VJT6000 User Guide V1.3 (Re-saved)

VJT6000 Series User Guide Page 1

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NOTE: This Machine has been shipped EMPTY of oil.

DO NOT operate this machine until it has been filled with

hydraulic oil.

Requirement: 7 litres, Tellus 32 hydraulic oil or equivalent.

Refer to Section 7 of this manual for the correct Oil Fill and De-airing procedure


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Contents 1. Overview ................................................................................................................... 5 2. Main Screen Contents ............................................................................................. 8

2.1 System Overview .............................................................................................. 8 2.2 Test Status ......................................................................................................... 9 2.3 Test Specifications ........................................................................................... 9 2.4 Sample Specifications .................................................................................... 10

3. Using VJT6000 series .......................................................................................... 11

3.1 Specifying the test before it begins. ............................................................. 11 3.1.1 The Name of the Test ........................................................................... 11 3.1.2 Operating Parameters ............................................................................. 12 3.1.3 Stopping Conditions ............................................................................... 12 3.1.4 Tare Conditions ....................................................................................... 13 3.1.5 Sample Type and Dimensions.................................................................. 14

3.2 Test Control Operations ................................................................................ 15 3.2.1 Automatic Test Mode .............................................................................. 15 3.2.2 Manual Test Mode .................................................................................... 17

3.3 Storing, Viewing and Printing Results ......................................................... 19 3.3.1 Detailed Results ......................................................................................... 20 3.3.2 Summary Results ...................................................................................... 20

4. Calibration and Setup ............................................................................................ 21

4.1 Transducer Calibration .................................................................................... 21 4.1.1 Zero and Span Adjustments ..................................................................... 21 4.1.2 Linearisation Adjustments ....................................................................... 23 4.1.3 Printing Out the Results ......................................................................... 23

4.2 VJT6000 Series Equipment ........................................................................... 24 4.3 Logged Data Management .............................................................................. 25

4.3.1 Clearing The Logs ..................................................................................... 25 5. Advanced Options ................................................................................................. 26

5.1 Raw Data Setup ................................................................................................ 26 5.2 Automatic Control Tuning ............................................................................... 27

5.2.1 PID Control ............................................................................................... 27 5.2.2 Equipment ................................................................................................ 28

6. Serial Port Specifications ..................................................................................... 30

6.1 Starting or Stopping a Test ............................................................................. 30 6.2 Reading Test Status ......................................................................................... 30 6.3 Reading Test Results ....................................................................................... 30

7. Hydraulic Set-up & Maintenance .......................................................................... 31

7.1 Oil Fill And De-airing Procedure ..................................................................... 31 7.1.1 Filling The Machine With Oil..................................................................... 31 7.1.2 De-airing Of The Hydraulic Piston ........................................................... 32

7.2 Daily Maintenance ............................................................................................ 33 7.2.1 General ....................................................................................................... 33 7.2.2 Piston Dust Cover ..................................................................................... 33 7.2.3 Piston Cover Activating Arm .................................................................... 34 7.2.4 Hydraulic Oil ............................................................................................... 34


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8. Troubleshooting .................................................................................................... 35

8.1 Identification Hydraulic ................................................................................ 35 8.2 Identification - Electrical .................................................................................. 37 8.3 Common Faults ................................................................................................ 39

8.3.1 Fast pump not working ............................................................................. 39 8.3.2 Loss of calibration data ............................................................................ 39 8.3.3 Receiving Test Data From VJT6000 Series To A PC .............................. 40


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1. Overview A summary of the range available within the VJT6000 series and what is possible with the concrete compression machines. The VJT6000 series of digital compression machines covers both manual and automatic machines in a range of capacities to BS1881, EN12390. The most commonly offered machines are: VJT6000-15M digital manual machine, capacity 1500kN VJT6000-15A digital automatic machine, capacity 1500kN VJT6000-2M digital manual machine, capacity 2000kN VJT6000-2A digital automatic machine, capacity 2000kN VJT6000-3M digital manual machine, capacity 3000kN VJT6000-3A digital automatic machine, capacity 3000kN Other capacities are available, contact the office for details.


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There is a selection of distance piece accessories to accompany the compression machines ranging from 20 to 100mm, but the recommended combination of distance pieces that will give the greatest flexibility is:- 1 x VJT6020-30 30mm height 1 x VJT6020-50 50mm height 1 x VJT6020-80 80mm height 1 x VJT6020-100 100mm height

Your concrete compression machine is capable of carrying out compression tests in either Automatic or Manual Control modes. The following tests can be executed:

Compression Tests. Loads can be applied over a LOW range from 0 to 400 kN through a HIGH range up to 2000 kN (or to the maximum capacity of the machine) at a configurable ramping rate.

