Instruction manual for dhr v2.2

Unit Test DHR2000 Version 2.2 of 24

Calibration Procedure

Unit Test Scientific Sdn. Bhd.

MALAYSIA

INSTRUCTION MANUAL FOR

UNIT TEST COMPRESSION TEST

MACHINE

MODELS : AD 200/EL & AD 300/EL

Semi-Auto & Manual Digital Type (DHR 2000 V2.2)

Supply & Service by:

UNIT TEST SCIENTIFIC SDN BHD

No. 27 & 29, 3rd Floor,

The Highway Centre, Jalan 51/205,

46050 Petaling Jaya, Selangor, West Malaysia.

Tel : +603 7781 7585 / 7784 1843, Fax : +603 7781 7586

Email : [email protected] [email protected]

Website : www.unittest.com.my

mailto:[email protected]

mailto:[email protected]

http://www.unittest.com.my/




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Thank you for purchasing UNIT TEST compression test machine, quality Malaysian made product from UNIT

TEST SCIENTIFIC SDN. BHD. Being one of the pioneers & experienced testing equipment manufacturers,

UNIT TEST compression test machines have been exported worldwide for more than a decade ago. The

presence of UNIT TEST compression test machines can be felt throughout the world especially at the booming

modern construction projects, universities, testing laboratories, construction material factories, R & D centre’s,

colleges etc. The reliability, consistency & accuracy of the test results produced using UNIT TEST compression

test machine providing peace of mind to users.

For proper use of this machine, please read this manual carefully in order to ensure safe & correct operation.

Make sure only well trained & qualified personnel are allowed to operate this machine. Please refer to the

relevant test standard used for complete guide on making samples, testing method & interpretation of test

results.

Please fill in your company particular below :-

Company :

Telephone no. :

Email address :

Purchase date :

Remark :

Should you need parts replacement for this machine in the future or you need to purchase additional items,

please contact our office or your local agent.

Thank you for your continuous support.




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CONTENTS

1 Introduction 4

2 Operating procedure 4

3 Advanced Options 5

3.1 Raw Data Setup 5

3.2 Data base Initialization 6

4 Equipment 7

4.1 Clear Logs 8

4.2 Print Option 8

5 Setting sample type 9

6 Setting the Base, Rate & %Fail 10

7 Transferring the test result from DHR 2000 to computer 11

8 Retrieve test result & print 12

9 Test precautions 13

10 Calibration and Setup 14

10.1 Transducer Calibration 14

10.1.1 Zero and Span Adjustment 14

10.1.1.1 Linearisation Adjustment 15

11 Calibration procedure 16

12 DHR 2000 display features 20

13 DHR 2000 keypad features 22

14 Specifications 23

15 Maintenance 23

16 Control panel diagram 24




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1. INTRODUCTION

In construction industry, concrete plays a major role by becoming the main item to be used either in building or

highway projects. Concrete is a mixture of few materials such as cement, sand, aggregate, water, chemical etc.

The ratio of these materials being used will determine the strength of concrete to be produced. The quality of

concrete can be directly affected by its content mixed together. Therefore the quality of concrete must be

measurable in order to know the strength it can withstand for its relevant application. The ratio of the materials

used can then be controlled efficiently using UNIT TEST compression test machines.

2. OPERATING PROCEDURE

All procedures mentioned for semi-auto machine, except procedure for manual machine only in bracket ( )

1. Place a concrete sample onto the center of lower platen.

NOTE: Samples must be positioned exactly on the center of lower platen, using the guides provided on the platen. If the guides cannot support a particular

sample, draw lines on the platen so that the sample can be put at the center of the platen. Samples not positioned center enough may damage the upper ball

seating attached to the upper platen.

NOTE: Make sure the gap between the sample top surface & upper platen is not more than 15mm, as to avoid the machine piston from over traveled.

2. Close the safety fence.

3. Switch on the display & power pack by pressing the on/off switches.

4. Rotate the load release valve clockwise to stop the oil from flowing back to the tank.

NOTE: The load release valve must not be over-tightened, or its thread may damage. That’s why it’s advisable to rotate it using only 1 finger until it’s just

tight.

5. At the keypad, press MAN, ENTER TARE.

NOTE: If Weight & Reference need to be changed, after pressing MAN then move the arrow to Weight & Reference to change its value. Press ENTER after

changed. Then continue with ENTER & TARE.

