Ctm Manual (Compression Machine)

MANUALE DI ISTRUZIONI INSTRUCTION MANUAL

Digital Semi-automatic Compression Machine

with

Readout unit

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN 04/07/2011 i

Index

1. INTRODUCTION 1

1.1 Icons appearing in the manual ............................................................................................. 3

1.2 Manual revision history ....................................................................................................... 4

1.3 Symbols used ....................................................................................................................... 5

1.4 Intended use and improper use ............................................................................................ 6

1.5 Safety information ............................................................................................................... 7

1.6 Environmental risks and disposal ...................................................................................... 15

1.7 CE declaration ................................................................................................................... 16

2. DESCRIPTION 17

2.1 Frame ................................................................................................................................. 18

2.2 Compression platens and ball seating ................................................................................ 18

2.3 Loading cylinder assembly ................................................................................................ 18

2.4 Hydraulic unit .................................................................................................................... 18

2.5 Readout unit ....................................................................................................................... 19

2.6 System block diagram........................................................................................................ 21

2.7 Connections ....................................................................................................................... 22

2.8 Identification plate ............................................................................................................. 23

2.9 Commands and controls .................................................................................................... 24 2.9.1 Flow control valve ......................................................................................................... 25

2.10 Technical specifications ..................................................................................................... 26

3. INSTALLATION 29

3.1 Shipment ............................................................................................................................ 30

3.2 Unpacking and inspection .................................................................................................. 31 3.2.1 How to remove the equipment from the shipping crate ................................................. 32

3.3 Positioning of the unit and space requirements ................................................................. 34

3.4 Installing and positioning of the display ............................................................................ 36

3.5 Electrical requirements ...................................................................................................... 37

3.6 Electrical connections ........................................................................................................ 38

4. USE OF THE EQUIPMENT 40

4.1 Switching on the equipment .............................................................................................. 41

4.2 Test parameters setting ...................................................................................................... 42

4.3 Carry out a test ................................................................................................................... 43

4.3.1 Use of the load control valve ......................................................................................... 45

4.3.2 Testing a sample ............................................................................................................ 46

4.4 Serial port .......................................................................................................................... 50

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

04/07/2011 Wizard Basic Rev.4 EN ii

4.5 Use of the integrated printer Q0701/UP2 (optional) ......................................................... 51 4.5.1 Installation of the printer paper ...................................................................................... 51

4.5.2 Setting of the date and enabling/disabling the date printout ........................................... 52

4.6 Stopping the cycle via the Emergency button ................................................................... 53

4.7 Switching off the unit ........................................................................................................ 54

5. MAINTENANCE 55

5.1 Operator’s preventive maintenance .................................................................................. 57 5.1.1 Checking the status of the safety devices ....................................................................... 58

5.1.2 Checking the oil level in the tank ................................................................................... 60

5.2 Authorized service engineer maintenance actions ............................................................ 61 5.2.1 Checking the centering of the ram assembly .................................................................. 62

5.2.2 Checking the hydraulic circuit........................................................................................ 64

5.2.3 Checking the status of distance pieces ........................................................................... 66

5.2.4 Performing the maintenance of the spherical seat .......................................................... 67

5.2.5 Calibration of the load channel....................................................................................... 68

5.2.5.1 Calibration verification................................................................................................... 69

5.2.5.2 Calibration ...................................................................................................................... 74

5.2.6 Checking the stability of the frame ................................................................................ 79

5.2.7 Replacing the oil of the hydraulic circuit ....................................................................... 81

6. DIAGNOSTICS & TROUBLESHOOTING 83

6.1 Troubleshooting ................................................................................................................ 84 6.1.1 Adjustment of the maximum load .................................................................................. 87

6.1.2 Adjustment of the rapid approach speed ........................................................................ 88

6.1.3 Sticking of the floating piston ........................................................................................ 89

6.1.4 Oil leakage from below the control knob ....................................................................... 90

6.1.5 The load does not increase ............................................................................................. 92

7. SPARE PARTS 93

8. SCHEMATICS AND DRAWINGS 98

This instruction manual is an integral part of the machine and should be read before using the machine and be safely kept for future reference. CONTROLS reserves all rights of this manual, no part or whole can be copied without the written permission of CONTROLS . The proper use of this machine must be strictly adhered to, any other use must be considered as incorrect. The manufacturer cannot be held responsible for damage caused by incorrect use of the machine. The machine must not be tampered with for any reason. In case of tampering, the manufacturer declines any responsibility of functioning and safety of the machine. This Manual is published by CONTROLS. CONTROLS reserves the right to update its manuals without notification in order to correct possible typing errors, mistakes, updating of information and/or updating of programs and/or accessories. Such changes will be inserted in the latest edition of the current manual.

This present in English is the original version of the manual. Printed in Italy


Wizard Basic Rev.4 EN 04/07/2011 1

1. INTRODUCTION

NOTE: The present manual is updated for the product it is sold with in order to grant an adequate reference in operating and maintaining the equipment. The manual may not reflect changes to the product not impacting service operations. This semi-automatic compression testers represent the basic equipment for concrete testing. These machines are ideal for control and commercial laboratories to test cubes, cylinders or blocks to different international Standards. The WIZARD BASIC readout unit features an analog input for load sensor and includes a alphanumerical display and a 5 key touch keyboard. A serial integrated thermal printer option is available (code 50-Q0701/UP2) and has to be requested when ordering the equipment to be fitted in the factory. Some models can be fitted with block testing platens. Main features are: o Class 1 machines starting from 10% of the full scale o Simultaneous display of applied load, corresponding specific load and load rate; o Input of sample area; o Input of load rate; o Transmission of the test data at the end of the test via RS232 serial port; o Calibration using coefficient; o Optional integrated serial printer. The system is mainly composed by: o Compression frame with platens (see relevant documentation) o Loading cylinder assembly o Hydraulic unit o Readout unit with channel input for load sensor and alphanumerical display. The machine must be completed with suitable distance pieces conforming to the specimen size. Front and rear transparent guards protect the operator from the fragments that may be ejected by the sample under test.

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04/07/2011 Wizard Basic Rev.4 EN 2

The hydraulic unit provides the oil to supply the load ram assembly that compresses the sample being tested. The readout unit is located above the hydraulic unit; during the test phase, the user is guided by a series of symbols that help keeping the proper loadrate. The device must be used in compliance with the procedures described in this manual. Never use the device for purposes different from those herewith indicated. This manual is applicable for units having firmware version equal to/higher than V2.1 and equipped with the emergency button.

Fig. 1-1 Please read this manual thoroughly before you start using the equipment.

NOTE: This manual concerns all available versions of compression machines equipped with WIZARD BASIC readout unit. However detailed information relative to the compression frames are provided by their relevant manuals.

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1.1 Icons appearing in the manual

This icon indicates a NOTE; please read thoroughly the items marked by this picture.

This icon indicates a WARNING message; the items marked by this icon refer to the safety aspects of the operator and/or of the service engineer.

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1.2 Manual revision history

Revision/Date Change description Rev. 1 6 July 2009

Manual release

Rev. 2 12 November 2010

New manual version

Rev. 3 02 March 2011

Updated procedure to install the printer paper (see chapter 4.5.1)

Rev 4 06 July 2011

Added setting of date on printouts (for units equipped with firmware revision 2.1 or higher)



1.3 Symbols used

In this manual and on the equipment itself, apart from the symbols indicated on the control panel, the following icons are also used:

Symbol Description

Mains switch: O = device not connected to the mains line I = device connected to the mains line

Emergency stop

Dangerous voltage

Hand injury

Conformity to the CE Directive



1.4 Intended use and improper use

The digital semi-automatic compression machines can only be used to perform building material tests to relevant international standards as specified on the last version of CONTROLS general catalogue.

The unit is designed to be operated by one operator that has to install the necessary distance pieces, load-unload the sample and start the test. During normal operation the working area of the equipment is the front side where the operator’s controls and the display are located. The operator is responsible of starting-up the equipment, performing the test sequence, shutting down the equipment and eventually stopping it in case any emergency conditions are met. The operator must be trained on the correct use of the machine and the relative safety aspects of its use. The machine should be used following the procedures described in this manual. Never use the machine for reasons other than those for which it was designed and manufactured. Any other use of the machine is to be considered improper, not foreseen and hence dangerous. CONTROLS will not be responsible for improper use of the machine.



1.5 Safety information WARNING: Please read this chapter thoroughly. CONTROLS designs and builds its devices complying with the related safety requirements; furthermore it supplies all information necessary for correct use and the warnings related to use of the equipment. CONTROLS will not to be held responsible for: • use of the equipment different than the intended use,

• damages to the unit, to the operator, caused both by installation and maintenance procedures different than those described in this manual supplied with the unit, and by wrong operations,

• mechanical and/or electrical modifications performed during and after the installation, different than those described in this manual

The unit is not designed to be used in an explosive atmosphere. Installation and any technical intervention must only be performed by qualified technicians authorized by CONTROLS. Only authorised personnel can remove the covers and/or have access to the components under voltage. During normal use, if the operator detects irregularities or damages, he/she should immediately inform the authorized technical personnel. Maintenance and service activities can only be performed by skilled authorized technical personnel that have been properly trained on the residual risks of the equipment. It is responsibility of the purchaser to make sure that the operators have been properly instructed concerning the safety issues and the residual risks related to the equipment.



