manual controls c807

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

Apparatus: Microprocessor Controlled Universal Testing Machine Mod. 70-C0807/C70-C0810/C70-C0820/C

70-C0820/C

INDEX

1 Safety aspects ................................................................................................................ ........ page 2

2 Functions of the machine ..................................................................................................... 2

3 Operating principles .......................................................................................................... .... 2

4 General description ........................................................................................................... .... 2

5 Assembly and installation requirements ............................................................................. 3

6 Initial start-up .............................................................................................................. ........... 4

7 Fault finding ................................................................................................................. .......... 5

8 Spare parts ................................................................................................................... .......... 5

9 Accessories ................................................................................................................... ......... 6

10 Maintenance .................................................................................................................. ......... 9

11 Technical data ............................................................................................................... ......... 10

12 Universal Winsoft Testing .................................................................................................... . 15

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INSTRUCTION MANUAL

NoticeNo part of this document may be copied or reproduced in any form or by any means without the prior written consent of ControlsS.p.a.

1 Safety and security devicesSafe working practices should be observed at all times when using the equipment described in this manual.Only suitably qualified or trained personnel should be entrusted to use any equipment using high voltages.Equipment requiring specialist knowledge should be used by personnel trained in its use. It is most important that the contentsof this manual is studied and understood before proceeding to use any equipment in a working situation.The machine is equipped with the following protection devices:- Overload protection valve: this valve triggers the pump cut-out when the pressure exceeds 650 bar.- Electric protection of full scale: this feature interferes when the load exceeds the full scale.- Piston travel limit switch: operates when the maximum vertical displacement of the upper crosshead is exceeded.

2 Functions of the machineFor tensile tests on steel rods up to 40 mm dia. and steel plate up to 75 × 30 mm size.For compression tests up to 200kN cap. using the accessory 70-C807/1 (models 70-C807/C) or 70-C902/9 (models 70-C810/C) and up to 2.000 kN using the accessory70-C820/1 (models 70-C820/C).For transverse and bending test using the accessories70-C807/2, 70-C807/3, 70-C810/2, 70-C820/3 for models 70-C807/C, 70-C810/C, 70-C820/C (see page 272 of generalcatalogue).

3 Operating principlesThe lower end of the steel rebar specimen is placed in the lower grippers and the upper end in the upper mobile grippers ofthe testing frame.During operation the hydraulic pump located in the control console increases the pressure in the cylinder assembly of themachine and moves the mobile part of the frame and the upper gripper, applying load to the specimen up to failure which isrecorded on the display unit.The compression test follows the same operating principle with the exception of the specimen which is placed on acompression platen (see accessory 70-C807/1).

4 General descriptionI Machine frame, piston/cylinder assembly, electronic load cell- Steel base on which the rigid steel frame housing the lower grippers is bolted.- Piston/cylinder assembly mounted on top of the rigid frame. The piston incorporates the electronic load cell.- Mobile frame consisting of four high tensile strength columns, upper crosshead directly connected to the piston,

intermediate crosshead with compression platen and lower crosshead housing the upper grippers.- Vertical daylight adjustable with intervals of 50 mm (model 70-C807/C only).- Hydraulically operated opening and vertical adjustment of grippers by two independent auxiliary cylinders controlled by

the pedant hand control. This unique feature makes the machine extremely easy to operate enabling one man to performthe test in a very short time.

Grippers- Three sets of standard grippers supplied with the machine to perform tensile tests on rounds and flats.- Two sets of grip liners supplied with the machine to provide maximum bearing and holding surface for specimens of all

sizes.Safety features- Pressure switch which automatically stops the machine when the oil pressure goes over the maximum permissible.- Max. travel limit switch to stop the mobile frame in its upper position.- Emergency push button.

II Control consoleThe lower section houses the hydraulic assembly which comprises:- Hydraulic pump- Proportional valve- Hydraulic valves- Heat exchanger to control the oil temperature- Oil tankThe upper part houses the electronic microprocessor control console driven by a P.C.

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INSTRUCTION MANUAL

The control console serves principally for the following functions:- Conditionning and conversion of all the analogical signals to send to P.C.- Control of the valves and the safety devices.- Automation of the test, maintain constant load rate in the elastic phase and strain rate in the plastic phase.- Interaction with the P.C. to control the various tests.- Resolution: 1/120000 (e.g. the sensitivity of the 600kN model is 30 N)- Accuracy: ± 0.5%, ± 1 digit

The rear panel comprises the RS 232 output.

5 Assembly and installation requirements1 Foundations

At least 20 days before the arrival of the machine it is advisable to start the foundation work according to the encloseddrawing. Check also if there is a problem to transport the machine into the final position in the laboratory to install themachine on the foundations bolts to enable installation to be carried out when the machine arrives.

2 Arrival of the machine in the laboratoryThe machine frame and the control console are packed separately in horizontal position. A can hydraulic oil is alsoincluded and has to be poured in the oil tank of the power pump before switching on the machine.

3 Erection of the machineThe machine must be lifted by the hook openings shown in fig. (1).

Caution : The weight of the machine is:2300 kg. (models 70-C807/C)2500 kg (models 70-C810/C)4000 kg (models 70-C820/C)Once the machine is in the correct place, it has then to be set in a perfectly vertical position by means of the adjustmentsscrews (see fig. 3) using a spirit level as shown in fig. 4.Fix the adjustment screws with the nut, use if necessary intermediary shims and bolt the machine permanently with thefoundation anchor bolts.

4 Assembly and installationAfter installation of the machine frame, set the control console near to the frame at a distance of about 20 to 30 cm andcarry out the tubing and electrical connections (see fig.2).Since they carry a particular reference, no error is possible.Connect the remote control (see fig. 13).Remove the rear panel of control unit (fig. 8), unwind the electrical lead (fig.9) and pull the electrical lead through the gapin the side panel (fig. 10).Pull out the electronic cable and the pendant hand control (fig. 11) passing through the window in the side panel (fig.12).

5 Preliminary checks5.1 Check the available voltage in the laboratory; the machine is designed for 380 V, 50 Hz, 3 Ph. + Earth and 0.

The maximum power is 2,5 kW (fig. 7).5.2 Verify if the connections are correctly made by observing the direction of rotation of the pump motor (clock wise)

as follows:- Switch on switch “POWER” (fig.15)- Press button “PUMP” (fig.17)- Press button “JOG” on hand control (fig.18)

The mobile frame of the machine should move upward. If not, invert two phases of the plug. Do not invert the phasesinside the control console.

- Let mobile crosshead return it’s lower position by pressing the “UNLOAD” button on the hand control.

5.3 To remove air from the hydraulic circuit move the mobile frame (up and down) using the button as described above.5.4 Check that the oil level is correct on the oil level indicator.5.5 In case it is necessary to add new oil, use hydraulic transmission oil, gradation ISO VG 46 conforming to ISO 3448

specs. Any of the oil listed on page 13 can be used.5.6 Remove all packing from testing area (if fitted for transportation). For 70-C820 only, remove the steel plates locking

the piston to the cylinder.

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INSTRUCTION MANUAL

6 Initial start-up6.1 Tensile test

6.1.1 Mounting of the gripping headsThe machine is supplied with 3 sets of gripping jaws:

- C807/10 Gripping jaws for flat specimens - maximum area: 30 × 75 mm and round specimens up to 8 mm diameter.(Minimum thickness or diameter: 5 mm).

- C807/12 Gripping jaws for round specimens of 9 to 19 mm diameter.

- C807/14 Gripping jaws for round specimens from 19 to 40 mm diameter.Furthermore the gripping heads are supplied with 2 sets of wear platens - reference C807/16 and C807/18 - whichare placed between the gripping jaws and the conical seat of the gripping heads.

- These wear platens must always remain within the dimensions of and must never protrude above or below theside plates when grips are closed, so as not to stress one part of the gripping jaw only, causing possible damage.

