50 Pilot Compact Rev 2 en 23 11 2012

COMPACT-Line
Automatic Compression Machines
MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni PILOT COMPACT-Line
Instruction Manual PILOT COMPACT-Line
Index
1. INTRODUCTION 1
1.1 Icons appearing in the manual ............................................................................................. 6
1.2 Manual revision history ....................................................................................................... 7
1.3 Symbols used ....................................................................................................................... 8
1.4 Intended use and improper use ............................................................................................ 9
1.5 Safety information ............................................................................................................. 10
1.6 Environmental risks and disposal ...................................................................................... 19
1.7 CE declaration ................................................................................................................... 20
2. DESCRIPTION 21
2.1 Frame ................................................................................................................................. 22
2.1.1 For EN testers for cubes, cylinders and blocks .............................................................. 22
2.1.2 For ASTM testers for cylinders...................................................................................... 22
2.1.3 For testers for cubes, cylinders and blocks .................................................................... 22
2.2 Compression platens .......................................................................................................... 23
2.2.1 For EN testers for cubes, cylinders and blocks .............................................................. 23
2.2.2 For ASTM testers for cylinders...................................................................................... 23
2.2.3 For general utility testers for cubes, cylinders and blocks ............................................. 23
2.3 PILOT, Automatic power and control system ................................................................... 24
2.4 Connections ....................................................................................................................... 25
2.5 Identification plate ............................................................................................................. 26
2.6 Commands and controls .................................................................................................... 27
2.7 Technical specifications..................................................................................................... 28
3. INSTALLATION 33
3.1 Shipment ............................................................................................................................ 34
3.2 Unpacking and inspection.................................................................................................. 36
3.2.1 How to remove the equipment from the shipping crate ................................................. 37
3.3 Positioning of the unit and space requirements ................................................................. 39
3.4 Mounting the control unit .................................................................................................. 41
3.5 Positioning the display....................................................................................................... 42
3.6 Electrical requirements ...................................................................................................... 43
3.7 Electrical connections ........................................................................................................ 44
3.8 Hydraulic connections of a second frame .......................................................................... 45
3.9 Install the paper into the printer ......................................................................................... 48
PILOT COMPACT Line Rev.2 EN i 23/11/2012

Manuale di Istruzione Console PILOT COMPACT-Line
Instruction Manual Console PILOT COMPACT-Line
4. USE OF THE EQUIPMENT 49

4.1 Switching on the equipment.............................................................................................. 50
4.2 Main menu ........................................................................................................................ 52
4.2.1 TEST RUN screen .......................................................................................................... 53
4.2.1.1 TEST RUN screen .......................................................................................................... 60
4.2.2 FILE MANAGER (TEST ARCHIVE) screen ............................................................... 67
4.2.2.1 Printing of all tests in the archive ................................................................................... 70
4.2.3 OPTIONS menu ............................................................................................................. 71
4.2.3.1 SELECT LANGUAGE option ....................................................................................... 71
4.2.3.2 DATE AND TIME screen .............................................................................................. 72
4.2.3.3 TEST OPTION screen.................................................................................................... 73
4.2.4 MANUAL COMMANDS screen ................................................................................... 75
4.2.5 ABOUT screen ............................................................................................................... 77
4.3 Carry out a test .................................................................................................................. 78
4.3.1 Selection of the frame to use (for units equipped with optional dual-output selector
block) 80
4.3.2 Testing a sample ............................................................................................................. 81
4.4 Stopping the cycle via the Emergency button ................................................................... 89
4.5 Switching off the unit........................................................................................................ 90
5. MAINTENANCE 91
5.1 Operator’s preventive maintenance .................................................................................. 93
5.1.1 Checking the status of the safety devices ....................................................................... 94
5.1.2 Checking the oil level in the tank ................................................................................... 97
5.2 Authorized service engineer maintenance actions ............................................................ 98
5.2.1 Checking the centering of the ram assembly .................................................................. 99
5.2.2 Checking the hydraulic circuit...................................................................................... 101
5.2.3 Checking the status of distance pieces ......................................................................... 103
5.2.4 Performing the maintenance of the spherical seat ........................................................ 104
5.2.5 Checking the calibration of the load channel ............................................................... 105
5.2.5.1 Calibration verification................................................................................................. 108
5.2.5.2 Calibration .................................................................................................................... 112
5.2.6 Checking the stability of the frame .............................................................................. 119
5.2.7 Replacing the oil of the hydraulic circuit ..................................................................... 121
23/11/2012 ii PILOT COMPACT Line Rev.2 EN

6. DIAGNOSTICS & TROUBLESHOOTING 123

6.1 System (Hidden) menu .................................................................................................... 124
6.1.1 ADC CHANNELS SETTINGS option ........................................................................ 126
6.1.2 SERIAL NUMBER option .......................................................................................... 128
6.1.3 PID SET UP option ...................................................................................................... 129
6.1.4 MEMORY RESET option ........................................................................................... 135
6.1.5 DIAGNOSTIC option .................................................................................................. 136
6.1.6 FACTORY option ........................................................................................................ 136
PILOT COMPACT Line Rev.2 EN iii 23/11/2012

This instruction manual is an integral part of the machine and should be read before using the machine and be
safely kept for future reference.
CONTROLS reserves all rights of this manual, no part or whole can be copied without the written permission of
CONTROLS .
The proper use of this machine must be strictly adhered to, any other use must be considered as incorrect.
The manufacturer cannot be held responsible for damage caused by incorrect use of the machine.
The machine must not be tampered with for any reason. In case of tampering, the manufacturer declines any
responsibility of functioning and safety of the machine.
This Manual is published by CONTROLS.

CONTROLS reserves the right to update its manuals without notification in order to correct possible typing
errors, mistakes, updating of information and/or updating of programs and/or accessories.
Such changes will be inserted in the latest edition of the current manual.
The present in English is the original version of the manual. Printed in Italy
23/11/2012 iv PILOT COMPACT Line Rev.2 EN

1. INTRODUCTION
NOTE:
The present manual is updated for the product it is sold with in order to grant an adequate
reference in operating and maintaining the equipment.
The manual may not reflect changes to the product not impacting service operations.
This new generation of Compact-Line Automatic compression testers, adopting the

innovative CVI TECH concept, is the result of our continuous application and research to
upgrade testing machines with the last technologies, taking into account client
requirements and International standards.
The PILOT Compact-Line Automatic compression testers, represent the more

sophisticated and advanced evolution of the usual compression testers. These models
satisfy, first of all, the requirement for the automatic accurate and constant load rate
application and soft platen-to-specimen contact from the very beginning of the ramp,
conforming to standards. The test cycle with closed loop digital feedback is automatically
performed by simply pressing the start button. The other important innovation concern
the “ES technology” which features the accurate oil flow control with no oil dispersions,
silent operation, cold oil temperature and, finally, low energy consumption saving over
the 30% energy compared to traditional systems. The automatic test procedure, once the
specimen has been positioned and centered and the machine switched on is:
o Set test parameters, including load rate, on the touch screen (can be avoided by
default for repetitive tests)
o Press the start button on the touch screen and turn the hydraulic valve ON
o The machine automatically starts the rapid platen approach, switches to the test
speed with soft upper platen-to-specimen contact and, finally, releases the
pressure upon specimen failure
o Save the test including data results and load/time graph. The test execution
conforming to standard can be, consequently, proved.
PILOT COMPACT Line Rev.2 EN 1 23/11/2012

Main features are:

o Automatic test cycle. Correct test execution according to selected Standards, is
continuously and automatically controlled
o Dual user interface display and PC
o Accuracy Class 1 (EN) and Class A (ASTM) starting from 10% of full scale. On
request from 1% with special calibration procedure.
o Compatible with the new, intuitive and smart DATA MANAGER Software.
Very easy to use, complete with many functions, totally flexible, open to network
comunications
o Adopt the latest ES Energy Saving technologies. For reduction of power
consumption and silent operation
o Double stage hydraulic pump with rapid approach and precise oil flow control.
Allowing high throughput of accurate tests (up to 40 per hour)
o Soft platen-to-specimen contact and smooth load rate control from the very
beginning of the ramp
o Optional control of a second frame
o Optional internal graphic printer including Load-Time plot
o Allow remote verification of settings and performances. For easy debugging of
unexpected malfunctions.
Here is the list of models available and their relevant main specifications:
MAIN CHARACTERISTICS OF EN TESTERS FOR CUBES, CYLINDER TO EN

12390-4
2000 kN cap.
50-C46C02 PILOT Automatic Compact-Line compression tester, 2000 kN cap. for cubes
up to 200 mm and cylinders up to dia. 160x320 mm. 230 V, 50-60 Hz, 1 ph
50-C46C04 Same as above but 110 V, 60 Hz, 1 ph
3000 kN cap.
4000 kN cap.
23/11/2012 2 PILOT COMPACT Line Rev.2 EN

MAIN CHARACTERISTICS OF EN TESTERS FOR CUBES, CYLINDER AND

BLOCKS TO EN 12390-4 AND EN 772-1
2000 kN cap.
50-C47C02 PILOT Automatic Compact-Line compression tester, 2000 kN cap. for
blocks, cubes up to 200 mm and cylinders up to dia. 160x320 mm. 230 V, 50-60 Hz, 1 ph
3000 kN cap.
4000 kN cap.
MAIN CHARACTERISTICS OF TESTERS FOR CYLINDER TO ASTM C39,

AASHTO T22
1500 kN cap.
50-C12C02 PILOT, Automatic Compact-Line compression tester, 1500 kN cap. for
testing cylinders up to dia. 160x320 mm. 230 V, 50-60 Hz, 1 ph
2000 kN cap.
3000 kN cap.
2000 kN cap. (high stiffness frame)
50-C42C02 PILOT, Automatic Compact-Line compression tester, 2000 kN cap., high
stiffness frame, for testing cylinders up to dia. 160x320 mm. 230 V, 50-60 Hz, 1 ph
50-C52C02 PILOT, Automatic Compact-Line compression tester, 3000 kN cap., high
stiffness frame, for testing cylinders up to dia. 160x320 mm. 230 V, 50-60 Hz, 1 ph

MAIN CHARACTERISTICS OF TESTERS, STANDARD AND HIGH

STIFFNESS FRAMES, FOR CYLINDERS AND CUBES
1500 kN cap.
50-C13C02 PILOT, Compact-Line Automatic compression tester, 1500 kN cap. for
testing cylinders up to dia. 160x320 mm, cubes up to 150 mm . 230 V, 50-60 Hz, 1 ph
2000 kN cap.
testing cylinders up to dia. 160x320 mm, cubes up to 150 mm . 230 V, 50-60 Hz, 1 ph
50-C43C02 PILOT, Compact-Line Automatic compression tester, 2000 kN cap.high
stiffness frame, for testing cylinders up to dia. 160x320 mm, cubes up to 150 mm . 230
V, 50-60 Hz, 1 ph
3000 kN cap.
50-C34C02 PILOT, Compact-Line Automatic compression tester, 3000 kN cap., for
testing cylinders up to dia. 160x300 mm and cubes up to 200 mm. 230 V, 50-60 Hz, I ph
50-C54C02 PILOT, Compact-Line Automatic compression tester, 3000 kN cap., high
stiffness frame, for testing cylinders up to dia. 160x300 mm and cubes up to 200 mm. 230
V, 50-60 Hz, I ph
MAIN CHARACTERISTICS OF TESTERS, STANDARD AND HIGH

STIFFNESS FRAMES, FOR BLOCKS, CYLINDERS AND CUBES
2000 kN cap.
testing cylinders up to dia. 160x320 mm, cubes up to 200 mm and blocks. 230 V, 50-60
Hz, 1 ph
3000 kN cap.
testing cylinders up to dia. 160x320 mm, cubes up to 200 mm and blocks. 230 V, 50-60
Hz, 1 ph

The machine must be completed with suitable distance pieces conforming to the
specimen size.
The device must be used in compliance with the procedures described in this manual.
Never use the device for purposes different from those herewith indicated.
This manual is applicable for units having firmware release equal to/higher than 2.09.
Fig. 1-1
Please read this manual thoroughly before you start using the equipment.

1.1 Icons appearing in the manual
This icon indicates a NOTE; please read thoroughly the items marked by this picture..
This icon indicates a WARNING message; the items marked by this icon refer to the
safety aspects of the operator and/or of the service engineer.

1.2 Manual revision history
Revision/Date Change description

Rev. 1 Manual release
5th October 2012
Rev. 2 Modified according to firmware revision 2.09
23rd November 2012

1.3 Symbols used

In this manual and on the equipment itself, apart from the symbols indicated on the
control panel, the following icons are also used:
Symbol Description
Mains switch:
O = device not connected to the mains line
I = device connected to the mains line
Emergency stop switch
Dangerous voltage
Hand injury
Conformity to the CE Directive

1.4 Intended use and improper use

The PILOT automatic compression testers can only be used to perform building material
tests according to the relevant international standards.
The unit is designed to be operated by one operator that has to install the necessary
distance pieces, load-unload the sample from the frame, input the test parameters and start
the test.
During normal operation the working area of the equipment is the front side where the
operator’s controls and the display are located.
The operator is responsible of starting-up the equipment, performing the test sequence,
shutting down the equipment and eventually stopping it in case any emergency conditions
are met.
The operator must be trained on the correct use of the machine and the relative safety
aspects of its use.
The machine should be used following the procedures described in this manual.
Never use the machine for reasons other than those for which it was designed and
manufactured. Any other use of the machine is to be considered improper, not foreseen
and hence dangerous.
CONTROLS will not be responsible for improper use of the machine.