The machine is equipped with the following devices to limit the residual risks in using it: • Emergency button that allows stopping the machine in case anomalous conditions

that may jeopardize the operator safety are encountered; • Max. pressure valve to avoid machine overloading;

Fig. 1-2

Max pressure valve Lever A to release piston pressure

Emergency button



• Ram travel switch (standard on EN equipment, optional on other versions to be fitted and connected in the factory) to prevent the excessive piston travel; when triggered it disables the functioning of the pump motor.

Fig. 1-3

• Front and rear transparent fragment guard (rigid or flexible depending on the equipment versions).

Fig. 1-4

• Access panels equipped with screws.

Limit switch

Front fragment guard



The following table lists those parts of the equipment that may present some residual risks for the safety of the personnel if the instructions provided in this manual are not duly followed.

Personnel Area with residual risks Operator The sample during load-unloading phase into the unit, due to its weight and

sharp surfaces. Use suitable personal protection devices (e.g. gloves, protective shoes, etc.). The distance pieces and platens during the installation phase, due to their weight. Use suitable personal protection devices (e.g. gloves, protective shoes, etc.). The area around the frame during the execution of the test, in case of test on explosive samples and with the front and rear fragment guards not in place.

The gap between the sample and the upper platen during the compression phase, although the maximum speed is very low (max. 40mm/min).

Technical personnel Above listed areas Area around the hydraulic tubes, due to the high pressure of the oil, in case the tubes are damaged or not properly attached Areas around compartments closed by removable panels Areas around compartments that contain electrical parts For continued fire protection, replace fuses with same type and rating. Also, in case of failure, components may only be replaced by using original spare parts. It is in the responsibility of the purchaser to insure that fire prevention policies are properly implemented according to the CE provisions.

Personnel responsible of transportation and moving of the equipment

Raising and moving of the equipment from the wooden crate must be performed by people properly trained and equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to follow the instructions above may endanger the personnel involved.



Here follows a list of all WARNINGs present in the manual; please see relevant chapters for full details on each related safety issue. WARNING: When operating with the covers open/removed and the unit is attached to the mains line, care must be taken as high voltage is present in some parts of the unit (e.g. electrical panel). Only authorized and qualified service technicians are allowed to open /remove covers.

WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel. WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking.

WARNING: Raising and moving of the equipment must be performed by people properly trained and equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to follow the instructions above may endanger the personnel involved. WARNING: The wooden crate is high; be careful in balancing while raising it.

WARNING: If the instructions to remove the equipment from the shipping box are not carefully followed, damages to the equipment cabinet may result. This will void the warranty terms of the equipment.



WARNING: Do not stand under suspended loads WARNING: Considering the weight of the equipment and the footprint (see chapter 2.10), check the maximum allowed floor load before installation. WARNING: Make sure to use proper fixing bolts according to the type of floor of the installation place. CONTROLS cannot be considered responsible in case of injures to the operator or damages to the equipment if the above instructions are not duly followed. WARNING: If the equipment is brought from a cold environment into a heated room, condensation on and in the unit can constitute a danger and lead to malfunctioning of the unit when started. Wait to connect and operate the unit until it is at room temperature. WARNING: The general grounding must comply with the rules in force; a wrong quality of the grounding could be dangerous for the operator’s safety and cause bad function of the electrical devices. WARNING: Covers/doors can only be removed/opened by maintenance people, by using relevant tools/keys. These tools and keys are for use by maintenance personnel only. Never leave the tools and keys attached to the unit as this may endanger operator safety.

After performing maintenance/repair, make sure that all covers/doors are properly closed and locked.



WARNING: Be careful and use proper personal protection devices (e.g. gloves, protective shoes) while loading/unloading samples from the test frame, due to the sample weight and sharp surfaces.

WARNING: Be careful and use proper personal protection devices (e.g. gloves, protective shoes) while handling distance pieces and platens due to their weight.

WARNING: Always close the front door and place the rear guard while executing the tests. Also use proper personal protection devices (e.g. glasses) in order to avoid injures due to fragments of samples ejected during the test (e.g. in case of test on explosive samples ).

WARNING: Although the maximum speed of the loading piston is very low (max. 40mm/min), to avoid injures during the compression phase, always close the front door and place the rear guard while executing the tests. Also avoid putting hands/fingers in the gap between the sample and the upper platen.

WARNING: Failing to perform the recommended maintenance actions or maintenance performed by unauthorized people can void the warranty. CONTROLS will not be responsible for maintenance and service actions performed by unauthorized people.

WARNING: Before opening/removing the covers, disconnect the mains supply to the device and wait at least 5 minutes.



WARNING: Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved by CONTROLS can be used. CONTROLS will not be responsible for damages to the equipment or personnel injures in case of use of improper material and/or operations not carried out by authorized technical personnel.

WARNING: For continued fire protection, replace fuses with same type and rating. Also, in case of failure, components may only be replaced by using original spare parts. It is in the responsibility of the purchaser to ensure that fire prevention policies are properly implemented according to the CE provisions. WARNING: Avoid pouring water, even accidentally, or other liquids into the device, as this could cause short circuits. Before cleaning the device, disconnect it from the mains line.

WARNING: Refer to qualified service organization authorized by CONTROLS to carry out the maintenance actions described in the chapter “Authorized service engineer maintenance action”. CONTROLS has not to be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed. WARNING: Before performing the CALIBRATION it is vital to carefully read and understand the procedure described hereunder. If any doubts remain, contact CONTROLS service department for further clarification. CONTROLS will accept no responsibility for any inconvenience caused by wrongful calibration. WARNING: Refer to qualified service organization authorized by CONTROLS to carry out the service maintenance actions described in the chapter “Diagnostic and Troubleshooting”. CONTROLS has not to be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed. WARNING:

Pressing the key for 10 seconds or more will erase the functioning parameters of the equipment ( e.g. Full scale, calibration coefficient, units, etc). It is therefore recommended not to perform this action unless strictly necessary and/or authorized by CONTROLS personnel.

Manuale di Istruzioni WIZARD BASICInstruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

1.6 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

The above symbol, when attached to the equipment or to the relevant packaging, indicates that the product must be disposed of separately from other rubbish at the end life. Therefore, at the end of its useful life, the owner should dispose osuitable collection point for electrical and electronic products provided by the local authorities. The correct disposal of this product and the subsequent treatment encourages the manufacture of products using rethe product caused by improper disposal. Improper disposal of the product is subject to penalties as foreseen by the local regulations.


15

Environmental risks and disposal


The above symbol, when attached to the equipment or to the relevant packaging, indicates that the product must be disposed of separately from other rubbish at the end

Therefore, at the end of its useful life, the owner should dispose osuitable collection point for electrical and electronic products provided by the local

The correct disposal of this product and the subsequent treatment encourages the manufacture of products using re-cycled materials and limits the environmental impact of the product caused by improper disposal.

Improper disposal of the product is subject to penalties as foreseen by the local

04/07/2011


The above symbol, when attached to the equipment or to the relevant packaging, indicates that the product must be disposed of separately from other rubbish at the end of its useful

Therefore, at the end of its useful life, the owner should dispose of the product in a suitable collection point for electrical and electronic products provided by the local

The correct disposal of this product and the subsequent treatment encourages the imits the environmental impact of

Improper disposal of the product is subject to penalties as foreseen by the local



1.7 CE declaration This page shows a copy of the CE declaration. The original is supplied with the equipment as a separate document.



2. DESCRIPTION

Refer to the following figures for main components identification.

Fig. 2-1

Rif Description 1 Front guard 2 Upper platen with spherical seat 3 Lower platen 4 Piston travel indicator 5 Readout unit 6 Hydraulic unit 7 Pump motor switch 8 Flow control valve

2

3

1

4

5

6

8

7



NOTE: This manual concerns all versions of the equipment. However detailed information relative to the compression frames are provided by the relevant manuals.

2.1 Frame

Made of welded steel.

2.2 Compression platens and ball seating

The two compression platens are hardened and rectified. The upper platen is fitted to a ball seating, the lower platen has marks to allow the exact centring of samples.

2.3 Loading cylinder assembly

Made of special steel. The ram is surface hardened, rectified and lapped. The maximum travel of the ram is indicated on the appropriate indicator. A micro-switch avoids the expulsion of the ram in the case of incorrect use (standard on EN frame, optional to be fitted in the factory on other frames).

2.4 Hydraulic unit

The hydraulic unit consists of: o Tank o pump o motor o valve Before describing the single components of the machine, the following definitions should be noted: o Useful oil volume: is the volume of oil that can be managed by the machine o Working oil volume: is the volume of oil required by the ram to execute the full

stroke.