6. Press the rapid approach switch continuously to raise up the sample to upper platen faster. When the sample

has just touches the upper platen, let go the rapid approach switch.

7. Rotate the speed controller clockwise (push the speed controller forward for manual machine) until the Base

value is achieved.

8. With reference to the +5% & -5% speed indicator bar, control the speed so that it is as near as possible to

the center of the bar.

9. When the sample is about to crushed, the motor will tend to slow down due to lots of strength at the sample

(ending stage). Increase the speed to the +5% side as far as possible.

10. Once the display shows “Now Printing, Please Wait”, rotate the load release valve anti-clockwise one round

to release the oil back to the tank.

11. Remove the crushed sample & clean the machine with brush or cloth.

12. Repeat the complete procedure to start a new test.




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***ATTENTION LABORATORY SUPERVISOR***

These are the passcodes for ENG and SETUP. You may wish to remove this page

and keep in a safe place separate from the Instruction Manual to avoid

unauthorized adjustment of the calibration data.

Entry code for ENG key : 4298

3. ADVANCED OPTIONS

This chapter shows you how to tune your DHR2000 instrument in order to operate effectively.

From the Main Screen (CHAPTER 2) press the ENG key to access these options. You will need to enter a

valid Pass code in order to be allowed. This pass code is given when the instrument is delivered and should

be stored in a safe place.

3.1 Raw Data Setup

Select each of the transducer to be programmed choosing the NEXT option as appropriate. The

display will show the current input reading (in Raw Divisions) so that any changes you make can

instantly be observed.

i. Filter this is a value that determines how many readings are taken to

average out noisy line. A value of 30 is recommended for most cases, but you can

determine the best setting by applying some load and changing the filter value.

Observe when the raw reading stops changing rapidly.

ii. Amplifier This is the gain to be applied to the signal received from the

transducer. To set it, select a value 01, 02, 04, 08, 16, 32 or 64 (other values are

accepted but internally they are always rounded off to one of the values indicated

above). Apply Full-Scale load and observe that the raw reading covers the expected

range. You may need to increase or decrease the Gain setting as appropriate.

The programmed values are also included in the Channel Calibration printouts described on

CHAPTER 10.




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3.2 Data base Initialization

By choosing this option, you can reset your instrument to factory default values. It is divided into

initialization of metric (Init Metric) or imperial (Init Imperial). If you choose Init Metric, the

following happens: -

i. All memory logs are erased.

ii. Equipment Setup:-

Type: Compression

Units: Metric

Peak Hold? Yes

Query Abort? Yes

Show Proceed: No

Sensitivity: 10

SwitchOver: 002050 (kN)

Over load: 002020 (kN)

*Custom Details *Back

iii. New Test Setup:-

Stage: 01/02

Index: AAAAAA

Reference: 000001

%Fail: 20

Type: Compression

Base: 0010.0 (kN)

Rate: 0006.0 kN/s

Target: 0000.0 (kN)

*Taring Conditions*

*Clear TARE*

*Sample*

*Back*

iv. Transducer Input defaults.

These fields are not altered. This means that your Calibration and Linearisation data is

preserved. The only way to change this is by recalibrating again.




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4. EQUIPMENT

There are a number of features, which can be configured to suit your installation or preferences. This

option can be selected via SETUP key followed by option 3.

i. Units? Select Metric or Imperial. The units used will change

between kN and Lbf, mm and in, MPa and PSI.

ii. Peak Hold? Select YES to freeze the display of the maximum load

detected during a test, or NO if this is not required. Note

that this option affects only the display on the Main Screen.

iii. Query Abort? Select YES to make sure that a warning is given

whenever a test is aborted (pressing the ABORT key)

manually. This can help to prevent ending a test

inadvertently. Otherwise, select NO.

iv. Sensitivity? Enter the percentage error measured while a test is running

that will fill the error box shown on the Main Screen (CHAPTER 2). Usually the

%Error Band is 05, but note that entering a value of 00 will effectively prevent the

box from being shown.

v. SwitchOver: Enter the loading level at which the instrument will

automatically switch from the Range to the HIGH transducer ranges. This is

applicable to Compression Tests only.

vi. Over load: To prevent the frame being damaged by applying a large

loading, you can define a level above which the instrument giving a long bleep,

indication that the machine is overloaded. You have to switch off the power

switch immediately.

vii. *CUSTOMISE* You can define text to appear as Headers and Footers in all

printouts available (Test Results and Transducer Calibration). Enter for example a

description or your Company’s name, Customer details, etc.

viii. *TARE* You define here the parameters to be used during the

Taring Stage of a test execution – see CHAPTER 3.

