50-C92AXX, 50-C13A0X

50-C23A0X, 50-C34A0X

Compression and flexural testers

MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni
Instruction Manual

Index
1. INTRODUCTION 4
1.1 Icons appearing in the manual ............................................................................................. 9
1.2 Manual revision history ..................................................................................................... 10
1.3 Symbols used ..................................................................................................................... 11
1.4 Intended use and improper use .......................................................................................... 12
1.5 Safety information ............................................................................................................. 13
1.6 Environmental risks and disposal ...................................................................................... 22
1.7 CE declaration ................................................................................................................... 23

2. DESCRIPTION 24
2.1 Frames ............................................................................................................................... 27
2.2 Compression platens .......................................................................................................... 27
2.3 Hydraulic power unit ......................................................................................................... 27
2.4 WIZARD 2 display unit..................................................................................................... 27
2.5 Connections ....................................................................................................................... 28
2.6 Identification plate ............................................................................................................. 29
2.7 Commands and controls .................................................................................................... 30
2.7.1 Flow control valve ......................................................................................................... 31
2.8 Technical specifications..................................................................................................... 32

3. INSTALLATION 38
3.1 Shipment ............................................................................................................................ 39
3.2 Unpacking and inspection.................................................................................................. 42
3.2.1 How to remove the equipment from the shipping crate ................................................. 43
3.3 Positioning of the unit and space requirements ................................................................. 45
3.4 Mounting the control unit .................................................................................................. 47
3.5 Positioning of the display .................................................................................................. 48
3.6 Electrical requirements ...................................................................................................... 49
3.7 Electrical connections ........................................................................................................ 50
3.8 Hydraulic connections ....................................................................................................... 52
3.9 Installation of the printer paper.......................................................................................... 55

4. USE OF THE EQUIPMENT 56

4.1 Switching on the equipment .............................................................................................. 57
4.2 MAIN MENU .................................................................................................................... 58
4.2.1 TEST RUN menu ........................................................................................................... 59
4.2.2 ARCHIVE menu ............................................................................................................ 65
4.2.3 OPTIONS menu ............................................................................................................. 66
4.2.3.1 CLOCK option ............................................................................................................... 66
Rev.1 EN 1 23/08/2018
 Manuale di Istruzione
Instruction Manual
4.2.3.2 UNIT OF MEASURE option ......................................................................................... 67
4.2.3.3 DELETE ARCHIVE option ........................................................................................... 67
4.2.3.4 RESULTS option ........................................................................................................... 68
4.2.3.5 LANGUAGE option ...................................................................................................... 68
4.2.4 CALIBRATION menu ................................................................................................... 69
4.3 Carry out a test .................................................................................................................. 70
4.3.1 Selection of the frame to use for 50-C92A2X machine.................................................. 72
4.3.2 Use of the load control valve .......................................................................................... 73
4.3.3 Testing a sample ............................................................................................................. 74
4.4 Stopping the cycle via the Emergency button ................................................................... 79
4.5 Switching off the unit........................................................................................................ 81

5. MAINTENANCE 82
5.1 Operator’s preventive maintenance .................................................................................. 84
5.1.1 Checking the status of the safety devices ....................................................................... 85
5.1.2 Checking the oil level in the tank ................................................................................... 88
5.2 Authorized service engineer maintenance actions ............................................................ 89
5.2.1 Checking the centering of the ram assembly .................................................................. 90
5.2.2 Checking the hydraulic circuit........................................................................................ 92
5.2.3 Checking the status of distance pieces ........................................................................... 94
5.2.4 Performing the maintenance of the spherical seat .......................................................... 95
5.2.5 Checking the calibration of the channels ........................................................................ 96
5.2.5.1 Calibration verification................................................................................................... 98
5.2.5.2 Calibration .................................................................................................................... 102
5.2.6 Replacing the oil of the hydraulic circuit ..................................................................... 107

6. DIAGNOSTICS & TROUBLESHOOTING 109

6.1 System (Hidden) menu.................................................................................................... 110
6.1.1 CHANNELS SET-UP option ....................................................................................... 112
6.1.1.1 ACTIVE CHANNEL option ........................................................................................ 112
6.1.1.2 FULL SCALE and PRELOAD settings ....................................................................... 113
6.1.2 SERIAL NUMBER option ........................................................................................... 114
6.1.3 MEMORY RESET option............................................................................................ 115

23/08/2018 2 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

Rev.1 EN 3 23/08/2018
 Manuale di Istruzione
Instruction Manual

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.

50-C92AXX
These Multipurpose compression / flexure testers have been designed for various
applications in which a limited maximum load is requested, together with a large testing
space. They are suitable to determinate compressive strength on lightweight concrete,
soil-cement specimen, high strength cement and refractory.
The large testing space is ideal for performing, with the suitable accessory, splitting tests
and flexural tests on concrete specimens. The pedestal is not included and has to be
ordered separately (code: 50-C99/B).

They are available in the two different versions:

Single compression station, 500 kN or 600 kN cap.:

for compression tests on low strength specimens. The Class 1 accuracy can be extended
from 1% of testing machine full scale with special calibration procedures.

Double station model, 600/15 kN cap.:

extends the possible applications to flexural tests on cement and com pression tests on
low strength specimens. The Class 1 accuracy can be extended with special calibration
procedures (see Technical Specifications).

Frames and compression platens

High rigidity solid one piece steel frame. Spherical seat allows free alignment at the
initial contact with the specimen. For compression platens see Technical. Pedestal (code:
50-C99/B) not included.

WIZARD 2 Semi-Automatic Power and Control system

Dual stage pump: low pressure/high delivery for fast piston approach and high
pressure/low volume for loading. Fitted with special hand operated pressure-compensated
proportional valve for the manual preset of load rate.
Load measurement: set up of specimen dimensions; easy preload zeroing; real time
display of load and stress; real time display of applied load rate by symbols for easy
adjustment; digital calibration; effective resolution 1/65000; LAN port for PC connection.
The WIZARD 2 can be factory fitted with an internal serial printer.

Safety features
Includes: pressure valve to avoid machine overloading; piston travel limit switch;
emergency stop button; front door and rear transparent guard.

23/08/2018 4 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

The automatic test procedure, once the specimen has been positioned and centered and
the machine switched on is:

• Set test parameters, including load rate, on the touch screen (can be avoided by
default for repetitive tests);
• Press the start button on the touch screen;
• Move the oil delivery valve upwards;
• The machine automatically starts the rapid platen approach, switches to the test
speed once the specimen comes into contact with the upper platen and, finally,
releases the pressure upon specimen failure;
• Save the test including data results and load/time graph. The test execution
conforming to standards can be easily proved;
• Move the oil delivery valve downwards.

Main features are:

• Multipurpose machine ideal for Central laboratories, for testing Cement, Mortars,
Resins, Refractory, Lightweight concrete, Soil-cement specimens etc;
• digital control system with wide high-contrast display 4x20 characters and 6 keys
membrane keyboard;
• real time display of load and stress and applied load rate by symbols for easy
adjustment;
• accuracy Class 1 (EN) and Class A (ASTM) starting from 10% of full scale;
• special calibration starting from few kilonewtons available on request;
• optional control of a second frame for single chambers testers. Active frame selection
via manual lever;
• optional internal graphic printer;
• universal compression testers, in practice, suitable to house various accessories for
testing cement, mortar, resins and other materials;
• LAN port for PC connection and data transmission during test execution;
• Data storage on removable USB pen drive.