The tank contains sufficient oil to feed the ram during the test. It is dimensioned to feed all the test frames produced by CONTROLS with a capacity up to 3000 kN; in all these cases the useful oil volume of the machine is more than the working oil volume of the test frame.

NOTE: The hydraulic unit is compatible with rams of test frames manufactured by CONTROLS up to 3000 kN. Before connecting frames of higher capacity or made by other manufacturers, ensure that the working oil volume of the frame to be connected is less than the useful oil volume. The usable oil volume is given in next page. In case of doubt please refer our technical service department.

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The power system consists of a dual stage pump: low pressure/high delivery (max. 7 bar) for fast piston approach (up to 40 mm/min) and high pressure/low volume (up to 650 bar, 0.50 litres/min) for loading. It is optimised to prevent any overheating effect even under intensive use and severe working conditions. The pump is fitted with a special proportional valve, hand control (pacemeter system) which features the accurate preset of load rate by the precise control of oil flow. The self compensated “Pacemeter” system maintain the preset load rate all over the test requiring just occasional operator intervention on the valve knob. The performance of this semiautomatic system are very close to those one of the Automatic testing systems. The motor which drives the pump is of a alternate current type and is activated at the beginning of the test through a dedicated switch. Apart from the hold valve which is not visible and not subject to regulation, the unit is fitted with 2 safety valves. The regulation of the safety valves must only be made by qualified persons. Main features of the Hydraulic unit are: o Dual stage pump o Centrifugal low pressure high delivery stage for rapid approach and radial multi-

piston high pressure stage for test execution o 720 W power o 6 litres oil capacity o 4 litres useful oil capacity o 50 mm ram travel o 40 mm/min fast approach speed.

2.5 Readout unit

Microprocessor based instrument used to read and process readings of applied load in failure tests on concrete, cement and other building materials. The instrument is housed in a light alloy case designed to satisfy various ergonomic aspects; it has a front panel in antiscratch polyester with a 5 key touch keyboard and alphanumerical display. The connector for a load sensor (load cell or pressure transducer), mains connector with filter, fuse and switch, and RS232 serial port are situated in the rear panel. Main features of the hardware are: o Main board made using latest components and SMD technology; o One analogical channel for connection of pressure transducer or strain gauge load

cell, with 32,000 point resolution; o Serial output port with 9600 baud rate for PC connection; o Internal serial output for connection of 40 column printer (optional accessory

Q0701/UP2); o Alpha-numerical display 2 lines x 16 characters; o 5 key touch keyboard.



Main features of the firmware are: o Simultaneous display of applied load, corresponding specific load and load rate; o Input of sample area; o Input of load rate; o Transmission of test data at the end of the test via RS232 serial port; o Calibration using coefficients; o Optional integral printer.



2.6 System block diagram

Fig. 2-2



2.7 Connections The next figure shows the position of the connectors/ports used to connect the different modules composing the equipment and equipment itself with external devices.

Fig. 2-3

Ref. Description 1 Readout unit power cable receptacle with mains switch and line fuse 2 Pressure transducer 3 Serial port for PC 4 Pump motor 5 Motor switch 6 Emergency stop

1

2

4

5

3

6



2.8 Identification plate The identification plate is located on the rear side of the equipment, near the power cable.

Fig. 2-4



2.9 Commands and controls

This chapter describes the commands and controls of the equipment. The operator’s interface description of the readout unit is provided in chapter 4.2 of the present manual.

Fig. 2-5

Ref. Description 1 Keyboard 2 Readout unit mains switch 3 Pump motor switch 4 Emergency button

1

2

3

4



2.9.1 Flow control valve

Fig. 2-6

Ref. Description

1 Load gradient adjustment knob (clockwise to decrease; counter clockwise to increase)

2 Flow control lever (back for rapid approach; forward to control load rate with the load gradient adjustment knob)

3 Oil supply lever (up to recycle oil in the tank; down to supply oil to the piston)

1

2

3



2.10 Technical specifications

Main characteristics ASTM Cylinder testers

Product Digital semi-automatic compression tester

Manufacturer CONTROLS Cernusco s/N (MI) Italy

Product code 230VAC 50Hz 1Ph 50-C2122 50-C3122



Capacity 1300 kN 1500 kN

Power 750 W

Method of power entry Power cable with plug

Computer connection Serial port RS232

Platen 165 mm diam.

Ram travel 50 mm

Max vertical daylight 370 mm 370 mm

Max horizontal daylight 235 mm 280 mm

Fast approach speed 40 mm/min approx.

Max. working pressure 650 bar

Oil output at max. pressure 0.3 l/min approx.

Oil tank capacity (approx.) 6 litres

Useful oil volume (approx.) 4 litres

Working oil volume (approx.) 2 litres

Acoustic pressure 77 db (A)

Net weight (approx.) 280 Kg 410 Kg

Overall dimensions W x H x D [mm]

650 x 890 x 400 700 x 920 x 420



Main characteristics ASTM/AASHTO Cylinder and cube testers



Product code 230VAC 50Hz 1Ph 50-C3422 50-C4422 50-C5422



Capacity 1500 kN 2000 kN 3000 kN

Power 750 W



Platen 216 mm diam. 216 mm diam. 300 mm diam.

Ram travel 50 mm

Max vertical daylight 340 mm 350 mm 350 mm

Max horizontal daylight 280 mm 330 mm 370 mm








Net weight (approx.) 400 Kg 550 Kg 750 Kg


700 x 920 x 413 770 x 1000 x 430 810 x 1070 x 560



Main characteristics EN models






Capacity 2000 kN 3000 kN

Power 750 W



Platen 300 mm diam.

Ram travel 50 mm

Max vertical daylight 350 mm 350 mm

Max horizontal daylight 370 mm 370 mm








Net weight (approx.) 890 Kg 1110 Kg


920 x 1030 x 440 1010 x 1100 x 500

Environmental conditions

Operating temperature + 10 ÷ + 40°C

Operating humidity ≤ 50%RH @ 40°C



3. INSTALLATION

The instructions indicated in this chapter enable you to perform a correct installation and interfacing in order to grant a regular operation of the equipment. Included are initial inspection procedure, power requirements and instructions for installing the unit. The information in this chapter is intended for authorized service-trained personnel. CONTROLS can supply the assistance and the necessary technical advice for pre-installation, all the pre-installation phases are at the purchaser’s charge and must be performed complying with the indications given below. WARNING: When operating with the covers open/removed and the unit is attached to the mains line, care must be taken as high voltage is present in some parts of the unit (e.g. electrical panel). Only authorized and qualified service technicians are allowed to open /remove covers.

WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel. WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking.



3.1 Shipment

The equipment is normally shipped in a wooden crate having the following dimensions and gross weight depending on the model:

Model Gross weight Overall dimensions

Minimum fork lift length

C212X 370 Kg 950 x 700 x 1050mm 1200mm C312X 440 Kg 950 x 700 x 1050mm 1200mm C342X 490 Kg 950 x 700 x 1050mm 1200mm C442X 640 Kg 950 x 700 x 1050mm 1200mm C542X 840 Kg 950 x 700 x 1150mm 1200mm C462X 980 Kg 950 x 700 x 1150mm 1200mm C562X 1210 Kg 1100 x 700 x 1250mm 1200mm Use a proper fork lift with minimum fork length as above indicated to raise and move the wooden crate (see figure below).

Fig. 3-1

WARNING: Raising and moving of the equipment must be performed by people properly trained and equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to follow the instructions above may endanger the personnel involved. WARNING: The wooden crate is high; be careful in balancing while raising it.



3.2 Unpacking and inspection The unit was carefully checked both mechanically and electrically before shipment; it should be inspected for any damage that may have occurred in transit. NOTE: If the shipping container or packaging material is damaged, it should be kept until the unit has been mechanically and electrically checked. If there is mechanical damage and/or the contents are incomplete (see the shipping list), please notify the local CONTROLS representative. If the shipping container is damaged or shows sign of stress, notify the carrier as well as the CONTROLS representative. Save the shipping material for carrier’s inspection. Also take some pictures. Here follows the procedure for the unpacking of the equipment.

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3.2.1 How to remove the equipment from the shipping crate The following table shows the net weight of the different models of the equipment:

Model Net weight C212X 280 Kg approx. C312X 350 Kg approx. C342X 400 Kg approx. C442X 550 Kg approx. C542X 750 Kg approx. C462X 890 Kg approx. C562X 1120 Kg approx.

Follow the instructions below to remove it from the shipping crate: 1. Inspect shipping crate (see NOTES above); 2. Open the shipping crate; 3. Cut and remove vacuum bag (if present) to expose the equipment; 4. The machine must only be lifted up by the eyebolt(s) screwed in on the top of the

machine. Do not lift it by any other part to avoid damaging the equipment (see Fig. 3-2).