Flexural Tests. Loads can be applied in finer detail in the range 0 to 100 kN also at a configurable ramping rate.

Fine Time Tests. Loads can be applied over the full LOW and HIGH ranges in up to 5 stages. Each stage includes a configurable ramping rate and a period during which a specified load is maintained.

The instrument has been designed to be capable of:

Maintaining the load ramping rate selected (in Automatic mode) Monitoring the effectiveness or error of the selected ramping rate Holding the Maximum load obtained before the sample fails Calculating the failure stress on the concrete sample under those conditions.

In addition, it stores results from the last 200 tests and can be connected via its built-in serial port to a Printer or PC to retrieve those results. The instrument also accepts commands via the same serial port to Start or Stop a test as well as to retrieve Status information. It provides all the facilities necessary to Calibrate the transducers used and to provide linearisation compensation if required.

Calibration Load Cell (not included with machine)

Lower Platen (supplied with machine)

30mm & 100mm Distance Pieces in situ

Ball Seat


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It is fully configurable in its operation, allowing you to fine tune its performance to match the compression frame in use, the alarm conditions and many other parameters. This guide expands on the specifications presented above to review: Chapter 2 describes the contents of the display. What is shown on the screen and how these fields vary with various test operation and configuration actions. Chapter 3 guides you through the test procedure: Specifications. Test identification Sample details Operating Parameters Stop conditions

Manual or Automatic Control Taring Stage Following through the Status reports Aborting a Test

Storing, Reviewing and Printing Results Chapter 4 shows you how to calibrate your transducers and to configure all other instrument parameters that affect its operation Chapter 5 shows you how to make use of the Advanced configuration options to fine tune the Automatic control program so that the error during load ramping is kept as small as possible. Chapter 6 documents the commands available via the instrument's serial port to control a test and to obtain status and results information. Chapter 7 gives details of the oil fill and de-airing procedure that must be done before the instrument can be used, and daily maintenance that must be carried out to keep the instrument in the best possible working order. Chapter 8 is a troubleshooting section which identifies the main hydraulic and electrical components and gives solutions to some common problems that can occur. The instrument itself provides further instructions available by pressing the key HELP from any of the screens. Press the same key again to remove it.


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2. Main Screen Contents This is what you see when the instrument powers up and from where most options are accessed.

Each VJT6000 series machine is tested prior to dispatch and the contrast settings will remain set. Should you need to change the contrast, press the 8 key on the keypad and adjust the brightness accordingly. Normally the screen is split into 4 sections, namely: System Overview, Test Status, Test Specifications and Sample Specifications.

2.1 System Overview This field describes the transducer range currently in use. It is applicable for Compression tests. The load at which the LOW range ends and the HIGH range begins is configurable (see Chapter 4) by default this is set at 400kN. This picture represents the oil flow valve, white if the valve is open, black if closed. When a test is NOT running, or during the Tare Stage of a Manual mode test (Chapter 3), or during Transducer Calibration (Chapter 4), you control the valve by pressing the key 6 to open or close it alternatively. This picture represents the Fast pump, white if the pump is stopped, black if running. When a test is NOT running, or during the Tare Stage of a Manual mode test (Chapter 3), or during Transducer Calibration (Chapter 4), you control the pump by pressing the key 5 to start or stop it alternatively. This field describes the mode of operation for a running test. When a test is NOT running, it shows the mode last used (Chapter 3). A test is started in either Automatic mode by pressing the key AUTO or Manual mode by pressing the key MAN. This field is the instantaneous error between the actual load applied during ramping and the load demanded by the rate used. It grows in either the positive or negative direction up to a maximum configurable band (Chapter 4). Note that it is also possible to configure the instrument so that this field is NOT displayed.

MANUAL AUTO

+5% -5%

?????

LO HI


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This is the current value of the selected transducer and the Units (usually kN) used. It will change as load is applied and the transducer reacts. It is also possible to magnify this section of the screen by pressing the key 4. You would normally do this while a test is running so that the information is clearer. Press the same key again to return to the complete screen.

2.2 Test Status This field describes the current operation of the test. The following stages exist:

Idle When not running Taring The initial stage, when reading is zeroed Ramping When controlling the rate at which load is applied Peak Hold When the sample begins to fail. The field below is

frozen to indicate the point at which this began Success When the test has been completed successfully Aborted When the test has been manually stopped.