Maximum This is the maximum loading that will be allowed to be tared. If the

level is exceeded when a test is tared, the test will be aborted.




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4.1 Clear Logs

This will erase the non-volatile memory, removing the results of any previous tests carried out by your

DHR2000 instrument.

A warning will be presented first, to avoid erasing data inadvertently. You can choose to proceed or to

cancel the request.

4.2 Print Option

1. Data and Summary

2. Data Only

3. Summary Only

4. Back




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5. SETTING SAMPLE TYPE

To access to sample type selection, press the DP TEST key. Press the up/down keys () to select for

SAMPLE & press ENTER. Display will show the following samples selection :-

1. Standard cylinder

2. Standard Cube

3. Non Stdrd Cylinder

4. Non Stdrd Cube

5. Beam Block

6. Special Area

1. Standard Cylinder : Press key no. 1. For example if the sample to be tested is

a 150mm x 300mm height standard , move the arrow to Diam. & press

ENTER. Press the up/down keys to select 0150 & press ENTER. Move the

arrow to Length & press ENTER. Press the required Length of 0300 & press

ENTER. Then press ABORT to exit.

2. Standard cube : Press key no. 2. For example if the sample to be tested is a

150mm standard cube, move the arrow to Cube & press ENTER. Press the

up/down keys to select 0150 & press ENTER. Then press ABORT to exit.

3. Non Stdrd Cylinder : Press key no. 3. For example if the sample to be tested

is a 151mm x 303mm height non-standard cylinder, move the arrow to

Diam. & press ENTER. Press the required diameter of 0151 & press ENTER.

Move the arrow to Length & press ENTER. Press the required length of

0303 & press ENTER. Then press ABORT to exit.

4. Non Stdrd Cube : Press key no. 4. For example a cube sample may have

measured dimensions of non-standard width 151mm, length 152mm & depth

153mm. Move the arrow to Width, Length & Depth & key in the required

dimensions accordingly. Then press ABORT to exit. Please refer to the

following cube diagram of the actual position to be put into the machine :

Width

Depth

Length

5. Beam Block : Press key no. 5. For example the beam sample may have

dimensions as in the diagram below :-




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500mm

100mm

100mm

Move the arrow key to Width & press ENTER. Press the required width of 0100 & press ENTER. Move the

arrow to Length & press ENTER. press 0300 & press ENTER. The Length is the distance between the bottom

rollers of flexural machine of 300mm apart for this beam size, not the length of the beam sample. (for 150 x

150 x 750mm beam, the bottom roller distance is 450mm) Move the arrow to Depth & press ENTER. Key in

the required 0100 & press ENTER. Then press ABORT to exit.

NOTE : Do not enter the sample Weight at this part. The Weight can be entered easily during the

Manual operation. Please refer to the Manual operating procedure.

6. SETTING THE BASE, RATE & % FAIL

The Base, Rate & % Fail features can be accessed by pressing the DP TEST key & if necessary to change, make

sure the correct Sample is selected first. For example to set the Rate at 6.8kN/s, press the DP TEST key & move

the arrow to Rate & press ENTER. Press 0068 & press ENTER to confirm. Follow the same procedure to set for

Base & % Fail if required. Refer to DHR 2000 display features (CHAPTER 12) for further explanation on

these 3 features.




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7. TRANSFERING THE TEST RESULT FROM DHR 2000 TO COMPUTER

1. Use an optional RS232 serial cable of 25 pin male (to display) & 9 pin female (to computer) commonly

known as modem cable.

2. Follow the below setting in computer prior to transfer data from DHR 2000 display :

3.