6.1.2 For this reason, depending on the diameter or the thickness of the specimen, it is always necessary to use oneset of the two wear platens available as shown in the table, otherwise the seat of the gripping jaws may beirreparably damaged.

Wearing plate C807/16, thickness9 mm

Wearing plate C807/18, thickness14 mm

GrippersC807/14

GrippersC807/10

GrippersC807/12

GrippersC807/10

for for for for

rounds from 19to 40 mm



rounds from 5 to20 mm

6.1.3 The machine is delivered with one set of gripping jaws already mounted to the gripping heads. In order to replacethem, proceed as follows:

6.1.4 Remove completely the four screws (fig.28). Put the tool supplied with the machine into the hole provided in theside plates and move laterally to remove either the wearing plate or the gripper (fig. 29, 30, 31, 32, 33).

6.1.5 Replace if necessary, the wearing plate depending upon the size of the specimen as mentioned in 6.1.2.Place the new grippers provided that the contact faces between the wearing plates and the grippers have beenpreviously greased using the special grease supplied with the machine.Important note. Possible noises or creating occurring during the test could be caused by insufficient greasing.Grease immediately the parts as above indicated to avoid possible seizing and damage. Only use the molybdenumgrease as supplied with the machine.

6.2 Changing the vertical daylight ( Models C807/C only)The machine is usually delivered adjusted to the minimum vertical daylight which is about 100 mm corresponding to thedistance between the two crossheads holding the grippers. This distance added to the piston stoke of 250 mm make itpossible to test the most common size of steel rebar specimens which are cut to the usual length of 400 mm approx.The vertical daylight (or better the distance between the two crossheads holding the grippers) can however be easilyincreased in steps of 50 mm up to 500 mm. The maximum distance obtainable during the test is 500 + 250 = 750 mm.To change the vertical daylight proceed as follow:

6.2.1 Switch on the power pump and move the frame upward by pressing the top button of the keyboard (fig. 17 and 18)

6.2.2 Place the two rods delivered with the machine in the position shown in fig. 19 and 20 which has the purpose ofblocking in position the upper crosshead during the vertical adjustment operations.

6.2.3 Unscrew the four bushes as shown in fig. 21 and 22.6.2.4 Remove the two half threaded rings from each column as shown in fig. 23.

The two half rings are marked 1 - 1, 2 - 2 etc. Do not mix half ring of different marks.6.2.5 Move the frame downwards and remove the two half rings from the lower end of each column. (see fig. 25)

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INSTRUCTION MANUAL

6.2.6 Move upwards to decrease or downwards to increase the vertical daylight and correctly place in the proper housingthe two half rings (not threaded) for each column in the desired position (steps of 50 mm). See fig 24 and 25.

6.2.7 Move the frame upwards until the upper crosshead also moves upwards.6.2.8 Replace the two half a threaded rings in position for each columns finding the right position by the locating pins

(see fig. 26)6.2.9 Screw the bushes on by hand (see fig. 27)

Important note: This bushes have to be tightened again by hand during the first tension test to assure the besttightening. This procedure should be followed when the vertical daylight is changed.The machine is now ready to operate.

7 Fault finding7.1 Excessive noise of the pump

Excessive noise of the pump indicates that oil is missing in the tank. Refill and control oil level.If noise continues, check suction filter inside the tank and if it is clogged, request exchange from Controls (see fig. 34,35, 36, 37)

7.2 Noise coming from the gripping systemNoises emitted from the gripping system are due to a lack of lubrication.Grease gripping jaws as described (fig. 33)

7.3 Excessive oil temperature (beyond 55 to 60 °C)If the oil temperature exceed 55 to 60 °C, it means that the cooler thermostat is deteriorated or that the electric motor whichdrives the air cooling fan, does not work. To reach the thermostat remove the front panel and using a screwdriver rotateback or forward the central knob to find the typical "Clik" of the electric contact. If this does not happen it means that thethermostat is broken and has to be substituted.

7.4 The servovalve does not regulate the loading speedThe cause of an imperfect load control is to be sought in an imperfect function of the servovalve. Replace the oil filterlocated beside the servovalve as already specified in pos. 7.1.The filter has to be ordered to Controls.

7.5 Figures missing on the digital displayMissing figures on the digital display are due to a fault of the electronic circuit. Remove the faulty part and ship to Controlsfor repair or ask for the visit of our Service Dept.

7.6 Slipping of specimens in the gripping systemThis phenomenon can have different causes, i.e.:- Excessive wear of gripping jaws (replacement)- Lack of graphite grease (grease in the described way)- The wear platens are not adequate for the diameter or the thickness of the specimen (see list of spare parts and

proceed to their replacement). (see 6.2.1)- Gripping jaw not suitable to the dimensions of the specimens (use different set of gripping jaws).

7.7 The machine does not develop any pressureThis may have different causes:- Losses in the hydraulic circuit. In this case, it is recommended to check all the hydraulic connections (external) and

then, by removing the rear or the front panel of the control console, the internal hydraulic connections and tightenif necessary.

- Losses in the hydraulic pump.In this case, request instruction from Controls to be able to take the necessary steps.In case all the above described recommendations should not bring about the expected success, please contactour After Sales Dept.

8 Spare parts70-C807/10 Flat gripper for flat specimen up to 70x35 mm and round specimens from 5 to 9 mm dia. Four pieces are requiredper set70-C807/12 Vee gripper for round specimens from 9 to 19 mm dia. Four pieces are required per set70-C807/14 Vee gripper for round specimens from 19 to 40 mm dia. Four pieces are required per set70-C807/16 Grip liner 9 mm thick. Four pieces are required per set70-C807/18 Grip liner 14 mm thick. Four pieces are required per set70-C901/21 Graphite grease. Can of 1 kg2.3314.004.0 Oil filter

9 AccessoriesAccessories for compression tests on concrete specimens

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INSTRUCTION MANUAL

Models70-C901/5Lower platen, upper platen and spherical seat for compression tests on 70-C820 series testers.Dim. 310x435 mm.Weight 150 kg approx.

70-C902/9Lower platen 277x210 mm and upper platen 176 mm dia. with spherical seat.For 70-C807 and 70-C810 series only.Weight 40 kg approx.

Note.The vertical clearance with the above accessories are 610 mm for model 70-C901/5 and 400 mm for model 70-C902/9.

Accessories for test on electrowelded steel screen and steel strandsModels70-C901/20Gripper for electrowelded steel screenIt has to be used with the standard grips for flat specimens 70-C807/10 supplied with the universal tester.Weight 5 kg approx.

70-C901/31Grip for strands from 9.3 to 15.2 mm dia.Four pieces are required to perform the test. Weight 5 kg approx.

Electric extensometerTesting on steel70-C961 Coaxial extensometer for tensile strength testingIntroductionExtensometers used for measuring the elongation of specimens in tension, particularly in thecase of steel or brittle materials, are only able to detect strain during the first stage of the test, or rather, while the brittle materialsconserve their elasticity.With such traditional devices tensile strength tests cannot be carried out to the specimen’s breaking point, thereby forcing theoperator to intervene during the test to disconnect the extensometer itself from the specimen or to activate expensive andsophisticated release mechanisms.Other optical systems are able to detect breaking point strains, but are extremely expensiveand complex.This simple and economic system, the result of our experience in this field, fully satisfies theserequirements because:- it is applied directly to the specimen- it remains connected until failure- it measures extension with high precision in the elastic and plastic stage- with the appropriate simple adjustments, it can be connected to almost all testing machines- it avoids markings on the test pieces

DescriptionThe extensometer is basically made from three separate tubular sections, joined telescopically to one another. The middlesection, delimited by the larger diameter, determines the measuring base which, as is well-known, must be 5 times thediameter of the specimen (in the case of failure point measurements). The two end sections consist of two mechanisms forgripping the specimen. One carries the electrical extensometer, the other checks it.

