Manual Gyrocompactador

76-B252X, 76-B252X/E, 76-B252X/A, 76-B252X/AE
Gyratory Compactor
MANUALE DI ISTRUZIONI INSTRUCTION MANUAL
Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP
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 ...................................................................................... 13 CE declaration ................................................................................................................... 14
2. DESCRIPTION
2.1 2.2 2.3 2.4 2.5
15
System block diagram........................................................................................................ 17 Connections ....................................................................................................................... 18 Identification plate ............................................................................................................. 19 Commands and controls .................................................................................................... 20 Technical specifications..................................................................................................... 22
3. INSTALLATION
3.1 3.2 3.3 3.4 3.5 3.6 3.7
23
Shipment ............................................................................................................................ 24 Unpacking and inspection.................................................................................................. 25

3.2.1 How to remove the equipment from the shipping crate ................................................. 26
Assembling-positioning of the unit and space requirements ............................................. 28 Electrical requirements ...................................................................................................... 31 Electrical connections ........................................................................................................ 32 Connecting the compressed air source............................................................................... 33 Installing the GYROCOMP software ................................................................................ 34
4. USE OF THE EQUIPMENT

4.1 4.2
38
Switching ON the equipment............................................................................................. 39 Description of the GYROCOMP operators interface ....................................................... 40

4.2.1 4.2.1.1 4.2.2 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.3.4 4.2.4 TEST RUN menu ........................................................................................................... 41 TEST PERFORMANCE menu ...................................................................................... 44 FILE MANAGER (TEST ARCHIVE menu) ................................................................ 50 OPTIONS menu ............................................................................................................. 53 SELECT LANGUAGE screen ....................................................................................... 53 OPERATOR NAME screen ........................................................................................... 54 DATE AND TIME screen ............................................................................................. 55 TEST OPTION screen ................................................................................................... 56 MANUAL COMMANDS menu .................................................................................... 57
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Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP 4.2.4.1 4.2.4.2 4.2.4.2.1 4.2.4.2.2 4.2.4.3 4.2.4.3.1 4.2.4.3.2 MOULD ROTATION option ......................................................................................... 58 CHANNELS READOUT option ................................................................................... 60 HEIGHT (SAMPLE) option .......................................................................................... 60 LOAD option.................................................................................................................. 61 PISTON CALIBRATION menu .................................................................................... 62 HEIGHT (SAMPLE) option .......................................................................................... 63 LOAD option.................................................................................................................. 66 Description of main screen ............................................................................................. 70 Menu bar ........................................................................................................................ 70 Machine status bar .......................................................................................................... 71 Main menu bar ............................................................................................................... 71 Real time readout for GYROCOMP machine ................................................................ 72 MANUAL COMMANDS/SOFTWARE SETTINGS .................................................... 73 TEST PERFORMANCE (REMOTE mode) .................................................................. 75 Data import (tests performed in Local mode on GYROCOMP) .................................... 79 Test database management ............................................................................................. 80 Single test elaboration .................................................................................................... 82 Test group comparison (mix design) .............................................................................. 83 Mix, Client and Procedure Database management ......................................................... 86 Serial port setting for printer .......................................................................................... 87 Serial port setting for PC connection.............................................................................. 88 USB port......................................................................................................................... 88 Changing the lower and upper platens ........................................................................... 90 Preparing the sample ...................................................................................................... 94 Executing the test in LOCAL mode (via commands on the touchscreen display) ....... 104 Executing the test in REMOTE mode (via commands on the computer)..................... 110
4.3
Description of the GYROCOMP software ....................................................................... 69

4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.1.4 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8
4.4
Serial port .......................................................................................................................... 87

4.4.1 4.4.2 4.4.3
4.5
Carry out a test .................................................................................................................. 89

4.5.1 4.5.2 4.5.3 4.5.4
4.6 4.7
Stopping the equipment via the Emergency button ........................................................ 113 Switching off the unit...................................................................................................... 114
5. MAINTENANCE
5.1
5.1.1 5.1.2 5.1.3 5.1.4 5.1.5
115
Operators preventive maintenance ................................................................................ 116

Cleaning of the sample mould and relevant accessories .............................................. 117 Cleaning of the upper piston and relevant rollers ......................................................... 118 Cleaning of the lower plate and relevant surrounding .................................................. 119 Empting of the compressed air filter ............................................................................ 120 Checking the status of the safety devices ..................................................................... 121 Checking the gyratory angle......................................................................................... 123 Checking the calibration ............................................................................................... 124 HEIGHT (SAMPLE) option ........................................................................................ 126 LOAD option................................................................................................................ 128
5.2
Authorized service engineer maintenance actions .......................................................... 122

5.2.1 5.2.2 5.2.2.1 5.2.2.2
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6. DIAGNOSTICS & TROUBLESHOOTING

6.1
6.1.1 6.1.2 6.1.3 6.1.4
130
System (Hidden) menu .................................................................................................... 131

ADC CHANNELS SETTINGS option ........................................................................ 133 SERIAL NUMBER option .......................................................................................... 134 MEMORY RESET option ........................................................................................... 135 ARCHIVE RESET option ........................................................................................... 136
6.2
Troubleshooting ............................................................................................................... 137
7. SPARE PARTS 8. SCHEMATICS AND DRAWINGS
138 145
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Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP
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.
The gyratory compactor is used for research and testing of the compactability of granular materials, like no-slump concrete, soil, pavement materials and other similar materials. The measuring results give information of the compaction properties of a mass. The GYROCOMP compacts the sample with a shear-compaction principle. Compaction requires two distinct and essential elements: pressure and shear movement. Shear movement under pressure permits particles to move closer to one another and into more closely packed position. The force (F), applied to a material, is obtained by compressing the mass in a test cylinder between top and bottom plates. Gyratory movement of the cylinder during a test creates the required shear. Compaction with the gyratory principle can be represented as follows: The geometric form of the work sample is a cylinder with slightly inclined ends. This inclination () rotates around the central axis of the sample cylinder during the test, one complete rotation being defined as a work cycle. A known amount of shear movement is produced with every work cycle. Internal shear is illustrated in the figure beside, in which the sample is divided into finite elements. Shear occurs as each element slides relative to the adjoining elements. The sample can be used for further testing and experiments if desired. Main features of the GYROCOMP are: High productivity Compact and lightweight High reliability and accuracy Certified EN and AASHTO (depending on the model) Full safety and ergonomics Integrated electro-mechanical extruder (standard or optional, depending on the model) Calibrated by exclusive ILS.
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The GYROCOMP allows the adjustment of the vertical pressure on the sample, the mould rotation speed and the mould gyratory angle, granting a perfect calibration of all the parameters and the test performance conforming both to AASHTO T312/Superpave procedure and EN 12697-31, and its supplied complete with traceable calibration certificate of vertical load and internal angle, performed with the exclusive ILS device conforming to EN 12697-31 Annex C procedure. GYROCOMP grants high test repeatability. The unit is equipped with a touchscreen control panel that makes the interface easy and user-friendly, showing the test graph in real time, and allows, when needed, the connection and a remote test control by PC. On board firmware includes 12 standard languages and the software language can be user set making the interface adapt to any user needs. The machine is easy to adjust and calibrate. All the test parameters are displayed in real time during the test, and all the settings are easily accessible on the machine, with specially dedicated procedures to make all the verification procedures easy and userfriendly. The new worktop with integrated motorized extruder allows the reduction of the working time between two test, due to the fast, safe and powerful mould extraction. The safety of the machine is dramatically increased by a safety door, heavy duty to resist accidental damage and transparent to allow the user to monitor constantly the test performance. The safety door is mounted on sliding rails, and its provided with a handle, for easy use. A safety switch included in the door prevents the machines operation when the door is open. 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 1.10 April 2011.
Fig. 1-1
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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. 24 June 2011 Change description First manual release
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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 button
Dangerous voltage
Hand injury
Hot surface
Conformity to the CE Directive
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1.4
Intended use and improper use

The GYROCOMP can only be used to compact granular materials, like soil, pavement materials and other similar materials according to the Standards EN 12697-31 and AASHTO T312/Superpave. The unit is designed to be operated by one operator that has to load the hot material into the mould, install the mould into the machine, start the test, unload the mould from the machine and extrude the sample from the mound (e.g. using the sample extruder that can be supplied with the equipment). During normal operation the working area of the equipment is the front side and the righthand 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, once pressed, turns OFF the equipment thus stopping all movements of the equipment (e.g. mould motor, extruder motor, pneumatic actuators, etc.); Sliding door equipped with safety microswitch that, when the door is open, stops the mould motor; Detachable upper plate of the sample extruder to protect the operators hands in case the extruder is inadvertently activated without the mould; Access panels to internal devices fixed with screws.
EMERGENCY button
Sample extruder with removable upper plate
Safety microswitch for sliding door
Fig. 1-2
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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
Technical personnel
Area with residual risks The mould and the material to compacted as they must be pre-heated at approx. 150C (refer to the suitable standard) before installing into the equipment. Use suitable personal protection devices (e.g. thermal gloves, etc.). The upper plate of the sample extruder although it is detachable. Never activate the sample extruder when the mould is not mounted on the extruder itself. Above listed areas 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.
Personnel responsible of transportation and moving of the equipment
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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: Raising and moving of the equipment must be performed by people properly trained and equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to follow the instructions above may endanger the personnel involved.
WARNING: The wooden crate is high; be careful in balancing while raising it.
WARNING: If the instructions to remove the equipment from the shipping box are not carefully followed, damages to the equipment cabinet may result. This will void the warranty terms of the equipment.
WARNING: Do not stand under suspended loads
WARNING: Considering the weight of the equipment and the footprint (see chapter 2.5), check the maximum allowed floor load before installation.
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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.
WARNING: For safety reasons, opening the front cover will disable all movements.
WARNING: The CALIBRATION menu is reserved to the authorised service personnel and should only be entered when the calibration needs to be changed. CONTROLS will not be responsible for any damage caused by improper setting of these parameters. Warranty will be void if this menu is used by unauthorised personnel.
WARNING: Both sample material and mould must be pre-heated in a oven at approx. 150C before performing the test (refer to the suitable standard). Use suitable personal protection devices (e.g. thermal gloves) to handle sample and mould.
WARNING: Do not extract the sample when it is cold. Temperature should not be lower than 50C. Extraction of cold sample can damage the extraction unit. If asphalt is cold, it is necessary to heat the mould with the sample in the oven. Use personal protection devices (e.g. thermal gloves) to handle the sample mould.
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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: 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: 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: Do not use the MEMORY RESET function unless authorized by CONTROLS Service department. CONTROLS will not be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed.
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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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 separately from other rubbish at the end of its useful life. Therefore, at the end of its useful life, the owner should dispose of the product in a suitable collection point for electrical and electronic products provided by the local authorities. The correct disposal posal of this product and the subsequent treatment encourages the manufacture of products using re-cycled re cycled materials and limits the environmental impact of the product caused by improper disposal. Improper disposal of the product is subject to penalties as foreseen by the local 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. 8 1 2 9 10 11 3 12
13
Right-hand panel 5 14 6 15 7
16 17
18 Rear panel Fig. 2-1 B2522 with electromechanical extruder code B2520/15 (optional)
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Rif 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Description EMERGENCY button Touch screen display START push button STOP push button Upper plate Turn-table Sample extruder push buttons (UP-DOWN) Mains switch Compressed air pressure regulator POWER ON lamp USB port (for printer connection) RS232 serial port (for PC connection) Gyratory angle indicator Power cord socket with line fuses Compressed air input Output socket for sample extruder power cord Compressed air filter (5m) Turn-table speed adjustment
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2.1
System block diagram
Fig. 2-2
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2.2
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
Left-hand panel
Rear panel Fig. 2-3 Rif 1 2 3 4 5 Description USB port (for printer connection) RS232 serial port (for PC connection) Power cord socket Output socket for sample extruder power cord Compressed air input
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2.3
Identification plate
The identification plate is located on the rear side of the equipment, near the power cable.
Rear panel
Fig. 2-4
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2.4
Commands and controls