Rev.1 EN 5 23/08/2018
 Manuale di Istruzione
Instruction Manual

Here is the list of models available and their relevant main specifications:

Single testing chamber models

50-C92A02
600 kN cap., WIZARD 2 Semi-automatic COMPACT-Line compression tester, load
measurement with pressure transducer. 230 V, 50-60 Hz, 1ph

50-C92A03
Same as above but 220V, 60 Hz, 1ph

50-C92A04
Same as above but 110V, 60 Hz, 1ph

50-C92A12
500 kN cap., WIZARD 2 Semi-automatic COMPACT-Line compression tester, load
measurement with load cell. 230 V, 50-60 Hz, 1 ph

50-C92A13
Same as above but 220V, 60 Hz, 1ph

50-C92A14
Same as above but 110V, 60 Hz, 1ph

Double testing chambers models

50-C92A22
15/600 kN cap., WIZARD 2 Semi-automatic COMPACT-Line Double Station
compression tester, load measurement of the 15 kN station with high precision load cell
and 600 kN station with pressure transducer. 230 V,50-60 Hz, 1 ph

50-C92A23
Same as above but 220V, 60 Hz, 1ph

50-C92A24
Same as above but 110V, 60 Hz, 1ph

The machine must be completed with suitable distance pieces conforming to the
specimen size.

23/08/2018 6 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

50-C13A0X/C23A0X/C34A0X
Frame
Rigid welded steel construction. Spherical seat allows free alignment at the initial contact
with the specimen.

Compression platens
See table. Traceable certificate of surface hardness available on request.

Wizard, Semi-Automatic power and control system

Dual stage pump: low pressure/high delivery for fast piston approach and high
pressure/low volume for loading. Special hand operated pressure-compensated
proportional valve for the manual preset of load rate requiring just occasional operator’s
intervention.

Hardware
2 analogue channels, 4 x 20 characters alphanumeric display, 65˙000 points high
resolution/stability analogue channels, sampling rate 50/sec, large storage capacity for
test data on USB memory stick, ethernet port to download data to PC using the SW/TRM
software.

Firmware
Simultaneous display of load, specific load and actual load rate, LAN connection to PC
for data transmission in real time, easy firmware update through Ethernet port, memory
management with options to display tests stored on USB memory stick, download data to
internal printer or PC, delete single tests or reset the entire memory, Multi-coefficient
calibration procedure with automatic storage of data without manual editing (using a
suitable load cell and readout unit), language and units selection (kN, ton, lbf).

Safety features
Includes: Max. pressure valve to avoid machine overloading; piston travel limit switch;
emergency stop button; front and rear flexible transparent fragment guard.

Main features are:

• Rigid welded steel construction
• Accuracy Class 1 (EN) starting from 10% of full scale (from 1% on request)
• 2 channels for load sensors with 65000 div. resolution (better than 0.01% of full scale)
• Unlimited store capacity on USB pen drive of test data downloadable to PC via LAN
port
• Digital readout unit with wide high-contrast display 4 x 20 characters and 6 keys
membrane keyboard
• Real time display of load/stress and applied load rate by symbols for easy adjustment
• Dual stage pump: low pressure/high delivery for fast piston approach and high
pressure/low volume for loading
• Special hand operated pressure-compensated proportional valve for the manual preset
of load rate requiring just occasional operator’s intervention
• Optional control of a second frame
• Optional internal printer

Rev.1 EN 7 23/08/2018
 Manuale di Istruzione
Instruction Manual

Here is the list of models available and their relevant main specifications:

50-C13A02
WIZARD 2, Semi- Automatic Compact-Line Gen. Util. compression tester, 1500 kN
cap., for cubes up to 150 mm and cylinders up to dia. 160 x 320 mm. 230 V, 50 Hz, 1 ph.

50-C13A03
Same as above but 220 V, 60 Hz, 1 ph.

50-C13A04
Same as above but 110 V, 60 Hz, 1 ph.

50-C23A02
WIZARD 2, Semi- Automatic Compact-Line Gen. Util. compression tester, 2000 kN
cap., for cubes up to 150 mm and cylinders up to dia. 160 x 320 mm. 230 V, 50 Hz, 1 ph.

50-C23A03
Same as above but 220 V, 60 Hz, 1 ph.

50-C23A04
Same as above but 110 V, 60 Hz, 1 ph.

50-C34A02
WIZARD 2, Semi-Automatic Compact-Line Gen. Util. compression tester, 3000 kN cap.,
for cubes up to 200 mm and cylinders up to dia. 160 x 320 mm. 230 V, 50 Hz, 1 ph.

50-C34A03
Same as above but 220 V, 60 Hz, 1 ph.

50-C34A04
Same as above but 110 V, 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 1.05.

Fig. 1-1

Please read this manual thoroughly before you start using the equipment.

23/08/2018 8 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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.

Rev.1 EN 9 23/08/2018
 Manuale di Istruzione
Instruction Manual

1.2 Manual revision history

Revision/Date Change description

Rev. 1 Manual release
August 23rd 2018

23/08/2018 10 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

Rev.1 EN 11 23/08/2018
 Manuale di Istruzione
Instruction Manual

1.4 Intended use and improper use

The 50-C92AXX WIZARD 2 Multipurpose Compression and Flexural 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.

23/08/2018 12 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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.

Rev.1 EN 13 23/08/2018
 Manuale di Istruzione
Instruction Manual

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;

• Max. pressure valve to avoid machine overloading;

Emergency button

Max. pressure valve

Fig. 1-2

23/08/2018 14 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

• Ram travel switch to prevent the excessive piston travel; when triggered it disables
the functioning of the pump motor;

Limit switch

Fig. 1-3
• Front door and rear transparent fragment guard;

Front fragment guard

Fig. 1-4
Rev.1 EN 15 23/08/2018
 Manuale di Istruzione
Instruction Manual

• On the motor connection box, input for ram travel microswitches to prevent the
excessive piston travel; when triggered it disables the functioning of the pump motor;

Connector for overtravel microswitch

Fig. 1-5

• Access panels to internal parts locked with screws.

23/08/2018 16 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

Rev.1 EN 17 23/08/2018
 Manuale di Istruzione
Instruction Manual

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

23/08/2018 18 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.8), 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 650 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 TEST PARAMETERS value is not properly set, it will cause improper functioning
of the machine (e.g. if the value is too high the machine will not be 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.

Rev.1 EN 19 23/08/2018
 Manuale di Istruzione
Instruction Manual

WARNING:
The CALIBRATION 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:
Be careful and use proper personal protection devices (e.g. gloves, protective shoes)
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.

23/08/2018 20 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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.

Rev.1 EN 21 23/08/2018
 Manuale di Istruzione
Instruction Manual

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.