Start

Accessories

Create shortcut on desktop

to skip these steps Communications

Hyperterminal

Enter file name & click OK

Enter Com 1 or Com 2 & click OK

Bits per second : 9600

Data bits : 8

Parity : None

Stop bits : 1

Flow control : Xon/Xoff

Click Apply & OK

4. Transfer options :

a) Transfer automatically test detail after each test

-computer is set & connected to computer during testing or

b) Transfer later after testing

-select test detail by pressing key no.2 or test summary by

pressing key no.3. Then press ENTER to select Print option to

transfer the test results to PC. Press up/down keys to select test

detail page to transfer.

5. 'Save As' to any desired folder & location after transferring.

6. To open in Microsoft Excel for graphical representation or analysis, double click on Excel icon, select

Open, Files of type : All Files & select the saved hyperterminal file. The data in Excel format may look

a little messy, so some amendment is necessary.

NOTE : Depending on the size of data stored, the DHR 2000 memory will become full. If this happen then press key no. 7, press passcode 4298, press ENTER,

press key no. 3 to select Clear Logs & press ENTER to clear all test result in the memory.

NOTE : Passcode shall be kept confidential by superior or manager in charge, to avoid unauthorised changes.

NOTE : If unable to transfer, switch the position of the orange & grey wire at the DHR electronic board connector.




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8. RETRIEVE TEST RESULT & PRINT

The DHR 2000 display is also able to connect to certain printers by using an optional RS232 serial cable of both

sides 25 pin male. Some examples of A4 paper printers that can be connected such as Panasonic KX-P1131 &

Epson LQ-300+. Please note that the Epson printer needs to be set to correct baud rate of 9600, 8 data bits &

None parity before it can be used.

Another commonly used is the Star SP700 mini printer which uses 76mm paper rolls. The only setting for this

printer is to off the dip switch no.4 located at the

bottom of the printer (remove the steel cover using a '+' screwdriver & total of 10

dip switches can be seen) To print during testing, simply connect & on the printer. It will print the test detail

immediately after sample crushed. To print the test detail or summary anytime after test, follow the simple

procedure as below :-

NOTE : The 2 A4 printers mentioned above have been used by our customers. There may be other

compatible printers in the market can be tried, as long as the printers have serial port. But printers with

both serial & parallel ports are slowly obsolete in the market due to its low demand. Another alternative

will be the 76mm paper roll mini printer as mentioned above.

A) PRINTING TEST DETAIL (1 TEST PER PAGE)

1. Press key no. 2.

2. Press the up/down keys to select for the desired page.

3. Press ENTER.

4. Press key no. 1 to select PRINT. Now the printer will start printing the test detail.

5. Press ABORT twice to exit from the test detail after finish printing.

B) PRINTING TEST SUMMARY (10 TEST PER PAGE)

1. Press key no. 3.

2. Press the up/down keys () to select for the desired page.

3. Press ENTER.

4. Press key no. 1 to print all tests.

5. Press ABORT twice to exit from the test summary after finish printing.




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9. TEST PRECAUTIONS

1. Before testing of concrete samples, make sure the following settings are

correct according to the requirement of the relevant samples to be tested :

Compression mode, Base, Rate, %Fail, sample type (Standard Cylinder or

Standard Cube) & Dimensions (Width, Depth & Length).

2. The best clearance between the sample & upper platen should be

about 10mm. It should not exceed 25mm. Clearance that is bigger than

25mm will cause the piston to be over travel which may damage the piston &

cylinder. To solve this problem, use the suitable thickness of distance piece

or you may order from Unit Test Scientific or your local agent.

3. For testing of concrete cylinders, make sure both ends of the cylinder are

being capped evenly as required by the standard. Cylinders that are not

capped have uneven surface that may damage the machine alignment.

4. For testing of concrete cubes, make sure the uneven surface is facing out

(facing the machine operator) & only very flat surface touches both upper &

lower platens.

5. Always keep the machine in clean condition after use.

6. Not suitable to test block samples, as it may damage the component

part of top platen & causing machine alignment problem. (Please

enquire for block testing machine)

7. Should the voltage supplied to the machine is fluctuating (not stable), use a

voltage regulator or stabilizer connecting to the machine. Unstable voltage

will damage the machine digital part.

8. Always position the sample on the center of lower platen using the guides or

lines provided. Sample that is out of the center can damage to machine

alignment.

9. Not suitable for testing of smaller samples such as 50mm mortar cube or

40x40x160mm mortar prism. A smaller capacity & more precise machine shall

be used.

