone Value (PSV) Test.
The PSV Test is a friction test that calculates a measure of resistance to skidding,
performed using a Skid Resistance Tester.
Road Safety
The use of PSV’s in road construction has had a major influence in the reduction of
accidents.
Standards
In order to understand and carry out the PSV Test, one of the following documents is
necessary:
BS 812 Pt 114, BS EN 1097-8:2000, ASTM E303.
Operation Overview
Fourteen specimen aggregate samples are clamped around a rotating Road Wheel.
These samples are subjected to two timed stages of abrasive polishing under a
loaded rubber tyre. First by Corn Emery grit, and secondly by Flour Emery powder.
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Machine Features
•Heavy welded steel mainframe, standing on adjustable anti-vibration mounts.
•A steel main spindle running in sealed ball bearings, protected by a labyrinth
seal. (The spindle is axially loaded to eliminate end-play).
•3Ø motor with speed control and an adjustable timing belt drive.
•A digital timer enabling accurate tests.
•Accurately machined moulds for the manufacture of specimens.
•Specimens located on a Road Wheel by rubber rings and held by a simple side
fixing.
•Tyred wheel easily removed for replacing worn tyres.
•Water, gravity fed, from a high level tank through a calibrated flow meter.
•A removable Collecting Tray for spent abrasive and water.
•A mechanical lifting device to lower and raise the loaded tyre to the running
surface.
•24V AC feeders and control circuits for safety.
•An Electro-magnetic safety switch to ensure that removable safety covers are in
place.
•Tamper-proof machine screws on access covers.
•Electrical hazard warning labels.
•CE certified.
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1. INSTALLATION AND LEVELLING.
1.1 On receipt. Inspect the unit for any damage incurred during transit. Check the
loose components against the Packing List below.
Qty Item
1 Operating Instructions
4 Specimen Moulds
2 Mould Plates
1 Flour Spreader
1 Feeder Unit (Corn Emery)
1 Feeder Unit (Flour Emery)
1 Water Tower & Bracket Assembly
1 Drip Tray
1 Tyred Wheel (Flour Emery)
4 Anti-Vibration Mounting Pads
1 1.2mm Hexagon Socket Wrench
1 4mm Hexagon Socket Wrench
1 5mm Hexagon Socket Wrench
1 6mm Hexagon Socket Wrench
1 17mm Hexagon Socket Wrench
4 Rubber Rings (Road Wheel)
1 Certificate for Tyre Rubbers
1 Weight
1.2 Fit the following loose packed items on to the machine:
(a) Corn Emery Feeder Unit (Black Hopper) to the Mounting Block on the
top right hand side of the machine.
(b) Drip Tray below the Road Wheel.
(c) Water Tower & Bracket Assembly, inc. water feed pipe. Do not over
tighten the pipe gland, but ensure it is airtight.
(d) The Weight onto the Pivoted Arm. This operation requires two
personnel.
1.3 BS812 requires the machine to be rigidly mounted on a firm and level
concrete base. The Anti-vibration Mounting Pads supplied are considered
acceptable for mounting on any firm and rigid level surface.
1.4 Levelling. It is important when levelling the machine to maintain the running
face across the tyre in a horizontal plane. This can be achieved by placing a
spirit level laterally across the Pivoted Arm of the machine and adjusting the
front in relation to the rear. When running, with the Flour Emery Feeder in
operation and with the correct water/powder ratio, the slurry formed on the
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tyre will tend to take up a distinct track at some position across the running
face of the tyre. The object of this levelling procedure is to ensure that this
track is centrally disposed across the tyre.
1.5 Check that the Corn Emery Tyred Wheel is fitted to the Pivoted Arm, and that
this arm is lifted clear of the Road Wheel by turning the Handwheel (situated
behind the weight), fully clockwise. Remove the front cover from the machine.
Then remove the large retaining screw on the end of the Main Spindle (using
the 17mm Hexagonal Socket Wrench), and pull the Road Wheel off.
