Wartung Und Reparatur Engl Rev-3.1

TESTING Bluhm & Feuerherdt GmbH
Herstellung und Vertrieb

von Baustoffprüfgeräten
Motzener Str. 26b

DE-12277 Berlin
Tel. +49(0)30/710 96 45-0
Fax +49(0)30/710 96 45-
98
www.testing.de
Maintenance and Repair
Multi station Vicat-Needle device

1.036x
1
1.036X Multistation Vicat Device
Meaning of this manual

Please read this manual carefully and completely before you begin to repair / to maintain.
Table of contents page
1. Maintenance and error tracking .............................................................................................. 3

1.1 Error description ..................................................................................................................... 3
1.2 The keys of the handset unit ................................................................................................. 4
1.3 Checking and maintenance .................................................................................................... 5
1.3.1 VicatMPMChek-Software ................................................................................................... 5
1.3.2 Checking, functional test ............................................................................................... 6
1.4 Firmware update .................................................................................................................... 7
1.4.1 Remove rear cover ........................................................................................................ 7
1.4.2 Connect programmer and install firmware ................................................................... 7
1.4.3 Cancel old settings and define new coordinates .......................................................... 7
2. Water circulation ....................................................................................................................... 8
2.1 Cleaning of the filter ............................................................................................................... 8
2.2 Cooling circulation .................................................................................................................. 9
2.3 Cleaning of the heat exchanger ........................................................................................... 10
2.4 Vent cooling system ............................................................................................................. 11
2.5 Basin exchange .................................................................................................................... 12
2.6 Correction of actual values at the temperature control ........................................................ 20
2.7 Connecting temperature sensor ........................................................................................... 21
2.8 Replacing heat exchanger ................................................................................................... 22
2.9 Replace pump or flow sensor............................................................................................... 24
3. Drop rod lift ............................................................................................................................. 25
3.1 Adjusting drop rod ................................................................................................................ 25
3.2 Magnet ................................................................................................................................. 28
4. Drives ....................................................................................................................................... 31
4.1 Bevel gears for Z-Axis .......................................................................................................... 31
4.1.1 Changing the bevel gears or a stepper motor ............................................................. 31
4.2 Bevel gears for Y-Axis .......................................................................................................... 32
4.3 Bevel gears for X-Axis .......................................................................................................... 32
4.4 Spindle and linear guide of the Z-axis .................................................................................. 33
4.5 Spindle and linear guide of the Y-Axis ................................................................................. 33
4.6 Spindle and linear guide of the X-Axis ................................................................................ 33
4.6.1 Cleaning the spindle of the X-Axis .............................................................................. 34
4.6.2 Relieve tension of X-Spindle ....................................................................................... 35
4.7 Encoder ................................................................................................................................ 36
4.7.1 Checking or changing an encoder ............................................................................... 36
4.8 Limit switches ....................................................................................................................... 37
4.8.1 Z-Axis........................................................................................................................... 37
4.8.2 Y-Axis .......................................................................................................................... 38
4.8.3 X-Axis .......................................................................................................................... 38
5. Supervising the device ........................................................................................................... 39
6. Emergency stop ...................................................................................................................... 40
7. Wiring plan .............................................................................................................................. 41
8. Maintenance list ...................................................................................................................... 67
9. List of spare parts ................................................................................................................... 69
10. Aftersales service ................................................................................................................... 70
10.1 Issue of this manual ............................................................................................................. 70
10.2 Copyright .............................................................................................................................. 70
10.3 Spare parts supply ............................................................................................................... 70
2
1. Maintenance and error tracking

Maintenance and repair by qualified staff only!
1.1 Error description
Error Cause Action Page

Too few or Air in cooling circulation Remove filter,
9
no water flow vent system
Filter polluted Clean filter 6
Heat exchanger polluted Clean heat exchanger 8
Difference in displayed temperature wrong Offset Correction of actual value 18
Temperature control displays ap- Connection failure of sensor inside Check connection of temperature
prox. 200°C and is not adjustable the plug, screw not tight, contact sensor at temperature control 19
resistance too high
Drop rod is not grabbed[JN1] Magnet moves with difficulty / jams Re-adjust magnet or guideway of
OR the magnet
Drop rod is not taken 26
OR
Drop rod is taken but is dropped im-
Light sensor doesn´t recognize Only for older versions: the 4th
mediately
drop rod while hole (opposite side of drop rod)
lying on the magnet pin must be sealed[JN2], light opaque
Emergency Stop is activated without Variations in air pressure Adjust sensitivity of air pressure
36
visible reason sensor
Safety strips squeesed over bas- Check safety strips
sin[JN3] edge
Huge differences between measure- Drop rod not fixed Adjust clearance of bevel gear
29
ments or too much clearance Adjust clearance of drop rod
23
at bevel gear of z-axis
Steady correction of moving ways Encoder loose or out of function, Encoder: tighten clamping, check
32
cable loose or out of function cable
Axis are not moving – no error dis- Emergency stop switch defective Replace switch according to wir-
49
played ing plan
Switch of reference or limit is trig- Adjustment of centre of one sample Re-adjust centre of sample by
gered during measurement is not correct. pushing button “D”
Trigger-screws are loose Tighten back-nut
35
(for Z-axis use Loctite)
Cone washer unit is not working af- Default setting is Press button “C” to choose the
ter update “needle washer unit” washer unit
Reference search not successful Gear loose Tighten gear 31
(sound from motor without motion)
Timeout during moving to position Mandrel moves with difficulty Clean mandrel 34
Possibly loss of drop rod caused by Re-adjust magnet oder magnet 26

