www.impact-test.com User Guide

User Guide

www.impact-test.com www.impact-test.co.uk www.impact-testsets.co.uk

Universal Compression/Tension Machine

TS500

Impact Test Equipment Ltd www.impact-test.co.uk - www.impact-test.com

www.impact-testsets.co.uk

www.impact-test.co.uk www.impact-test.com www.impact-testsets.co.uk

Impact Test Equipment Ltd. Building 21 Stevenston Ind. Est.

Stevenston Ayrshire

KA20 3LR

T: 01294 602626 F: 01294 461168

E: sales@impact-test.co.uk

Test Equipment www.impact-test.co.uk

Test Sieves & Accessories www.impact-test.com

Test Sets to International Standards www.impact-test.co.uk

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ContentsCHAPTER 1 GENERAL INFORMATION

1.1 GENERAL1.2 IDENTIFICATION1.3 USAGE1.4 APPLIANCE CHARACTERISTICS1.5 APPLIANCE STRUCTURE

CHAPTER 2 SAFETY INFORMATION2.1 GENERAL SAFETY STANDARDS2.2 PROTECTION2.3 DANGEROUS AREAS AND RESIDUAL RISKS2.4 NOISE

CHAPTER 3 INSTALLATION3.1 TRANSPORT3.2 UNPACKING3.3 LOCATION3.4 OIL LEVEL CHECK AND DRAIN SYSTEM3.5 ELECTRICAL CONNECTION

CHAPTER 5 SOFTWARE DESCRIPTIONCHAPTER 6 USE

6.1 SUGGESTIONS6.2 PREPARATION6.3 SPECIMEN POSITIONING6.4 SWITCHING THE APPLIANCE ON6.5 NORMAL STOP6.6 EMERGENCY STOP6.7 RESTART AFTER EMERGENCY STOP6.8 SWITCHING OFF6.9 TEST START UP

CHAPTER 7 DIAGNOSTICSCHAPTER 8 MAINTENANCE

8.1 EXTRAORDINARY MAINTENANCECHAPTER 9 DEMOLITION

9.1 PRESERVATION9.2 SCRAPPING

Chapter 1 GENERAL INFORMATION

1.1 GENERAL

USERS OF THIS MANUAL: Transporter - Installer - User – Maintenance worker - Demolisher. Carefully read the entire manual which contains important information for safe and efficient use of

the appliance. This manual is an integral part of the product and is only relevant to the appliance it refers to. This manual should be carefully preserved and easily available for the entire technical life of the

appliance. Should the used appliance be sold, it must be sold together with the manual and other documents. The manufacturer does not accept any responsibility for direct or indirect damage to people, things

or animals and use of the appliance in different conditions from those foreseen. The manufacturer reserves the right to make changes to the documentary information or the

appliance it refers to without advance notice. Typographical rules:

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ATTENTIONThe attention signs indicate that a lack of or partial observation of such procedurescan damage the appliance or those linked to it.

DANGERThe danger signs indicate that a lack of or partial observation of such procedurescan cause injuries or damage to the health of the operator.

1.2 IDENTIFICATION

MANUFACTURER IDENTIFICATION: See the title on the first page.APPLIANCE IDENTIFICATION: See the identification number on the appliance.

1.3 USAGE

The control panel allows the load from the pressure transducers or the load cells in the test machine tobe read; it can carry out compression, flexion and indirect tensile tests on concrete or mortar. Thesoftware can create a file containing the characteristics of a series of specimens, therefore beingeasily recalled before the test is carried out. The control panel also allows the test results to be printedand any read data to be exported using RS232 transmission to a PC for electronic filing.

This appliance is for the exclusive use which it has been conceived for.Any other use is considered improper and therefore negligent.

ATTENTION The instructions in this manual are exclusively for correct appliance usage.

