77-Wheel Tracker - Rev 3 - EN - 28 - 06 - 2013

PAVELAB
Wet & Dry

Wheel Tracker Machines
MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni Wet & Dry Double Wheel Tracker
Instruction Manual Wet & Dry Double Wheel Tracker
Index
1. INTRODUCTION 1
1.1 Icons appearing in the manual ............................................................................................. 4
1.2 Manual revision history ....................................................................................................... 5
1.3 Symbols used ....................................................................................................................... 6
1.4 Intended use and improper use ............................................................................................ 7
1.5 Safety information ............................................................................................................... 8
1.6 Environmental risks and disposal ...................................................................................... 14
1.7 CE declaration ................................................................................................................... 15
2. DESCRIPTION 16
2.1 Connections ....................................................................................................................... 23
2.2 Identification plate ............................................................................................................. 24
2.3 Commands and controls .................................................................................................... 25
2.4 Technical specifications..................................................................................................... 26
3. INSTALLATION 27
3.1 Shipment ............................................................................................................................ 28
3.2 Unpacking and inspection.................................................................................................. 29
3.2.1 How to remove the equipment from the shipping crate ................................................. 30
3.3 Positioning of the unit and space requirements ................................................................. 31
3.4 Mounting the computer tray .............................................................................................. 34
3.5 Electrical requirements ...................................................................................................... 35
3.6 External connections.......................................................................................................... 36
3.6.1 Electrical connection ...................................................................................................... 36
3.6.2 Water connections (for models PV33B0X, PV33E0X, PV33A0X, PV31A0X) ............ 37
3.7 Removing the arm shipping support .................................................................................. 38
3.8 Installing the displacement transducers ............................................................................. 39
3.8.1 Installing displacement transducer potentiometric type ................................................. 39
3.8.2 Installing displacement transducer LDT type ................................................................ 40
3.9 Filling the test chamber with water.................................................................................... 41
Rev.3 EN i 28/06/2013
Manuale di Istruzione Wet & Dry Double Wheel Tracker
4. USE OF THE EQUIPMENT 45

4.1 Operator’s interface description ........................................................................................ 46
4.1.1 Pull down menu description ........................................................................................... 47
4.1.2 Top bar description......................................................................................................... 48
4.1.3 Monitor bar description .................................................................................................. 49
4.1.4 Side command bar description ....................................................................................... 50
4.1.5 NEW TEST screen ......................................................................................................... 51
4.1.6 PREHEATING FUNCTION screen............................................................................... 55
4.1.7 LIST OF TESTS menu ................................................................................................... 57
4.1.7.1 LIST OF TESTS screen ................................................................................................. 59
4.1.7.2 SINGLE TEST REPORT REVIEW screen ................................................................... 61
4.1.7.2.1 Data processing as per EN 12697-22 Procedure A ........................................................ 63
4.1.7.2.2 Data processing as per EN 12697-22 Procedure B ......................................................... 64
4.1.7.2.3 Data processing as per AASHTO T324 ......................................................................... 65
4.1.7.2.4 No processing ................................................................................................................. 66
4.1.8 LIST OF MIXTURES screen ......................................................................................... 67
4.1.9 LIST OF PROCEDURES screen ................................................................................... 68
4.1.10 LIST OF CUSTOMERS screen ..................................................................................... 69
4.1.11 SETTINGS screen .......................................................................................................... 70
4.1.11.1 GENERAL SETTINGS screen ...................................................................................... 71
4.1.11.2 CALIBRATION screen .................................................................................................. 74
4.1.11.3 CUSTOMIZATION LANGUAGES screen ................................................................... 75
4.1.11.4 MANUAL COMMANDS screen ................................................................................... 76
4.1.11.5 EVENTS LOG screen .................................................................................................... 77
4.2 Replacing the wheels ........................................................................................................ 78
4.3 Loading the sample ........................................................................................................... 84
4.4 Carry out tests in water ..................................................................................................... 91
4.5 Carry out tests in air .......................................................................................................... 96
4.6 Stopping the machine via the emergency button ............................................................ 101
4.7 Switching OFF the machine............................................................................................ 102
5. MAINTENANCE 103
5.1 Operator’s preventive maintenance ................................................................................ 104
5.2 Authorised service engineer maintenance actions .......................................................... 105
5.2.1 Lubrication and checking of the tensioning of the wheel arm crank chain .................. 106
5.2.2 Greasing of the ball bearings of the wheel arm crank shaft.......................................... 107
5.2.3 CALIBRATION screen ................................................................................................ 108
28.06.2013 ii Rev.3 EN
6. DIAGNOSTICS & TROUBLESHOOTING 110

6.1 MANUAL COMMANDS screen .................................................................................... 111
6.2 Troubleshooting ............................................................................................................... 113
6.3 Carriage motor driver setting parameters ........................................................................ 116
7. SPARE PART 117
8. SCHEMATICS AND DRAWINGS 127
Rev.3 EN iii 28/06/2013

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.
This present in English is the original version of the manual. Printed in Italy
28.06.2013 iv Rev.3 EN
1. INTRODUCTION
NOTE:
The present manual is updated for the product it is sold with in order to grant an adequate
reference in operating and maintaining the equipment.
The manual may not reflect changes to the product not impacting service operations.
The wheel tracking test is used for determining the susceptibility of Hot Mix Asphalt
(HMA) to deform under load by measuring the rut depth formed by repeated passes of a
loaded wheel at a fixed temperature.
The two methods EN 12697-22 and Hamburg Type AASHTO T324, are available:
• Test environment: Dry and Wet for EN and Wet for AASHTO Standard
• Rubber Wheel dia. 203x 50 mm width EN and Steel wheel dia. 203x47 mm width
AASHTO.
The following table shows the different versions of the machine according to the type of
test and to the Standard they comply with:
EN 12697-22 &
EN 12697-22 AASHTO T324
AASHTO T324
Test in 77-PV31A05, PV31A06

