CTM Manual (Compression Machine)

Digital Semi-automatic Compression Machine with Readout unit
MANUALE DI ISTRUZIONI INSTRUCTION MANUAL
Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC
Index
1. INTRODUCTION
1.1 1.2 1.3 1.4 1.5 1.6 1.7
Icons appearing in the manual ............................................................................................. 3 Manual revision history ....................................................................................................... 4 Symbols used ....................................................................................................................... 5 Intended use and improper use ............................................................................................ 6 Safety information ............................................................................................................... 7 Environmental risks and disposal ...................................................................................... 15 CE declaration ................................................................................................................... 16
2. DESCRIPTION
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
17
Frame ................................................................................................................................. 18 Compression platens and ball seating ................................................................................ 18 Loading cylinder assembly ................................................................................................ 18 Hydraulic unit .................................................................................................................... 18 Readout unit ....................................................................................................................... 19 System block diagram........................................................................................................ 21 Connections ....................................................................................................................... 22 Identification plate ............................................................................................................. 23 Commands and controls .................................................................................................... 24
2.9.1 Flow control valve ......................................................................................................... 25
2.10 Technical specifications..................................................................................................... 26
3. INSTALLATION
3.1 3.2 3.3 3.4 3.5 3.6
29
Shipment ............................................................................................................................ 30 Unpacking and inspection.................................................................................................. 31

3.2.1 How to remove the equipment from the shipping crate ................................................. 32
Positioning of the unit and space requirements ................................................................. 34 Installing and positioning of the display ............................................................................ 36 Electrical requirements ...................................................................................................... 37 Electrical connections ........................................................................................................ 38
4. USE OF THE EQUIPMENT

4.1 4.2 4.3
40
Switching on the equipment .............................................................................................. 41 Test parameters setting ...................................................................................................... 42 Carry out a test ................................................................................................................... 43
4.3.1 4.3.2 Use of the load control valve ......................................................................................... 45 Testing a sample ............................................................................................................ 46
4.4
Serial port .......................................................................................................................... 50 i

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Wizard Basic Rev.4 EN
Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC
4.5
Use of the integrated printer Q0701/UP2 (optional) ......................................................... 51

4.5.1 4.5.2 Installation of the printer paper ...................................................................................... 51 Setting of the date and enabling/disabling the date printout ........................................... 52
4.6 4.7
Stopping the cycle via the Emergency button ................................................................... 53 Switching off the unit........................................................................................................ 54
5. MAINTENANCE
5.1
5.1.1 5.1.2
55
Operators preventive maintenance .................................................................................. 57

Checking the status of the safety devices ....................................................................... 58 Checking the oil level in the tank ................................................................................... 60 Checking the centering of the ram assembly .................................................................. 62 Checking the hydraulic circuit........................................................................................ 64 Checking the status of distance pieces ........................................................................... 66 Performing the maintenance of the spherical seat .......................................................... 67 Calibration of the load channel....................................................................................... 68 Calibration verification................................................................................................... 69 Calibration ...................................................................................................................... 74 Checking the stability of the frame ................................................................................ 79 Replacing the oil of the hydraulic circuit ....................................................................... 81
5.2
Authorized service engineer maintenance actions ............................................................ 61

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.5.1 5.2.5.2 5.2.6 5.2.7
6. DIAGNOSTICS & TROUBLESHOOTING

