IPC Global

OPERATING
AND
MAINTENANCE
MANUAL
Firmware Version 2.04

HWMAN 2_04.DOC
By C Sinadinos
Sep 22, 2005
SPECIFICATIONS

Size: (including stand and specimen extraction unit) 197(H) X (76)D X (45)W cm

Weight: (excluding stand and specimen extraction unit) 240 kg

Shipping weight: 410 kg

Mould diameter: 99.90 to 100.00 mm inside diameter

149.90 to 150.00 mm inside diameter
Mould height: 270 mm
Mould wall thickness 10 mm
Mould finish: (inside) Smoother than 0.4µm rms
Mould surface hardness: More than 48 Rockwell C

Platens dimensions: 99.70 to 99.75 mm diameter

149.70 to 149.75 mm diameter
Platens hardness: More than 48 Rockwell C

Vertical force: 0 to 20 kN ± 100N. (See Note 1)

Gyratory angle: 0.02 to 3 ± 0.02 degrees. (See Note 1)
Gyration rate: 3 to 60 ± 0.1 gyrations per minute.

Number of gyrations: 0 to 999

Vertical stress 10 to 999 kPa
Minimum specimen height: 50 mm.

Mains power: 120 V AC, 60 Hz, 2 A

230 V AC, 50 Hz, 1A

Air supply: Clean, dry air.

Operating pressure: 800 to 1000 kPa
Air flow capacity: Min. 5 Litres/Sec.

Note 1: Servo-control of gyratory angle and vertical force.

GENERAL OVERVIEW

The IPC Servopac is a servo-controlled multi-axis pneumatic loading system designed for the
laboratory production of asphalt specimens having characteristics that closely resemble those
obtained from such material as laid in-situ. The machine is a stand alone unit which includes an
intelligent controller and pendant with an integrated key-pad, liquid crystal display and printer
interface. The intelligent controller of the machine can store data from several compaction runs, is
independently calibrated, and provides a coded data interface via a dedicated serial
communications port for monitoring and control purposes.

An optional IBM compatible personal computer may be connected to the coded data interface on
the machine to provide a user friendly monitor for data retrieval, display and data archival facilities
together with machine control functions.
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Compaction is achieved by the simultaneous action of static compression and the shearing action
resulting from the motion of the centre line of the test specimen which generates a conical surface
of revolution, of 2 Φ angle at the apex, while the ends of the test specimen remain perpendicular to
the axis of the conical surface (Figure 1).

Figure 1 - Test specimen motion diagram.

The vertical force (compression) is applied using a digital servo (load) controlled, pneumatic
actuator (Figure 2). A load cell is used to measure the vertical force and this signal is used to
accurately set and maintain the vertical stress during compaction.

The vertical actuator is connected to an intermediate plate via the load cell. The intermediate plate
attaches to the top loading platen assembly via a rolling plate. This mechanism allows the top
platen to move freely in two dimensions (similar to an X-Y table), so as to follow the arc scribed by
the top of the specimen, with minimal friction.

The gyratory motion is implemented using three, digital servo (position) controlled pneumatic
actuators, each moving up and down in a sinusoidal motion, 120 degrees out of phase with each
other. A displacement transducer is used to measure the displacement of each gyratory motion
actuator and this signal is used to accurately set and maintain the gyratory angle during
compaction.

The three gyratory motion actuators are attached to a mould carrier which clamps the mould
securely during compaction. A pneumatically operated base pedestal, located in the centre of the
mould carrier assembly, is used to lower the mould and its contents into position prior to clamping.
The mould is unclamped and the base pedestal raised, automatically, at the completion of the
compaction process.

For safety reasons an enclosure, with a sliding glass door at the front, encloses the machine. The
door opens and closes automatically. An electrical interlock prevents operation if the door fails to
close.

A specimen extraction unit is located at the front of the machine. The extraction ram operates
pneumatically and derives its air supply from the main unit. The connecting tube is coiled to allow
the extraction unit to be detached from the main unit and rest on the floor without the need to
disconnect it.

To reduce the amount of lifting required by an operator, (in the home position) the top of the
specimen extraction unit is level with the top of the mould carrier. When mounted on the stand
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provided, the top of the specimen extraction unit is the height of a standard height workbench. By
positioning the Servopac next to an adjoining work bench, the need to lift a full mould is completely
eliminated. The operator places the required amount of hot mixed asphalt (HMA) in the mould and
slides it from the workbench to the extraction unit then over the mould carrier. When the
compaction process has been completed, the operator slides the mould forward and across over
the extraction platen and ejects the specimen.