jammed magnet guideway
3
1.2 The keys of the handset unit

1. during menu-navigation:
Go back to previous view.
2. during setting positions:
select Z-Axis
1. during menu-naviga-
1. Press during start up to
tion: „no“
move to maintenance posi-
2. during setting posi-
tion.
tions: select Y-Axis
2. Pressing this key during
setting positions moves the
selected axes forward.
3. Pressing the key inside
menu for humidity parame-
1. feature: „yes“ ters moves cursor forward.
2. during setting posi-
tions: select X-Axis
1. Pressing this key during

Pressing this key dur- start up enters menu to se-
ing start up enters lect sensor.
menu to reject restora- 2. during setting positions:
tion. save value
3. When measurements
are interrupted, pressing
this key enters menu for
1. Pressing this key setting the penetration time
during start up enters (only for programs with ex-
menu Hardware check tension .OCT or
(Only for maintenance .OCT_EXTW).
personnel).
2. Switching the sign 1. Pressing this key during
of the offset for relative start up enters menu to set
humidity inside the positions.
menu for relative hu- 2. When measurements
midity offset. are interrupted, pressing
this key enters also menu
1. Pressing this key during start up to set positions.
Pressing this key during start enters menu to input parameters for
up enters menu to delete the humidity sensor (ASTM).
EPROM data. 2. Pressing the key inside menu for 1. Pressing this key during start up
Attention the device must humidity parameters moves cursor enters menu to select washer units.
then be re-adjusted! 2. Within all other menus: cancel
back.
3. Pressing this key during setting
positions moves the selected axes
backward. Pressing this key during start up enters
menu to switch ON/OF the pump for cone
(gypsum).
4
1.3 Checking and maintenance

1.3.1 VicatMPMChek-Software
Some functions of the Vicat test device can be tested by VicatMPMCheck-Software.
Please press “A“ on the remote control and switch on the test device.
Than start VicatMPMCheck-Software and connect Vicat device via
„Prüfautomat“– „Verbinden“.
Status of light barrier Humidity sensor

Switch status of limit switches
Pressure sensor
Flow sensor Reference for axis,

puts encoder val-
ues to „0“
Magnet
on/off*
Encoder positions
Needle wash Moving the axis
unit on/off
Cone wash Bridges open limit

unit on/off switches
pump for Safety bars venting

cone wash
unit
Picks up
drop rod
Switches on Temperature control Checking of max. moving ways
for a short time
* Attention
Do not switch on magnet for more than 30 sec.!
Magnet overheats and may be destroyed!
Make sure to reference Z-axis before moving the axes!
Note VicatMPM-Software is still in Beta-Status, connection errors to the
 Vicat device or freezing of the firmware at Vicat device may occur.

In this case restart Vicat device and software. (Password Zip-file:
#710964538#)
5
1.3.2 Checking, functional test
For partial tests of the apparatus, use VicatMPMCheck-Software (page: 5).

To check and correct the needle positions press key „D“ on the handset unit when
switching on the device to open the appropriate menu.
Checking of Default Tools / procedure