6.1
6.1.1 6.1.2 6.1.3 6.1.4 6.1.5
83
Troubleshooting ................................................................................................................ 84
Adjustment of the maximum load .................................................................................. 87 Adjustment of the rapid approach speed ........................................................................ 88 Sticking of the floating piston ........................................................................................ 89 Oil leakage from below the control knob ....................................................................... 90 The load does not increase ............................................................................................. 92
7. SPARE PARTS 8. SCHEMATICS AND DRAWINGS
93 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
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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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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 Rev. 1 6 July 2009 Rev. 2 12 November 2010 Rev. 3 02 March 2011 Rev 4 06 July 2011 Change description Manual release New manual version Updated procedure to install the printer paper (see chapter 4.5.1) Added setting of date on printouts (for units equipped with firmware revision 2.1 or higher)
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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
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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 operators 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.
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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.
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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;
Emergency button
Lever A to release piston pressure
Max pressure valve
Fig. 1-2
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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.
Limit switch
Fig. 1-3 Front and rear transparent fragment guard (rigid or flexible depending on the equipment versions).
Front fragment guard
Fig. 1-4 Access panels equipped with screws.
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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 Operator
Area with residual risks 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
Personnel responsible of transportation and moving of the equipment
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. 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.
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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.
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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 operators 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.
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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.
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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.
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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 of its useful life. Therefore, at the end of its useful life, the owner should dispose of o the product in a suitable 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 re-cycled re materials and limits imits the environmental impact of the product caused by improper disposal. Improper disposal of the product is subject to penalties as foreseen by the local regulations.
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1.7
CE declaration
This page shows a copy of the CE declaration. The original is supplied with the equipment as a separate document.
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2.
DESCRIPTION
Refer to the following figures for main components identification.
6 7
3 8 4
Fig. 2-1 Rif 1 2 3 4 5 6 7 8 Description Front guard Upper platen with spherical seat Lower platen Piston travel indicator Readout unit Hydraulic unit Pump motor switch Flow control valve
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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 multipiston 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.
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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.
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2.6
System block diagram
Fig. 2-2
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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.
1 2
3 4 5 6
Fig. 2-3
Ref. 1 2 3 4 5 6
Description Readout unit power cable receptacle with mains switch and line fuse Pressure transducer Serial port for PC Pump motor Motor switch Emergency stop
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2.8
Identification plate
The identification plate is located on the rear side of the equipment, near the power cable.
Fig. 2-4
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2.9
Commands and controls