23/08/2018 22 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

Rev.1 EN 23 23/08/2018
 Manuale di Istruzione
Instruction Manual

2. DESCRIPTION
Refer to the following figures for main components identification.

5
6
1

8
3

4 10

11

Fig. 2-1 Machine with 600 kN frame, code 50-C92A0X

Ref. Description
1 Upper platen with spherical seat
2 Front guard
3 Lower platen
4 Piston travel indicator
5 Control unit
6 Flow control valve
7 AC motor dual stage hydraulic pump with MOTOR ON switch
8 EMERGENCY BUTTON
9 ON/OFF Hydraulic valve
10 Speed selector (rapid approach, test speed)
11 Oil tank

23/08/2018 24 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

9
4
10

11
5
12

Fig. 2-2 Machine with 500 kN frame, code 50-C92A1X

Ref. Description
1 Load cell
2 Upper platen with spherical seat
3 Front guard
4 Lower platen
5 Piston travel indicator
6 Control unit
7 Flow control valve
8 AC motor dual stage hydraulic pump with MOTOR ON switch
9 EMERGENCY BUTTON
10 ON/OFF Hydraulic valve
11 Speed selector (rapid approach, test speed)
12 Oil tank

Rev.1 EN 25 23/08/2018
 Manuale di Istruzione
Instruction Manual

6
1

2 7

4 8

9
10

5
11
12
13

Fig. 2-3 – Machine with 2 frames (600 kN and 15 kN), code 50-C92A2X

Ref. Description
1 Load cell on 15 kN frame
2 Upper platens with spherical seats
3 Front guard
4 Lower platen
5 Piston travel indicator
6 Control unit
7 Flow control valve
8 AC motor dual stage hydraulic pump with MOTOR ON switch
9 EMERGENCY BUTTON
10 ON/OFF Hydraulic valve
11 Frame selector lever (lever UP=Frame #1, lever DOWN=Frame #2)
12 Speed selector (rapid approach, test speed)
13 Oil tank

23/08/2018 26 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

2.1 Frames
High rigidity solid one piece steel frame. Spherical seat allows free alignment at the
initial contact with the specimen. There is a 600 kN frame, model code 50-C92A0X and a
500 kN frame, model code 50-C92A1X.
There is also a second testing chamber with a 15 kN frame, only in model code 50-
C92A2X.

2.2 Compression platens

165 mm dia., surface hardness 55 HRC, flatness tolerance 0.02 mm.

2.3 Hydraulic power unit

Dual stage pump: low pressure/high delivery for fast piston approach and high
pressure/low volume for loading. Fitted with special hand operated pressure-compensated
proportional valve for the manual preset of load rate.

2.4 WIZARD 2 display unit

For load measurement. The unit feature: set up of specimen dimensions; easy preload
zeroing; real time display of load and stress; real time display of applied load rate by
symbols for easy adjustment; digital calibration; effective resolution 1/65000; LAN port
for PC connection.
The WIZARD 2 system can be factory fitted with an internal serial printer (50-
C10A/PR).

Rev.1 EN 27 23/08/2018
 Manuale di Istruzione
Instruction Manual

2.5 Connections

1 3 4 5

Fig. 2-4

Ref. Description
1 Input socket CH1 for load sensor
2 Input socket CH2 for load sensor (normally not activated, see chapter 6.1.1 of
this manual to activate)
3 LAN port for PC connection
4 USB port for data storage (USB pen drive)
5 Power cord receptacle

WARNING:
Do not use the USB port to re-charge batteries of external devices (e.g mobile phone,
audio-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.

23/08/2018 28 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

2.6 Identification plate

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

Fig. 2-5

Rev.1 EN 29 23/08/2018
 Manuale di Istruzione
Instruction Manual

2.7 Commands and controls

This chapter describes the commands and controls of the equipment. The operator’s
interface description and the use of the buttons of the control unit is provided in chapter
4.2 of the present manual.

4
1

Front view Rear view

Fig. 2-6

Rif. Description
1 Control unit with display and keyboard
2 EMERGENCY BUTTON
3 Pump motor push button
4 Control unit power ON switch

23/08/2018 30 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

2.7.1 Flow control valve

1
3

Fig. 2-7

Ref. Description
Load gradient adjustment knob (clockwise to decrease; counter clockwise to
1
increase)
Flow control lever (back for rapid approach; forward to control load rate with
2
the load gradient adjustment knob)
3 Oil supply lever (up to recycle oil in the tank; down to supply oil to the piston)

Rev.1 EN 31 23/08/2018
 Manuale di Istruzione
Instruction Manual

2.8 Technical specifications

Main characteristics
50-C92AXX WIZARD 2 Compression and Flexural machines, multipurpose
Product
models
Manufacturer CONTROLS Liscate (MI) Italy
Type Single Chamber Single Chamber Double Chamber
Models 50- C92A0X C92A1X C92A2X
Product code 230VAC version 50-60
50-C92A02 50-C92A12 50-C92A22
Hz, 1 ph

Product code 220VAC version 60

50-C92A03 50-C92A13 50-C92A23
Hz, 1 ph

Product code 110VAC version 60

50-C92A04 50-C92A14 50-C92A24
Hz, 1 ph
Capacity [kN] 600 500 600/15
Load measurement sensor Pressure transducer Load cell Pressure
transducer/Load cell
Class 1 range 60 kN ÷ 600 kN 50 kN ÷ 500 kN 60 kN ÷ 600 kN
1.5 kN ÷ 15 kN
With 50-C0050/CAL2 15 kN ÷ 600 kN - 15 kN ÷ 600 kN
With 50-C0050/CAL5 - - 0.75 kN ÷ 15 kN
With 50-C0050/CAL - 5 kN ÷ 500 kN -
Single phase line voltage 110 VAC/220 VAC/230 VAC +10%, -10%
Frequency 50-60 Hz/60 Hz
Power 750 W
Method of power entry Power cable with plug
Computer connection LAN port
Platens dia. [mm] 165x30 165x30 165x30
Hardness [HRC] 55 55 55
Flatness [mm] 0.02 0.02 0.02/0.02
Ram travel [mm] 50 50 50/30
Max vertical daylight 345 240 345/205
[mm]*
Horizontal daylight [mm] 265 265 265
Fast approach speed 40 mm/min approx.
Max. working pressure 650 bars
Oil output at max. pressure 0.3 l/min approx.
Oil tank capacity (approx.) 6 liters
Acoustic pressure < 70db(A)
Overall dimensions (lxdxh) See next figures
[mm]
Net weight approx. (with pedestal) 286 286 340
kg:
Net weight approx. (without 226 226 280
pedestal) kg:
[*] To be adjusted using the suitable distance pieces.

23/08/2018 32 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

Main characteristics
Model 50- C13A02 C23A02 C34A02
C13A04 C23A04 C34A04
Capacity kN (lbf) 1500 (335,000) 2000 (450,000) 3000 (660,000)
Max vertical daylight, 340 (13.4") 350 (13.8") 350 (13.8")
mm* (inches)
Horizontal daylight, mm 265 (10.4") 340 (13.4") 370 (14.6")
(inches)
Max. piston travel*, mm 50 (2") 50 (2") 50 (2")
(inches)
Platen dimensions, mm dia. 216 (8.5") dia. 216 (8.5") dia. 300 (11.8")

Platen surface hardness 55.5 HRC (600 HV) 55.5 HRC (600 HV) 55.5 HRC (600 HV)

Platens flatness toll, mm 0.03 (0.0012") 0.03 (0.0012") 0.03 (0.0012")

(inches)
Overall dimensions, mm 810 x 425 x 1085 835 x 440 x 1090 805 x 450 x 1160
(inches) (31.9" x 16.7" x 42 .7") (32.9" x 17.3" x 42 .9") (31.7" x 17.7" x 4 5.7")

Weight approx., kg 305 525 755

Environmental conditions
Operating temperature + 10 ÷ + 40°C
Operating humidity ≤ 50%RH @ 40°C

Rev.1 EN 33 23/08/2018
 Manuale di Istruzione
Instruction Manual

All the machines must be fixed to the floor using expandable fixing bolts as shown in
next figures:

WARNING:
Make sure to use proper fixing bolts according to the type of floor of the installation
place. CONTROLS cannot be considered responsible in case of injures to the operator or
damages to the equipment if the above instructions are not duly followed.