Fig. 3-2



WARNING: If the instructions to remove the equipment from the shipping box are not carefully followed, damages to the equipment cabinet may result. This will void the warranty terms of the equipment.

WARNING: Raising and moving of the equipment must be performed by people properly trained and equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to follow the instructions above may endanger the personnel involved. WARNING: Do not stand under suspended loads 5. Before powering on the unit, check for loose connections of cables inside the

equipment.



3.3 Positioning of the unit and space requirements WARNING: Considering the weight of the equipment and the footprint (see chapter 2.10), check the maximum allowed floor load before installation. The unit must be placed on a flat and level surface. The area around the equipment must be kept free from obstacles and from substances that may cause sliding of the personnel. It is responsibility of the purchaser to provide an installation place with adequate lighting. Parts used to build the machine and electrical/electronics component are fire-proof. It is anyway the responsibility of the owner of the equipment to make sure that the installation place is equipped with proper fire extinguishing systems and that the operators have been instructed on the relevant procedures. Use a proper mean to bring the unit to the installation place. Place the unit in its final location, taking into account the free space around the unit: the equipment requires at least 100 cm of clearance on the front and at least 50 cm on the 3 sides for maintenance and service purposes.

Fig. 3-3

50cm



Also consider that mains connection is achieved through the mains cable socket on the rear side of the equipment cabinet. The unit requires adequate air circulation around it to assure proper cooling of the internal devices. The machine must be fixed to the floor using expandable fixing bolts as shown in fig. below.

Fig. 3-4

Model a mm b mm c mm

C212X 215 285 Dia 13 C312X 250 310 Dia 13 C342X 250 310 Dia 13 C442X 330 350 Dia 13 C542X 370 390 Dia 13 C462X 565 260 Dia 13 C562X 655 320 Dia 13 WARNING: Make sure to use proper fixing bolts according to the type of floor of the installation place. CONTROLS cannot be considered responsible in case of injures to the operator or damages to the equipment if the above instructions are not duly followed. WARNING: If the equipment is brought from a cold environment into a heated room, condensation on and in the unit can constitute a danger and lead to malfunctioning of the unit when started. Wait to connect and operate the unit until it is at room temperature.



3.4 Installing and positioning of the display Mount the WIZARD BASIC unit as shown below, placing it so as to get the best possible view of the display and then block into position using the knurled locking handle.

Fig. 3-5



3.5 Electrical requirements The next table shows the electrical specifications of the equipment:

Item Specifications Mono phase voltage 110VAC/220VAC/230VAC +6%, -10% Frequency 50Hz/60Hz Maximum power 750 W

The equipment shall be connected to a proper earth system, the efficiency of which shall be checked by qualified personnel. Earth shall be via the power cable, as specified above. WARNING: The general grounding must comply with the rules in force; a wrong quality of the grounding could be dangerous for the operator’s safety and cause bad function of the electrical devices. The power supply line shall be equipped with a safety device (breaker and ground fault switch) properly sized with respect to the electrical specifications provided above.



3.6 Electrical connections

The sockets for electrical connection are on the rear panel of the readout unit, these are for the load sensor, serial port, and mains supply fitted with filter, delayed fuse and switch. 1. Make sure the mains switch is of the control unit is turned OFF before connecting the

power cable then connect the mains cable to a suitable single-phase socket/panel (see chapter 3.5);

2. Connect the load sensor to the connector LOAD.

Fig. 3-6

3. Make sure the mains switch of the pump motor is turned OFF then connect its mains cable to a suitable single-phase socket/panel (see chapter 3.5);

Fig. 3-7

Readout unit mains cable input and switch

Frame load sensor cable



4. Connect the PC serial cable, if present, to the RS232 connector (for use of the serial

ports, printer and RS232 see chapter 4.4);

Fig. 3-8

5. Refer to chapter 4.1 to turn ON the unit.

LOAD PC

serial port

Control unit power switch



4. USE OF THE EQUIPMENT

This chapter describes the operator’s interface and the execution of a test.

WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel. WARNING: Covers/doors can only be removed/opened by maintenance people, by using relevant tools/keys. These tools and keys are for use by maintenance personnel only. Never leave the tools and keys attached to the unit as this may endanger operator safety.




4.1 Switching on the equipment 1. Once all the connections have been made correctly, switch ON the unit via the power

switch on the readout unit;

Fig. 4-1

2. Press the button on the keyboard for 1 second; the display will switch ON and the following message will appear;

Fig. 4-2

3. “1.X” represents the version of the installed firmware; after a short while the

following message will appear on the display;

Fig. 4-3

4. The load is shown (in kN) as is the specific load (in Mpa) and an indicator of the load

rate which is active during the test. Before going further, carefully read instructions provided in chapter 4.2.

Power switch



4.2 Test parameters setting

Press key to access the set test parameters menu. The display will show as follows:

4-4

The AREA parameter is that of the surface area on the sample being tested (in mm²). For example, a 150 mm cube would have an area of 22500 mm². The RATE parameter is the load rate intended to be applied during the test. This can be expressed as Kpa/s or N/s. Note that 100 kpa corresponds to 0.1 N/mm².

Use the and keys to set the values, press to pass from one field to another. WARNING:


The selected field is indicated by the symbol #. Upon completion press to return to the previous screen.



4.3 Carry out a test

The present chapter provides the guide for the execution of a test.

WARNING: Be careful and use proper personal protection devices (e.g. gloves, protective shoes) while loading/unloading samples from the test frame, due to the sample weight and sharp surfaces.

WARNING: Be careful and use proper personal protection devices (e.g. gloves, protective shoes) while handling distance pieces and platens due to their weight.

WARNING: Always close the front door and place the rear guard while executing the tests. Also use proper personal protection devices (e.g. glasses) in order to avoid injures due to fragments of samples ejected during the test (e.g. in case of test on explosive samples ).

WARNING: Although the maximum speed of the loading piston is very low (max. 40mm/min), to avoid injures during the compression phase, always close the front door and place the rear guard while executing the tests. Also avoid putting hands/fingers in the gap between the sample and the upper platen.



Before starting any test check that: • The test frame is free from residual of previous sample and that the surface of the

platens are clean; • Depending on the size of the sample, use proper distance pieces to reduce the

daylight, also considering that the piston total travel is 50mm.

Fig. 4-5

1. Switch ON the readout unit and wait 15 minutes warm up time;



4.3.1 Use of the load control valve

The load rate is controlled using the special valve with dial gauge handle mounted on the pump. The correct load rate can be set by following the load rate indicator on the WIZARD BASIC and rotating the load rate valve either clockwise or counter clockwise. NOTE: By rotating the valve clockwise the load rate is decreased, by rotating counter-clockwise the rate is increased. Next instructions describe its use in the different phases of the test.

1) Beginning of the test (rapid approach): Lever A up and Lever B back : Maximum piston speed upwards;

2) Load control phase: Lever A up and lever B slowly forward: Piston speed upwards controlled by load rate control valve;

3) Load rate adjustment: Turn the knob until getting proper load rate (read load rate indicator on the WIZARD BASIC display);

4) End of the test: Lever B slowly back and lever A down to discharge the oil pressure.

�

A B

A B

A B



4.3.2 Testing a sample 1. Before starting the test, the display will show the following;

4-6

2. Place the sample in the test frame and make sure the front and rear guards are in

place, turn ON the pump motor by pressing the relevant switch (note that the pump motor switch is self retaining when the mains electricity supply is connected); in the meantime set lever A up and lever B back on the flow control valve (rapid approach phase);

Fig. 4-7

3. Zero the display by pressing the key. We recommend that the zero is made during the rapid approach phase, before the sample comes into contact with the upper platen. If necessary the display can be zeroed more than once;

NOTE: Do not zero the load reading once the sample has been subjected to loading.

�

A

B



4. Once the sample comes into contact with the upper platen/bearer, with lever A up,

turn lever B slowly forward to control the speed of the piston with the flow control valve;

Fig. 4-8

When the sample comes into contact with the upper platen, and during the whole test, the display will update in real time the applied load and the corresponding specific load. The display will also show a load rate indicator which use symbols to indicate the actual load rate being applied compared to the theoretical load rate set as described above. The meaning of the symbols that appear on the screen are as follows:

= = = the actual load rate corresponds to the theoretical load rate ± 10%

= the actual load rate corresponds to the theoretical load rate ± 15%

– the actual load rate corresponds to the theoretical load rate – 15…25%

– – the actual load rate corresponds to the theoretical load rate – 25…50%

– – – the actual load rate corresponds to the theoretical load rate – more than 50%

+ the actual load rate corresponds to the theoretical load rate + 15…25%

+ + the actual load rate corresponds to the theoretical load rate + 25…50%

+ + + the actual load rate corresponds to the theoretical load rate + more than 50%.