The Servopac has a high speed data acquisition and control system, on a single printed circuit
board, built into the base of the machine. This board is used to control all aspects of the operation
of the machine, as well as data acquisition and storage. Test data for the last twelve tests is stored,
in non-volatile memory, for subsequent retrieval.

The basic machine has an LCD display and keypad, which allows the basic functions to be
accessed and altered ie. vertical stress, angle and speed of gyration, target specimen height and/or
number of gyrations etc., as well as displaying the specimen height and number of gyrations during
the compaction process. An optional personal computer (PC) may be connected to the Servopac to
access an increased number of modes and features and generate graphical plots. The display and
keypad built into a control pendant, may be omitted if not required. ie. when a PC is permanently
assigned to the machine.

The control pendant comprises a 2 line LCD alpha numeric display, 6 key switches and a ‘beeper’.
The display is used to view control parameters, compaction data and other user information. The
beeper is used to annunciate key activation and draw attention to error messages indicated on the
display.

The control pendant is connected to the Servopac via an umbilical cord, which plugs into the back
of the machine. The connecting cable is a standard 25 to 25 way computer lead, for ease of
replacement in case of damage. Two locating pegs mounted on the front of the machine allows the
pendant to be attached securely to the Servopac when used on the machine or detached and used
remotely, as required.

The optional PC user interface is designed as an ‘application’ supported by the Microsoft Windows
98 and Windows XP operating system environment. As a Windows based application, the ‘look and
feel’ of the facilities available is the same as all other Windows based applications so as to give the
experienced Windows user a feeling of instant familiarity. Windows provides full support for device
independent printing of graphical plots and text data from the application. Specimen data,
measured by the machine controller, is displayed by the PC in real time as a test proceeds. The
final data retrieved is stored in the form of readable ASCII text files on the PC. The software is
capable of re-viewing archived ASCII data files either stored on the PC, or retrieved from the
machine controller. (Refer to PC-Based Servopac monitor reference manual)

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Figure 2 - Servopac parts and accessories
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UNPACKING INSTRUCTIONS

The Servopac is packed in two wooden cases. The large case contains the main unit and the
smaller case contains the specimen extraction unit, stand, control pendant, mould(s) and other
associated hardware.

The main unit has been placed on its side and secured to the bottom of the case using four coach
screws and brackets (A), two at each end. Two lifting handles (B & C), on the side facing upwards,
have been provided to facilitate lifting using slings. (See Fig. 3)

To unpack the main unit:

• Remove top cover of large packing case.

• Remove securing screws (A).
• Attach slings to lifting handles B & C and raise the unit clear of packing case.
• Remove packing case.
• Gently lower the unit onto two lengths of wood located directly under, and in line with, the two
pairs of button head screws used to attach the downwards facing side cover.
• Attach slings to the lifting handle (B) fixed to the top of the unit.
• Stand the Servopac up by raising the top of the unit whilst chocking the two pieces of angle iron
(A) fixed to the bottom of the unit.
• Remove the two brackets (A) located at the top of the unit and replace screws and washers.
• Relocate lifting handles B & C, one handle either side, as required to facilitate further handing.
ie. Locate lifting handles to the upper position for lifting using a crane, locate lifting handles to
the lower position for lifting using a fork lift. (See Fig. 4)

IMPORTANT NOTE: Do not lift or lever the Servopac by the bottom cover! This could result
in damage to the printed circuit board and/or transducers located in the base of the unit.

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Figure 3 - Packing details

Figure 4 - Handling details

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INSTALLATION INSTRUCTIONS (Refer to Figures 3, 4 & 5)