1.5 Safety information
WARNING:
Please read this chapter thoroughly.
CONTROLS designs and builds its devices complying with the related safety
requirements; furthermore it supplies all information necessary for correct use and the
warnings related to use of the equipment.
CONTROLS will not to be held responsible for:

• use of the equipment different than the intended use,
• damages to the unit, to the operator, caused both by installation and maintenance
procedures different than those described in this manual supplied with the unit, and
by wrong operations,
• mechanical and/or electrical modifications performed during and after the
installation, different than those described in this manual
The unit is not designed to be used in an explosive atmosphere.
Installation and any technical intervention must only be performed by qualified

technicians authorized by CONTROLS.
Only authorised personnel can remove the covers and/or have access to the components
under voltage.
During normal use, if the operator detects irregularities or damages, he/she should
immediately inform the authorized technical personnel.
Maintenance and service activities can only be performed by skilled authorized technical
personnel that have been properly trained on the residual risks of the equipment.
It is responsibility of the purchaser to make sure that the operators have been properly
instructed concerning the safety issues and the residual risks related to the equipment.

The machine is equipped with the following devices to limit the residual risks in using it:
• Emergency button that switches OFF the unit once pressed, thus stopping the raising
of the piston;
Emergency button
Fig. 1-2
• Max. pressure valve to avoid machine overloading.
Max. pressure valve
Fig. 1-3
• Ram travel limit microswitch to prevent the excessive piston travel; when triggered
it disables the functioning of the pump motor.
Limit microswitch
Fig. 1-4
• Front and rear transparent fragment guard.
Front fragment guard
Fig. 1-5

• Dual input for ram travel microswitches to prevent the excessive piston travel; when
triggered it disables the functioning of the pump motor.
Dual input for

over-travel
microswitches Fig. 1-6
• Access panels to internal parts locked with screws.

The following table lists those parts of the equipment that may present some residual
risks for the safety of the personnel if the instructions provided in this manual are not
duly followed.
Personnel Area with residual risks

Operator The sample during load-unloading phase from the frame, due to its weight
and sharp surfaces. Use suitable personal protection devices (e.g. gloves,
protective shoes, etc.).
The distance pieces and platens during the installation phase on the frame,
due to their weight. Use suitable personal protection devices (e.g. gloves,
protective shoes, etc.).
The area around the frame during the execution of the test, in case of test on
explosive samples and with the front and rear fragment guards not in place.
The gap between the sample and the upper platen on the frame during the
compression phase, although the maximum speed is very low (max. 40
mm/min).
Technical personnel Above listed areas
Area around the hydraulic tubes, due to the high pressure of the oil, in case
the tubes are damaged or not properly attached
Areas around compartments closed by removable panels
Areas around compartments that contain electrical parts
For continued fire protection, replace fuses with same type and rating. Also,
in case of failure, components may only be replaced by using original spare
parts. It is in the responsibility of the purchaser to insure that fire prevention
policies are properly implemented according to the CE provisions.
Personnel Raising and moving of the equipment from the wooden crate must be
responsible of performed by people properly trained and equipped with suitable personal
transportation and protection devices (e.g. gloves, helmet, etc.). Failure to follow the
moving of the instructions above may endanger the personnel involved.
equipment

Here follows a list of all WARNINGs present in the manual; please see relevant chapters
for full details on each related safety issue.
WARNING:
Do not use the USB port to re-charge batteries of external devices (e.g mobile phone,
audio-video players, etc.). It is also mandatory to connect/disconnect the USB memory
stick with the unit OFF.
CONTROLS will not be held responsible for damages to persons and/or properties in
case these instructions are not strictly followed.
WARNING:
When operating with the covers open/removed and the unit is attached to the mains line,
care must be taken as high voltage is present in some parts of the unit (e.g. electrical
panel). Only authorized and qualified service technicians are allowed to open /remove
covers.
WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.
WARNING:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.
WARNING:
Raising and moving of the equipment must be performed by people properly trained and
equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to
follow the instructions above may endanger the personnel involved.
WARNING:
The wooden crate is high; be careful in balancing while raising it.
WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damages to the equipment cabinet may result. This will void the warranty terms
of the equipment.
WARNING:
Do not stand under suspended loads

WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.7), check the
maximum allowed floor load before installation.
WARNING:
Make sure to use proper fixing bolts according to the type of floor of the installation
place. CONTROLS cannot be considered responsible in case of injures to the operator or
damages to the equipment if the above instructions are not duly followed.
WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.
WARNING:
The general grounding must comply with the rules in force; a wrong quality of the
grounding could be dangerous for the operator’s safety and cause bad function of the
electrical devices.
WARNING:
Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved
by CONTROLS can be used. CONTROLS will not be responsible for damages to the
equipment or personnel injures in case of use of improper material and/or operations not
carried out by authorized technical personnel.
WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/buttons. These tools and buttons are for use by maintenance personnel only. Never
leave the tools and buttons attached to the unit as this may endanger operator safety.
After performing maintenance/repair, make sure that all covers/doors are properly closed
and locked.
WARNING:
If the START TEST PARAMETER value is not properly set, it will cause improper
functioning of the machine (e.g. if the value is too high the machine will not be able to
sense the failure of the sample and therefore will continue pressing the sample and never
stop).
This may result in damages to the equipment and/or danger for the operator. CONTROLS
will not be considered responsible in these events.
WARNING:
The MANUAL COMMANDS menu is reserved to the authorised service personnel.
CONTROLS will not be responsible for any damage caused by improper setting of these
parameters. Warranty will be void if this menu is used by unauthorised personnel.

WARNING:
Be careful and use proper personal protection devices (e.g. gloves, protective shoes)
while loading/unloading samples from the test frame, due to the sample weight and sharp
surfaces.
WARNING:
while handling distance pieces and platens of the frame due to their weight.
WARNING:
Always close the front door and place the rear guard on the frame while executing the
tests. Also use proper personal protection devices (e.g. glasses) in order to avoid injures
due to fragments of samples ejected during the test (e.g. in case of test on explosive
samples ).
WARNING:
Although the maximum speed of the loading piston of the frame is very low (max. 40
mm/min), to avoid injures during the compression phase, always close the front door and
place the rear guard while executing the tests. Also avoid putting hands/fingers in the gap
between the sample and the upper platen.
WARNING:
Before releasing the EMERGENCY BUTTON make sure that the lever of the hydraulic
ON/OFF valve is in the lower positions (discharge position).
WARNING:
Before turning the equipment OFF make sure that the lever of the hydraulic ON/OFF
valve is in the lower positions (discharge position).
WARNING:
Failing to perform the recommended maintenance actions or maintenance performed by
unauthorized people can void the warranty.
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
Before opening/removing the covers, disconnect the mains supply to the device and wait
at least 5 minutes.

WARNING:
For continued fire protection, replace fuses with same type and rating. Also, in case of
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the
maintenance actions described in the chapter “Authorized service engineer maintenance
action”. CONTROLS has not to be held responsible for damages to the equipment and/or
injuries to personnel in case the above is not strictly followed.
WARNING:
The CALIBRATION menu should only be entered when the calibration needs to be
changed. Do not enter into this menu for any other reason. Before entering the
CALIBRATION menu it is vital to carefully read and understand the procedure
described hereunder. If any doubts remain, contact CONTROLS service department for
further clarification.
CONTROLS will accept no responsibility for any inconvenience caused by wrongful
calibration.
WARNING:
Do not use the MEMORY RESET function unless authorized by CONTROLS Service
department. CONTROLS will not be held responsible for damages to the equipment
and/or injuries to personnel in case the above is not strictly followed.
WARNING:
Do not access to the DIAGNOSTIC option unless specifically authorized by the technical
personnel of CONTROLS. CONTROLS will not be held responsible for damages to
persons or properties in case this is not strictly followed.
WARNING:
Do not access to the FACTORY option unless specifically authorized by the technical

1.6 Environmental risks and disposal
INFORMATION TO THE OWNER OF THE EQUIPMENT
The above symbol, when attached to the equipment or to the relevant packaging, indicates
that the product must be disposed of separately from other rubbish at the end of its useful
life.
Therefore, at the end of its useful life, the owner should dispose of the product in a
suitable collection point for electrical and electronic products provided by the local
authorities.
The correct disposal of this product and the subsequent treatment encourages the
manufacture of products using re-cycled materials and limits the environmental impact of
the product caused by improper disposal.
Improper disposal of the product is subject to penalties as foreseen by the local

regulations.

1.7 CE declaration
This page shows a copy of the CE declaration. The original is supplied with the
equipment as a separate document.

2. DESCRIPTION
Refer to the following figures for main components identification.
5
1
2 7
Fig. 2-1
Ref. Description
1 Upper platen with spherical seat
2 Front guard
3 Lower platen
4 Piston travel indicator
5 Control unit with touch screen display
6 Power unit with emergency button
7 DC motor hydraulic pump
8 Frame selector lever (optional, lever UP=Frame #1, lever DOWN=Frame #2)
9 ON/OFF Hydraulic valve

2.1 Frame
2.1.1 For EN testers for cubes, cylinders and blocks
Four column high stiffness welded frame tested for stability to EN 12390-4. Heavy duty
spherical seat in lubricating oil bath, allowing initial free alignment at the initial contact
with the specimen and automatic jamming up to the end of test.
2.1.2 For ASTM testers for cylinders
The 1500, 2000 and 3000 kN models series 50-C12xxx, 50-C22xx and 50-C32xxx
feature a standard welded steel construction while the 2000 and 3000 kN cap., series 50-
C42xxx and 50-C52xxx feature a four column high stiffness welded frame. Spherical seat
allowing initial free alignment at the initial contact with the specimen and automatic
jamming up to the end of test.
2.1.3 For testers for cubes, cylinders and blocks

The 1500, 2000 and 3000 kN models series 50-C13xxx, 50C23xxx and 50-C34xxx series
feature a rigid welded steel construction while the 2000 and 3000 kN cap., series 50-
C43xxx and 50-C54xxx feature a four column high stiffness welded frame. Spherical
seat allows initial free alignment at the initial contact with the specimen and automatic
jamming up to the end of test.

2.2 Compression platens
2.2.1 For EN testers for cubes, cylinders and blocks
Series 50-C46xxx and 50-C56xxx are fitted with 300 mm dia. platens which are suitable
for testing cylinders up to dia. 160x320 mm and cubes up to 200 mm.
Serie 50-C68xxx is fitted with 305x305 mm platens which are suitable for testing
cylinders up to dia. 160x320 mm and cubes up to 300 mm.
For both surface hardness is 55 HRC, flatness tolerance 0.03 mm. Traceable certificate of
surface hardness available on request.
Series 50-C47xxx and 50-C57xxx are fitted with rectangular platens 310x510 mm that
are suitable for testing cylinders up to dia. 160x320 mm, cubes up to 200 mm and blocks.
Surface hardness 55.5 HRC (600 HV) , flatness tolerance 0.05 mm. Traceable certificate
of surface hardness available on request.
2.2.2 For ASTM testers for cylinders
Series 50-C12xxx, 50-C22xxx, 50-C32xxx, 50-C42xxx and 50-C52xxxseries are fitted

with round platens 165 mm dia. suitable for testing cylinders up to dia. 160x320 mm
conforming to ASTM and AASHTO standards.
Surface hardness 55 HRC, flatness tolerance 0.02 mm. Traceable certificate of surface
hardness available on request.
2.2.3 For general utility testers for cubes, cylinders and blocks
Series 50-C13xxx, 50C23xxx and 50-C43xxx are fitted with 216 mm dia. platens which
are suitable for cylinders up to dia. 160x320 mm and cubes up to 150 mm.
Series 50-C34xxx and 50-C54xxx are fitted with 300 mm dia. platens which are suitable
for testing cylinders up to dia. 160x320 mm and cubes up to 200 mm.
For both surface hardness is 55 HRC, flatness tolerance 0.03 mm. Traceable certificate of
surface hardness available on request.
Series 50-C25xxx and 50-C35xxx are fitted with rectangular platens 310x510 mm that
are suitable for testing cylinders up to dia. 160x320 mm, cubes up to 200 mm and blocks.
Surface hardness 55.5 HRC (600 HV) , flatness tolerance 0.05 mm. Traceable certificate
of surface hardness available on request.

2.3 PILOT, Automatic power and control system

These features are common to all models and versions.
Dual stage pump, centrifugal for fast approach and multi-piston for loading, DC motor,
ES Energy Saving technology to reduce the power consumption and ensure silent
operation.
Hardware
132,000 points effective resolution, three channels, touch screen graphic display 240x128
pixel, sampling rate 50/sec, large storing capacity on USB pen drive, test data
downloadable to PC, Ethernet port, real time management software (optional)
Firmware
Simultaneous display of load-specific load , actual load rate and load/time graph; LAN
connection to PC; advanced memory management; multi coefficient calibration.