10.DURING EMERGENCY, SWITCH OFF THE MACHINE IMMEDIATELY &

RELEASE THE MANUAL LOAD RELEASE VALVE.




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10. CALIBRATION AND SETUP

This chapter shows you how to operate DHR2000 instrument in order to set it up to run efficiently.

From the Main Screen (CHAPTER 10), press the SETUP key to access these options. You will need to enter

a valid Passcode in order to be allowed. This passcode is given when the instrument is delivered and should

be stored in a safe place.

10.1 Transducer Calibration

*** IMPORTANT ***

During calibration operation, you can control the applied load by operating the external

Speed Control Pot.

Note also that your DHR2000 instrument processes the electronic signals received from

the transducers according to the Filtering and Amplification parameters defined in

CHAPTER 5.

10.1.1 Zero and Span Adjustments

i. First of all select the transducer Range or FLEXURAL range by positioning the cursor next to the

channel identification line and then pressing the ENTER key until the required one is shown.

ii. Next select the Scale field and enter the required load value at Full Scale, normally 2000 (HIGH)

sometimes maybe 1500, 3000, 4000 or 5000 and depends on machine capacity and 100 (FLEXURAL)

kN respectively.

iii. Select and activate the *CLEAR* option to start a new calibration. You will be warned about the

implications of clearing calibration data previously stored. You can then choose to proceed or not.

iv. Make sure that the oil valve is closed, the fast pump is off and no load is currently being applied with

Speed Control Pot is set to give a steady oil flow rate. When the readings are stable, and the platen is off

the seating position, select the *ZERO* option. The transducer reading should now show 0000.0, and

the field labeled Zero will display the offset measured at this time.

v. Now start the fast pump to close the day light and then switch off the fast pump. Slowly apply the load

until the Full Scale level has been reached. Maintain the load using the Speed Control Pot so that the

readings are stable, and then select the *GAIN* option. The transducer should now show the same value

as that configured on the Scale entry (step ii above), and the field labeled Gain will display the raw

transducer divisions at this point.




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vi. Open the oil valve to release the loading. The first stage of a transducer calibration is now complete.

vii. Repeat the above procedure from iii to vi for Range and FLEXURAL range where applicable.

10.1.1.1 Linearisation Adjustments

The DHR2000 instrument allow you define an interpolation table of up to 20 points for each channel to

correct small variations in transducer linearity throughout the complete measuring range.

Each table entry consists of an Expected reading and the corresponding measured value. You move

between entries by using the arrow keys. Select a field for editing by pressing the ENTER key. Note that

not all entries need to be used.

i. Apply the load manually until the Expected loading is achieved.

ii. Enter the Measured field. You can either:-

Make a note of the transducer reading displayed at the bottom of the screen and copy it into the

Measured Column, or

Press the TEST key to let DHR2000 do this automatically for you. Note that this wills only works if

the transducer reading is within +/- 5% of the expected value, otherwise the instrument reject the

option.

iv. Continue with all table entries as above. Press the ABORT key to end the

adjustments and return to the previous screen.




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11. CALIBRATION PROCEDURE

All UNIT TEST compression testing machines have been calibrated in the factory using our load cells.

However once it arrives in your country, the machine may experience slight inaccuracy due to transportation,

different load cell used & environment. You should have your machine calibrated by your local authority once

the machine has been put at your permanent place. Make sure the machine is placed onto a flat & level cement

or concrete surface to prevent from unstable force distribution during crushing that may contribute to doubts.

UNIT TEST compression testing machines can be calibrated easily & adjustment to desired accuracy can be

fine-tuned easily through its user friendly calibration function, even after long term of usage. Please read &

follow the simple procedures before attempting to perform calibration on this machine

Very importantly, calibration devices (load cell or load column) used must be positioned as center as

possible on the machine lower platen. Use a ruler or caliper to position the device on the lower platen so

that all distance a, b, c & d are the same :-

Load cell that is not positioned on the center of lower platen may damage the machine alignment & can cause

inconsistent readings.

A) CHECKING THE INITIAL ACCURACY

1. Place the load cell (or proving ring, load column or other suitable capacity of force measuring devices)

on the center of lower platen.

2. Make sure the clearance between load cell & upper platen is not more than 25mm. If the clearance is too

much, add suitable thickness of distance piece to reduce to the smallest possible clearance. If still unable

to reduce, place flat hardened steel onto the load cell.