This is the Maximum detected load applied to the sample before it begins to fail. It is frozen while a test is running, and released by starting a new Test. These are the current clock settings. The internal battery maintains the clock running even when the instrument is switched off. To set it, press the key 1 and follow the instructions given on the screen shown.

2.3 Test Specifications All these fields are configured as described in Chapter 3. Each test is identified by a 6 character number which you can enter as required. The value shown is that defined for the last test used but increments automatically. This is the load at which the error between the measured and the required load ramping will begin to be displayed. In Automatic test mode, it also marks the beginning of the Ramping test stage. This is the rate of increase of load required. This field shows the percentage of load decrease from the Maximum required to be detected in order to stop the test automatically. This is the Tare value currently in use. It will vary with each test as the Taring stage proceeds. The field therefore provides an indication of idle load on the frame.

181.3 (kN)

Status

Peak

dd/mm/yy hh:mm:ss

Reference

Base (kN)

Rate (kN/S)

% Fail

Tare (kN)


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2.4 Sample Specifications All these fields are also configured as described in Chapter 3. There are 7 types of samples that can be used. Standard Cylinder, Standard Cube, Non Standard Cylinder, Non Standard Cube, Beam Block, Gravel (ACV) and Capped Cylinder. This field shows the name of that type currently in use. Each sample has certain dimensions which you can enter and are shown by these fields. Note that some dimensions for Standard Cube or Cylinder are fixed by the instrument. This is the sample area calculated using the above dimension. This field is continuously calculated from the Maximum load value shown on the Current Status section of the screen and the dimensions entered above.

Sample Type

Diam x Height

Area (mm2)

Stress (mPa)


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3. Using VJT6000 series This section guides you through the test procedures for both manual and automatic control, and details the procedure for storing, reviewing and printing results.

3.1 Specifying the test before it begins.

From the main screen, press the key DP to display the options for the tests available. Choose the type of test to be carried out, Flexural, Compression or Fine Time. Use the arrow keys to highlight the test required then press the ENTER key. 33..11..11 TThhee NNaammee ooff tthhee TTeesstt

The Reference is a 6 character number automatically incremented by the instrument for every new test to speed up the identification, although you can reset it to whatever number meets your needs. This number is tagged to each test so that it can be identified among all other test results logged. If you wish to change this field, use the arrow keys to highlight Reference then press the ENTER key to select the Reference field.


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33..11..22 OOppeerraattiinngg PPaarraammeetteerrss For the Flexural and Compression tests, you need to provide the following information, this is entered by selecting the appropriate field from the menu shown in section 3.1.1:

Base is the load (in kN) at which the automatic ramping starts and the error begins to be calculated. Normally this happens soon after the Taring stage is completed at low loads.

Rate is the increase (in kN/Second) in load required for the new test. In Automatic test mode, the instrument controls the load applied using this ramp as a guide. In Manual mode, you must adjust the load using the Speed control pot. In either case, the error measured by the instrument is the difference between the actual load on the sample and the load that should exist given the rate of increase configured here.

For a Fine Time test, you also need to configure:

Stage select 1 of 5 stages. Each stage consists of a Target Load level to be reached, the Rate at which the instrument will increase the applied load until the level defined above is reached, and a Holding Time during which the applied load will be maintained before proceeding to the next stage.

Rate is the increase (in kN/Second) in load required for the stage selected above. In Automatic test mode, the instrument controls the load applied using this ramp as a guide. In Manual mode, you must adjust the load using the Speed control pot. In either case, the error measured by the instrument is the difference between the actual load on the sample and the load that should exist given the rate of increase configured here.

Hold (in minutes) is the period to hold the applied load when the Target Level below is reached, before moving onto the next stage.

Level is the load (in kN) to be reached at the rate defined above. 33..11..33 SSttooppppiinngg CCoonnddiittiioonnss For the Flexural and Compression Tests, you also need to configure a failure condition, this is entered by selecting the appropriate field from the menu shown in section 3.1.1: Failure is the percentage drop in load from the Maximum detected value while

the test is running. As soon as the load falls below this margin, the test is stopped and its results logged. A new test can then be carried out.

For a Fine Time test, the Test will stop either when all Stages have been completed or when a Stage has been configured with a Holding Time of 0 minutes.


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33..11..44 TTaarree CCoonnddiittiioonnss From the Set-up menu shown in section 3.1.1 use the arrow keys to highlight the Tare field then press the ENTER key.

Drop Time is the time (in seconds) allowed for the platen to drop after the initial daylight closing operation.

