Gyratory Compactor

CRT-
CRT-GYR-
GYR-1730
1730-
30-08
CRT-GYR
Gyratory Compactor
User Manual

Revision: Issue 7 Date: Dec 2016

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Cooper Research Technology Ltd
Unit 1
Albert Court,
Peasehill Road,
Ripley,
Derbyshire, DE5 3AQ, United Kingdom

Tel: 01773 512174

Fax: 01773 512175

E-Mail: [email protected]
Web: www.cooper.co.uk

VAT Registration Number: GB558 4456 08

All copyright © reserved to Cooper Research Technology Ltd 2006.

Cooper Research pursues a policy of continuous development and product improvement. The
specifications in this document may therefore be changed without notice.

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Contents

Document overview……………………………………………………………………….. P.4

Glossary of Terms, Abbreviations and Definitions…………………………………. P.5
Typographical Conventions……………………………………………………………... P.6
Product Overview…………………………………………………………………………. P.7
General Description………………………………………………………………………… P.7
Machine Elements………………………………………………………………………….. P.8
Controls……………………………………………………………………………………… P.9
Installation………………………………………………………………………………….. P.10
Location……………………………………………………………………………………… P.10
Electrical Supply……………………………………………………………………………. P.10
Pneumatic Supply…………………………………………………………………………... P.11
Software Installation………………………………………………………………………… P.11
Operation……………………………………………………………………………………. P.12
Start up the Compactor…………………………………………………………………….. P.12
Load the Software…………………………………………………………………………... P.12
Performing a Compaction………………………………………………………………….. P.12
Mould Extraction…………………………………………………………………………….. P.13
Maintenance………………………………………………………………………………... P.15
Quality Certificate…………………………………………………………………………. P.18
Warranty…………………………………………………………………………………….. P.19
Copyright…………………………………………………………………………………….. P.19
Force Majeure……………………………………………………………………………….. P.19
Jurisdiction…………………………………………………………………………………… P.19

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Document Overview

This manual contains comprehensive information about the operation and maintenance of
the CRT-GYR Gyratory Compactor EN.

Please take the time to read this manual as it contains information on the installations,
maintenance and use of the GYR

This manual is aimed at general users of the GYR, including Lab Technicians,
Maintenance Technicians and Technical Users.

This manual should be strictly observed. Cooper Research Technology accepts no liability
for damage caused by disregarding the information contained in this manual or other
related documents.
i

For more information contact Cooper Research Technology – www.cooper.co.uk i

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Glossary of Terms, Abbreviations and Definitions
Abbreviations Description
CRT Cooper Research Technology
EN European Norm
kPa Kilo Pascal
GYR Gyratory Compactor
cfm Cubic Feet/Min.
mm Millimetres
Hmin(mm) Defined in the Standard
mPa Mega Pascal

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Typographical Conventions
Icon Description
This icon denotes a caution, which advises you of precautions to
! take to avoid injury to equipment or loss of data.
This icon denotes a note, which alerts you to important information,
i further information in this document or other sources such as
manuals, data sheets, literature etc.
Bold text indicates a reference to a physical or software control, or a
Bold
user interface screen.

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Product Overview
This section provides an overview of the GYR

General Description
The CRT-GYR gyratory compactor is the third series of gyratory compactor from the
Cooper Group. It is specifically designed to meet the EN and AASHTO requirements, be
high quality and user friendly.

The gyratory motion is generated with a precise eccentric which is factory calibrated to
o o
0.82 +/-0.02 (note: the CRT-GYR can be set to achieve angles outside of this range).
Speed of gyration is accurately controlled with an inverter and is accurate to greater than
0.5 rpm.

Load is applied with a 160mm diameter pneumatic cylinder and each compaction load
controlled with a pressure regulator. The pneumatics has a switchable pressure so that
600kPa can be achieved for both 100mm and 150mm specimens. The specimen height is
measured with a 250mm stroke linear transducer.

Test software allows the user to select compaction methods based on achieving a target
density, or specified number of gyrations. The number of gyrations, compaction depth and
density are logged to disc and displayed on screen. Percentage void content is calculated
and displayed on screen.

The desktop PC is connected to the gyro through a high speed Ethernet connection.

Emulsion mixtures can be compacted using perforated moulds.