NOTE : Clearance more than 25mm will probably cause the machine piston to be over-traveling & may damage the piston & cylinder. The ideal clearance

between the load cell & upper platen will be about 10mm

3. Switch on the machine & press MAN, ENTER, TARE. Close the machine load release valve.

4. Press the rapid approach switch & watch the load cell moving up fast to the upper platen.




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5. When the load cell almost touches the upper platen, release the rapid approach switch.

6. Operate the manual speed controller until the desired 1st reading of calibration force shown at load cell

(e.g. 400kN) & immediately decrease the machine speed to hold the pressure.

NOTE : BS EN 12390-4:2000 requires calibration starting at 20% of the machine capacity then upwards of at least 5 equip-spaced forces. Example for

2000kN machine, forces to be calibrated are 400kN, 800kN,1200kN, 1600kN, 2000kN. But if testing condition requires calibrating below 400kN, then

additional small capacity device shall be used (e.g. 500kN load cell) to calibrate 100kN, 200kN & 300kN.

NOTE : When the load cell almost reaches the desired force, slow down the speed controller so that the reading can be hold easily.

7. Record the reading shown on the machine display (e.g. maybe 404kN)

8. Repeat the control of manual speed controller to apply force onto the load cell, until the load cell shows

the second required calibration value (e.g. 800kN) & record the value immediately shown on machine

display (e.g. maybe 811kN)

9. Repeat the whole applying force to load cell & recording the machine reading for the rest of the

calibration forces.

10. Below is an example of machine’s initial accuracy :

Applied force at load cell (kN) Machine reading (kN) % Error

400 410 2.50

800 809 1.13

1200 1177 -1.92

1600 1633 2.06

2000 1965 -1.75

NOTE : % Error = Machine reading – Applied Force x 100

Applied force

B) ENTERING THE LOAD CELL VALUE TO RANGE SCALE

Depending on reference test standard, certain % error that is out of tolerance is not acceptable (e.g. the error for

400kN is 2.50% which is out of ± 1.0% error requirement for Class 1 machine).If adjustment is necessary, it’s

better to clear all the factory calibrated values by following the below procedure.

NOTE : But if all the % errors are acceptable, no adjustment is needed.

NOTE : It is recommended to perform the procedure in this PART B if the errors recorded are about 3% & above because it is difficult to correct the error

for each force as mentioned in PART D. Otherwise if the errors are 3% & below, skip PART B & C to proceed to PART D to adjust minor errors in the

Linearisation section which has already been entered in factory.

1. Press key no. 7.

2. Press passcode 4298.

3. Press key no. 1 to select Calibration. Now the screen is at Range I/P.

4. Press the up/down key ( ) to move the arrow () to Clear Scale & press ENTER.

5. Press ENTER again to confirm clearing all calibration data.

6. Re-enter the Scale as 2000 kN.

7. Move the arrow to Set Zero & press ENTER.




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8. Press ENTER again to confirm clearing the initial load value.

9. Move the arrow to Set Gain. (DON’T PRESS ENTER YET)

10. Close the machine load release valve.

11. Operate the machine until the load cell showing 2000kN & immediately hold the pressure.

12. Press ENTER (the arrow already at Set Gain)

13. Press ENTER again to confirm entering the 2000kN scale to transducer.

14. Open the load release valve.

NOTE : At Range, Scale must be 2000Kn, Scale is machine capacity. (E.g. if machine is 2000kN capacity, then Scale is 2000kN & if machine is 3000kN capacity, then Scale is 3000kN) If the Scale at ranges is not correct, then key in the right scale accordingly.

15. Press ABORT to exit to setup menu & press ABORT again to exit to main screen.

C) CHECKING THE ACCURACY AFTER ENTERED THE LOAD CELL VALUE & LINEARISE

(MINIMISE) THE ERRORS

Repeat the whole procedure as in PART A to check the accuracy again for the desired forces. The result may

look like the following example :


400 404 1.00

800 809 1.13

1200 1211 0.92

1600 1618 1.13

2000 1978 -1.10

As shown in the result, there may be slight error even after enter the load cell value which is normal. If you are

satisfied with the results, no adjustment is needed.If adjustment is necessary reduce the forces to less than

±1.0%, please proceed to the following procedure:

1. At main screen, press key no. 7.

2. Press passcode 4298.

3. Press key no. 1 to select Calibration.

4. Move arrow to Range.

5. Move arrow to Linearisation & press ENTER.

6. Key in all the calibration results as illustrated in the example above as follows :-




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No. Expected Measured 01 000400 000404 02 000800 000809 03 001200 001211 04 001600 001618 05 002000 001978 06 000000 000000 07 000000 000000 08 000000 000000 09 000000 000000 10 000000 000000

7. After key in all the forces above, press ABORT to exit to setup menu & press ABORT again to exit to

main screen.

