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VJT6000 User Guide V1.3 (Re-Saved)
VJT6000 User Guide V1.3 (Re-Saved)
VJT6000 User Guide V1.3 (Re-Saved)
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VJ Technology LTD
User Guide
V JT 6 0 00
Concrete
C o m p r e s s io n
M a c h in e s
Version 1.0
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NOTE:
This Machine has been
shipped EMPTY of oil.
DO NOT operate this machine
until it has been filled with
hydraulic oil.
Requirement: 7 litres, Tellus 32
hydraulic oil or equivalent.
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Contents
1. Overview ................................................................................................................... 5
2. Main Screen Contents ............................................................................................. 8
2.1 System Overview .............................................................................................. 8
2.2 Test Status ......................................................................................................... 9
2.3 Test Specifications ........................................................................................... 9
2.4 Sample Specifications .................................................................................... 10
3. Using VJT6000 series .......................................................................................... 11
3.1 Specifying the test before it begins. ............................................................. 11
3.1.1
The Name of the Test ........................................................................... 11
3.1.2 Operating Parameters ............................................................................. 12
3.1.3 Stopping Conditions ............................................................................... 12
3.1.4 Tare Conditions ....................................................................................... 13
3.1.5 Sample Type and Dimensions.................................................................. 14
3.2 Test Control Operations ................................................................................ 15
3.2.1 Automatic Test Mode .............................................................................. 15
3.2.2 Manual Test Mode .................................................................................... 17
3.3 Storing, Viewing and Printing Results ......................................................... 19
3.3.1 Detailed Results......................................................................................... 20
3.3.2 Summary Results ...................................................................................... 20
4. Calibration and Setup............................................................................................ 21
4.1 Transducer Calibration .................................................................................... 21
4.1.1 Zero and Span Adjustments ..................................................................... 21
4.1.2 Linearisation Adjustments ....................................................................... 23
4.1.3 Printing Out the Results ......................................................................... 23
4.2 VJT6000 Series Equipment ........................................................................... 24
4.3 Logged Data Management .............................................................................. 25
4.3.1 Clearing The Logs ..................................................................................... 25
5. Advanced Options ................................................................................................. 26
5.1 Raw Data Setup ................................................................................................ 26
5.2 Automatic Control Tuning ............................................................................... 27
5.2.1 PID Control ............................................................................................... 27
5.2.2 Equipment ................................................................................................ 28
6. Serial Port Specifications ..................................................................................... 30
6.1 Starting or Stopping a Test ............................................................................. 30
6.2 Reading Test Status......................................................................................... 30
6.3 Reading Test Results....................................................................................... 30
7. Hydraulic Set-up & Maintenance .......................................................................... 31
7.1 Oil Fill And De-airing Procedure ..................................................................... 31
7.1.1 Filling The Machine With Oil..................................................................... 31
7.1.2 De-airing Of The Hydraulic Piston ........................................................... 32
7.2 Daily Maintenance ............................................................................................ 33
7.2.1 General ....................................................................................................... 33
7.2.2 Piston Dust Cover ..................................................................................... 33
7.2.3 Piston Cover Activating Arm .................................................................... 34
7.2.4 Hydraulic Oil............................................................................................... 34
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8. Troubleshooting .................................................................................................... 35
8.1 Identification Hydraulic ................................................................................ 35
8.2 Identification - Electrical.................................................................................. 37
8.3 Common Faults ................................................................................................ 39
8.3.1 Fast pump not working ............................................................................. 39
8.3.2 Loss of calibration data ............................................................................ 39
8.3.3 Receiving Test Data From VJT6000 Series To A PC.............................. 40
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1. Overview
A summary of the range available within the VJT6000 series
and what is possible with the concrete compression
machines.
The VJT6000 series of digital compression machines covers both manual and
automatic machines in a range of capacities to BS1881, EN12390. The most
commonly offered machines are:
VJT6000-15M
VJT6000-15A
VJT6000-2M
VJT6000-2A
VJT6000-3M
VJT6000-3A
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It is fully configurable in its operation, allowing you to fine tune its performance to
match the compression frame in use, the alarm conditions and many other
parameters.
This guide expands on the specifications presented above to review:
Chapter 2 describes the contents of the display. What is shown on the screen and
how these fields vary with various test operation and configuration actions.
