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Resodyn RAM5 Installation And Operation Manual

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RAM5 Acoustic Mixer
Installation and Operation Manual

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  • Page 1 RAM5 Acoustic Mixer Installation and Operation Manual...

  • Page 2: Table Of Contents

    Setup, Configuration and Troubleshooting Screen ..............22 Alarming ..........................24 Log Files..........................25 Troubleshooting..................27 Care and Maintenance ................29 Hydraulic System ........................30 Mechanical System .........................38 Cooling System Overview .......................41 Electrical/Controls System ......................43 RAM5 General Maintenance Procedures................47 Required Fluids ........................49 Resodyn Acoustic Mixers, Inc www.resodynmixers.com...

  • Page 3: Safety, Support And Warranty Information

    Operation Manual, Rev. 12.11.2012 Safety, Support and Warranty Information Every effort has been made to assure that the RAM5 is easy to use, reliable and safe. This section will outline general safety considerations and define caution and warning symbols used in this document.

  • Page 4: Important Safety Notes

    Be cautious of pinch points on mixer lid. Trouble Shooting and Service The RAM5 systems should only be operated when it is in good working condition. If the system shows any signs of visible damage or fails to operate as outlined in this manual, the system should not be operated.

  • Page 5: Warranty

    Seller will, at its option, repair or replace the affected Products. The warranties provided herein will apply only to those Products and integral components thereof that are identified by a unique Resodyn part number and for any Service provided by Resodyn employees or their authorized agents. Seller does not warrant any third party Products or Service even if included with other Resodyn Branded Products or Service.

  • Page 6: Introduction

    ® This user’s guide describes the RAM5 ResonantAcoustic mixer and explains its operation. This chapter provides an overview of the RAM5 and contains general information important to correct use. ResonantAcoustic® Mixing (RAM) Overview The RAM technology approach for acoustic mixing works on the principle of creating micro- mixing zones throughout the entire mixing vessel as well as macro (bulk) material flow fields.
  • Page 7 RAM5 Installation and Operation Manual, Rev. 12.11.2012 motion, Figure 1. The resonant frequency is defined as the frequency at which the mechanical energy in the system can be conserved between potential energy stored in the springs and as kinetic energy in the moving masses.
  • Page 8 As such, higher damping materials typically require higher intensities to achieve the same payload acceleration compared to the lower damped materials. The RAM5 mixer is controlled by setting the desired acceleration and the mixer automatically controls the frequency and intensity.
  • Page 9 RAM5 Installation and Operation Manual, Rev. 12.11.2012 energy. The result of operating at resonance, as shown by the red and green curves, is that the amplitude of the oscillations reaches a maximum, while the power required is at a minimum.

  • Page 10: System Overview

    The two-hand control pushbuttons are used to open and close the mixer lid. The HMI is a touch screen computer (Hazardous Location RAM5’s do not have a touch screen) that allows the operator to enter desired mix parameters and monitor machine operation and status.

  • Page 11: Acoustic Enclosure

    Removable Panel for inspection and maintenance. These panels are removable via four quick Figure 6: RAM5 Acoustic Enclosure and Resonator release compression clamps. Resonator The Resonator is the mixer itself. It consists of the metal plate masses, springs, eccentrics, and drive system.

  • Page 12: Installation

    Entry/fitting: Top entry, electrical enclosure, ¾” Swagelok style tube compression fittings. o RAM5 Mixers can be configured to be cooled via dedicated chillers that supply a 60/40 water glycol mixture, or facility cooling water with an internal water/glycol system. The graph in Figure 7 provides the flow and temperature requirements to provide adequate cooling to the mixer.
  • Page 13 RAM5 Installation and Operation Manual, Rev. 12.11.2012  Compressed air may be required, the pressure and flow of which are machine dependent. Refer to the Supplemental Information for pressure, flow, and pipe fitting requirements for compressed air.  Ensure oil reservoir is filled with oil recommended in Maintenance Section.

  • Page 14: Specifications

    RAM5. General Items  The RAM5 is made out of steel with either a powder coated finish or zinc plating. The mix container holder is fabricated from steel.  A control panel mounted to the Electrical Enclosure allows for process control and real time monitoring of pertinent machine parameters.

  • Page 15: Controls

    RAM5 Installation and Operation Manual, Rev. 12.11.2012  Internal 1, 120VAC control transformer (on non Hazardous Location RAM5s).  Sealed, liquid cooled Electrical Enclosure.  Power-saving regenerative servo drives powering 10hp motors.  Control circuit breakers for protection and isolation of the control circuits.