This chapter describes the commands and controls of the equipment. The operators interface description and the use of the keys of the control unit is provided in chapter 4.2 of the present manual.
6 1 7 2 8
Right-hand panel
5 10
Rear panel
Fig. 2-5
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Rif 1 2 3 4 5 6 7 8 9 10
Description EMERGENCY button Touch screen display START push button STOP push button Sample extruder push buttons (UP-DOWN) Mains switch Compressed air pressure regulator POWER ON lamp Gyratory angle indicator Turn-table speed adjustment
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2.5
Technical specifications
Main characteristics
Product Manufacturer Product code 230VAC/50-60Hz Product code 110VAC/60Hz Reference standard Single-phase line voltage Power Motorized extruder Compacted specimen size Sample height Consolidation pressure Angle of gyration Speed of gyration Number of gyrations Compressed air Method of power entry Computer connection Acoustic pressure Net weight (machine only approx.) Overall dimensions machine (W x D x H) Overall dimensions motorized extruder (W x D x H) Optional B2522 B2524 AASHTO T312, SHRP M-002
GYROCOMP Gyratory compactor CONTROLS Cernusco s/N (MI) Italy B2522/E B2524/E EN12697-10 EN12697-31 B2522/A B2524/A AASHTO T312, SHRP M-002 B2522/AE B2524/AE EN12697-10 EN12697-31
110 or 230 VAC +6%, -10% 1000 W Optional Included Included
150 100mm dia. 80 to 170mm (150mm dia.); 50-125 (100mm dia.) 80-800kPa (150mm dia.); 160-1400kPa (100mm dia.) Adjustable from 0.70 to 1.40 deg; factory set to: 1.16 internal 1.16 internal 0.82 internal 0.82 internal 1.25 external 1.25 external 15-60 RPM 0-999 Minimum 8 bars continuous, 100 litres/min Power cable with plug Serial port RS232 70 dB(A) 100 Kg 500 mm x 615 mm x 1070 mm 500 mm x 750 mm x 810 mm
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 [Kg] 170 125 Overall dimensions [mm] 800 x 800 x 1350 1050 x 800 x 1250 Minimum fork lift length [mm] 1200 1200
Model GYROCOMP all models Motorized extruder code 76B2520/15
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 GYROCOMP all models Motorized extruder code 76-B2520/15 Net weight 100 Kg 50Kg
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 horizontal bar located on top of it. Do not lift it by any other part to avoid damaging the equipment (see Fig. 3-2). 5. The motorized extruder can be removed by using a fork-lift.
Horizontal bar
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
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3.3
Assembling-positioning of the unit and space requirements

WARNING: Considering the weight of the equipment and the footprint (see chapter 2.5), 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/electronic components 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. The GYROCOMP is shipped dismounted from the motorized extruder (optional) that also acts as base stand. First fix the base stand to the floor by using proper fixing bolts and making reference to the drawing below.
Fig. 3-3
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Then raise the equipment with a proper mean using a rope engaging the upper bar on the unit and fix it to the base stand (e.g. extruder) by using the 4 x M8 screws and relevant washers provide (see next drawing, GYROCOMP unit viewed from below).
Fig. 3-4
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Fig. 3-5 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.
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
Electrical requirements
The next table shows the electrical specifications of the equipment:
Item Mono phase voltage Frequency Maximum power
Specifications 110 or 230VAC +6%, -10% 50Hz/60Hz 1000 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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3.5
Electrical 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
Right-hand panel 3
Rear panel Fig. 3-6 Rif 1 2 3 4 Description USB port (for printer connection) RS232 serial port (for PC connection) Power cord socket Output socket for sample extruder power cord
NOTE: When the machine is installed for the first time, it is recommended to leave the machine ON for at least 8 hours so as to fully charge the internal battery. In case it get discharged, the clock on the display will be zeroed.
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3.6
Connecting the compressed air source

1. Attach the unit to a compressed air source through the relevant connector located on the rear side of the equipment (ref. 1 in following figure) using the tube with proper fitting provided with the equipment; Make sure that the compressed air source is able to provide minimum 8 bars continuous, 100litres/min; Adjustment of the pressure is carried out before starting the test (refer to chapter 4.5.3 or 4.5.4), acting on the knob of the pressure regulator (ref. 2 in next figure).
2. 3.
Right-hand panel
Rear panel Fig. 3-7 Rif 1 2

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Description Compressed air port Compressed air pressure regulator 33

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3.7
Installing the GYROCOMP software

The minimum requirements of the PC are the following: Operating system Windows XP or Windows Vista or Windows Seven (32-64 bit) 250GB hard disk 1GB of RAM memory (2 GB with Windows Vista or Windows Seven) CD - ROM 1 free RS232 serial port or USB RS232 converter.
Installation procedure: 1. Insert CD ROM in the PC. After a few seconds the installation program will start up automatically. If it does not start up, open the file D:\SETUP.EXE (where D:\ indicates the CD ROM being used). Next follow the simple instructions given on the screen;
Fig. 3-8
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Fig. 3-9
2. ;
Press NEXT to start the installation process (f necessary by clicking on BACK one can return to the previous menu);
Fig. 3-10
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3.
Tick on the ACCEPT THE TERMS OF THE AGREEMENT and press NEXT to proceed;
Fig. 3-11 4. Enter the requested information and press NEXT to proceed;
Fig. 3-12
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5.
Review the information shown on the display and press INSTALL to proceed;
Fig. 3-13 6. When the installation is complete the following window will appear;
Fig. 3-14 7. Click on FINISH to end the process. 8. The installation program has created a new file named GYROCOMP in the programs list. At the same time the program is inserted in the bar of programs. Re-start the PC before entering the program for the first time; 9. Set the COM port by referring to chapter 4.3.2.
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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 connections have been correctly done, switch ON the unit via the mains switch located on the right hand side of the equipment; the white POWER ON pilot light will lit;
Mains switch
POWER ON pilot light
Fig. 4-1 2. The display will show the CONTROLS logo for a few seconds and then the main menu appears;
Fig. 4-2 3. If required, launch the GYROCOMP software by double-clicking on the relevant icon on the PC screen and enable the remote mode: the unit will emit a beep and the message REMOTE will appear on the touchscreen display (top row). Refer to chapter 4.3 for the explanation of the GYROCOMP software. NOTE: When the machine is installed for the first time, it is recommended to leave the machine ON for at least 8 hours so as to fully charge the internal battery. In case it gets discharged, the clock on the display will be zeroed.
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4.2
Description of the GYROCOMP operators interface

The GYROCOMP can be fully controlled by means of its the touchscreen display located on the front panel. It can also be controlled by using the GYROCOMP software, supplied with the equipment and installed on a PC (refer to chapter 4.3 for the relevant description). The main menu of the touchscreen display offers five choices: o TEST RUN: This menu is used to perform the test. It allows the choice of the type of test, the type of sample with the relevant description and finally to perform the test with the acquisition and elaboration of the relevant data; o FILE MANAGER: This menu allows accessing to the data stored in the test archives; o OPTIONS: This menu allows setting date & time, language, units, operator name and parameters for data transmission to PC and/or printer; o MANUAL COMMANDS: this menu allows activating/de-activating the turntable motor and to read its speed, moving the piston up and down and reading the transducers (Channel 1: Pressure-vertical load; Channel 2:sample height). It also allows accessing to the CALIBRATION menu (the latter is password protected); o INFO: it shows a screen with general information and the version of the firmware installed on the equipment. The system is equipped with a touch screen display that allows activating the different functions just touching the relevant icons on the screen. To activate the icons on the screen use the pointer provided with the equipment or a finger. A soft touch is enough to activate the function. NOTE: Hitting the screen heavily may damage it. Never use a pen or a sharp object as damage may result. The warranty will be void in case the screen is damaged due to improper use.
WARNING: For safety reasons, opening the front cover will disable all movements.
Touch the CONTROLS icon previous menu. Touch this icon to return to previous screen
in upper-left corner on the screen to return to
Fig. 4-3 Below the options present in the MAIN MENU are described in detail. The CALIBRATION menu is described in chapter 5.2.2.
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4.2.1
TEST RUN menu