Fig. 2-8 Dimension and fixing of 50-C92A0X

23/08/2018 34 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

Fig. 2-9 Dimension and fixing of 50-C92A1X

Rev.1 EN 35 23/08/2018
 Manuale di Istruzione
Instruction Manual

Fig. 2-10 Dimension and fixing of 50-C92A2X

23/08/2018 36 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

It is possible to mount a pedestal (accessory code: 50-C99/B) on all 3 types of machines:

50-C92A0X 50-C92A1X 50-C92A2X

Fig. 2-11

Rev.1 EN 37 23/08/2018
 Manuale di Istruzione
Instruction Manual

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:
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.

23/08/2018 38 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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
50-C92A0X with
386 Kg 1150x850x1570 mm
pedestal
1500 mm
without
286 Kg 1000x700x1250 mm
pedestal
50-C92A1X with
386 Kg 1150x850x1570 mm
pedestal
1500 mm
without
286 Kg 1000x700x1250 mm
pedestal
50-C92A2X with
440 Kg 1150x850x1570 mm
pedestal
1500 mm
without
350 Kg 1250x850x1400 mm
pedestal
Use a proper fork lift with minimum fork length as above indicated to raise and move the
wooden crate (see figure below).

Fig. 3-1 100 Kg wooden crate

Rev.1 EN 39 23/08/2018
 Manuale di Istruzione
Instruction Manual

Fig. 3-2 60 Kg wooden crate

Fig. 3-3 70 Kg wooden crate

23/08/2018 40 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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.

Rev.1 EN 41 23/08/2018
 Manuale di Istruzione
Instruction Manual

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.

23/08/2018 42 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

50-C92A0X 270 Kg approx.
50-C92A1X 280 Kg approx.
50-C92A2X 340 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. 3-4);

Ropes Ropes

Eye bolts Eye bolts

Fig. 3-4

NOTE:
The eye bolt (marked in red) on the second frame is not used to remove the equipment
from the shipping crate.

Rev.1 EN 43 23/08/2018
 Manuale di Istruzione
Instruction Manual

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:
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:
Do not stand under suspended loads

5. Before powering on the unit, check for loose connections of cables inside the
equipment.

23/08/2018 44 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

3.3 Positioning of the unit and space requirements

WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.8), 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/electronic 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 enough space around, for maintenance and service purposes.

Fig. 3-5

Rev.1 EN 45 23/08/2018
 Manuale di Istruzione
Instruction Manual
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.

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.

It is possible to fix directly the machine on the floor, or fix the pedestal on the floor
and after, fix the machine on the pedestal by lifting up the unit, as in chapter 3.2.1.

Fig. 3-6

23/08/2018 46 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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. 3-7

2. Use a 4 mm Allen key to firmly lock the grub screw.

Fig. 3-8

Rev.1 EN 47 23/08/2018
 Manuale di Istruzione
Instruction Manual

3.5 Positioning of 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. Loosen the screw shown in next pictures;

Screw to loosen

Fig. 3-9

2. Position the control unit as desired;

3. Tighten the screw holding the control unit in the desired position.

23/08/2018 48 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

3.6 Electrical requirements

The next table shows the electrical specifications of the equipment:

Item Specifications
Mono phase voltage 110VAC/220VAC/230VAC
+10%, -10%
Frequency 50-60Hz/60Hz
Maximum power 750W

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.

Rev.1 EN 49 23/08/2018
 Manuale di Istruzione
Instruction Manual

3.7 Electrical connections

The sockets for electrical connection are on the rear panel of the equipment, these are for
the load sensors, displacement transducers, USB memory stick and LAN ports, and mains
supply fitted with filter, fuses and mains switch.

1. Connect the power cord to the control unit;

2. Connect the available load sensor(s) depending on the application in use making
reference to the table below;

1 3 4 5

Fig. 3-10

Ref. Description
1 Input socket CH1 for load sensor
2 Input socket CH2 for load sensor (normally not activated, see chapter 6.1.1 of
this manual to activate)
3 LAN port for PC connection
4 USB port for data storage (USB pen drive)
5 Power cord receptacle

NOTE:
When the unit is installed for the first time, it is recommended to leave the unit ON for at
least 8 hours so as to fully charge the internal battery. In case it gets discharged, the clock
on the display will be zeroed.

23/08/2018 50 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

3. Also connect the overtravel microswitch of the frame to the relevant socket on the
rear of the motor box;

Connector for overtravel microswitch

Fig. 3-11

4. In case two frames are connected to the same hydraulic unit, a y-cable must be used
(e.g. Code S000.45940019);

5. Refer to chapter 4.1 for the activation of the equipment.

Rev.1 EN 51 23/08/2018
 Manuale di Istruzione
Instruction Manual

3.8 Hydraulic connections

This chapter explains where to connect the hydraulic hose to supply the frame. In case the
device is equipped with the dual output hydraulic block (code C10B/2F to be installed in
the factory) it will be possible to connect a second frame.

WARNING:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.

NOTE:
The two frames cannot be driven simultaneously by the control unit.

23/08/2018 52 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

1. With the unit OFF and unplugged from the mains, connect the flexible tube supplied
to the selector block and tighten properly the relevant fixing nuts;

WARNING:
Due to the high pressure inside the hydraulic circuit (up to 650 bars) only tubes approved
by CONTROLS can be used. CONTROLS will not be responsible for damages to the
equipment or personnel injures in case of use of improper material and/or operations not
carried out by authorized technical personnel.

Connection for 2nd

frame on the dual-
output block

Connection for 1st

frame on the dual-
output block

Fig. 3-12

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);

Rev.1 EN 53 23/08/2018
 Manuale di Istruzione
Instruction 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 might 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. 3-13

23/08/2018 54 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

3.9 Installation of the printer paper

The printer (optional) is supplied with a roll of thermal paper which should be installed
before starting the unit.

Proceed as follows:
1. Open the paper roll compartment by pressing the OPEN key;
2. Move down the plastic cover to the maximum opening;
3. Place the paper roll making sure that it unrolls in the proper direction as shown;
4. Take out the paper and close the plastic cover;
5. Push on the plastic cover to lock it;
6. Tear off the exceeding paper using the jagged edge.

Fig. 3-14

Rev.1 EN 55 23/08/2018
 Manuale di Istruzione
Instruction Manual

4. USE OF THE EQUIPMENT

This chapter describes the operator’s interface and the execution of a test.

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:
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.

23/08/2018 56 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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;

Mains switch

Fig. 4-1

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.

The green light of the printer (optional) will lit, the display will first show a start up
screen and after 5 seconds a screen with the status of the system interfaces;

Fig. 4-2
2. Follow two information screens with the configuration and status of the device

(press the key to access the second of these screens);

Fig. 4-3

3. Press again to proceed and access the MAIN MENU.

Rev.1 EN 57 23/08/2018
 Manuale di Istruzione
Instruction Manual

4.2 MAIN MENU

The MAIN MENU is accessed after turning ON the and pressing the key twice.

Fig. 4-4

It comprises the following choices:

• TEST RUN: this is the screen used to conduct tests on specimens; it allows inputting
the specimen data, units, load rate and peak sensitivity;
• CALIBRATION: it displays the actual reading of the selected load channel and
allows accessing to the calibration table (password protected);
• ARCHIVE: access to this option is only allowed if a memory stick is plugged into the
USB port on the rear panel of the instrument; it allows scrolling among the stored
tests, download data to the PC (connected via the LAN port), printout through the
optional internal printer;
• OPTIONS: it allows setting date and time, the criteria to download data to the USB
memory stick and printout on the internal optional printer, selection of the unit to use
and erasing of the stored test data.