UsesThe extensometer is fixed to the specimen prior to testing, an operation that takes only a few seconds. The specimen is placedin the machine’s grips and the electrical transducer cable is connected to the measuring and/or display system; everythingis now ready for testing.The electronic transducer works on a release mechanism which means that, once failure has been achieved, the two endsections remain attached to the specimen portion.Given its construction in three mechanically unconnected parts, the extensometer suffers no stress. It is however vital that themachine’s grips hold onto the fractured specimen.The extensometer is then mechanically and electrically disconnected, ready for use on another specimen.

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INSTRUCTION MANUAL

Available modelsAs already mentioned, the diameter of the test piece is used as the measuring base.

The table below indicates which models are available for the structural steel sector or for allsteel within a 40% “strain” limit.

Other models for other materials can be supplied on request.

70-C961/A 70-C961/B 70-C961/C 70-C961/D 70-C961/E

Measuringrange dia. mm

(min/max)5/13 12/19 19/25 25/35 32/41

spacers forspecimens dia.

mm

5,5 - 6 - 6,57 - 7,5 - 8 - 99,5 - 10 -10,5

11,3

12 - 14 - 16 19,5 - 2025 - 25,2 - 28

29,932 - 33,7 - 36

measuring base 5 × d 5 × d 5 × d 5 × d 5 × d

transducerstroke

30 50 50 100 100

size a) 130 150 160 220 250

b) 55 65 70 80 90

c) 55 60 65 75 85

Approx. weight from 100 to 500 g

Flexure test on concrete beamsModels70-C970Flexure attachment

ApplicationUsed for flexure test on concrete beams up to 200x200x1000 mm and beam test type A and B.

StandardsUNI 10020-71, UNI 6133, ASTM C 293.

General description and specificationsMaximum distance between lower bearers is 1100 mm and upper bearing assembly can receive either one single bearer ortwo bearers to perform flexure test on third point loading.It can accommodate concrete prisms up to 20x20x100 cm and beam forms type A or B to perform beam test.Weight approx. Net 120 kg

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INSTRUCTION MANUAL

Accessories for compression, transverse and bending test on universal testers. UNI 558, 559, 564

Compression testModels70-C807/1Compression device for 70-C807 testers

70-C902/9Compression device for 70-C810 testers



ApplicationUsed to perform compression tests on the universal testers.

General description and specificationsThe set comprises upper and lower platens which are surface ground and hardened. The upper platen is fitted with a sphericalseat.

Transverse testModels70-C807/2Transverse test device for 70-C807 testers

70-C810/21Transverse test device for 70-C810

70-C820/2Transverse test device for 70-C820

ApplicationUsed to perform the flexure test on the universal testers.

General description and specificationsThe set comprises a lower beam with two mobile bearers and an upper bending edge.

Bending test. ASTM A 615Models70-C807/31Bending test device for 70-C807 testers

70-C810/3Bending test device for 70-C810 testers

70-C820/31Bending test device for 70-C820 testers

ApplicationUsed to perform the bend test on the servocontrolled universal testers.

General description and specificationsThe set comprises a lower beam with two mobile bearers and an upper bending edge.

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INSTRUCTION MANUAL

10 MaintenanceFor an efficient maintenance of the machine, it is important to carry out periodically the following operations:

10.1 Periodically clean the tension and compression testing spaces. In particular, clean the gripping jaws and take off any scalewhich may fall from the specimen during the tensile test. If a thorough cleaning procedure should not be possible, it isrecommended to entirely dismantle the gripping system and clean it with a solvent, bearing in mind that the gripping partsthen have to be greased with graphite grease.

10.2 Periodically grease the points of the hydraulic control of the gripping system.

10.3 Check the oil level and refill, if necessary, with DEXRON II ATF FLUID hydraulic oil (see table below)

10.4 Check the alignment of the machine and carry out the necessary corrections by means of the adjustment screws. (Thisis to match possible movements in the concrete foundation).

10.5 Replace hydraulic oil every 400 hours operation

Hydraulic oil for automatic compression machinesSuitable types: automatic transmission (DEXRON II ATF FLUID)

KRAMEDART/ACRAM KRAMEDART/ACRAM KRAMEDART/ACRAM KRAMEDART/ACRAM KRAMEDART/ACRAM EPYT/OPIT EPYT/OPIT EPYT/OPIT EPYT/OPIT EPYT/OPIT

PIGA NORXEDFTA

OCOMA FTAIINORXED

IPA NORXEDFTAEBULIPA

NORVEHC DIULFNOISSIMSNARTCITAMOTUANORVEHC

FLE GCITAMFLE

NOXXE DIULFNOISSIMSNARTCITAMOTUA

TAIF A/IG

ANIF FTANORXED

FLUG DIULFNOISSIMSNARTCITAMOTUA

PI DIULFNORXED

LIBOM 022FTA

LLEHS IINORXEDFTA

OCAXET 0758DIULFCITAMAXET

LATOT NORXED

DRAUGNAV IIXEDDIULFFTA

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11 Technical data

Models

Specifications 70-C807/CMax. test load (kN)- in tension 600- in compression 200

Measurement load ranges

Minimum reading value 10 N

Tensile test- max. distance between grips (mm) 750- grip set for rods 2- grip set for plates 1- grip liners (sets) 2- gripping system hydraulic with

remote control- max. rod size (mm dia.) 40- max. plate size (mm) 75x30

Compression test- accessory required 70-C807/4- max. distance between platens (mm) 660

Transverse test- accessory required 70-C807/2

Bending test- accessory requires 70-C807/31

Test speed (mm/min) 0-195

Crosshead adjustment speed (mm/min) 675

Max. piston stroke (mm) 250

Mechanical adjustment of vertical clearance (mm) 400

Distance between columns (mm) 282

Power (watt) 2700

Dimension and approx. weights(lxdxh/kg)- testing frame (piston fully out) 707x537x2740/1400- servocontrolled power unit 565x540x1800

Total approx. gross weight 2300 kg

Shipping cubage (m3 ) 4.5

70-C810/C 70-C820/C

1000 1000200 2000

Automatic changeover of scale sensitivity

1 kN 1 kN

700 7002 21 12 2hydraulic with hydraulic withremote control remote control40 4075x30 75x30

70-C810/1 70-C820/4660 675

70-C810/21 70-C820/2

70-C810/3 70-C820/31

0-110 0-83

690 500

620 610

- -

295 330

2700 2700

860x635x3630/1900 955x635x3960/2900565x540x1800 565x540x1800

2500 kg 4000 kg

5.5 7

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Universal Winsoft Testing Program (UWT)The UWT is a program working in Windows 95 that drives the testing machine and provides data acquisition and processingfor Controls Automatic Universal Testing Machine 70-C0807/C, 70-C0810/C, 70-C0820/C according EN and ASTMspecifications, by means of an interface board installed in the computer.It is also possible to manage a Database of the tests and drive the certificate printout with graphs for each single test and batchcertificates for groups of single tests.

Personal computer installation and connectionThe Personal Computer has to be connected to the control console of the machine.On the right hand side of the control console two serial cable are provided.They have to be connected to the related RS 232 ports of the computer.In order to make proper connection, check the reference figure attached to the connectors. The electric mains supply cableof the control console is located on the right hand side.On the left hand side of the console, four cables are provided, corresponding to the following description:

A) cable with 3 pin connector for the limit switch installed on the testing frameB) cable with 5 pin connector for load cellC) cable with 6 pin connector for encoderD) cable with quick connection for coaxial extensometer (cat. 70-C0961/A..... 70-C0961/E)

The cables A), B), C) have to be connected to the related connectors installed on the frame.

Fig. 1

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INSTRUCTION MANUAL

Once the above mentioned connections have been made, connect the control console to the mains and switch to "power on",then switch on the computer. In Windows (using the mouse) select the "UWT" program. The page showing Controls logo andtest/function selection keys will appear (Refer fig. 1 of instruction manual).