1.5 APPLIANCE STRUCTURE

A UNIVERSAL TENSILE/COMPRESSIONMACHINE

B CONTROL – ACQUISITION UNIT

G Piston position indicatorChecks the position of the piston compared to its MAX run.ATTENTION: Never pass the MAX limit

Charter 2 SAFETY INFORMATION

2.1 GENERAL SAFETY STANDARDS

The use, transport, installation, maintenance and demolition of the appliance are only permittedby QUALIFIED PERSONNEL. Qualified personnel means people who, due to their training, experienceand education, as well as knowledge of the relevant standards, limitations and measures, have beenauthorised by the plant safety manager to carry out any necessary activity and are able to recognise andavoid any possible danger. The individual must be adequately prepared in order to avoid impropriate useof the equipment. The individual must be thoroughly educated even concerning any protection deviceswhich the machine is supplied with. Such devices must always be mounted and checked daily. Theconstructor offers suitable training courses and declines every responsibility for damage caused to thingsor people due to improper, incorrect and negligent use by unqualified personnel.

A

BG---------

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The manufacturer recommends meticulous compliance with the instructions, procedures and suggestionscontained in this manual and the safety legislation in force within the work place, even for the use ofprovided safety devices whether they are integrated with the appliance or separate.

Check the machine responds to the standards in force in the State it has been installed in. The instructions manual must be carefully consulted by the safety managers of the laboratory or the

construction site, by the equipment operators and any internal and external maintenance personnel.The manual must be kept well and always near to the equipment so that it can be easily consultedwhenever necessary.

Any tampering with the appliance (electrical, mechanical or other) not pre-emptively authorised in writingby the manufacturer is considered abusive and exempts the manufacturer from any responsibility.

The removal or tampering with safety devices entails a violation of the safety standards. Themanufacturer declines all responsibility for any damage caused by tampering or modifications to theequipment.

Machine use is only allowed in areas where there is no risk of explosions or fires. Only the original fittings can be used. The use of unoriginal fittings exonerates the manufacturer from all

responsibility. Check there are no conditions of danger during machine use. Stop the machine immediately should it be

working irregularly and consult Service Assistance in the authorised dealer.

The manufacturer does not assume any responsibility for direct or in direct damage caused to people,things or animals following a lack of observation of the safety standards and instructions in this manual.

2.2 PROTECTION

DEFINITION: Protections are all the safety measures that consist of the use of specific technical means(repairs, safety devices) to protect people from dangers which cannot be limited reasonably in design.

DANGER Tampering with the protections or any appliance modification could cause risks tousers or other exposed people.The manufacturer does not assume any responsibility for direct or in direct damageto people, things or animals following tampering with the protections.

FIXED AND MOBILE REPAIRSThe appliance is supplied in two versions:- Without protection grids adapted only for tests on specimens which do not present phenomena ofexplosion in the breakage phase.- With protection grid suitable for tests on specimens of any type

Check the supplied appliance is appropriate for the specimens that are to be tested.If any doubt, should any protection repairs not be planned, application of the protection kit supplied uponrequest is necessary.The manufacturer declines all responsibility for damage caused to things or people should the abovewarnings not be adhered to.

PASSIVE SAFETY DEVICESPassive safety devices are the devices or solutions which eliminate or reduce the risks to the operatorwithout any active intervention on behalf of the operator.

The piston has a hydraulic safety system for the upper and lower runs.

2.3 DANGEROUS ZONES AND RESIDUAL RISKS

A danger zone is any zone inside or near the appliance where a person is at risk of injury or damage tohealth.There are residual risks for the operator during any intervention procedure.Such risks can be eliminated by carefully following the procedures shown in this manual and by using theappropriate individual protection devices.

ATTENTION Should installation not be carried out by the Manufacturer, employ only appropriatelytrained personnel for the movement of heavy objects.

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GENERAL STANDARDS Before appliance use check it is found in suitable working conditions and that its parts are

not detective or worn. Carry out any necessary maintenance operations. Pay attention to the danger of electric shocks for direct or indirect contact due to unforeseen damage

to the electrical system. Do not submit the appliance to violent impact. Do not expose the appliance to fire, welding sparks or extreme temperatures. Do not allow the appliance to come into contact with corrosive substances. Do not wash the appliance with jets of water.

THROUGHOUT USE For the sake of the operator’s safety do not touch any part of the appliance in movement throughout

and use the appropriate Individual Protection Devices. When the test is being carried out pay attention to the potential danger of finger or limb crushing and

the possible fall of parts on feet or other parts of the body. Do not wear loose clothing, ties, chains, watches or anything else which could be caught in

the appliance when in movement.