Limit switch - function switches VicatMPMChek-Software
Limit switch –switch lever Straight, unbent Optical
Limit switch - screws tight Allen key
Emergency stop-Function switches VicatMPMChek-Software
(switches/bars)
Emergency stop- status of bars and soft und not porous Optical, Mechanical
hoses
Water basin / cooling system leakproofness Optical
Flow 100﹪ Flow gauge
status filter (Sieves, sponges) clean, intact Optical
status hoses (chalk) clean, flexible Optical
pump works Flow gauge
Ball valves Smooth-running, tight Manual, Optical
Temperature control function, actual value Reference thermometer
Bevel gear Status, Smooth-running Optical, Acoustic
Tooth belt Status, Smooth-running Optical, Acoustic
Drive screw Status, Smooth-running Optical, Acoustic
Encoder-Function Reproduceable values VicatMPMChek-Software
max/min
Screws at drives tight Allen key
Drop rod in guideway Smooth-running, free from Manual
play
Weight of drop rod 300g ±1g balance
Status of needle unbent Optical
Fitting of the fixation slices Straight contact, no wob- Manual, Optical
bling
Fitting of the centring slices Centring of the Vicat ring Manual, Optical
Position of the needle to wash unit centric VicatMPMChek-Software
Position needle to test pot centric VicatMPMChek-Software
Test measurement differences < 0,2mm Test body
Wash unit - function Brushes rotate VicatMPMChek-Software
Wash unit – status brushes Surrounding needle Optical
Cable connections Tight closes Manual
fan (power supply, cooling, control unit) function Optical / Acoustic
VicatMPM-Software Compatible to Firmware*
Ini-files Up to date
Firmware Version Actual for this Hardware
*
Firmware Software
until 140811 2.0 2.4
from 150707 2.1 3.0
6
1.4 Firmware update
It may be necessary to update firmware to eliminate errors or to add new features.
1.4.1 Remove rear cover
To install new firmware the rear cover has to be removed.

In case of a 12 station Vicat device just pull out the control box.
unscrew these 4 screws interface for programming
1.4.2 Connect programmer and install firmware
Connect adaptor cable with PICkit3, plug in USB-cable into PICkit3.

Then plug adaptor cable at control box into 8pin „Debug“-socket.
Connect USB-cable of the PICkit3 with PC (Laptop).
Switch ON Vicat device.
Attention! Please push Emergency stop to avoid any unwanted movements of
the device during programming!
Start software „PICkit 3 Programmer“.
Choose via „File“ – „Import Hex“ the correct firmware and install by click on „Write“.
Switch OFF the device and remount the rear cover or put back the control box.
Undo the emergency stop.
1.4.3 Cancel old settings and define new coordinates
Erase old date in EPROM to avoid errors in program run.

Press button „0“ during switching on, confirm erasing data in EPROM by pressing „1“.
Choose now the correct wash unit by pressing „C“ (default is needle wash unit).
Restart the device by switching OFF and ON.
Press “D” to redefine the coordinates of the positions like described in the manual
chapter 5.2.
7
2. Water circulation
2.1 Cleaning the filter
The procedure is the same for all devices with filter at the basin
(6,8 und 12 stations).
1 Loose knurled 2 Remove filter

screws cartridge.
3 Remove and
4 Clean and dry the
clean the spon-
sieve
ges
Put in:
5 1. filter cartridge 6
2. sponge fine Screw tight
3. sponge coarse and vent.
 Fill the basin with water before putting in

the filter cartridge. The sieve has to be dry to
prevent air bubbles underneath it!
Note The sponges have to be wet when putting in to prevent sucking air

into the system.
In case the pump is not providing water please switch off the water
temperature control, remove filter cartridge, open both ball valves
and remove some water. Then close ball valves and switch on wa-
Ⅰ ter temperature control. (repeat procedure if necessary [7])
8
2.2 Cooling circulation
vent basin
filter
Ball valve
Ball valve
Heat exchanger
pump
9
2.3 Cleaning of the heat exchanger
In case that a cleaning of the cooling circulation system with citric acid and warm wa-
ter is not sufficient and the flow is still too few. The heat exchanger must be cleaned.
To do this, remove the hoses from the T-piece near the pump and from the heat ex-
changer. Cover the hose receptacle of the heat exchanger well with fabric!
Then blow with compressed air into the hose coming from the pump to remove the
sludge from the heat exchanger. Then reconnect the hoses. Fill the device and vent
air if necessary.
Remove these hoses

(Press on the ring and pull
off the hose.)
Attention! While blowing compressed air through

the heat exchanger solid particles may
fly out of the opposite side!
Take protective actions!
10
2.4 Vent cooling system
If the water cycle does not work (no flow), the pump must be vented!
Switch off the pump and remove the filter.
Then open both ball valves to drain out few amount of water until no more air bubbles
are visible in the hose (see picture).
Close the ball valves and switch on the pump.
If necessary, repeat the procedure.
If the water cycle is working, insert the filter as described in point (2.1).
Remove the In case, there is air inside

filter first! the pump, you will see air-
bubbles in the hose after
opening the ball valves.
Close both ball valves
when there are no more
air bubbles in the hose.
The flow is controlled with an accuracy of ±3% and is shown on the remote control
with „F: 99%” as well as on the PC software
The flow is an indicator for permeability of the filter and the water circulation system.
MP: 12 Probe 3
MZ: 14708 sec
ET: 37.1 mm F: 99%
NM: 1:23 Probe 4
11
2.5 Basin exchange

1. Drain the water completely out!
2. undo screws on both sides
3. Lift hood just a little bit and

disconnect two connectors
4. undo these six screws
12
5. Remove the hood on the rear.
6. Undo these four screws

without red marking on
both sides
7. Remove both hoods on

the side.
Be careful with cables on
the left side.
Connections of emer-
gency stop must not be
interchanged!
Danger of short circuit!
13
8. Undo these two screws.

and remove the cover.
10. Disconnect all plugs from the PCBs und mark

them if necessary.
(Attention, note locking of the plugs!)
11. Undo these screws and re-

move the block
Note cable routing!
12. remove tooth belt
13. Undo screw and pull off

cogged belt pulley
14. disconnect all plugs

und remove motor
(see next pictures)
14
16. undo these four screws
17. Undo screws und lay bar beside the device.