Stop Level is the force (in kN) above which the fast pump is automatically stopped.

Maximum is the maximum force (in kN) that will be allowed to be tared. If this level is exceeded when a test is tared, the test will be aborted.


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33..11..55 SSaammppllee TTyyppee aanndd DDiimmeennssiioonnss From the Set-up menu shown in section 3.1.1 use the arrow keys to highlight the Sample field then press the ENTER key. Select the type appropriate to the sample to be tested. Depending on your selection, you will then need to enter its dimensions.

Standard Cylinder Select the diameter from the options presented (50, 75, 100, 150 or 200

mm) Enter the sample height Enter the sample weight

Standard Cube

Select the width from the options presented (50, 75, 100, 150 or 200 mm) Enter the sample height Enter the sample weight

Non Standard Cylinder Enter the sample diameter Enter the sample height Enter the sample weight

Non Standard Cube

Enter the sample width Enter the sample height Enter the sample weight

Beam Block

Enter the sample width Enter the sample height Enter the sample weight

Capped Cylinder

Enter the sample diameter Enter the sample height Enter the sample weight


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3.2 Test Control Operations 33..22..11 AAuuttoommaattiicc TTeesstt MMooddee To start a test in Automatic mode please press the AUTO key, this will then give you a screen to check the test details. Move the arrow keys to highlight Proceed then press the ENTER key. You can terminate a test at any time after it has started by pressing the ABORT key.

3.2.1.1 Taring Stage

The first stage in a new concrete test is known as the Taring stage, where any loads present on the frame before the actual control can be eliminated.

Taring is divided into 3 stages: 1. Initial Platen Up The oil valve is closed and the fast pump starts until the load

reaches a configurable small level Pump-Off (Chapter 4)

2. Platen Down The fast pump stops and the oil valve opens to allow the platen to drop. This phase lasts for up to a configurable Tare Period (Chapter 4) at the end of which the load is cleared by the program.

3. Tared Platen Up The oil valve is closed and the fast pump starts again

increasing the load. The fast pumps then stops at the same level as before but the loading continues to be applied under the instruments control until a configurable Base level (Chapter 4) has been achieved.

When the test is started a new screen appears containing status fields from the Main Screen described in Chapter 2 that will allow you to follow the completion of this Taring stage.


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3.2.1.2 Ramping Control

The next stage in a test is known as the Ramping stage, where load is continuously applied at an increasing Rate previously configured. This rate is under electronic control See Chapter 5 for performance fine tuning. During this stage, a deviation error between applied and measured load is continuously calculated and displayed (if enabled). The instrument also holds the maximum load it detects.

3.2.1.3 Stopping The Test

For Compression and Flexural tests, the instrument also detects any drop in loading that match the Stop conditions previously configured. When these are met, the test is completed and its results stored. For Fine Time tests, when the Target loading level is reached for the current time stage, the instrument will maintain that load for the period specified. After that, it continues with the next stage until all stages are finished. The test is then completed and its results stored Please refer to section 3.3 for a description of the test results.


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33..22..22 MMaannuuaall TTeesstt MMooddee To start a test in Manual mode please press the MAN key, this will then give you a screen to check the test details. Move the arrow keys to highlight Proceed then press the ENTER key. You can terminate a test at any time after it has started by pressing the ABORT key.

3.2.2.1 Taring Stage

The first stage in a new concrete test is known as the Taring stage, where any loads present on the frame before the actual control can be eliminated.

Taring is divided into 2 stages: 1. Initial Platen Up Press the key 6 to close the oil valve. Then press the key 5 to

start the fast pump. When the load reaches a configurable small level Pump-Off (Chapter 4) you must press those keys again to proceed to the next stage.

2. Platen Down Wait for a little time to allow the transducer reading to settle.

When ready, press the key 0 to carry out the actual taring. The test can then proceed under complete manual control.

When the test is started a new screen appears containing status fields from the Main Screen described in Chapter 2 that will allow you to follow the completion of this Taring stage.


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3.2.2.2 Ramping Control

The next stage in a test is known as the Ramping stage. You must apply the load manually using the Speed Control pot. Try to increase this load at the Rate previously configured. During this stage, a deviation error between applied and measured load is continuously calculated and displayed (if enabled). The instrument also holds the maximum load it detects.

3.2.2.3 Stopping the Test

For Compression and Flexural tests, the instrument also detects any drop in loading that match the Stop conditions previously configured. When these are met, the test is completed and its results stored. For Fine Time tests, when the Target loading level is reached for the current time stage, the instrument will maintain that load for the period specified. After that, it continues with the next stage until all stages are finished. The test is then completed and its results stored Please refer to section 3.3 for a description of the test results.