On the main menu press on the icon following screen will appear: to activate the TEST RUN menu; the
Fig. 4-4 The SPECIMEN DATA screen allows the input of descriptive and dimensional characteristics of the sample and the input of the test parameters. Touch on the area of the parameter to modify (the relevant field will be highlighted), use the buttons and to set the parameters, use the buttons and
to move among the different digits of the alphanumeric fields.
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List of input parameters: NO TEST: numerical value which can be between 0 and 65535; ID: is an alpha-numerical identification code made up of 10 characters. During input use the buttons and buttons to select the characters; to move the cursor and the and
DIAM.: sample diameter selectable between 100 and 150mm; WEIG.: weight of the sample used to calculate the density; AGE: age of the sample in MIN; T: temperature of the sample in C; MAX. THEOR DENSITY: maximum theoretical density of the sample; ANGLE: gyratory angle that can be set from 0,7 to 1,4 approx; this value must match the angle set into the equipment and readable on the index located on the right hand side of the (see ref. 9 of Fig. 2-5); LOAD: load applied on the sample; it can be set between 50-1000kPa; CYCLES:duration of the test in number of cycles; it can be set between 2 and 999 cycles; EXTRA: number of extra cycles to carry out after the end of the test (e.g. after the number of CYCLES has been carried out) with the sample still loaded; END T.:criteria to end the test; it can be selected among: - HEIGHT L: the test will be ended once the indicated sample height is reached, even if the number of cycles set for the test is not reached yet (value can be set between 0 to 300 mm); - DENSITY L: the test will be ended once the indicated sample density is reached, even if the number of cycles set for the test is not reached yet (value can be set between 0 to 9999 kg/m^3); HEIGHT L and DENSITY L Activation of one of the 2 target value disabile the other one; NOTE: descriptive alphanumeric field.
Once all settings are done, press the CONTROLS logo of the screen to exit from the SPECIMEN DATA menu. on the upper-left corner
Fig. 4-5
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The system will require a confirmation; pressing ACCEPT, the set parameters will be stored; pressing ABORT, the set parameters will not be stored and the system reverts to the previous parameters;
Fig. 4-6 At the end of this phase the system will show the screen TEST PERFORMANCE that will allow starting the test on the sample.
Fig. 4-7
NOTE: The message LOCAL shown on the upper part of the screen indicates that the equipment is controlled by the commands present on the touch screen. The machine can also be controlled by an external PC and, in this case, the message REMOTE will be shown in the upper part of the. Switching between LOCAL and REMOTE mode can only be achieved by acting on the software on the PC (see chapter 4.3) when the unit is set into the MAIN MENU.
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4.2.1.1
TEST PERFORMANCE menu

Once all the desired settings have been made, the GYROCOMP will enter the test screen. The type of test depends on the selection made in the previous screen. This is the main function of the unit, it allows the acquisition of the data during the test and to make the relative calculations in real time. The following screen is shown and is made up of the following components: 2
1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

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Fig. 4-8 Date and time Record number (number of tests stored in the memory) Test identification Sample diameter Number of cycled carried out/total Pressure value Turn table speed Sample height (updated in real time) Calculated density Percentage of the theoretical maximum density (if set into the MAX. THEOR DENSITY) Percentage of the void content (if set into the MAX. THEOR DENSITY different than 0) Sample height axis Graph area Cycle number axis ABORT TEST push button NEW TEST push button TEST RESULT MANAGEMENT push button Shortcut to OPTION screen. 44
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The reading of the height of the the sample and the load according to the number of cycles carried out is updated realtime. realtime If the load value goes outside the +/+/ 5% of the set value, the relevant reading will blink. blink When this screen is shown, show the unit is ready to start the test. It is possible sible to exit this status by pressing the icon ; on the screen. The system will behave the same way as the test has been completed and the message TEST COMPLETED will be shown on the screen. screen The other icons present on the screen are not active. active To start the test press the green START push button on the equipment front panel. panel The start up of the turn table rotation is delayed with respect to the application of the load on the sample by the piston. piston When the test starts, the display will show the following screen with the message TEST IN PROGRESS.
Fig. 4-9
NOTE: During the execution of the test, the icons shown on the right side of the screen are not active. The test can be stopped by pressing the STOP red d push button located on the equipment front panel.
During the whole execution of the test, except for the first 30 seconds, the equipment checks the proper maintenance of the load with respect to the value set into the SPECIMEN DATA menu. The value should not vary more than +/+/ 250 N with respect to the set one. A bigger difference will not stop the test that will be completed; the message ATT. PRESSURE! will be shown on the bottom of the screen.
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The test will end when: the he set number of cycles have hav been reached, or the set HEIGHT limit has been reached, or the set DENSITY limit has been reached. reached The TEST COMPLETED message will be shown on the display.
Fig. 4-10 At the end of the test, or upon stopping stopping the test, the piston will return to the initial position (up). At this point it will be possible to: Start a new test by pressing the icon ; this action cause the appearing of a popup that will allow entering the sample weight; weight Access the FILE MANAGER MANAG menu by pressing the icon show the following popup pop on the screen: ; this action will
Fig. 4-11
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To save the test in the memory press the button ; upon doing this you will note that the number of saved test files will increase by one. . It is possible to store up to 65535 tests ests, any attempt to memorize more than this number will result in i the test file not being saved; To send the same report in ASCII format to a PC via the RS232 serial port press the button on the screen;
To print a test report on the A4 printer via the USB port (if enabled) press the icon . Before doing this check that the printer is connected to the USB port, it is switched ON and on line. The function above descrive are influences by the setting in the TEST OPTION menu. (chapter chapter 4.2.3.4).
Press the icon to close this window and return to the TEST PERFORMANCE menu.
Pressing the icon
will cause the he display of the following popup: pop
Fig. 4-12
Press the icon to access the SPECIMEN DATA menu; ; this can be used in case it is requested to perform a new test with different settings with respect to the previous ones (make make reference to chapter 4.2.1 for further details).
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Press the icon to access the MANUAL COMMANDS screen of the sample HEIGHT sensor (displacement displacement transducer); transducer
Fig. 4-13 With this screen it is possible to: to 1. Raise and lower the piston by means of the icons and desired direction (the selected command will be highlighted); highlighted) ; first select the
Fig. 4-14
Then press the green START push button on the front panel of the equipment to execute the movement; to de-select de the command highlighted lighted on the screen press the red STOP push button on the equipment front panel. panel
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2.
Store the value read by the displacement transducer of the sample mould in use as follows: 1. 2. Press ress the icon ic several times to select the type of sample mould (100mm or 150mm); Place the proper reference spacer (100mm or 150mm) provided with the equipment on the turn table; table Press the icon (the symbol will be highlighted); Press the green START pushbutton to lower the piston; Once the piston will be in touch with the upper side of the reference spacer, spacer press and keep pressed the icon for at least 2 seconds and then release it; the system will require confirmation: confirmation
3. 4. 5.
Fig. 4-15 o o action Press ACCEPT to store the new reading or ABORT to end this action; Press the red STOP pushbutton on the equipment front panel to disable the movement of the piston. piston
NOTE: The reference values for the 2 types of moulds (100mm ( and 150mm) are factory stored and normally do not need to be updated. updated
NOTE: The present screen will only allow activating the MANUAL COMMANDS of the HEIGHT. To access the screen that will allow using the whole set of MANUAL COMMANDS, press the relevant icon on the MAIN MENU screen. screen
Touch the CONTROLS logo the menus above described.
in the upper-left left corner of the screen to exit from
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4.2.2
FILE MANAGER (TEST ARCHIVE menu)
On the main menu press on the icon to activate the FILE MANAGER (TEST ARCHIVE) menu; the following screen will appear. Saved files are stored in the Disk On Module memory. The memory can be used to file up to a maximum of 65535 tests (graph included). Here below there is an example of the file management screen. The main elements are: 1 2
4 5 3
Fig. 4-16 1. 2. 3. 4. 5. Data area Record number (position of displayed test in the memory sequence; 1 to 1000) Data OPTIONS command To display the data of the previous stored test To display the data of the next stored test.
Each test file can be shown on the display, printed on a USB printer or downloaded to a PC through the RS232 Serial Port.
Use the buttons and to scroll through the various stored tests. Each test is identified by as sequential position in the memory (item 2 in the above screen).
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to display the available functions provided within the TEST Press the button ARCHIVE screen (OPTIONS popup).
Fig. 4-17
to erase the test from the memory. Press ACCEPT to confirm or Press the button operation ABORT to abort this operation. Press the button to send the selected test in ASCII format to the PC via the serial port. First make sure that the PC is connected to the RS232 serial port p of the equipment and it is ready to acquire the data. data to print the selected test, Press the button , including the graph grap (the latter will temporary appear on the display). display First make sure that the printer is connected to the USB port of the equipment and that it is on line. line
Press the button Press the button
to show on the display the graph of the selected test. test to show the test data in tabular format.
Fig. 4-18
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Icons Icons
and and
allow accessing to the previous or next line. allow accessing to the previous or next page. page to return to the TEST ARCHIVE
pop press the icon From the OPTIONS popup, screen.
Touch the CONTROLS logo the TEST ARCHIVES menu.
in the upper-left left corner of the screen to exit from
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4.2.3
OPTIONS menu
On the main menu press on the icon following screen will appear: to activate the OPTIONS menu; the
Fig. 4-19 This menu allows the selection of language, input of name or code number of the operator, setting of date and time, setting of test options (unit of measurement, data printout, storage etc).
Touch the CONTROLS logo the OPTIONS screen.
in the upper-left corner of the screen to exit from
4.2.3.1
SELECT LANGUAGE screen
Press the button on the screen and then select the desired language. The languages available in total are 12.
Touch the CONTROLS logo in the upper-left corner of the screen to exit from this screen (press ACCEPT or ABORT to confirm exiting).
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4.2.3.2
OPERATOR NAME screen
Press the button
on the screen and to access this function.
Fig. 4-20 The operator name is one of the pieces of data that is stored in the test file.
To customize this option use the buttons and the buttons and
and
to change the characters
to move from one character to another.
All alphanumerical characters (in upper and lower case) are available together with a number of symbols. Touch the CONTROLS logo in the upper-left corner of the screen to exit from this screen (press ACCEPT or ABORT to confirm exiting).
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4.2.3.3
DATE AND TIME screen
Press the button
Fig. 4-21
Press the buttons and select the parameter to change.
to set the parameters and the button
to
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4.2.3.4
TEST OPTION screen
Press the button
Fig. 4-22
Select the desired field on the screen and press the buttons parameters. The TEST OPTIONS screen includes the following fields: o
and
to set the
AUTOPRINT, AUTOSTORE, AUTODOWNLOAD: allows setting the functions for printout and data transmission as described below: - AUTOPRINT: when ENABLED, activates the print function at the end of the test (via the selected printer); - AUTOSTORE: when ENABLED, activates the automatic saving of the test results at the end of the test; - AUTODOWNLOAD: when ENABLED, activates the communication in ASCII format with the PC; when DISABLED, data transmission will not take place. PRINTER: allows selecting the type of printer in use: o Selecting USB option, data to print will be transmitted via the USB port of the GYROCOMP; o Selecting RS-232C option, data to print will be transmitted in ASCII format via the RS232 serial port of the GYROCOMP (in this case, the thermal printer code 82-P0172 can be used).
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4.2.4
MANUAL COMMANDS menu
On the MAIN MENU press on the icon menu; the following screen will appear:
to activate the MANUAL COMMANDS
Fig. 4-23 This menu allows to: Activate/deactivate the turntable motor and read the relevant speed; speed Read the readings of the different transducers of the equipment; equipment Carry out the calibrations of the equipment transducers trans (see chapter 5.2.2). The front door is equipped with a safety microswitch that stops the mould rotation motor when the door is open. The following message will be shown in case the front door is open while operating with wi the MANUAL COMMANDS menus
Fig. 4-24 Close the door, press OK to continue and the START green pushbutton on the front panel in case a movement has to be carried out.
WARNING: The CALIBRATION menu is reserved served to the authorised service personnel and should only be entered when the calibration needs to be changed. CONTROLS will not be responsible for any damage caused by improper setting of these parameters. Warranty will be void if this menu is used by unauthorised un personnel.
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4.2.4.1
MOULD ROTATION option
Pressing the icon shown:
of the MANUAL COMMANDS the following owing screen will be
Fig. 4-25
to enable the rotation of the turntable; the motor will start after Press the icon pressing the green START push button on the front nt panel of the equipment. equipment
Fig. 4-26
To exit from this status, press the icon
on the screen.
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Press the green START pushbutton on the equipment front panel to activate the rotation of the turntable. While the turntable is rotating, the relevant speed is measured by a magnetic sensor and is diplayed on the screen. Standard speed is 30 RPM approx. and can be adjusted by acting on the speed adjustment knob (item #10 of Fig. 2-5).
Fig. 4-27
Turntable rotation can be stopped by pressing the red STOP pushbutton on the equipment front panel.
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4.2.4.2
CHANNELS READOUT option
to access the MANUAL COMMANDS which , via a pull down Press the icon menu, will allow selecting between the two following options: options HEIGHT (SAMPLE) LOAD (VERTICAL). This menu allows reading the output of the 2 transducers (displacement displacement transducer for the t sample HEIGHT; pressure transducer for the LOAD) and can be used for diagnostic purposes.
4.2.4.2.1
HEIGHT (SAMPLE) option