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Machine Elements

2 5

Part No. Part Description Quantity

1 Main Actuator 1
2 Mould Extruder 1
3 Front Control Panel 1
4 Top Safety Door 1
5 Bottom Safety Door 1
6 Air Inlet Regulator 1
7 Mould Retaining Bar Locking Pin 1
8 Mould Retaining Bar 1
9 Main Ram 1

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Controls

Front Panel Mould Extractor

1 2

Right hand side Right hand side Back panel

6 7

Part No. Part Description

1 Air pressure gauge
2 Safety reset button
3 Power on/off button
4 Mould extractor raise/lower switch
5 EMERGENCY STOP push button
6 Pressure regulator switch
7 Main isolator

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Wire colour Function
Green/Yellow Earth
Blue Neutral
Brown Live
Installation

This section describes the basic tasks that must be carried out when the machine is first
installed, moved to a new location or if the software needs to be installed.

Location

The machine should be located in a dry and adequately ventilated room. To ensure
efficient operation, it must not be placed in direct sunlight or against heat-emitting
surfaces. The machine should be conveniently located to allow access all round.

Warning: be aware that cables may be stretched across the path when moving items
around.
To avoid hazards of this type, place a mat or a cable cover over the wire and tubing.

Electrical Supply

Warning: the following operations should only be carried out by suitable qualified staff.

The machine requires a 220-240V A.C. 50Hz supply.

This equipment should not be installed on a RCD protected supply. If it is a legal

requirement for RCD protection to be fitted, then a Type B or B+ RCD must be
fitted.

This equipment is NOT supplied with a plug. An appropriate mains lead with bare wire
ends will be provided with each cable core identified accordingly (see table below).

Wire colour Function

Green/Yellow Earth
Blue Neutral
Brown Live

Note: the colours of the wires in the mains lead of this appliance might not correspond i
with the colour marking identifying the terminals in the wall socket.
Note: it is not recommended that the GYR is powered from a supply that contains a RCD.
Use of a RCD might result in the supply tripping when the machine is switched on.
i

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Pneumatic Supply

Warning: the following operations should only be carried out by suitably qualified staff.

The machine requires a pneumatic supply with a minimum pressure of 6bar, maximum
10bar. 7bar is required to achieve test load on 150mm diameter specimen, 10cfm. The
machine is supplied with 8mm tubing for connection to the compressed air supply. The
supply should be attached to the Air Inlet Regulator.

Software Installation

It is important to ensure the Cooper software is installed before the NI software.

Contact Cooper Research Technology for assistance.

Connect the USB from the PC to the machine, if the PC pops up with a window asking to
install new hardware then insert the disc provided which is labelled ‘BELKIN Gigabit USB
2.0 Network adapter’ and follow these steps:
- Follow the steps in the install wizard, once complete a new local area network
connection will be available.
- Open ‘network connections’ which can be accessed through the settings part of
the windows start menu.
- Locate the new connection and right click, and select properties. The window
below should appear, ensure ‘Belkin F5D5055’ is in the text box in ‘Connect
using:’

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- Highlight ‘Internet Protocol (TCP/IP)’ and click the properties button.
- Select ‘use the following IP address’ and enter the values shown below:

- Click ‘OK’ once the values have been entered to confirm.

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Operation
This section describes how to use GYR and its software to perform a compaction.

Start up the Compactor

The GYR is controlled by the PC which should be positioned to the right hand side of the
machine. To turn on the machine and start the software follow this procedure:
1. Ensure the machine is connected to the electrical and pneumatic supplies.
2. Turn the isolator switch on the rear panel to the “I” position.
3. Turn the red knob on the air inlet to the “SUP” position. Ensure the pressure
gauge reads 0.6mpa minimum. If the pressure is reading less than this pull the
centre black knob up and ensure it is fully open.
4. Press the power button on the front panel.
5. Connect the USB to the machine and PC.
6. Turn on the PC and wait for windows to load.

Load the software

Click Start >> All Programs >> CRT >> Gyratory Compactor. The following screen will
appear. The system check panel and calibration factors are for use by CRT engineers
only.

Performing a compaction

To perform a compaction click Compaction. The following screen will appear.

Note: you can return at any point by clicking Previous.