2.4 Connections
The next figure shows the position of the connectors/ports used to connect the different
modules composing the equipment and equipment itself with external devices.
2 9
3 8
6 7
Fig. 2-2
Rif. Descrizione
1 Power cable receptacle with mains switch and line fuse
2 Pressure transducer/load-cell connector channel #2
5 LAN connector for PC connection (data download, firmware update, etc.)
6 Connectors for overtravel microswitches of the frames
7 Connector for hydraulic pump DC motor
8 USB port to connect a memory stick for test data storage
9 Not used
WARNING:
2.5 Identification plate

The identification plate is located on the rear side of the equipment control unit, near the
power cable.
Fig. 2-3

2.6 Commands and controls

This chapter describes the commands and controls of the equipment. The operator’s
interface description and the use of the touch screen display is provided in chapter 4.2 of
the present manual.
3
6
Fig. 2-4
Rif. Descrizione
1 Touch screen display
2 POWER ON lamp
3 EMERGENCY BUTTON
4 Frame selector lever (optional, lever UP=Frame #1, lever DOWN=Frame #2)
5 ON/OFF hydraulic valve
6 Power ON switch

2.7 Technical specifications
Main characteristics of EN testers for cubes, cylinder to EN 12390-4

Product PILOT Compact Line Automatic Compression Machines
Manufacturer CONTROLS Cernusco s/N (MI) Italy
Product code 230VAC version 50-C46C02 50-C56C02 50-C68C02
Capacity 2000 kN 3000 kN 4000 kN
Single phase line voltage 110 VAC/230 VAC +10%, -10%
Frequency 50/60 Hz
Power 750 W
Method of power entry Power cable with plug
Computer connection LAN port
305 x 305 mm
Platens dimensions Dia. 300 mm Dia. 300 mm
(square)
Ram travel 50mm
Max. Vertical daylight 350 mm 350 mm 520 mm
Max. Horizontal daylight 350 mm 370mm 425 mm
For specimen size:
Cubes cm 10, 15, 20 10, 15, 20 10, 15, 20, 30
Cylinders cm (dia.x h) 10x20, 15x30, 16x32 10x20, 15x30, 16x32 10x20, 15x30, 16x32,
mm mm 25x50 mm
Fast approach speed 40 mm/min approx.
Max. working pressure 650 bar
Oil output at max. pressure 0.3 l/min approx.
Oil tank capacity (approx.) 6 liters 10 liters
Acoustic pressure < 70db(A)
Net weight (approx.) 700 Kg 1030 Kg 2030 Kg
965 x 495 x 1100 1070 x 560 x 1470
Overall dimensions (l x d x h) 875 x 440 x 1030 mm
mm mm

Main characteristics of EN testers for cubes, cylinder and blocks to EN 12390-4 and EN 772-1
Capacity 2000 kN 3000 kN 4000 kN
Frequency 50/60 Hz
Power 750 W
Platens dimensions 310 x 510 mm 310 x 510 mm 310 x 510 mm
Ram travel 50mm
Max. Vertical daylight 350 mm 350 mm 520 mm
Max. Horizontal daylight 350 mm 370 mm 425 mm
For specimen size:
Cubes cm 10, 15, 20 mm 10, 15, 20 mm 10, 15, 20, 30 mm
Cylinders cm (dia.x h) 10x20, 15x30, 16x32 10x20, 15x30, 16x32 10x20, 15x30, 16x32,
mm mm 25x50 mm
Blocks Within platen dim. Within platen dim. Within platen dim.
Oil tank capacity (approx.) 6 liters 10 liters
Net weight (approx.) 760 Kg 1130 Kg 2080 Kg
965 x 625 x 1100 1070 x 700 x 1470
Overall dimensions (l x d x h) 875 x 600 x 1030 mm
mm mm

Main characteristics of testers for cylinder to ASTM C39, AASHTO T22

Product code 230VAC version 50-C12C02 50-C22C02 50-C32C02 50-C42C02* 50-C52C02*
Product code 110VAC version 50-C12C04 50-C22C04 50-C32C04 50-C42C04* 50-C52C04*
Capacity 1500 kN 2000 kN 3000 kN 2000 kN 3000 kN

Frequency 50/60 Hz
Power 750 W
Platens dimensions Dia 165 mm
Ram travel 50mm
Max. Vertical daylight 370 mm 380 mm 380 mm 405 mm 405 mm
Max. Horizontal daylight 280 mm 340 mm 370 mm 350 mm 370 mm
For specimen size:
Cylinders cm (dia.xh) 10x20 (4x8”), 10x20 (4x8”), 10x20 (4x8”), 10x20 (4x8”), 10x20 (4x8”),
15x30 (6x12”) 15x30 (6x12”) 15x30 (6x12”) 15x30 (6x12”) 15x30 (6x12”)
16x32 mm 16x32 mm 16x32 mm 16x32 mm 16x32 mm
Oil tank capacity (approx.) 6 liters
Net weight (approx.) 370 Kg 530 Kg 730 Kg 580 Kg 1000 Kg
655 x 375 x 725 x 410 x 765 x 455 x 875 x 440 x 965 x 495 x
Overall dimensions (l x d x h)
930 mm 1000 mm 1070 mm 1030 mm 1100 mm
[*] High stiffness four column welded frame

Main characteristics of testers for cylinders and cubes

Product code 230VAC version 50-C13C02 50-C23C02 50-C43C02* 50-C34C02 50-C54C02*

Product code 110VAC version 50-C13C04 50-C23C04 50-C43C04* 50-C34C04 50-C54C04*
Capacity 1500 kN 2000 kN 2000 kN 3000 kN 3000 kN

Frequency 50/60 Hz
Power 750 W
Platens dimensions Dia 216 mm Dia 300 mm
Ram travel 50mm
Max. Vertical daylight 340 mm 350 mm 375 mm 350 mm 350 mm
Max. Horizontal daylight 280 mm 340 mm 350 mm 370 mm 370 mm
For specimen size:
Cylinders cm (dia.xh) 15x30 15x30 15x30 15x30 15x30
(6x12”) (6x12”) (6x12”) (6x12”) (6x12”)
16x32 mm 16x32 mm 16x32 mm 16x32 mm 16x32 mm
10, 15 10, 15 10, 15 10, 15, 20 10, 15, 20
Cubes cm
Net weight (approx.) 390 Kg 550 Kg 650 Kg 780 Kg 1060 Kg
655 x 375 x 725 x 410 x 875 x 440 x 765 x 455 x 965 x 495 x
Overall dimensions (l x d x h) 930 mm 1000 mm 1030 mm 1070 mm 1100 mm
[*] High stiffness four column welded frame

Main characteristics of testers for cylinders, cubes and blocks

Product code 230VAC version 50-C25C02 50-C35C02
Product code 110VAC version 50-C25C04 50-C35C04
Capacity 2000 kN 3000 kN
Frequency 50/60 Hz
Power 750 W
Platens dimensions 310 x 510 mm 310 x 510 mm
Ram travel 50mm
Max. Vertical daylight 350 mm 350 mm
Max. Horizontal daylight 340 mm 370 mm
For specimen size:
Cylinders cm (dia.x h) 15x30 mm (6”x12”) 16x32 mm 15x30 mm (6”x12”) 16x32 mm
Cubes cm 10, 15, 20 mm 10, 15, 20 mm
Blocks Within platen dim. Within platen dim.
Net weight (approx.) 630 Kg 840 Kg
Overall dimensions (l x d x h) 725x 560 x 1000 mm 765 x 600 x1070 mm
Environmental conditions
Operating temperature + 10 ÷ + 40°C
Operating humidity ≤ 50%RH @ 40°C

3. INSTALLATION
The instructions indicated in this chapter enable you to perform a correct installation and
interfacing in order to grant a regular operation of the equipment.
Included are initial inspection procedure, power requirements and instructions for
installing the unit.
The information in this chapter is intended for authorized service-trained personnel.
CONTROLS can supply the assistance and the necessary technical advice for pre-
installation, all the pre-installation phases are at the purchaser’s charge and must be
performed complying with the indications given below.
WARNING:
When operating with the covers open/removed and the unit is attached to the mains line,
care must be taken as high voltage is present in some parts of the unit (e.g. electrical
panel). Only authorized and qualified service technicians are allowed to open /remove
covers.
WARNING:
WARNING:

3.1 Shipment
The equipment is normally shipped in a wooden crate having the following dimensions
and gross weight depending on the model:
Minimum
Overall dimensions
Models Gross weight fork lift
(L x D x H)
length
C46C0X 780 Kg 1050x800x1350 mm 1500mm
C56C0X 1130 Kg 1200x800x1450 mm 1500 mm
C68C0X 2190 Kg 1400x900x1850 mm 2000 mm
C47C0X 840 Kg 1050x800x1350 mm 1500 mm
C57C0X 1230 Kg 1000x800x1450 mm 1500 mm
C67C0X 2240 Kg 1400x900x1900 mm 2000 mm
C12C0X 440 Kg 800x800x1350 mm 1500 mm
C22C0X 620 Kg 1050x800x1250 mm 1500 mm
C32C0X 810 Kg 1050x800x1350 mm 1500 mm
C42C0X 660 Kg 1050x800x1350 mm 1500 mm
C52C0X 1100 Kg 1200x800x1450 mm 1500 mm
C13C0X 460 Kg 800x800x1350 mm 1500 mm
C23C0X 640 Kg 1050x800x1250 mm 1500 mm
C43C0X 730 Kg 1050x800x1350 mm 1500 mm
C34C0X 860 Kg 1050x800x1350 mm 1500 mm
C54C0X 1160 Kg 1200x800x1450 mm 1500 mm
C25C0X 710 Kg 1050x800x1350 mm 1500 mm
C35C0X 920 Kg 1050x800x1350 mm 1500 mm
Use a proper fork lift with minimum fork length as above indicated to raise and move the
wooden crate (see figure below).
Fig. 3-1

WARNING:
WARNING:
The wooden crate is high; be careful in balancing while raising it.

3.2 Unpacking and inspection

The unit was carefully checked both mechanically and electrically before shipment; it
should be inspected for any damage that may have occurred in transit.
NOTE:
If the shipping container or packaging material is damaged, it should be kept until the unit
has been mechanically and electrically checked.
If there is mechanical damage and/or the contents are incomplete (see the shipping list),
please notify the local CONTROLS representative.
If the shipping container is damaged or shows sign of stress, notify the carrier as well as
the CONTROLS representative. Save the shipping material for carrier’s inspection. Also
take some pictures.
Here follows the procedure for the unpacking of the equipment.

3.2.1 How to remove the equipment from the shipping crate

The following table shows the net weight of the different models of the equipment:
Model Net weight
C46C0X 700 Kg approx.
C22C0X 530 kg approx.
Follow the instructions below to remove it from the shipping crate:
1. Inspect shipping crate (see NOTES above);
2. Open the shipping crate;
3. Cut and remove vacuum bag (if present) to expose the equipment;
4. The equipment must only be lifted up by the eyebolts screwed in on the top of the
frame. Do not lift it by any other part to avoid damaging the equipment (see Fig. 3-2).
Eye bolts Ropes
Fig. 3-2
WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damages to the equipment cabinet may result. This will void the warranty terms
of the equipment.
WARNING:
WARNING:
Do not stand under suspended loads
5. Before powering on the unit, check for loose connections of cables inside the
equipment.

3.3 Positioning of the unit and space requirements
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.7), check the
maximum allowed floor load before installation.
The unit must be placed on a flat and level surface.
The area around the equipment must be kept free from obstacles and from
substances that may cause sliding of the personnel.
It is responsibility of the purchaser to provide an installation place with

adequate lighting.
Parts used to build the machine and electrical/electronics component are fire-proof.
It is anyway the responsibility of the owner of the equipment to make sure that the
installation place is equipped with proper fire extinguishing systems and that the
operators have been instructed on the relevant procedures.
Use a proper mean to bring the unit to the installation place.
Place the unit in its final location, taking into account the free space around the unit: the
equipment requires at least 100 cm of clearance on the front and at least 50 cm on the 3
sides for maintenance and service purposes.
50cm
Fig. 3-3

Also consider that mains connection is achieved through the mains cable socket on the
rear side of the equipment cabinet.
The unit requires adequate air circulation around it to assure proper cooling of the internal
devices.
The machine must be fixed to the floor using expandable fixing bolts as shown in fig.
below.
Fig. 3-4
Modello a mm b mm c mm
C46C0X 565 260 13
C56C0X 655 320 13
C68C0X 760 365 13
C47C0X 565 260 13
C57C0X 655 320 13
C67C0X 760 365 13
C12C0X 250 310 13
C22C0X 330 350 13
C32C0X 370 390 13
C42C0X 565 260 13
C52C0X 655 320 13
C25C0X 330 350 13
C35C0X 370 390 13
C34C0X 370 390 13
C54C0X 655 320 13
WARNING:
Make sure to use proper fixing bolts according to the type of floor of the installation
place. CONTROLS cannot be considered responsible in case of injures to the operator or
damages to the equipment if the above instructions are not duly followed.
WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.

3.4 Mounting the control unit

The control unit assembly is normally shipped dismantled from the frame.
To mount it on the frame:
1. Fit the control unit assembly shaft into the relevant housing on the right hand side of
the frame;
Fig. 3-5
2. Use a 4 mm Allen key to firmly lock the grub screw.
Fig. 3-6

3.5 Positioning the display

Depending on the lighting of the laboratory and the height of the operator, it may be
necessary to adjust the positioning of the display to ensure optimum visibility.
1. Access to the fixing screw of the control unit from the access hole located under the
control unit itself (use a 5mm Allen key) and loosen the screw;
Access hole
Fig. 3-7
2. Position the control unit as desired;
3. Tighten the screws holding the control unit in the desired position.