• Place Servopac stand in position, leaving sufficient space between the back of the stand and the
wall.
• Remove the two brackets (A) located at the base of the unit and replace the securing screws
with the adjustable feet supplied.
• Place the Servopac on the stand.
• Remove the lifting handles and replace the securing screws and washers.
• Save the lifting handles for possible use at a later time.
• If supplied; fit control pendant to the Servopac via locating pegs fitted to the R/H side cover.
Connect one end of the pendant cable (DB25-DB25) supplied to the control pendant and the end
to connector labelled “Pendant” on the lower rear panel of the Servopac.
• Connect air supply and mains power to the Servopac.
• Turn on mains switch and apply air: The door should open, the loading shaft retract fully and the
mould carrier assume a level position.
• Sit base pedestal on to mould raising actuator shaft, located in the centre of the mould carrier.
Note: Do not adjust the domed head bolt fitted to mould raising actuator shaft, it has been
factory set to the correct height.
• Fit mould location dowel pins supplied in holes provided, at the top of the mould carrier.
• Secure top loading platen to the loading shaft. (100 mm or 150 mm)
• Position specimen extraction unit on the floor in front of the Servopac.
• Connect one end of the coiled tube supplied to the air fitting located on the front of the Servopac
and the other end to the air fitting located on the specimen extraction unit.
• Sit specimen extraction unit on stand directly in front of main unit, with extraction unit apron
inside Servopac enclosure.
• Adjust the four leveling glides so that the Servopac is level and the extraction unit apron is just
resting on the two hexagonal spacers located in front of the mould carrier.
• Position the extraction unit so that the holes in the apron line up with the threaded hole of the
hexagonal spacers.
• Secure apron using the screws provided.

IMPORTANT NOTE: Air supply must be clean and dry. Failure to comply may result in
damage to the servo valves. IPC recommend the use of an automatically draining water trap,
fitted with a 5 micron filter, in line with the air supply to the Servopac. In high humidity
climates it may be necessary to use a refrigerated dryer.

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 Figure 5 - Setting up details
SAFETY WARNINGS

The IPC Servopac is a state of the art gyratory compactor with a host of safety features, for your
safety. IPC can not anticipate every example of improper use which may result in an accident or
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damage to the machine. So please, consult IPC or your dealer if a particular use is not specified in
this manual.

To ensure minimum operator risk, IPC recommends the following safety precautions:

• Power up Servopac before applying air.

• Do not operate the Servopac with side covers removed or door open.
• Wear safety glasses when preparing an asphalt specimen.
• Wear heat resistant gloves when handling hot items.
• When moving the mould, hold it firmly with both hands.
OPERATING INSTRUCTIONS

IMPORTANT NOTE: If a printer is connected to the Servopac; ensure the Servopac is

powered up before applying power to the printer.

IMPORTANT NOTE: Power up Servopac before applying air. Ensure control pendant displays
“IPC Servopac” message. Otherwise, turn power off for approx 20 seconds and before
turning power back on.

When the machine is powered up, the loading ram is fully retracted, and mould carrier assumes
home position. ie. the mould carrier is horizontal and level with the specimen extraction apron.

When compaction is initiated, the loading ram descends until the selected stress is applied to the
specimen and the gyratory motion commences. The gyratory angle increases from zero to the
selected angle and is accurately maintained during the compaction process.

When one of the termination criteria is met, the gyratory angle reduces to zero, the mould carrier
returns to home position, and the loading ram retracts.

Control pendant operation

Unless a dedicated PC has been assigned to the Servopac; the control pendant is the primary user
interface. The ‘START’ key initiates a new test, the ‘STOP’ key terminates it, and the (increment),
↓ (decrement), ‘NEXT’ and ‘ENTER’ keys manipulate the displayed information as described below.
The exact function of each key depends on the operating mode.

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 Figure 6
Control pendant

Operating modes

View mode

This mode is entered on power up. On power up the control pendant displays: “IPC Servopac”
followed by the software version number. Either the ‘NEXT’ key or the (increment), ↓ (decrement)
keys may be used to scroll through the date and time settings followed by the test parameters, line
by line, in the following order, followed by any test data, if it exists. If data exists, specimen height at
the completion of each gyration may be reviewed by using the (increment), ↓ (decrement) keys.

Year: XXXX
Month: XX
Day: XX
Hour: XX
Minute: XX
# Gyrations: XXX
Height mm: XXX.X
Stress kPa XXX
Angle Deg: X.XXX
Gyrations/min: XX
Mould dia mm: XXX

Similarly, the ‘NEXT’ key or the (increment), ↓ (decrement) keys may be used to scroll through test
data, two lines at a time.

Following the last menu item, the displayed item resets to "# Gyrations" and sequential scrolling is
repeated through the menu items in the same order. ie. The date and time is not displayed again.
Test parameters may be altered from ‘Edit mode’.

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Edit mode

To alter a test parameter, scroll through the menu items, in ‘View mode’, until the test parameter
you wish to alter appears on the bottom line of the display, then press ‘ENTER’. Edit mode is
indicated by the flashing cursor over the character on the bottom right hand corner of the display.
Use the (increment), ↓ (decrement) keys to set the test parameter to desired value. The keys may
be held down to rapidly change parameters. To exit ‘Edit mode’ operate the ‘ENTER’ key once
more. The ‘NEXT’ key may also be used to exit ‘Edit mode’. Using the ‘NEXT’ key, exits ‘Edit mode’
and also advances the display to the next test parameter.