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 1. Open the bottom safety door by rotating the knob and pulling the door towards
you. Open the top safety door by lifting up until the magnets hold the door in
place.
2. Open the mould retaining bar by lifting the retaining pin up and pulling the bar
towards you.
3. Place the bottom platen into the bottom of mould. We recommend paper disks are
placed between platens and material. Note: the 100mm bottom platen should be
inserted such that the smaller diameter is towards the bottom.
4. Place a known mass of material into the mould.
5. Position top platen on top of the material.
6. Select compaction type (either number of gyrations, target density or target
height).
7. Enter specimen reference (this number can be made up of any alphanumeric
characters).
8. Select data file path by clicking on the file icon. Test data is stored by default in
“C” drive >> gyratory compaction >> gyratory data.
9. Enter mould diameter either 100mm or 150mm.
10. Select the test type (EN 12697-31 Specimen preparation, EN 12697-31 Void
Content analysis, or AASHTO T312-09).
11. Enter the material mass.
12. For EN 12697-31 Void Content analysis, enter hmin(mm).

Click next. The following screen appears:

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Select the correct pressure for size of mould by turning the pressure regulator on the right
hand side of machine to either Low for 100mm moulds or High for 150mm moulds.

Follow the on screen instructions:

1. Insert mould into machine.
2. Close mould retaining bar and ensure locking pin is pushed fully down.
3. Close the safety doors. Top door first then bottom door.
4. Press begin compaction when ready to start compaction.

Note: you can return to the test setup screen by clicking back to setup. i

Press the safety reset switch on the front panel. The switch light turns from red to green
and compaction begins: mould locks in place and main ram comes down.
Note: test data is plotted every 5 x gyrations. i

When compaction is finished the main ram will raise and the mould is released. Open the
safety doors, open the mould retaining bar and slide the mould out of the machine.

Mould Extraction

1. Slide the mould over the mould extraction ram. Ensure it seats under the retaining
rim.
2. Turn the mould extraction switch to the up position. The mould will be extracted.
3. After the mould has been extracted turn the switch back to the down position.

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maintenance
This section contains details on general and routine maintenance of the GYR.
Warning: the following operations are to be carried out by skilled staff only.

Maintenance Schedule
Note: the following maintenance should be carried out by skilled staff. For further information
regarding maintenance contact Cooper Research Technology. i
ID Interval Description Ref
1 Daily Ensure any foreign objects that may have fallen into the tray,
crevices etc. are removed.
2 Daily Check control panel warning lights.
3 Weekly Visually check the hydraulic oil reservoir, if low top up and
check for leaks.
4 Weekly All tubing and fittings on the pneumatic circuits to be checked
for leaks and rectified accordingly.
5 Weekly Lubricate the main ram using a light oil eg. WD40.
5 3 months Service the motor MP1
6 3 months service the gearbox MP2
7 Yearly change air inlet filters

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MP1 - Service the motor

Before any intervention, the motor, auxiliary circuits and/or accessories must be disconnected
from the mains.

In particular:

• Check disconnection from the electrical mains.

• Provide suitable protections from exposed live parts.
• Double check that accidental restarts are not possible under any circumstances.
It is recommended that periodical checks of motor operating conditions are scheduled as a
routine maintenance practice.

Check particularly on the following:

1. Check that operation is smooth and absorbed current within rated value.
2. Keep motor clean and fan cowl unobstructed by accumulation of dust or foreign
particles.
3. Check that seal rings are in good condition.
4. Check that lead-in wires and all wirings are safely and tightly secured.
5. If condensate draining holes are provided, remove periodically the screws that close
the holes and allow the condensate to drain.
6. Standard bearings are grease packed for life and in general no periodical maintenance
is required; it is good practice however to check their condition and eventually replace
them after approx. 3 years.
The motor does not have to be removed for normal inspections unless the bearings need to be
replaced. In this case, the operations should be performed by specialised personnel and with
appropriate tools.

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MP2 – Service the gearbox

Warning: before doing any work on the unit, the operator must first switch off the power to the
gear unit and ensure that it is out of service, as well as taking all necessary precautions
against it being accidentally switched on again or its parts moving without warning (due to
suspended loads or similar external factors). Furthermore all additional environmental safety
precautions must be taken (e.g. elimination of residual gas or dust, etc).

• Before doing any maintenance work, activate all safety equipment and if necessary,
inform persons working in the vicinity. In particular, mark off the area around the unit
and prevent access to any equipment which, if activated might be the cause of
unexpected health and safety hazards.
• Replace worn components with original spare parts only.
• Use the lubricants (oil and grease) recommended by the manufacturer.
• When working on the gear unit always replace gaskets and seals with new original
ones.
• If a bearing requires replacement, it is good practice to also replace the other bearing
supporting the same shaft.
• We recommend replacing the lubricating oil after all maintenance work.