2. ELECTRICAL INSTALLATION.
2.1 Check that the electrical specification of the machine is suitable for the
available supply. The unit is wired through the Flexible Cable provided.
Connection to the supply can be either through a fused three-pin plug, or
preferably through a fused switch connected as follows:
Brown - Live
Blue - Neutral
Green/Yellow - Earth
The fuse must be rated at:
•13 Amps on 220 / 240v AC.
•16 Amps on 110v AC.
Running the machine supply voltage through a 30mA RCD (Residual Current
Device) is recommended.
2.2 With the Feeder located in its Mounting Block, electrically connect the Feeder
Unit by pushing the miniature plug fitted to the flexible lead into the socket of
the feeder.
2.3 The Control Unit electronically controls the machine. This is situated at the
back of the machine. Separate switches give control of the Start/Stop
operation, the Feeders, and the Motor speed. The motor will only operate if
the front cover is in place, and the timer has been pre-set. The Feeder
will only operate with the Motor switch in the ON position.
2.4 Protection fuses are fitted to the Control Unit panel for the incoming supply
voltage and the 24V displays supply. Fuse rating as marked.
2.5 The START/STOP switch indicates the electrical status of the machine.
a) The central “eye” of the switch glows dimly when power is applied. This
indicates a state of “readiness”, i.e. the safety cover is in place, internal
interlocks are engaged and 24V AC is available to the feeders.
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b) On depressing the START button, the “eye” will glow brightly.
c) An unlit “eye”, indicates that the machine has either “timed out” or the
safety cover isn’t fitted.
3. PREPARING SPECIMENS.
3.1 Sand, Cement, and Mortar Specimens are now considered obsolete.
3.2 Resin Specimens - It is essential to retain the Metal Backing Plate firmly
clamped to the mould until the resin has completely cured. Premature
withdrawal will allow the specimen to lift at the ends and from a radius smaller
than that required to match the mounting surface of the wheel, with a resultant
cracking of the specimen and uneven running of the tyre.
3.3 Further information on the preparation of specimens is detailed in BS EN
1097-8:2000.
4. MOUNTING SPECIMENS ON THE ROAD WHEEL.
4.1 Remove the Road Wheel from the machine using the 17mm Hexagonal
Socket Wrench. Lay the Road Wheel flat on a firm level surface. With the
6mm Hexagonal Socket Wrench, withdraw the 6 socket cap retaining screws
securing the Front Clamping Ring. Note: There are 3 ‘Jacking’ holes provided
in this ring to facilitate easy removal.
4.2 Place a rubber ring over the Road Wheel periphery and locate the specimens
into the Rear Clamping Ring. Lift the rubber ring to locate it between the
specimen and the chamfer machined on the outer diameter of the clamping
ring locating groove. Tie a cord around the periphery of the specimens to hold
them tight to the wheel.
4.3 Place the second rubber ring over the specimens and fix the Front Clamping
Ring to the wheel. Check that this rubber ring is correctly located and that the
specimens are correctly seated. Tighten the 6 socket cap fixing screws and
remove the cord.
4.4 The specimens should now be held firmly without any damaging pressure
exerted. Ensure that a true running surface has been obtained.
4.5 Mount the Road Wheel on to the machine Main Spindle and lock the
Retaining Disc and Screw into position, using the 17mm Hexagonal Socket
Wrench.
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5. WATER FEED.
5.1 Remove the Water Tank Lid and fill the tank to a level so that the water is
approximately 25mm from the tank lip. Refit the Water Tank lid and ensure
that it is secure. Open the valve on the tank outlet and adjust the knurled knob
at the base of the flowmeter to the required flow. (Nominally 110 cc/min).
NOTE: Do not close this valve completely as this can damage the needle.
5.2 A full tank of water will last for approximately one hour. Repeated fillings will
be required for tests exceeding this period.
NOTE: Care must be taken when refilling the water tank during operation.
Spillage could result in an electrical malfunction. If practical, suspend the test
and remove the power before refilling the Water Tank.