TRANSPORT Throughout transport ensure the appliance is suitably supported when being lifted. Do not stand directly in line with the application of force and do not put personnel where there are

loads which have not been suitably supported by mechanical devices.

RISK OR DANGER IPDFINGER OR LIMB CRUSHING REINFORCED GLOVESSPARK PROTECTION PROTECTION GLASSES

The manufacturer declines all responsibility for direct or in direct damage caused to people, things oranimals and due to the lack of attention paid to the aforementioned precautions or the lack of use ofsuitable Individual Protection Devices (consult the current accident-prevention standards in force).

2.4 NOISE

The air noise emission levels shown do not necessarily imply the levels of exposure to the worker.The levels of exposure to the operator are obviously linked to the emission levels of the appliance; howeverother factors influence the levels of exposure to the operator: length of exposure, environmentalcharacteristics, the presence of other machines, etc.The appliance emission levels allow anyway an estimate to be carried out on the dangers due to noise.

Average continuous equivalent acoustic pressure level Laeq to the distance of 1 m 75 dB(A)

Standard EN ISO3746

DANGER Continuous use of the appliance and machines predictably present in the installationenvironment could cause a heightened daily personal exposure to noise. If the dailypersonal exposure is equal to or more than 85 dB(A) it is advisable to use theIndividual Protection Devices (protective headphones, plugs, etc.). If the dailypersonal exposure is equal to or more than 90 dB(A) it is compulsory to useIndividual Protection Devices (protective headphones, plugs, etc.). For furtherinformation consult the standards in force in the country of installation

Chapter 3 INSTALLATION

DANGER Consult the chapter DANGEROUS ZONES AND RESIDUAL RISKS beforeproceeding

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3.1 TRANSPORT

The instructions in this section must be respected during the transportation phase of the appliance insituations of

Appliance storage First installation Relocation

The appliance is usually sent and delivered packaged in a wooden case to be moved by a forklift truck.

ATTENTION Movement of cases with lifting machines must be carried out with due care andpaying particular attention to the correct way up as shown on the packages. Takethe usual and logical precautions to avoid tipping and blows.

ATTENTION Protect the appliance and its kit from atmospheric agents. Water and humidity canoxidise some elements of the appliance, irreversibly damaging them.

3.2 UNPACKING

After removing the packaging, check the body of the machine and that no parts are visibly damaged. Shouldthere be any doubts DO NOT USE THE MACHINE and refer to the dealer.

ATTENTION The elements used for packing (plastic bags, polystyrene, nails, screws, pieces ofwood, etc.) must be kept out of the reach of children as they are potential sources ofdanger. These elements must be put in suitable collection centres.

ATTENTION Before throwing the packing away ensure they do not contain any elements of themachine such as fittings, utensils, instructions, documents, etc.

3.3 LOCATION

The equipment must be placed in an ideal position and environment for the use it has been conceived for(laboratory use and protected from atmospheric agents) and that the machine is placed by a qualifiedoperator.

ALLOWED TEMPERATURE: from +10°C to +38°CALLOWED RELATIVE HUMIDITY: from 30% to 95%MAXIMUM HEIGHT OVER SEA LEVEL: 1000 m

As previously mentioned, the appliance has not been designed for construction site use, but for laboratoryuse, therefore it should be used in an environment with as constant a temperature as possible.

ATTENTION Should, for any reason, the appliance be used in an environment with a differenttemperature to the one it has been calibrated for, carry out a new calibration of thepress in order to avoid incorrect data reading during the tests.

GENERAL ADVICE The machine must be installed in an area which allows ease of access to all parts so that

maintenance may be carried out. Unauthorised people and objects which could be potential sources of danger must not be permitted

in the area surrounding the machine. The press must be moved by a forklift truck which is able to support the machine mass. For optimal use a smooth concrete is recommended, at floor level, so that the load reading device

(manometer or digital) is at eye level of the operator. This must mainly work in front of the machine.