Chapter 3 guides you through the test procedure:
Specifications.
Test identification
Sample details
Operating Parameters
Stop conditions
Manual or Automatic Control
Taring Stage
Following through the Status reports
Aborting a Test
Storing, Reviewing and Printing Results
Chapter 4 shows you how to calibrate your transducers and to configure all other
instrument parameters that affect its operation
Chapter 5 shows you how to make use of the Advanced configuration options to fine
tune the Automatic control program so that the error during load ramping is kept as
small as possible.
Chapter 6 documents the commands available via the instrument's serial port to
control a test and to obtain status and results information.
Chapter 7 gives details of the oil fill and de-airing procedure that must be done before
the instrument can be used, and daily maintenance that must be carried out to keep
the instrument in the best possible working order.
Chapter 8 is a troubleshooting section which identifies the main hydraulic and
electrical components and gives solutions to some common problems that can occur.
The instrument itself provides further instructions available by pressing the key HELP
from any of the screens. Press the same key again to remove it.
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Each VJT6000 series machine is tested prior to dispatch and the contrast settings will
remain set. Should you need to change the contrast, press the 8 key on the keypad
and adjust the brightness accordingly.
Normally the screen is split into 4 sections, namely: System Overview, Test Status,
Test Specifications and Sample Specifications.
HI
This field describes the transducer range currently in use. It is applicable for
Compression tests. The load at which the LOW range ends and the HIGH range
begins is configurable (see Chapter 4) by default this is set at 400kN.
This picture represents the oil flow valve, white if the valve is open, black if closed.
When a test is NOT running, or during the Tare Stage of a Manual mode test (Chapter
3), or during Transducer Calibration (Chapter 4), you control the valve by pressing the
key 6 to open or close it alternatively.
This picture represents the Fast pump, white if the pump is stopped, black if running.
When a test is NOT running, or during the Tare Stage of a Manual mode test (Chapter
3), or during Transducer Calibration (Chapter 4), you control the pump by pressing the
key 5 to start or stop it alternatively.
?????
MANUAL AUTO
+5%
-5%
This field describes the mode of operation for a running test. When a test is NOT
running, it shows the mode last used (Chapter 3). A test is started in either Automatic
mode by pressing the key AUTO or Manual mode by pressing the key MAN.
This field is the instantaneous error between the actual load applied during ramping
and the load demanded by the rate used. It grows in either the positive or negative
direction up to a maximum configurable band (Chapter 4). Note that it is also possible
to configure the instrument so that this field is NOT displayed.
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181.3 (kN)
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This is the current value of the selected transducer and the Units (usually kN) used. It
will change as load is applied and the transducer reacts.
It is also possible to magnify this section of the screen by pressing the key 4. You
would normally do this while a test is running so that the information is clearer. Press
the same key again to return to the complete screen.
Peak
dd/mm/yy hh:mm:ss
This field describes the current operation of the test. The following stages exist:
Idle
When not running
Taring
The initial stage, when reading is zeroed
Ramping
When controlling the rate at which load is applied
Peak Hold
When the sample begins to fail. The field below is
frozen to indicate the point at which this began
Success
When the test has been completed successfully
Aborted
When the test has been manually stopped.
This is the Maximum detected load applied to the sample before it begins to fail. It is
frozen while a test is running, and released by starting a new Test.
These are the current clock settings. The internal battery maintains the clock running
even when the instrument is switched off. To set it, press the key 1 and follow the
instructions given on the screen shown.
Reference
Base
(kN)
Rate
(kN/S)
% Fail
Tare
(kN)
Each test is identified by a 6 character number which you can enter as required. The
value shown is that defined for the last test used but increments automatically.
This is the load at which the error between the measured and the required load
ramping will begin to be displayed. In Automatic test mode, it also marks the
beginning of the Ramping test stage.
This is the rate of increase of load required.
This field shows the percentage of load decrease from the Maximum required to be
detected in order to stop the test automatically.
This is the Tare value currently in use. It will vary with each test as the Taring stage
proceeds. The field therefore provides an indication of idle load on the frame.
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Sample Type
There are 7 types of samples that can be used. Standard Cylinder, Standard Cube,
Non Standard Cylinder, Non Standard Cube, Beam Block, Gravel (ACV) and
Capped Cylinder. This field shows the name of that type currently in use.