Run mode

‘Run mode’ is entered from ‘View mode’ by operating the ‘START’ key. This should be done after
the mould has been lowered and locked using the ‘MOULD LOWER’ button followed by the
‘MOULD LOCK’ button, in that order (see typical operating sequence). The door will lower
automatically before the test commences.

When a new test is initiated the pendant displays a test or “Run” number followed by the test data.
The run number is generated by the machine and incremented each time a new test is initiated.
The run number is used to identify an individual test during data retrieval. (See ‘Data retrieve
mode’). The test data is displayed in the following format:

Gyration # XXX
Height mm: XXX.XX

The top line displays the gyration number, the bottom line displays the specimen height at the
completion of that particular gyration.

The display is updated at the completion of each gyration until the termination condition(s) are
satisfied or until the ‘STOP’ key is operated, at which point the system returns to ‘View mode’.

Data retrieve mode

To enter ‘Data retrieve mode’ hold the ‘NEXT’ key down until a double beep is detected. To review
test data from the last four tests, use the (increment), ↓ (decrement) keys to scroll through the
available run numbers until the desired run number appears on the bottom line of the display.
Operate the ‘ENTER’ key to retrieve the test data. The system will return to ‘View mode’ with the
retrieved data displayed as if the test has just been completed.

Calibration mode

WARNING: This mode should only be entered by persons authorised to perform calibration.

To enter ‘Calibration mode’ hold the ‘STOP’ key down until a double beep is detected. The following
message is then displayed on the control pendant:

Calibration mode
press enter

After pressing ‘Enter”, the ‘NEXT’ key can be used to scroll through the following list of calibration
functions:

Exit Calibration
Vertical force
Vertical displ
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 Gyratory angle
Set Cal defaults
System Tuning

IMPORTANT NOTE: If you have inadvertently entered ‘Calibration mode’ use the ‘NEXT’ key
to scroll through the menu items until “Exit Calibration” is displayed and press the ‘ENTER’
key.

Setting calibration defaults

This is only necessary when powering up the Servopac for the very first time. ie. During
manufacture or in the event the control board is replaced. To set calibration to default values, use
the ‘NEXT’ key to scroll through the menu items until “Set Cal defaults” is displayed and operate the
‘ENTER’ key.

Calibrating vertical force

To successfully calibrate the vertical force you require a force measurement device. ie A proving
ring or load cell and indicator with a suitable range and capacity (referred to in the procedure as the
reference). During the calibration sequence a force of approx. 1,200 kg is applied by the system.
Please ensure the top loading platen is fitted to the loading shaft for the duration of this procedure.
If the force measurement device is less than 90 mm high you will require some packing spacers
between the force measurement device and the base pedestal to ensure that the loading ram
comes in contact with the top of the force measurement device.

To calibrate vertical force use the ‘NEXT’ key to scroll through the menu items until “Vertical force”
is displayed and operate the ‘ENTER’ key. The pendant shall display the message “Ensure ram
clear and press Enter” followed by “Adjusting offset” when the ‘ENTER’ key is operated. This is
used to negate any electrical offset in the load cell and the mass of the loading ram and associated
hardware.

Place the force measurement device on the base pedestal and operate the ‘ENTER’ key. The
loading ram will descend, a force of approx. 1,200 kg shall be applied, and the internal load cell
output is indicated as the “measured value”. The pendant shall display: “Set span” on the top line
and measured load on the bottom line.

Use the (increment), ↓ (decrement) keys to set the measured value, displayed on the pendant, as
close as possible to the value indicated by the reference force measuring device and operate the
‘ENTER’ key.

Calibrating gyratory angle

To successfully calibrate the gyratory angle you require two sets of three spacers. ie. Three
spacers 77.00 mm long and three spacers 68.50 mm long. The spacers are used as gauge blocks
to set a pre-defined distance between the bottom of the mould carrier and base plate. They are to
be placed on the base plate directly under the mould carrier on a pitch diameter of approximately
250 mm, and 120° to each other, when prompted by the system.

To calibrate gyratory angle, use the ‘NEXT’ key to scroll through the menu items until “Gyratory
angle” is displayed and operate the ‘ENTER’ key. The system will direct you through the calibration
process.