The reading of the sample height is achieved by means of a potentiometric transducer mounted on the pneumatic actuator. actuator
Fig. 4-28
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4.2.4.2.2
LOAD option
The load value is achieved by means of a pressure transducer located at the output of the compressed air pressure regulator. regulator The load value is displayed even when it is not applied to the sample and has to be intended as the capability of the equipment to apply appl this load to the sample.
Fig. 4-29
The icon
allows setting the unit between N and kPa. The value read as kPa is to set the mould type). type)
influenced by the type of mould m set (press the icon
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4.2.4.3
PISTON CALIBRATION menu
Press the icon screen:
of the MANUAL COMMANDS menu to access the following
Fig. 4-30 Use the pull down menu to select one the following options: HEIGHT (SAMPLE) LOAD (VERTICAL). This menu allows reading the output of the 2 transducers (displacement transducer for the sample HEIGHT; pressure transducer for the LOAD) and to perform the relevant calibration.
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4.2.4.3.1
HEIGHT (SAMPLE) option o

The sample height reading is achieved with with a potentiometric transducer mounted mo on the pneumatic actuator. actuator The icons and allows changing the position (height) of the piston. pis
Fig. 4-31 The icon of the selected movement will be highlighted. highlighted The movement will take place after having activated the power circuitry of the equipment by pressing the green START push button located on the front panel.
Fig. 4-32 The movement of the piston can be stopped by pressing the red STOP pushbutton on the front panel of the equipment. e
NOTE: It is not possible to reverse the movement of the piston without pressing pressi the red STOP pushbutton first.
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ncludes the following icons/functions: The screen also includes Icon to activate/de-activate activate/de the calibration coefficient of the selected channel: channel
pressing the icon causes the application of the calibration coefficient (symbol shown in the icon); ; press the icon again to de-activate de the calibration coefficient (symbol Icon
- shown);
to zero the reading of the selected channel; channel
Icon to access the calibration function (password protected; refer to chapter 5.2.2). This function allows calibrating the the displacement transducer of the sample height;
3. Icon to store the value read by the height transducer depending on the type of mould in use; to perform this function: function 1. 2. Press the icon several eral times to select the type of sample mould (100mm or 150mm); Place the proper reference spacer (100mm or 150mm) provided with the equipment on the turn table; table Press the icon (the symbol will be highlighted); Press the green START pushbutton to lower the piston;
3. 4.
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5.
Once the piston will be in touch with the upper side of the reference spacer, press and keep pressed the icon for at least 2 seconds and then release it: the system will require confirmation: confirmation
Fig. 4-33 o o Press ACCEPT to store the new reading or ABORT to end this action; action Press the red STOP pushbutton on the equipment front panel to disable the movement of the piston.
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4.2.4.3.2
LOAD option
The load value is achieved by means of a pressure transducer located located at the output o of the compressed air pressure ssure regulator. The load value is displayed even when it is not applied to the sample and has to be intended as the capacity of the equipment to apply this load to the sample.
The icons
and
allows changing the position (height) of the piston. pis
Fig. 4-34 he icon of the selected movement will be highlighted. The The movement will take place after having activated the power circuitry of the equipment by pressing the green START push button located on the front panel.
Fig. 4-35
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The movement of the piston can be stopped by pressing the red STOP pushbutton on the front panel of the equipment.
NOTE: It is not possible to reverse the movement of the piston without pressing the red STOP pushbutton first.
NOTE: When moving the piston downward, the reading on the display will be highlighted with the symbol to indicate that the reading is taken while the load is applied.
Fig. 4-36
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The screen also includes the following icons/functions: Icon to activate/de-activate activate/de the calibration coefficient of the selected channel: channel
pressing the icon causes the application application of the calibration coefficient (symbol shown in the icon); press the icon again to de-activate de the calibration coefficient (symbol Icon
- shown);
to zero the reading of the selected channel; channel
Icon to access the calibration function (password protected protec refer to chapter 5.2.2). ). This function allows calibrating the pressure transducer;
WARNING: The CALIBRATION menu is reserved to the authorised service personnel and should only be entered when the calibration needs to t be changed. CONTROLS will not be responsible for any damage caused by improper setting of these parameters. Warranty will be void if this menu is used by unauthorised personnel.
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4.3
Description of the GYROCOMP software

The GYROCOMP software allows to: 1. Elaborate laborate and print results coming from tests performed locally on GYROCOMP then imported into the software; software 2. Perform erform tests by controlling in remote mode the GYROCOMP machine. The connection between the machine and the PC is achieved via the RS232/C serial seria port (item #2 of Fig. 3-6 3 ) and a serial port on the PC. The serial interconnection cable is supplied with the equipment. equipment Its configuration is pin to pin. If the PC does not have a serial port, an RS232/C serial-USB USB connector can be used (not supplied with the equipment). The status of the machine (LOCAL: controlled by the touchscreen display; REMOTE: controlled by the PC) is shown in the upper row of the touchscreen display.
Fig. 4-37 Switching from one status to the other (LOCAL-REMOTE) can only be done when the machine is set into the MAIN MENU or the TEST PERFORMANCE menu. The correct sequence to activate the machine and the software is: Turn ON the machine and wait until the MAIN MENU appears on the display; Run the software by double-clicking double clicking on the relevant icon on the PC desktop. The CONTROLS logo will appear on the PC screen. Once the connection is established, the GYROCOMP will emit an audible beep and its display will show the TEST PERFORMANCE screen with the message REMOTE on the top row.
Fig. 4-38
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4.3.1
Description of main screen

The following picture shows the main screen of the GYROCOMP software.
Fig. 4-39 Here follows the description of the different fields that can be identified on the screen.
4.3.1.1
Menu bar
FILE EXIT: exit from the software; LANGUAGE: language selection from the list; HELP: displays software info (About).
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4.3.1.2
Machine status bar
MOTOR: motor working (green light) or in stand-by (red light); PISTON: piston moving UP or DOWN (green when moving); REMOTE: connection between software and GYROCOMP is enabled (green light); EMERGENCY: Red when a machine malfunction is detected (not used in this version); DOOR: Red when the door safety switch is active (door open); PRESSURE: Red when the detected piston pressure is out from the target (2.5% in stand-by condition, 250N during the test).
4.3.1.3
Main menu bar
Go to MAIN PAGE (TEST PAGE) or, from MAIN PAGE, start a NEW TEST START TEST (active just when Remote mode is enabled) STOP TEST (active just when Remote mode is enabled) SAVE TEST (active just when Remote mode is enabled and the test is performed) Go to TEST DATABASE / Data elaboration MANUAL COMMANDS / Software settings Go to MIXES DATABASE Go to CLIENTS DATABASE Go to PROCEDURES DATABASE
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4.3.1.4
Real time readout for GYROCOMP machine
CYCLES: cycle counter (during the test performance); HEIGHT: sample height / internal LVDT readout (the readout depends on the last test settings defined); DENSITY: sample density readout (the readout depends on the last test settings defined); VOID: % of voids of the compacted sample (the readout depends on the last test settings defined); SPEED: mould rotating speed; PRESSURE: actual load [N] or pressure [kPa] applied to the specimen. The pressure readout depends on the last test settings defined; Software status field.
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4.3.2
MANUAL COMMANDS/SOFTWARE SETTINGS

