Ingersoll Rand Roller Dd 16 Manual
Hey all, I am working on a Ingersoll Rand Dual Drum Vibratory Compactor. Model DD-158HFA.
This unit was purchased right around 2006 or 2007, the owner has had a problem with it for years where for no reason the parking brake comes on randomly. Obviously they cant operate like that. The mechanics have troubleshot down through all of the switches and hydraulics and are stumped. The dealer, Volvo, is also at a loss and cant figure it out. Basically it looks like there is a random fault in the VANSCO Control Module that runs the whole machine. The dealer cant help and isnt able to get a new one due to the changeover from IR to Volvo. What I am doing is taking out the Vansco unit and replacing it with a mobile hardened PLC, I have the manuals from IR and have figured most of the Inputs and Outputs.
Dd 16 Detroit Diesel
I have programmed the safety interlocks required. The only thing I am not sure of is the Vibrations per min signal, and what type of a signal is coming from the drum speed sensors. I am assuming that the VPM signal is an analog signal from the controller to the gauge on the console, probably 0-5Vdc.
The drum speed sensors probably output either a pulse output like an encoder or mag pickup, or an analog output, but more than likely a pulse output. Any thoughts on these two signals? Thanks, Will. Ben, thanks for the reply, yes the mechanics said they can get the controller, and they have replaced the switches, and a bunch of the harnesses. Even had the boys from Volvo out and they were stumped. When I was called out to begin with, they asked me if I could connect to the controller and diagnose the issue, no way to do that other than with the breakout box which they cant get.
I told them that they could go through it with a fine tooth comb and trace out all the wiring, but they didnt want to do that either. So basically what I proposed is that I design and program a new ECM with onboard diagnostics to read all of the fault codes. This I can do because I have error detection on all of the inputs, and I can monitor all of the current on the outputs, if something goes out of whack, I just have to plug in one of my mobile screens and the errors show up there in plain language. Engine faults as well as I can read J1939 off the engine. They decided to go for it even though I said it would be fairly pricey, but its much less than buying a new roller, as this one is useless as it sits. In auto mode the controller controls the speed of the roller and the frequency of vibration. It is supposed to maintain roller speed in relationship to frequency to produce 12 impacts per foot, this can be adjusted by using different resisters.
Results 97 - 144 of 458 - Ingersoll Rand VR-1044 PARTS MANUAL BOOK TELESCOPIC HANDLER FORKLIFT 13192000 IR. Ingersoll-Rand DD-22 DD-24 DD-32 Vibratory Compactor Parts Manual 59482695. Dated August 16, 1999.
Frequency is changed by the controller by detecting different amplitudes through the frequency sensors at the drum. It is very important to not over speed the vibratory shafts when in high amplitudes as the bearings will not last.
If you are designing a new controller I would be careful. The liability of this could be the end of you. Also the dealer and Volvo will most likely not support the machine after such a modification. I dont think Volvo is supporting this piece of equipment very well up here anyway, but thats besides the point.
Ben whats the max speed of this type of roller when operating? I can match speed to VPM easily enough using a frequency counting input and a PID closed loop function in my controller to drive the Sauer 90S pump.
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As for liability, I will have a release signed. As well, if I can figure out what is cause the fault, I will fix it and replace the original ECU. But I cant do that until I can actually read the faults.
Ben, its not like this is the first time I have done this. I have built other machines from the ground up with electronic controlled drives, including full steering as well as propulsion and engine control. The manufacturer designed the machine with electronic controlled propulsion, I am doing the same thing. As for safety, I have copied all of the safety interlocks that the original machine has, operator not present, seat switch, E-stop you name it, its in there. I am no rookie at this and have been working on equipment for years. I am also an electronic technologist and a hydraulic specialist, so I know what I am talking about when it comes to Hydraulic EDC drives.
You want to see some of my handywork, go here.
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