Limit switches stay connected!
18. unscrew energy chain here
15
19. Unscrew spindle off from slide

here
20. Slide can be taken off

by removing these screws.
Hold the slide carefully

while unscrewing !
21. unscrew all sheets
22. Disconnect temperature sensor from Pin 10 and 12.

(Pay attention to polarity, mark if necessary)
16
23. unscrew these four screws.
24. Unscrew the tempera-

ture sensor and pull out
wires carefully!
25. Unscrew washer unit here and dis-

connect the two wires.
26. pull off hoses here.
17
27. Pull off the thick

hoses
28. remove fixation plates
29. unscrew these pins
18
30. push out the basin by pushing on each side carefully.
31. While mounting in the basin

please just push on the edges
to not damage the basin.
19
2.6 Correction of actual values at the temperature control
Measure temperature with reference thermometer.
push both buttons simultanously until „P0“ appears in display

(4 Sekunden)
Push button several times until „P6“ appears in display
Keep pushing button and correct by or actual value
push both buttons simultanously until you return to actual value dis-
play
(4 Sekunden)
(After 60 sec without input you will return automaticaly to actual value display).
20
2.7 Connecting temperature sensor
Undo these six screws
Check these two connec-

tions and tight them if nec-
essary!
Controller 24V
21
2.8 Replacing heat exchanger
If you need to replace the heat exchanger (malfunction of Peltier elements or there is
a leakage) please do following:
1. Put the device in maintenance position (because of weight distribution) and

disconnect power supply.
2. Open front plate like described in chapter 3.7, disconnect D-Sub and both power-
cables. Then unscrew temperature sensor and put front plate aside.
3. Pull off both hoses from the heat exchanger at front and backside.
Pull out temperature sensor and unscrew the EMC spring.
Disconnect 24V plug.
24V connection
Temperature
sensor
Hose connection
at backside
Hose connection
EMC spring
at front
22
4. Pull the device carefully over the edge of the table, until the six screws of the heat
exchanger are accessible.
six screws of the

heat exchanger
Attention!
A second person should hold the device to ensure safety.
5. Undo screws and pull out heat exchanger

Note
 Alternative to maintenance position you can drive the X-Axis

to X-max-position by VicatMPMCheck-Software
6. Please, do the mounting of a new heat exchanger in reverse order.
23
2.9 Replace pump or flow sensor
1. Open front plate like described in chapter 3.7 and disconnect D-Sub.
2. Unscrew electric connection of the pump or flow sensor off from the control box.
3. Pull out control box carefully all the way to the stop.
Connection of flow sensor
Connection of pump
4. Unscrew pump or flow sensor and pull off hoses

Attention!
Do not tear off cables of the control box while pulling out the box!
Screws of the pump Flow sensor
24
3. Drop rod lift

3.1 Adjusting drop rod
1. undo these
four screws
2. Lift the hood a little bit (if

necessary pull the left side out-
wards to not touch the lift com-
ponents).
3. pull off two plugs
MV* DS**
* Magnetic valve
** Pressure switch
25
4. Remove the hood
By untighten of the nuts and turning of

the threaded pin you can adjust the
drop rod along the Y-axis.
By untighten of the nuts you can ad-

just the drop rod along the X-axis.
26
The drop rod has to be in the

middle and parallel to the notch
Drop rod has to fit as centric as

possible in the feed-through
The drop rod has to be

exactly right angular (90°)
Finally check if the drop rod is smooth going with almost no backlash.
Mounting of the hood in reverse order.

