Controls WIZARD 2 50-C13A0X Instruction Manual Download Page 1

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MANUALE DI ISTRUZIONI

INSTRUCTION MANUAL

50-C92AXX, 50-C13A0X

50-C23A0X, 50-C34A0X

Compression and flexural testers

Summary of Contents for WIZARD 2 50-C13A0X

Page 1: ...MANUALE DI ISTRUZIONI INSTRUCTION MANUAL 50 C92AXX 50 C13A0X 50 C23A0X 50 C34A0X Compression and flexural testers...

Page 2: ......

Page 3: ...on plate 29 2 7 Commands and controls 30 2 7 1 Flow control valve 31 2 8 Technical specifications 32 3 INSTALLATION 38 3 1 Shipment 39 3 2 Unpacking and inspection 42 3 2 1 How to remove the equipment...

Page 4: ...us of the safety devices 85 5 1 2 Checking the oil level in the tank 88 5 2 Authorized service engineer maintenance actions 89 5 2 1 Checking the centering of the ram assembly 90 5 2 2 Checking the hy...

Page 5: ...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 respon...

Page 6: ...le with special calibration procedures Double station model 600 15 kN cap extends the possible applications to flexural tests on cement and com pression tests on low strength specimens The Class 1 acc...

Page 7: ...elivery valve downwards Main features are Multipurpose machine ideal for Central laboratories for testing Cement Mortars Resins Refractory Lightweight concrete Soil cement specimens etc digital contro...

Page 8: ...Semi automatic COMPACT Line compression tester load measurement with load cell 230 V 50 60 Hz 1 ph 50 C92A13 Same as above but 220V 60 Hz 1ph 50 C92A14 Same as above but 110V 60 Hz 1ph Double testing...

Page 9: ...display tests stored on USB memory stick download data to internal printer or PC delete single tests or reset the entire memory Multi coefficient calibration procedure with automatic storage of data w...

Page 10: ...0 C23A03 Same as above but 220 V 60 Hz 1 ph 50 C23A04 Same as above but 110 V 60 Hz 1 ph 50 C34A02 WIZARD 2 Semi Automatic Compact Line Gen Util compression tester 3000 kN cap for cubes up to 200 mm a...

Page 11: ...9 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...

Page 12: ...Manuale di Istruzione Instruction Manual 23 08 2018 Rev 1 EN 10 1 2 Manual revision history Revision Date Change description Rev 1 August 23rd 2018 Manual release...

Page 13: ...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 connecte...

Page 14: ...equipment is the front side where the operator s controls and the display are located The operator is responsible of starting up the equipment performing the test sequence shutting down the equipment...

Page 15: ...ons 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...

Page 16: ...ine is equipped with the following devices to limit the residual risks in using it Emergency button that switches OFF the unit once pressed thus stopping the raising of the piston Max pressure valve t...

Page 17: ...l Rev 1 EN 23 08 2018 15 Ram travel switch to prevent the excessive piston travel when triggered it disables the functioning of the pump motor Fig 1 3 Front door and rear transparent fragment guard Fi...

Page 18: ...16 On the motor connection box input for ram travel microswitches to prevent the excessive piston travel when triggered it disables the functioning of the pump motor Fig 1 5 Access panels to internal...

Page 19: ...and the upper platen on the frame during the compression phase although the maximum speed is very low max 40 mm min Technical personnel Above listed areas Area around the hydraulic tubes due to the h...

Page 20: ...e 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...

Page 21: ...e electrical devices WARNING Due to the high pressure inside the hydraulic circuit up to 650 bars only tubes approved by CONTROLS can be used CONTROLS will not be responsible for damages to the equipm...

Page 22: ...es due to fragments of samples ejected during the test e g in case of test on explosive samples WARNING Although the maximum speed of the loading piston of the frame is very low max 40 mm min to avoid...

Page 23: ...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...

Page 24: ...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 authorit...

Page 25: ...Manuale di Istruzioni Instruction Manual Rev 1 EN 23 08 2018 23 1 7 CE declaration This page shows a copy of the CE declaration The original is supplied with the equipment as a separate document...