They are:

tensile test on rounds

tensile test on flats

tensile test on non standard specimens

transverse test or cold bending

compression / flexion

calibration/manual driving

machine parameters configuration menu

other tests (void)

other tests (void)

other tests (void)

info

help/general machine description

exit

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Test procedure / functions related to selection keys

Tensile test on rounds

The tensile test on rounds is performed according to ISO EN 10002 and ASTM A 370.Round bars can be machined or non-machined, deformed or plain. (Refer fig. 2 of instruction manual).Once the test selection key has been activated, the set up and test starte page appears.

Fig. 2

This page consists of two parts; to the left, the part containing drive keys; to the right, the part containing description andadministrative keys.The part on the left side comprises the following sections(from top to bottom):

- Selection of the strain measuring apparatus: encoder or extensometer.

- Encoder . The encoder, an optic scansion instrument, is installed on the testing frame. The encoder transmits themovement data of the mobile frame cross beam along with the upper jaws.Therefore, the mobile cross beam movement corresponds to the elongation of the test piece. It has to be consideredthat the movement measured includes the relative movement of the jaws (due to the grips wedging in the jaws), anyslipping of the test piece and the elastic strain of the frame during the test. For this reason, it is recommended not tocalculate the elastic modulus of test pieces (E key disabled) when this type of transducer is used.

- Extensometer . Controls supplies coaxial type extensometers that allows accurate measurement of only the test pieceelongation, up until failure.Each extensometer can be connected to a range of bar diameters in such a way that the setof Controls coaxial extensometers coversthe complete range of bar diameters that are accepted by Controls universaltesting machines; from 5,5 mm to 36 mm.The extensometer test selection consists of two keys ; the right hand one selects the extensometer according to its diameterrange

"A" from 5,5 to 11 mm;"B" from 12 to 16 mm;"C" from 19,5 to 20 mm;"D" from 25 to 30 mm;"E" from 32 to36 mm ).

Entry of test piece data and parameters selection for test setting up (central section ).After the introduction of the weight and the length of the specimen ( Lt ) in the appropriate boxes, the equivalent diameter

and the equivalent section, along with the linear mass (kg/m) are processed.According to the Standards it is declared if the specimen is proportional or not ,the max distance between marks (Lo) and, ifused, the extensometer base length (Le) should be entered.

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The series of parameters foreseen by the Standards is complete, but some of them are disabled and can be activated at thedescretion of the operator.The following parameters are activated by "default":"Fm" ; "Rm" ; "A" ; "ReH" ; "ReL" ; "Lu".Their boxes are displayed in the next page containing the tensile test graph.The "ReH" and "ReL" parameters can be replaced by the "Rp" optional parameter ( not proportional strenght) when alloy steelswithout evident yield are to be tested.Other parameters such as "E"; "Rt"; "Ae"; "At"; "Ag"; "Agt"; "Su"; "Z" are disabled (optional) but they can be activated by theoperator. - Lower section : "pump" on /off switch; "CELL" box for indication of eventual load cell tension (KN) due to the specimen

clamping in the jaws, accompanied by the "zero" key; "START TEST" key.- The right hand part of the page, descriptive and administrative, consists of three sections .- The upper section, "specimen", identification, is descriptive as the user enters the information required in such a way that

the test piece identification is definite. Most of the boxes are self evident, however the "label" box needs to be mentioned.

In this box the user enters an alphanumeric code that, correlated to the "certificate number" (lower section of the descriptive/administrative part of the page), identifies the specimen for the test filing and for the recall of the single test certificate or batchcertificate. In the "sample" box the description and identification of the bar from which the specimen has been cut, is entered.The "position ,direction of sample" box is optional and, when activated, allows to specify the position and direction of samplingfrom the bar.

- Leaving out the central section, which is self explaining, the lower section includes the "certification" part where, in the"number" box, the operator enters an alphanumeric code that will be the reference for filing and recall from memory,through the " OPEN" key .

It is suggested that the literal part of the code consists of the name (or part) of the "CLIENT" .The "HELP" and "EXIT" keys command the "help on line" and the escape from "tensile on rounds" section .Note: in the next test, once the page containing the graph has been completed, the data entered for the previous test are

represented.

The user can then modify this as required ( in the "LABEL" box a subsequent alphanumeric code related to the new specimenshould be entered).Access to the next page, the graph, is reached by pressing the "START TEST" key. (Refer fig. 3 of instruction manual).

Fig. 3

This page , showing the graph that developes in real time during the tensile test, consists of the following parts:- the diagram, "Y" axis in N/mm2 and "X" axis in % strain.- At the lower right hand corner is a set of commands comprising the "STOP" emergency key, two keys with arrows, one

key with a circled cross, one key with a cross and one key with a "hand". The two keys with arrows show the completetest plot; the "circled cross" key is the tool for ZOOM (by the available dot it is possible to define a portion of the graphto be zoommed ,"drag and drop" function);the key with a cross has the function for dots positioning. For this purpose ,onright hand side, a set of four keys (left,up, right,down) are provided for the fine movement of the dot selected by the keywith the cross (ReH, ReL, Rp).The key with a hand is a tool for moving the complete graph (panning).

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- In the lower part are the keys "PRINT" for printout, "SAVE" to save diagram with its values, "OPEN" to recall, "HELP"on line and "EXIT" to return to the previous page (next test).Referring to the keys "SAVE" and "PRINT", we point out that by "SAVE" the following window that opens asks if it isrequired to save one single test on one certificate or more tests on one certificate (batch certificate). Similarly, the "PRINT"key opens a window that asks if it is necessary to print one single test on one certificate or a batch certificate identifiedby one alphanumeric certificate number.Furthermore, it also asks if, in case of a single test certificate printout, if the seperate graph printout is required. (Referfig. 4 & 5 of instruction manual).

Fig. 4 Fig. 5

Testing procedureOnce the Universal Testing Frame has been set up for tensile tests on rounds, the test has to be performed according to thefollowing procedure:- select, using the mouse, the UWT program. The page with Controls logo appears as well as the test menu keys. Select

"TENSILE TEST ON ROUNDS" and the first page will appear. (Refer fig. 2 of instruction manual) .

Switch on the pump, using the mouse. It is recommended that the pump is left running for immediate operation with the mobilekeyboard pushbottons on the frame.Choose the type of test piece elongation measuring system: encoder or coaxial exensometer. If encoder is selected, select"Encoder" key using the mouse.

Encoder testing procedure1a) digit the weight and the total length of the bar (Lt).

The computer calculates the linear mass and the equivalent section and diameter.2a) mark references on the specimen and digit the distance (Lo) between the extreme reference marks. The "Le" box is

disabled. If reference marks are not made, digit the internal distance measured between the opposite grips into the "Lo"box, once the specimen has been clamped. Indicate, by using the mouse, if the specimen is proportional or not.

3a) place the bar between the jaws . Push the "JOG UP" pushbutton on the mobile keyboard of the frame to raise the upperjaw conveniently. Push the lower and then the upper jaws opening command pushbuttons. Place one end of the bar to be teseted between the lower jaws and by the appropriate pushbutton of the keyboard closethe grips.By pushing the "JOG DOWN" pushbutton, move down the mobile crossbeam of the frame until the upper end of the baris positioned between the upper jaws. Returning to the computer, push the "0" key and close the grips of the upper jawsby pushing the appropriate pushbutton of the mobile keyboard. Check if the "CELL" box shows an eventual positive ornegative value in kN. By pushing alternatively "JOG" (up) and "JOG" (down), minimize as much as possible the shownvalue in kN. Then push "0" for the residual force zeroing.The specimen is now ready for the test.