3.6 Electrical requirements

The next table shows the electrical specifications of the equipment:
Item Specifications
Mono phase voltage 230VAC / 110VAC
+6%, -10%
Frequency 50Hz/60Hz
Maximum power 750 W
The equipment shall be connected to a proper earth system, the efficiency of which shall
be checked by qualified personnel. Earth shall be via the power cable, as specified above.
WARNING:
The general grounding must comply with the rules in force; a wrong quality of the
grounding could be dangerous for the operator’s safety and cause bad function of the
electrical devices.
The power supply line shall be equipped with a safety device (breaker and ground fault
switch) properly sized with respect to the electrical specifications provided above.

3.7 Electrical connections

The sockets for electrical connection are on the rear panel of the equipment, these are for
the load sensors, USB and LAN ports, auxiliary connections and mains supply fitted with
filter, fuses and switches.
1. Connect the power cord to the control unit;
2. Connect the load sensor of frame #1 the socket of channel #1. If present, connect the
load sensor of frame #2 the socket of channel #2. If the system is equipped with one
frame only, use channel #1 to connect the relevant load. It is not possible to connect a
single channel to a socket different than channel #1.
Power cord
Cable sensor frame #2

Cable sensor frame #1
Pump motor cable
Cable from overtravel

microswitch of frame #1
Connector to short the

second input for
overtravel
microswitches (in case
the second frame is not
present)
Fig. 3-8
3. Connect the cable of the overtravel microswitch of frame #1;

4. Connect the cable of the overtravel microswitch of frame #2; if the latter is not
present, connect the shorting plug provided with the equipment (this is aimed at
closing the protection circuit for the enabling of the pump motor, see previous
picture);
5. Connect the connector of the pump motor;
6. Refer to chapter 4.1 for the activation of the equipment.
NOTE:
When the machine is installed for the first time, it is recommended to leave the machine
ON for at least 8 hours so as to fully charge the internal battery. In case it get discharged,
the clock on the display will be zeroed.

3.8 Hydraulic connections of a second frame

This chapter explains where to connect the hydraulic hose to supply second frame
provided that the device is equipped with the dual output hydraulic block (code C10C/2F
to be installed in the factory).
The first frame is normally already connected to the relevant output of the distribution
block.
WARNING:
NOTE:
The two frames cannot be driven simultaneously by the control unit.

1. With the unit OFF and unplugged from the mains, connect the flexible tube supplied
to the second output of the selector block and tighten properly the relevant fixing
nuts;
WARNING:
Connection for 2nd

frame on the dual-
output block
Connection for 1st

frame on the dual-
output block
(normally already
connected)
Fig. 3-9
2. After making the hydraulic connections, check the oil level in the tank via the
transparent level indicator (the oil should be max. at half of the indicator); if
necessary refill the oil tank (refer to chapter 5 of this manual);

3. If the capacity of the second frame is higher than the one of the frame already
connected to the equipment, the max. pressure valve may need to be re-adjusted:
a. Locate the max. pressure adjustment valve;
b. Use a 6mm Allen key to remove the cap
c. Use a flat screw driver to turn counter-clockwise the valve to reduce the max.
pressure;
d. Adjust the valve by turning the screw clockwise until it intervenes at the full
scale of the frame;
e. Turn the screw still ¼ of turn clockwise;
f. Re-install the cap.
Connection for 2nd

frame on the dual-
output block
Valve to adjust
max. pressure
Fig. 3-10

3.9 Install the paper into the printer

The printer (optional) is supplied with a roll of thermal paper that must be loaded into the
unit.
1. Open the lid of the printer by applying light pressure on the sides of the same;
Fig. 3-11
2. Place paper in the direction indicated in the next image;
Fig. 3-12
3. Close the lid until it locks.

4. USE OF THE EQUIPMENT

This chapter describes the operator’s interface and the execution of a test.
WARNING:
WARNING:
tools/buttons. These tools and buttons are for use by maintenance personnel only. Never
leave the tools and buttons attached to the unit as this may endanger operator safety.
and locked.

4.1 Switching on the equipment

1. Once all the connections have been made correctly and the USB memory stick has
been inserted into the relevant port on the rear panel (in case data storage into the
memory is required) switch ON the unit via the power switch on the rear panel: the
POWER ON lamp and the green LED on the printer will lit (the LED on the printer
will be red in case anomalous conditions on the printer are found e.g. lack of paper,
in this case refer to chapter 3.9);
Mains switch
Fig. 4-1
WARNING:
2. The display will first show the CONTROLS logo followed by a screen with the
event counters and a number of information of the device;
Fig. 4-2

The system is equipped with a touch screen display that allows activating the
different functions just touching the relevant icons on the screen.
3. Using the pointer provided with the equipment, touch the screen to activate the main
menu;
Fig. 4-3
NOTE:
Hitting the screen heavily may damage it. Never use a pen or a sharp object as damage
may result. The warranty will be void in case the screen is damaged due to improper use.
4. The buttons and on the screen allows access to additional menu

pages containing further icons / functions not directly visible in this screen.
NOTE:
When the machine is installed for the first time, it is recommended to leave the machine
ON for at least 8 hours so as to fully charge the internal battery. In case it get discharged,
the clock on the display will be zeroed.

4.2 Main menu

The main menu offers five choices:
o TEST RUN: This menu is used to perform a test to failure. It allows the choice of
channel, the type of the test, the type of sample with relative description and finally to
perform the test with the acquisition and elaboration of the applied load;
o FILE MANAGER: this menu allows access to the data stored in the external USB
memory stick;
o OPTIONS: this menu allows the setting of date, language, measurement unit, setting
of data transmission and printer;
o MANUAL COMMANDS: this menu allows manual control of the test frames for
calibration purposes and allows access to CALIBRATION menu to be used to enter
those dedicated functions for the calibration of the instrument (this menu is password
protected and is reserved to CONTROLS authorized personnel).
o INFO: it shows a screen with general information and the version of the firmware
installed on the equipment.
On the top row of the screen the 2 following symbols may appear and has the following
meanings:
• indicates that the unit is connected to a PC via the LAN port, using the
DATAMANAGER program (optional); in this case the touch screen display does not
operate and the commands are given via the computer (refer to the manual of the
DATAMANAGER program);
• indicates that an anomalous condition has been detected:

o APPROACHING LIMIT time is over, indicating that the daylight is too big
and distance pieces must be added (also see PID SETUP chapter 6.1.3);
o the load detected exceeds the capacity of the frame.
Touch the CONTROLS icon in upper-left corner on the screen to return to

previous menu.
Touch this icon to return

to previous screen
Fig. 4-4
Below the options present in the MAIN MENU are described in details.

4.2.1 TEST RUN screen
On the MAIN MENU press on the icon to access the screen for the selection of
the channel (frame) to use for the test; the following screen will appear:
Fig. 4-5
Select the desired channel by pressing the relevant icon, the system will show a screen
that allows selecting among 10 pre-set test profiles;
NOTE:
Previous screen only appears in case the PILOT has 2 channels activated, otherwise the
system will go directly to the next screen.
Fig. 4-6

Select the desired profile by pressing the relevant icon, the system will show the
following screen with test parameters;
Fig. 4-7
The profile screen allows the input of descriptive and dimensional characteristics of the
sample and the input of the test parameters.
The input data is used by the PILOT system in the management of the test. It is important
to input the exact data with regards to the dimensions of the sample and load rate; this
data also forms part of the test parameters which will be saved along with the test results.
This screen contains the following fields:

o TEST-SET: 01: Editable alphanumeric field to give a name to the selected profile;
the given name will then appear in the profile selection screen (Fig. 4-6);
o NoTEST: it increases by one before a starting a new test;
o ID: is an alpha-numerical identification code made up of 10 characters. Use the
buttons and to move among the digits and the buttons and
to select the desired character;

o OP (Operator name) editable;
o Test type selectable among:
o COMPRESSION
o FLEXURE
o INDIRECT TENSILE
o OTHER;
o Type of sample selectable among:
o For COMPRESSION test:
o CUBE
o CYLINDER
o BLOCK
o ELEMENT
o OTHER;
o For FLEXURE test:
o BEAM
o KERB
o SLAB
o OTHER;

o For INDIRECT TENSILE tests:

o PAVER BLOCK
o CONCRETE
o OTHER;
o For OTHER test:
o OTHER;
o SAMPLE DIMENSIONS (A, B, C): size of the sample
o AREA: is calculated automatically and cannot be modified unless OTHER type of
sample is selected;
o WEIGHT: weight of the sample in grams;
o AGE: age of the sample in hours and days;
o TEST SPEED: this is the load gradient to be applied during the test. The units can
be selected between MPa/s and N/s (or kg/cm²*s and kg/s, psi/s and lbf/s);
o PEAK (Peak sensitivity): the peak sensitivity value, expressed in engineering units,
is a value corresponding to a decrease in load upon which the instrument, during a
test, considers the sample as failed and hence stops the test. The suggested values are
10 to 30 kN for compression tests on concrete, 1 to 3 kN for flexure tests on concrete
or compression tests on cement, 0.1 to 0.3 kN for flexure test on cement. As a
general rule the value must be proportional to the failure load and lower than the
failure load otherwise the machine will not stop automatically upon sample failure;
The name of the profile presently selected is shown in the upper part of the screen and
can be edited. When exiting and saving the new name will be updated in the list.
Touch on the area of the parameter to modify (the relevant field will be highlighted), use
the buttons and or touch several times the desired field to set the
parameters, use the buttons and to move among the different digits of the
alphanumeric fields.
For FLEXURE tests only, two extra data are added:
o DISTANCE “L” between the lower bearers;
o METHOD OF LOADING, with selection between, two point loading or central
loading depending of the number of upper bearers being used.
For INDIRECT TENSILE tests and COMPRESSION tests on BLOCKS, two extra data
are added:
o COEFFICIENTS K1 AND K2, these are explained below.
When OTHER type of sample is selected the following additional parameter appears on
the screen:
o TARGET, operator’s settable load target value that will cause ending of the test once
the set load value is reached.

Formulas used for COMPRESSION tests:

Formulas used for FLEXURE tests:

Formulas used for INDIRECT TENSILE tests:

Once all settings are done, press the CONTROLS logo on the upper-left corner of
the screen to exit from the present menu.
.
Fig. 4-8
The system will require a confirmation; pressing ACCEPT, the set parameters will be
stored in the presently selected profile; pressing ABORT, the set parameters will not be
stored and the system reverts to the previous parameters.
At the end of this phase the system enters the COMPRESSION screen of the selected
channel (in this case only channel 1 is available).
Fig. 4-9

4.2.1.1 TEST RUN screen

Once all the desired settings have been made, the PILOT will enter the test screen.
The type of test depends on the selection made in the previous screen (Compression,
Flexure, Indirect tensile).
This is the main function of the unit, it allows the acquisition of the applied load of the
test frame and to make the relative calculations in real time.
The sequence of the operations relative to the failure testing of samples are managed
within this menu.
The following screen is shown and is made up of the following components:

15 2
3 11
12
4
5 13
6
14
7
8 10 9
Fig. 4-10
1. Date and time
2. Record number (number of tests stored in the memory)
3. Specimen area
4. Applied load
5. Strength (resistance)
6. Test speed
7. Trend indicator of actual load rate with respect to theoretical load rate
8. Dimensions Y axis (% of the full scale)
9. Dimensions X axis (in seconds)
10. Graph Area
11. START TEST command
12. NEW TEST command
13. TEST RESULT MANAGEMENT command
14. Shortcut to SPECIMENT DESCRIPTION menu
15. Indicator for the position of the lever of the manual ON/OFF hydraulic valve (in this
case the lever of the valve is down).
The test screen has two formats, with and without the graph. With the test NOT running,
it is possible to switch from one format to the other by touching the display for more than
2 seconds.

The handle of the ON/OFF manual hydraulic valve has to be used during the execution of
the test:
• handle turned down when the motor is not running; allows releasing the pressure and
returning the piston of the press in its rest position;
Fig. 4-11
• Handle turned up when the motor is running, to drive the press piston up to apply
pressure to the sample;
Fig. 4-12
NOTE:
To help the operator the display shows the position of the lever in the different phases of
the tests (see ref. 15 of Fig. 4-10)

When the test phase is started the screen will show the message TEST IN PROGRESS.
Once the sample comes into contact with the upper platen/bearer a change in the noise
from the pump will be noted as the PILOT controls the load rate throughout the test with
its P.I.D. closed loop system. Once the system reaches equilibrium the noise will remain
constant.
Fig. 4-13
The test can be stopped at any time by pressing the button or the icon .
The display constantly updates the values of load and resistance in real time.
Fig. 4-14
During the execution of the test, the display of deviation of actual load rate (field 7 of
previous figure Fig. 4-10) from the theoretical load rate shows a series of symbols as
described below:
=== Actual load rate corresponds with theoretical load rate ± 1%
= Actual load rate = theoretical load rate ± 1….10%
– Actual load rate = theoretical load rate - 10%
–– Actual load rate = theoretical load rate – 10…25%
––– Actual load rate = theoretical load rate by more than – 25%
+ Actual load rate = theoretical load rate + 10…15%
++ Actual load rate = theoretical load rate + 15….25%
+++ Actual load rate = theoretical load rate by more than + 25%.