D) CHECKING THE ACCURACY AFTER LINEARISATION & CORRECTING MINOR ERRORS

Repeat the whole procedure as in PART A to check the accuracy again for the desired forces. The

LINEARISED result may look like the following example :


400 401 0.25

800 799 -0.25

1200 1205 0.42

1600 1617 1.06

2000 1977 -1.15

Although Linearisation has been done, it sometimes may or may not adjusting the machine reading to be the

same as the applied force perfectly. As shown in example above, the errors at 1600kN & 2000kN already

exceeded ±1.0%. Again if the results are satisfying, no adjustment is necessary. But if it’s a requirement for

errors to be ±1.0% or less, then a minor adjustment should be done as follows:-

1. Enter into the Linearisation page in Range by following the procedure as in PART C (step 1 to step 5)

2. Press the up/down key ( ) to move the arrow () to “1618”kN at the “Measured” section.

3. Since there is an error of 17kN (machine reading 1617kN – applied force 1600kN), you need to add this

17kN error to the force “1618”kN at the “Measured” section. Press ENTER & change the reading to

1635kN. Press ENTER again.

4. Press the up/down key ( ) to move the arrow () to “1978”kN at the “Measured” section.

5. Since there is an error of -23kN (machine reading 1977kN-applied force 2000kN), you need to deduct

this 23kN error from the force “1978”kN at the “Measured” section. Press ENTER & change the reading

to 1955kN. Press ENTER again.

6. Press ABORT twice to exit to the main screen.

7. Now repeat the whole procedure as in PART A to take another series of force readings. Now all the

errors should be minimized to within ±1.0%.




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11. DHR 2000 DISPLAY FEATURES

1. Force value : Displaying the current force value in kN. It will increase accordingly when pressure is

applied to the machine piston.

2. Speed indicator bar : Indicates the current loading speed according to the set Rate. To be controlled by

user manually.

3. Status : Loading status of the machine, either Ready (not operating), Started (operating), or Finish

(Sample crushed, machine has stopped)

4. Peak : Is the maximum force achieved after the sample has crushed.

5. Date & Time : Showing the current date & time. Only need to set once.

6. Reference : Showing the test number. It will increase in sequence by itself if not set.

7. Base : When set at 10kN, the speed indicator bar will start to show only when the load reaches 10kN in

order to eliminate initial unstable speed caused by deadweight. (Factory default & recommended Base is

10kN. The minimum sample failure value should not be less than the Base value. For example if the

sample crushed at 8.6kN, then the Base must be set at 5kN. The Rate set must be less than the Base

value. For example if the rate is set at 12kN/s, then the Base must be set at 15kN or 20kN))

8. Rate : User preset loading speed in kN/s. Must be set according to sample's test standard.

9. % Fail : Preset percentage of damage at the concrete sample in order for the machine to inform the user

to stop the operation. (see Note below)




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10. Tare : Temporary storage for the initial tared (zeroed) force value upon starting of operation. Not

adjustable.

11. Standard cube : Preset sample type (standard or non-standard cube, standard or non-standard cylinder,

beam block & special area)

12. Dimensions : Description of sample dimension (width, depth & length)

13. Sample size : Measurement of sample dimensions in mm.

14. Area : Area of sample surface that is in contact with upper platen.

15. Stress : Auto calculation of concrete strength in Mpa obtained from the peak value & Area.

NOTE : The following diagram is an example of preset % Fail

10% 20% 40%

Factory preset for % Fail is 15% to 20%. But if the sample damages too much or explodes before the machine

informs to stop, reduce the % Fail. But the % Fail should not be set too low causing the machine to inform even

before the sample reaches its maximum strength. There is no standard guideline for % Fail & if it’s necessary to

reduce it, trial & error for the same samples few times as illustrated at the graph below :-

Strength (Mpa)

Maximum

strength achieved

even before the machine

inform the user to stop

% Fail The minimum % Fail must be determined so that the machine will stop only after maximum strength is

achieved. It may vary for different sample types.