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3.3 Storing, Viewing and Printing Results Your VJT6000 series instrument is capable of storing the results of up to 200 tests in its non volatile memory. The information in a test result includes: Reference The identification number for a test, configured as

described in Chapter 3. Date and Time When the test was carried out Test Mode Automatic or Manual as appropriate Test Type Compression, Flexural or Fine Time, as appropriate Test Result Successful, Aborted or Overload Peak Load The maximum measured load during the test Base Load The load at which Ramping started Tared Load The load removed during the Taring stage Sample Type Standard Cylinder, Standard Cube, Non Standard Cylinder, Non Standard Cube or Beam Block Sample Area Cross sectional (width x Depth) Sample Density Weight / Volume (Area x Height) Peak Stress Peak Load / Area measured during the test. For Compression or Flexural Tests Pace Rate The increase in loading used during the test Failure Band The Stop criteria used during the test For Fine Time Tests Last Stage Index (1 to 5) when the sample failed Pace Rate The increase in loading used during that stage Target Level The loading achieved during that stage Holding Time The period during which the load was maintained. Each test is referenced by a number 1 to 200 according to its position in the memory, where 1 is the most recent test. The results are always stored when a test ends, either successfully or not. They are available for as long as the logs are not erased. When the logs are full, the oldest logged results are replaced with new data. You can also erase all logs using the Advanced Options described in Chapter 5.


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33..33..11 DDeettaaiilleedd RReessuullttss Press the key 2 to view most of the results described above. Please note that some of them are not available because of screen space limitations, but all can eventually be accessed when sent to a Printer or PC serial port.

At the top of the screen you will see the field Page / Pages. This gives you an indication of how many logs are stored. Use the AUTO key to view previous test results, or the MAN key to return to newer ones. Pressing the ENTER key presents the option to produce a printout of detailed results for the logged set currently displayed. You must connect a Printer or a PC to the serial port of your instrument as described in Chapter 6 of this manual. Press the ABORT key to return to the main screen.

33..33..22 SSuummmmaarryy RReessuullttss Press the key 3 to view the most important data items from the results information described above.

At the top of the screen you will see the field Page / Pages This gives you an indication of how many logs are stored. Use the AUTO key to view previous test results, or the MAN key to return to newer ones. Pressing the ENTER key presents the option to produce a printout of summary results either for the logged set currently displayed or for ALL stored results held in the instruments memory. You must connect a Printer or a PC to the serial port of your instrument as described in Chapter 6. Press the ABORT key to return to the main screen.


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4. Calibration and Setup This chapter shows you how to set up your VJT6000 Series instrument in order for it to run efficiently. From the Main Screen (Chapter 2) press the Setup key 7 then select the CALIBRATION mode 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.

4.1 Transducer Calibration 44..11..11 ZZeerroo aanndd SSppaann AAddjjuussttmmeennttss 1. First select the transducer LOW range, HIGH 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.

2. Next, move the arrow keys to select the Scale field. This will be factory set with

the low range at 400.0 and the high range at 2000, 3000 or 4000 kN depending on the machine capacity, but can be altered if necessary by pressing the ENTER key and inputting the required value.

Note your VJT6000 Series instrument processes the electronic signals received from the transducers according to the Amplification and Filtering parameters defined in Chapter 5


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3. Select and activate the CLEAR option to start new a new calibration. You will be warned about the implications of clearing calibration data previously stored. You can then choose to proceed or not.

4. Make sure that the solenoid valve is closed, the fast pump is off and no load is

currently being applied with speed pot set to give a steady oil flow rate. When the readings are stable, and the platen is off the seating position (not in contact with upper ball seating), select the ZERO option. The transducer reading should now show 0, and the field labelled Zero will display the offset measured at this time, please write this down for future reference.

5. Now start the fast pump to close the daylight and then switch off the fast pump

once the contact is made with the upper ball seating. 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 reading should now show the same value as that configured on the Scale entry (step 2 above), Again write down the value against the label marked gain.

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


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44..11..22 LLiinneeaarriissaattiioonn AAddjjuussttmmeennttss The VJT6000 series instrument allows you to define an interpolation table of up to 10 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. 1. Please enter the first field (Expected) according to the measurements to be

carried out at each stage. 2. Apply the load manually until the Expected loading is achieved. 3. 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 key DP to let VJT6000 series instrument do this automatically for you. Note that this will only work if the transducer reading is within +/- 5% of the expected value, otherwise the instrument rejects the option.