From the main menu page press the icon SOFTWARE SETTINGS menu. to enter the MANUAL COMMANDS /
Fig. 4-40 Here follows a description of the different functions available: MOTOR: Manually enable/disable motor for mould rotation; this field can be used to check/adjust the speed of the turntable. Press the icon and check the speed from the realtime readout (see chapter 4.3.1.4); adjustment of the speed is achieved by acting on the knob item #10 of Fig. 2-5); SETUP: Set the COM port used to connect GYROCOMP to PC;
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CALIBRATION: Set the offset for height calibration, for 100 or 150mm dia. mould Prepare the mould as described in chapter 4.5.1, then press the icon of the PISTON field (the piston will get in touch with the mould); in the CALIBRATION field tick the diameter of the used mould (100mm or 150mm); then press the icon following popup appears on the screen; to store the new calibration, the
Fig. 4-41 PISTON: Manually move the piston up / down, or stop it; LOCK: Enable connection between software and GYROCOMP, allowing remote control of the machine.
NOTE: To enable the remote control, GYROCOMP has to be switched on, and the GYROCOMP control panel must be in MAIN MENU or TEST PERFORMANCE MENU.
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4.3.3
TEST PERFORMANCE (REMOTE mode)

Check the software is connected to GYROCOMP in remote mode (see chapter 4.3.2). Push the icon to start a new test. A window requiring to input the sample weight appears. Insert the sample weight. It is possible to insert all the test parameters manually, or to select a previously saved TEST PROCEDURE.
By pushing the icon the right side.
, the procedure database is displayed on
Fig. 4-42 From the database, it is possible to select a procedure. From the top bar it is possible to: Select the procedure; Cancel the selection and exit from the database; Create a new procedure; Modify an existing procedure; Delete a procedure (a confirmation message will appear).
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In case of selection of CREATE A NEW PROCEDURE EXISTING PROCEDURE displayed.
or MODIFY AN
, a popup window with all the procedure details is
Fig. 4-43
It is possible to define all the test parameters: SAMPLE DIAMETER: 100 or 150 mm; TEST PRESSURE or Load: usually 600kPa; SAMPLE AGE; CYCLES: duration of the test, depending on the used specifications; EXTRA CYCLES: optional cycles to be applied beyond the test duration, test data are not collected during these cycles; Optional LIMITS (height and density): if a very long duration is chosen, it is possible to stop the test when a target height or density is reached. If the target height or density is not reached, the test will stop when the maximum number of cycles is reached; GYRATORY ANGLE: the angle that has been mechanically set on GYROCOMP TEMPERATURE: the target sample temperature.
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Once the procedure parameters have been defined or selected, it is possible to define the mix property. It is possible to select it from the list (showing the last mixes used) or, if DATABASE is selected, to select it from the full mixes database.
Fig. 4-44 From the database, it is possible to select a mix. From the top bar it is possible to: Create a new mix; Modify an existing mix; Delete a mix (a confirmation message will appear). In case CREATE A NEW MIX or MODIFY AN EXISTING MIX is selected, a popup menu with the Mix details is displayed
Fig. 4-45 It is possible to define the Mix properties: MIX name, to identify the mix in Unique way; FILLER details (description, % on the aggregate mix, specific gravity); AGGREGATE details (description, specific gravity); BITUMEN details (description, specific gravity); NOTES. The GMM (MAXIMUM THEORETICAL DENSITY) is automatically calculated by volumetric way. The BITUMEN CONTENT in volume is automatically calculated.
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To save the new/modified mix, push SAVE. Select the mix (by doubleclicking the mix from the list).
NOTE: It is possible not to select any Mix from the database, by selecting GENERIC from the list. It will be possible to assign the Mix to the test in the test database. In case the mix is not selected, it is possible to input manually the GMM data from the test window in order to calculate/display the %GMM data during the test.
It is now possible to start the test by pushing the button. A confirmation message appears, and to start the test the START green push button on the front side of the machine has to be pushed. During the test, the test results are displayed in real time (CYCLE COUNTER, HEIGHT, DENSITY, % VOIDS, ROTATION SPEED and VERTICAL FORCE or PRESSURE). The graph displays in real time HEIGHT/CYCLES and DENSITY/CYCLES. From the bottom side of the graph is it possible to enable the auto-scale, to change the X and Y axis scale, to enable the logarithmic scale on X axis. At the end of the test, save the test by pushing the disk icon. The test will be added to the test database.
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4.3.4
Data import (tests performed in Local mode on GYROCOMP)

Connect the software to GYROCOMP and enable Remote mode (see chapter 4.3.2). On the main menu page, push the TEST DATABASE DOWNLOAD button. button, then push the DATA
An data import management window will be displayed.
Fig. 4-46
Push the icon to connect the software to the tests saved in GYROCOMP. After the list appears, a window asking if a CSV copy of the test database has to be saved. By checking/unchecking the tests (each row corresponds to one test), select the ones that have to be imported in the software test database (the ones marked with X on the first column).
Once the selection is complete, push to import tests from GYROCOMP. They will appear in the test database, without any Mix assigned to the test.
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4.3.5
Test database management
From the main page, push
to enter the TEST DATABASE page.
The list of the performed tests (saved with the software or imported from GYROCOMP) is displayed.
Fig. 4-47 From the left bar is possible to: Return to the Test Database Page; Go to Single Test Elaboration page; Elaborate Data in Single Test; Export the selected test as CSV file; Return to Main page.
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In the page is it possible to review and manage all the tests in the database. It is possible to: Filter the database by dragging and dropping the column headers to the yellow top bar; icon on the left side of each row; Display the full data for each test, by pushing the If not done before running the test, it is possible to assign a MIX to each test. Once the test is chosen, the MIX data appear on the right side. It is possible to check the mix properties, to choose a MIX from the list or to open and assign a MIX from the database (see Chapter 4.3.3); From the test database, it is possible to assign a client to each mix, choosing it from the CLIENT DATABASE. For the CLIENT DATABASE, see chapter 4.3.8.
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4.3.6
Single test elaboration

From the Test database page, select a test from the list. Then push the test elaboration page. again to enter
Fig. 4-48 From the elaboration page, it is possible to modify the fields highlighted in yellow: GMB (measured), the specific gravity of the compacted sample measured by hydrostatic weight. It allows to increase the density and void data of the performed tests, by adding a correction factor. If blank or zero, the software will measure voids as calculated by the volumetric density; Acceptance criteria (MIN and MAX GMM for 3 different number of gyrations), given by the reference technical specifications. Once the yellow fields are filled, push to elaborate the test and display the graph. It is now possible to print the single test certificate by pushing the PRINT button on the bottom side of the window. The printout window allows to print both test certificate with graph and test table with density and voids results cycle by cycle.
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4.3.7
Test group comparison (mix design)

From the TEST DATABASE window it is also possible to assign different tests to different test groups, to run some comparison between different mixes for Mix Design purposes. It is possible to compare up to 4 group composed by 1 to 4 tests. The tests in each group must be performed on the same mix, and different tests have to be performed with the same test procedure to be comparable. It is recommended that different mixes to be put in comparison have different % of bitumen, in order to make a suitable Mix Design evaluation.
Fig. 4-49 From the TEST DATABASE window, from the panel on the right bottom side it is possible: ADD SELECTED TEST: add the selected test from the database to the comparison. Every test with a new mix will be added to a new group. Every test with an already added mix will be added to the same group; EMPTY COMPARISON LIST: remove all the tests in the comparison; SAVE GROUP IN DATABASE: once the choice is complete, it is possible to save the groups in a Database. A window asking to input the Group name is displayed. LOOK FOR GROUP IN THE DATABASE: to repeat the elaboration of a previously saved Group, it is possible to open it from the database. A window showing the it is possible to see the details of the tests database is saved, and pushing composing the group; ELABORATION: complete the test choice for comparison and pass to multiple test elaboration window.
NOTE: the single tests in the group must be still available in the test database to make this feature available
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Fig. 4-50 By pushing ELABORATION the multiple test elaboration window is displayed.
Fig. 4-51
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From this page it is possible: From the bottom side of the window, fill the yellow cells with the acceptance criteria defined in the reference technical specifications (Min and Max GMM for 3 different numbers of gyrations) Push CALCULATION WITH ACTUAL CRITERIUM in order to update all the graphs and results on the basis of these criteria. The results are calculated. It is possible to elaborate the results in the following way: 1. From the top right side, choose the MIX to be displayed. 2. Push SINGLE GROUP AVERAGE to display the average results for the chosen MIX; 3. Push PRINT AVERAGE to print the average results of the chosen MIX; 4. Push GROUP COMPARATIVE to display the comparative results of the different MIXES (the comparative window will appear).
Fig. 4-52 5. Push PRINT COMPARATIVE to print the MIX comparative results.
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4.3.8
Mix, Client and Procedure Database management
From the main page, it is possible to select to open the CLIENT DATABASE or
to open the MIX DATABASE, to open the PROCEDURE DATABASE.
Fig. 4-53 In each database it is possible to: Create a new MIX/CLIENT/PROCEDURE (a popup window will be displayed see chapter 4.3.3); Modify and existing Mix/Client/Procedure (a popup window will be displayed see chapter 4.3.3); Delete an existing procedure. Once create or modified, the MIX/CLIENT/PROCEDURE will be available for choice in standard operation as described in the relevant chapters.
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4.4
Serial port
The GYROCOMP is fitted with the following communication ports: o Serial RS232C port for Printer or P.C. connection; o USB port for A4 printer.
USB port RS232C port
Fig. 4-54
4.4.1
Serial port setting for printer

Set the PRINTER option in the TEST OPTIONS menu to RS-232C (see chapter 4.2.3.4); the RS-232C port on the rear panel of the GYROCOMP will be set to transmit data to a serial printer with the following settings: 9600 baud, 8 data bit, 1 Stop bit, no parity. All fields transmitted are ended with CR and LF. We recommend our printer 84-P0172 is used.
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4.4.2
Serial port setting for PC connection

The RS-232C port on the rear panel of the GYROCOMP is set to transmit data to a PC with the following settings: 57600 baud, 8 data bit, 1 Stop bit, no parity. All fields transmitted are ended with CR and LF. The data transmission protocol is compatible with the GYROCOMP software provided with the equipment, used to read, process, save and print test results. The software can also be used to control the functioning of the whole equipment (see chapter 4.3)
4.4.3
USB port
The control unit is equipped with a USB port that can be used to connect HP A4 printers to obtain the printout of a test report in A4 format . Recommended printer model is type HP Printer Officejet 6000 or other printers that have the communication protocol HP PCL3 E or PCL3 GUI. In general, printer to use must be as simple as possible (e.g. only printers without integrated scanner and/or USB hub and or LCD display, etc.). Contact CONTROLS to obtain information on other compatible models.
NOTE: The printer must be connected and turned ON before switching ON the equipment as it must be seen by the GYROCOMP during its boot phase.
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4.5
Carry out a test