4a) Fill the descriptive/administrative data as required on the right hand side of the page (Refer fig. 2 of instruction manual).5a) Push "START TEST" key. The next page containing the graph (fig. 3) appears and at the same time that the machine

starts the tensile test.6a) In real time load and displacement signals are transmitted and the tensile plot develops on the graph. The X and Y axis

scales can be modified during the test according to the needs.7a) Once the sample has been broken, in relation with the optional parameters selected, the following elements are displayed

in the graph:- One reference line overlapped on the elastic part of the curve (E - modulus best fit).- ReH and ReL or Rp data- The Rt dot

Usually software positions them (automatically) in the most convenient way; in case this positioning is not evident, for

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INSTRUCTION MANUAL

istance when curve does not show evident yield, it is necessary to position normally the dots and to check the correspondingvalues in to their proper boxes placed right side the graph.It is suggested, for a better accuracy, to position manually the dots then to use the "Zoom command" and then the reachthe fine adjustement of the dots.By the same procedure it is possible to position again the dots and the reference line already processed automatically atchoise of the operator.If the Lw measure has been taken and is has entered in to the proper box, the "A" value will be given by:

Lu - Lo--------- x 100 Lo

8a) By "ESC" program comes back to the previous page (fig. 2). By the command "Save" the Test is stored in memory (thediagram is saved according the last processing).It is now possible to perform a new Test or escape to the main menu.

Important Note: During the test it is always possible to stop the test by use of the "STOP" key. In this case the pump runscontinuously but the electromagnetic valves open and stop the load increase.

Extensometer testing procedureSelect "Extensometer" in the proper box.

1b) Digit weight and total length (Lt) of the specimen. The computer calculates the linear mass and the equivalent area anddiameter.

2b) Indicate, with the mouse, if the specimen is proportional or not and digit in the appropriate box the extensometer baselength (Le), which is 5 times the bar diameter. If, for complete test reliability, it is desired to mark the specimens withreference lines or dots, digit the Lo value as well. Select eventual optional parameters such as "E" (Modulus of Elasticity),"Rt" and others and, "Rp" parameter, if testing alloy steelsthat do not show evident yield. The selection of "Rp" excludesthe defalut parameters ReH and ReL.

3b) Fill the descriptive/administrative data at the right hand part of the page (fig. 2).4b) fit the coaxial extensometer and fasten it at the central part of the test piece. For detailed procedure, see the instruction

manual of extensometers 70-C0961/A ....70-C0961/E.Connect the proper cable that connects the control console to the displacement transducer of the extensometer.

5b) Now place the specimen or the unmachined bar, between the jaws (see 4a).6b) Push "START TEST" key. The next page containing the graph appears and at the same time that the machine starts

tension test7b) In real time load and displacement signals are transmitted and tensile plot develops on the graph.8b) Once the test piece has been failed, Fm, Rm, ReH, ReL, and A values are displayed in their boxes.

If Lu measurement is taken, (advisable if specimen breaks outside the extensometer), and it is entered in its box, theA value is given by

Lu-Lo---------- x 100 Lo

If Rp function has been activated, ReL and ReH are then disabled; it is necessary to manually position on the diagramone line parallel to the Elastic phase at a prefixed intercept value to X axis corresponding to a given % deviation fromproportional, ex. 0,2%.The other optional parameters, if selected on the first page (fig. 1), appear at right hand side of the graph along with the"default" parameters.

9b) The group of keys positioned at the lower right hand corner of the graph (fig. 3) allow the modification of axis scales, toselect part of the plot with subsequent zoom in order to give the operator the possibility to move ReH, ReL, Rp parametersdots along the curve and position them with the max accuracy.

10b) The "SAVE" key is used to store the test and it is possibile to return to the previous page (fig. 2) if another test is required.With the "EXIT" key it is possbile to escape from this section of the program.Remember that with "SAVE" and "PRINT" and related dialog windows (fig. 4-5) it is possible to store and print a singletest in a certificate or a batch test certificate where many single tests are grouped by one alphanumeric code (Certificatenumber).Important Note: During the test it is always possible to stop the test by use of the "STOP" key. In this case the pumpruns continuously but the electromagnetic valves open and stop the load increase.

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INSTRUCTION MANUAL

Tensile test on flats

Flat specimens have rectangular uniform section.To perform tensile test on flats first of all mount the proper grips cat. 70-C0807/10 into the jaws on the frame.Once the above mentioned test has been selected, from the main menu, it can be performed by following a procedure similarto the one on rounds with encoder.

The tensile test on flats is performed according to ISO EN 10002 and ASTM A 370.Once the test selection key has been activated, the set up and test starting page appears.The page consists of two parts; to the left, the part containing the drive keys, to the right, the part containing description andadministration keys.The part on the left comprises the following sections (from top to bottom):

- Selection of the strain measuring apparatus: encoder.

EncoderThe encoder, an optic scansion instrument, is installed on the testing frame. The encoder transmits the movement data ofthe mobile frame cross beam along with the upper jaws.Therefore, the mobile cross beam movement corresponds to the elongation of the test piece. It has to be considered thatthe movement measured includes the relative movement of the jaws (due to the grips wedging in the jaws), any slipping ofthe test piece and the elastic strain of the frame during the test. For this reason, it is recommended not to calculate the elasticmodulus of test pieces (E key disabled) when this type of transducer is used.

- Entry of test piece data and parameters selection for test setting up ( central section ).After the introduction of the weight and the length of the specimen ( Lt ) in the appropriate boxes, the equivalent diameterand the equivalent section ,along with the linear mass (kg/m) are processed.According to the Standards it is declared if the specimen is proportional or not ,the max distance between marks (Lo) and,if used , the extensometer base length (Le) should be entered.The series of parameters foreseen by the Standards is complete, but some of them are disabled and can be activated atthe descretion of the operator.The following parameters are activated by "default" :"Fm" ; "Rm" ; "A" ; "ReH" ; "ReL" ; "Lu".Their boxes are displayed in the next page containing the tensile test graph.The "ReH" and "ReL" parameters can be replaced by the "Rp" optional parameter ( not proportional strenght) when alloysteels without evident yield are to be tested.Other parameters such as "E"; "Rt"; "Ae"; "At"; "Ag"; "Agt"; "Su"; "Z" are disabled (optional) but they can be activated bythe operator.

- Lower section : "pump" on /off switch; "CELL" box for indication of eventual load cell tension (KN) due to the specimenclamping in the jaws, accompanied by the "zero" key ; "START TEST" key.

- The right hand part of the page, descriptive and administrative, consists of three sections .- The upper section, "specimen", identification, is descriptive as the user enters the information required in such a way that

the test piece identification is definite. Most of the boxes are self evident, however the "label" box needs to be mentioned. In this box the user enters an alphanumeric code that, correlated to the "certificate number" (lower section of the descriptive/administrative part of the page), identifies the specimen for the test filing and for the recall of the single test certificate orbatch certificate. In the "sample" box the description and identification of the bar from which the specimen has been cut,is entered .The "position ,direction of sample" box is optional and ,when activated, allows to specify the position anddirection of sampling from the bar.

- Leaving out the central section, which is self explaining, the lower section includes the "certification" part where, in the"number" box, the operator enters an alphanumeric code that will be the reference for filing and recall from memory, throughthe " OPEN" key.It is suggested that the literal part of the code consists of the name (or part) of the "CLIENT" .The "HELP" and "EXIT" keys command the "help on line" and the escape from "tensile on rounds" section.

Note: in the next test, once the page containing the graph has been completed, the data entered for the previous test arerepresented.

The user can then modify this as required ( in the "LABEL" box a subsequent alphanumeric code related to the new specimen should be entered).Access to the next page, the graph, is reached by pressing the "START TEST" key. (Refer fig. 3 of instruction manual).

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INSTRUCTION MANUAL

This page , showing the graph that developes in real time during the tensile test, consists of the following parts :- the diagram, "Y" axis in N/mm2 and "X" axis in % strain.- At the lower right hand corner is a set of commands comprising the "STOP" emergency key, two keys with arrows, one

key with a circled cross, one key with a cross and one key with a "hand". The two keys with arrows show the completetest plot; the "circled cross" key is the tool for ZOOM (by the available dot it is possible to define a portion of the graph tobe zoommed ,"drag and drop" function);the key with a cross has the function for dots positioning. For this purpose ,on righthand side, a set of four keys (left,up, right,down) are provided for the fine movement of the dot selected by the key withthe cross (ReH, ReL, Rp).The key with a hand is a tool for moving the complete graph (panning).