Use the keys to select the desired item of the MAIN MENU (it
will be highlighted by a box on the display) and confirm the selection with the

key.

The following chapters will describe in detail the different menus.

NOTE:
When the unit is installed for the first time, it is recommended to leave the unit ON for at
least 8 hours so as to fully charge the internal battery. In case it gets discharged, the clock
on the display will be zeroed.

23/08/2018 58 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.2.1 TEST RUN menu

After accessing TEST RUN menu, if two channels have been activated into the system

(see chapter 6.1.1 for channel activation), use the keys to select the

desired channel and press the key to confirm it.

Fig. 4-5
Otherwise the system will directly go to the following screen.

Fig. 4-6

The following parameters are displayed on the screen (use the key to access the
different parameters on the screen):

• NoTEST: this is the test number that is automatically incremented by one for any
new test;

• IdTEST: alphanumeric field that can be edited by the operator to identify the test.

Use the keys to scroll the different digits and the keys the

to set the characters (alphanumeric characters plus standard

symbols are available);

• AREA: area of the specimen that can be freely edited by the operator. Use the keys

to scroll the different digits and the keys to

set the figure;

Rev.1 EN 59 23/08/2018
 Manuale di Istruzione
Instruction Manual

• RATE and UNIT: reference load rate for the test. It will be used by the system
during the execution of the test to provide indications to the operator for proper

setting of the load control valve of the compression machine. Use the keys

to scroll the different digits and the keys to set the

figure; the unit can be selected in the same way by pressing the

keys; for the UNIT, use the keys to set it;

• PEAK: 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 data acquisition. 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 the data acquisition
automatically upon sample failure;

After setting all test parameters, press the key to proceed, the system will
require confirmation to save the changes:

Fig. 4-7

Press the key to save (or the button to keep the old parameters) and
to access to the TEST EXECUTION screen.

23/08/2018 60 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

B C

D E

Fig. 4-8

This screen shows:

A. The channel number selected for the test
B. The actual load value measured by the load sensor connected to the WIZARD 2
C. The strength (resistance) of the sample
D. The test speed
E. The trend indicator of actual load rate with respect to the theoretical set load rate
F. Date and time.

At this point, the WIZARD 2 is ready to carry out the test on the sample as follows.

The load rate is controlled using the special valve with dial gauge handle mounted on the
pump. The correct load rate can be set by following the load rate indicator on the
WIZARD 2 and rotating the load rate valve either clockwise or counter clockwise.

NOTE:
By rotating the valve clockwise, the load rate is decreased, by rotating counter-clockwise
the rate is increased.

Rev.1 EN 61 23/08/2018
 Manuale di Istruzione
Instruction Manual

Next instructions describe its use in the different phases of the test.

A A
B B

2) Load control phase:

1) Beginning of the test (rapid approach):
Lever A up and lever B slowly forward: Piston
Lever A up and Lever B back: Maximum piston
speed upwards controlled by load rate control
speed upwards;
valve;

A
B

3) Load rate adjustment: 4) End of the test:

Turn the knob until getting proper load rate (read Lever B slowly back and lever A down to
load rate indicator on the WIZARD 2 display); discharge the oil pressure.

23/08/2018 62 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

1. Start the hydraulic pump of the compression machine and apply load;

2. Before the sample comes in touch with the machine upper platen, zero the load

reading on the WIZARD 2 display by pressing the key;

3. The system will start updating the load value on the screen once the PRELOAD
value is reached (see chapter 6.1.1 to set the PRELOAD value);

Fig. 4-9

4. Adjust the load rate by acting on the flow control valve of the compression machine
and taking as a reference the trend indicator on the display; meaning of the symbols
on trend indicator is as follows:
=== 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%.

5. During the execution of the test the system sends the load versus time data via the
LAN port;

6. When the sample fails, the display will show the test results (maximum load and
resistance) and the system will emit an audible alarm (5 beeps) to inform the
operator; the trend indicator will also show the symbol *****. In case the full scale
of the system was reached before the failure of the sample, the system will only emit
the audible alarm;

Fig. 4-10

Rev.1 EN 63 23/08/2018
 Manuale di Istruzione
Instruction Manual

7. At this point turn OFF the pump and release the hydraulic pressure on the
compression machine;

8. At the end of the test it is possible to print the results on the internal printer

(optional) by pressing the key and send the data to computer via the LAN

port by pressing the key. The printout can also take place automatically at
the end of the test depending on the setting of the item AUTOPRINT (must be
ENABLED to print) in the TEST RESULTS OPTIOS screen (see chapter 4.2.3.4).

If AUTOSAVE in TEST RESULTS OPTIOS screen is set to ENABLED (see

chapter 4.2.3.4) the system will also store the test data into the USB memory stick.

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.

To proceed with a further test, press the key; press the key instead to
return to the MAIN MENU.

23/08/2018 64 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.2.2 ARCHIVE menu

Saved files are stored in an USB memory stick to be connected on the dedicated port
located on the rear panel of the WIZARD 2. The number of tests that can be stored
depends on the capacity of the memory stick.

On the MAIN MENU select the option ARCHIVE and press the key to access
the ARCHIVE MANAGER screen.

Fig. 4-11

Use the to select the desired option and the key to proceed.
Selecting the VIEW SINGLE RECORD option, the system will show the last test stored
as follows.

Fig. 4-12

Use the keys to scroll through the different stored tests.

NOTE:
Access to the VIEW SINGLE RECORD screen is not possible if the memory stick is not
connected into the USB port of the control unit or there are not test stored into it.

Press the key to return to the ARCHIVE menu.

Select the other 2 options to print all records on the internal printer (optional device) or to
send all data to the computer via the LAN port. After activating the action with the

key, the system will require a confirmation before proceeding.

The command to erase the archive is in the OPTIONS menu (see chapter 4.2.3.3).

Rev.1 EN 65 23/08/2018
 Manuale di Istruzione
Instruction Manual

4.2.3 OPTIONS menu

Accessing the OPTIONS from the MAIN MENU, the system will show the following
screen.

Fig. 4-13

Use the to select the desired option and the key to proceed.

4.2.3.1 CLOCK option

Select the CLOCK option to set DATE AND TIME.

Fig. 4-14

Use the key to scroll among the different parameters, the

keys to select the digit to change and the keys to set it.

At the end, press the key to exit and confirm the changes with the

key (or again to exit without changes).

23/08/2018 66 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.2.3.2 UNIT OF MEASURE option

It allows selecting among three different units:

• kN and mm
• Ton and mm
• Lbf and inch.

Fig. 4-15

Once entered, use the keys to select the desired unit, then
key twice to confirm the change and return to the OPTIONS menu.

NOTE:
When the unit is changed all tests in the archive are no longer valid and must be deleted.

4.2.3.3 DELETE ARCHIVE option

Access this screen to erase the data stored into the USB memory stick. Double

confirmation via the key is required by the system before erasing the stored
data.

Rev.1 EN 67 23/08/2018
 Manuale di Istruzione
Instruction Manual

4.2.3.4 RESULTS option

Access this screen to set the following TEST RESULT OPTIONS:

• AUTOPRINT: in case it is ENABLED, the system will automatically print the data
at the end of the test, on the internal printer (optional device). In case it is

DISABLED, the printout can take place by pressing the key at the end of
the test;
• AUTOSAVE: in case it is ENABLED, the data are automatically stored at the end of
the test into the memory stick attached to the USB port on the rear panel. In case it is
DISABLED, data transfer will not take place and there are no other methods to
transfer them.