In this way it is possible to follow the accuracy of the machines automatic functioning. In
normal conditions the machine can keep to the set load rate within +/- 1% apart from the
very beginning and end of the test when numerous adjustments are made. If the closed
loop action needs to be improved it is possible to alter the parameters of the P.I.D.(refer
to the service department).
The central area of the screen shows the graphical representation of load versus time.
A large part of the display is dedicated to this function allowing the operator to evaluate
the progress of the test through the load against time graph. The X axis shows the time at
the start of the test its full scale is 150 sec. The maximum possible scale is 600 sec. (10
minutes).
The Y axis shows the load. At the start of the test its full scale is 50% of the capacity of
the frame.
During the test the graph is shown in real time, and the scale of the axis are optimised by
the software (autoscale function with steps of 25%).
When sample is near to fail, an increase of the pump noise will be noted due to the system
that has to compensate for the high deformation of the sample.
Upon sample failure the display shows the message TEST COMPLETED and the values
of maximum load and resistance are shown in large digits in the area of the graph as
shown below:
Fig. 4-15
At the same time the pump will stop.
Turn the manual valve lever down to release the residual pressure and allow the piston to
return to its rest position.

To save the data into the archive it is necessary to have fitted an USB memory stick into
the relevant port on the rear panel of the equipment, then touch the button on the
screen. The system will show the following screen
Fig. 4-16
WARNING:
To save the test in the memory press the button ; upon doing this you will note
that the number of saved test files will increase by one. The maximum number of tests to
store depends on the capacity of the external memory stick fitted into the control unit.
To print a test report on the internal serial printer (if present) press the . Before
doing this, make sure that the paper is loaded into the printer (see chapter 3.9). An
example of a typical printout is given below:

Settings of the present options are described in chapter 4.2.3.3.
Press the button to close this window and return to the TEST RUN screen.
To perform a new test, press the button on the screen: the graph of the previous
test will be cancelled from the display and the axis scales will return to their initial values,
the results of the previous test are cancelled and the values of load and resistance zeroed.
To change the test parameters or the sample description press the button on the
screen. Then enter in sample description menu and follow the instruction previously
provided.
Before starting a test, it is also possible to set the display in order it will not show the
graph. Starting from the following screen:
Fig. 4-17
Touch the display in the center for at least 2 seconds, the following screen will appear:
Fig. 4-18

Proceed with the test as previously described.
This setting will be valid for all next tests; to return to previous setting (test with graph),
touch the center of the screen for at least 2 seconds before starting the test.
Touch the CONTROLS logo in the upper-left corner of the screen to exit from
the TEST RUN screen.

4.2.2 FILE MANAGER (TEST ARCHIVE) screen
Saved files are stored in an USB memory stick to be connected on the dedicated port
located rear panel of the control unit. The number of tests that can be stored depends on
the capacity of the memory stick.
On the main menu press on the icon to activate the FILE MANAGER (TEST
ARCHIVE) menu; the following screen will appear:
Here below there is an example of the file management screen. The main elements are:
1 2
Fig. 4-19
Description of the meaning of the different fields of this screen is provided in next page.
NOTE:
Access to the TEST ARCHIVE screen is not possible if the memory stick is not
connected into the USB port of the control unit. In this case, test data cannot be stored.
WARNING:
Do not use the USB port to re-charge batteries of external devices (e.g. mobile phone,

1. Data area
2. Record number (position of displayed test in the memory sequence; 1 to 99999)
3. Command to select single test or the complete memory . This

selection affects the PRINT, DOWNLOAD and CANCEL functions. Press on this
icon to toggle from one condition to the other
4. Data OPTIONS command
5. To display the data of the previous stored test
6. To display the data of the next test stored.
Each test file can be shown on the display, printed on a serial printer or downloaded to a
PC through the LAN port.
Use the buttons and to scroll through the various stored tests. Each test is
identified by as sequential position in the memory (item 2 in the above screen).
Press the button to display the available functions provided within the TEST
ARCHIVE screen.
Fig. 4-20
Press the button to cancel the test from the memory: depending on the selection
previously done (see item 3 of previous Fig. 4-19) the system will ask confirmation to
cancel the present test or the whole test memory
Fig. 4-21

Press ACCEPT to confirm or ABORT to abort this operation.
On the TEST ARCHIVE screen popup, press the button to print the displayed
test on the internal printer (if present).
On the TEST ARCHIVE screen popup, press the button to view the test graph.
On the TEST ARCHIVE screen popup, press the button to exit from the popup.
the FILE MANAGER (TEST ARCHIVE) screen.
Test data are saved in the memory stick as GRXXXXX.txt file (one file for each test,
XXXXX = is the test number as saved into the control unit of the machine) and has the
following format:
where the first column is the TIME and the second is the LOAD. These files can be use to
plot the tests on the PC using commercial programs.

4.2.2.1 Printing of all tests in the archive
When the multiple test function is activated on the TEST ARCHIVE screen (see next
figure) it is possible to print all tests stored in the archive.
Multiple tests selection
Fig. 4-22
To print all tests:
1. Press the button to display the OPTIONS popup;
Fig. 4-23
2. Press the button , all tests in the archive will be printed in sequence.

4.2.3 OPTIONS menu
On the MAIN MENU press on the icon to activate the OPTIONS menu; the
following screen will appear:
Fig. 4-24
This menu allows the selection of language, setting of date and time, setting of test
options (unit of measurement, data printout, storage etc).
the OPTIONS screen.
4.2.3.1 SELECT LANGUAGE option
Press the button on the screen and then select the desired language. The
languages available in total are 9.
Fig. 4-25
the OPTIONS screen.

4.2.3.2 DATE AND TIME screen
Press the button on the screen and to access this function.
Fig. 4-26
Press the buttons and to set the parameters and the button to
select the parameter to change.
this screen (press ACCEPT or ABORT to confirm exiting).

4.2.3.3 TEST OPTION screen
Press the button on the screen and to access this function.
Fig. 4-27
Select the desired field on the screen and press the buttons and to set the
parameters.
The TEST OPTIONS screen includes the following fields:
o UNIT OF MEASURE: The firmware allows for readings to be expressed and
calculated in kN and tonnes. Note that for each load measurement unit, the load rate
or stress rate may be selected. Depending on this selection the system will optimise
the display in terms of resolution and number of digits to be shown.
The firmware uses the following conversion factors:
1 kN = 0.101971 Ton
When moving from one measuring unit to another, there is no need to re-calibrate the
instrument (provided this was previously calibrated).
o AUTOPRINT: when ENABLED, activates the print function via the internal printer
(if present);
o AUTOSTORE: when ENABLED, activates automatic saving in the USB memory
stick connected to the port on the rear side of the control unit;
o PRINT GRAPH: when ENABLED, activate the print out of the graph on the
internal printer (if present).
WARNING:

o START TEST PARAMETER: this parameter, normally set to 1, is used to intervene

on this very first instant of loading before the machine follows the pre-set load
gradient.
The parameter has a multiplying effect, therefore it is sufficient to increase or

decrease it to increase or decrease the pre-load. When tests are made on samples of
large dimensions with the use of deformable capping (such as fibre boards, carton or
concrete blocks), we recommend that a value of between 5 and 10 is set.
Vice versa, a value of below 1 should be set for very small samples where a low load
gradient is being used.
WARNING:
If the START TEST PARAMETER value is not properly set, it will cause improper
functioning of the machine (e.g. if the value is too high the machine will not be able to
sense the failure of the sample and therefore will continue pressing the sample and never
stop).
This may result in damages to the equipment and/or danger for the operator. CONTROLS
will not be considered responsible in these events.
this screen (press ACCEPT or ABORT to confirm exiting).

4.2.4 MANUAL COMMANDS screen

This menu allows the display of the load read by the enabled channel(s) and to use the
machine in manual mode, that is the operator may apply the load, changing the load rate
starting from zero.
On the main menu press on the icon to activate the MANUAL COMMANDS
menu; the following screen will appear to select the desired channel:
Fig. 4-28
NOTE:
Once the desired channel has been selected, the following screen will be shown:
2 3
4
1
5
6
8
7
9 10 11 12 13
Fig. 4-29
This function allows the checking of the calibration of the machine by comparing the load
indicated by the display with a reference load indicator to check linearity and
repeatability. When this screen is accessed the value of load of the selected channel will
be shown as a small value (near zero) which corresponds to the electronic zero of the
amplified signal.
WARNING:
The MANUAL COMMANDS menu is reserved to the authorised service personnel.
CONTROLS will not be responsible for any damage caused by improper setting of these
parameters. Warranty will be void if this menu is used by unauthorised personnel.
The main information displayed is:

1. Load reading; during the load phase, if the set full scale value is reached, the load
figure on the screen will blink, the pump motor will stop and the message
OVERLOAD will be shown on the screen while the internal buzzer will be activated
2. Channel selection
3. Position of the lever of the hydraulic ON/OFF valve:
i. UP position at start and during the load phase,
ii. DOWN position at the end of the test to discharge the pressure, after pressing
the STOP button, when reaching the full scale value beyond 5%, after the
piston overtravel microswitch has been triggered
4. Pump START/STOP command
5. Zero function
6. Button to access CALIBRATION menu (password protected and reserved to
authorized CONTROLS technical personnel)
7. Button to access the set up of desired level of load that the machine will
automatically reach and maintain. This function is active when the load applied is
higher than the 5% of the full scale
8. Load rate
9. Every time is pressed, it increases the speed of the pump motor of 1%
10. Every time is pressed, it increases the speed of the pump motor of 0.1%
11. Every time is pressed, it halves the current value % of set speed
12. Every time is pressed, it decreases the speed of the pump motor of 0.1%
13. Every time is pressed, it decreases the speed of the pump motor of 1%.

4.2.5 ABOUT screen
Pressing the icon will access a screen that shows general information of the
system and version of the firmware installed.
Fig. 4-30
this screen.

4.3 Carry out a test

The present chapter provides a quick guide for the execution of a test. Full details on the
various screens and options accessed are provided in chapter 4.2.
WARNING:
while loading/unloading samples from the test frame, due to the sample weight and sharp
surfaces.
WARNING:
while handling distance pieces and platens of the frame due to their weight.
WARNING:
Always close the front door and place the rear guard on the frame while executing the
tests. Also use proper personal protection devices (e.g. glasses) in order to avoid injures
due to fragments of samples ejected during the test (e.g. in case of test on explosive
samples ).
WARNING:
Although the maximum speed of the loading piston of the frame is very low (max. 40
mm/min), to avoid injures during the compression phase, always close the front door and
place the rear guard while executing the tests. Also avoid putting hands/fingers in the gap
between the sample and the upper platen.

Before starting any test check that:

• The test frame is free from residual of previous sample and that the surface of the
platens are clean;
• Depending on the size of the sample, use proper distance pieces to reduce the
daylight on the press (leave a gap of at least 3-4mm), also considering that the piston
total travel is 50mm.
Fig. 4-31

4.3.1 Selection of the frame to use (for units equipped with optional dual-output
selector block)
Depending on the type of test to perform, select the relevant frame by means of the frame
selector lever here after shown:
• Lever UP to select Frame #1;
• Lever DOWN to select Frame #2.
Frame selector lever
Fig. 4-32

4.3.2 Testing a sample
1. Switch ON the machine and wait 15 minutes warm up time;
2. Place the sample in the test frame and close front door and rear guards (see previous
WARNIGS);
Fig. 4-33
3. Before starting with the test, make sure the handle of the manual valve is turned down
and that the piston of the compression frame is in its rest position;
Fig. 4-34

4. From the main menu select the TEST RUN option;
Fig. 4-35
5. Select the channel/frame to use for the test, the system will show the following
screen;
NOTE:
Fig. 4-36
6. Select one the pre-set profiles or one of the profiles not yet set on which it will be
possible to save the test settings;
Fig. 4-37
7. Set the test parameters;
8. Once done, touch the CONTROLS logo in upper-left corner of the screen;
Fig. 4-38
9. Press ACCEPT to save the settings; the system enters the TEST RUN screen;
Fig. 4-39

10. When ready, turn the handle of the manual valve up and press the button on
the screen to start the test (message TEST IN PROGRESS shown on the display);
Fig. 4-40
11. Once the sample comes into contact with the upper platen/bearer a change in the
noise from the pump will be noted as the PILOT controls the load rate throughout
the test with its P.I.D. closed loop system. Once the system reaches equilibrium the
noise will remain constant.
The display constantly updates the values of load and resistance in real time and
shows the set load rate in the lower left hand corner, whilst the actual applied load
rate is also shown on the display.
Fig. 4-41

During the execution of the test, the display of deviation of actual load rate (field 7
of previous figure Fig. 4-10) from the theoretical load rate shows a series of symbols
as described below:
=== Actual load rate corresponds with theoretical load rate ± 1%
= Actual load rate = theoretical load rate ± 1….10%
– Actual load rate = theoretical load rate - 10%
–– Actual load rate = theoretical load rate – 10…25%
––– Actual load rate = theoretical load rate by more than – 25%
+ Actual load rate = theoretical load rate + 10…15%
++ Actual load rate = theoretical load rate + 15….25%
+++ Actual load rate = theoretical load rate by more than + 25%.
In this way it is possible to follow the accuracy of the machines automatic

functioning. In normal conditions the machine can keep to the set load rate within +/-
1% apart from the very beginning and end of the test when numerous adjustments
are made. If the closed loop action needs to be improved it is possible to alter the
parameters of the P.I.D.(refer to the service department).
The central area of the screen shows the graphical representation of load versus time.
A large part of the display is dedicated to this function allowing the operator to
evaluate the progress of the test through the load against time graph. The X axis
shows the time at the start of the test its full scale is 150 sec. The maximum possible
scale is 600 sec. (10 minutes).
The Y axis shows the load. At the start of the test its full scale is 50% of capacity of
the frame.
During the test the graph is shown in real time, and the scale of the axis are
optimised by the software (autoscale function with steps of 20%).
Upon sample failure the display shows the message TEST COMPLETED and the
values of maximum load and resistance are shown in large digits in the area of the
graph as shown below:
Fig. 4-42
At the same time the pump will stop.