3.4 OIL LEVEL CHECK AND DRAIN SYSTEM

Follow the instructions acquisition unit

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3.5 ELECTRICAL CONNECTION

Follow the instructions acquisition unit

Chapter 4 APPLIANCE CHARACTERISTICS

4.1 APPLIANCE DIMENSIONS AND MASS

WIDTH 470mmLENGTH 410mmHEIGHT 1875mmMASS 800 Kg circa

MAX COMPRESSION LOAD 1500 kNMAX TENSILE LOAD 500 kNMAX PISTON RUN 120 mmAVERAGE SPECIMEN LENGTHPROVINO

490 mm

DISTANCE BETWEEN THE JAWS 272/392 mmLIGHT BETWEEN THE COLUMNS 270 mm

Chapter 5 SOFTWARE DESCRIPTION

Follow the instructions acquisition unit

Chapter 6 USE

DANGER Consult the chapter DANGEROUS ZONES AND RESIDUAL RISKS beforeproceeding

6.1 SUGGESTIONS

Check the appliance has been installed correctly and that it has been placed in suitable working conditionsbefore use; check its parts are not detective, damaged or worn. Carry out any necessary ordinary andextraordinary maintenance operations.

Before every test always analyse the material characteristics of the specimen and try to predict the behaviourunder load, and carry out all the necessary precautions.

DANGER With special materials with explosive properties there is the potential danger of bitscoming from the specimen. If so equip the appliance with the appropriate protectivedevices.

6.2 PREPARATION

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Tensile testsBefore carrying out a tensile test ensure the machine is equipped with jaws adapted to the specimen to betested.Should the jaws have to be substituted proceed as follows (see attachment B1):

1. Picture 2 : Unscrew with the appropriate spanner the two screws which fix the container plate to thetensile head

2. Picture 3 : Loosen the lateral closure screws; simply loosen them and remove them3. Remove the container plate from the tensile head and rest it on the work space; the jaws and

relevant movement knobs will also be removed with it.4. Picture 4 : Turn the movement knobs so that they unscrew the knob and jaws; during this operation

push the knob against the plate so it does not come away from the plate itself5. After the jaws have been separated from the knobs choose the new ones suitable for the specimen

to be tested and attach them to the relevant knobs, carrying out the operation inversely to above6. When the jaws have been joined to the knobs and the plate, put the plate on the respective tensile

head, screwing up and tightening the previously unscrewed screws. N.B. the screws are part of theresistant structure of the tensile head and must always be tightened correctly; first tightenthe 2 front screws which fix the plate to the tensile head and then the 4 lateral screws

FIGURA 1 FIGURA 2

FIGURA 3 FIGURA 4

6.3 SPECIMEN POSITIONING

Compression testsPosition the specimen on the inferior compression plate and check the distance between the upper surfaceof the specimen and the upper plate is not more than the remaining piston run, verifiable with the pointer.

Tensile testsLower the inferior knobs and insert the specimen. Heighten and tighten the upper knobs. Position thehydraulic compression selector and press the load gradient so it makes the lower clasp rise until thespecimen is inserted in the upper clasp. Unscrew the upper knobs; lower them completely so the specimenis seized.

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ATTENTION When the upper knobs are lowered, unscrew them (at least 3 turns) so that there isspace between the knobs themselves and the upper clasp.

Close the protection of the upper clasp.

6.4 SWITCHING THE APPLIANCE ON

Check the load-unload knob is open (turn in an anti-clockwise direction) and switch the machine on with themaster switch.Position the hydraulic selector according to the test type to be carried out (tensile, compression).

6.5 NORMAL STOP

Follow the instructions acquisition unit

6.6 EMERGENCY STOPFollow the instructions acquisition unit

ATTENTION Test suspension in itself results in its cancellation.

6.7 RESTART AFTER EMERGENCY STOP

DANGER Before restarting the machine detect and remove the cause of the emergency stop.

Simply turn the master switch to “I” to restart the machine, which will restore the normal functions.

6.8 SWITCHING OFF

Follow the instructions acquisition unit

6.9 TEST START UP

Before using the appliance regularly check it is working correctly by carrying out at least one complete emptycycle according to the previous instructions.Should there be any problem consult the chapter “DIAGNOSTICS”.If the instructions in this manual do not provide the solution to the problem, contact Sales Assistance.