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

adjustments and return to the previous screen. 44..11..33 PPrriinnttiinngg OOuutt tthhee RReessuullttss Select the PRINT option to obtain a hardcopy of the calibration results described above. You must connect a Printer or a PC to the serial port of your instrument as described in Chapter 6.


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4.2 VJT6000 Series Equipment There are a number of features, which can be configured to suit your installation requirements or preferences. To access these options from the Main Screen (Chapter 2), press the Setup key 7, select the EQUIPMENT mode and then select the test required.

1 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.

2 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.

3 Show Proceed Select YES to make sure that a confirmation is given before a

test can proceed. This can help to verify all conditions. 4 Error Band Enter the percentage error measured while a test is running that

will fill the error box shown on the Main Screen (Chapter 2) Usually this is 5%, but note that entering a value of 0 will effectively prevent the box from being shown.

5 Switchover Enter the loading level at which the instrument will automatically

switch from the LOW to the HIGH transducer ranges. This is applicable to Compression Tests only (default value is 400.0).

6 Overload To prevent the frame being damaged by applying a large loading,

you can define a level above which the instrument automatically shuts down, opens the oil valve and releases all loads.

(default value is set to the machine capacity, ex. 2000 kN) 7 Min Failure Enter the minimum value that must be reached before a test can

fail, this can help prevent spurious errors on the sample. 8 Customisation 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 Companys name, Customer details, etc.


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4.3 Logged Data Management The following options are available.

44..33..11 CClleeaarriinngg TThhee LLooggss This will erase the non volatile memory, removing the results of any previous tests carried out by your VJT6000 series instrument. A warning will be presented first, to avoid erasing data inadvertently. You can choose to proceed or to cancel the request.


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5. Advanced Options This chapter shows you how to tune your VJT6000 Series instrument in order to operate effectively. From the Main Screen (Chapter 2) press the Engineering key 9 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. Select the category you require from the menu then press the ENTER key.

5.1 Raw Data Setup Select each of the transducers 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.

1. Filter This is a value that determines how many readings are taken to

average out noisy lines. It is set to a default value of 20 which is recommended for most cases, changes should not be made without prior consultation. The maximum filter value is 100 and minimum is 20.

2. Amplifier This is the gain to be applied to the signal received from the transducer. It is set to a default value of 32 which is recommended for most cases, changes should not be made without prior consultation. Other values that may be accepted are 1, 2, 4, 8, 16, or 64. Apply Full Scale load and observe that the raw reading covers the expected range.

The programmed values are also included in the Channel Calibration printouts described on Chapter 4.


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5.2 Automatic Control Tuning Your VJT6000 series instrument uses an advanced program during Automatic Tests execution to maintain the applied load close to the Ramping rate selected when the test is initially setup. This special program is controlled by a number of parameters set by default to values that have been determined reasonable for most concrete crushing frames. However, to cover variations introduced by different manufacturing batches, those parameters are made available to you to change if necessary. 55..22..11 PPIIDD CCoonnttrrooll From the main Engineering screen shown at the start of this section, select PID Control (Proportion Integral Derivative) to access this option, then enter the relevant sample type that was specified earlier. Selecting a Sample type as described in Chapter 3 (Standard Cylinder, Non Standard Cylinder, Standard Cube, Non Standard Cube, Beam Block, Gravel and Capped Cylinder) automatically selects 1 of 7 settings respectively. For each one of those settings you can change:

1. Direct This affects how quickly an error between Applied Load and

Measured load is reduced. This value has been factory set at 40 and should NOT be changed without prior consultation.

2. Integral This affects how smoothly small errors between Applied and Measured loads are reduced. This value has been factory set at 20 and should NOT be changed without prior consultation.

3. Max Rate This is the maximum percentage amount by which the pump speed is adjusted.

4. Zero Output This is a percentage value representing the range setting to be used to apply load when a zero error exists between Ramp values and Measured values.

Changing these parameters will affect the operation of your instrument and should only be altered if really necessary. You must ensure that only reasonable values are entered. You may find it necessary to consult your supplier for advice.


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5. Taring Speed This is the percentage speed at which the pump is run during

the taring stage. 6. Start Up Speed This is the percentage speed at which the pump is run during

the start-up stage. 7. Compens Speed This is only applicable to sample options 6 and 7 (Gravel ACV

and Capped Cylinder). It is used to adjust the speed when changing from a high flow pump to a low flow pump.