Put on the hood so far to connect plugs then put the hood completely back in place
and screw tight.
27
3.2 Magnet
Turn this gear clockwise until

the screws are accessible.
Undo both countersunk screws

by an Allen key 2,5mm.
Grab the magnet core und

push the guiding block to the
right to remove it*.
Then take out the

magnet core.
Mount the new parts in re-

verse order.
Consider mounting position!
* Above the guiding block is maybe a small metal plate, which is also needed for the
new guiding block (Magnet blocks or moves with difficulty)
Check ease of motion
Tight magnet again.
Check cleanliness.
28
If the magnet blocks or moves with difficulty, you have to adjust like the following:
Turn this gear clockwise

until the screws are acces-
sible.
Loose both countersunk
screws by a 2,0mm Allen
key.
Adjust the magnet to move
without difficulties.
* Alternative you can reach the screws of the magnet also via these two holes
but you have to dismount the motor before.
29
Check ease of motion

Tight magnet again.
Check cleanliness.
30
4. Drives
4.1 Bevel gears for Z-Axis
Bevel gears for Z-Axis have to be backlash-free and without offset to each other.
Right Wrong
Without offset With offset
The screws on the bevel gears must be tight.
Check these screws!
Do not screw these

pin-screws *but glue
them in.
* tightening these screws will cause imbalance
4.1.1 Changing the bevel gears or a stepper motor

If a change of the bevel gears or a stepper motor is necessary, please undo the
clamp screws und unscrew the stepper motor. Please do so for Y-Axis and Z-Axis.
To change bevel gears of the X-Axis, the stepper motor does not need to be un-
screwed.
Each stepper motor is attached with four screws and spring washers
You will find the electrical connection of stepper motor and encoder nearby the step-
per motor.
31
4.2 Bevel gears for Y-Axis
Bevel gears for Y-Axis have to be backlash-free and without offset to each other.
Right Wrong
Without offset With offset
Check these screws! Do not screw these pin-

screws *but glue them in.
* tightening these screws will cause imbalance
4.3 Bevel gears for X-Axis
The X-Axis is tooth belt driven. That means that the cogged belt pulleys have to align
and the tooth belt need to be stretched properly. Allowed deflection for one material
thickness of the belt at maximum.
Axial alignment
of tooth belt
Do not screw these Check these screws!

pin-screws* but glue
them in.
32
4.4 Spindle and linear guide of the Z-axis
All spindles inside the device are ball-type linear drive.

Ball bushings are used as guideway for the Z-axis.
Check these screws.
4.5 Spindle and linear guide of the Y-Axis

These screws are only
slightly tightened and
glued.
Check these screws of the

guideway
4.6 Spindle and linear guide of the X-Axis
These 4 screws are only

slightly tightened and
glued.
Check these screws of the

two guideways
33
4.6.1 Cleaning the spindle of the X-Axis
After prolonged operation of the device in a dusty environment, dust deposits on the
spindle of the X-drive and may block the X-drive.
Then you need to clean the spindle.
Wipe the spindle with a soft, lint-free cloth and spray with a light oil. Then use the
VicatMPMChek software to move between Min-X and Max-X position. Also clean
and oil the spindle on opposite side. Repeat these procedures several times to clean
the balls in the ball nut of the spindle.
Spindle
Spindle nut
34
4.6.2 Relieve tension of X-Spindle
If cleaning does not help, you can relieve tension of the X-Spindle to relieve some of
the ball bearings.
To do this unscrew the rear cover. Then the right cover, bear in mind that you need to
loose only the unmarked screws!
Carefully remove the right cover.
Just loosen these screws.
Next, loosen the 4 screws of the bearing plate.

If you can turn easier the spindle now, pressure on the ball bearing was too high and
led X-Spindle to blocking.
Loosen these 4 screws.
Now you can put plates or washers with a thickness of 0.1-0.5mm between the bear-
ing plate and base plate and screw the bearing plate again.
Always check the smooth running of the X-spindle.
The spindle must not slide back and forth!
Then screw on the covers again.
35
4.7 Encoder
All three axes are equipped with encoders for positioning.
4.7.1 Checking or changing an encoder
Encoder locked.
To check if the encoder is screwed on tightly, please do:

- Open interlock, insert Allan key into the opening
- Turn motor by hand until Allan-key locks in
- Now you can check the screw of the encoder
Encoder opened
Opening for Allan key
To change encoder put in a small screwdriver here and lever up to remove encoder.
Unloose screw of encoder.
36
4.8 Limit switches
All three axes are equipped with a reference switch and a limit switch.
The screws of the limit switches have to be tightened firmly so the limit switch cannot
move. Please also check the status of the contact lug.
Contact lug
Screws
Please check all six limit switches.
4.8.1 Z-Axis
Both limit switches for Z-Axis are of identical construction and are connected by a ca-
ble with a 3-pin socket housing (Molex KK).
Setting screw for

Reference
Ref. Z
Setting screw for

Limit
Limit Z
Attention! Turn off the device while adjusting the limit switches of Z-axis!
The needed Allen-key has to be feed through behind transfer
PCB and may cause an electrical short circuit that will de-
stroy the main PCB as well!
The reference switch has to be adjusted in that way that the lifting plate goes up as
far as possible without bumping.
The same applies to limit switch for lifting plate going down (limit).
To check the adjustments use the VicatMPMCheck-Software. While moving between
Min and Max position the limit switches must remain inactive.
If the limit switches are adjusted correctly, fix them with marking ink.
37
4.8.2 Y-Axis
Both limit switches of the Y-Axis are different.