Fig. 4-16

4.2.3.5 LANGUAGE option

It allows selecting the language of the messages on the display.

Fig. 4-17

Once entered, use the keys to select the desired unit, then
key twice to confirm the change and return to the OPTIONS menu.

23/08/2018 68 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.2.4 CALIBRATION menu

This menu shows the display of the load read by the selected channel (CH1 or CH2),
either in engineering unit and in bits, and allows activating the editing of the calibration
(password protected).

Fig. 4-18

This function allows the checking of the calibration of the unit by comparing the
load/displacement indicated by the display with a reference load/displacement indicator
to check linearity and repeatability. When this screen is accessed the value of
load/displacement of the selected channel will be shown as a small value (near zero)
which corresponds to the electronic zero of the amplified signal.

WARNING:
The CALIBRATION 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.

Refer to chapter 5.2.5 for full details on the use of the CALIBRATION menu.

Rev.1 EN 69 23/08/2018
 Manuale di Istruzione
Instruction Manual

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:
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:
Be careful and use proper personal protection devices (e.g. gloves, protective shoes)
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:
If the TEST PARAMETERS value is not properly set, it will cause improper functioning
of the machine (e.g. if the value is too high the machine will not be 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:
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).

23/08/2018 70 Rev.1 EN
Manuale di Istruzioni
Instruction Manual
Before starting any test check that:
• The test frame is free from residual of previous sample and that the surfaces 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. 4-19

Distance pieces to adjust the vertical daylight:

65-L1000/20
Distance piece dia. 165x20 mm. Weight 3,2 kg

65-L1000/30
Distance piece dia. 165x30 mm. Weight 4,7 kg

65-L1000/40
Distance piece dia. 165x40 mm. Weight 6,4 kg

65-L1000/68
Distance piece dia. 165x68 mm. Weight 10,5 kg

Rev.1 EN 71 23/08/2018
 Manuale di Istruzione
Instruction Manual

4.3.1 Selection of the frame to use for 50-C92A2X machine

Depending on the type of test to perform, select the relevant frame by means of the frame
selector lever here after shown:
• Lever UP to select Frame #1;
• Lever DOWN to select Frame #2.

Frame selector
lever

Fig. 4-20

23/08/2018 72 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.3.2 Use of the load control valve

The load rate is controlled using the special valve with dial gauge handle mounted on the
pump. The correct load rate can be set by following the load rate indicator on the
WIZARD 2 and rotating the load rate valve either clockwise or counter clockwise.

NOTE:
By rotating the valve clockwise, the load rate is decreased, by rotating counter-clockwise
the rate is increased.

Next instructions describe its use in the different phases of the test.

A A
B B

2) Load control phase:

1) Beginning of the test (rapid approach):
Lever A up and lever B slowly forward: Piston
Lever A up and Lever B back: Maximum piston
speed upwards controlled by load rate control
speed upwards;
valve;

A
B

3) Load rate adjustment: 4) End of the test:

Turn the knob until getting proper load rate (read Lever B slowly back and lever A down to
load rate indicator on the WIZARD 2 display); discharge the oil pressure.

Rev.1 EN 73 23/08/2018
 Manuale di Istruzione
Instruction Manual

4.3.3 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);

3. After accessing TEST RUN menu, if two channels have been activated into the

system (see chapter 6.1.1 for channel activation), use the keys to

select the desired channel and press the key to confirm it.

Fig. 4-21

Otherwise the system will directly go to the following screen;

Fig. 4-22

4. Set the test parameters as needed and press the key to proceed, the system
will require confirmation to save the changes:

Fig. 4-23

23/08/2018 74 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

5. Press the key to save (or the button to keep the old parameters)
and to access to the TEST EXECUTION screen;

Fig. 4-24

6. When ready, turn ON the pump motor by pressing the relevant switch (note that the
pump motor switch is self retaining when the mains electricity supply is connected);
in the meantime, set lever A up and lever B back on the flow control valve (rapid
approach phase);

Fig. 4-25

7. Before the sample comes in touch with the machine upper platen, zero the load

reading on the WIZARD 2 display by pressing the key. This may be

necessary to eliminate loads which may be indicated because of friction of the thrust
group or the effect of the weight of distance pieces;

NOTE:
Do not zero the load reading once the sample has been subjected to loading.

Rev.1 EN 75 23/08/2018
 Manuale di Istruzione
Instruction Manual

8. Once the sample comes into contact with the upper platen/bearer, with lever A up,
turn lever B slowly forward to control the speed of the piston with the flow control
valve;

A
B

Fig. 4-26

9. The system will start updating the load value on the screen once the PRELOAD
value is reached (see chapter 6.1.1 to set the PRELOAD value);

Fig. 4-27

10. Adjust the load rate by acting on the flow control valve and taking as a reference the
trend indicator on the display; meaning of the symbols on trend indicator is as
follows:
=== Actual load 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%.

23/08/2018 76 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

Fig. 4-28

11. When the sample fails, the display will show the test results (maximum load and
resistance) and the system will emit an audible alarm (5 beeps) to inform the
operator; the trend indicator will also show the symbol *****. In case the full scale
of the system was reached before the failure of the sample, the system will only emit
the audible alarm;

Fig. 4-29

12. Turn OFF the pump motor by pressing the relevant switch, then turn lever B slowly
back and lever A down to discharge the oil pressure;

Fig. 4-30

Rev.1 EN 77 23/08/2018
 Manuale di Istruzione
Instruction Manual

13. At the end of the test it is possible to print the results on the internal printer

(optional) by pressing the key and send the data to computer via the LAN

port by pressing the key. The printout can also take place automatically at
the end of the test depending on the setting of the item AUTOPRINT (must be
ENABLED to print) in the TEST RESULTS OPTIOS screen (see chapter 4.2.3.4).

If AUTOSAVE in TEST RESULTS OPTIOS screen is set to ENABLED (see

chapter 4.2.3.4) the system will also store the test data into the USB memory stick;

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.

14. To proceed with a further test, press the key; press the key
instead to return to the MAIN MENU.

23/08/2018 78 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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.

EMERGENCY BUTTON

Fig. 4-31

Rev.1 EN 79 23/08/2018
 Manuale di Istruzione
Instruction Manual

Pressing this button will stop the pump motor (its switch will be released and will return
in the “0” position) thus stopping the movement of the piston.

To release the hydraulic pressure, turn lever B slowly back and lever A down.

Fig. 4-32

After clearing the emergency condition:

• To release the emergency button turn it clockwise;
• To restart the motor, its power switch must be pressed.

23/08/2018 80 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4.5 Switching off the unit

At the end of a test, make sure data storing into the USB memory have been completed,
then remove residuals of the samples.

Return the unit to the MAIN MENU and switch the equipment OFF via the mains switch
on the control unit.

Mains switch

Fig. 4-33

Rev.1 EN 81 23/08/2018
 Manuale di Istruzione
Instruction Manual

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.

Failing to perform the recommended maintenance actions or maintenance performed by

unauthorized people can void the warranty.

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:
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:
Covers/doors can only be removed/opened by maintenance people, by using relevant
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.

23/08/2018 82 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

WARNING:
Due to the high pressure inside the hydraulic circuit (up to 650 bars) only tubes approved
by CONTROLS can be used. CONTROLS will not be responsible for damages to the
equipment or personnel injures in case of use of improper material and/or operations not
carried out by authorized technical personnel.

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:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.