This chapter describes the commands and controls of the equipment. The operators interface description of the readout unit is provided in chapter 4.2 of the present manual.
Fig. 2-5
Ref. 1 2 3 4
Description Keyboard Readout unit mains switch Pump motor switch Emergency button
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2.9.1
Flow control valve
1 3 2
Fig. 2-6
Ref. 1 2 3
Description Load gradient adjustment knob (clockwise to decrease; counter clockwise to increase) Flow control lever (back for rapid approach; forward to control load rate with the load gradient adjustment knob) Oil supply lever (up to recycle oil in the tank; down to supply oil to the piston)
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2.10
Technical specifications
Main characteristics ASTM Cylinder testers
Product Manufacturer Product code 230VAC 50Hz 1Ph Product code 220VAC 60Hz 1Ph Product code 110VAC 60Hz 1Ph Capacity Power Method of power entry Computer connection Platen Ram travel Max vertical daylight Max horizontal daylight Fast approach speed Max. working pressure Oil output at max. pressure Oil tank capacity (approx.) Useful oil volume (approx.) Working oil volume (approx.) Acoustic pressure Net weight (approx.) Overall dimensions W x H x D [mm]
Digital semi-automatic compression tester CONTROLS Cernusco s/N (MI) Italy 50-C2122 50-C2123 50-C2124 1300 kN 750 W Power cable with plug Serial port RS232 165 mm diam. 50 mm 370 mm 235 mm 40 mm/min approx. 650 bar 0.3 l/min approx. 6 litres 4 litres 2 litres 77 db (A) 280 Kg 650 x 890 x 400 410 Kg 700 x 920 x 420 370 mm 280 mm 50-C3122 50-C3123 50-C3124 1500 kN
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Main characteristics ASTM/AASHTO Cylinder and cube testers Product Manufacturer Product code 230VAC 50Hz 1Ph Product code 220VAC 60Hz 1Ph Product code 110VAC 60Hz 1Ph Capacity Power Method of power entry Computer connection Platen Ram travel Max vertical daylight Max horizontal daylight Fast approach speed Max. working pressure Oil output at max. pressure Oil tank capacity (approx.) Useful oil volume (approx.) Working oil volume (approx.) Acoustic pressure Net weight (approx.) Overall dimensions W x H x D [mm] 400 Kg 700 x 920 x 413 340 mm 280 mm 216 mm diam. Digital semi-automatic compression tester CONTROLS Cernusco s/N (MI) Italy 50-C3422 50-C3423 50-C3424 1500 kN 50-C4422 50-C4423 50-C4424 2000 kN 750 W Power cable with plug Serial port RS232 216 mm diam. 50 mm 350 mm 330 mm 40 mm/min approx. 650 bar 0.3 l/min approx. 6 litres 4 litres 2 litres 77 db (A) 550 Kg 770 x 1000 x 430 750 Kg 810 x 1070 x 560 350 mm 370 mm 300 mm diam. 50-C5422 50-C5423 50-C5424 3000 kN
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Main characteristics EN models Product Manufacturer Product code 230VAC 50Hz 1Ph Product code 220VAC 60Hz 1Ph Product code 110VAC 60Hz 1Ph Capacity Power Method of power entry Computer connection Platen Ram travel Max vertical daylight Max horizontal daylight Fast approach speed Max. working pressure Oil output at max. pressure Oil tank capacity (approx.) Useful oil volume (approx.) Working oil volume (approx.) Acoustic pressure Net weight (approx.) Overall dimensions W x H x D [mm] 890 Kg 920 x 1030 x 440 350 mm 370 mm 40 mm/min approx. 650 bar 0.3 l/min approx. 6 litres 4 litres 2 litres 77 db (A) 1110 Kg 1010 x 1100 x 500 Digital semi-automatic compression tester CONTROLS Cernusco s/N (MI) Italy 50-C4622 50-C4623 50-C4624 2000 kN 750 W Power cable with plug Serial port RS232 300 mm diam. 50 mm 350 mm 370 mm 50-C5622 50-C5623 50-C5624 3000 kN
Environmental conditions Operating temperature Operating humidity + 10 + 40C 50%RH @ 40C
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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 preinstallation, all the pre-installation phases are at the purchasers 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.
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3.1
Shipment
The equipment is normally shipped in a wooden crate having the following dimensions and gross weight depending on the model: Gross weight 370 Kg 440 Kg 490 Kg 640 Kg 840 Kg 980 Kg 1210 Kg Minimum fork lift length 1200mm 1200mm 1200mm 1200mm 1200mm 1200mm 1200mm
Model C212X C312X C342X C442X C542X C462X C562X
Overall dimensions 950 x 700 x 1050mm 950 x 700 x 1050mm 950 x 700 x 1050mm 950 x 700 x 1050mm 950 x 700 x 1150mm 950 x 700 x 1150mm 1100 x 700 x 1250mm
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.
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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 carriers 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 C212X C312X C342X C442X C542X C462X C562X Net weight 280 Kg approx. 350 Kg approx. 400 Kg approx. 550 Kg approx. 750 Kg approx. 890 Kg approx. 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
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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.
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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.
50cm
Fig. 3-3
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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 C212X C312X C342X C442X C542X C462X C562X a mm 215 250 250 330 370 565 655 b mm 285 310 310 350 390 260 320 c mm Dia 13 Dia 13 Dia 13 Dia 13 Dia 13 Dia 13 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.
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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
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3.5
Electrical requirements
The next table shows the electrical specifications of the equipment:
Item Mono phase voltage Frequency Maximum power
Specifications 110VAC/220VAC/230VAC +6%, -10% 50Hz/60Hz 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 operators 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.
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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.
Readout unit mains cable input and switch
Frame load sensor cable
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
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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);
Control unit power switch
LOAD
PC serial port Fig. 3-8
5. Refer to chapter 4.1 to turn ON the unit.
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4.
USE OF THE EQUIPMENT