12. Turn the manual valve lever down to release the residual pressure and allow the
piston to return to its rest position;
13. To save data and print it is necessary to have an USB memory stick in the USB port
located on the rear panel of the equipment and touch the button on the
screen. The system will show
Fig. 4-43
WARNING:
14. To save the test in the memory press the button ; upon doing this you will
note that the number of saved test files will increase by one. The number of tests that
can be stored depends on the capacity of the USB memory stick in use.

15. To print a test report on the internal printer (if present) press the . Before
doing this check that the paper is loaded into the printer (see chapter 3.9). An
example of a typical printout is given below
Present settings are explained in chapter 4.2.3.3.
16. Press the button to close this window and return to the TEST RUN screen.
Before starting a test (see previous step 9), it is also possible to set the display in order it
will not show the graph. Starting from the following screen:
Fig. 4-44

Touch the display in the center for at least 2 seconds, the following screen will appear:
Fig. 4-45
Proceed with the test as previously described.
This setting will be valid for all next tests; to return to previous setting (test with graph),
touch the center of the screen for at least 2 seconds before starting the test.

4.4 Stopping the cycle via the Emergency button

In case dangerous conditions are encountered during the execution of a test cycle, it is
possible to stop the machine by pressing the EMERGENCY BUTTON.
Pressing this button will stop the movement of the piston and turn OFF the Control unit,
to release the pressure of the hydraulic circuit lower the handle of the manual valve.
Releasing the emergency button (turn it clockwise) will bring the unit back to the start up
condition (MAIN MENU shown on the display).
WARNING:
Before releasing the EMERGENCY BUTTON make sure that the lever of the hydraulic
ON/OFF valve is in the lower positions (discharge position).
EMERGENCY BUTTON
Lower the lever of the

manual valve
Fig. 4-46

4.5 Switching off the unit

At the end of a test, make sure all printout and data storing into the USB memory have
been completed, then remove residuals of the samples.
Return the unit to the MAIN MENU and switch the equipment OFF via the mains switch
on the control unit.
Mains switch on control unit
Fig. 4-47
WARNING:
Before turning the equipment OFF make sure that the lever of the hydraulic ON/OFF
valve is in the lower positions (discharge position).

5. MAINTENANCE
As with all electrical equipment, this unit must be used correctly and maintenance and
inspections must be performed at regular intervals. Such precautions will guarantee the
safe and efficient functioning of the equipment.
Periodic maintenance consists of inspections made directly by the test operator and/or by
the authorized service personnel.
Maintenance to the equipment is responsibility of the purchaser and must be performed as

stated by this chapter.

WARNING:
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
at least 5 minutes.
WARNING:
WARNING:
tools/buttons. These tools and buttons are for the use of maintenance people only. Never
leave them attached to the unit as this may endanger operator safety.
and locked.

WARNING:
WARNING:
For continued fire protection, replace fuses with same type and rating. Also, in case of
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
WARNING:

5.1 Operator’s preventive maintenance

The inspections made directly by the operator are the following:
Action Who When

Check to ensure that there is no Operator Before every working session
external damage to the equipment,
which could jeopardise the safety of
use
Clean and dry platens, distance Operator At the end of each working
piece and ram of the frame from the session
sample debris
General inspection Operator Weekly
Check the status of the hydraulic Operator Weekly
tubes against leakages and damages
Check status of the safety devices: Operator Weekly
EMERGENCY BUTTON, max.
pressure valve, piston over travel
switch and relevant cable on the
frame, front door and rear
transparent guard on the frame
(refer to chapter 5.1.1 for their
identification)
Check status and functioning of the Operator Weekly
operator's commands
Check the level of the oil in the Operator Monthly
tank (see chapter 5.1.2)
Check that all label and rating Operator Monthly
plates are intact and properly
attached

5.1.1 Checking the status of the safety devices

The machine is equipped with the following devices to limit the residual risks in using it:
• Emergency button that switches OFF the unit once pressed, thus stopping the raising
of the piston;
Emergency button
Fig. 5-1
• Max. pressure valve to avoid machine overloading.
Max. pressure valve
Fig. 5-2

• Ram travel limit microswitch to prevent the excessive piston travel; when triggered
it disables the functioning of the pump motor.
Limit microswitch
Fig. 5-3
• Front and rear transparent fragment guard.
Front fragment guard
Fig. 5-4

• Dual input for ram travel microswitches to prevent the excessive piston travel; when
triggered it disables the functioning of the pump motor.
Dual input for

over-travel
microswitches Fig. 5-5

5.1.2 Checking the oil level in the tank
WARNING:
Check the oil level in the tank via the transparent level indicator (the oil
should be max. at half of the indicator); if necessary refill the oil tank.
Oil level indicator
Fig. 5-6
The following type of oil can be used:
Brand Type
Agip ATF Dexron
Api Apilube ATF Dexron
Chevron Chevron automatic transmission fluid
Elf Elfmatic G
Exxon Automatic transmission fluid
Fiat GI/A
Fina Dexron ATF
Gulf Automatic transmission fluid
IP Dexron fluid
Mobil ATF 220
Shell ATF Dexron II
Total Dexron
Vanguard ATF fluid DEX II

5.2 Authorized service engineer maintenance actions

In addition to the maintenance actions performed by the operator, the performance of the
equipment is checked and, if necessary corrected, during the maintenance activities
performed by the authorized service engineer, in accordance with the indications
provided in the present manual.
The following table lists the maintenance actions and the relevant timing:
Action Who When

Checking the centering of the ram Authorized service
Yearly or before carrying
assembly (see chapter 5.2.1) engineer
out the calibration of the
Checking the hydraulic circuit (see Authorized service
load channel(s) and the
chapter 5.2.2) engineer
checking of the stability of
Checking the status of distance Authorized service
the frame through the force
pieces (see chapter 5.2.3) engineer
transfer test with the strain
Performing the maintenance of the Authorized service
gauged column
spherical seat (see chapter 5.2.4) engineer
Checking the calibration of the load Authorized service Yearly or more frequently
channel (see chapter 5.2.5) engineer depending on the quality
procedures of the
laboratory
Checking the stability of the frame Authorized service Yearly or more frequently
through the force transfer test with engineer depending on the quality
the strain gauged column (see procedures of the
chapter 5.2.6) laboratory
Status of the internal and external Authorized service Yearly
cables wear and tear and fastenings engineer
Grounding of all the accessible Authorized service Yearly
conductive parts engineer
Replacing the oil of the hydraulic Authorized service Every 3 years or more
circuit (see chapter 5.2.7) engineer frequently in very cold or
humid environments (where
condensation may form in
the oil tank)
WARNING:

5.2.1 Checking the centering of the ram assembly
The proper centering of the ram assembly assures proper and uniform distribution of the
force to the sample during the execution of the compression test.
This check is normally carried out before checking the calibration of the system and
checking the stability of the frame through the force transfer test with the strain gauged
column.
This checking should also be carried out if tests on high strength concrete/explosive
samples are often carried out.
To check the centering of the ram assembly:
1. Remove the lower platen and distance pieces;
2. On the compression frame remove the cover of the ram assembly to expose its fixing
brackets;
Fig. 5-7
3. Use a straight edge and a tape measure to check the centering of the ram assembly in
all directions with respect to the columns of the compression frame;
Fig. 5-8

4. If it is not centered more than 1mm in one or more directions, loosen the ram fixing
nuts and screws and use a rubber hammer to re-center it properly;
Fig. 5-9
5. Also check that the ram is properly positioned from a rotational point of view by
taking as reference the position of the oil supply tube with respect to the columns of
the frame on the rear of the ram;
Fig. 5-10
6. At the end firmly lock the ram assembly in place by tightening the relevant
brackets/nuts and screw.

5.2.2 Checking the hydraulic circuit
Due to the high pressure inside the hydraulic circuit (up to 700 bars) a periodical check
on the hydraulic components is required.
WARNING:
WARNING:
Proceed as follows:
1. Remove the lower platen and distance pieces;
2. On the compression frame remove the cover of the ram assembly to expose its fixing
brackets;
Fig. 5-11
3. On the rear of the equipment check the following points for oil leakages:
o Connection point of the pressure transducer
o Input port of the oil on the ram assembly
o Both ends of the hydraulic tube and along the hydraulic tube itself
o Output of the manual valve on the front side
o Slot between the piston and the ram assembly;

Fig. 5-12
4. In case of oil leakages, check the single item(s) and replace the relevant gasket/O-
ring;
5. Then check the oil level in the tank (refer to chapter 5.1.1) and, if needed, re-fill the
oil tank as described in chapter 5.2.7;
6. At the end, use compressed air to clean the slot between piston and cylinder
and the base of the compression frame.

5.2.3 Checking the status of distance pieces
To assure proper and uniform distribution of the force to the sample during the execution
of the compression test, status of distance pieces and platens must be periodically
checked.
This check is normally carried out before checking the calibration of the system and
checking the stability of the frame through the force transfer test with the strain gauged
column.
This checking should also be carried out if tests on high strength concrete/explosive
Checking the status of distance pieces requires:

• Checking that the surfaces of the distance pieces are not damaged (free of deep dents
and incisions);
• Checking the planarity of the lower and upper surface;
• Checking the status of the centering screw;
• Checking that, once the distance pieces are installed on the machine, they do not tilt
pushing them from the top.
Fig. 5-13

5.2.4 Performing the maintenance of the spherical seat
The status of the spherical seat heavily influences and determines the proper performance
of the compression machine as it must ensure proper and uniform distribution of the force
to the sample during the execution of the compression test.
The maintenance of the spherical seat is normally carried out before checking the
calibration of the system and before checking the stability of the frame through the force
transfer test with the strain gauged column.
The maintenance should also be carried out if tests on high strength concrete/explosive
Performing the maintenance on the spherical seat requires its removal from the equipment
and its complete disassembling to check and maintain its internal components.
Refer to qualified service organisation authorized by CONTROLS to perform the

maintenance on the spherical seat.
WARNING:

5.2.5 Checking the calibration of the load channel
The load values displayed by the machine are conditioned by the calibration coefficients.
The calibration of the system must be checked periodically to ensure proper performance.
The calibration procedure here after described conform to the European standard
EN12390-4.
The main steps of the procedure can be summarized as follows:

1. Control of the calibration; if the machine is within the limits of the standard, the
procedure ends, otherwise proceed with step 2;
2. Calibration of the machine (e.g. adjustment of the force measurement device of the
machine);
3. New control of the calibration (repeat step 1).
Steps 2 and 3 above are required if the machine is not within the limits indicated by the
standards.
Step 1 above consists of:

o Application of several levels of force (at least 5) ranging from 20% to 100% of the
full scale of the machine;
o For each level of force, compare the force measured by the compression machine (the
“indicated force”) with the force measured by a calibrated force measurement device
(the “true force”)
For class 1 machine the requirement of EN12390-4 are the following:

o Relative accuracy error within the range ±1%;
o Relative repeatability error within the range ±1%;
o Relative zero error within the range ±0,2%.
The same procedure can also be applied for equipment complying with the ASTM C39
standard, that requires an accuracy ±1% for any value displayed within the verified
loading range and the provision to display true 0 reading at 0 load.

To check the calibration of the load channels, the MANUAL COMMANDS screen must
be accessed from the system MAIN MENU by pressing on the button ; the
following screen will appear to select the channel to use:
Fig. 5-14
Once the desired channel has been selected, the following screen will be shown:
NOTE:
2 3
4
1
5
6
8
7
9 10 11 12 13
Fig. 5-15

The main information displayed is:

1. Load reading; during the load phase, if the set full scale value is reached, the load
figure on the screen will blink, the pump motor will stop and the message
OVERLOAD will be shown on the screen while the internal buzzer will be activated
2. Channel selection
3. Position of the lever of the hydraulic ON/OFF valve:
i. UP position at start and during the load phase,
ii. DOWN position at the end of the test to discharge the pressure, after pressing
the STOP button, when reaching the full scale value beyond 5%, after the
piston overtravel microswitch has been triggered
4. Pump START/STOP command
5. Zero function
6. Button to access CALIBRATION menu (password protected and reserved to
authorized CONTROLS technical personnel)
7. Button to access the to the set up of desired levels of load that the machine will
automatically reach and maintain. This function is active when the load applied is
higher than the 5% of the full scale
8. Load rate
9. Increases the speed of the pump motor of 1%
10. Increases the speed of the pump motor of 0.1%
11. Button to halve the current value % of set speed
12. Decreases the speed of the pump motor of 0.1%
13. Decreases the speed of the pump motor of 1%.
The load values are conditioned by the calibration coefficients.

5.2.5.1 Calibration verification
To verify the calibration the unit should be left switched on for at least 15 minutes to
allow the thermal equilibrium of the electronic components. Then proceed as follows:
1. From the main menu press the button to select the MANUAL COMMANDS
menu;
Fig. 5-16
2. Correctly place the reference instrument (e.g. load cell) between the compression
platens of the test machine. Check that the free vertical span is approximately
between 5 and 25 mm, use suitable distance pieces if necessary;
3. When ready, turn up the handle of the manual valve and press the button . The
pump will start immediately and the ram of the test machine will start to rise. During
this phase, before the load cell is subjected to load, zero the load reading by pressing
the button . At the same time the load rate shown on the display will go from
0% to that corresponding to the rapid approach, normally 20-30% unless otherwise
set by the manufacturer;
NOTE:
The load rate may have values between 0 and 100%, corresponding to the minimum and
maximum load rates respectively.