They do not have a cable but a 3–pin-socket board (Molex KK).
At reference switch on one side, at limit switch on the other side.
Limit Y Ref. Y
Ref. Y Limit Y
Screws with back nut can adjust both limit switches.

* Limit switch Y can be relocated additionally.
Adjustment of the limit switches like described in chapter 4.8.1.
4.8.3 X-Axis
Limit switches of the X-Axis are the same as Y-axis.
Ref. X
Limit X
Screws with back nut can adjust both limit switches.
Adjustment of the limit switches like described in chapter 4.8.1.
38
5. Supervising the device

The functions of the Vicat device are supervised permanently by software.
Here is an excerpt of the software supervision:
Switch ON
Checking interface „Uart1“

(TMCM-connection) message: „Time out Uart1“
Ⅰ
Checking drop rod
(Query light barrier interrupted) message: drop rod missing **
Search reference Z-Axis*** Ⅱ Ⅲ

(Moving to Ref.-Z) Stops at every open limit and reference Timeout check
switch and emergency stop (bars and
switches)*
Search reference Y- Axis*** Ⅱ Redo search

(Moving to Ref.-Y) Ⅲ reference
Search reference X- Axis*** Ⅱ

(Moving to Ref.-X) Ⅲ
Checking needle Ⅰ Moving to maintenance position

(Moving to washing unit and dropping shortly) Ⅱ Prompt: needle broken
Ⅲ
Connection to PC Ⅰ
Moving to washing unit Ⅱ
Synchronizing of time Ⅲ
Receiving of data, if avaiable
Perform testing Ⅰ
(Checking test results, for values greater than Ⅱ
40mm needle will be checked) Ⅲ
* Outside a reference search opening of a limit or end switch will stop the device. A new reference
search will be done.
** Can also be caused by jammed magnet, drop rod will not be lifted.
*** If one of these points is not finished successfully; a loose gear may be the cause.
39
6. Emergency stop
The device is equipped with safety strips that will stop all movements of the device
when they are touched.
The hood with safety strips is the same for all Vicat devices (6, 8 and 12 stations)!
In the display of the remote control appears a description of the cause of stopping:
Emergeny Stop
During moving
to position
This emergency stop can only be cancelled by PC-Software. The device will do a ref-
erence search and continue with measuring.
If you need to put in or take out samples during measurement, the measure proce-
dure should be interrupted (see “Software manual“, chapter 4.3).
- +
Safety strips
Adjustment of the sensitivity of the strips (sensor)
Note
Safety strips work by pressure changes. To avoid an emergency
 stop caused by changing air pressure, the system is vented during

downtime every 5min.
If the emergency stop is activated anyhow, you can adjust the sen-
Ⅰ sitivity of the sensor.
40
7. Setting coordinates of the washing unit (needle and cone*)

The device has to be re-calibrated when the needle or glass plates have been
changed. Setting coordinates of the washing unit is also indicated if the needle does
not hit the opening of the washing unit correctly.
Press „D“ during
reference search Confirm by pressing „1“
Washer at Position 1
Reference search for Set coordinates?
axis XYZ in progress yes: 1 back: 3
no: 2 cancel: C
The drop rod moves to the washing unit and will be lowered.
Z
Set Pos1 coordinates
X: 1 B< F> E C
Y: 2 B< F> E C
Z: 3 B< F> E C
Y X
Button “1“ chooses the X-axis, button “F“ moves drop rod to the right , button „B“ to
the left.
Save the correct position of the needle by pressing „E“.
Button “2“ chooses the Y-axis, button “F“ moves drop rod to the right , button „B“ to
the left.
Button “3“ chooses the Z-axis, button “F“ moves drop rod to the right , button „B“ to
the left.
Leave the menu „coordinates of the washing unit” by pressing “C“.
41
B X-Axis F F Y-Axis B
needle and brushes have
B
The needle has to be to be in one line
centered over opening
Die Aufnahme
Z-Axis
der Nadel sollte
kurz über den
F
Bürsten stehen.
Each press of the buttons moves the drop rod a little bit. If necessary press buttons
several times to bring the drop rod into the right position.
Hint:
 Each axis has to be saved separately.
Now the centres of the samples:
Press „2“ to confirm Press „1“ to confirm
set washing unit to

set XY coordinates
Pos1 coordinates?
of sample 1?
Yes: 1 Back: 3
Yes: 1 Back: 3
No: 2 Exit: C
No: 2 Exit: C
Only X and Y axis can be set here, like described above.
42
B X-Axis F F Y-Axis B
The needle has to be above the highest point of the opening to be centered.
1.) X-axis 2.) Y-axis
After reaching the correct position, press „E“ to save and press „C“ to exit menu.
Press „2“ to switch to next sample position. Repeat procedure until the centres of all
samples are set.
Than menu „setting zero level“ occurs:
For defining the zero levels, put in the glass plates

confirm by pressing „1“ without Vicat rings into sample positions.
Nullhoehe der Proben zero level

bestimmen?
Ja: 1 Zurueck: 3
Nein: 2 Beenden: C
Start the automatic process by pressing „1“.