This chapter describes the operators interface and the execution of a test.
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.
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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;
Power switch
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.
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4.2
Test parameters setting
Press key follows:
to access the set test parameters menu. The display will show as
4-4 The AREA parameter is that of the surface area on the sample being tested (in mm). For example, a 150 mm cube would have an area of 22500 mm. 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/mm.
Use the to another.
and
keys to set the values, press
to pass from one field
The selected field is indicated by the symbol to the previous screen.
#. Upon completion press
to return
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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.
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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;
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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.
A B
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;
A B
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.
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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.
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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 1525% the actual load rate corresponds to the theoretical load rate 2550% the actual load rate corresponds to the theoretical load rate more than 50% the actual load rate corresponds to the theoretical load rate + 1525% the actual load rate corresponds to the theoretical load rate + 2550% the actual load rate corresponds to the theoretical load rate + more than 50%.
4-9
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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
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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;
B A
Fig. 4-12
7. To print and/or download the data to the PC via the serial port press the
key;
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. To start another test proceed from step 1; if the test parameters need to be changed refer to chapter 4.2.
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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.
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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
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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 button shown:
. on the front panel and keep on pressing the
until the display is blank. Release the button, the following display will be
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 symbol to select the function DATE PRINT, it will be highlighted by the to access this menu.
#. Press the button
Fig. 4-15
Press the button to move among the available fields and the date and activate/de-activate the date printout.
to set
NOTE: The date is not updated automatically. It needs to be changed by the operator following the procedure above described.
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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.
B A
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.
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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.
Readout unit mains switch
Fig. 4-17
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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: 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.
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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.
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5.1
Operators preventive maintenance

The inspections made directly by the operator are the following:
Action Check to ensure that there is no external damage to the equipment, which could jeopardise the safety of use Clean and dry platens, distance piece and ram from the sample debris General inspection Check the status of the hydraulic tubes against leakages and damages 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) Check status and functioning of the operator's command Check the level of the oil in the tank (see chapter 5.1.2) Check that all label and rating plates are intact and properly attached
Who Operator
When Before every working session
Operator
At the end of each working session Weekly Weekly Weekly
Operator Operator Operator
Operator Operator Operator
Weekly Monthly Monthly
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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;
Emergency button
Lever A to release piston pressure
Max pressure valve
Fig. 5-1
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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).
Limit switch
Fig. 5-2 Front and rear transparent fragment guard.
Front fragment guard
Fig. 5-3
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5.1.2
Checking the oil level in the tank
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.
Oil level indicator
Fig. 5-4 The following type of oil can be used: Brand Agip Api Chevron Elf Exxon Fiat Fina Gulf IP Mobil Shell Total Vanguard
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Type ATF Dexron Apilube ATF Dexron Chevron automatic transmission fluid Elfmatic G Automatic transmission fluid GI/A Dexron ATF Automatic transmission fluid Dexron fluid ATF 220 ATF Dexron II Dexron ATF fluid DEX II
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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 Checking the centering of the ram assembly (see chapter 5.2.1) Checking the hydraulic circuit (see chapter 5.2.2) 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) Checking the stability of the frame through the force transfer test with the strain gauged column (see chapter 5.2.6) Status of the internal and external cables wear and tear and fastenings Grounding of all the accessible conductive parts Replacing the oil of the hydraulic circuit (see chapter 5.2.7)
Who Authorized service engineer Authorized service engineer Authorized service engineer Authorized service engineer Authorized service engineer
When 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
Yearly or more frequently depending on the quality procedures of the laboratory Authorized service Yearly or more frequently engineer depending on the quality procedures of the laboratory Authorized service engineer Authorized service engineer Authorized service engineer Yearly Yearly Every 3 years or more frequently in very cold or humid environments (where condensation may form in the oil tank)
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5.2.1
Checking the centering of the ram assembly

The proper centering of the ram assembly assures proper and uniform distribution of the 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. out To check the centering of the ram assembly: 1. 2. Remove the lower platen and distance pieces; On the compression frame remove r the cover of the ram assembly to expose its fixing brackets;
Fig. 5-5 3. Use a straight edge and a tape measure to check the centering of the ram assembly in all directions with respect to the columns column of the compression frame;
Fig. 5-6
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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. 63
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5.2.2
Checking the hydraulic circuit