8. Max Output This is the maximum percentage output speed of the pump. 55..22..22 EEqquuiippmmeenntt From the main Engineering screen shown at the start of this section, select Equipment to access this option. By using the arrow keys to highlight the required category, you can change various aspects of the machines basic set-up as indicated below:

Selecting the Initialize option will allow the data base to be initialized. By choosing this option, you can reset your instrument to factory default values. The following happens: 1. The contrast is turned off and must be reset by pressing key 8 then selecting from

the menu presented. All memory logs are erased. 2. Instrument defaults:

Units: metric Percentage Error: 5 Peak Hold: Yes Query Abort: Yes Show Proceed: No Switchover: 400 kN Overload: 2050 kN Min Failure: 50kN Max Tare: 10 kN Stop Level: 8 kN Tare Timeout: 10 mins Drop Time: 2 secs


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3. Test defaults:

Type: Compression Reference: ------ Mode: Automatic Rate: 6 kN/S Base: 10 kN %Fail 20 Sample: Standard Cylinder Diameter: 50 mm Height: 75 mm

4. 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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6. Serial Port Specifications This chapter describes the commands available via the serial port that allow a PC to control the instrument or extract test results data.

6.1 Starting or Stopping a Test This will be only in Automatic mode, using configuration entered directly via the screen, as described on Chapter 3. Transmit Receive Action S0501 (Cr) S0501=01 Starts the test C0501 (Cr) C0501=00 Stops the test

6.2 Reading Test Status Transmit Receive Action R0501 (Cr) XXXX Prints the current measured load. The exact format for each transducer input is described on Chapter 2. R0502 (Cr) XXXX Prints the maximum (Peak) load detected

during the current test. It follows the same format as described on Chapter 2.

6.3 Reading Test Results Transmit Receive Action S0504 (Cr) ******* Prints results for the last test. The actual

contents are described on Chapter 3.

The serial port on your VJT6000 series instrument is configured as: Baud Rate: 9600 Parity: None Stop Bits 1 Data Bits 8

This configuration is fixed and cannot be altered.


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7. Hydraulic Set-up & Maintenance This chapter gives details of the initial oil fill and de-airing procedure required before the instrument can be used and of daily maintenance that must be carried out in order to keep the instrument in good working order. 7.1 Oil Fill And De-airing Procedure Important Note Concrete compression machines are oil filled hydraulic devices. Due to shipping laws the machines are usually supplied drained of oil. The machine must be refilled with oil prior to operation. The machine requires approximately 7 litres of Tellus 32 hydraulic oil or equivalent. 77..11..11 FFiilllliinngg TThhee MMaacchhiinnee WWiitthh OOiill.. ENSURE THE UNIT IS POWERED OFF. Remove the back panel from the machine, then locate and remove the oil filler plug as shown below.

Fill the oil tank with Tellus 32 hydraulic oil using a funnel and filter until the oil is just below the top of the indication tube (older machines may have a MAX indication line) care should be taken to ensure no dirt or grit gets into the tank. Replace the oil filler cap and proceed to the de-airing instructions.

OIL LEVEL CORRECT

OIL FILLER PLUG


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77..11..22 DDee--aaiirriinngg OOff TThhee HHyyddrraauulliicc PPiissttoonn

Loosen the oil supply pipe fitting slightly (about quarter of a turn). Using the keypad, enter calibration mode of the machine by pushing key 7, followed by your passcode. Close the solenoid valve by pressing key 6 once (pressing twice will open again). With the valve closed the manual pace control will be active. Carefully operate the PACE control dial to slowly raise the platen until you see oil emerging from the oil supply pipe fitting. Ensure all of the air has dispersed before stopping the machine by reducing the pace to zero. Clean away any excess oil that has emerged from the hole and tighten the fitting with as much force as possible. It is important that this fitting is very tight. NOTE: It is normal for air to be trapped in the oil return pipe and this will not affect the operation of the machine. The machine is now ready for calibration. It is important that the machine is calibrated in-situ prior to testing.

OIL RETURN PIPE

OIL SUPPLY PIPE

SUPPLY PIPE FITTING


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7.2 Daily Maintenance The following checks should be carried out on a daily basis to help maintain the machine in good working order. 77..22..11 GGeenneerraall The machine should be kept in a general state of cleanliness with all debris cleared away after each batch of tests. The main parts of the digital compression machine that need daily maintenance are indicated below.