Diam x Height
Each sample has certain dimensions which you can enter and are shown by these
fields. Note that some dimensions for Standard Cube or Cylinder are fixed by the
instrument.
Area
(mm2)
Stress (mPa)
This field is continuously calculated from the Maximum load value shown on the
Current Status section of the screen and the dimensions entered above.
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From the main screen, press the key DP to display the options for the tests available.
Choose the type of test to be carried out, Flexural, Compression or Fine Time. Use
the arrow keys to highlight the test required then press the ENTER key.
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Rate is the increase (in kN/Second) in load required for the new test. In
Automatic test mode, the instrument controls the load applied using this ramp
as a guide. In Manual mode, you must adjust the load using the Speed
control pot. In either case, the error measured by the instrument is the
difference between the actual load on the sample and the load that should
exist given the rate of increase configured here.
Rate is the increase (in kN/Second) in load required for the stage selected
above. In Automatic test mode, the instrument controls the load applied using
this ramp as a guide. In Manual mode, you must adjust the load using the
Speed control pot. In either case, the error measured by the instrument is the
difference between the actual load on the sample and the load that should
exist given the rate of increase configured here.
Hold (in minutes) is the period to hold the applied load when the Target Level
below is reached, before moving onto the next stage.
Level is the load (in kN) to be reached at the rate defined above.
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Drop Time is the time (in seconds) allowed for the platen to drop after the
initial daylight closing operation.
Stop Level is the force (in kN) above which the fast pump is automatically
stopped.
Maximum is the maximum force (in kN) that will be allowed to be tared. If this
level is exceeded when a test is tared, the test will be aborted.
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Standard Cylinder
Select the diameter from the options presented (50, 75, 100, 150 or 200
mm)
Enter the sample height
Enter the sample weight
Standard Cube
Select the width from the options presented (50, 75, 100, 150 or 200 mm)
Enter the sample height
Enter the sample weight
Beam Block
Enter the sample width
Enter the sample height
Enter the sample weight
Capped Cylinder
Enter the sample diameter
Enter the sample height
Enter the sample weight
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Platen Down
The fast pump stops and the oil valve opens to allow the
platen to drop. This phase lasts for up to a configurable Tare Period (Chapter 4)
at the end of which the load is cleared by the program.
3.
Tared Platen Up The oil valve is closed and the fast pump starts again
increasing the load. The fast pumps then stops at the same level as before but
the loading continues to be applied under the instruments control until a
configurable Base level (Chapter 4) has been achieved.
When the test is started a new screen appears containing status fields from the Main
Screen described in Chapter 2 that will allow you to follow the completion of this
Taring stage.
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Platen Down
Wait for a little time to allow the transducer reading to settle.
When ready, press the key 0 to carry out the actual taring. The test can then
proceed under complete manual control.
When the test is started a new screen appears containing status fields from the Main
Screen described in Chapter 2 that will allow you to follow the completion of this
Taring stage.
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Reference
Each test is referenced by a number 1 to 200 according to its position in the memory,
where 1 is the most recent test.
The results are always stored when a test ends, either successfully or not. They are
available for as long as the logs are not erased. When the logs are full, the oldest
logged results are replaced with new data. You can also erase all logs using the
Advanced Options described in Chapter 5.
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At the top of the screen you will see the field Page / Pages. This gives you an
indication of how many logs are stored. Use the AUTO key to view previous test
results, or the MAN key to return to newer ones.
Pressing the ENTER key presents the option to produce a printout of detailed results
for the logged set currently displayed. You must connect a Printer or a PC to the serial
port of your instrument as described in Chapter 6 of this manual.
Press the ABORT key to return to the main screen.
At the top of the screen you will see the field Page / Pages This gives you an
indication of how many logs are stored. Use the AUTO key to view previous test
results, or the MAN key to return to newer ones.
Pressing the ENTER key presents the option to produce a printout of summary results
either for the logged set currently displayed or for ALL stored results held in the
instruments memory. You must connect a Printer or a PC to the serial port of your
instrument as described in Chapter 6.
Press the ABORT key to return to the main screen.
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3. Select and activate the CLEAR option to start new a new calibration. You will be
warned about the implications of clearing calibration data previously stored. You
can then choose to proceed or not.