water DWT PAVETRACK,
Hamburg double wheel
tracker, conforming to
AASHTO T324, water
specimen conditioning
system. Complete with
stainless steel wheels.
Test in 77-PV32E05, PV32E06
air DWT PAVETRACK,
Dry double wheel
tracker, conforming to
EN 12697-22 Small Size
Device, air specimen
conditioning. Complete
with rubber tire wheels.
Test in 77-PV33E05, PV33E06 77-PV33A05, PV33A06 77-PV33B05, PV33B06
air and DWT PAVETRACK, DWT PAVETRACK DWT PAVETRACK Wet
in Wet and dry double Hamburg double wheel and Dry double wheel
water wheel tracker, tracker, conforming to tracker conforming to
conforming to EN AASHTO T324, air and Hamburg type AASHTO
12697-22 Small Size water specimen conditioning T324 and EN 12697-22
Device, air and water system. Complete with Small Size Device.
specimen conditioning. stainless steel wheels. Complete with both
Complete with rubber stainless steel wheels and
tire wheels. rubber tire wheels
Rev.3 EN 1 28/06/2013
All machine versions can be upgraded with the automatic system which lifts one of the
wheel from the specimen that has reached the rut target continuing the test on the other
specimen.
Main features of the machines are:
• Meets or exceed AASHTO or EN standards depending on the model

• Available versions for tests in water, tests in air and tests both in air and water
• Massive use of stainless steel in the machine construction, not limited to parts in
contact with water
• PC interface
• Double wheel with single wheel testing option
• High accuracy temperature control (±0.5°C) for both water and air environment
• Motorized lifting system of the wheels assembly for easy removal of slabs
• Independent lifting option system of the loading wheel at the rut depth target
continuing the test, without interruption, with the other wheel
• Slab mould capacity 400x300 mm or 360 x 300 mm (for 320 x 260 mm slab). The
greatest slab dimension is oriented as the wheel travel.
• PC and software included.
The following models are available:
PAVELAB, UNIVERSAL AASHTO/EN DOUBLE WHEEL TRACKER
Air and Water conditioned specimens

77- PV33B05 PAVELAB DWT Wet and Dry double wheel tracker. Conforming to
Hamburg type AASHTO T324 and EN 12697-22 Small Size Device, air and water
conditioning. Complete with both stainless steel and rubber wheels, PC, two 400x300 mm
moulds and two 360 x 300 mm moulds (suitable for 320x260 mm slabs). 380 V, 50 Hz, 3
ph.
77- PV33B06 PAVELAB DWT Wet and Dry double wheel tracker. Conforming to
Hamburg type AASHTO T324 and EN 12697-22 Small Size Device, air and water
conditioning. Complete with both stainless steel and rubber wheels, PC, two 400x300 mm
moulds and two 360 x 300 mm moulds (suitable for 320x260 mm slabs). 220 V, 60 Hz, 3
ph.
PAVELAB, DOUBLE WHEEL TRACKER, EN VERSION
Air conditioned specimens

77-PV32E05 PAVELAB DWT Wet and Dry double wheel tracker. Conforming to EN
12697-22 Small Size Device. Complete with PC, two 400x300 mm moulds. 380 V, 50
Hz, 3 ph.
Hz, 3 ph.
Air and Water conditioned specimens

Hz, 3 ph.
Hz, 3 ph.
28.06.2013 2 Rev.3 EN
PAVELAB, HAMBURG TYPE DOUBLE WHEEL TRACKER
Standard Water conditioning specimens version

77-PV31A05 PAVELAB DWT Hamburg Type double wheel tracker. Conforming to
AASHTO T324, water specimen conditioning. Complete with PC and two 360 x 300 mm
moulds (suitable for 320x260 mm slabs). 380 V, 50 Hz, 3 ph.
AASHTO T324, water specimen conditioning. Complete with PC and two 360 x 300
mm moulds (suitable for 320x260 mm slabs). 220 V, 60 Hz, 3 ph.
Air and Water conditioned specimens version

AASHTO T324, air and water specimen conditioning. Complete with PC and two 360 x
300 mm moulds (suitable for 320x260 mm slabs). 380 V, 50 Hz, 3 ph.
AASHTO T324, air and water specimen conditioning. Complete with PC and two 360 x
300 mm moulds (suitable for 320x260 mm slabs). 380 V, 50 Hz, 3 ph.
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 machines with serial number higher than 13003553. On
machines with earlier serial numbers refer to the equipment manual in rev.1.
Please read this manual thoroughly before you start using the equipment.
NOTE:
The present manual is applicable for units manufactured from July 2013 onward
Rev.3 EN 3 28/06/2013
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.
28.06.2013 4 Rev.3 EN
1.2 Manual revision history
Revision/Date Change description

Rev. 1 Manual first release
13th May 2013
Rev. 2 • Updated residual risks table (chapter 1.5);
31st May 2013 • Modified command panel (for units with serial number
higher than 13003553);
• Updated procedure to replace the wheels (chapter 4.2)
• Added spare part list (chapter 7).
Rev. 3 • Modified commands panel for machine versions
28th June 2013 equipped with AIR test capability /(see chapters 2.3).
Rev.3 EN 5 28/06/2013
1.3 Symbols used

In this manual and on the equipment itself, apart from the symbols indicated on the
control panel, also the following icons are 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
Hot surface
Conformity to the CE Directive
28.06.2013 6 Rev.3 EN
1.4 Intended use and improper use