6. CORN EMERY FEED.
6.1 Locate the Corn Emery Feeder in its Mounting Block and align centrally over
the Feed Chute. Plug the flexible feeder lead into its socket on the side of the
Feeder Hopper. Switch on and check the free rotation of the feeder (i.e. the
Drive Pulley is rotating at its nominal speed of 6 rpm=). The feeder is factory
set to operate within the required limits of 20 to 35 gms / min. (Nominally 27
gms / min). The rate of feed can be finely adjusted by setting the Slide Plate
on the front of the hopper, using the 4mm Hexagonal Socket Wrench. Varying
the hopper height using the 4 M5 screws effects coarse adjustment.
=Note: The Corn Feeder Drive Belt rotates at approximately 2½ rpm.
6.2 Switch off the feeder. Fill the hopper with Corn Emery abrasive. (A full hopper
will last approximately one hour). Switch on and check the feed over a short
period of time. Check that the abrasive flows freely down the chute to the
point of contact of the tyred wheel with the specimen.
6.3 Adjust the water flow at a rate sufficient to carry the Corn Emery at a steady
rate down the chute without blocking. Excess water reduces the effective
polishing.
6.4 Reset the Timer to zero before starting the timed test.
6.5 With the machine running, lower the tyred wheel onto the specimens by
rotation of the handwheel situated behind the weight. The machine will stop
automatically upon reaching the Timer pre-set figure.
6.6 Adjust the Road Wheel rotation speed to 320-rpm ±5 with the Speed Control
on the Control Unit. (The speed can be “locked in position” by pressing down
the lever on the speed control potentiometer).
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6.7 On completion of the timed run, raise the pivoted arm clear of the Road
Wheel. Disconnect the machine from the supply voltage. Release the
safety cover and remove the Road Wheel from the machine. Thoroughly
clean out the spent abrasives.
6.8 It is essential to clean the feeder thoroughly at the end of each run.
7. FLOUR EMERY FEED.
7.1 Lift the Tyred Wheel Cover and change the Corn Emery Tyre for the Flour
Emery Tyre by unscrewing and withdrawing the Locating Screw. Remove the
black Blanking Plate from the cover.
7.2 Locate the Flour Emery Powder Spreader on to the Tyred Wheel Cover (2
Hexagonal Socket Cap Head Screws). Check that the spreader is set level
and at the correct height to allow the tip of the felt pad to just clear the
running face of the tyre.
7.3 Locate the Flour Emery Feeder into its Mounting Block on top of the
mainframe and align with the Flour Spreader aperture. Insert the plug
originally located in the Corn Emery Feeder into the Flour Emery Feeder.
Switch on and check the free rotation of the feeder (i.e. the Drive Pulley is
rotating at its nominal speed of 1½ RPM). The Feeder Unit is factory set to
operate within the limits of 2 to 4 gms/min. (Nominally 3 gms/min). The rate of
feed may be finely adjusted by setting the slide plate on the front of the
hopper. Varying the hopper height using the 4 M5 screws carries out coarse
adjustment.
7.4 Fill the Hopper with Flour Emery Powder. Switch on and check the feed over
a short period of time, check that the powder flows freely into the powder
spreader at all times.
7.5 Adjust the water feed to within the limits required. Ideally the water/powder
mix should produce slurry which will just adhere to the running surface of the
tyre. A dry mix will produce a hard crust and a wet mix will tend to wash the
wheel clean.
7.6 Reset the Timer to zero before starting the timed test.
7.7 Adjust the Road Wheel rotation speed to 320-rpm ±5 with the Speed Control
on the Control Unit.
7.8 On completion of the timed run, raise the pivoted arm clear of the Road
Wheel. Disconnect the machine from the supply voltage. Release the
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safety cover and remove the Road Wheel from the machine. Thoroughly
clean out the spent abrasives.
7.9 It is essential to clean the feeder thoroughly at the end of each run.
8. GENERAL CONDITIONS.
8.1 These operating conditions are complementary to BS812 Pt.114 & BS EN
1097-8:2000 or ASTM E303.