- In the lower part are the keys "PRINT" for printout, "SAVE" to save diagram with its values, "OPEN" to recall, "HELP" online and "EXIT" to return to the previous page (next test).Referring to the keys "SAVE" and "PRINT", we point out that by "SAVE" the following window that opens asks if it is requiredto save one single test on one certificate or more tests on one certificate (batch certificate). Similarly, the "PRINT" key opensa window that asks if it is necessary to print one single test on one certificate or a batch certificate identified by onealphanumeric certificate number.Furthermore, it also asks if, in case of a single test certificate printout, if the seperate graph printout is required. (Refer fig.4 & 5 of instruction manual).

Testing procedureOnce the Universal Testing Frame has been set up for tensile tests on rounds, the test has to be performed according to thefollowing procedure:

- select, using the mouse, the UWT program. The page with Controls logo appears as well as the test menu keys. Select"TENSILE TEST ON FLATS" and the first page will appear.

Switch on the pump, using the mouse. It is recommended that the pump is left running for immediate operation with the mobilekeyboard pushbottons on the frame.- select "ENCODER" key using the mouse.1a) digit the section dimensions of the test piece.

The computer calculates the section area.2a) mark references on the specimen and digit the distance (Lo ) between the extreme reference marks. The "Le" box is

disabled. If reference marks are not made, digit the internaldistance measured between the opposite grips into the "Lo" box, once the specimen has been clamped. Indicate, by usingthe mouse, if the specimen is proportional or not.

3a) place the bar between the jaws . Push the "JOG UP" pushbutton on the mobile keyboard of the frame to raise the upperjaw conveniently. Push the lower and then the upper jaws opening command pushbuttons.Place one end of the bar to be teseted between the lower jaws and by the appropriate pushbutton of the keyboard closethe grips.By pushing the "JOG DOWN" pushbutton, move down the mobile crossbeam of the frame until the upper end of the baris positioned between the upper jaws. Returning to the computer, push the "0" key and close the grips of the upper jawsby pushing the appropriate pushbutton of the mobile keyboard. Check if the "CELL" box shows an eventual positive ornegative value in kN. By pushing alternatively "JOG" (up) and "JOG" (down), minimize as much as possible the shownvalue in kN. Then push "0" for the residual force zeroing.The specimen is now ready for the test.

4a) Fill the descriptive/administrative data as required on the right hand side of the page5a) Push "START TEST" key. The next page containing the graph (fig. 3) appears and at the same time that the machine

starts the tensile test.6a) In real time load and displacement signals are transmitted and the tensile plot develops on the graph. The X and Y axis

scales can be modified during the test according to the needs.7a) Once the specimen has failed, Fm, Rm, ReH, ReL, and A values are displayed in their boxes. If the Lu measurement has

been taken and is entered in its box, A value will be processed according to

Lu LoLo

x 100-

8a) By command "SAVE" the test is stored and the previous page appears (fig.2) ready for another test.Use "EXIT" key to escape from the program.

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INSTRUCTION MANUAL

Tensile test on non standard specimens

Non standard test specimens are samples of unusual shape, according to particular production design such as: hooks, chains,shaped flats, etc. for which it is often necessary to provide special grips.Generally, the tensile test is run by following the "tensile test on rounds" procedure.

Transverse or cold testing test

The transverse test consists of a flexion on a steel bar positioned on two lower roller bearerss. The bar is stressed by an uppercentral roller bearer by means of cat. 70-C0807/2 or 70-C0810/21 or 70-C0820/2 accessories.According to UNI 559, the transverse test, is used to measure, in the proportional elastic phase, the flexural strength for a givendeflection or,conversely, the deflection for a given flexural load.Therefore, the load cell and the encoder supply data for a load /deflection graph plot.If, instead, the user has to perform the cold bending test, according to ASTM E 290 and UNI 564, the accessories cat. 70-C0807/31 or 70-C0810/3 or 70-C0820/31 along with the 70-C0807/5, 70-C0807/6, 70-C0807/7, 70-C0808/7 tools have to bemounted on the tensile testing machine frame.

Test procedure1) Position the support with two lower rollers of the accessory 70-C0807/2 or 70-C0810/21 or 70-C0820/2 on the lower part

of the mobile frame cross beam and fasten; fit the appropriate upper roller bearer, selected from the transverse testaccessories, to the internal part of the fixed frame cross beam,(for detailed mounting procedure, see the related accessoryinstructions).

2) Select ,from the menu page, the test concerning the above mentioned test. A first page appears on which the administrative/descriptive data have to be entered, as well as the test configuration data, such as distance between the lower rollers andthe diameter of the upper mandrel. With the "PUMP" and "START TEST" keys the test starts and at the same time thesecond page containing the graph appears where the "Y" axis is expressed in KN and the "X" axis is expressed in mm ofdeflection. The test should be stopped during the advanced plastic phase, at a certain deflection , by operator choice, bypushing the "STOP" key.The key with a "cross", for the manual movement of the dots, will put the operator in the position to obtain the load valueat a given deflection or to obtain the deflection value at a given load.The "SAVE" and "PRINT" keys allow the test storage and the test certificate printout.

3) When the "cold bending test" is requested,the operator has to install the proper accessory,as mentioned before. He willrun the test and enter the results of the visual inspection in the "NOTE" section, according to the requirements of thStandards.

Compression / flexural test

The compression test refers to cubic or cylindrical concrete specimens and the flexural test on concrete learns..The ralated accessory is Cat 70-C807/4 or 70-C810/1 or 70-C820/4, or 70-C970.They consists of upper and lower compression platens and spherical seat or steel beamwith two knifes and upper or singleknife.It is nevertheless advisable to point out that the universal testing frame is not properly indicated for running many routinecompression tests, due to the large quantity of hydraulic oil involved.Infact it accumulates considerable elastic energy and can release it suddenly when the sample is broken.

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INSTRUCTION MANUAL

Test procedure1) Place the lower compression platen on the lower internal part of the mobile crossbeam of the universal testing frame. Fit

the spherical seat and the upper platen to the internal upper part of the fixed crossbeam by means of the shaped connectionpin (for detailed procedure refer to the accessory instruction manual).

2) Select , from the menu page, the compression test. (Refer fig. 6 of instruction manual).

Fig. 6

In this page enter the descriptive specimen data ,as requested by the boxes (the computer calculates the area and densityof the sample), and the administrative data.

3) To perform the test, position the sample between the compression platens. Switch on the pump using the "PUMP" key and,by the"JOG UP" pushbutton of the mobile keyboard,raise the mobile crossbeam until the clearance between the sampleand the upper platen is 5/10 mm.

Select compression or flexion Test by mouse in the proper box. Digit the administrative parameters and enter the equivalentarea of the specimen.

A) In case of compression Test the equivalent area corresponds to the section of the sample between compression platens.

B) In case of flexural Test the equivalent area is given by:

1) Aeq 2 x d1 x d2

3 x l mm

22=

if the flexural Test has been made by one central upper knife

2) Aeq d1 x d2

l mm

22=

if the flexural Test has been made by upper knifesWhere:d1 = base lenght of the beam (mm)d2 = thickness of the beam (mm)l = distance between two lower knifes (mm)

Remember to enter the area (equivalent) of the sample always.Other wise the Test cannot procede.Zero the load by "ZERO" key and start the test. The sample is brought to the upper platen and is broken in compression. Oncethe sample has failed the machine stops automatically and and the max breaking load and stress values are displayed in theirboxes. The "STOP" key interrupts the test manually."SAVE", "OPEN", "PRINT" keys save the test, recall, print test certificates (single test certificates or batch test certificates).