The PAVELAB – Double Wheel Tracker machine can only be used to perform tests on
asphalt slabs and cores according to the Standard EN12697-22 and AASHTO T324.
The unit is designed to be operated by one operator that has to load-unload the sample
in/from the mould and then the mould in/out the machine; the sample is contained into a
mould and has to be pre-heated (e.g. in external oven or directly into the unit) at a
temperature up to 70°C depending on the test method.
During normal operation the working area of the equipment is its front part where the
operator’s controls and computer 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.
Rev.3 EN 7 28/06/2013
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.
28.06.2013 8 Rev.3 EN
The machine is equipped with the following devices to limit the residual risks in using it:
• EMERGENCY BUTTONS (2 buttons, one per equipment side) that allows stopping
the equipment in case of anomalies that may endanger the operator safety; the
following functions are disabled after pressing the EMERGENCY BUTTONS:
movement of the wheel arms, heating resistors (both air and water depending on the
model), water pump, air circulation motor;
• Magnetic safety switches on the sliding doors to stop the movement of the wheel
arms once opened;
• Removable panels locked with screws.
Doors magnetic
safety switches
EMERGENCY BUTTON
(on both sides of the
cabinet)
Fig. 1-1
Rev.3 EN 9 28/06/2013
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 Upper part of the machine test chamber, when wheel arm is moving, due to
the risk of hand crushing
The sample mould, due to the temperature it has to be pre-heated to before
loading it into the wheel tracker machine, in case they are heated with an
external device and protective means are not in use (e.g. gloves)
All metal surfaces inside the thermo-regulated chamber of the wheel tracker
machine, in case protective means are not in use (e.g. gloves)
The area where the sample mould is installed, due to the weight of the
mould itself loaded with the sample.
Technical personnel Above listed areas
In case the doors of the thermo-regulated chamber are opened during the
execution of the test, the microswitches stop the movement of the sample
carriage. Although the breaking time of the carriage is quite short, it is
recommended to wait until its movement is completely stopped before fully
opening the doors
Areas around compartments that contain moving mechanical parts
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
28.06.2013 10 Rev.3 EN
Here follows a list of all WARNINGs present in the manual; please see relevant chapters
for full details on each related safety issue.
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 time. 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:
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:
Considering the weight of the equipment and the footprint (see chapter 2.4), check the
maximum allowed floor load before installation.
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:
The weights are heavy (30 Kg approx.). Use proper lifting means to lift them by means of
the eyebolts. Wear proper personal protection devices to avoid injuries while mounting
the weights.
Rev.3 EN 11 28/06/2013
WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/keys. These tools and keys are for use by maintenance personnel only. Never leave
the tools and keys 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:
It is recommended that the operator perform the specified maintenance actions before
each session of operations.
If the operator detects irregularities or damage, he should immediately inform the
Maintenance department.
WARNING:
The sample is loaded into the equipment pre-heated in an external oven at a temperature
of 70°C. Use proper protective means (e.g. gloves) to prevent burns while handling the
sample.
WARNING:
The thermoregulated chamber reaches temperatures up to 70°C. Use proper protective
means (e.g. gloves) to prevent burns while handling the sample and operating with the
front doors opened.
WARNING:
The sample mould is heavy. Pay great attention while handling it and use proper
protection means.
WARNING:
Accessing to the ADVANCED CONFIGURATION parameters is allowed to
CONTROLS authorized technical personnel only. Setting the wrong configuration not
matching the hardware of the machine may damage it. CONTROLS will not be
responsible for any damage caused by improper setting of these parameters and/or
unauthorized access to this menu. Warranty will be void if this menu is used by
unauthorized personnel.
WARNING:
Never start the thermoregulation with the covers removed as this may cause damages to
the equipment. CONTROLS will not be held responsible in case of improper use and the
warranty will be void.
28.06.2013 12 Rev.3 EN
WARNING:
Accessing to the CALIBRATION-MODIFICATION screen is allowed to CONTROLS
authorized technical personnel only. CONTROLS will not be responsible for any damage
caused by improper setting of these parameters and/or unauthorized access to this menu.
Warranty will be void if this menu is used by unauthorized personnel.
WARNING:
The manual activation of the different components is not monitored by the machine.
Therefore damages may result in case of wrong operation (e.g. activation of the WATER
HEATING RESISTORS without water in the test chamber). CONTROLS will not be
held responsible for damage to person/property caused by the improper use of this
program.
WARNING:
Failing to perform the recommended maintenance actions or maintenance performed by
unauthorized people can void the warranty.
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
Before opening/removing the covers, disconnect the mains supply to the device and wait
at least 5 minutes.
WARNING:
For continued fire protection, replace fuses with same type and rating. Also, in case of
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the electronic compartment
of the device, as this could cause short circuits. Before cleaning the device, disconnect it
from the mains line.
WARNING:
failure, components may only be replaced by using original spare parts.
Rev.3 EN 13 28/06/2013
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 the 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.
Please refer to the local laws and regulations for proper disposal of the product.
28.06.2013 14 Rev.3 EN
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.3 EN 15 28/06/2013
2. DESCRIPTION
Refer to the following drawings with numerical references while reading this chapter.
These drawings show the machine from different views to better identify the different
main components.
Machine body
Sheet steel, powder coated with epoxy resin. See-through hinged cover.
Loaded wheel system

Depending on the model, equipment is fitted with double stainless steel wheel, 203 mm
dia. x 47 mm wide, or double solid rubber tyre, 203 mm dia. x 50 mm wide [1].
The wheel load [2] for all systems is 705 N. The system includes a motorized lifting
system of the wheel assembly at the end of the test [3].
The lifting device is equipped with a microswitch that senses the fully down position [4].
The combined AASHTO/EN versions (see models 77-PV33B05 and 77-PV33B06) are
supplied complete with both set of stainless and rubber wheels.
Wheel tracking carriage

The wheels acting on the test specimens housed in their moulds are moved 230 mm
backwards and forwards in a fixed horizontal plane. The movement is generated by a 3-
phase AC motor with gear box [5] and a crank system [6]. The speed is adjustable, via a
motor inverter driven by the PC, from 20 to 30 cycles per minute (40 to 60 passes). A
magnetic sensor counts the cycles [7]. An optical sensor [8] detects the central position of
the wheels on the slabs and triggers the acquisition of the displacement transducers [9].
The slab mounting system can hold moulds of 360x300 mm (for 320 x 260 mm slabs)
and 400x300 mm, 40, 50, 60, 70, 80 90 and 100 mm thick. The greatest slab dimension is
oriented as the wheel travel. Special slab moulds for circular samples from coring or
gyratory compactors, are also available.
Temperature control system