4-9

A B



Thus it is possible to check that the correct load rate is being applied throughout the test and make any adjustments that may be necessary acting on the flow control valve knob;

Fig. 4-10

5. At the end of the test the display will show the failure load and corresponding specific load;

4-11



6. Turn OFF the pump motor by pressing the relevant switch, then turn lever B slowly

back and lever A down to discharge the oil pressure;

Fig. 4-12

7. To print and/or download the data to the PC via the serial port press the key; WARNING:


8. To start another test proceed from step 1; if the test parameters need to be changed refer to chapter 4.2.

A

B



4.4 Serial port The instrument is fitted with a RS232 serial port which transmits the value of the read

load once the key pressed. The settings of the serial port are: o baud rate: 9600 o data bit: 8 o stop bit: 1 o parity: none o flow control: none For the connection of the instrument to a PC or serial printer (e.g. 84-P0172) use exclusively the cable available from CONTROLS. The data transmitted can be acquired with the program D-TERMINAL (CONTROLS code Q0800/TRM) or with the program Hyperterminal normally installed on the computers. WARNING:




4.5 Use of the integrated printer Q0701/UP2 (optional) This printer must be factory installed. It cannot be installed at a later date. The printer is active when the instrument is switched ON; a green led indicates that the printer is active and working correctly. If the green led flashes it means the printer is not working correctly, the paper is finished or its front panel has not been closed correctly. The feed key is used to manually advance the paper. Follow the instructions below to correctly insert the paper roll.

4.5.1 Installation of the printer paper

The printer is supplied with a roll of thermal paper which should be installed before starting the unit. Proceed as follows: 1. Open the paper roll compartment by pressing the OPEN key; 2. Move down the plastic cover to the maximum opening; 3. Place the paper roll making sure that it unrolls in the proper direction as shown; 4. Take out the paper and close the plastic cover; 5. Push on the plastic cover to lock it; 6. Tear off the exceeding paper using the jagged edge.

Fig. 4-13



4.5.2 Setting of the date and enabling/disabling the date printout

Switch ON the unit via the power switch on the rear panel of the read out unit; the printer will be activated but the display will remain blank.

Press and keep pressed the button .

Turn ON the unit with the button on the front panel and keep on pressing the

button until the display is blank. Release the button, the following display will be shown:

Fig. 4-14

This menu allows changing the following functions: FULL SCALE, CALIBRATION (refer to chapter 5.2.5.1 for details on these functions) and DATE PRINT.

Use the button to select the function DATE PRINT, it will be highlighted by the

symbol #. Press the button to access this menu.

Fig. 4-15

Press the button to move among the available fields and to set the date and activate/de-activate the date printout. NOTE: The date is not updated automatically. It needs to be changed by the operator following the procedure above described.

�



4.6 Stopping the cycle via the Emergency button

In case dangerous conditions are encountered during the execution of a test cycle, it is possible to stop the machine by pressing the EMERGENCY BUTTON. Pressing this button will stop the pump motor (its switch will be released and will return in the “0” position) thus stopping the movement of the piston. To release the hydraulic pressure turn lever B slowly back and lever A down.

Fig. 4-16

After clearing the emergency condition: • To release the emergency button turn it clockwise; • To restart the motor, its power switch must be pressed.

A

B



4.7 Switching off the unit

At the end of a test, remove residuals of the samples.

To switch OFF the readout unit press the button on the keyboard for at least 1 second then turn the power OFF via the mains switch located on the rear panel.

Fig. 4-17

Readout unit mains switch



5. MAINTENANCE

As with all electrical equipment, this unit must be used correctly and maintenance and inspections must be performed at regular intervals. Such precautions will guarantee the safe and efficient functioning of the equipment. Periodic maintenance consists of inspections made directly by the test operator and/or by the authorized service personnel. Maintenance to the equipment is responsibility of the purchaser and must be performed as stated by this chapter. Failing to perform the recommended maintenance actions or maintenance performed by unauthorized people can void the warranty. WARNING: Failing to perform the recommended maintenance actions or maintenance performed by unauthorized people can void the warranty. CONTROLS will not be responsible for maintenance and service actions performed by unauthorized people.

WARNING: Before opening/removing the covers, disconnect the mains supply to the device and wait at least 5 minutes.

WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel. WARNING: Covers/doors can only be removed/opened by maintenance people, by using relevant tools/keys. These tools and keys are for the use of maintenance people only. Never leave them attached to the unit as this may endanger operator safety.




WARNING: Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved by CONTROLS can be used. CONTROLS will not be responsible for damages to the equipment or personnel injures in case of use of improper material and/or operations not carried out by authorized technical personnel.

WARNING: For continued fire protection, replace fuses with same type and rating. Also, in case of failure, components may only be replaced by using original spare parts. It is in the responsibility of the purchaser to ensure that fire prevention policies are properly implemented according to the CE provisions. WARNING: Avoid pouring water, even accidentally, or other liquids into the device, as this could cause short circuits. Before cleaning the device, disconnect it from the mains line.

WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking.



5.1 Operator’s preventive maintenance

The inspections made directly by the operator are the following:

Action Who When Check to ensure that there is no external damage to the equipment, which could jeopardise the safety of use

Operator Before every working session

Clean and dry platens, distance piece and ram from the sample debris

Operator At the end of each working session

General inspection Operator Weekly Check the status of the hydraulic tubes against leakages and damages

Operator Weekly

Check status of the safety devices: max. pressure valve, piston over travel switch and relevant cable (if present), front and rear transparent guard (refer to chapter 5.1.1 for their identification)

Operator Weekly

Check status and functioning of the operator's command

Operator Weekly

Check the level of the oil in the tank (see chapter 5.1.2)

Operator Monthly

Check that all label and rating plates are intact and properly attached

Operator Monthly



5.1.1 Checking the status of the safety devices The machine is equipped with the following devices to limit the residual risks in using it: • Emergency button that allows stopping the machine in case anomalous conditions

that may jeopardize the operator safety are encountered; • Max. pressure valve to avoid machine overloading;

Fig. 5-1

Max pressure valve Lever A to release piston pressure

Emergency button



• Ram travel switch to prevent the excessive piston travel; when triggered it disables

the functioning of the pump motor (optional to be fitted and connected in the factory).

Fig. 5-2

• Front and rear transparent fragment guard.

Fig. 5-3

Limit switch

Front fragment guard



5.1.2 Checking the oil level in the tank WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking. Check the oil level in the tank via the transparent level indicator (the oil should be max. at half of the indicator); if necessary refill the oil tank.

Fig. 5-4

The following type of oil can be used:

Brand Type Agip ATF Dexron Api Apilube ATF Dexron Chevron Chevron automatic transmission fluid Elf Elfmatic G Exxon Automatic transmission fluid Fiat GI/A Fina Dexron ATF Gulf Automatic transmission fluid IP Dexron fluid Mobil ATF 220 Shell ATF Dexron II Total Dexron Vanguard ATF fluid DEX II

Oil level indicator



5.2 Authorized service engineer maintenance actions

In addition to the maintenance actions performed by the operator, the performance of the equipment is checked and, if necessary corrected, during the maintenance activities performed by the authorized service engineer, in accordance with the indications provided in the present manual. The following table lists the maintenance actions and the relevant timing:

Action Who When Checking the centering of the ram assembly (see chapter 5.2.1)

Authorized service engineer Yearly or before carrying out

the calibration of the load channel(s) and the checking of the stability of the frame through the force transfer test with the strain gauged column

Checking the hydraulic circuit (see chapter 5.2.2)

Authorized service engineer

Checking the status of distance pieces (see chapter 5.2.3)


Performing the maintenance of the spherical seat (see chapter 5.2.4)


Checking the calibration of the load channel(s) (see chapter 5.2.5)


Yearly or more frequently depending on the quality procedures of the laboratory

Checking the stability of the frame through the force transfer test with the strain gauged column (see chapter 5.2.6)


Yearly or more frequently depending on the quality procedures of the laboratory

Status of the internal and external cables wear and tear and fastenings


Yearly

Grounding of all the accessible conductive parts


Yearly

Replacing the oil of the hydraulic circuit (see chapter 5.2.7)


Every 3 years or more frequently in very cold or humid environments (where condensation may form in the oil tank)

WARNING: Refer to qualified service organization authorized by CONTROLS to carry out the maintenance actions described in the chapter “Authorized service engineer maintenance action”. CONTROLS has not to be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed.

04/07/2011

5.2.1 Checking the centering of the ram assembly

The proper centering of the ram assembly assures force to the sample during the execution of the compression test. This check is normally carried out before checking the calibration of the system and checking the stability of the frame through the force transfer test with the strain gauged column. This checking should also be carried out if tests on high strength concrete/explosive samples are often carried out To check the centering of the ram assembly: 1. Remove the lower platen and distance pieces; 2. On the compression frame r

brackets;

3. Use a straight edge and a tape measure to check the centering of the ram assembly all directions with respect to the column

Manuale di IstruzioneInstruction Manual

Wizard Basic 62

the centering of the ram assembly

The proper centering of the ram assembly assures proper and uniform distribution force to the sample during the execution of the compression test.