4. Make sure that the solenoid valve is closed, the fast pump is off and no load is
currently being applied with speed pot set to give a steady oil flow rate. When the
readings are stable, and the platen is off the seating position (not in contact with
upper ball seating), select the ZERO option. The transducer reading should now
show 0, and the field labelled Zero will display the offset measured at this time,
please write this down for future reference.
5. Now start the fast pump to close the daylight and then switch off the fast pump
once the contact is made with the upper ball seating. Slowly apply the load until
the Full Scale level has been reached. Maintain the load using the Speed Control
pot so that the readings are stable, and then select the GAIN option. The
transducer reading should now show the same value as that configured on the
Scale entry (step 2 above),
Again write down the value against the label marked gain.
6. Open the oil valve to release the loading. The first stage of a transducer
calibration is now complete
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Peak Hold
Select YES to freeze the display of the maximum load detected
during a test, or NO if this is not required. Note that this option affects only the
display on the Main Screen.
Query Abort Select YES to make sure that a warning is given whenever a test is
aborted (pressing the ABORT key) manually. This can help to prevent ending a
test inadvertently.
Show Proceed
Select YES to make sure that a confirmation is given before a
test can proceed. This can help to verify all conditions.
Error Band Enter the percentage error measured while a test is running that
will fill the error box shown on the Main Screen (Chapter 2) Usually this is 5%, but
note that entering a value of 0 will effectively prevent the box from being shown.
Switchover Enter the loading level at which the instrument will automatically
switch from the LOW to the HIGH transducer ranges. This is applicable to
Compression Tests only (default value is 400.0).
Overload
To prevent the frame being damaged by applying a large loading,
you can define a level above which the instrument automatically shuts down,
opens the oil valve and releases all loads.
(default value is set to the machine capacity, ex. 2000 kN)
Min Failure Enter the minimum value that must be reached before a test can
fail, this can help prevent spurious errors on the sample.
Customisation
You can define text to appear as Headers and Footers in all
printouts available (Test Results and Transducer Calibration). Enter for example a
description or your Companys name, Customer details, etc.
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5. Advanced Options
This chapter shows you how to tune your VJT6000 Series
instrument in order to operate effectively.
From the Main Screen (Chapter 2) press the Engineering key 9 to access these
options. You will need to enter a valid passcode in order to be allowed. This passcode
is given when the instrument is delivered and should be stored in a safe place. Select
the category you require from the menu then press the ENTER key.
1. Filter
This is a value that determines how many readings are taken to
average out noisy lines. It is set to a default value of 20 which is recommended for
most cases, changes should not be made without prior consultation. The
maximum filter value is 100 and minimum is 20.
2. Amplifier This is the gain to be applied to the signal received from the
transducer. It is set to a default value of 32 which is recommended for most cases,
changes should not be made without prior consultation. Other values that may be
accepted are 1, 2, 4, 8, 16, or 64. Apply Full Scale load and observe that the raw
reading covers the expected range.
The programmed values are also included in the Channel Calibration printouts
described on Chapter 4.
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1. Direct
This affects how quickly an error between Applied Load and
Measured load is reduced. This value has been factory set at 40 and should
NOT be changed without prior consultation.
2. Integral
This affects how smoothly small errors between Applied and
Measured loads are reduced. This value has been factory set at 20 and should
NOT be changed without prior consultation.
3. Max Rate
This is the maximum percentage amount by which the pump
speed is adjusted.
4. Zero Output
This is a percentage value representing the range setting to
be used to apply load when a zero error exists between Ramp values and
Measured values.
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5. Taring Speed
This is the percentage speed at which the pump is run during
the taring stage.
6. Start Up Speed
This is the percentage speed at which the pump is run during
the start-up stage.
7. Compens Speed This is only applicable to sample options 6 and 7 (Gravel ACV
and Capped Cylinder). It is used to adjust the speed when changing from a high
flow pump to a low flow pump.
8. Max Output
This is the maximum percentage output speed of the pump.
5.2.2 Equipment
From the main Engineering screen shown at the start of this section, select
Equipment to access this option. By using the arrow keys to highlight the required
category, you can change various aspects of the machines basic set-up as indicated
below:
Selecting the Initialize option will allow the data base to be initialized. By choosing
this option, you can reset your instrument to factory default values. The following
happens:
1. The contrast is turned off and must be reset by pressing key 8 then selecting from
the menu presented. All memory logs are erased.