  • Page 16: Operation - Quick Start

    Chiller is running if the Electrical Enclosure’s disconnect switch is in the “On” position. If your RAM5 is equipped with a Hazardous Location Option, please consult the Training Manual and Supplemental Information for a description of the purge cycle that occurs at startup.
  • Page 17 RAM5 Installation and Operation Manual, Rev. 12.11.2012 supervisors or technicians to characterize a mixing process, which will then be programmed as a recipe for the operators. The Auto Mode will be covered in subsequent sections. Do not use sharp objects on the touch screen. Sharp objects can damage the touch screen.
  • Page 18 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Recipe Mode Recipe Mode provides a means of pre-programming a mix profile without operator intervention. The Supervisor login level can generate a recipe’s definition by defining segments that specify time duration at a specific g level.

  • Page 19: Completion

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Completion Opening the lid and removing the mix container completes the mixing cycle.  When the middle section of the status bar contains the word “ready”, the mixer lid can be opened by pressing both of the “Open” pushbuttons located below the HMI Computer.

  • Page 20: Hmi Overview And Configuration

    Certain features of the Main Screen will update depending on the operational mode selected, current status, and the configured options for the RAM5 Mixer. While in recipe mode, the title bar of the Main Screen will read “Recipe Mode”, and will read “Auto Mode” while in auto mode.
  • Page 21 RAM5 Installation and Operation Manual, Rev. 12.11.2012 The Main Screen is divided into 5 operation panes or sections. These sections are as follows:  Controls Pane.  Indicators Pane.  Recipe and Mix Timer Pane.  Navigation Pane.  Status Bar.

  • Page 22: Setup, Configuration And Troubleshooting Screen

    Pressing the Mode button launches the Mode Select dialog, where the operator can choose between Auto and Recipe Mode. Manual Mode is currently reserved for Resodyn personnel only. Also note that switching between Recipe and Auto modes is not possible when the machine is running because both buttons are disabled.
  • Page 23 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Items that are not contained within the tab control are:  The Main Screen button which closes the Setup, Configuration and Troubleshooting and shows the Main screen.  Acceleration, Phase Angle, Intensity, and Frequency indicators.

  • Page 24: Alarming

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Data Tab The Data Tab allows for log file management by listing data log files, alarm log files, and mix log files. From this tab files can be copied, or deleted one-by-one, or the entire grouping can be deleted or copied.

  • Page 25: Log Files

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Oil Temperature Alarm Cooling Temperature Alarm Trip Points (in deg F) Trip Points (in deg F) High-High High-High High High Low-Low Low-Low Figure 13: Alarms Dialog Log Files Several different types of log files are automatically generated by the HMI program. All log files are stored on the hard drive as comma-separated-variable files for easy viewing in Microsoft Excel.
  • Page 26 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Log file directories are limited to 100 mega bytes. Alarms will be posted to the alarming system when file size exceeds 100 mega bytes, and the oldest files will be deleted one per day when the log file directory exceeds 110 mega bytes.

  • Page 27: Troubleshooting

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Troubleshooting Here are some simple solutions to check before contacting your Resodyn Acoustic Mixers service representative. Use the following chart to resolve operational problems. If the problem persists contact your customer service representative.
  • Page 28 RAM5 Installation and Operation Manual, Rev. 12.11.2012 and valve line-up is correct Pump is not running Check alarm log for an oil pump error and contact customer service if alarm cannot be cleared Turn machine off and contact Broken hydraulic line...

  • Page 29: Care And Maintenance

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Care and Maintenance Resodyn Acoustic Mixers, Inc www.resodynmixers.com...

  • Page 30: Hydraulic System

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Hydraulic System Frame View Eccentric View Resodyn Acoustic Mixers, Inc www.resodynmixers.com...
  • Page 31 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Reservoir Breather Vent Access 1. Remove either the front or right side acoustic panel, (See Section - Acoustic Panel Removal-Installation) the reservoir breather vent is located on the front right upper surface of the oil reservoir.
  • Page 32 RAM5 Installation and Operation Manual, Rev. 12.11.2012 2. The oil level should sit at the line engraved in the oil tank center of the sight glass +0 inch / - 1/2 inch. 3. If the oil level is below acceptable limits, oil must be added, and to the contrary, if the oil level is above operable limits due to overfill, excess oil must be removed.
  • Page 33 RAM5 Installation and Operation Manual, Rev. 12.11.2012 2. Ensure that the RAM5 is off and the hydraulic pump motor is not running prior to performing this procedure. 3. Due to the positioning and low profile nature of the hydraulic reservoir, it is impractical to provide a drain port for the hydraulic reservoir;...
  • Page 34 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Oil Filter Replacement 1. Take new filter and smear a thin film of clean oil on the gasket. (See Section – Spare Parts). 2. To minimize the amount of air introduced into the hydraulic system, fill the oil filter element with new hydraulic oil.
  • Page 35 RAM5 Installation and Operation Manual, Rev. 12.11.2012 5. Remove the tank side compression fitting from the suction filter. 6. If the suction filter is to be cleaned and re- used, clean using a suitable solvent and brush. Allow the solvent to completely dry prior to re- installation.
  • Page 36 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Replacement 1. This procedure is the same for all flex lines identified in this section other than the Eccentric Flex Oil Supply Line. 2. If the Eccentric Flex Oil Supply Line is to be replaced, it is not necessary to remove the oil from the oil reservoir, otherwise, the oil reservoir muse be emptied below the level of the tank end of the line to be replaced.
  • Page 37 1. Remove all acoustic panels. (See Section - Acoustic Panel Removal- Installation). Inspection 1. Ensure that the RAM5 is off and is not running prior to performing this procedure. 2. Remove the eccentric cover plates on eccentric assemblies 1 and 2 by removing the 4 button head cap screws.