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INSTRUCTION MANUAL

Calibation / manual testUsing the "calibration menu" it is possible to perform the calibration of force and displacement signals coming from load celland displacement transducers , extensometer or encoder. The dedicated menu is dislayed by the program page of fig. 7.

Fig. 7

This part of the program can also be used for manuallly controlled tests, and data is displayed in term of force (KN) anddisplacement (mm).On the left hand part of the monitor, there are three boxes that display the transducer reading.

1) The section "LOAD" shows the load value of the load cell installed into the load piston of the frame. It is possible to activateor disable the function "HOLD" by selecting "PEAK" or "NO PEAK".The "ZERO" key zeroes the display and, by the "SELECT CHANNEL" option it is possible to select the calibration load scale,that is divided in two ranges:

1(st) = up to 10% of full scale2(nd) = up to 100% of full scale

In the "coeff" boxes is the calibration constant of the selected scale. It should be noted that the machine passes from thefirst scale to the second scale automatically during the automatic tests.

2) The "Displacement- Encoder" section displays the frame crossbeam positioning. The related signal comes from theencoder. The "ZERO" key zeroes the related display.

3) The "Displacement- Extensometer " section displays the transducer reading (Cat 70-C961/A...../E). It is possible to selectthe model of extensometer (A,B,C,D or E) by the option "Select channel".The calibration coefficient is displayed in the "coeff" box.The "ZERO" key zeroes the reading.

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INSTRUCTION MANUAL

On the right hand part of the monitor are the command keys for the hand driving of the machine, as shown in (fig. 7):

high speed load ramp

low speed load ramp

load ramp zeroing (load maintaining phase )

slow decrease load ramp

fast decrease load ramp

preset speed number: 0 = null speed

4095 = max speed

According to the preset speed, the computer drives the proportional flow valve installed into the hydraulic power unit.(Refer fig. 9 of instruction manual).

switch ON / switch OFF key. The led shows the status of pump. (Refer fig. 10 of instruction manual).

Fig. 4 Fig.5

Electromagnetic valve driving keys:"LOAD" = high pressure command"ALT" = high pressure command stop"UNLOAD" = high pressure unload command

With the "HELP" key the Help on line appears , with the "EXIT" key the program returns to the main menu.

ProcedureTo perform the calibration of the machine it is necessary to use a calibration apparatus such as the load cell (e.g. cat 82- E100/CS or 82- E100/DS or 82-E100/ES - 600 KN - 1000 KN - 2000 KN capacity respectively) according to the capacity of theuniversal testing machine, along with the tester cat 84-P50/B for load calibration and reference blocks (prefeably accompaniedby certificate) for displacement transducer calibration.

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INSTRUCTION MANUAL

Calibration of loadPosition the load verification instrument between the compression platens of the machine, then operate as follows:a) switch on the pump using the appropriate key.b) select the scale for which the calibration is required by selecting on "SELECT CHANNEL"; the first scale covers the range

up to 10% of total capacity; the second scale covers the range from 10% up to 100%.c) by pushing "JOG UP" pushbutton of the mobile keyboard bring the dynamometer (load cell) to a distance of 5/10 mm from

the upper compression platen. Then release the pushbutton.d) push "LOAD" key (the red led lights up) in order to abilitate the high pressure. Then push the "fast load ramp" key (the "OUT"

display increases by 100 divisions) to start the load phase.e) before the load cell comes into contact with the upper compression platen, it is advisable to zero the load display by pushing

the "ZERO" key.f) during the loading phase it is possible to increase or decrease the load speed according to the operator need by pushing

the "LOAD CONTROL" section keys. It is also possible to maintain the load by pushing the "load maintaining" key or byzeroing the "OUT" displayed value.

g) to stop the loading cycle push the "load maintaining " key and then the "UNLOAD" key.This causes the machine piston to descend. It is possible to stop it by pushing "ALT" key. So, the distance between theload cell and the upper compression platen will be sufficent in order to be in condition to repeat the load cycle and avoidthe piston going down to its rest position.

h) To repeat the procedere start from point (c).i) If the calibration needs to be adjusted,it is sufficient to correct the coefficient related to the selected scale.

The coefficient has to be modified by a % equal to the measured error: eg.Coeff. = 0,11000Mean measured error = + 1,3%New coeff. = 0,11000 - 1,3% = 0,10857.

l) To verify the calibration on the two ranges it is necessary to perform the operations by starting from point b) and by selectingChannel 1 first and then Channel 2 .

Calibration of EncoderThe displayed value in the "encoder "box is the numeric equivalent of the digital pulses transmitted by the encoder. For thisvalue no calibration is necessary, but it is possible to check the accuracy.Zero the display by pushing the "ZERO" key. It is to be pointed out that the encoder is bidirectional : it increases when the mobilecrossbeam goes up and decreases when it goes down.

Calibration of Coaxial ExtensometersEach coaxial extensometer model has a proper calibration coefficient.To perform the calibration follow the instruction:a) Select the type of the connected extensometer through the "SELECT CHANNEL" key. The calibration coefficient is

displayed in the "coeff" box.b) Place the transducer stem in its retracted position , but avoide retracting the stem completely.c) Zero the display by pushing the "ZERO" key.d) Extend the stem by a known distance.e) Verify the display error and, if necessary, correct the coefficient value as already explained at point i) of " load calibration"

paragraph "i".f) Repeat from point "b" to check the new calibration value.

The above mentioned procedure has to be followed for all the extensometers supplied . Pay attention to the correct selectionof the extensometer type that has been choosen.Important note: whenever it is requested to modify the calibration coefficients, it is necessary to know the PASSWORD thatis asked when the "coeff" key is pushed. The PASSWORD is available on the first line of "TOOLTIP.DOC" file.

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INSTRUCTION MANUAL

Universal testing machine constants setting up menu (Refer fig. 11 of instruction manual).

Fig. 11

This menu includes all the software constants that contribute to the machine operation.At the left hand part of the page are transducer setting parameters.Such parameters have been entered by CONTROLS and cannot be modified.At the right hand part are the setting parameters related to the tests that the machine can perform; they are:(Refer fig. 12/a of instruction manual).

Fig. 12/a Fig. 12/b

Sensitivity is the aptitude to show the failure of the sample in an automatic way.For the tensile tests it is possible to select three sensitivity levels.

- HIGH: the machine stops whenever a 10% load drop occurs.- NORMAL : the machine stops whenever a 25% load drop occurs.- LOW: the machine stops whenever a 50% load drop occurs.

For round bars it is suggested to use NORMAL sensitivity.With this sensitivity level the machine can operate at optimum condition for the majority of this type of specimen.LOW sensitivity is suggested for specimens that show stepped collapse.For concrete compression tests it is possible to enter the sensitivity value in KN directly. During the compression test themachine stops automatically when the load drop corresponds to the preset sensitivity load value. It is suggested to enter smallvalues ( e.g. 5..10 KN ) due to the substantial rigidity of the material.

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INSTRUCTION MANUAL

The values to be entered into the section "RATES" are the preset speeds that the machine use during the tests. The load rateis expressed in N/sqmm * s and has to be preset by the operator.For tensile tests the load rate values are included between 2 and 30 N/sqmm*s . It is however suggested , for better accuracy,to use intermediate values, for instance 10 or 15 N/sqmm*s . It is to be pointed out that the machine operates in load controlduring the elastic phase and in strain control from the yield point to failure.The passage from the first mode to the second mode occurs automatically.In case of compression test on concrete the load rate value has to be entered according the requirements of the Standards.The PASSWORD activates the menu. It is therefore necessary to know the secret code that is however available on the firstline of "TOOLTIP.DOC" file .The "APPLY" key saves the settings that have been entered, "HELP" opens the help on line and "EXIT" returns to the mainmenu.

Note: The P.C. supplied with the universal testing machine is integrating part of it. Therefore the P.C. cannot be used for otherapplication. Particulary it is strictly recommended not to modify settings, over all the ones of the control panel of Windows 95.It is suggested to connect to P.C. to a UPS unit in order not to loose data due to fault of electric supply.Controls S.p.A. accept no responsabilities for any problems caused by any unautorized modifications of any part of thesoftware and hardware system.