Page 26: ...e with 600 kN frame code 50 C92A0X Ref Description 1 Upper platen with spherical seat 2 Front guard 3 Lower platen 4 Piston travel indicator 5 Control unit 6 Flow control valve 7 AC motor dual stage h...

Page 27: ...on 1 Load cell 2 Upper platen with spherical seat 3 Front guard 4 Lower platen 5 Piston travel indicator 6 Control unit 7 Flow control valve 8 AC motor dual stage hydraulic pump with MOTOR ON switch 9...

Page 28: ...per platens with spherical seats 3 Front guard 4 Lower platen 5 Piston travel indicator 6 Control unit 7 Flow control valve 8 AC motor dual stage hydraulic pump with MOTOR ON switch 9 EMERGENCY BUTTON...

Page 29: ...rance 0 02 mm 2 3 Hydraulic power unit Dual stage pump low pressure high delivery for fast piston approach and high pressure low volume for loading Fitted with special hand operated pressure compensat...

Page 30: ...ate 3 LAN port for PC connection 4 USB port for data storage USB pen drive 5 Power cord receptacle WARNING Do not use the USB port to re charge batteries of external devices e g mobile phone audio vid...

Page 31: ...Manuale di Istruzioni Instruction Manual Rev 1 EN 23 08 2018 29 2 6 Identification plate The identification plate is located on the rear side of the equipment control unit near the power cable Fig 2 5...

Page 32: ...controls of the equipment The operator s interface description and the use of the buttons of the control unit is provided in chapter 4 2 of the present manual Front view Rear view Fig 2 6 Rif Descrip...

Page 33: ...f Description 1 Load gradient adjustment knob clockwise to decrease counter clockwise to increase 2 Flow control lever back for rapid approach forward to control load rate with the load gradient adjus...

Page 34: ...kN 500 kN 60 kN 600 kN 1 5 kN 15 kN With 50 C0050 CAL2 15 kN 600 kN 15 kN 600 kN With 50 C0050 CAL5 0 75 kN 15 kN With 50 C0050 CAL 5 kN 500 kN Single phase line voltage 110 VAC 220 VAC 230 VAC 10 10...

Page 35: ...0 14 6 Max piston travel mm inches 50 2 50 2 50 2 Platen dimensions mm dia 216 8 5 dia 216 8 5 dia 300 11 8 Platen surface hardness 55 5 HRC 600 HV 55 5 HRC 600 HV 55 5 HRC 600 HV Platens flatness tol...

Page 36: ...g bolts as shown in next figures WARNING Make sure to use proper fixing bolts according to the type of floor of the installation place CONTROLS cannot be considered responsible in case of injures to t...

Page 37: ...Manuale di Istruzioni Instruction Manual Rev 1 EN 23 08 2018 35 Fig 2 9 Dimension and fixing of 50 C92A1X...

Page 38: ...Manuale di Istruzione Instruction Manual 23 08 2018 Rev 1 EN 36 Fig 2 10 Dimension and fixing of 50 C92A2X...

Page 39: ...Manuale di Istruzioni Instruction Manual Rev 1 EN 23 08 2018 37 It is possible to mount a pedestal accessory code 50 C99 B on all 3 types of machines 50 C92A0X 50 C92A1X 50 C92A2X Fig 2 11...

Page 40: ...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 volta...

Page 41: ...m fork lift length 50 C92A0X with pedestal 386 Kg 1150x850x1570 mm 1500 mm without pedestal 286 Kg 1000x700x1250 mm 50 C92A1X with pedestal 386 Kg 1150x850x1570 mm 1500 mm without pedestal 286 Kg 1000...

Page 42: ...Manuale di Istruzione Instruction Manual 23 08 2018 Rev 1 EN 40 Fig 3 2 60 Kg wooden crate Fig 3 3 70 Kg wooden crate...

Page 43: ...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 pe...

Page 44: ...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...

Page 45: ...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 equipmen...

Page 46: ...l 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 he...

Page 47: ...responsibility of the purchaser to provide an installation place with adequate lighting Parts used to build the machine and electrical electronic component are fire proof It is anyway the responsibil...

Page 48: ...ONTROLS cannot be considered responsible in case of injures to the operator or damages to the equipment if the above instructions are not duly followed WARNING If the equipment is brought from a cold...