This check is normally carried out before checking the calibration of the system and checking the stability of the frame through the force transfer test with the strain gauged

This checking should also be carried out if tests on high strength concrete/explosive carried out.

To check the centering of the ram assembly:

Remove the lower platen and distance pieces;

On the compression frame remove the cover of the ram assembly to expose its fixing

Fig. 5-5

Use a straight edge and a tape measure to check the centering of the ram assembly with respect to the columns of the compression frame;

Fig. 5-6



proper and uniform distribution of the


This checking should also be carried out if tests on high strength concrete/explosive

to expose its fixing

Use a straight edge and a tape measure to check the centering of the ram assembly in frame;



4. If it is not centered by more than 1mm in one or more directions, loosen the ram

fixing nuts and screws and use a rubber hammer to re-center it properly;

Fig. 5-7

5. Also check that the ram is properly positioned from a rotational point of view by taking as reference the position of the oil supply tube with respect to the columns of the frame on the rear of the ram;

Fig. 5-8

6. At the end firmly lock the ram assembly in place by tightening the relevant brackets/nuts and screw.

04/07/2011

5.2.2 Checking the hydraulic circuit Due to the high pressure inside the hydraulic circuit (up to 700 bars) on the hydraulic components is required. WARNING: Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved by CONTROLS can be used. CONTROLS will not be responsible for damages to the equipment or personnel carried out by authorized technical personnel.

WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking

Proceed as follows: 1. Remove the lower platen and distance pieces;

2. On the compression frame remove the cover of the ram assembly to expose its fixing

brackets;

3. On the rear of the equipment check

o Connection point of the pressure transducero Input port of the oil on the ram assemblyo Both ends of the hydraulic tube and along the hydraulic tube itselfo Output of the flow control valve on the front sideo Slot between the piston and the ram assembly;


Wizard Basic 64

the hydraulic circuit

Due to the high pressure inside the hydraulic circuit (up to 700 bars) a periodical on the hydraulic components is required.

Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved by CONTROLS can be used. CONTROLS will not be responsible for damages to the equipment or personnel injures in case of use of improper material and/or operations not carried out by authorized technical personnel.

To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking.

Remove the lower platen and distance pieces;


Fig. 5-9

On the rear of the equipment check the following points for oil leakages:point of the pressure transducer

Input port of the oil on the ram assembly of the hydraulic tube and along the hydraulic tube itself

flow control valve on the front side the piston and the ram assembly;



periodical check

Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved by CONTROLS can be used. CONTROLS will not be responsible for damages to the

injures in case of use of improper material and/or operations not

To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves


the following points for oil leakages:

of the hydraulic tube and along the hydraulic tube itself



4. In case of oil leakages, check the single item(s) and replace the relevant gasket/O

ring; 5. Then check the oil level in the tank (refer to chapter

oil tank as described in chapter 6. At the end, use compressed air to clean the slot between piston and cylinder and the

base of the compression frame.


65

Fig. 5-10

In case of oil leakages, check the single item(s) and replace the relevant gasket/O

Then check the oil level in the tank (refer to chapter 5.1.2) and, if needed, reoil tank as described in chapter 5.2.7;

At the end, use compressed air to clean the slot between piston and cylinder and the base of the compression frame.

04/07/2011

In case of oil leakages, check the single item(s) and replace the relevant gasket/O-

) and, if needed, re-fill the

At the end, use compressed air to clean the slot between piston and cylinder and the

04/07/2011

5.2.3 Checking the status of distance pieces To assure proper and uniform distribution of the force to the sample during the execution of the compression test, checked. This check is normally carried out before checking the calibration of thchecking the stability of the frame through the force transfer test with the strain gauged column. This checking should also be carried out if tests on high strength concrete/explosive samples are often carried out. • Checking the status of di• Checking that the surfaces of the distance pieces are not damaged (free of deep dents

and incisions); • Checking the planarity of the lower and upper surface;• Checking the status of the centering screw• Checking that, once

pushing them from the top.


Wizard Basic 66

the status of distance pieces

To assure proper and uniform distribution of the force to the sample during the execution of the compression test, status of distance pieces and platens must be periodically


This checking should also be carried out if tests on high strength concrete/explosive samples are often carried out.

Checking the status of distance pieces requires: Checking that the surfaces of the distance pieces are not damaged (free of deep dents

Checking the planarity of the lower and upper surface; Checking the status of the centering screw; Checking that, once the distance pieces are installed on the machine, they do not tilt pushing them from the top.

Fig. 5-11



To assure proper and uniform distribution of the force to the sample during the execution periodically

e system and checking the stability of the frame through the force transfer test with the strain gauged

This checking should also be carried out if tests on high strength concrete/explosive

Checking that the surfaces of the distance pieces are not damaged (free of deep dents

distance pieces are installed on the machine, they do not tilt



5.2.4 Performing the maintenance of the spherical seat The status of the spherical seat heavily influences and determines the proper performance of the compression machine as it must ensure proper and uniform distribution of the force to the sample during the execution of the compression test. The maintenance of the spherical seat is normally carried out before checking the calibration of the system and before checking the stability of the frame through the force transfer test with the strain gauged column. The maintenance should also be carried out if tests on high strength concrete/explosive samples are often carried out. Performing the maintenance on the spherical seat requires its removal from the equipment and its complete disassembling to check and maintain its internal components. Refer to qualified service organisation authorized by CONTROLS to perform the maintenance on the spherical seat.




5.2.5 Calibration of the load channel The load values displayed by the machine are conditioned by the calibration coefficients. The calibration of the system must be checked periodically to ensure proper performance. The calibration procedure here after described conform to the European standard EN12390-4. The main steps of the procedure can be summarized as follows: 1. Calibration verification; if the machine is within the limits of the standard, the

procedure ends, otherwise proceed with step 2; 2. Calibration of the machine (e.g. adjustment of the force measurement device of the

machine); 3. New calibration verification (repeat step 1). Steps 2 and 3 above are required if the machine is not within the limits indicated by the standards.

Step 1 above consists of: o Application of several levels of force (at least 5) ranging from 20% to 100% of the

full scale of the machine; o For each level of force, compare the force measured by the compression machine (the

“indicated force”) with the force measured by a calibrated force measurement device (the “true force”)

For class 1 machine the requirement of EN12390-4 are the following: o Relative accuracy error within the range ±1%; o Relative repeatability error within the range ±1%; o Relative zero error within the range ±0,2%.

The same procedure can also be applied for equipment complying with the ASTM C39 standard, that requires an accuracy ±1% for any value displayed within the verified loading range and the provision to display true 0 reading at 0 load. When the WIZARD BASIC is supplied with a Compression frame it is factory calibrated and no calibration is necessary at the time of installation.



5.2.5.1 Calibration verification

1. Turn ON the mains switch on the rear panel of the instrument; the printer will be activated but the display will remain blank;

2. To access the calibration function, with the unit display still switched OFF, press the

key and keep it pressed whilst switching on the unit using the key on the front panel, keep it pressed until the screen appears completely empty. When

the key is released the following screen will appear:

Fig. 5-12

3. Leave the equipment switch ON for at least 15 minutes to allow the thermal equilibrium of the electronic components;

4. Use the key to select the desired function which will be highlighted by the

symbol #. Press the key to access the selected function;

WARNING:




5. The FULL SCALE function allows the input of the full scale of the test frame. This

value should only be modified when installing the WIZARD BASIC for the first time on a test frame. The screen will show:

Fig. 5-13

6. Input the desired value using the and keys. Upon completion press

to exit;

NOTE: Do not access this parameter unless it is required modifying the full scale selected into the readout unit.

7. Press the key to select the CALIBRATION function and press key to access it; the screen will show:

Fig. 5-14

A) represents the load in kN; B) represents the gain multiplication constant.

WARNING:

Pressing the key for 10 seconds or more will erase the functioning parameters of the equipment ( e.g. Full scale, calibration coefficient, units, etc). It is therefore recommended not to perform this action unless strictly necessary and/or authorized by CONTROLS personnel. 8. Correctly place the reference instrument (e.g. load cell) between the compression

platens of the test machine. Check that the free vertical span is approximately between 5 and 25 mm, use suitable distance pieces if necessary;

�

A B



9. When ready, turn ON the pump motor by acting on the relevant switch (note that the

pump motor switch is self retaining when the mains electricity supply is connected); in the meantime set lever A up and lever B back on the flow control valve (rapid approach phase); and the ram of the test machine will start to rise;

Fig. 5-15

10. During this phase, before the load cell is subjected to load, zero the load reading

by pressing the key ; NOTE: Do not zero the load reading once the load cell has been subjected to loading.