Chapter 7 DIAGNOSTICS

This chapter introduces and discusses simple problems which could arise when the machine is working.

ATTENTION All the maintenance procedures, check and control, as well as all the repairoperations on parts of the machine or the electrical system, must be carried out bythe appropriately qualified, professional personnel.

INCONVENIENCE POSSIBLECAUSE

REMEDY

The appliance does not turn on afterpressing the master switch

No supply Check the master switch is workingcorrectlyCheck electrical voltage is present in thecontrol board

Fuse breakage Substitute the broken fuses with new onesof equal capacity.

The piston doesn’t rise or fall Broken electricalsupply

Contact Technical Service Assistance.

Broken motor Contact Technical Service Assistance.Broken hydraulicram

Contact Technical Service Assistance.

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Open hydrauliccircuit

Close the B9 load-unload knob

Insufficient loadgradient

Correctly regulate the load gradientdevice.

B7 hydraulicselector notcorrectly positioned

Correctly position the hydraulic selector.

ATTENTION Contact Technical Sales Assistance for any other problem not listed on the previoustable or should the malfunctioning persist after the intervention of the operator inaccordance with the previously mentioned courses of action.

Chapter 8 MAINTENANCE

DANGERConsult the chapter “DANGEROUS ZONES AND RESIDUAL RISKS” beforeproceeding.

DANGERAll the maintenance operations must be carried out when the machine is switched offand with the supply cable physically unplugged from the Knife switch

DANGERQualified professional personnel must carry out every maintenance operation(including light operations) on the appliance.

DANGEROnly original spare parts can be used. The use of unoriginal parts relieves themanufacturer from all responsibility.

8.1 EXTRAORDINARY MAINTENANCE

DANGERTampering with the protections or any modification of the appliance can cause risksto the operator and other exposed personnel.

The manufacturer does not assume any responsibility for direct or indirect damage to people, thingsor animals due to tampering with the protections.

The load reading unit contains an automatic motor protection switch. Proceed as follows should thisdevice be used for resetting:

1. Switch the appliance off.2. Isolate the appliance from the supply network by disconnecting the supply cable.3. Open the reading unit (by removing the cover) paying attention to the internal cables which

connect the fixed components to the cover with the mother board.4. Press the key on the automatic switch marked “I”.5. Close the reading unit again, connect the supply cable, switch the appliance on and check it

functions correctly.6. Should the automatic switch act again, electrically check the motor or contact service assistance.

For extraordinary maintenance operations (repairs, substitutions and any other operation notdescribed in this manual), directly refer to the Manufacturer.

Chapter 9 DEMOLITION

9.1 PRESERVATION

The electrical supply must be disconnected in the case of preservation for a long period.Carry out all the necessary routine maintenance operations.Lubricate the small, unpainted parts with small amount of oil and cover the machine to protect it from dust.

9.2 SCRAPPING

Should it be decided that the machine is to be no longer used, proceed as follows:

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Disconnect the electrical supply network by removing the connecting cable therefore making it unusable. Make the potential sources of danger harmless, such as sharp or protruding parts.Dismantle the machine; divide it into similar parts and dispose of according to the standards in force.

Recycling notice for the disposal of electrical and electronical devices

This symbol, placed on the device or on the package and/or on the documentation, suggest thatthe device shouldn’t be dispose together with other home garbage at the end of its life cycle.To avoid further environment, or health-care damages, caused by the unsuitable disposal ofgarbage, we kindly recommend the user to separate this device from other different types ofgarbages and to recycle it in a responsible way to avoid the arguable reuse of material

resources. Indeed users must take care at the disposal of the equipment that have to be discarded, takingthem away to the next recycling site for the appropriate recycling treatment for electrical and electronicaldevices. Gathering and Recycling deplete devices allow the preservation of natural resources and grant forthem the adequate treatment respecting health and environment.For further information about your local recycling site please contact your local city hall or city wastetreatment department. The developer, as producer of electrical and electronical devices, will provide tofinance the recycling and treatment services for deplete devices that will come back through these recyclingsite, accordingly the local statement.