Page 49: ...control unit The control unit assembly is normally shipped dismantled from the frame To mount it on the frame 1 Fit the control unit assembly shaft into the relevant housing on the right hand side of...

Page 50: ...ing of the laboratory and the height of the operator it may be necessary to adjust the positioning of the display to ensure optimum visibility 1 Loosen the screw shown in next pictures Fig 3 9 2 Posit...

Page 51: ...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...

Page 52: ...ble load sensor s depending on the application in use making reference to the table below Fig 3 10 Ref Description 1 Input socket CH1 for load sensor 2 Input socket CH2 for load sensor normally not ac...

Page 53: ...l microswitch of the frame to the relevant socket on the rear of the motor box Fig 3 11 4 In case two frames are connected to the same hydraulic unit a y cable must be used e g Code S000 45940019 5 Re...

Page 54: ...ame In case the device is equipped with the dual output hydraulic block code C10B 2F to be installed in the factory it will be possible to connect a second frame WARNING To avoid direct contact with t...

Page 55: ...be used CONTROLS will not be responsible for damages to the equipment or personnel injures in case of use of improper material and or operations not carried out by authorized technical personnel Fig...

Page 56: ...a Locate the max pressure adjustment valve b Use a 6mm Allen key to remove the cap c Use a flat screw driver to turn counter clockwise the valve to reduce the max pressure d Adjust the valve by turni...

Page 57: ...before starting the unit Proceed as follows 1 Open the paper roll compartment by pressing the OPEN key 2 Move down the plastic cover to the maximum opening 3 Place the paper roll making sure that it u...

Page 58: ...s are replaced the protective devices are to be properly attached and tested Any manipulation of the safety devices endangers the operating personnel WARNING Covers doors can only be removed opened by...

Page 59: ...obile phone audio video players etc It is also mandatory to connect disconnect the USB memory stick with the unit OFF CONTROLS will not be held responsible for damages to persons and or properties in...

Page 60: ...instrument it allows scrolling among the stored tests download data to the PC connected via the LAN port printout through the optional internal printer OPTIONS it allows setting date and time the crit...

Page 61: ...ollowing parameters are displayed on the screen use the key to access the different parameters on the screen NoTEST this is the test number that is automatically incremented by one for any new test Id...

Page 62: ...nding to a decrease in load upon which the instrument during a test considers the sample as failed and hence stops the data acquisition The suggested values are 10 to 30 kN for compression tests on co...

Page 63: ...spect to the theoretical set load rate F Date and time At this point the WIZARD 2 is ready to carry out the test on the sample as follows The load rate is controlled using the special valve with dial...

Page 64: ...up and Lever B back Maximum piston speed upwards 2 Load control phase Lever A up and lever B slowly forward Piston speed upwards controlled by load rate control valve 3 Load rate adjustment Turn the...

Page 65: ...load rate corresponds with theoretical load rate 1 Actual load rate theoretical load rate 1 10 Actual load rate theoretical load rate 10 Actual load rate theoretical load rate 10 25 Actual load rate t...

Page 66: ...INT must be ENABLED to print in the TEST RESULTS OPTIOS screen see chapter 4 2 3 4 If AUTOSAVE in TEST RESULTS OPTIOS screen is set to ENABLED see chapter 4 2 3 4 the system will also store the test d...

Page 67: ...EW SINGLE RECORD option the system will show the last test stored as follows Fig 4 12 Use the keys to scroll through the different stored tests NOTE Access to the VIEW SINGLE RECORD screen is not poss...

Page 68: ...n Fig 4 13 Use the to select the desired option and the key to proceed 4 2 3 1 CLOCK option Select the CLOCK option to set DATE AND TIME Fig 4 14 Use the key to scroll among the different parameters t...

Page 69: ...red use the keys to select the desired unit then key twice to confirm the change and return to the OPTIONS menu NOTE When the unit is changed all tests in the archive are no longer valid and must be d...

Page 70: ...lace by pressing the key at the end of the test AUTOSAVE in case it is ENABLED the data are automatically stored at the end of the test into the memory stick attached to the USB port on the rear panel...