The present chapter provides a quick guide for the execution of a test. Full details on the various screens and options for both unit used in local mode (commands via the touchscreen display integrated in the unit) and unit used via the GYROCOMP software (PC) are provided in chapters 4.2 and 4.3 respectively.
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4.5.1
Changing the lower and upper platens

The GYROCOMP can perform tests on sample with 150mm diameter and 100mm diameter. All units are standard equipped with upper and lower platens for 150mm diameter samples. B0250/4 must be In case of tests on 100mm diameter sample, the optional kit code 76-B0250/4 purchased. o install the upper and lower platens 100mm diameter (similar procedure Act as follows to to install the 150mm platens): platens) Turn the unit ON and close the front door; From the MAIN MENU select the MANUAL COMMANDS screen and then press icon to select the PISTON CALIBRATION CALIBRATIO menu;
Fig. 4-55
Press the button and then press the START (green) pushbutton on the equipment front panel to lower the piston;
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Open the front door and turn the equipment OFF;
Fig. 4-56 Loosen the 6 bolts on the upper platen and the 6 bolts on the lower platens in order to remove them;
Fig. 4-57 Clean the contact surfaces, install the 100mm sample plates plates and lock them in place by tightening the 6 fixing bolts on each platen;
Fig. 4-58
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After installing the 100mm platens (or 150mm platens), , it will be necessary to store into the system memory a new zeroing for the sample height transducer; first of all prepare a sample mould as shown below (also refer to figure of page 94 for components identification);
End plate
Height calibration device Mould
End plate Distance plate (see table below)
Bottom plate Fig. 4-59

100mm sample Compacted sample ample height 50-70mm 70mm 90-100mm 100mm 150mm sample Compacted sample ample height 80-120 120mm 140-180mm 0mm Number of distance plate(s) 1 0 Number of distance plate(s) 2 1
Fig. 4-60 (Height calibration ion device for 100mm sample)

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Bring the sample mould above prepared carefully into the device between the upper and lower platens, turn ON the equipment and close the front door; From the MAIN MENU select the MANUAL COMMANDS screen and then press icon to select the PISTON CALIBRATION menu;
Fig. 4-61 Select the HEIGHT option within the CHANNEL field; 1. Press the icon 150mm); several times to select the type of sample mould (100mm or
Press the button and then press the START (green) pushbutton on the equipment front panel to lower the piston; the movement will stop when the upper platen will get in touch with the end plate in the sample mould; 2. Press ress and keep pressed the icon system will require confirmation; for at least 2 seconds and then th release it; the
Fig. 4-62 3. Press ACCEPT to store the new reading or ABORT to end this action; 4. Press the red STOP pushbutton on the equipment front panel to disable the movement mo of the piston.
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4.5.2
Preparing the sample

Refer to the suitable Standard to prepare the sample for the test. Both sample material and mould must normally be preheated at approx. 150C (refer to the suitable standard). WARNING: Both sample material and mould must be pre-heated in a oven at approx. 150C before performing the test (refer to the suitable standard). Use suitable personal protection devices (e.g. thermal gloves) to handle sample and mould. The accessories (to be ordered separately from the machine) used to prepare the sample for the test are shown in next picture:
1 6 5
11
2 3 7 4
10
Fig. 4-63 Code 76-B0250/5 Description Accessory for 100mm dia. sample including: #1 Sample mould #2 Distance plate 38mm height for low sample #3 Bottom plate #4 End plates Item #5, extra 100mm dia. distance plate (height 38mm) for low sample (as #2 above) Accessory to compact 100mm dia. sample including: #6 Height calibration device #7 GYROCOMP 100mm upper and lower platens Accessory for 150mm dia. sample including: #8 Sample mould #9 Bottom plate #10 End plates Item #11, 150mm dia. distance plate (height 50mm) for low sample 94
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Here follows the description to prepare a sample for 150mm dia. sample (for 100mm dia. sample use the relevant corresponding accessories): 1. Heat all needed accessory to approx. 150C (refer to suitable standard); 2. Take the bottom plate #9 and lubricate it by using some grease (apply the grease on its flat surface and on the edge);
Fig. 4-64
Fig. 4-65
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3. Place the sample mould into the sample extruder, raise its plate by pressing the ARROW UP pushbutton in order to help placing the bottom plate #9 into the mould;
Fig. 4-66
Fig. 4-67
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4. If needed, place the distance plate #11 (grease it properly);
Fig. 4-68
Fig. 4-69
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5. Take one end plate #10 and place over it a disk paper (this will avoid sticking the sample to the metal parts);
Fig. 4-70
Fig. 4-71
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6. Grease the free side of the end plate #10 and place it over the distance plate #11 (or directly in touch with the bottom plate #9 in case the distance plate #11 is not in use);
Fig. 4-72
Fig. 4-73 7. Lower the extruder plate by pressing the relevant DOWN pushbutton;
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8. Place the mould above prepared on a scale and zero the reading (tare);
Fig. 4-74 9. Then portion a suitable amount of sample into the mould;
Fig. 4-75 NOTE: Avoid separation. Keep the mass well mixed.
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Here follows some considerations on the quantity of sample to pour into the mould: It is recommended to put that much mass into the cylinder, that in the end of the test the height of the specimen is about 150-160 mm (or with reduction plate 100-110 mm) for 150 specimens. If there is too much sample in the cylinder, the compaction process gets slower and it is difficult to compare the result with the previous tests. If the sample reaches a too low height, the vertical force disappear (mechanical end of movement) and the compaction process will stop. The height of the 150 sample depends on the final density and mass amount in the following way: H = (G/) x 56.589 Where: H = sample height, [mm] = sample density, [kg/m3] G = sample weight, [g] for 100 the equation is: H = (G/) x 127.32 Where: H = sample height, [mm] = sample density, [kg/m3] G = sample weight, [g] 10. Take note of the weight of the sample to be input into the system before starting the test; 11. Take the second end plate #10, place over it a disk paper and place them into the mould (the paper must face the sample);
Fig. 4-76
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12. The drawing below summarizes the configuration of the sample mould at the end of the preparation (refer to Fig. 4-63);
End plate (item #10) Paper disk
Sample material Mould (item #8) Paper disk End plate (item #10) Distance plate (item #11, see table below) Bottom plate (item #9) Fig. 4-77 100mm sample Compacted sample height 50-70mm 90-100mm 150mm sample Compacted sample height 80-120mm 140-180mm Number of distance plate(s) 1 0 Number of distance plate(s) 2 1
13. Grease the upper platen and the bearing of the GYROCOMP;
Fig. 4-78
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Fig. 4-79 14. Bring the sample mould carefully into the device between the upper and lower platens. Set the lower end of the mould round the lower platen. The mould is placed correctly, when it covers the lower platen and the upper collar leans against the roller bearings. It is essential to be careful in handling, because the machine is a very accurate instrument and careless handling of the mould may worsen the measuring accuracy.
Fig. 4-80 WARNING: Both sample material and mould must be pre-heated in a oven at approx. 150C before performing the test (refer to the suitable standard). Use suitable personal protection devices (e.g. thermal gloves) to handle sample and mould. 15. Close the front transparent door and proceed with the test by referring to chapters 4.5.3 or 4.5.4.
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4.5.3
Executing the test in LOCAL mode (via commands on the touchscreen display)
1. With the unit ON from at least 15 minutes, press the TEST RUN icon the MAIN MENU to access the SPECIMEN DATA MENU; from
Fig. 4-81 2. Review all test parameters, change if necessary (touch on the area of the parameter to modify, the relevant field will be highlighted, use the buttons and to
set the parameters, use the buttons and to move among the different digits of the alphanumeric fields) , and enter the sample weight taken at step 10 of previous chapter 4.5.2;
3. Once all settings are done, press the CONTROLS logo on the upper-left corner of the screen to exit from the SPECIMEN DATA menu.
Fig. 4-82
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confirmation pressing ACCEPT, the set parameters will be 4. The system will require a confirmation; stored; pressing ABORT, the set parameters will not be stored and the system reverts to the previous parameters; parameters
Fig. 4-83 5. At the end of this phase the system will show the screen TEST PERFORMANCE that will allow starting the test on the sample. sample Adjust the compressed air pressure by acting on the relevant knob on the side panel panel of the equipment (see item #7 of figure 2.5) until the LOAD-PRESSURE set point is reached (the figure on the screen will be shown in reverse when the actual reading is beyond 2% % of the set point and, when in REMOTE, the relevant figure on the PC will be shown in red text); text
Fig. 4-84 6. When this screen is shown, the unit is ready to start the test. test It is possible to exit this status by pressing the icon ; on the screen. The system will behave the same way as the test has been completed and the message TEST COMPLETED will be shown on the screen. The other icons present present on the screen are not active;
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7. To start the test press the green START push button on the equipment front panel. The start up of the turn table rotation is delayed with respect to the application of the load on the sample by the piston. The test can be stopped by pressing the STOP red push button located on the equipment front panel;
NOTE: The reading of the height of the sample and the load according to the number of cycles carried out is updated realtime. If the load value goes outside the +/- 5% of the set value, the relevant reading will blink.
8. When the test starts, the display will show the following screen with the message TEST IN PROGRESS;
Fig. 4-85
NOTE: During the execution of the test, the icons shown on the right side of the screen are not active. The test can be stopped by pressing the STOP red push button located on the equipment front panel.
9. During the whole execution of the test, except for the first 30 seconds, the equipment checks the proper maintenance of the load with respect to the value set into the SPECIMEN DATA menu. The value should not vary more than +/- 250 N with respect to the set one. A bigger difference will not stop the test that will be completed; the message ATT. PRESSURE! will be shown on the bottom of the screen;
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10. The test will end when: the he set number of cycles have been reached, or the set HEIGHT limit has been reached, or the set DENSITY limit has been reached. The TEST COMPLETED message will be shown on the display. display
Fig. 4-86 11. At the end of the test, or upon stopping the test, the piston will return to the initial position (up). (up) At this point it will be possible to: Start a new test by pressing the icon ; this action cause the appearing of a popup that will allow entering the sample weight; weight Access the FILE MANAGER menu by pressing the icon will show the following followin popup on the screen: ; this action
Fig. 4-87
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To save the test in the memory press the button ; upon doing this you will note that the number of saved test files will increase by one. It is possible to store up to 65535 tests, any attempt to memorize more than this number will result in the test file not being saved; To send the same report to a PC via the RS232 serial port press the button on the screen; To print a test report on the A4 printer via the USB port (if enabled) press the icon . Before doing this check that the printer is connected to the USB port, it is switched ON and on line. The function above descrive are influenced by the setting in the TEST OPTION menu. (chapter 4.2.3.4).
Press the icon to close this window and return to the TEST PERFORMANCE menu.
12. Open the door, lift the cylinder off of the lower piston and pull it out off the apparatus in upright position;
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13. Place the sample mould on the extruder (using the horseshoe adapter in case of 100mm diameter sample mould) and press the pushbutton on the extruder to remove the compacted sample from the mould; the thin sheets are removed from the ends of the sample with a twisting motion;
Fig. 4-88
14. Between tests wipe sand and slurry from the mould collar and the end plates with e.g. a paper towel. The mould and the end plates can be used in the next test immediately. In addition, clean the bottom plate of the mould by washing or wiping. Stuck bitumen or similar on the device can be scraped out and wiped with solvent, if needed, also between tests.
NOTE: After cleaning the unit, add slightly oil of vaseline on steel surfaces to prevent corrosion. When you finish testing, wash the parts with water or with a suitable solvent and dry them / apply oil on steel surfaces.
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4.5.4
Executing the test in REMOTE mode (via commands on the computer)