Rev.1 EN 83 23/08/2018
 Manuale di Istruzione
Instruction Manual

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

NOTE:
Previous table indicates also the maintenance actions to be performed on the frames
normally connected to the control console.

23/08/2018 84 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

5.1.1 Checking the status of the safety devices

• Emergency button that switches OFF the unit once pressed, thus stopping the raising
of the piston;

• Max. pressure valve to avoid machine overloading;

Emergency button

Fig. 5-1
Max. pressure valve

Rev.1 EN 85 23/08/2018
 Manuale di Istruzione
Instruction Manual

• Ram travel switch to prevent the excessive piston travel; when triggered it disables
the functioning of the pump motor;

Limit switch

Fig. 5-2
• Front door and rear transparent fragment guard;

Front fragment guard

Fig. 5-3
23/08/2018 86 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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

Connector for overtravel microswitch

Fig. 5-4

Rev.1 EN 87 23/08/2018
 Manuale di Istruzione
Instruction Manual

5.1.2 Checking the oil level in the tank

WARNING:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.

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. 5-5

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

23/08/2018 88 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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 5.2.4) 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 5.2.6) engineer frequently in very cold or
humid environments (where
condensation may form in
the oil tank)

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.

NOTE:
Previous table indicates also the maintenance actions to be performed on the frames
normally connected to the control console.

Rev.1 EN 89 23/08/2018
 Manuale di Istruzione
Instruction Manual

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. 5-6
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. 5-7

23/08/2018 90 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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. 5-8
5. Also check that the ram is properly positioned from a rotational point of view by
taking as reference the position of the oil supply tube with respect to the columns
of the frame on the rear of the ram;

Fig. 5-9
6. At the end firmly lock the ram assembly in place by tightening the relevant
brackets/nuts and screw.

Rev.1 EN 91 23/08/2018
 Manuale di Istruzione
Instruction Manual

5.2.2 Checking the hydraulic circuit

Due to the high pressure inside the hydraulic circuit (up to 650 bars) a periodical check
on the hydraulic components is required.

WARNING:
Due to the high pressure inside the hydraulic circuit (up to 650 bars) only tubes approved
by CONTROLS can be used. CONTROLS will not be responsible for damages to the
equipment or personnel injures in case of use of improper material and/or operations not
carried out by authorized technical personnel.

WARNING:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.

Proceed as follows:

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. 5-10

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 flow control valve on the front side
o Slot between the piston and the ram assembly;

23/08/2018 92 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

Fig. 5-11

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 5.1.2) and, if needed, re-fill the
oil tank as described in chapter 5.2.6;

6. At the end, use compressed air to clean the slot between piston and cylinder and the
base of the compression frame.

Rev.1 EN 93 23/08/2018
 Manuale di Istruzione
Instruction Manual

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
samples are often carried out.

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. 5-12

23/08/2018 94 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

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
samples are often carried out.

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:
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.

Rev.1 EN 95 23/08/2018
 Manuale di Istruzione
Instruction Manual

5.2.5 Checking the calibration of the channels

The load values displayed by the readout unit are conditioned by the calibration
coefficients.

The calibration is required to perform periodical checks (e.g. preventive maintenance),

when attaching the WIZARD 2 to the transducers of an existing machine and/or when a
new transducer is connected to it (e.g. replacement of a defective transducer).

The main steps of the procedure can be summarized as follows:

1. Calibration verification; if the unit is within the limits of the standard, the procedure
ends, otherwise proceed with step 2;
2. Calibration of the unit (e.g. adjustment of the force measurement device connected to
the unit);
3. New calibration verification (repeat step 1).

Steps 2 and 3 above are required if the unit is not within the limits indicated by the
standards.

Step 1 above consists of:

o Application of several levels of force (at least 5) ranging from 20% to 100% of the
full scale of the frame;
o For each level of force, compare the measured value by WIZARD 2 with the values
measured by a calibrated external device (e.g. a loadcell with relevant readout unit).

The verification and calibration are carried out by activating the CALIBRATION option
from the MAIN MENU.

WARNING:
The CALIBRATION menu is reserved to the authorised service personnel and should
only be entered when the calibration needs to be changed. 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.

23/08/2018 96 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

After selecting the CALIBRATION, if two channels have been activated into the system

(see chapter 6.1.1 for channel activation), use the keys to select the

desired channel and press the key to confirm it.

Fig. 5-13

Otherwise the system will directly go to the following screen.

2
Fig. 5-14

For the selected channel, the screen shows:

1. The actual load read by the load sensor attached to the WIZARD 2 unit in
engineering unit;
2. The actual load read by the load sensor attached to the WIZARD 2 unit in bits.

During the load measurement phase, if the set full scale value is reached, the figure on the
screen will blink and the message OVERLOAD will be shown on the screen while the
internal buzzer will be activated until the load is returned within the full scale limits.

Rev.1 EN 97 23/08/2018
 Manuale di Istruzione
Instruction Manual

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. Activate the CALIBRATION MENU by selecting the CALIBRATION option on

the MAIN MENU;

Fig. 5-15

2. Correctly place the reference instrument (e.g. load cell) between the compression
platens of the test frame;

3. When ready, turn ON the pump motor by acting on the relevant switch (note that the
pump motor switch is self-retaining when the mains electricity supply is connected);
in the meantime, set lever A up and lever B back on the flow control valve (rapid
approach phase); and the ram of the test machine will start to rise;

Fig. 5-16

23/08/2018 98 Rev.1 EN
Manuale di Istruzioni
Instruction Manual

4. During this phase, before the reference cell is subjected to any load, zero the reading

by pressing the key;

NOTE:
Do not zero the load reading once the load cell has been subjected to loading.

NOTE:

The key can be pressed several times to zero the load reading on the display

before the frame start the loading phase. The key will not be active if an
increase of at least 0.25% of the full scale is detected by the load sensor.

5. When 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 set lever A up, turn lever B slowly forward to control the speed of the
piston with the flow control valve;

A
B

Fig. 5-17

Rev.1 EN 99 23/08/2018
 Manuale di Istruzione
Instruction Manual

6. Adjust the load rate by acting on the flow control valve knob;

Fig. 5-18
7. Once the load cell is under load, a moderate speed should be used, making
adjustments with the flow control valve knob as described above. 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;

8. To interrupt the load, turn OFF the pump motor switch and turn lever B slowly back
and lever A down to discharge the oil pressure;

Fig. 5-19

9. Make at least 3 load-unload cycles, arriving at the full scale of the load sensor
connected to the WIZARD 2, so as to stabilize the signals. After this, proceed with
the check and compare the values shown by the WIZARD 2 with those of the
reference load cell;

23/08/2018 100 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

10. Check the readings given by the WIZARD 2 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 loadcell. It is also possible to check the calibration at
lower loads if the compression frame has been so calibrated;

11. If the percentage deviation is higher than permitted tolerances, the unit should be re-
calibrated by altering the calibration coefficient so as to obtain the best possible
linearity. To do this the edit calibration function should be accessed. After this the
verification process shall be repeated so as to check the new calibration.

Rev.1 EN 101 23/08/2018

 Manuale di Istruzione
Instruction Manual

5.2.5.2 Calibration

Access to this function should be made after that the calibration verification has been
carried out (see chapter 5.2.5.1).

This menu allows the calibration to be adjusted so as to optimise the linearity of the
system. The operator can divide the full scale of the testing unit in up to a maximum six
user definable steps. The software then automatically foresees the interpolation of these
steps so as to calculate the calibration curve of the unit over its complete range.