Page 71: ...the display with a reference load displacement indicator to check linearity and repeatability When this screen is accessed the value of load displacement of the selected channel will be shown as a sma...

Page 72: ...g in case of test on explosive samples WARNING If the TEST PARAMETERS value is not properly set it will cause improper functioning of the machine e g if the value is too high the machine will not be a...

Page 73: ...sample use proper distance pieces to reduce the daylight on the press leave a gap of at least 3 4mm also considering that the piston total travel is 50mm Fig 4 19 Distance pieces to adjust the vertica...

Page 74: ...4 3 1 Selection of the frame to use for 50 C92A2X machine Depending on the type of test to perform select the relevant frame by means of the frame selector lever here after shown Lever UP to select Fr...

Page 75: ...kwise the load rate is decreased by rotating counter clockwise the rate is increased Next instructions describe its use in the different phases of the test 1 Beginning of the test rapid approach Lever...

Page 76: ...vious WARNIGS 3 After accessing TEST RUN menu if two channels have been activated into the system see chapter 6 1 1 for channel activation use the keys to select the desired channel and press the key...

Page 77: ...mains electricity supply is connected in the meantime set lever A up and lever B back on the flow control valve rapid approach phase Fig 4 25 7 Before the sample comes in touch with the machine upper...

Page 78: ...ue Fig 4 27 10 Adjust the load rate by acting on the flow control valve and taking as a reference the trend indicator on the display meaning of the symbols on trend indicator is as follows Actual load...

Page 79: ...emit an audible alarm 5 beeps to inform the operator the trend indicator will also show the symbol In case the full scale of the system was reached before the failure of the sample the system will on...

Page 80: ...OPTIOS screen see chapter 4 2 3 4 If AUTOSAVE in TEST RESULTS OPTIOS screen is set to ENABLED see chapter 4 2 3 4 the system will also store the test data into the USB memory stick WARNING Do not use...

Page 81: ...1 EN 23 08 2018 79 4 4 Stopping the cycle via the Emergency button In case dangerous conditions are encountered during the execution of a test cycle it is possible to stop the machine by pressing the...

Page 82: ...ill be released and will return in the 0 position thus stopping the movement of the piston To release the hydraulic pressure turn lever B slowly back and lever A down Fig 4 32 After clearing the emerg...

Page 83: ...Switching off the unit At the end of a test make sure data storing into the USB memory have been completed then remove residuals of the samples Return the unit to the MAIN MENU and switch the equipmen...

Page 84: ...r 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 removi...

Page 85: ...ed 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...

Page 86: ...k the status of the hydraulic tubes against leakages and damages Operator Weekly Check status of the safety devices EMERGENCY BUTTON max pressure valve piston over travel switch and relevant cable on...

Page 87: ...23 08 2018 85 5 1 1 Checking the status of the safety devices Emergency button that switches OFF the unit once pressed thus stopping the raising of the piston Max pressure valve to avoid machine overl...

Page 88: ...l 23 08 2018 Rev 1 EN 86 Ram travel switch to prevent the excessive piston travel when triggered it disables the functioning of the pump motor Fig 5 2 Front door and rear transparent fragment guard Fi...

Page 89: ...nual Rev 1 EN 23 08 2018 87 On the motor connection box input for ram travel microswitches to prevent the excessive piston travel when triggered it disables the functioning of the pump motor Fig 5 4 C...

Page 90: ...the transparent level indicator the oil should be max at half of the indicator if necessary refill the oil tank Fig 5 5 The following type of oil can be used Brand Type Agip ATF Dexron Api Apilube ATF...

Page 91: ...alibration of the load channel see chapter 5 2 5 Authorized service engineer Yearly or more frequently depending on the quality procedures of the laboratory Checking the stability of the frame through...

Page 92: ...the stability of the frame through the force transfer test with the strain gauged column This checking should also be carried out if tests on high strength concrete explosive samples are often carrie...

Page 93: ...d use a rubber hammer to re center it properly Fig 5 8 5 Also check that the ram is properly positioned from a rotational point of view by taking as reference the position of the oil supply tube with...