4. When the load cell is close to the upper platen of the compression machine it is
recommended that the load rate is decreased so as to not apply a shock load to the
cell. To do this press and keep pressed the button ; an immediate fall in the
noise level from the pump and a fall in the load rate will be noticed. Vice versa to
increase the load rate press the button . The button when pressed, will
immediately set the load rate at half of the present rate, this is very useful when one
must quickly pass from the rapid approach speed to a much lower speed;
5. Once the load cell is under load, a moderate speed should be used, making
adjustments with the buttons or to change the speed of 0,1% per

step. By taking the load rate close to zero it is possible to stop the load increase and
maintain an almost constant pressure. The value of the applied load is updated in real
time on the display. To interrupt the load application press and turn the
handle of the hydraulic pump down: the pump will stop and the ram will return to its
initial position. Before checking the calibration the machine should be taken to its
maximum capacity 3 or 4 times so as to obtain a stabilised signal from the load
sensors. After this check the readings given by the PILOT system against that of the
reference load cell. Normally this is done at values of 10%, 15%, 20%, 40%, 60%,
80% and 100% of the full scale of the compression machine. It is also possible to
check the calibration at lower loads if the compression machine has been so
calibrated;
6. If the percentage deviation is higher than permitted tolerances, the unit should be re-
calibrated by changing the calibration coefficient so as to obtain the best possible
linearity. To do this the CALIBRATION menu should be accessed. After this the
manual mode will be entered and the above mentioned procedure repeated so as to
check the new calibration.

As alternative to the adjustment of the pump motor speed in manual mode with the use of
the buttons , , , , , it is also possible to set level of

loads (e.g. level of loads to check the calibration comparing to an external reference
system) that the unit will reach and maintain automatically.This function is achieved by
the use of the button highlighted in the following screen of the MANUAL
COMMANDS:
Fig. 5-17
This button is active only when the pump motor is ON and the measured load is higher
than the 5% of the full scale.
1. Pressing the button the motor will stop and the system will ask to enter a
target value to reach for the load:
Fig. 5-18

2. Input the load value to reach using the arrows buttons and then press the button
to confirm; the pump motor will start to reach the set level of load;
Fig. 5-19
3. The achievement of the entered load value will be done gradually, first running the
pump motor at high speed and then, approaching the target value, slowing down the
speed up to stop it at the set value; once the set value is reached the system will emit
an audible alarm;
4. Repeat steps 1 to 3 for the other load levels in order to carry out the calibration
verification;
5. At the end of the whole procedure press the button and lower the lever of the
manual hydraulic ON/OFF valve. This way, the pump motor will stop, the hydraulic
pressure will be discharged and the piston will return to the rest position.

5.2.5.2 Calibration
Access to this menu should be made after that to the MANUAL COMMANDS and
verification of the linearity error of the calibration.
This menu allows the calibration to be adjusted so as to optimise the linearity of the
system (unit + load sensors + test frame). The operator can divide the full scale of the
testing unit in up to a maximum six user definable fields, this allowing the input of up to
six calibration coefficients (one for each field). The software then automatically foresee
the interpolation of these fields so as to calculate the calibration curve of the unit over its
complete range. This allows extremely accurate calibration even at very low loads whilst
using one reading scale and one load sensor.
WARNING:
The CALIBRATION menu should only be entered when the calibration needs to be
changed. Do not enter into this menu for any other reason. Before entering the
CALIBRATION menu it is vital to carefully read and understand the procedure
described hereunder. If any doubts remain, contact CONTROLS service department for
further clarification.
CONTROLS will accept no responsibility for any inconvenience caused by wrongful
calibration.
1. On the MANUAL COMMANDS screen select the channel to calibrate;
2. From the MANUAL COMMANDS press the button to activate the

CALIBRATION screen; the system will ask for a password;
Fig. 5-20
3. Input the password using the buttons and . The password is 00101.
Next press the button to confirm;

4. The CALIBRATION MENU will appear (see below). Before describing this menu
and its functions, it is important to fully describe the calibration procedure;
Fig. 5-21
5. The calibration table is composed by couple of data e.g. real load value achieved with
a reference system (reference loadcell and relevant readout unit) and the
corresponding values read by the electronics of the PILOT. The applied loads should
remain within the calibrated measurement range of the test frame, normally from
10% or 20% up to 100% of the full scale.
The aim of the calibration is to obtain class 1 classification of the frame within this
measurement range. However, it may be necessary to extend this accuracy to lower
loads in which case it will be necessary to use a reference load cell of appropriate
capacity and accuracy. The recorded readings, that is the values displayed by the
PILOT at known reference loads, will be used for the interpolation.
On the basis of these readings and the general linearity of the system, determine the
range you wish to calibrate. PILOT system allows the calibration to be made on up
to 6 points which are then automatically interpolated by the unit to compensate for
any non linearity of the system (i.e. the test frame, PILOT and load sensor).
If the system is sufficient linear and the measurement range is from 10-20% to full
scale it is sufficient to use one calibration point, normally between 40 and 50% of
the full scale. This calibration is of the linear type, that is it is based on a single
calibration coefficient with no interpolation. This is the easiest and quickest
calibration method and is the standard method which is normally used.
If class 1 calibration must be reached at particularly low loads, it is necessary to

make more readings above all at the beginning of the measurement range. Normally
readings are made at 1%, 3%, 5%, 10% and 50-70%.
Particular operator experience or needs may lead to the use of other measurement
values.
If the system linearity is not acceptable within the field 10% to 100% full scale, we
recommend the following values, 10%, 20%, 60%, 100%. Particular operator
experience or needs may lead be the use of other values.

6. After accessing the CALIBRATION menu of the desired channel the screen will
show the values relative to the last calibration made (if such a calibration has been
made);
Fig. 5-22
7. Otherwise the screen shows the default parameters with a one point calibration
(normally the zero point and a point at the half of the full scale of the frame). The
first column on the left (TRUE FORCE) shows the reference load values (values to
reach and read on an external reference system), the second column (BIT ADC), the
reading of the PILOT control unit in row values;
Fig. 5-23

8. If instead the existing calibration must be completely cancelled, press the button
; the system will ask confirmation before erasing the calibration;
Fig. 5-24
9. Here follows an example of calibration points to set for a 2000kN frame either for a
1-point calibration and a 5-point calibration (plus the first point for both that must
always be set to zero):
1-point calibration 5-point calibration

TRUE FORCE TRUE FORCE
00000.0 00000.0
01000.0 00020.0
00000.0 00060.0
00000.0 00100.0
00000.0 00200.0
00000.0 01200.0
10. After setting the TRUE FORCE values, press the CONTROLS logo in
upper-left corner of the screen to exit the present screen and access the screen to
achieve the different calibration points;
Fig. 5-25

11. After having placed a reference load cell in the test frame make at least three
load/unload cycles activating the pump with the button and adjusting the
speed with the following buttons:
Increases the Increases the Halves the Decreases the Decreases the
speed of the speed of the present speed speed of the speed of the
pump motor of pump motor of of the pump pump motor of pump motor of
1% 0,1% motor 0,1% 1%
12. Set the lever of the hydraulic ON/OFF valve to the UP position to apply the load; at
the end de-activate the pump motor by pressing the button and lower the
lever of the hydraulic ON/OFF pump to discharge the oil and lower the piston of the
frame;
13. To start the procedure to achieve the calibration points press the button and
set the lever of the hydraulic ON/OFF valve to the UP position to apply the load: the
piston will start to raise at the rapid approach speed set into the functional parameters
of the unit;
Fig. 5-26
14. Before the loadcell will touch the upper platen of the frame, press the button ;
to acquire the first calibration point, the zero point without any load applied (on the
display this point will be identified as );
NOTE:
During this phase the button is not active.

15. After saving the first calibration point (zero value), the system will propose the
second calibration point with the value previously set; this is indicated by the
message on the screen, use the arrows buttons to adjust the
speed of the pump motor and stop the piston when the target value previously set is
reached reading it on the external reference system (loadcell plus readout unit);
Fig. 5-27
16. Once this value read on the external reference system is reached, press the button
to acquire the second calibration point; the system will propose the third
calibration point indicating it on the display with the message
;
Fig. 5-28

17. Proceed by repeating previous steps 15 and 16 until acquiring all calibration steps
previously set;
Fig. 5-29
18. Once the last point has been acquired, the system will show the following screen;
lower the lever of the hydraulic ON/OFF valve to allow the piston to move to its rest
position;
Fig. 5-30
19. Press the button ACCEPT to save the new calibration or ABORT to keep the old one;
20. Once done, touch the CONTROLS logo in upper-left corner of the screen to
return to the MANUAL COMMANDS screen;

5.2.6 Checking the stability of the frame
The proper application of the load to the sample can be tested through the force transfer
test carried out with the strain gauged column.
This testing procedure conforms to the European standard EN12390-4.
This test checks the performance of the compression machine under loading and the
uniformity of the force transferred from the machine to the sample.
The cylindrical Strain Gauged Column simulates the concrete sample and can measure
the stress transferred along the wall of the sample.
The Strain Gauged Column can read the applied force through 4 independent Wheastone
bridges located peripherally along the wall of the cylinder. A dedicated electronic unit
switches and independently balances each bridge, simultaneously displays the 4 bridges
and has an accuracy within the limits ±0,1% or 5µm strain.
A dedicated 150mm square stainless steel plate allows proper positioning of the Strain
Gauged Column during the tests.
Fig. 5-31
The above picture shows the Strain Gauged Column code 82-E0105/1,the force transfer
digital tester code 82-P0804/E and the printer code 82-P0172 that can be used to carry out
the Force transfer test.

The Force Transfer Test allows checking the behaviour of the machine in order for it to
provide accurate force values and to crush the sample “regularly” as shown below
Fig. 5-32
If instead the machine crushes samples as shown in the next drawings, it may not be
applying the load uniformly and this can be discovered by means of the Force Transfer
Test.
Fig. 5-33

checking of the compression machine as described in this chapter.
WARNING:

5.2.7 Replacing the oil of the hydraulic circuit
WARNING:
Periodically the oil of the hydraulic circuit must be completely replaced.
1. Discharge the old oil via the drainage screw;
Drainage screw
(view from below)
Fig. 5-34

2. Collect the old oil and dispose it in accordance with the local
regulations;
3. Refill the tank (6 litres approx.) with the oil type shown in next table;
Brand Type
Agip ATF Dexron
Api Apilube ATF Dexron
Chevron Chevron automatic transmission fluid
Elf Elfmatic G
Exxon Automatic transmission fluid
Fiat GI/A
Fina Dexron ATF
Gulf Automatic transmission fluid
IP Dexron fluid
Mobil ATF 220
Shell ATF Dexron II
Total Dexron
Vanguard ATF fluid DEX II
4. Let the pump run and check oil level in the tank via the transparent level
indicator (the oil should be max. at half of the indicator);
Oil refil port
Oil level indicator
Fig. 5-35
5. Top up if necessary.

6. DIAGNOSTICS & TROUBLESHOOTING

The present chapter provides information on the diagnostic programs present in the
system and on the troubleshooting of the most common problems.
Depending on the problem encountered, the troubleshooting is carried out by dividing the
system into functional blocks.
WARNING:
at least 5 minute.
WARNING:
tools/buttons. These tools and buttons are for the use of maintenance people only. Never
leave them attached to the unit as this may endanger operator safety. After performing
maintenance/repair, make sure that all covers/doors are properly closed and locked.
WARNING:
WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the service
maintenance actions described in the chapter “Diagnostic and Troubleshooting”.
CONTROLS has not to be held responsible for damages to the equipment and/or injuries
to personnel in case the above is not strictly followed.

6.1 System (Hidden) menu
This menu allows setting a number of functioning parameters of the system and
performing procedures reserved to CONTROLS authorized service organisation.
WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the service
maintenance actions described in the chapter “Diagnostic and Troubleshooting”.
CONTROLS has not to be held responsible for damages to the equipment and/or injuries
to personnel in case the above is not strictly followed.
To access the SYSTEM (HIDDEN) MENU:
1. Turn OFF the unit;
2. Touch the display in any point with a finger, switch ON the machine and
release the finger from the display after 10 seconds approx; the
following screen will be shown
Fig. 6-1

3. Use the buttons and to input the password 00202 and
confirm it by pressing the button . The system will show he

following screen:
Fig. 6-2
4. The following options are available in the SYSTEM MENU:

• ADC CHANNELS SETTINGS
• SERIAL NUMBER
• MEMORY RESET
• PID SET UP
• DIAGNOSTIC
• FACTORY.
The following pages describe the above mentioned options.

6.1.1 ADC CHANNELS SETTINGS option
It allows setting into the PILOT control unit the working parameters of the
frame connected.
Fig. 6-3
The following table shows the parameters set up for CONTROLS frames.
Frame type Capacity [kN] Preload [kN] Approach[%]

Concrete compression 5000 kN 5000 20 35
Concrete compression 4000 kN 4000 20 35
Concrete compression 3000 kN 3000 15 32,5
Cement compression 250 kN 250 0,50 15
Cement flexure 15 kN 15 0,05 12
Concrete flexure 100 kN 100 0,50 20
Concrete flexure 150 kN 150 0,50 20
Concrete flexure 300 kN 300 1 20
NOTE:
The ADC CHANNELS SETTINGS parameter are factory set in case the
PILOT is sold already equipped with relevant frame(s).