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. Access the CALIBRATION screen and select the channel to calibrate (the latter is
only required if also the second channel has been activated into the system);

Fig. 5-20

2. The calibration of the system is performed by loading the system to a number of

known load steps (maximum 6 load steps, including the first step that is always 0)
that are achieved by making reference to an external reference system (e.g. loadcell
plus its match readout unit) and taking note of the bits reading on the display of the
WIZARD 2 at these load steps (see figures highlighted in previous figure). The
applied load steps should remain within the calibrated measurement range of the test
frame, normally from 10% or 20% up to 100% of the full scale.
The recorded readings, that is the values displayed by the WIZARD 2 at known
reference loads, will be used for the calculation of the calibration coefficients.

If the system is sufficiently 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 more accurate 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.

23/08/2018 102 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

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.
Proceed as here after described to operate the compression machine and achieve the
different load steps;
3. Correctly place the reference instrument (e.g. load cell) between the compression
platens of the test frame;
4. When ready, turn ON the pump motor by acting on the relevant switch (note that the
pump motor switch is self-retaining when the mains electricity supply is connected);
in the meantime, set lever A up and lever B back on the flow control valve (rapid
approach phase); and the ram of the test machine will start to rise;

Fig. 5-21
5. 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 set lever A up, turn lever B slowly forward to control the speed of the
piston with the flow control valve;

A
B

Fig. 5-22

Rev.1 EN 103 23/08/2018

 Manuale di Istruzione
Instruction Manual

6. Adjust the load rate by acting on the flow control valve knob;

Fig. 5-23
7. Once the load cell is under load, a moderate speed should be used, making
adjustments with the flow control valve knob as described above. 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;

8. Take note of the bit reading for the given load step;

9. Proceed with the other load steps and take note of the relevant bit readings;

10. Once finished, to interrupt the load, turn OFF the pump motor switch and turn lever
B slowly back and lever A down to discharge the oil pressure;

Fig. 5-24

23/08/2018 104 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

11. After assessing the bit readings at the different load steps (previous step 2), access

the EDIT calibration screen by pressing the key, the system will require
entering a password;

Fig. 5-25

12. Enter the password 00101 by using the keys to select the digits

to change and the keys to set it. Confirm it by pressing the

key. The EDIT CALIBRATION screen for the selected channel will be
displayed.
Left column: load step Right column: bit reading

Row #1

Row #2

Row #3

Fig. 5-26

This screen is composed by a table with two columns and six rows (the second group
of three rows is on a second display page). The figures on the left column are the
load steps that have been previously achieved by reading on the external reference
system while the figures on the right column are the corresponding bit readings
previously noted;

Rev.1 EN 105 23/08/2018

 Manuale di Istruzione
Instruction Manual

13. Enter the first load step (typically 0) on the left column of the first row on the display

(use the keys to select the digits to change and the

keys to set the figure), then press the key to access the figure on
the right column on the display and enter the corresponding bit reading previously
recorded;

14. Press again the key to access the second row, left column, enter the load

step, press to access the right column row and enter the corresponding bit
reading previously noted for this step;

15. Once all rows on the first page are completed, pressing the key brings to
the second page with rows from 4 to 6;

16. Proceed in this way until entering all the load steps and bit readings previously

recorded. At the end press the key to complete the calibration procedure,
the system will ask for a confirmation;

Fig. 5-27

17. Press the key to accept the new calibration or the key to exit
without altering the existing calibration. The system will return to the MAIN
MENU;

18. Repeat the calibration verification (see chapter 5.2.5.1) to make sure the system is
now behaving linearly within the required load range and tolerance.

23/08/2018 106 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

5.2.6 Replacing the oil of the hydraulic circuit

WARNING:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.

Periodically the oil of the hydraulic circuit must be completely replaced.

1. Discharge the old oil via the drainage screw;

Drainage screw
(view from below)

Fig. 5-28

Rev.1 EN 107 23/08/2018

 Manuale di Istruzione
Instruction Manual

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. 5-29

5. Top up if necessary.

23/08/2018 108 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

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:
Before opening/removing the covers, disconnect the mains supply to the device and wait
at least 5 minutes.

WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
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:
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:
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.

Rev.1 EN 109 23/08/2018

 Manuale di Istruzione
Instruction Manual

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. Press and hold the key, turn ON the unit via its MAIN
SWITCH on the rear panel: after a few seconds, the unit will show
following screen;

Fig. 6-1

3. Hold the key for another 2 seconds then release it, the system
will ask for a password;

Fig. 6-2

23/08/2018 110 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

4. Enter the password 00202 by using the keys to select the digits

to change and the keys to set it. Confirm it by pressing the

key. The SYSTEM MENU is now displayed;

Fig. 6-3
5. The following options are provided in this menu:
• CHANNELS SET-UP: allows activating/de-activating the second channel and
setting the FULL SCALE and PRELOAD values for the active channels;
• SERIAL NUMBER: allows setting the SERIAL NUMBER of the unit that is
shown at switch ON;
• MEMORY RESET: allows resetting the unit to its default settings.

Use the keys to select the desired option and the key
to access it.

The following pages describe in detail the above mentioned options.

Rev.1 EN 111 23/08/2018

 Manuale di Istruzione
Instruction Manual

6.1.1 CHANNELS SET-UP option

It allows setting into the WIZARD 2 control unit the working parameters of
the frame connected.

Fig. 6-4
The following functions are available within this menu.

6.1.1.1 ACTIVE CHANNEL option

It allows activating/de-activating the second channel into the unit.

To activate/de-activate the second channel press the key to bring the cursor to

the CHn selection and use the keys to set the desired status:
• CH1 = 1 channel active
• CH2 = two channels active

Fig. 6-5

When 2 channels are active, the SELECT CHANNEL screen will appear
before running a test and performing the calibration.

Fig. 6-6

NOTE:
The ADC CHANNELS SETTINGS parameter are factory set in case the
WIZARD 2 is sold already equipped with relevant load sensor(s).

23/08/2018 112 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

6.1.1.2 FULL SCALE and PRELOAD settings

Use the key to bring the cursor to the desired parameter to change, the

keys to select the digits to change and the keys

to set the value. Then press the key to access the next parameter to change.

Once all the CHANNEL SET-UP OPTIONS has been set, press key to exit

and confirm the changes by pressing the key (or the key again to exit
without changing the present settings); the system will revert to the SYSTEM MENU.

Rev.1 EN 113 23/08/2018

 Manuale di Istruzione
Instruction Manual

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 6.1.3).

The serial number will be shown on the display at switch ON.

Once the serial SERIAL NUMBER option is accessed, the system will show
the following screen:

Fig. 6-7

Use the keys to select the digits to change and the

keys to set the serial number. Once finished, press the key confirm

and exit (or the key to exit without changing the present settings); the system
will revert to the SYSTEM MENU.

23/08/2018 114 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

6.1.3 MEMORY RESET option

The MEMORY RESET option allows erasing the whole system memory,
including calibration coefficients, full scale, language selection, measurement units, etc.

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

Press the key to proceed, the system will ask for a further
confirmation. During the memory reset, the display will show the message
DELETING ALL DATA. At the end, it will revert to the SYSTEM MENU.

If instead this function was accessed by mistake, press the key to

exit without resetting the memory.

After performing the MEMORY RESET all working parameters of the equipment must
be re-entered.

Rev.1 EN 115 23/08/2018

 Manuale di Istruzione
Instruction Manual

Note:

23/08/2018 116 Rev.1 EN

Manuale di Istruzioni
Instruction Manual

Note:

Rev.1 EN 117 23/08/2018