8.2 All guards are to be securely placed into position when test is in progress.
8.3 The machine should be sited in a draught free, dry and dust free location.
8.4 When cleaning the machine do not use a pressure hose directed against the
bearings or electrical components.
9. ROUTINE MAINTENANCE AND ADJUSTMENT.
9.1 Isolate the machine electrically before attempting any maintenance.
9.2 All bearings are grease packed on assembly and do not require any routine
attention.
9.3 Before each test very lightly oil the Sintered Bronze Bushes situated on the
Pivot Pin of the Pivoted Arm, and wipe clean.
9.4 Drive Belt Adjustment. Remove the rear cover over the Drive Pulleys.
Slacken the 4 Motor Slide Plate nuts. Adjust the tensioning screw below the
Motor Slide Plate. Tighten the 4 Motor Slide Plates nuts. A slack drive belt will
jump the teeth and a tight one will overload the bearings.
9.5 Rubber Tyre Replacement. To change a tyre, remove the 3 Hexagonal
Socket Cap Screws within the Wheel Hub and lightly press on the raised
centre of the Hub, on the same side of the wheel from which the cap head
screws were withdrawn.
9.6 Timed Tests.The Timer should be pre-set to the required test time by the
Operator. Using the procedure outlined at paragraph 10. The machine will
stop automatically when the pre-set time is reached. The Timer is pre-set at
the factory to 3 hours.
9.7 The Timer operates on an additive principle. To start an initial series of
tests the Timer must be reset to zero by depressing the RED Button (on
the timer fascia). If a test is interrupted/suspended within the pre-set time,
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there is no need to reset the Timer to continue the test. The machine can be
restarted with the Start/Stop Switch in the normal manner. The machine will
continue its test until the pre-set time is reached.
9.8 The Feeder Units must be set with a gap between the bottom of the Hopper
and the surface of the belt to allow free rotation. If necessary, adjustment is
carried out using the 4 M5 Slotted Screws. The normal factory setting is
0.25/0.38mm.
9.9 The Motor Switch has a “no volt” release trip for safety (i.e. the motor needs to
be restarted by depressing the ‘START’ button).
9.10 When the Road Wheel is removed, ensure that it is replaced the correct way
round. The front of the wheel is either stamped “FRONT” or marked by a
“Yellow Disc” on the side facing outwards.
9.11 Not In Use. When the machine is not in use, lightly oil the Main Spindle and
Road Wheel Bore. Remove the Tyred Wheel(s) and store appropriately.
9.12 Further maintenance information is outlined in BS EN 1097-8: 1999 Annex C.
NOTE : The machine will not start until the removable front
cover is in place, and the timer has been pre-set.
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10. TIMER SETTING / ADJUSTMENT.
10.1 To set / adjust the timer
a) Press Red Button (Reset).
b) Press P(Program button).
c) Press the horizontal arrow key to select required digit. Displayed in the
format ‘hh.mm.ss’.
d) Press the vertical arrow key to select required number.
e) Repeat ‘c’ and ‘d’ until the required time is set.
Note: The Timer is not adjustable whilst the machine is running.
10.2 To adjust the road wheel R.P.M.
While the machine is running the RPM is displayed on the digital readout. To alter the
speed of the Road Wheel turn the adjustment control clockwise or anti-clockwise as
required.
Note: Minimum and maximum shaft rotation speeds (approximately 310 & 446 rpm)
have been factory set.
Adjustable Timer
Digital RPM
Display
RPM Adjustment
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*
For later models please refer to Appendix A
*
- 14 -
System Diagram
MAINS CONTROL
PROXIMITY
SWITCH
MAGNETIC
SWITCH
FEEDERS
MOTOR
INTERCONNECTION
BOX
INVERTER
CONTROL
MAINS
MOTOR
G1 CP1 CP2 CP3
G2
G3
G4
G5
G6
MAINS IN CONTROL UNIT
M
- 15 -
FAULT DIAGNOSIS
PROBLEM CAUSE SOLUTION
Machine will not start No power
Stop/Start not
illuminated
Timer not set/reset
or timed out
1. Check supply fuse
2. Check 10A fuse in
Control Unit
Fit/Refit safety cover.