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13. DHR 2000 KEYPAD FEATURES

Key features :

1. DP, TEST - Change Compression / Flexural mode, Base, Rate, % Fail & Sample type.

2. 0 (TARE) - To tare off (zero) any initial value during beginning of test.

3. HELP - Simple explanation on Channel Calibration (refer to instruction manual for detail explanation)

4. 1 (CLOCK) - Adjust the Time & Date

5. 2 (PRINT) - Show 1 test result in detail per page. Press the keys to view the previous result. Press

ENTER & select PRINT to print or transfer the result to computer.

6. 3 (SUM) - Show 10 test results in summary per page. Press the keys to view the previous 10 results.

Press ENTER & either select PRINT (to print / transfer the current page only) or PRINT ALL (to print

transfer the first until the last result)

7. 4 (SCR) - Press to zoom the display bigger. Press again to return to original size.

8. 5 – No function

9. 6 (SOL) – No function

10. 7 (SETUP) - Calibration setup (confidential password required), overload trigger & clear memory. (FOR

CALIBRATION USE ONLY)

11. 8 – No function

12. 9 (ENG) - Raw data to amplify the transducer value & PID control for automatic setup of motor speed &

parameter. (FOR FACTORY & CALIBRATION USE ONLY)

13. - For moving the arrow cursor up or down

14. MAN () - For machine operation in Manual mode. Press MAN (change the Reference, Weight etc. if

required), ABORT & TARE (TARE must be pressed for all manual modes) Also for moving the arrow

cursor up or down.




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15. ENTER - Press ENTER to change a data & ENTER again to fix the data after changing.

16. ABORT - Exit from a setting or page in the screen. Also use to cancel the machine operation at any time

during testing.

14. SPECIFICATIONS

1. 2 channel programme (Compression mode 0.1 kN resolution & Flexural mode 0.01 kN resolution)

connectable to 2 machine frames with 1 controller.

2. Storage of test results in memory & transferring of data to computer or printer.

3. Large 75 x 125mm clear LCD display c/w zoom function.

4. User input of loading Rate for manual controls of testing speed.

5. Sample type, size & weight selectable for auto calculation of Mpa & Density.

6. User friendly operation with simple & clear page by page instruction.

7. Calibration c/w passcode protection & accuracy adjustment system (linearisation) for achieving ±1.0%

accuracy over the whole calibrated range.

8. User input of testing limit (overload) in kN for automatic alarm trigger.

9. Machine frame built to be tough, long lasting & providing very consistent test results. Used for testing

various sizes & types of standard concrete samples.

10. Power : 240V, 50Hz, 1ph

15. MAINTENANCE

1. There is virtually very minimal maintenance for this machine. However it is very important that the user

follow each & every correct operating procedure to ensure this machine is always in perfect working

condition.

2. Pay attention to the Precaution section especially on the positioning of samples, testing smaller samples,

piston traveling limit, etc.

3. Inspect the top & bottom platen for wear by checking its flatness to observe if they are dented.

4. This machine only use hydraulic oil grade 68, which should be changed ideally once a year. The oil level

should be always full. Open the nut of the square oil tank located at bottom of power pack. Insert your finger

into the oil tank. If you can touch the oil, it’s full. If you can’t touch, then you need to top up.

5. Occasionally check if the protective rubber cover does not tear off causing oil leakage. Before changing a

new rubber cover, replace with new hydraulic oil grade 68.

6. It is a normal National Standard requirement to request for calibration at least once a year, after relocating the

machine or repair which is likely to affect the machine accuracy.




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16. CONTROL PANEL DIAGRAM

Rapid Approach Switch (2)

Power Switch (1)

Key

Speed Controller (4)

Load Release Valve (3)

Power Switch (1)

Key

Speed Control Knob (5)

Speed Control Lever (4)

Load Release Valve (3)

Oil Tank

Nut

Inlet

Outlet

Rapid Approach Switch (2)

Instruction manual for dhr v2.2

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Transcript of Instruction manual for dhr v2.2