AASHTO Hamburg Type standard prescribe the test to be performed in a water bath over
a range of 25 to 70°C ±1°C. This is achieved via a water recirculation system equipped
with heating resistors [10] and relevant thermostat [11] within the water chamber, water
re-circulation pump [12] and water inlet electrovalve [13]. The thermoregulation is
controlled by 2 temperature probes that can be either fitted into the slabs or left in their
holder to measure the water temperature [14].
The EN standard instead, prescribe either air or water environment. In case of heated air
environment, the specimen, during testing, must be maintained at constant specified
temperature ±1°C. The air thermal control is achieved via a heater with fan [15] equipped
with resistors [16], temperature probe and thermal switch [17] and air diffuser [18]. In
both systems a water level of about 20 mm above the sample has to be maintained.
Impression measurement system

Each wheel is fitted with linear transducer measurement system for deformations 0 to 20
mm ±0.1 mm [9]
28.06.2013 16 Rev.3 EN
Testing software
User friendly Windows® software. The operator can set the (fully customizable) test
execution conforming AASHTO or EN standards following in real time the test
evolution: water (or air) temperature, specimen temperature, rut depth, and the graph
deformation/cycles with the specimen profile, metric or Imperial unit selection. Export
test data to CSV Format (Excel), file management concerning tests, asphalt mix, clients,
etc.
Safety features
Double EMERGENCY BUTTON (one per side of the machine) that allows stopping the
equipment in case of anomalies that may endanger the operator safety; the following
functions are disabled after pressing the EMERGENCY BUTTONS: movement of the
wheel arms, heating resistors (both air and water depending on the model), water pump,
air circulation motor.
Software with different screen background color for water or air temperature control.
The machine stops automatically opening the protection.
Air temperature overheating protection system.
Motor protection and other standard safety applications.
Standard outfit
The machine is supplied complete with PC, Testing software and moulds (see chapter
2.4).
Rev.3 EN 17 28/06/2013
9
8
2
18
2
Fig. 2-1 Wheel movement carriage components
28.06.2013 18 Rev.3 EN
6
2
3 5
13 12
Fig. 2-2 Water thermoregulation components
Rev.3 EN 19 28/06/2013
6
2
18
17
15
16
Fig. 2-3 Air thermoregulation components
28.06.2013 20 Rev.3 EN
9 8 9
18
Fig. 2-4 Impression measuring system components
Rev.3 EN 21 28/06/2013
11
14
10
18
10
19
14
Fig. 2-5 Test chamber components
28.06.2013 22 Rev.3 EN
2.1 Connections
The next figure shows the position of the connectors/ports used to connect the equipment
with the external devices.
4 5
3
Fig. 2-6
Ref. Description
1 Power cable socket
2 USB port for PC connection
3 Water drain valve
4 Water OUT connector
5 Water IN connector
Rev.3 EN 23 28/06/2013
2.2 Identification plate

The identification plate is located on the side panel of the equipment, near the power
cable socket.
Fig. 2-7
28.06.2013 24 Rev.3 EN
2.3 Commands and controls

This chapter describes the commands and controls of the equipment. The operator’s
interface description is provided in chapter 4.1 of the present manual.
5
1 3
2 4
7
10
9
Fig. 2-8
Ref. Descrizione
1 READY lamp: ON with the power circuitry enabled
2 POWER ON push button: to enable power circuitry
HEATING STATUS lamp: blinks while the thermoregulation is heating to
3 indicate the activation of the heating elements. Turns OFF when the setpoint
temperature is reached
TEMPERATURE CONTROL ON lamp: turns ON when the thermoregulation is
4
enabled via the computer
5 MAINS ON led (white): ON when MAINS SWITCH is turned ON
6 CPU RUNNING led (green): blinks when the machine electronics is running
7 WARNING led (red): ON when the EMERGENCY BUTTON(S) is/are pressed
8 EMERGENCY BUTTONS (one per side of the equipment)
9 MAINS SWITCH
10 PC Program (refer to chapter 4.1 of the present manual)
Rev.3 EN 25 28/06/2013
2.4 Technical specifications

General features
Product Wet & Dry Double Wheel tracker machine
Manufacturer CONTROLS Cernusco s/N (MI) Italy
Reference standard AASHTO/ EN EN AASHTO AASHTO EN

Type of test In air and water In air and water In air and water In water In air
Product code 400VAC/50Hz 77-PV33B05 77-PV33E05 77-PV33A05 77-PV31A05 77-PV32E05
Product code 220VAC/60Hz 77-PV33B06 77-PV33E06 77-PV33A06 77-PV31A06 77-PV32E06
Stainless steel
dia.
203x47mm; Rubber tyre Rubber tyre
Two Loaded wheels Stainless steel Stainless steel
Dia. Dia.
Rubber tyre dia. 203x47mm dia. 203x47mm
203x50mm 203x50mm
Dia.
203x50mm
Displacement motion Wheels movement through AC motor and crank device
Table travel 230mm
Wheel speed Variable between 20 and 30 cycles per minute
Wheel load 705 N by weight
Temperature range From ambient temperature to 70°C
Water: 3 x
Air: by air
Water: 3 x 1500W heaters, re-circulating pump, 1500W heaters,
blower with
automatic feed and control level; re-circulating
Temperature control heaters
pump,
Air: by air blower with heaters controlled by the controlled by
automatic feed
electronic system the electronic
and control
system
level
Temperature control accuracy ±0.5°C for both water and air
Rut depth transducer range 20 mm, 0.1 mm accuracy
Moulds for slabs (see below [*]) “1” “2” “3” “4” “5”
Slab thickness Adjustable from 40 to 100 mm
Rated line voltage three-phase 400/220VAC +6%, -10%
Line frequency 50/60Hz
Power rating 5500 W 5500 W 5500 W 5500 W 4600 W
Method of power entry Cable with plug
Computer connection USB
Noise level (noise filtered A) ≤70db
Net weight approx. 600 kg
Overall dimensions (l x d x h) 1540 x 1020 x 1600 mm
Environmental conditions
Operating temperature + 5 ÷ + 40°C
Operating humidity ≤ 50%RH @ 40°C
[*] 1, 3, 5: two 400 x 300mm moulds and two 360 x 300mm moulds (for 320 x 260mm slabs)
2, 4: two 400 x 300mm moulds
28.06.2013 26 Rev.3 EN
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 phase 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:
Rev.3 EN 27 28/06/2013
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
PV31A0X, PV32E0X, 900 Kg approx 1900 x 1400 x 2000 mm 2000 mm
PV33E0XPV33A0X,
PV33B0X
Use a proper fork lift with minimum fork length as above indicated to raise and move the
wooden crate (see figure below).
Fig. 3-1
WARNING:
28.06.2013 28 Rev.3 EN
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
Rev.3 EN 29 28/06/2013
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