2. Instrument defaults:
Units:
Percentage Error:
Peak Hold:
Query Abort:
Show Proceed:
Switchover:
Overload:
Min Failure:
Max Tare:
Stop Level:
Tare Timeout:
Drop Time:
metric
5
Yes
Yes
No
400 kN
2050 kN
50kN
10 kN
8 kN
10 mins
2 secs
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3. Test defaults:
Type:
Reference:
Mode:
Rate:
Base:
%Fail
Sample:
Diameter:
Height:
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Compression
------
Automatic
6 kN/S
10 kN
20
Standard Cylinder
50 mm
75 mm
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Receive
S0501=01
C0501=00
Action
Starts the test
Stops the test
Receive
XXXX
Action
Prints the current measured load. The
exact format for each transducer input
is described on Chapter 2.
R0502 (Cr)
XXXX
Receive
*******
Action
Prints results for the last test. The actual
contents are described on Chapter 3.
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OIL FILLER
PLUG
Fill the oil tank with Tellus 32 hydraulic oil using a funnel and filter until the oil is just
below the top of the indication tube (older machines may have a MAX indication line)
care should be taken to ensure no dirt or grit gets into the tank. Replace the oil filler
cap and proceed to the de-airing instructions.
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SUPPLY PIPE
FITTING
OIL RETURN PIPE
OIL SUPPLY PIPE
Loosen the oil supply pipe fitting slightly (about quarter of a turn).
Using the keypad, enter calibration mode of the machine by pushing key 7, followed
by your passcode.
Close the solenoid valve by pressing key 6 once (pressing twice will open again).
With the valve closed the manual pace control will be active.
Carefully operate the PACE control dial to slowly raise the platen until you see oil
emerging from the oil supply pipe fitting. Ensure all of the air has dispersed before
stopping the machine by reducing the pace to zero.
Clean away any excess oil that has emerged from the hole and tighten the fitting with
as much force as possible. It is important that this fitting is very tight.
NOTE: It is normal for air to be trapped in the oil return pipe and this will not
affect the operation of the machine. The machine is now ready for calibration. It
is important that the machine is calibrated in-situ prior to testing.
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7.2.1 General
The machine should be kept in a general state of cleanliness with all debris cleared away
after each batch of tests. The main parts of the digital compression machine that need daily
maintenance are indicated below.
Limit Switch
Hydraulic Oil Filling Cap
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Level correct
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8. Troubleshooting
This chapter is a troubleshooting section which identifies the
main components, provides schematics and gives solutions to
some common problems that can occur.
Solenoid
Valve
Pressurising Pump Motor
Dust Filter
Oil Filler Cap
Pressure Transducer
Mechanical Non-Return Valve
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Pressurising
Pump Motor
Pressure
Relief Valve
Solenoid
Valve
Dust Filter
Oil Filler Cap
Pressure Transducer
Mechanical Non-Return Valve
Note: The pressure relief valve is Factory Set at VJ Tech and should NOT be
adjusted without prior consultation with our technical department.
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PSU0001
ADC Channel 1
PSU0002
ADC Channel 3
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RS232-1
Solenoid
Pump
DC Power In
Stepper Motor
AC Power In
Keypad
Backlight
Hydraulic RAM
Limit Switch
Valve
ADC Channel 1
ADC Channel 3
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From the Transfers menu, select Receive Text File then enter a suitable file name,
for example TEST001.TXT.
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When the test is complete the VJT6000 will transmit the data to the PC.
VJT6000 --- Report Header
VJT6000 Materials Tester
Test Summary
Reference
Date (dd/mm/yy)
Time (hh:mm)
000005
04/08/04
17:03
Type :
Load at Fail (kN)
Base : (kN)
Rate : kN/s
%Fail:
Tare : (kN)
Compression
0300.3
0010.0
0006.0
20
-000.2
Sample
Sample Area mm2
Density: Kg/m3
Stress at Fail MPa
Result:
Standard Cylinder
04417.8
0301.8
00067.97
Finish
You may at any time close the file by pressing the STOP button shown at the bottom
of the screen.
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