three points will be captured for each sample posi-
tion. Three measured points will be captured for
each sample station and there out the accurate po-
sition of the glass plate is calculated.
The progress of the measurement is shown on the display.
43
Zero level is defined as the Z-coordinate when the needle touches the glass plate.
The slope of the plane is calculated for each sample in direction X and Y.
Xo – zero level coordinate X-Axis

Yo - zero level coordinate Y-Axis
Zo - zero level coordinate Z-Axis
The inclination of each glass plate with respect to the zero point coordinates of the
machine is corrected during the measurement according to the formula below:
Z = Zo + a(X-Xo) + b(Y-Yo)
X = (X-Xo)
Y = (Y-Yo)
Z = (Z-Zo)
a= Z/ X
b= Z/ Y
When the points of all samples are captured, the menu for starting the process shows
up again.
To exit the measurement menu press „C“.
* The cone is calibrated the same as the needle. The cone wash unit has also a cone
dryer that also can be calibrated. To not block the wash unit the cone has to dive per-
fectly centred into the wash unit. Measure the sample centres and heights just like
the needle.
cone dryer
The cone has to be centred

accurately!
44
8. Wiring plan
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
8. Maintenance list
Maintenance for PC-controlled Vicat device
Check / Adjust Note O.K.
Limit switches function / status
Ref. X function
contact lug
firmly fixed
Limit X function
contact lug
firmly fixed
Ref. Y function
contact lug
firmly fixed
Limit Y function
contact lug
firmly fixed
Ref. Z function
contact lug
firmly fixed
Limit Z function
contact lug
firmly fixed
Emergency stop (pressure sensor / switch) IMPORTANT!
function / pinch protection
status of hoses (porous, elastic)
status of rubber edge (porous, elastic)
Temperature control
system and basin not leaking
streaming 100% with clean filter
status filter (sieve, sponges)
hoses (furring, in general)
pump function
manual blocking valve (smooth-running, leakproofness)
Settings temperature controller (by company Störk)
temperature Control (Function)
comparing with reference thermometer (Offset P6= )
temp. upper Set=19,7 Set actual=
temp. lower P1=20,0 P1 actual =
hysterese P2=0,1 P2 actual =
hysterese P3=0,1 P3 actual =
Check mechanic system
status gear wheels smooth-running
wear down
Tooth belt smooth-running
wear down
belt tension
Guideways smooth-running, free from play
Ball bearing smooth-running, free from play
67
Check screws: firmly tightened?

spindle X-Axis
gear wheels X-Axis
encoder X-Axis
spindlel Y-Axis
gear wheels Y-Axis
encoder Y-Axis
spindle Z-Axis
gear wheels Z-Axis
encoder Z-Axis
guideway X-Axis
guideway Y-Axis
guideway Z-Axis
other screws
Check spindles X-Axis (smooth-running, clean, slightly oiled)
Y-Axis (smooth-running, clean, slightly oiled)
Z-Axis (smooth-running, clean, slightly oiled)
Check drop rod
fixation (free from play)
smooth-running in the guideway (free fall)
rectangular to ground plate of Z-Axis
wheight: EN=300g±1; ASTM=300g±0,5; Gipsum=100g±1
status needle (straight, length=50mm-2) Ø EN=1.13 / ASTM=1.0
magnet (smooth-running / function)
Testing stations Fixation of fixing rings
Fixation of fixing rings with Vicat ring
Same level of the glas plates
Check measurement system
calibrate device (position cleaning unit / samples middle and height)
measurement with test specimen (40,0 / 35,7 / 20 / 0,2 / 0,0)
Cleaning unit function
brushes (attrition)
Plug connections Screwed tightly
Cable undamaged
Fan Cooling unit
Power supply
Control
PC Operating system
VicatMPM-Version
System-time
changed configuration files (*.ini)
Devices.ini / Languages.ini / Report.ini / Standards.ini / System.ini
Firmware Version
Replace time interval
brushes
cable
Gear wheels
pump
Limit switch
Cleaning with citron acid
Software Version (Update)
Date: …………. Type: ………………. Serial No.: …….... Device checked: ………………..
68
9. List of spare parts