PV31A0X, PV32E0X, 600 Kg approx.
PV33E0XPV33A0X, PV33B0X
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. Using a fork-lift (minimum fork length = 1200 mm) raise the equipment and remove
it from the shipping crate paying attention to its balancing (see next figure below). Do
not lift by any other part to avoid damaging the equipment.
Fig. 3-2
WARNING:
Before powering on the unit, check for loose connections of cables inside the equipment.
28.06.2013 30 Rev.3 EN
3.3 Positioning of the unit and space requirements
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.4), check the
maximum allowed floor load before installation.
The unit must be placed on a flat and level surface.
The area around the equipment must be kept free from obstacles and from
substances that may cause sliding of the personnel.
It is responsibility of the purchaser to provide an installation place with

adequate lighting.
Parts used to build the machine and electrical/electronics component are fire-proof.
It is anyway the responsibility of the owner of the equipment to make sure that the
installation place is equipped with proper fire extinguishing systems and that the
operators have been instructed on the relevant procedures.
Use a proper mean (e.g. fork lift) to bring the unit to the installation place.
Place the unit in its final location, taking into account the free space around the unit: the
equipment requires at least 1mt. of clearance all around to allow accessing the testing
chamber from both sides.
The unit shall not be placed under direct flow of heated/conditioned air as this may impair
the thermal stability of the system.
Also consider that mains connection is achieved through the mains cable socket on the
right side of the equipment cabinet.
The unit requires adequate air circulation around it to assure proper cooling of the internal
devices.
Rev.3 EN 31 28/06/2013
Once the installation place has been reached, adjust the feet of the equipment in order to
achieve its proper levelling.
Use a spirit level and place it on the supports of the sample moulds parallel and
orthogonal with respect to the movement of the wheel.
Spirit level position to check leveling orthogonally
Spirit level position to check leveling parallely
Fig. 3-3
Then lock the feet by means of the relevant counter-nuts.
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.
28.06.2013 32 Rev.3 EN
Please refer to next drawing for proper positioning of the unit.
1 meter
Fig. 3-4
For service/maintenance purposes, removal of the rear panel may also be required. Make
sure this is possible, e.g. moving temporary the equipment away from the rear wall.
Rev.3 EN 33 28/06/2013
3.4 Mounting the computer tray

The machine is shipped with the computer tray dismounted from the unit.
Refer to drawing below to assemble the tray.
Fig. 3-5
28.06.2013 34 Rev.3 EN
3.5 Electrical requirements

The next table shows the electrical specifications of the equipment:
Item Specifications
220/400 VAC
Three-phase voltage
+6%, -10%
Frequency 50/60 Hz
Maximum power models PV33B0X, PV33E0X, PV33A0X, PV31A0X 5500 W
Maximum power models PV32E0X 4600 W
The equipment shall be connected to a proper earth system, the efficiency of which shall
be checked by qualified personnel. Earth shall be via the power cord, 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.3 EN 35 28/06/2013
3.6 External connections
3.6.1 Electrical connection
The power supply of the machine is achieved with a power cord connected to the relevant
receptacle on the rear side of the machine.
The connection with the computer is achieved via an USB port located on the front panel
of the machine, below the computer tray.
USB port
Power cord receptacle
Fig. 3-6
28.06.2013 36 Rev.3 EN
3.6.2 Water connections (for models PV33B0X, PV33E0X, PV33A0X, PV31A0X)
The unit requires the connection to a source of water to fill up the test chamber.
This is achieved via 2 connectors located on the left-hand panel of the machine.
2 3
1
Fig. 3-7
Ref. Description
1 Water drain valve
2 Water OUT connector (see NOTE below)
3 Water IN connector
Filling of the test chamber is controlled by an electrovalve commanded by the computer

(see chapter 4.4).
NOTE:
The system does not have a drain pump. Therefore, the drain tube has be routed directly
into the drain sump and the maximum allowed difference in level is 20 to 30 cm.
Rev.3 EN 37 28/06/2013
3.7 Removing the arm shipping support

To avoid damages to the equipment, the 2 wheel arms are held on supports during the
shipment.
With the machine still turned OFF remove these supports material before operating the
equipment.
NOTE:
Make sure the wheels are not left in contact with the sample slab or the mould when the
machine is not in use (switched OFF or on stand-by). This may cause damage to the
rubber wheel (ovalization), thus leading to incorrect results or to further damage to the
equipment. Replace the rubber wheel in case of doubt.
28.06.2013 38 Rev.3 EN
3.8 Installing the displacement transducers

The machine is shipped with the displacement transducers removed/loose from the wheel
arms to avoid damages during transportation. Two types of displacement transducers are
used according to the machine versions. Procedure below describes the installation
procedures for both types of transducers.
3.8.1 Installing displacement transducer potentiometric type