1. Check the software is connected to GYROCOMP in remote mode (see chapter 4.3.2). 2. Push the icon to start a new test. A window requiring to input the sample weight appears. Insert the sample weight. 3. It is possible to insert all the test parameters manually, or to select a previously saved TEST PROCEDURE.
4. By pushing the icon on the right side.
, the procedure database is displayed
Fig. 4-89 5. From the database, it is possible to select a procedure; In case of selection of CREATE A NEW PROCEDURE PROCEDURE or MODIFY AN EXISTING
, a popup window with all the procedure details is displayed;
6. Set the test parameters; 7. Once the procedure parameters have been defined or selected, it is possible to define the mix property. It is possible to select it from the list (showing the last mixes used) or, if DATABASE is selected, to select it from the full mixes database; 8. Adjust the compressed air pressure by acting on the relevant knob on the side panel of the equipment (see item #7 of figure 2.5) until the LOAD-PRESSURE set point is reached (the figure on the screen will be shown in reverse when the actual reading is beyond 2% of the set point and, when in REMOTE, the relevant figure on the PC will be shown in red text);
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9. Once all test parameters have been set, it is now possible to start the test by pushing the button. A confirmation message appears, and to start the test the START green push button on the front side of the machine has to be pushed. During the test, the test results are displayed in real time (CYCLE COUNTER, HEIGHT, DENSITY, % VOIDS, ROTATION SPEED and VERTICAL FORCE or PRESSURE). The graph displays in real time HEIGHT/CYCLES and DENSITY/CYCLES. From the bottom side of the graph is it possible to enable the auto-scale, to change the X and Y axis scale, to enable the logarithmic scale on X axis. At the end of the test, save the test by pushing the disk icon. The test will be added to the test database. 10. Open the door, lift the cylinder off of the lower piston and pull it out off the apparatus in upright position; WARNING: Both sample material and mould must be pre-heated in a oven at approx. 150C before performing the test (refer to the suitable standard). Use suitable personal protection devices (e.g. thermal gloves) to handle sample and mould.
11. Place the sample mould on the extruder (using the horseshoe adapter in case of 100mm diameter sample mould) and press the pushbutton on the extruder to remove the compacted sample from the mould; the thin sheets are removed from the ends of the sample with a twisting motion;
Fig. 4-90
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12. Between tests wipe sand and slurry from the mould collar and the end plates with e.g. a paper towel. The mould and the end plates can be used in the next test immediately. In addition, clean the bottom plate of the mould by washing or wiping. Stuck bitumen or similar on the device can be scraped out and wiped with solvent, if needed, also between tests.
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4.6
Stopping the equipment 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.
EMERGENCY button
Fig. 4-91 Pressing the EMERGENCY BUTTON will turn the equipment OFF thus stopping all movements (e.g. mould motor, extruder motor, pneumatic actuators, etc.). The POWER ON lamp will remain lit to indicate that the mains switch is still turned ON. To recover normal functioning status, release the emergency button (turn it clockwise) and restart the test as usually.
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4.7
Switching off the unit

At the end of a test session: switch OFF the equipment via the mains switch (the POWER ON pilot light will turn OFF); close the external compressed air supply; refer to chapter 5.1 (Maintenance) to clean the unit and prepare it for the next working session.
Mains switch
POWER ON pilot light
Fig. 4-92
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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.
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 Cleaning of the sample mould and relevant accessories (see chapter 5.1.1) Cleaning of the upper piston, relevant rollers, lower plate and relevant surrounding (see chapters 5.1.2 and 5.1.3) Empting of the compressed air filter (see chapter 5.1.4)
Who Operator
When Before every working session
Operator
Operator
At the end of each working session or more frequently if required At the end of each working session or more frequently if required Weekly or more frequently depending on the status/layout of the local compressed air circuit Weekly Weekly
Operator
General inspection Check status of the safety devices: emergency button, front door safety switch and relevant cable;removable plate of sample extruder (refer to chapter 5.1.5 for their identification) Check status and functioning of the operator's command and pilot light Check that all label and rating plates are intact and properly attached
Operator Operator
Operator Operator
Weekly Monthly
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5.1.1
Cleaning of the sample mould and relevant accessories

Between tests wipe sand and slurry from the mould collar and the end plates with e.g. a paper towel. The mould and the end plates can be used in the next test immediately. In addition, clean the bottom plate of the mould by washing or wiping. Stuck bitumen or similar on the device can be scraped out and wiped with solvent, if needed, also between tests.
Procedures above is also explained at the end of the chapter that describes the execution of the test (see chapter 4.5.3).
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5.1.2
Cleaning of the upper piston and relevant rollers

Wipe the dirt of from the edges and the flat surface of the piston. If needed, the upper piston can be lowered as follows: Turn the unit ON and close the front door; From the MAIN MENU select the MANUAL COMMANDS screen and then press icon to select the PISTON CALIBRATION menu;
Fig. 5-1
Press the button and then press the START (green) pushbutton on the equipment front panel to lower the piston; 1. If slurry or bitumen runs out of the sample cylinder cylinder during testing, it will also rise on the top of the upper piston. When cleaning the device, splashing water should be avoided. Never pour or spray on the device; 2. After cleaning the unit, add slightly oil grease on steel surfaces to prevent corrosion. corrosio Multipurpose grease can be added to the rollers, other unpainted steel surfaces and specimen extruder after some time, if needed.
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5.1.3
Cleaning of the lower plate and relevant surrounding

1. Switch off the power supply and switch off the source of compressed air; 2. Remove the sample cylinder out of the unit; 3. Brush or wipe the dirt from the slurry collect bowl. Hardened concrete can be gently removed with a screwdriver. The rest of bitumen can be wiped off with a suitable solvent; 4. In addition, clean the surroundings of the lower piston when necessary. If considerable amounts of water, bitumen or slurry run out during the test, cleaning has to take place immediately after the test; 5. After cleaning the unit, add slightly oil grease on steel surfaces to prevent corrosion.
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5.1.4
Empting of the compressed air filter

The filter of the compressed air is meant to collect possible condensation from the local compressed air circuit. It can be emptied in 2 ways: 1. With the compressed air connected, open the valve on the bottom of the filter by rotating it clockwise, then push it up to empty the container; at the end close valve by rotating it counter-clockwise;
Compressed air connected
Fig. 5-2 2. With the compressed air disconnected, remove the container by rotating it clockwise and empty; at the end fit the container in place and rotate it fully counter-clockwise.
Compressed air disconnected
Fig. 5-3
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5.1.5
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, once pressed, turns OFF the equipment thus stopping all movements of the equipment (e.g. mould motor, extruder motor, pneumatic actuators, etc.); Sliding door equipped with safety microswitch that, when the door is open, stops the mould motor; Detachable upper plate of the sample extruder to protect the operators hands in case the extruder is inadvertently activated without the mould; Access panels to internal devices fixed with screws.
EMERGENCY button
Sample extruder with removable upper plate
Safety microswitch for sliding door
Fig. 5-4
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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 gyratory angle (see chapter 5.2.1) Checking the calibration of the displacement transducer (HEIGHT) and the pressure transducer (LOAD) (see chapter 5.2.2) Status of the internal and external cables wear and tear and fastenings Grounding of all the accessible conductive parts
Who When Authorized service Yearly or more frequently engineer 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 Yearly engineer Authorized service Yearly engineer
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5.2.1
Checking the gyratory angle

The internal gyratory angle in the GYROCOMP compactor is calibrated with 76-B0255 ILS (Internal Load Simulator device) device, measuring the real working angle between the internal face of the mould cylinder and the pistons, with different tilting load levels (240 Nm, corresponding to the average tilting load on an asphalt mix, and a greater 425 Nm). Similar device to ILS can be used to measure the gyratory angle. Refer to CONTROLS technical service to perform the checking of the gyratory angle.
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5.2.2
Checking the calibration

The load value and the sample height value displayed by the machine are conditioned by the calibration coefficients. The calibration of the system must be checked periodically perio ly to ensure proper performance. performance
The front door is equipped with a safety microswitch that stops the mould rotation motor when the door is open. The following message will be shown in case case the front door is open while operating with the MANUAL COMMANDS menus.
Fig. 5-5
Close the door, press OK to continue and the START green pushbutton on the front panel in case a movement has to be carried carri out.
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To access the calibration menu: On the MAIN MENU press on the icon menu; the following screen will appear: to activate the MANUAL COMMANDS
Fig. 5-6
Press the icon screen:
of the MANUAL COMMANDS menu to access the following
Fig. 5-7 Use the pull down menu to select one the following options: HEIGHT (SAMPLE) LOAD (VERTICAL).
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5.2.2.1
HEIGHT (SAMPLE) option