Page 94: ...s not carried out by authorized technical personnel WARNING To avoid direct contact with the oil of the hydraulic circuit always wear protective gloves while performing the checking Proceed as follows...

Page 95: ...ck the single item s and replace the relevant gasket O ring 5 Then check the oil level in the tank refer to chapter 5 1 2 and if needed re fill the oil tank as described in chapter 5 2 6 6 At the end...

Page 96: ...hecking the stability of the frame through the force transfer test with the strain gauged column This checking should also be carried out if tests on high strength concrete explosive samples are often...

Page 97: ...ith the strain gauged column The maintenance should also be carried out if tests on high strength concrete explosive samples are often carried out Performing the maintenance on the spherical seat requ...

Page 98: ...easurement device connected to the unit 3 New calibration verification repeat step 1 Steps 2 and 3 above are required if the unit is not within the limits indicated by the standards Step 1 above consi...

Page 99: ...o the following screen Fig 5 14 For the selected channel the screen shows 1 The actual load read by the load sensor attached to the WIZARD 2 unit in engineering unit 2 The actual load read by the load...

Page 100: ...ENU by selecting the CALIBRATION option on the MAIN MENU Fig 5 15 2 Correctly place the reference instrument e g load cell between the compression platens of the test frame 3 When ready turn ON the pu...

Page 101: ...mes to zero the load reading on the display before the frame start the loading phase The key will not be active if an increase of at least 0 25 of the full scale is detected by the load sensor 5 When...

Page 102: ...top the load increase and maintain an almost constant pressure The value of the applied load is updated in real time on the display 8 To interrupt the load turn OFF the pump motor switch and turn leve...

Page 103: ...cell It is also possible to check the calibration at lower loads if the compression frame has been so calibrated 11 If the percentage deviation is higher than permitted tolerances the unit should be r...

Page 104: ...ystem is performed by loading the system to a number of known load steps maximum 6 load steps including the first step that is always 0 that are achieved by making reference to an external reference s...

Page 105: ...platens of the test frame 4 When ready turn ON the pump motor by acting on the relevant switch note that the pump motor switch is self retaining when the mains electricity supply is connected in the...

Page 106: ...taking the load rate close to zero it is possible to stop the load increase and maintain an almost constant pressure The value of the applied load is updated in real time on the display 8 Take note of...

Page 107: ...e keys to set it Confirm it by pressing the key The EDIT CALIBRATION screen for the selected channel will be displayed Fig 5 26 This screen is composed by a table with two columns and six rows the sec...

Page 108: ...enter the corresponding bit reading previously noted for this step 15 Once all rows on the first page are completed pressing the key brings to the second page with rows from 4 to 6 16 Proceed in this...

Page 109: ...lic circuit WARNING To avoid direct contact with the oil of the hydraulic circuit always wear protective gloves while performing the checking Periodically the oil of the hydraulic circuit must be comp...

Page 110: ...ATF Dexron Chevron Chevron automatic transmission fluid Elf Elfmatic G Exxon Automatic transmission fluid Fiat GI A Fina Dexron ATF Gulf Automatic transmission fluid IP Dexron fluid Mobil ATF 220 Shel...

Page 111: ...e 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 lock...

Page 112: ...t 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...

Page 113: ...ptions are provided in this menu CHANNELS SET UP allows activating de activating the second channel and setting the FULL SCALE and PRELOAD values for the active channels SERIAL NUMBER allows setting t...

Page 114: ...ng de activating the second channel into the unit To activate de activate the second channel press the key to bring the cursor to the CHn selection and use the keys to set the desired status CH1 1 cha...

Page 115: ...ter to change the keys to select the digits to change and the keys to set the value Then press the key to access the next parameter to change Once all the CHANNEL SET UP OPTIONS has been set press key...

Page 116: ...e MEMORY RESET function has been activated see chapter 6 1 3 The serial number will be shown on the display at switch ON Once the serial SERIAL NUMBER option is accessed the system will show the follo...

Page 117: ...ment 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...

Page 118: ...Manuale di Istruzione Instruction Manual 23 08 2018 Rev 1 EN 116 Note...

Page 119: ...Manuale di Istruzioni Instruction Manual Rev 1 EN 23 08 2018 117 Note...

Page 120: ......

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