Due to the high pressure inside the hydraulic circuit (up to 700 bars) a periodical check on the hydraulic components is required.
WARNING: To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves while performing the checking. 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;
Fig. 5-9 3. On the rear of the equipment check the following points for oil leakages: o Connection point of the pressure transducer o Input port of the oil on the ram assembly o Both ends of the hydraulic tube and along the hydraulic tube itself o Output of the flow control valve on the front side o Slot between the piston and the ram assembly;
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Fig. 5-10 4. In case of oil leakages, check the single item(s) and replace the relevant gasket/Ogasket/O ring; Then check the oil level in the tank (refer to chapter 5.1.2) ) and, if needed, re-fill re the oil 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.
5.
6.
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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, status of distance pieces and platens must be periodically checked. This check is normally carried out before checking the calibration of the 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. Checking the status of distance di pieces requires: 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; screw Checking that, once the distance pieces are installed on the machine, they do not tilt pushing them from the top.
Fig. 5-11
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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.
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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.
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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; 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:
2.
Fig. 5-12 3. Leave the equipment switch ON for at least 15 minutes to allow the thermal equilibrium of the electronic components; Use the symbol key to select the desired function which will be highlighted by the
4.
#. Press the
key to access the selected function;
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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 to exit;
and
keys. Upon completion press
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 to access it; the screen will show: A B
key
Fig. 5-14 A) represents the load in kN; B) represents the gain multiplication constant.
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;
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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.
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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;
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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 recalibrated 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;
B A
Fig. 5-18
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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; 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:
2.
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
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5.
Press A
key to access the CALIBRATION function; the screen will show: B
Fig. 5-21 A) represents the load in kN; B) represents the gain multiplication constant.
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;
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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.
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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;
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12. The screen will show: A B
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;
B A
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.
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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 5m 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.
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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.
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5.2.7
Replacing the oil of the hydraulic circuit
Periodically the oil of the hydraulic circuit must be completely replaced. 1. Discharge the old oil via the drainage screw (size 18mm spanner);
Drainage screw (view from below) Fig. 5-30
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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 Agip Api Chevron Elf Exxon Fiat Fina Gulf IP Mobil Shell Total Vanguard Type ATF Dexron Apilube ATF Dexron Chevron automatic transmission fluid Elfmatic G Automatic transmission fluid GI/A Dexron ATF Automatic transmission fluid Dexron fluid ATF 220 ATF Dexron II Dexron 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);
Oil refil port
Oil level indicator
Fig. 5-31 5. Top up if necessary.
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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: 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.
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6.1
Troubleshooting
The following table provides a list of possible causes and checks in case a faulty condition is encountered:
Type of fault The WIZARD BASIC does not turn ON
The WIZARD BASIC turns ON but the display remains completely blank
The WIZARD BASIC turns ON but the keyboard does not accept commands from the operator The load values on the display are always zero, or always full scale, or unstable
The load values on the display are not accurate
Actions 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. 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) 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). 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). Check the system calibration (See chapter 5.2.5)
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Type of fault The internal printer does not print
Actions 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 Check the status of the connection cable between WIZARD serial port does not receive BASIC and PC serial port, that it is properly attached on both data or does not receive them sides and that it is of the Pin-to-pin type; correctly 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 See chapter 6.1.1. maximum admitted load The rapid approach speed is See chapter 6.1.2. out of specification The load does not increase Possible cause: sticking of the floating piston, see chapter 6.1.3. uniformly The load increases at Possible cause: sticking of the floating piston, see chapter 6.1.3. maximum speed even if the flow control knob is adjusted for intermediate positions (it is not possible to control the load gradient) Oil leakage from below the Possible cause: wearing or breakage of the pin o-ring, see control knob 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.
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Readout unit mains switch
Readout unit line fuse
Readout unit power cable receptacle
Fig. 6-1
Keyboard (on front side)
Display board
5VCC power supply CPU board
Fig. 6-2
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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 remounting tap A.
Fig. 6-3
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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 remounting 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.
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6.1.3
Sticking of the floating piston
NOTE: All the following operations should be made without dismantling the flow control valve from the pump. ) as shown in figure fig below; 1. Unscrew the two threaded taps (one opposite the other)
Fig. 6-4 2. Using 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; below
Fig. 6-5 3. Carefully clean the floating piston and its seating with compressed air and clean the floating piston with liquid detergent. Pay attention not to damage the seating or the piston by scratching them. Simply clean them thoroughly and lubricate; lubricate 4. Lubricate the piston with the same oil used in the pump and replace in its housing (make sure it is facing the same direction as it was originally) and check it can move freely forwards and backwards. Remount and tighten the two threaded taps.
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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
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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.
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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
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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: 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.
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Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Codice ricambio/ Spare part code 68-Q0701/AR06 68-Q0502/R08 68-Q0701/AR05 68-Q0701/AR04 68-Q0701/AR01 68-Q0701/AR02 68-C5012/R27 68-C5012/R24 68-C5012/R25 68-C5012/R26
Descrizione Interruttore Fusibile 1,25AT (scatola di 10 pezzi) Alimentatore 5VCC Tastiera Scheda CPU WIZARD BASIC Display LCD Gruppo pompa Motore pompa con pulsante di emergenza 230VAC/50Hz Motore pompa con pulsante di emergenza 110VAC/60Hz Motore pompa con pulsante di emergenza 220VAC/60Hz Guarnizione pompa Valvola regolatrice di flusso Kit ricambi valvola manuale
Description
68-C5012/R13 68-R0031/B1 50-R0031/K 68-C5012/R14 68-C5012/R08 68-C3100/R07 82-P0354 82-P0354/ELT
Mains switch Fuse 1,25AT (pack of 10 pieces) 5VCC power supply Keybopard CPU board WIZARD BASIC LCD Display Pump assembly Pump motor with emergency button 230VAC/50Hz Pump motor with emergency button 110VAC/60Hz Pump motor with emergency button 220VAC/60Hz Pump gasket Flow adjustment valve Manual valve spare parts kit Piston overtravel Microswitch extra-corsa pistone microswitch Olio ATF ATF oil Tubo connessione idraulica Hydraulic connection tube Trasduttore di pressione 700 Pressure transducer 700 Bar Bard Cavo trasduttore di pressione Pressure transducer cable
Q.t in una macchina/ Q.ty in one unit 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 Lt. 1 1 1
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1 2
Fig. 7-1
4 6
Fig. 7-2
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Fig. 7-3
8 9 10
12
Fig. 7-4
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14
18 17
Fig. 7-5
16
11
Fig. 7-6
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8.
SCHEMATICS AND DRAWINGS