Reset timer or set timer
as per paragraph 10
No displays 24V supply failure Check 0.2A fuse in
Control Unit
Excessive vibration Drive belt too tight
Road Wheel loose
Adjust Drive Belt as per
paragraph 9.4
Check that the Road
Wheel retaining disc is
fitted and that the
securing screw is tight
Feeder(s) fail to
operate No power
Maladjusted feed
1. Check that the flexible
feeder cable is correctly
inserted into its socket
2. Adjust hopper height
to release pressure on
the belt
3. Adjust hopper slide
plate to allow free
rotation of the drive belt
Clogged Corn Feeder
chute Maladjusted feed /
water flow rate Adjust hopper slide plate
and/or water flow until
condition desists
Clogged Flour
Spreader chute Maladjusted feed /
water flow rate 1. Adjust hopper slide
plate to decrease the
flow rate of the emery
flour powder
2. Adjust the water flow
rate until the condition
desists
3. Check the alignment
of the Flour Spreader in
relation to the Road
Wheel
- 16 -
SUPPLY AND REPLACEMENTS PARTS.
1. AGGREGATE SUPPLIES
DESCRIPTION SUPPLY QUANTITY
Control Stone 25Kg Bag
Criggion Stone 25Kg Bag
Corn Emery 25Kg Bag
Flour Emery 25Kg Bag
Leighton Buzzard Sand†25Kg Tub
†Special Order Only.
2. REPLACEMENT PARTS
DESCRIPTION
Specimen Mould
Specimen Mould Plate
Tyred Wheel
Felt Seal - Main Spindle
Felt Pad - Flour Spreader
Rubber Rings (Set of 4)- Road
Wheel
Timing Belt
Drive Belt Feeder
Pneumatic Tyre (ASTM)
Factory Settings
Prior to despatch, the Accelerated Polishing Machine and its accompanying
accessories are tested mechanically and electrically. The table below details the
factory default parameters.
ITEM FACTORY SETTING
Flour Flow Rate 3 gms/min ±1
Corn Flow Rate 27 gms/min ±7
Water Flow Rate 110 cc/min
Load on Sample 725 N ± 10
Wheel Alignment ≤0.8mm
RPM (variable) 320 rpm ±5
Shaft Speed (min/max) 310 / 446 rpm
Timer (test time value) 3 hours
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PSV TESTS - PRODUCT RANGE
In accordance with BS EN 1097-8:2000, to determine the PSV it is necessary to use
the Skid Resistance Tester & Base Plate.
Skid Resistance Tester
Introduction
The Skid Resistance Tester was originally developed by the Transport Research
Laboratory (TRL) to study the problems in design and maintenance of public
highways. It’s also known as the British Pendulum Tester, Portable Skid Resistance
Tester and the Pendulum Tester.
The Skid Resistance Tester is used to test the Skid Resistance Value (SRV) of
existing road surfaces.
The Skid Resistance Tester measures the frictional resistance between a rubber
slider mounted on the end of a pendulum arm and the test surface. This provides
highway and flooring engineers with a routine method of checking the resistance of
wet and dry surfaces to slipping and skidding.
The Skid Resistance Tester has a robust and rigid design for protection against wear
and tear, weathering and dirt contamination.
The instrument is now used in many applications to test the slip resistance on
pedestrian walkways and flooring, within offices, hospitals, shopping centres and
factories, both at the design stage and also in the investigation of accidents.
Machine Operation
The Skid Resistance Tester is based on the Izod principle. A pendulum consisting of
a tubular arm rotates about a spindle attached to a vertical pillar. At the end of the
tubular arm a head of constant mass is fitted with a rubber slider. The pendulum is
released from a horizontal position so that it strikes the sample surface with a
constant velocity. The distance travelled by the head after striking the sample, is
determined by the friction to the sample surface. A reading of Skid Resistance
Values is obtained.
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