Note: the above instructions are aimed at ensuring efficient and safe operation of the gear
unit. The manufacturer declines all liability for injury and damage to components due to the
i
use of non-original spare parts and non-routine work, which modifies the safety requirements
without the express prior authorisation of the manufacturer. Refer to the specific spare parts
catalogue when ordering spare parts for the gear unit.

Warning: do not dump polluting liquids, worn parts and maintenance waste into the
environment. Dispose of all such materials as stipulated by applicable legislation.
• Observe the routine inspection and maintenance schedule.
• Before servicing or repairing internal components, allow the gear unit to cool down
completely before opening the casing so as to avoid burns from parts which are still
hot.
• Make sure, on completion of maintenance work, tighten all vent, filler and level plugs
to their specified torque.
• On completion of any maintenance work, all seals must be refitted and sealed as
prescribed. On gear units with double seal rings, the cavity between the two rings must
be packed with synthetic grease (fluorocarbon gel 880 ITP or equivalent product with
similar properties and application range) before assembly.
• Regardless of the type of gear unit, whenever a seal ring is replaced its lips should be
smeared with a thin layer of grease (fluorocarbon gel 880 ITP or equivalent product
with similar properties and application range) before assembly.
• Use only original spare parts for repairs.

Routine maintenance

Keep the gear unit at its maximum efficiency by following the routine maintenance schedule
specified by the manufacturer.
Good maintenance enables the unit to operate at its maximum performance over a long
service life in compliance with safety regulations.

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10

Frequency Component Type of work Operation

1000h External seals and Maintain or replace
Check oil level. Check
gaskets components as
for leaks by eye
required
3000h For gear units with Check for Replace if no longer
torque arm cracks/ageing fully effective

5000h Gear unit seals and Inspect carefully for Replace if aged or worn
gaskets wear/ageing of external
seals

Depending on the temperature reached by the lubricant, it should be replaced at the intervals
indicated in table below:
o
Oil temperature t( C) Hours
t<65 25000
65<t<80 15000
80<t<95 12500

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CRT-CALANG (Available as an accessory item at extra cost)

Using the Gyratory Compactor external angle gauge

[1] Enter the desired angle into the Dial gauge calculation spreadsheet (Main sheet tab) as
shown below to calculate the required throw in mm:

[2] Attach the dial gauge to the Gyratory compactor using the supplied mounting screws.

Please note there are three small phillips screws which attach the dial gauge to the
bracket (these are normally fitted before delivery), and two allen screws which attach
the dial gauge/bracket assembly to the gyratory compactor:

[3] Connect the dial gauge power supply cable to the mains supply:

[4] Power ON the dial gauge with the Green On/Off button, the dial gauge screen will
illuminate to indicate power is On.

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[5] If the display shows TIR and mm as shown below, the unit is ready for use (Go to Step
7) otherwise follow step 6 to setup the display:

TIR Symbol

mm Symbol

[6] If the display is locked (shown by a padlock symbol as below), press and hold the
in/mm and +/- buttons until the padlock disappears:

If ‘TIR’ is not shown on the display, press the ‘Mode’ button repeatedly until TIR shows
on the display, then press ‘PRESET’ to set TIR (Max-Min mode) as shown below:

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 Ensure the display is showing mm (not ‘in’) by pressing the in/mm button until mm is
shown on the bottom right of the display:

Also ensure that the display is set to three decimal places by pressing the ‘RES’ button
until three decimal places are shown.

Lock the unit to retain the settings for future use by pressing and holding the ‘in/mm’
and ‘+/-‘ buttons together until the padlock symbol is shown on the left of the display.

[7] Zero the dial gauge by pressing the ‘PRESET’ grey button, the display will show
0.000mm

[8] Run the gyratory compactor machine for at least 10 gyrations either in the normal
compaction mode or by running the motor in the gyratory compactor software check
panel.

It is not necessary to insert a mould for this.

[9] Once at least 10 gyrations are complete, the display on the dial gauge will indicate the
measured throw (Max-min) in mm:

Compare the indicated throw with the required throw calculated using the angle
spreadsheet in Step [1] above.

If the indicated throw is not within approximately +/-0.16mm of the required throw then
adjust the physical throw on the machine (Instructions for this are shown below) and
then repeat steps 7-9 above to recheck the new angle.

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[10] Instructions for adjusting the internal Angle.

a) Please remove the base plate by unscrewing the two screws (circled in image below). Please
retain the screws and base plate.