  • Page 38: Mechanical System

    Eccentric Assembly Inspection Access 1. Remove all acoustic panels. (See Section - Acoustic Panel Removal-Installation). Inspection 1. Ensure that the RAM5 is off and locked/tagged out prior to performing this procedure. 2. Remove the eccentric cover plates on eccentric assemblies 1 and 2 by removing the 4 button head cap screws.
  • Page 39 Drive Shaft Inspection Access 1. Remove both side acoustic panels. (See Section - Acoustic Panel Removal-Installation). Inspection 1. Ensure that the RAM5 is off and locked/tagged out prior to performing this procedure. 2. By hand grab drive shaft tube and rotate back and forth, check for any free play in the system and smooth motion.
  • Page 40 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Isolator Spring Inspection Access 1. Remove both side acoustic panels. (See Section - Acoustic Panel Removal-Installation). Inspection 1. The isolator springs are cylindrical rubber blocks located on top of the welded frame post and connect with the lower side of the resonator frame mass.

  • Page 41: Cooling System Overview

    Panel Removal-Installation). Inspection 1. Ensure that the RAM5 is off and locked/tagged out prior to performing this procedure. 2. The RAM5 cooling system requires little maintenance provided the cooling system is supplied with proper coolant. (See Section – Recommended Fluids).
  • Page 42 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Through the enclosure cooler. k. Exit the RAM5 through the Coolant return tube. 4. Inspect all fitting for leaks. 5. Inspect coolant lines for wear or corrosion. 6. Check the platform base for puddles, either dried or wet.

  • Page 43: Electrical/Controls System

    Cabinet Wiring Inspection Access 1. Open electrical cabinet. Inspection 1. Ensure that the RAM5 main power is off and locked/tagged out prior to performing this procedure. 2. Inspect wiring within the RAM5 electrical cabinet. 3. Check for loose connections. 4. Check for wires that look like they may have damaged insulation.
  • Page 44 4. With the power applied to the RAM5 remove and re-install the acoustic panels, verify that this operation is viewed in the Setup/Config Screen in the HMI. 5. With the power applied to the RAM5 open and close the payload lid, verify that this operation is viewed in the Setup/Config Screen in the HMI.
  • Page 45 RAM5 Installation and Operation Manual, Rev. 12.11.2012 Operation Sensor/Device Inspection  Oil Flow Switch  Oil Temp Sensor  Oil Pressure Switch  Coolant Flow Switch  Coolant Temperature Sensor Operation Sensor/Device Layout Overview Access 1. Remove both side acoustic panels. (See Section - Acoustic Panel Removal-Installation).
  • Page 46 3. Open the Setup/Config Screen in the HMI, and identify the readout for the Oil Pressure Switch. 4. Start the RAM5 and verify that the pressure switch readout on the HMI reads predictably with the operation of the machine. 5. Should the Oil Pressure Switch fail to transmit a signal to the HMI, replacement of the device may be required, contact customer service for assistance.

  • Page 47: Ram5 General Maintenance Procedures

    RAM5 General Maintenance Procedures General Inspection This is a general inspection is to be carried out whenever the RAM5 machine is accessed, and is more a point of practice than an actual procedure. Items to look for are pools of fluid on the machine platform, loose or damaged wiring, loose or damage fittings, broken fasteners, etc.
  • Page 48 1. Once all connections are closed and the reservoir is filled to the appropriate level, the RAM5 and oil pump are started. 2. The system will most likely run louder than normal as an air and oil mixture is moved through the piping and the oil pump.

  • Page 49: Required Fluids

    RAM5 Installation and Operation Manual, Rev. 12.11.2012 Required Fluids Resodyn Acoustic Mixers, Inc www.resodynmixers.com...

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