Limit Switch Hydraulic Oil Filling Cap Piston Dust Cover

Hydraulic Oil Level Indication Tube Piston Cover Activating Arm 77..22..22 PPiissttoonn DDuusstt CCoovveerr The piston dust cover should be checked to make sure the fixing screws are secure, and that there is no movement of the piston cover in the horizontal plane. Any movement of the cover could lead to the activating arm not being in the correct position to activate the limit switch.


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77..22..33 PPiissttoonn CCoovveerr AAccttiivvaattiinngg AArrmm The piston cover activating arm must be positioned directly underneath the limit switch actuator. The following photos show the correct positioning for the arm when the piston is in the start position and also fully raised.

77..22..44 HHyyddrraauulliicc OOiill The hydraulic oil used in the machine must be suitable for the climatic and environmental conditions of where it is being used, eg Shell Tellus 37. Care should be taken to keep the level topped up to just below the top of the indication tube as indicated below. Before filling up with any new oil, always ensure the piston is at its lowest position and a reasonable time has elapsed since the last test to allow any oil to return to the tank. Level too low Level correct


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8. Troubleshooting This chapter is a troubleshooting section which identifies the main components, provides schematics and gives solutions to some common problems that can occur. 8.1 Identification Hydraulic Main components as viewed from the rear of the machine: Fast Pump Solenoid Valve Valve

Pressurising Pump Motor

Dust Filter Pressure Transducer

Oil Filler Cap Mechanical Non-Return Valve


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Main components as viewed from above:

Pressure Relief Valve Adjuster See Note

Fast Pump Pressurising Pressure Solenoid Valve Pump Motor Relief Valve Valve

Dust Filter Oil Filler Cap Pressure Transducer

Mechanical Non-Return Valve Note: The pressure relief valve is Factory Set at VJ Tech and should NOT be adjusted without prior consultation with our technical department.


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8.2 Identification - Electrical Power Terminal Block ADC Channel 1 PSU0002

PSU0001 ADC Channel 3 ADC Channel 1 is for the internal pressure transducer. ADC Channel 3 is for an external pressure transducer if required.


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RS232-1 Solenoid Pump Valve DC Power In Stepper Motor AC Power In

Keypad ADC Channel 1 Backlight Hydraulic RAM ADC Channel 3

Limit Switch ADC Channel 1 is for the internal pressure transducer. ADC Channel 3 is for an external pressure transducer if required. RS232-1 is interface with customers PC.


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8.3 Common Faults 88..33..11 FFaasstt ppuummpp nnoott wwoorrkkiinngg Check the equipment settings to see if the fast pump is still selected. This is done as follows:- Select 9 on the keypad for the engineering functions Enter passcode supplied with the machine to gain access Select option 3 which is the equipment setup This should show if Fast Pump is set to on or off if it is set to off, then use the arrow keys to turn the option on and then exit out of this. 88..33..22 LLoossss ooff ccaalliibbrraattiioonn ddaattaa If calibration data is lost from the VJT6000 series machines, use the calibration data recorded at installation and follow this procedure:- Select the engineering function (key 9) Enter passcode supplied with the machine to gain access Select raw data Low range filter XX gain YY High range filter XX gain YY Where XX and YY are values from the original calibration. Select the set up function (key 7) Enter passcode supplied with the machine to gain access Low range filter XX gain YY High range filter XX gain YY Where XX and YY are values from the original calibration.


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88..33..33 RReecceeiivviinngg TTeesstt DDaattaa FFrroomm VVJJTT66000000 SSeerriieess TToo AA PPCC If problems are experienced with downloading test data, the following procedure should be followed: Connect computer serial port to the VJT6000 series machine RS232 port using a suitable RS232 cable. Run Terminal.exe program (normally supplied with the Windows operating system) then configure the communication protocols as shown. The following assumes that you have connected the instrument to COM1 port of the computer, if this port is not available you may use other available port:


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From the Transfers menu, select Receive Text File then enter a suitable file name, for example TEST001.TXT.


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When the test is complete the VJT6000 will transmit the data to the PC. VJT6000 --- Report Header VJT6000 Materials Tester Test Summary Reference 000005 Date (dd/mm/yy) 04/08/04 Time (hh:mm) 17:03 Type : Compression Load at Fail (kN) 0300.3 Base : (kN) 0010.0 Rate : kN/s 0006.0 %Fail: 20 Tare : (kN) -000.2 Sample Standard Cylinder Sample Area mm2 04417.8 Density: Kg/m3 0301.8 Stress at Fail MPa 00067.97 Result: Finish You may at any time close the file by pressing the STOP button shown at the bottom of the screen.

VJT6000 User Guide V1.3 (Re-saved)

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