ArtikelNr. Beschreibung Seite
1.0366-03.15N Flow meter complete 23
1.0366-03.02.01 Cooling element 22
1.0366-03.02 Heat exchanger 22
W-813-3350 Fan 418NXH 22
1.0366-02.03.13 Filter sponge coarse (PPI 30) 7
1.0366-02.03.14 Filter sponge fine (PU-Weichschaumstoff) 7
W-G460646 Rubber shoe
1.0366-01.25 Power switch (green) 24V
2.0401-19 2-pin rocker switch (red)
W-900210.003 Temperature controller ST710-KEBV.03
1.0366-02.02 Fixation disc 16
OR-90x3 O-Ring Ø90x3
1.0306.03G Glas plate
1.0302.02 Vicat-Ring Ø70/80 mm
1.0366-08 Cleaning unit
1.0366.08 Spare brushes for needle
1.0366-12 Cleaning unit for gypsum
1.0366-12.B Spare brushes for cone
1.0366-03.19K Temperature sensor
1.0366-02.03 Filter cartridge
W-464 4X16 Knurled screw DIN464 M4x16 7
Pn-004 restrictor valve 7
1.0366-02.07 Inlet bushing
W-609-6417 Emergency stop switch
1.0366.11 Power chain set for Z-, X- and Y-Axis
1.0366-03.20 Fan control
Pn-025 Polyurethan-Schlauch ø8x5
1.0366-03.21 Laing pump complete 23
1.0366-09.08R Reference switch. X/Y 37
1.0366-09-08L limit switch X/Y 37
W-472-8285 Micro switch (Reference Z-Axis) 36
Safety strip set (strips, tubes, caps)
1.0366-10 Handset unit
1.0366-07 Drop rod (300g)
1.0366.12 Drop rod (1kg) [ including weight and stopper]
1.0366.G-07 Drop rod (100g)
1.0366.10 Additional weight (700g) [including stopper]
69
10. Aftersales service

This manual was written with high diligence. All information is subject to change.
10.1 Issue of this manual

2.3st issue
03.2018
10.2 Copyright
Copyright by
This manual is for the operator and its personnel only.

It is not allowed to
 copy
 broadcast or
 share otherwise this manual or parts of it.
Misuse will be legally prosecuted.
10.3 Spare parts supply
Please adress your questions or inquiries for spare parts to:

Motzener Str. 26b
DE 12277 Berlin
Telefon:++49 / 30 / 710 96 45-0

Telefax: ++49 / 30 / 710 96 45-98
www.testing.de
70

Wartung Und Reparatur Engl Rev-3.1

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TESTING Bluhm & Feuerherdt GmbH

Herstellung und Vertrieb

Motzener Str. 26b

Maintenance and Repair

Multi station Vicat-Needle device

Meaning of this manual

Table of contents page

1. Maintenance and error tracking .............................................................................................. 3

1. Maintenance and error tracking

1.1 Error description

Error Cause Action Page

Possibly loss of drop rod caused by Re-adjust magnet oder magnet 26

1.2 The keys of the handset unit

1. Pressing this key during

1.3 Checking and maintenance

Status of light barrier Humidity sensor

Flow sensor Reference for axis,

Cone wash Bridges open limit

pump for Safety bars venting

Make sure to reference Z-axis before moving the axes!

Note VicatMPM-Software is still in Beta-Status, connection errors to the

 Vicat device or freezing of the firmware at Vicat device may occur.

1.3.2 Checking, functional test

For partial tests of the apparatus, use VicatMPMCheck-Software (page: 5).

Checking of Default Tools / procedure

1.4 Firmware update

It may be necessary to update firmware to eliminate errors or to add new features.

1.4.1 Remove rear cover

To install new firmware the rear cover has to be removed.

unscrew these 4 screws interface for programming

1.4.2 Connect programmer and install firmware

Connect adaptor cable with PICkit3, plug in USB-cable into PICkit3.

1.4.3 Cancel old settings and define new coordinates

Erase old date in EPROM to avoid errors in program run.

1 Loose knurled 2 Remove filter

 Fill the basin with water before putting in

2.2 Cooling circulation

2.3 Cleaning of the heat exchanger

Remove these hoses

Attention! While blowing compressed air through

2.4 Vent cooling system

Remove the In case, there is air inside

2.5 Basin exchange

2. undo screws on both sides

3. Lift hood just a little bit and

4. undo these six screws

5. Remove the hood on the rear.

6. Undo these four screws

7. Remove both hoods on

8. Undo these two screws.

9. Undo these four screws

10. Disconnect all plugs from the PCBs und mark

11. Undo these screws and re-

12. remove tooth belt

13. Undo screw and pull off

14. disconnect all plugs

15. Undo these four screws

16. undo these four screws

17. Undo screws und lay bar beside the device.

18. unscrew energy chain here

19. Unscrew spindle off from slide

20. Slide can be taken off

Hold the slide carefully