12 Determination of proof strength (non-proportional extension) (Rp)

12.1 The proof strength (non-proportional extension) is determined from the force/extension diagram by drawing a line parallelto the straight portion of the curve and at a distance from this equivalent to the prescribed non-proportional percentage,for example 0,2%. The point at which this line intersects the curve gives the force corresponding to the desired proofstrength (non-proportional extension). The latter is obtained by dividing this force by the original cross-sectional area ofthe test piece (S0) (see figure 3).

13 Determination of proof strength (total extension) (R t)

13.1 The proof strength (total extension) is determined on the force extension diagram by drawing a line parallel to the ordinateaxis (force axis) and at a distance from this equivalent to the prescribed total percentage extension. The point at whichthis line intersects the curve gives the force corresponding to the desired proof strength. The latter is obtained by dividingthis force by the original cross-sectional area of the test piece (So) (see figure 4).

13.2 The property may be obtained whitout plotting the force/extension diagram by using automatic devices.

14 Method of verification of permanent set strength (R r)

The test piece is subjected to a force for 10 s to 12 s corresponding to the specified stress and it is then confirmed, afterremoving the force, that the permanent set extension or elongation is not more than the percentage specified for the originalgauge length.

Stress Stress

Percentage elongationor Percentage extension

Figure 4. Proof strength, total extension(Rt)

Percentage extension

Figure 3. Proof strength, non-proportional extension (Rt)

Percentage extension

Figure 5. Permanent set strength (Rr)

Stress

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INSTRUCTION MANUAL

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3 d mmtsetralucricafohtgnellellarapehtforetemaiD

retemaidlanretniroeriwdnuorforetemaidro,eceipebutafo

4 D mm ebutaforetemaidlanretxE

5 Lo mm htgneleguaglanigirO

6 Lc mm htgnellellaraP

- Le mm htgneleguagretemosnetxE

7 Lt mm eceiptsetfohtgnellatoT

8 Lu mm erutcarfretfahtgneleguaglaniF

9 So mm 2 htgnellellarapehtfoaeralanoitcesssorclanigirO

01 Su mm 2 erutcarfretfaaeralanoitcesssorcmuminiM

11 Z %:aerafonoitcuderegatnecreP

21 - - sdnedeppirG

noitagnolE

31 - mm :erutcarfretfanoitagnolE

41 A %:erutcarfretfanoitagnoleegatnecreP

51 Ae % noisnetxetniopdleivegatnecreP

61 %mumixamtanoitagnolelanoitroporp-nonegatnecreP

ecrof Fm

71 % ecrofmumixamtanoitagnolelatotegatnecreP Fm

81 A % erutcarftanoitagnolelatotegatnecreP

91 - % noisnetxelanoitroporp-nonegatnecrepdeificepS

02 - % noisnetxelatotegatnecreP

12 - %ronoisnetxetestnenamrepegatnecrepdeificepS

noitagnole

ecroF

22 Fm N ecrofmumixaM

htgnertselisneT-htgnertsfoorP-htgnertsdleY

32 R He mm/N 2 htgnertsdleivreppU

42 R Le mm/N 2 htgnertsdleivrewoL

52 Rm mm/N 2 htgnertselisneT

62 Rp mm/N 2 noisnetxelanoitroporp-non,htgnertsfoorP

72 Rr mm/N 2 htgnertstestnenamreP

82 Rt mm/N 2 noisnetxelatot,htgnertsfoorP

- E mm/N 2 yticitsalefosuludoM

S - S

S x 100o u

o

L - L

L x 100u o

o

(Lu - Lo)

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(1) Attention: This machine is very heavy (2,300 kg).When moving it, always use the hook opening provided forthis purpose as indicated here.

(2) The control unit must be placed approximately 30 cmaway from the machine.

(3) To ensure that the machine is straight, screw the 4bolts securely into the floor.

(4) Carefully control that the machine is straight by usinga spirit level.

(5) Connect the hoses the machine to the control unit. (7) Check the electrical characteristics found on the nameplate on side of the machine.

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(8) Remove the rear panel of the control unit.

(9) Unwind the electrical lead.

(10) Pull the electrical lead through the gap in side panel.

(11) Pull out the electronic cable and keyboard.

(12) Pull out the window in the side panel the first electric.

(13) Hang the keyboard over the hook positioned on thefront panel of the machine.

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(14) Insert the appropriate keys attached to the end of theelectronic cables into the spaces marked "Load Cell" and"Limit Switch" toward the top of the machine.

(15) Turn on the main switch found on the front panel ofcontrol unit.

(16) Start the software program. (17) Start the hydraulic pump.

(18) A) Move the frame upward by pressening the buttonshown.

(19) B) Place the rods as shown.

The following photographs (A - J) show the consecutive steps to be taken in order to change the verticaldaylight

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(20) C) Move the frame down by pressening the upper leftbutton on the push button panel (JOG).

(21) D) Unscrew the four bushea as shown.

(22) E) Lift the bush. (23) F) Remove the two half threaded rings.

(24) G) Move the frame upwards or downwards dependingon the desrired vertical daylight required by the push buttonpanel.

(25) H) Replace the two half rings (not threaded) in thedesired position and move the frame upwards until the fourtwo half rings enter their seatings inside the lower plotter.

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(26) I) Replace the four half threaded rings in the desiredposition paying attention to the work number as they wereoriginally coupled.

(27) J) Screw the bushes on.

(28) Photograph A1. (29) Photograph B1.

(30) Photograph C1. (31) Phtograph D1: Place the rod and force it laterallytowards the left to remove the grip liners. Proceed in thesame manner for the right side.

The following photographs (A1 - F1) show the consecutive steps to be taken in order to change thegripper

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(32) Photograph E1. (33) Photograph F1: Grease the grip liners with the specialgrease supplied with the machine.

(34) Photograph A2. (35) Photograph B2.

The following photographs (A2 - D2) show the consecutive steps to be taken in order to change the oilfilter which needs to be done when red light illuminates on the front panel

(36) Photograph C2. (37) Photograph D2.

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

The following photographs (A3 - J3) show the consecutive steps to mount the accessories to carry outthe compression tests

(38) Photograph A3 (39) Photograph B3

(40) Photograph C3 (41) Photograph D3

(42) Photograph E3 (43) Photograph F3

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(44) Photograph G3 (45) Photograph H3

(46) Photograph I3 (47) Photograph J3

(48) Photograph A4 (49) Photograph B4

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

(50) Photograph C4

Rev.: 3 Man. MI0066 / 40

INSTRUCTION MANUAL

NOTE

United KingdomControls Testing Equipment LtdControls HouseIcknield WayTring, Hertfordshire HP23 4JX - U.K.Tel. +44-1442 828311Fax +44-1442 828466E-Mail: [email protected]

Head Office and FactoryCONTROLS S.r.l.Via Aosta, 6I-20063 Cernusco s/N. (MI)Tel. +39 02921841Fax +39 0292103333E-Mail: [email protected]: www.controls.it

FranceControls S.à.r.l.Zone Artisanale68130 Walheim, FRANCEtel. +33-03 89 402655fax +33-03 89 402645E-Mail: [email protected]

SpainEquipos de Ensayo Controls S.A.Poligono industrial arboledasC/Sabina, Nave 5, Manzana D45200 - ILLESCAS (TOLEDO)Teléfonos: 902 18 08 43Fax: 902 18 08 46E-Mail: [email protected]

[email protected]

MexicoEquipos de Ensaye Controls S.A. de c.v.Rio Churubusco No. 27Col. Portales C.P. 03300Delegacion Benito Juarez, Mexico, D.FTeléfonos y Fax +56-72-61-86, +55-39-32-29Corre electronico: [email protected]

manual controls c807

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