The sample height reading is achieved with wit a potentiometric transducer mounted mo on the pneumatic actuator. Refer to chapter 4.2.4.3.1 for the description of the different functions of this screen. To access the calibration function, press the icon password; . This function is protected by a
Fig. 5-8
Enter password 00101 and press the icon calibration table;
to confirm and access the
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The TRUE VALUEs are the reference values obtained with an external reference source; The DISPLAY values are the corresponding values measured by the machine; Entering of both TRUE VALUEs and DISPLAY values is achieved by touching the
relevant field on the display and pressing the icons and to set the desired value. The COEFF values are the coefficients calculated by the machine on the base of the input TRUE VALUEs and DISPLAY values.
Zeroing of the existing calibration values is achieved by pressing the icon (further confirmation will be required to ACCEPT or ABORT the action).
Storing of the new calibration values is achieved by pressing the icon confirmation will be required to ACCEPT or ABORT the action). Refer to CONTROLS technical service to perform the calibration procedure.
(further
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5.2.2.2
LOAD option
The load value is achieved by means of a pressure transducer located at the output o of the compressed air pressure ssure regulator. The load value is displayed even when it is not applied to the sample and has to be intended intended as the capacity of the equipment to apply this load to the sample. Refer to chapter 4.2.4.3.2 for the description of the different functions of this screen. To access the calibration function, press the icon password; . This function n is protected by a
Fig. 5-9
Enter password 00101 and press the icon calibration table;
to confirm and access the
Fig. 5-10 WARNING: The CALIBRATION menu is reserved to the authorised service personnel and should only be entered when the calibration needs to be changed. CONTROLS will not be responsible for any damage caused by improper setting of these parameters. Warranty will be void if this menu nu is used by unauthorised personnel.
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The TRUE VALUEs are the reference values obtained with an external reference source; The DISPLAY values are the corresponding values measured by the machine; Entering of both TRUE VALUEs and DISPLAY values is achieved by touching the
relevant field on the display and pressing the icons and to set the desired value. The COEFF values are the coefficients calculated by the machine on the base of the input TRUE VALUEs and DISPLAY values.
Zeroing of the existing calibration values is achieved by pressing the icon (further confirmation will be required to ACCEPT or ABORT the action).
Storing of the new calibration values is achieved by pressing the icon confirmation will be required to ACCEPT or ABORT the action). Refer to CONTROLS technical service to perform the calibration procedure.
(further
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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 2.1 of the present manual.
WARNING: Before opening/removing the covers, disconnect the mains supply to the device and wait at least 5 minute.
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6.1
System (Hidden) menu

This menu allows setting a number of functioning parameters of the system and performing procedures reserved to CONTROLS authorized service organisation.
To enter the SYSTEM (HIDDEN) MENU: 1. Switch the system OFF; 2. Touch the display in any point with a finger, switch ON the machine and release the finger from the display after 10 seconds approx; the following screen will be shown
Fig. 6-1
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3. Use the buttons
and
to enter password 00202 and . The system will show the
confirm it pressing the button following screen:
Archive
Reset Fig. 6-2 4. The following options are available in the SYSTEM MENU: ADC CHANNELS SETTINGS SERIAL NUMBER MEMORY RESET ARCHIVE RESET. The following pages describe the above mentioned options.
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6.1.1
ADC CHANNELS SETTINGS option
It allows setting into the GYROCOMP its full scales.
Fig. 6-3 Factory default values are: LOAD: 12000 N DEFORMAT: 175 mm To modify a parameter, touch the relevant area on the display and use the buttons
and
to set the parameter value.
NOTE: Buttons and present on the screen are not active.
Once done, touch the CONTROLS logo in upper-left corner of the screen and press the ACCEPT button to save the changes or ABORT to erase them and return to the SYSTEM MENU screen.
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6.1.2
SERIAL NUMBER option

This screen allows entering: The unit serial number it is normally set during the manufacturing of the unit and does not need to be changed unless the MEMORY RESET function has been activated (see chapter 6.1.3); The headers of the A4 format test report that can be obtained through the use of an Inkjet printer that can be connected to the USB port of the control unit (see chapter 4.4.3).
Fig. 6-4
To set the different fields, touch the relevant area on the screen and use buttons and to set the alphanumeric characters, use the buttons move from one digit to another. and to
Once done, touch the CONTROLS logo in upper-left corner of the screen and press the ACCEPT button to save the changes or ABORT to erase them and return to the SYSTEM MENU screen.
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6.1.3
MEMORY RESET option

The MEMORY RESET option allows erasing the whole system memory including, calibration coefficients, full scale, language selection, measurement units, etc. and the test data stored in the memory card. It can be used to completely reset the system in case of system memory corruption.
WARNING: Do not use the MEMORY RESET function unless authorized by CONTROLS Service department. CONTROLS will not be held responsible for damages to the equipment and/or injuries to personnel in case the above is not strictly followed.
Once this function is activated, the system will show the following screen;
Fig. 6-5 A double confirmation is requested before erasing the memory;
Fig. 6-6 After performing the MEMORY RESET all working parameters of the equipment must be re-entered.
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6.1.4
ARCHIVE RESET option

The ARCHIVE RESET option allows erasing the data collected during the execution of the tests. It can be used in case of corruption of the SD memory card. Once this function is activated, the system will show the following screen;
Fig. 6-7 A double confirmation is requested before erasing the memory.
Fig. 6-8
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6.2
Troubleshooting
Typical problems with test results: Sample not uniform in density: 1. Asphalt not put in unique movement in the mould, but with spoon or scoop; 2. Asphalt not properly mixed before being put in the mould; 3. Incorrect (low) asphalt temperature. Incorrect final sample density: 1. Incorrect height calibration; 2. Incorrect sample diameter (150 instead of 100, or opposite). Sample less compacted than expected: 1. Incorrect (low) asphalt temperature; 2. Incorrect (low) mould temperature; 3. Low asphalt quantity, or distance plate missing: GYROCOMP has reached its maximum piston stroke (height graph goes flat); 4. Incorrect (low) vertical pressure.
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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. The following general considerations have to be taken into account when replacing the boards of the equipment: If the SIGNAL CONDITIONING BOARD has to be replaced (item 11 of chapter 7) the calibration of the system must be checked/carried out as this board influences it; If the CPU board has to be replaced (item 10 of chapter 7), before removing it from the machine save the present calibration (see chapter 5.2.2 to access the CALIBRATION MENU); then enter the calibration data in the new CPU board.
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 19 20 21 22 23
Codice ricambio/ Spare part code 68-B2522/R01 68-B2522/R02 68-B2522/R03 68-B2522/R04 68-B2522/R05 68-B2522/R06 68-B2522/R07 68-B2522/R08 68-B2522/R09 68-B2522/R10 68-B2522/R11 68-B2522/R12 68-B2522/R13 68-B2522/R14 68-B2522/R15 68-B2522/R16 68-B2522/R17 68-B2522/R18 68-B2522/R19 68-B2522/R20 68-B2522/R21 68-B2522/R22 68-B2522/R23
Descrizione Pulsante emergenza Display touch screen Pulsante verde Pulsante rosso Interruttore principale Regolatore aria Lampada power ON Contatto NA Contatto NC Scheda CPU Scheda condizionamento segnali Scheda relay Interruttore magnetico di sicurezza Modulo di sicurezza Alimentatore 24VCC Teleruttore Trasduttore di pressione Alimentatore 12VCC Filtro di rete
Description Emergency button Touch screen display Green pushbutton Red pushbutton Mains switch Air regulator Power ON lamp NO contact NC contact CPU board Signal conditioning board Relay board Magnetic safety switch
Q.t in una macchina/ Q.ty in one unit 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Safety module 24VCC power supply Contactor Pressure transducer 12VCC power supply Line filter Hand-drill pneumatic Attuatore pneumatico trapano actuator Trapano Hand drill Elettrovalvola cilindri Electrovalve pneumatic pneumatici cylinders Electrovalve hand-drill Elettrovalvola attuatore trapano actuator
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6 3 7 4
Fig. 7-1
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10
11
12
Fig. 7-2 8 8
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13
Fig. 7-3
15
14 16
Fig. 7-4
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17
18
19
Fig. 7-5
20
21
Fig. 7-6
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22
23
Fig. 7-7
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8.
SCHEMATICS AND DRAWINGS

1. 2. 3. 4. 5. Control board (CPU) layout Signal conditioning board layout Machine electrical diagram Sample extruder electrical diagram Pneumatic diagram
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CONTROL BOARD (CPU) LAYOUT
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SIGNAL CONDITIONING BOARD LAYOUT
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MACHINE ELECTRICAL DIAGRAM
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EMERGENCY BUTTON
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SAMPLE EXTRUDER ELECTRICAL DIAGRAM
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PNEUMATIC DIAGRAM
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Notes:
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Notes:
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Notes:
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Notes:
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Manual Gyrocompactador

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76-B252X, 76-B252X/E, 76-B252X/A, 76-B252X/AE

MANUALE DI ISTRUZIONI INSTRUCTION MANUAL

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Shipment ............................................................................................................................ 24 Unpacking and inspection.................................................................................................. 25

4. USE OF THE EQUIPMENT

Switching ON the equipment............................................................................................. 39 Description of the GYROCOMP operators interface ....................................................... 40

Description of the GYROCOMP software ....................................................................... 69

Serial port .......................................................................................................................... 87

Carry out a test .................................................................................................................. 89

Operators preventive maintenance ................................................................................ 116

Authorized service engineer maintenance actions .......................................................... 122

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

6. DIAGNOSTICS & TROUBLESHOOTING

System (Hidden) menu .................................................................................................... 131

Troubleshooting ............................................................................................................... 137

7. SPARE PARTS 8. SCHEMATICS AND DRAWINGS

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Icons appearing in the manual

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manual revision history

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Conformity to the CE Directive

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Intended use and improper use

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Sample extruder with removable upper plate

Safety microswitch for sliding door

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Personnel responsible of transportation and moving of the equipment

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

WARNING: Do not stand under suspended loads

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

System block diagram

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Commands and controls

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

110 or 230 VAC +6%, -10% 1000 W Optional Included Included

Environmental conditions Operating temperature Operating humidity + 10 + 40C 50%RH @ 40C

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

Model GYROCOMP all models Motorized extruder code 76B2520/15

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

Unpacking and inspection

Here follows the procedure for the unpacking of the equipment.

Manuale di Istruzione GYROCOMP Instruction Manual GYROCOMP

How to remove the equipment from the shipping crate

Manuale di Istruzioni GYROCOMP Instruction Manual GYROCOMP

WARNING: Do not stand under suspended loads