In case it is not, to activate the second channel (CH2):
1. Touch the CHANNEL 1 area in the lower- center part of the screen (the
relevant field will be highlighted);
2. Press the ARROW KEYS to display CHANNEL 2 option;
3. Touch the CHANNEL 2 area, a second row of parameters will appear on

the display;
Fig. 6-4
4. For each channel, input the working parameters for frame CAPACITY,
PRELOAD and APPROACH (see previous table). To select a field,
touch the relevant area on the display and use the buttons and
to set the parameter value.
NOTE:
Buttons and present on the screen are not active.
5. Once done, touch the CONTROLS logo in upper-left corner of

the screen and press the ACCEPT button to save the changes and return
to the SYSTEM MENU screen.

6.1.2 SERIAL NUMBER option
This screen allows entering the unit serial number that it is normally set
during the manufacturing of the unit and does not need to be changed unless
the MEMORY RESET function has been activated (see chapter 6.1.4);
Fig. 6-5
To set the different fields, touch the relevant area on the screen and use buttons
and to set the alphanumeric characters, use the buttons and to

move from one digit to another.
Once done, touch the CONTROLS logo in upper-left corner of the

screen and press the ACCEPT button to save the changes and return to the
SYSTEM MENU screen.

6.1.3 PID SET UP option
This function allows accessing to the screen used to set the coefficients of the PID
control (Proportional, Integral, Derivate) which manages the performance of the
automatic test guaranteeing uniform application of set load rate by appropriately piloting
the oil flow. It is also possible to find the control parameters for the initial part of the test,
that is just after the pre-load.
All the parameters are separated for each channel.
Once this option is entered, the system shows the following screen:
Fig. 6-6
Here follows a description of the parameters and logic of the working of the servo control
system.
NOTE:
The P. UNDERSHOOT parameter shown in the screen above is reserved. Do not modify
its setting.
The constants of proportional, integral and derivates are fundamental parameters of the
software mathematics of the servo-control unit. In this respect we feel it useful to give a
brief introduction on the functioning logic of the servo-control of the PILOT system.
The logic is as follows: each time a load gradient is requested to be made, in reality the
machine is asked to act so that some variables (output or controlled variables) follow a
certain pattern by acting appropriately on other variables (input or control variables).
The relationship between control variables and controlled variables is nothing more than
a mathematical model which makes each controlled variable correspond to a respective
control variable.

For the PILOT 4, an hydraulic servo-controlled system, is illustrated in the following

chart:
Fig. 6-7
Thanks to the closed loop system, when the test machine is asked to perform a load ramp
with certain characteristics, the oil flow is controlled and corrected continuously (several
times per second) so as to respect those characteristics (particularly load rate) as best as
possible.
The accuracy of the control and hence the respect of the imposed load rate depends on a
number of inter-related factors:
• The soundness of the close loop logarithm;
• The speed of the system (data acquisition, elaboration and consequential intervention
etc.);
• The type of test; the type of test and sample also has an effect on the working of the
closed loop. For example a load rate controlled test on a weak sample could result in
the machine to be required to increase the oil flow in order to respect the load rate at a
pace faster than the whole system can perform. In this case it would be almost
impossible to respect the test speed and the real load rate would be less than the
theoretical one requested. This is a very extreme example, but it could occur.
Thus, whilst it is possible to intervene on the system (by CONTROLS) to optimise the
performance and on the type of test (by the operator) so as to avoid any critical points in
the test, it is also possible to intervene on the close loop logarithm so as to optimise
its performance.
The close loop used by CONTROLS is the PID type which has three variables that can be
freely set to alter the functioning.
Proportional closed loop constant K proportional:

Used to amplify the small errors between real and theoretical values (both positive and
negative) measured by the machine continuously so as to decide how to modify the oil
feed (increase or decrease) so as to near the theoretical load. The error is in effect the
main key that pilots the behaviour of the machine. If the real load rate is above the
theoretical one, the oil feed must be reduced and vice-versa. When this error has a certain
sign, after a few acquisitions and corrections with the same sign, normally the error will
change sign and the corrections will be with the opposite sign.

Thus the curve of the real load is always close to the theoretical one but never exactly
superimposed, it moves above and below it in cycles. The size of this oscillation can be
reduced by adjusting the K proportional constant. Indeed amplifying the error
proportionally the changing of the sign of the error will occur in a shorter time.
Theoretically, increasing K proportional infinitely the real and theoretical load graph
should coincide, however, above a certain threshold which depends upon the specific set
up of the test, amplifying the error produces resonate oscillations and instability instead
of increased precision.
Integrative closed loop constant K integral:

Is used to maintain the history of the test, that is what has happened just before that
moment in time. Allows the proportional amplification of the integral sum of the
differences (The errors) that have been read moment by moment between the theoretical
curve and the real curve cancelling those constant errors always of the same sign which
cannot be eliminated with the use of K proportional only. Also in this case there is a
maximum threshold value which should not be surpassed.
Derivative closed loop constant K derivative:

Is used to compensate systems with very long time constants. Allows the “smoothing” the
size of the oscillations to bring the system more quickly to the reference values. Also in
this case there is a maximum threshold value which should not be surpassed to avoid the
system being extremely instable or even out of control.
These parameters are factory set so as to optimise the system and thus do not need to be
altered by the operator. However, should it be felt necessary to alter the parameters for
particular user need, please contact CONTROLS Service Department for
further details.
After the PID parameters, on the screen the two control parameters which act at the first
part of the test are shown. These are:
• SET UP DELIVERY (%) which is the oil feed percentage (with respect to rapid
approach feed rate) which the system will apply for a certain time after the pre-load,
that is after the threshold load set in the system menu. This time is expressed in the
following parameter.
• SET UP TIME [s] is the time in seconds that the oil feed SET UP DELIVERY (%)
will be applied.
Before giving a complete description of the interaction logic of the control parameters,
we must introduce the final two parameters of the SYSTEM MENU, that is:
• Preload, is the threshold load above which at the beginning of the test during the
rapid approach (open loop) the PID controls intervene to give closed loop servo-
control. From this point onwards the oil flow is piloted so as to maintain the pre-set
load rate;
• Rapid approach, expresses the oil feed rate, with respect to the maximum, which the
system must apply during the rapid approach, that is from the start of the test to the
pre-load threshold. This parameter, together with the mechanics of the pump,
determines the speed that the ram rises when not subjected to load.

The functioning logic of the PILOT 4 system is as follows:

at the start of the automatic test the pump feeds the test frame ram the amount of oil
determined by the rapid approach parameter.
The ram will rise so as to close the free span and bring the sample into contact with the
upper platen. The pump continues to operate in this way until the set pre-load threshold
has been reached.
At this point the pump immediately changes speed so as to supply the set oil delivery (%)
for a set up time (s); this phase, which normally last for 3 or 4 seconds, allows the system
to stabilise itself and be ready for the servo-control without harsh variations of load and
oil feed.
Indeed, after this phase the control system enters a closed loop phase where the PID logic
elaborates, several times a second, the necessary instructions so as to maintain the pre-set
load rate and pilots the pump accordingly.
The servo-control remains active until the end of the test.
The system is calibrated by the manufacturer so as to optimise its performance in terms of

load rate control. However, certain tests may require the factory set parameters to be
modified. This is the case for failure tests on very weak or highly deformable samples
(e.g. concrete block with soft-board capping), or tests on very small samples with
extremely slow load rate (e.g. tests on cement samples using a 2000 kN or 3000 kN test
frame).
In the first case, to compensate for the high deformation at the beginning of the test it is
sufficient to increase the pre-load, even 5 to 7 times the factory set value. The idea is to
achieve the major part of the deformation during the rapid approach phase when the oil
feed is high.
In the second case, the opposite should be done, reducing the pre-load by 1/3 to ¼ and oil
delivery (%). The aim is to achieve a notable reduction of oil feed as soon as the sample
comes in contact with the upper platen and start the servo-control at a very low speed.
NOTE:
After the test, re-set the parameters to their factory set values. Contact CONTROLS
Service Department if you have any doubts.
The above two examples illustrate extreme cases, for standard tests the system can be
used with its factory settings.

To select the channel to set:
1. Touch the area CHANNEL # on the screen (the relevant field will be
highlighted);
2. Press the ARROW KEYS to display the desired channel;
3. Touch the CHANNEL # area;
4. Select a field of the parameter to change by touching the relevant area on
the display and use the buttons and to set the parameter
value.
NOTE:
Buttons and present on the screen are not active.
The following table shows the parameters set up for CONTROLS frames.
Frame type and code K Proportional K K Set up Set up P. Under

Integrative Derivative time delivery shoot
Concrete compression 25 20 20 3 80 25
5000 kN
4000 kN
3000 kN
2000 kN
1500 kN
Cement compression 40 30 20 2 110 50
250 kN
Cement flexure 15 kN 60 150 55 1 20 50
Concrete flexure 100 60 50 45 2 40 50
kN
kN
kN

Parameters common to all models/frames:
Parameters Value
Concrete units 60
APPROACHING LIMIT [SEC]
Cement units 30
ZEROING TIME [SEC] 2
NOTE:
The PID SET UP parameters are factory set in case the PILOT 4 is sold as a
machine already equipped with relevant frame.
Once done, touch the CONTROLS logo in upper-left corner of the screen and
press the ACCEPT button to save the changes and return to the SYSTEM MENU screen.

6.1.4 MEMORY RESET option
The MEMORY RESET option allows erasing the whole system memory
including calibration coefficients, full scale, language selection, measurement units, etc.
and the test data stored in the memory card.
It can be used to completely reset the system in case of system memory corruption.
WARNING:
Do not use the MEMORY RESET function unless authorized by CONTROLS Service
department. CONTROLS will not be held responsible for damages to the equipment
and/or injuries to personnel in case the above is not strictly followed.
Once this function is activated, the system will show the following screen;
Fig. 6-8
A double confirmation is requested before erasing the memory;
Fig. 6-9
After performing the MEMORY RESET all working parameters of the

equipment must be re-entered.

6.1.5 DIAGNOSTIC option
Reserved to the authorized technical personnel of CONTROLS.
WARNING:
Do not access to the DIAGNOSTIC option unless specifically authorized by the technical
6.1.6 FACTORY option
Reserved to the authorized technical personnel of CONTROLS.
WARNING:
Do not access to the FACTORY option unless specifically authorized by the technical

Notes:

Notes:

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COMPACT-Line

Automatic Compression Machines

PILOT COMPACT Line Rev.2 EN i 23/11/2012

4. USE OF THE EQUIPMENT 49

23/11/2012 ii PILOT COMPACT Line Rev.2 EN

6. DIAGNOSTICS & TROUBLESHOOTING 123

PILOT COMPACT Line Rev.2 EN iii 23/11/2012

This Manual is published by CONTROLS.

23/11/2012 iv PILOT COMPACT Line Rev.2 EN

This new generation of Compact-Line Automatic compression testers, adopting the

The PILOT Compact-Line Automatic compression testers, represent the more

PILOT COMPACT Line Rev.2 EN 1 23/11/2012

Main features are:

MAIN CHARACTERISTICS OF EN TESTERS FOR CUBES, CYLINDER TO EN

23/11/2012 2 PILOT COMPACT Line Rev.2 EN

MAIN CHARACTERISTICS OF EN TESTERS FOR CUBES, CYLINDER AND

MAIN CHARACTERISTICS OF TESTERS FOR CYLINDER TO ASTM C39,

PILOT COMPACT Line Rev.2 EN 3 23/11/2012

MAIN CHARACTERISTICS OF TESTERS, STANDARD AND HIGH

MAIN CHARACTERISTICS OF TESTERS, STANDARD AND HIGH

23/11/2012 4 PILOT COMPACT Line Rev.2 EN

PILOT COMPACT Line Rev.2 EN 5 23/11/2012

1.1 Icons appearing in the manual

23/11/2012 6 PILOT COMPACT Line Rev.2 EN

1.2 Manual revision history

Revision/Date Change description

PILOT COMPACT Line Rev.2 EN 7 23/11/2012

1.3 Symbols used

Emergency stop switch

Conformity to the CE Directive

23/11/2012 8 PILOT COMPACT Line Rev.2 EN

1.4 Intended use and improper use

PILOT COMPACT Line Rev.2 EN 9 23/11/2012

1.5 Safety information

CONTROLS will not to be held responsible for:

The unit is not designed to be used in an explosive atmosphere.

Installation and any technical intervention must only be performed by qualified

23/11/2012 10 PILOT COMPACT Line Rev.2 EN

Max. pressure valve

Front fragment guard

23/11/2012 12 PILOT COMPACT Line Rev.2 EN

Dual input for

• Access panels to internal parts locked with screws.

PILOT COMPACT Line Rev.2 EN 13 23/11/2012

Personnel Area with residual risks

23/11/2012 14 PILOT COMPACT Line Rev.2 EN

PILOT COMPACT Line Rev.2 EN 15 23/11/2012

23/11/2012 16 PILOT COMPACT Line Rev.2 EN

PILOT COMPACT Line Rev.2 EN 17 23/11/2012

23/11/2012 18 PILOT COMPACT Line Rev.2 EN

1.6 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

Improper disposal of the product is subject to penalties as foreseen by the local

PILOT COMPACT Line Rev.2 EN 19 23/11/2012

23/11/2012 20 PILOT COMPACT Line Rev.2 EN