Base Plate
Figure 1

b) Gently slacken (i.e. loosen the bolts, but DO NOT undo completely) the 4 bolts circled in
image (Figure 2) below to adjust the angle. This will allow bottom plate (i.e plate to which
the 4 bolts are fastened) to rotate for adjusting the angle.
c) Manually rotate the bottom plate. Clockwise rotation of the plate would allow you to
decrease the angle and anti-clockwise to increase the angle.
d) When the bottom plate is set at desired position, tighten the 4 bolts to hold the bottom
plate in position then use the CRT-CALANG device to measure the current angle.
e) Follow the steps b-d until desired angle (ex: 1.160 degrees) is set on the machine.
f) Once the desired angle is set, put the base plate back and fasten the plate with 2 screws
circled in above image (figure 1).

Figure 2
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[11] Once the indicated throw is as close as possible to the required throw (within +/-
0.16mm), enter the indicated throw in the angle spreadsheet as shown below to
calculate the actual set angle in Degrees:

[12] The new physical angle can now be entered into the software configuration file as
follows:

Open the ‘c:\gyratory compactor\utils\gyro.ini’ file in Windows Notepad:

Update the value next to the ‘TARGET ANGLE =’ field with the new angle then save and close
the gyro.ini file:

[12] The CRT-CALANG assembly can now be removed from the gyratory compactor.

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Warranty
Cooper Research Technology Limited undertake to repair or replace any goods manufactured or
supplied by it and in the reasonable judgement of Cooper Research Technology Limited to be
defective in material or workmanship.

a. Cooper Research Technology Limited shall be required to comply with this warranty where
such defective material or workmanship is found within 12 months from the date of delivery.

b. If required by Cooper Research Technology Limited, the buyer shall return or procure the
return of the goods alleged to be defective to Cooper Research Technology Limited who may
carry out repairs.

Cooper Research Technology Limited shall not be responsible under this warranty if:

a. The buyer shall not have paid all the invoices for goods and services supplied by Cooper
Research Technology Limited within the agreed time.

b. The goods have been improperly maintained, installed or operated.

c. The goods have been altered or modified so as to adversely affect the operation or use or
durability or so as to change their intended use.

d. The Cooper Research Technology Limited liability under warranty contained in this clause is
limited to repair or replacement of defective goods and making good defective workmanship.

Copyright
The contents of all Cooper Research Technology Limited catalogues and other literature published by
us are protected by copyright and may not be reproduced or used without written consent.

Force majeure
All contracts are subject to Cooper Research Technology Limited’s right to cancel the same in whole
or in part in case of war, rebellion, hostilities or any local or national emergency, Government action,
strikes, lock-outs or any other causes which are unforeseen or beyond the immediate control of
Cooper Research Technology Limited which affects or interferes with production, shipment, transit,
delivery or installation of goods subject to contract.

Jurisdiction
All contracts shall be deemed to have been made in England, unless otherwise agreed by Cooper
Research Technology Limited in writing and the construction, performance and validity thereof shall
be governed by English law.
In relation to sales where the buyer has his place of business outside the United Kingdom or its
residences outside the United Kingdom. All disputes with regard to the contract shall be settled by
arbitration in London in accordance with the rules for the time being of the International Chamber of
Commerce.

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 DECLARATION OF CONFORMITY

(2017)

We hereby certify that the machine stipulated below complies with all the relevant provisions of the
93/68/EEC - CE Marking Directive and the National Laws and Regulations adopting this Directive.
Modifications to the machine without the prior approval from the undersigned will render this
declaration null and void.

Machine Description: Gyratory Compactor

Product Range: CRT-GYR

Serial Number: CRT-GYR-1730-08

Manufacturer Address:
Cooper Research Technology
Unit 1
Albert Court
Peasehill Road
Ripley, Derbyshire
DE5 3AQ, United Kingdom

Is in Conformity with the Provisions of the following other EEC Directives

89/336/EC - Electromagnetic Compatibility Directive

73/23/EEC - Low Voltage Directive

Harmonized Standards Applied

BS EN ISO 12100-1:2003 Safety of Machinery – Basic concepts, General principles for design.
Part 1&2
BS EN ISO 12100-2:2003

BS EN 60204:1998 Safety of Machinery – Electrical Equipment

Signed:…………………………………………..

Name: Peter Grafton

Position: Managing Director

Date: 10.10.2017…………….

Unit 1, Albert Court, Peasehill Road,

Ripley, Derbyshire, DE5 3AQ,
United Kingdom, +44 1773 512174
VAT Number GB 558445608

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