�

A

B



11. When the load cell is close to the upper platen of the compression machine it is

recommended that the load rate is decreased so as to not apply a shock load to the cell. To do this set lever A up, turn lever B slowly forward to control the speed of the piston with the flow control valve;

Fig. 5-16

12. Adjust the load rate by acting on the flow control valve knob;

Fig. 5-17

13. Once the load cell is under load, a moderate speed should be used, making

adjustments with the flow control valve knob as described above. By taking the load rate close to zero it is possible to stop the load increase and maintain an almost constant pressure. The value of the applied load is updated in real time on the display;

A B



14. Before checking the calibration the machine should be taken to its maximum

capacity 3 or 4 times so as to obtain a stabilised signal from the load sensors. After this procedure, compare the readings given by the WIZARD BASIC system against that of the reference load cell. Normally this is done at values of 10%, 15%, 20%, 40%, 60%, 80% and 100% of the full scale of the compression machine. If the percentage deviation is higher than permitted tolerances, the unit should be re-calibrated by changing the calibration coefficient so as to obtain the best possible linearity (see chapter 5.2.5.2);

15. To interrupt the load, turn OFF the pump motor switch and turn lever B slowly back and lever A down to discharge the oil pressure;

Fig. 5-18

A

B



5.2.5.2 Calibration The calibration process should be made only after that the CALIBRATION VERIFICATION has been carried out and the results are outside the expected tolerances (see chapter 5.2.5.1). WARNING: Before performing the CALIBRATION it is vital to carefully read and understand the procedure described hereunder. If any doubts remain, contact CONTROLS service department for further clarification. CONTROLS will accept no responsibility for any inconvenience caused by wrongful calibration. 1. Turn ON the mains switch on the rear panel of the instrument; the printer will be

activated but the display will remain blank; 2. To access the calibration function, with the unit display still switched OFF, press the

key and keep it pressed whilst switching on the unit using the key on the front panel, keep it pressed until the screen appears completely empty. When

the key is released the following screen will appear:

Fig. 5-19

3. Leave the equipment switch ON for at least 15 minutes to allow the thermal

equilibrium of the electronic components;

4. Press the key to select the CALIBRATION function;

Fig. 5-20



5. Press key to access the CALIBRATION function; the screen will show:

Fig. 5-21

A) represents the load in kN; B) represents the gain multiplication constant.

WARNING:


6. Correctly place the reference instrument (e.g. load cell) between the compression

platens of the test machine. Check that the free vertical span is approximately between 5 and 25 mm, use suitable distance pieces if necessary;

A B



7. When ready, turn ON the pump motor by acting on the relevant switch (note that the

pump motor switch is self retaining when the mains electricity supply is connected); in the meantime set lever A up and lever B back on the flow control valve (rapid approach phase); and the ram of the test machine will start to rise;

Fig. 5-22

8. During this phase, before the load cell is subjected to load, zero the load reading

by pressing the key ; NOTE: Do not zero the load reading once the load cell has been subjected to loading.

�

A

B



9. When the load cell is close to the upper platen of the compression machine it is

recommended that the load rate is decreased so as to not apply a shock load to the cell. To do this set lever A up, turn lever B slowly forward to control the speed of the piston with the flow control valve;

Fig. 5-23

10. Adjust the load rate by acting on the flow control valve knob;

Fig. 5-24

11. Once the load cell is under load, a moderate speed should be used, making adjustments with the flow control valve knob as described above. By taking the load rate close to zero it is possible to stop the load increase and maintain an almost constant pressure. The value of the applied load is updated in real time on the display; act as to reach approximately 40 to 50% of the full scale of the frame;

A B



12. The screen will show:

Fig. 5-25

A) represents the load in kN. B) represents the gain multiplication constant.

By increasing or decreasing this constant C (using the and keys) the calibration is amplified or reduced in a linear mode over the whole scale; it is now possible to compare the displayed load and simultaneously adjust the calibration constant C in case of any difference between the load value shown on the display of the WIZARD BASIC and the value shown on the reference system;

13. At the end of the process, to interrupt the load, turn OFF the pump motor switch and turn lever B slowly back and lever A down to discharge the oil pressure;

Fig. 5-26

14. Upon completion exit the function by pressing button;

15. Repeat now the calibration verification process (see chapter 5.2.5.1) to make sure the equipment is now within the tolerances.

A

B

A B



5.2.6 Checking the stability of the frame The proper application of the load to the sample can be tested through the force transfer test carried out with the strain gauged column. This testing procedure conforms to the European standard EN12390-4 and is applicable to the equipment EN versions. This test checks the performance of the compression machine under loading and the uniformity of the force transferred from the machine to the sample. The cylindrical Strain Gauged Column simulates the concrete sample and can measure the stress transferred along the wall of the sample. The Strain Gauged Column can read the applied force through 4 independent Wheastone bridges located peripherally along the wall of the cylinder. A dedicated electronic unit switches and independently balances each bridge, simultaneously displays the 4 bridges and has an accuracy within the limits ±0,1% or 5µm strain. A dedicated 150mm square stainless steel plate allows proper positioning of the Strain Gauged Column during the tests.

Fig. 5-27

The above picture shows the Strain Gauged Column code 82-E0105/1,the force transfer digital tester code 82-P0804/E and the printer code 82-P0172 that can be used to carry out the Force transfer test.



The Force Transfer Test allows checking the behaviour of the machine in order for it to provide accurate force values and to crush the sample “regularly” as shown below

Fig. 5-28

If instead the machine crushes samples as shown in the next drawings, it may not be applying the load uniformly and this can be discovered by means of the Force Transfer Test.

Fig. 5-29

Refer to qualified service organization authorized by CONTROLS to carry out the checking of the compression machine as described in this chapter.




5.2.7 Replacing the oil of the hydraulic circuit WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking.

Periodically the oil of the hydraulic circuit must be completely replaced. 1. Discharge the old oil via the drainage screw (size 18mm spanner);

Fig. 5-30

Drainage screw (view from below)



2. Collect the old oil and dispose it in accordance with the local

regulations; 3. Refill the tank (6 litres) with the oil type shown in next table;

Brand Type Agip ATF Dexron Api Apilube ATF Dexron Chevron Chevron automatic transmission fluid Elf Elfmatic G Exxon Automatic transmission fluid Fiat GI/A Fina Dexron ATF Gulf Automatic transmission fluid IP Dexron fluid Mobil ATF 220 Shell ATF Dexron II Total Dexron Vanguard ATF fluid DEX II 4. Let the pump run and check oil level in the tank via the transparent level

indicator (the oil should be max. at half of the indicator);

Fig. 5-31

5. Top up if necessary.

Oil level indicator

Oil refil port



6. DIAGNOSTICS & TROUBLESHOOTING

The present chapter provides information on the diagnostic programs present in the system and on the troubleshooting of the most common problems. Depending on the problem encountered, the troubleshooting is carried out by dividing the system into functional blocks. During this phase, refer to the system block diagram of chapter 2.6 of the present manual. WARNING: Before opening/removing the covers, disconnect the mains supply to the device and wait at least 5 minute.

WARNING: Covers/doors can only be removed/opened by maintenance people, by using relevant tools/keys. These tools and keys are for the use of maintenance people only. Never leave them attached to the unit as this may endanger operator safety. After performing maintenance/repair, make sure that all covers/doors are properly closed and locked.

WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel.

WARNING: Refer to qualified service organization authorized by CONTROLS to carry out the service maintenance actions described in the chapter “Diagnostic and Troubleshooting”. CONTROLS has not to be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed.



6.1 Troubleshooting

The following table provides a list of possible causes and checks in case a faulty condition is encountered:

Type of fault Actions

The WIZARD BASIC does not turn ON

• Check the WIZARD BASIC power cable (See Fig. 6-1); • Check WIZARD BASIC mains switch (See Fig. 6-1); • Check WIZARD BASIC line fuse (See Fig. 6-1; Item 2 of

chapter 7); • Check that all cables within the WIZARD BASIC 3 are properly

attached (see schematics in chapter 8); • Check the output voltage (+5VCC) of the power supply of the

WIZARD BASIC (see Fig. 6-2, item 3 of chapter 7) and replace it if necessary.

The WIZARD BASIC turns ON but the display remains completely blank

• Open the rear panel of the WIZARD BASIC and check that all interconnection cables between the CPU board and the Display board are well attached (See Fig. 6-2);

• Check/replace the display board (See item 6 of chapter 7); • Check/replace the CPU board (See Fig. 6-2 and item 5 of chapter

7) The WIZARD BASIC turns ON but the keyboard does not accept commands from the operator

• Open the rear panel of the WIZARD BASIC and check that all interconnection cables between the CPU board and the keyboard are well attached (See Fig. 6-2);

• Replace the keyboard (See item 4 of chapter 7); • Replace the CPU board (See item 5 of chapter 7).

The load values on the display are always zero, or always full scale, or unstable

• Check that the load transducer cable is properly connected to the WIZARD BASIC (see chapter 3.6);

• Check that cable and connectors are not damaged; • Check the status of the transducer; • Check/replace the CPU board (See item 5 of chapter 7).

The load values on the display are not accurate

• Check the system calibration (See chapter 5.2.5)



Type of fault Actions

The internal printer does not print

• Open the rear panel of the WIZARD BASIC and check that all interconnection cables between the CPU board and the keyboard are well attached (See Fig. 6-2);

• Check for the presence of the paper and its proper insertion (see chapter 4.5.1).