1. 2. 3. 4. 5. Control board (CPU) layout Readout unit electrical diagram Readout components identification Motor electrical diagram Load sensor cable pinout
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CPU BOARD LAYOUT
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READOUT UNIT ELECTRICAL DIAGRAM
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READOUT UNIT COMPONENTS IDENTIFICATION
COMPONENT NAME 1FU2 1GD2 1QS2 1SC1 1SC3
COMPONENT DESCRIPTION CONTROL UNIT FUSE 1,25AT SWITCH MODE POWER SUPPLY 12VCC 2,5A SWITCH CONTROL CONSOLE CPU BOARD SIGNAL CONDITIONING BOARD CONTROL BOARD LCD TOUCH PANEL
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MOTOR ELECTRICAL DIAGRAM
EMERGENCY BUTTON
MAINS INPUT
MOTOR SWITCH
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LOAD SENSOR CABLE PINOUT
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Notes:
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CTM Manual (Compression Machine)

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Digital Semi-automatic Compression Machine with Readout unit

MANUALE DI ISTRUZIONI INSTRUCTION MANUAL

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

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

Shipment ............................................................................................................................ 30 Unpacking and inspection.................................................................................................. 31

4. USE OF THE EQUIPMENT

Serial port .......................................................................................................................... 50 i

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Use of the integrated printer Q0701/UP2 (optional) ......................................................... 51

Operators preventive maintenance .................................................................................. 57

Authorized service engineer maintenance actions ............................................................ 61

6. DIAGNOSTICS & TROUBLESHOOTING

7. SPARE PARTS 8. SCHEMATICS AND DRAWINGS

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Icons appearing in the manual

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Manual revision history

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Conformity to the CE Directive

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Intended use and improper use

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Lever A to release piston pressure

Max pressure valve

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Front fragment guard

Fig. 1-4 Access panels equipped with screws.

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Personnel responsible of transportation and moving of the equipment

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

WARNING: Do not stand under suspended loads

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzioni WIZARD BASIC Instruction Manual WIZARD BASIC

Wizard Basic Rev.4 EN

Manuale di Istruzione WIZARD BASIC Instruction Manual WIZARD BASIC

Compression platens and ball seating