Calibrating vertical displacement (Specimen height)

IMPORTANT NOTE: Calibration of the vertical force must be done prior to calibration of the
vertical displacement.
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To successfully calibrate the vertical displacement you require two spacers, one spacer 50.00 mm
long and one spacer 200.00 mm long. The spacers are used as gauge blocks to simulate two test
specimens of pre-defined height. Please ensure the top loading platen is fitted to the loading ram
and the bottom platen (supplied with each mould) is placed on the base pedestal for the duration of
this procedure. One or two stainless steel wearing plates may be added to the bottom platen if
wearing plates are going to be used during testing. ie. If only a top wearing plate is to be used
during testing, add one wearing plate to the bottom platen during calibration.

To calibrate vertical displacement, use the ‘NEXT’ key to scroll through the menu items until
“Vertical displ” is displayed and operate the ‘ENTER’ key. The system will direct you through the
calibration process.

System Tuning

WARNING: This mode should only be entered by persons authorised to perform calibration
and system setup parameters.

After pressing ‘Enter”, the ‘NEXT’ key can be used to scroll through the following list of system
tuning parameters:
Vert Gain 4000
Gyro Gain 1700
Angle Comp .02
Exit System Menu

These parameters can be altered using the “up” and “down” buttons on the pendant

Vert Gain
The Vertical Gain parameter allows adjustment of the dynamic performance of the vertical actuator.
The default value is 4000 and this should not normally need adjustment.

Gyro Gain
The Gyro Gain parameter allows adjustment of the dynamic performance of the servo actuators
controlling the gyratory angle. The default value is 1700 and this should not normally need
adjustment on a standard 3 degree machine. However, it may need adjustment to achieve optimum
control accuracy on a 6 degree machine when running unloaded or with very weak mixes.

Angle Comp
The Angle compensation parameter allows adjustment of the machine compaction characteristics
to match that of other brands of gyratory compactors. The default value is 0.02 degrees.

Exit System Menu

This selection exits from the system tuning menu back to the previous calibration menu.

Printing

The Servopac has a parallel interface port to accommodate a dot matrix printer.

Printing can only be initiated from ‘View mode’. To print displayed test data simply hold the ‘ENTER’
key down until a double beep is detected.
Typical operating sequence

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When the machine is powered up, the loading ram is fully retracted, and mould carrier assumes
home position, ie. the mould carrier is horizontal, level with the specimen extraction unit apron.

• Select desired test parameters as described above.

• Place the bottom platen in a heated mould.
• Add piece of filter paper if required.
• Add the required amount of hot mixed asphalt (HMA) in the mould.
• Add piece of filter paper if required.
• Slide the mould and its contents into the Servopac, until it comes to rest against the two locating
pegs fitted to the mould carrier.
• Operate the ‘MOULD LOWER’ button and verify that the mould has lowered through the centre
of the mould carrier.
• Operate the ‘MOULD LOCK’ button.
• Operate ‘START’ key. The door will lower automatically.
• When termination conditions are satisfied, the door will open and the mould will be unlocked and
raised.
• Slide the mould forward and across, over the extraction platen and eject the specimen by
operating the ‘EJECT’ switch.
• If a printer is connected to the Servopac, simply hold the ‘ENTER’ key down until a double beep
is detected to generate a printout.

MAINTENANCE

The Servopac requires minimal maintenance. Extensive use of “lubrication free” or “lubricated for
life” bearings has significantly reduced the amount of routine maintenance required. However,
general cleanliness of the machine is essential for trouble free operation.

Maintenance schedule

Before each test:

• Wipe off any grit from the top of the base pedestal, mould carrier and underneath the seating
ring located on the outside of the mould with a clean dry cloth.
• Clean off any bitumen which may have been deposited on to the top loading platen using
suitable solvent.

Daily

• Clean the mould(s), top and bottom platen(s), mould carrier and base pedestal with a degreasing
cleaner.

Every 40 hours of operation

• Remove base pedestal and specimen extraction unit and vacuum the entire base plate area.
• After vacuuming the area, clean the area with a clean dry cloth.
• Apply a light machine oil to the mould raising actuator shaft before replacing base pedestal.

Every 80 hours of operation

WARNING: Do not operate Servopac with side covers removed.

• Lubricate the three bolts that secure the mould carrier to the gyratory motion actuator shafts with
general purpose bearing grease. Inject grease, via the grease nipple located on the end of each

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 bolt, until the old grease drains from both sides of the spherical ball around each bolt. The bolts
can be accessed by removing the blanking plugs located on the back and sides of the machine.

Every 1000 hours of operation

• Contact IPC or your IPC dealer for a system overhaul.

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