The computer connected to the serial port does not receive data or does not receive them correctly

• Check the status of the connection cable between WIZARD BASIC and PC serial port, that it is properly attached on both sides and that it is of the “Pin-to-pin” type;

• Check the setting of the serial port on the PC (see chapter 4.4 of the present manual and the manual of the PC and communication software in use).

It is not possible to reach the maximum admitted load

• See chapter 6.1.1.

The rapid approach speed is out of specification

• See chapter 6.1.2.

The load does not increase uniformly

• Possible cause: sticking of the floating piston, see chapter 6.1.3.

The load increases at maximum speed even if the flow control knob is adjusted for intermediate positions (it is not possible to control the load gradient)

• Possible cause: sticking of the floating piston, see chapter 6.1.3.

Oil leakage from below the control knob

• Possible cause: wearing or breakage of the pin o-ring, see chapter 6.1.4.

The load does not increase • Possible cause: the valve has been removed from the pump and re-mounted with the by-pass lever in the wrong position, see chapter 6.1.5.



Fig. 6-1

Fig. 6-2

Readout unit power cable receptacle

Readout unit mains switch

Readout unit line fuse

5VCC power supply

Display board

CPU board

Keyboard (on front side)



6.1.1 Adjustment of the maximum load

To adjust the cut off pressure of the safety valve ref. 1 proceed as follows: 1. Heat the oil by running the pump for at least 15 minutes; 2. Unscrew tap A; 3. Using a screw driver unscrew B:

a. Rotate clockwise to increase the maximum pressure; b. Rotate anticlockwise to decrease the maximum pressure;

4. Once the adjustment has been made re-mount tap A.

NOTE: While adjusting screw B a small amount of oil may exit through the valve. We recommend that this oil is removed before re–mounting tap A.

Fig. 6-3

�



6.1.2 Adjustment of the rapid approach speed

To adjust the approach speed (normally it should be 40mm/minute) act on the valve Ref. 2 of Fig. 6-3: 1. Heat the oil by running the pump for at least 15 minutes; 2. Unscrew tap C; 3. Using a screw driver unscrew D:

a. Rotate clockwise to increase the rapid approach speed; b. Rotate anticlockwise to decrease the rapid approach speed;

Adjust as above described to achieve an approach speed of 40mm/minute; 4. Once the adjustment has teen made re-mount tap C.

NOTE: While adjusting screw B a small amount of oil may exit through the valve. We recommend that this oil is removed before re–mounting tap C.

NOTE: The adjustment of the valve could have an effect on the noise level of the pump.

NOTE: The adjustment of the valve could have an effect on the pump behaviour in the bypass mode.

�

�

�



6.1.3 Sticking of the floating piston

NOTE: All the following operations should be made withoutfrom the pump.

1. Unscrew the two threaded taps (one opposite

2. Using a suitable tool (e.g. a screw driver) press the its housing as shown in figure below

3. Carefully clean the floating piston and itsfloating piston with liquid piston by scratching them. Simply clean

4. Lubricate the piston with the same oil used

(make sure it is facing the same direction freely forwards and backwards. Remount and

�


89

Sticking of the floating piston

All the following operations should be made without dismantling the flow control valve

Unscrew the two threaded taps (one opposite the other) as shown in fig

Fig. 6-4

sing a suitable tool (e.g. a screw driver) press the floating piston out of one end of its housing as shown in figure below;

Fig. 6-5

Carefully clean the floating piston and its seating with compressed air and clean thefloating piston with liquid detergent. Pay attention not to damage the seating or thepiston by scratching them. Simply clean them thoroughly and lubricate

Lubricate the piston with the same oil used in the pump and replace in its sure it is facing the same direction as it was originally) and check it can move forwards and backwards. Remount and tighten the two threaded taps.

04/07/2011

dismantling the flow control valve

) as shown in figure below;

floating piston out of one end of

seating with compressed air and clean the attention not to damage the seating or the

them thoroughly and lubricate;

in the pump and replace in its housing originally) and check it can move

tighten the two threaded taps.



6.1.4 Oil leakage from below the control knob

NOTE: All the following operations should be made without dismantling the flow control valve from the pump.

1. Remove the control knob by unscrewing the grub screw as shown below;

Fig. 6-6

2. Remove the connection seating as shown in figure below;

Fig. 6-7

�



3. Completely unscrew the control pin, check the o-ring which is worn or damaged and

replace it (see item 13 of chapter 7) making sure not to damage the new o-ring during assembly (see figure below);

Fig. 6-8

4. Re-assemble all the parts.



6.1.5 The load does not increase

Possible cause of this behaviour is that the valve has been removed from the pump and re-mounted with the by-pass lever in the wrong position. 1. Unscrew the grub screw of figure below;

Fig. 6-9

2. Remove the lever and unscrew the shaft (see fig.below), re-screw the shaft until a slight resistance is felt with the shaft in this position, re-mount the lever vertically with the round plastic knob pointing upwards. This should be the correct position of the lever. Try the machine: if it does not work, reposition the lever either 10° ahead or behind until the correct position is found. Finally fix the lever by tightening the grub screw.

Fig. 6-10



7. SPARE PARTS

This chapter contains the list of spare parts. For each item, the following information is provided: • CONTROLS order code • Item description • Quantity in the unit Orders for spare parts have to be addressed to CONTROLS representatives. When ordering spare parts, please provide code number, serial number, year of manufacture and any other useful information of the unit involved. WARNING: Before opening/removing the covers, disconnect the mains supply to the device and wait at least 5 minute.

WARNING: Covers/doors can only be removed/opened by maintenance people, by using relevant tools/keys. These tools and keys are for the use of maintenance people only. Never leave them attached to the unit as this may endanger operator safety.


WARNING: All safety devices must be functional at all times. Damaged protective covers or devices must be replaced immediately. When safety components are replaced, the protective devices are to be properly attached and tested. Any manipulation of the safety devices endangers the operating personnel.

WARNING: For continued fire protection, replace fuses with same type and rating. Also, in case of failure, components may only be replaced by using original spare parts.



Ref. Codice ricambio/ Spare part code Descrizione Description

Q.tà in una macchina/ Q.ty in one

unit 1 68-Q0701/AR06 Interruttore Mains switch 1

2 68-Q0502/R08 Fusibile 1,25AT (scatola di 10 pezzi)

Fuse 1,25AT (pack of 10 pieces)

1

3 68-Q0701/AR05 Alimentatore 5VCC 5VCC power supply 1

4 68-Q0701/AR04 Tastiera Keybopard 1

5 68-Q0701/AR01 Scheda CPU WIZARD BASIC CPU board WIZARD BASIC 1

6 68-Q0701/AR02 Display LCD LCD Display 1

7 68-C5012/R27 Gruppo pompa Pump assembly 1

8 68-C5012/R24 Motore pompa con pulsante di emergenza 230VAC/50Hz

Pump motor with emergency button 230VAC/50Hz

1



1



1

11 68-C5012/R13 Guarnizione pompa Pump gasket 1

12 68-R0031/B1 Valvola regolatrice di flusso Flow adjustment valve 1

13 50-R0031/K Kit ricambi valvola manuale Manual valve spare parts kit 1

14 68-C5012/R14 Microswitch extra-corsa pistone Piston overtravel microswitch

1

15 68-C5012/R08 Olio ATF ATF oil 6 Lt.

16 68-C3100/R07 Tubo connessione idraulica Hydraulic connection tube 1

17 82-P0354 Trasduttore di pressione 700 Bard

Pressure transducer 700 Bar 1

18 82-P0354/ELT Cavo trasduttore di pressione Pressure transducer cable 1



Fig. 7-1

Fig. 7-2

1

2

3

6

5

4



Fig. 7-3

Fig. 7-4

7

12

8

9

10



11

14

16


97

Fig. 7-5

Fig. 7-6

04/07/2011

18

17



8. SCHEMATICS AND DRAWINGS

1. Control board (CPU) layout

2. Readout unit electrical diagram

3. Readout components identification

4. Motor electrical diagram

5. Load sensor cable pinout



CPU BOARD LAYOUT



READOUT UNIT ELECTRICAL DIAGRAM



READOUT UNIT COMPONENTS IDENTIFICATION

COMPONENT NAME COMPONENT DESCRIPTION

1FU2 CONTROL UNIT FUSE 1,25AT 1GD2 SWITCH MODE POWER SUPPLY 12VCC 2,5A 1QS2 SWITCH CONTROL CONSOLE 1SC1 CPU BOARD – SIGNAL CONDITIONING BOARD 1SC3 CONTROL BOARD LCD TOUCH PANEL



MOTOR ELECTRICAL DIAGRAM

MOTOR SWITCH

EMERGENCY BUTTON

MAINS INPUT



LOAD SENSOR CABLE PINOUT



Notes:

Ctm Manual (Compression Machine)

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