1. Align the transducer as shown in next picture (border between the plastic part and
the metal case aligned with the edge of the holder plate);
Fig. 3-8
2. Tighten the 4 fixing screws;
Fixing screws
Fixing screws
Fig. 3-9
3. Attach the electrical connector.
Rev.3 EN 39 28/06/2013
3.8.2 Installing displacement transducer LDT type

1. Align the transducer as shown in next picture (gap of approx. 2 mm between fixing
block and upper border of the transducer body);
2mm gap
Fig. 3-10
2. Tighten the 2 fixing screws;
Fixing screws
Fig. 3-11
3. Attach the electrical connector.
28.06.2013 40 Rev.3 EN
3.9 Filling the test chamber with water

This procedure describes the filling of the test chamber with water for the first time. This
is required on machines that have the WATER test function.
Normally, the test chamber is filled with water before starting the test (see chapter 4.4),
but the first fill up may require the triggering of the pump as here after described.
1. Connect the tubings to the water panel, close the drain valve and open the external
water supply (loading of the water in the machine will be controlled by the
program);
Water IN
Drain valve
Water OUT
Fig. 3-12
2. Turn ON the machine by means of the MAINS SWITCH (item #9 of figure in
chapter 2.3) and press the POWER ON push button to activate the power circuitry
(item #2 of figure in chapter 2.3), the READY lamp will turn ON (item #1 of figure
in chapter 2.3);
3. Start the DWT software by double-clicking the icon on the screen, the
following screen will be displayed;
Fig. 3-13
Rev.3 EN 41 28/06/2013
4. On the side command bar, press the SETTINGS icon to access the relevant
screen;
5. Press now the MANUAL COMMANDS icon on the side command bar of
the SETTINGS menu to access the MANUAL COMMANDS screen;
Fig. 3-14
WARNING:
Therefore damages may result in case of wrong operation (e.g. activation WATER
program.
28.06.2013 42 Rev.3 EN
6. When the tank is filled for the first time, it may be necessary to trigger the pump; to
do this, fully fill manually with water the tube below indicated before activating the
pump;
Tube to manually fill with water
Fig. 3-15
7. On the MANUAL COMMANDS screen press now the WATER FILLING button
to activate the pump, the relevant lamp will lit red and the water will start to
flow into the large chamber through the port shown below (press again the same
button in case you need to stop the water flow);
Chamber filling port
Large chamber
Small chamber
Fig. 3-16
Rev.3 EN 43 28/06/2013
8. The water will first fill up the large chamber and then will overflow into the small
chamber through the spillway; the water flow will automatically stop when proper
level in the small chamber is reached and sensed by the water level sensor.
Water level sensor
Spillway
Fig. 3-17
NOTE:
The above procedure may also be needed during the normal test activity with water, e.g.
in case the pump was completely emptied and therefore needs to be triggered again.
28.06.2013 44 Rev.3 EN
4. USE OF THE EQUIPMENT

This chapter describes the operator’s interface and the execution of a tests with the
different configurations of the machines.
WARNING:
WARNING:
tools/keys. These tools and keys are for use by maintenance personnel only. Never leave
the tools and keys attached to the unit as this may endanger operator safety.
and locked.
WARNING:
It is recommended that the operator perform the specified maintenance actions before
each session of operations.
If the operator detects irregularities or damage, he should immediately inform the
Maintenance department.
WARNING:
sample.
WARNING:
front doors opened.
WARNING:
protection means.
Rev.3 EN 45 28/06/2013
4.1 Operator’s interface description

This chapter describes the functions made available by the software controlling the
PAVELAB DWT machine.
Details on the execution of the test are provided in chapter 4.4 for tests in water and
chapter 4.5 for tests in air.
After activating the program on the PC (password at PC switch ON is “controls”), the

following screen will be displayed:
Fig. 4-1
The background color of the screen changes depending on the type of test selected:
• Light blue for tests in AIR
• Green for tests in WATER.
The screen is organized in different fields with the following main functions:
A. Pull-down menu area (see chapter 4.1.1).
B. Top bar, with live readings of DEFORMATION, TEMPERATURES, SPEED and
status of the machine (see chapter 4.1.2).
C. Side command bar, with buttons that allow operating the equipment; the number and
type of buttons may change depending on the function selected (see chapter 4.1.4).
D. Central area, with specific commands and display that depend on the function
selected.
E. Monitor bar, to monitor the different devices/sensors of the machine and its test type
setup (see chapter 4.1.3).
The next chapters describe the different functions of the software.

28.06.2013 46 Rev.3 EN
4.1.1 Pull down menu description
Fig. 4-2
Two options are available:

• FILE: it allows exiting the program by selecting the EXIT option.
• LANGUAGE: it allows selecting the language of the operator’s interface. It also
allows modifying/deleting existing languages by selecting the LANGUAGES
MANAGEMENT option in the list.
Fig. 4-3
Rev.3 EN 47 28/06/2013
4.1.2 Top bar description
A B C D
Fig. 4-4
The top bar shows the live readings of:

A. DEFORMATION: this is the reading of the 2 displacement transducers that measure
the deformation of the samples under the action of the wheels during the test cycle.
The measurement is taken in the central area of the sample, as specified by the
Standards, and is triggered by the optical sensor mounted on top of the wheel arm
assembly. SAMPLE 1 is the position on the side of the command panel, SAMPLE 2
is the position far from the command panel. The unit can be set as mm or inches in
the GENERAL SETTINGS menu (see chapter 4.1.11.1).
B. TEMPERATURES: the figures are shown only while the test is in progress. The
CENTER temperature refers to the probe located in the center of the test chamber.
The SAMPLE 1 refers to the probe to be fitted into the sample housed on the side of
the command panel. The SAMPLE 2 refers to probe of the sample housed far from
the command panel. In some cases, the SAMPLE 1 – 2 probes can be snapped into
the relevant clips on the wall of the test chamber, instead of being fitted into the
samples. The TEMPERATURES figures will be highlighted when the temperature
is outside the setup value ±1°C.
The unit can be selected between C° and F° in the GENERAL SETTINGS menu
(see chapter 4.1.11.1).
C. SPEED: it shows the figure for PASSES/MINUTES or CYCLES/MINUTE (1 cycle
= 1 pass forward + 1 pass backward). The unit can be set in the GENERAL
SETTINGS menu (see chapter 4.1.11.1).
D. Machine status display: it shows the present status of the machine:
• STAND-BY: machine idle, waiting for commands. Here it is possible to start the
test;
• PRE-HEATING: indicates that thermoregulation is active;
• DELAYED START: indicates that the test has been started but the machine is
still performing the PRE-HEATING phase and the wheels are not moving;
• TEST RUNNING: indicates that the test in progress with the wheels moving;
• TEST COMPLETED: indicates that the test has been completed due to the
achievement of the set limits (MAX NUMBER OF CYCLES or MAX RUT
DEPTH as set) or because it has been stopped.
28.06.2013 48 Rev.3 EN
4.1.3 Monitor bar description
The following functions are directly monitored on the bottom of the screen:
Fig. 4-5
• The leftmost box indicates the thermoregulation medium that can be WATER (the
background color of the screen will be green) or AIR (the background color of the
screen will be light blue). The thermoregulation medium can be changed in the
ADVANCE SETTINGS of the GENERAL SETTINGS panel (password protected).
• COMMunication: when this lamp is lit (green), it indicates that the machine is
connected to the PC via the USB cable.
• MOTOR: when this lamp is lit (red), it indicates that the wheel arm motor is active.
• ARM WHEELS: when this lamp is lit (red), it indicates that the wheel arm is down
on the sample.
• WHEEL 1 and WHEEL 2: when these lamps are lit (red) they indicate that the
wheels are lifted in the upper position by the independent wheel lifting device
(optional code 77-PV3UP10 to be mounted in the factory at the time of order).
• WATER LEVEL: when lit (red) it indicates that the water level in the test chamber
is low. Water level is monitored by a level switch in the test chamber. It is active
only if the thermoregulation medium is WATER. This lamp is present only when the
WATER setup is selected.
• DOOR: when this lamp is lit (red), it indicates that the door/s is/are open. The motor
is disabled with the doors open.
• EMERGENCY: when this lamp is lit (red), it indicates that the EMERGENCY
BUTTON(S) (one button on each side of the machine) is/are pressed. Pressure of the
EMERGENCY BUTTON(S) disables wheel arm motor, heating resistors of either
water and air thermoregulation, water pump and air circulation motor. This lamp is
duplicated by a dedicated lamp on the command panel (see item #7 of figure in
chapter 2.3).
Rev.3 EN 49 28/06/2013
4.1.4 Side command bar description
The following buttons are available on the side command bar:
NEW TEST button: this command is active if the test is not in progress. It
allows inputting the sample parameters to prepare for a new test. Pressing
this button will cause the erasing of some items of the single sample
parameters while the parameters in common for both samples will remain as
per previous test Refer to chapter 4.1.5.
START TEST button: this command is active if the test is not in progress. In
case the thermoregulation medium is AIR, pressing this button causes the
start of the test. In case the thermoregulation medium is WATER, pressing
this button the system will check the water level in the test chamber (through
the relevant level switch) and, if the level is low, will activate the electro-
valve to start the water filling. This process requires the confirmation by the
operator. Once the proper water level in the test chamber is achieved, the
operator can press this button again to start the test.
STOP TEST button: this button is active while a test is running. Once
pressed, the system will require a confirmation before being applied. After
stopping the test, the system will save the data gathered regardless the test
has been completed or stopped by the operator.
PREHEATING FUNCTION button: this button opens a panel that allows
entering the settings to apply for the pre-heat phase of the sample. Logic of
the commands of this panel depends on the type of test selected (WATER or
AIR). Refer to chapter 4.1.6.
LIST OF TESTS button: this button allows accessing the data of the tests
saved so far. The test data are saved at the end of the test, even when the test
is stopped prematurely by the operator. The screens allow performing data
processing, report printouts, data management, etc. Refer to chapter 4.1.7.
LIST OF MIXTURES button: this button allows accessing the screen to
manage the data of the mixtures stored into the system. Refer to chapter
4.1.8.
LIST OF PROCEDURES button: this button allows accessing the screen to
manage the data of the procedures stored into the system. Refer to chapter
4.1.9.
LIST OF CUSTOMERS button: this button allows accessing the screen to
manage the data of the customers stored into the system. Refer to chapter
4.1.10.
SETTINGS button: this button opens a screen that in turn allows accessing
further pages to manage GENERAL SETTINGS, CALIBRATION,
LANGUAGE CUSTOMIZATION, MANUAL COMMANDS, etc. Some of
these functions are password protected. Refer to chapter 4.1.11.
Here follows a detailed description of each function.
28.06.2013 50 Rev.3 EN
4.1.5 NEW TEST screen
The NEW TEST screen is displayed after pressing the button on the side
command bar.
Fig. 4-6
It includes a number of fields that allow entering the test data, some specific for the single
sample (SAMPLE 1 is the nearest to the command panel, SAMPLE 2 the one far from
the command panel).
The mandatory fields are identified with an “*” and must be filled in to proceed (in case
they are not filled in, an error message will prompt the operator accordingly).
It is also possible to enable disable the single sample position. In case one sample is not
installed into the test chamber, raise the wheel of the free position (only for machines
equipped the single wheel lifting device code 77-PV3UP10) or place a wooden piece of
proper thickness in the empty mould.
The mandatory fields are highlighted in red until they are filled in with a meaningful
value.
Some fields are enabled/disabled depending on the type of sample, some other can be
filled in by picking the selection from existing database.
Rev.3 EN 51 28/06/2013
Here follows a brief description of the fields specific for each of the 2 samples:
• SAMPLE NR: mandatory field, numerical format, cleared when starting a new test,
range 0 to 10000.
• SAMPLE ID: mandatory field, alphanumeric format, cleared when starting a new
test, range 20 characters.
• SAMPLE NAME: mandatory field, alphanumeric format, cleared when starting a
new test, range 20 characters.
• SAMPLE TYPE: mandatory field, pull down menu to select among GENERIC,
PLATE, CORE, DOUBLE CORE.
• SAMPLE LENGTH: disabled in case of CORE and DOUBLE CORE sample type,
unit mm or inches depending on the selection in the SETTING screen (see chapter
4.1.11), range 0 to 500.
• SAMPLE WIDTH: disabled in case of CORE and DOUBLE CORE sample type,
unit mm or inches depending on the selection in the SETTING screen (see chapter
4.1.11), range 0 to 500.
• SAMPLE DIAMETER: disabled in case of PLATE sample type, unit mm or inches
depending on the selection in the SETTING screen (see chapter 4.1.11), range 0 to
500.
• SAMPLE THICKNESS: mandatory field, unit mm or inches depending on the
selection in the SETTING screen (see chapter 4.1.11), range 0 to 200.
• SAMPLE WEIGHT:, unit Kg, range 0 to 20.
• SAMPLE MIXTURE: mandatory field, pull down menu to select among the store
mixtures, selecting NEW MIXTURES it brings directly to the LIST OF
MIXTURES screen (see chapter 4.1.8).
• SAMPLE AGE: unit DAYS, range 0 to 200.
Fields in common to the 2 samples are:
• MAX. RUT DEPTH: mandatory field, unit mm or inches depending on the selection
in the SETTING screen (see chapter 4.1.11), range 0 to 100 for mm and 0-to 4 for
inches.
• MAX. NUMBER OF CYCLES: mandatory field, unit CYCLES or PASSES
depending on the selection in the SETTING screen (see chapter 4.1.11), range 0 to
50000.
• TEST TEMPERATURE: mandatory field, unit °C or °F depending on the selection
in the SETTING screen (see chapter 4.1.11), range 25 to 70 for °C and 80 to 160 for
°F.
• WHEEL SPEED: mandatory field, unit CYCLE/MIN or PASSES/MIN depending
on the selection in the SETTING screen (see chapter 4.1.11), range 20 to 30 for
cycle/min and 40 to 60 for passes/min.
• DELAYED START: mandatory field, it allows setting a conditioning time for the
sample; the unit is MINUTES and starts counting after the set test temperature has
been reached (see chapter 4.1.6); the test will start after the DELAYED START time
is elapsed; range 1 to 120.
• CONDITIONING CYCLES: mandatory field, it allows setting a number of cycles
(max 5) to be performed before starting the test procedure. The conditioning cycles
are not considered in the test duration.
• TEMPERATURE LIMITS: mandatory field to set the tolerance that will be taken
into consideration by the system in order to warn the operator when starting the test
with the temperature still not in range.
• OPERATOR: mandatory alphanumerical field, range 20 characters.
28.06.2013 52 Rev.3 EN
The NEW TEST screen includes three buttons to perform the following actions:
• SAVE PROCEDURE: it allows saving into the LIST OF PROCEDURES database
the current set procedure.
• OPEN PROCEDURE: it allows loading the procedure parameters directly from one
of the procedures saved in the relevant database.
• DELETE DATA: after confirmation, it allows clearing all fields in the screen.
Once the data input has been completed correctly, the START TEST button becomes
active (green arrow) and it is possible to activate the test process.
If the test chamber temperature is still out of the set point value ± the TEMPERATURE
LIMITS, the system will show a popup to warn the operator, offering the possibility to
wait for the thermal stabilization or the skip it.
In case the thermoregulation medium is AIR, pressing this button causes the start of the
test (that may include a sample conditioning period).
In case the thermoregulation medium is WATER, pressing this button the system will
check the water level in the test chamber (through the relevant level switch) and, if the
level is low, will activate the electro-valve to start the water filling. This process requires
the confirmation by the operator. Once the proper water level in the test chamber is
achieved, the operator can press this button again to start the test.
At this point, the system will move the wheel arm downward and the wheel motor will be
activated.
During the execution of the test, the system will show the following screen:
Fig. 4-7
While the test is running, it will be possible to stop it by pressing the button on
the side command bar (confirmation by the operator is requested).
Rev.3 EN 53 28/06/2013
The graph area includes:

The sample deformation plot, updated every cycle, that shows the value of deformation
measured in the center of the sample versus the number of cycles (or passes, depending
on the setting) or time.
Fig. 4-8
The sample profile plot, updated every cycle, that shows the contour of the sample along
the whole travel of the wheel (230mm).
Fig. 4-9
A dedicated panel allows setting the appearance of the graphs.
Fig. 4-10
NOTE:
The figures of deformation shown in the upper-left display of the screen is the value
acquired by the system in the central part of the wheel travel, corresponding to the
115mm point on the contour graph.
28.06.2013 54 Rev.3 EN
4.1.6 PREHEATING FUNCTION screen
The PREHEATING FUNCTION screen is displayed after pressing the button on

the side command bar.
This function allows using the machine as an oven to preheat the sample before carrying
out the test (e.g. the EN Standard requires a preheating time of 8 hours).
Fig. 4-11
The following fields are available on this panel:

• TEMPERATURE SET: temperature value to reach for the test, numerical format,
unit °C or °F depending on the selection in the SETTING screen (see chapter
4.1.11), range 25 to 70 °C or 80 to 160°F.
• TEMPERATURE: actual temperature readout in the test chamber read by the central
probe, numerical format, unit °C or °F depending on the selection in the SETTING
screen (see chapter 4.1.11), the value shown is highlighted until it reaches the
TEMPERATURE SET value ±1°C.
• TIME: preheating duration time, numerical format, unit HH:MM, range 0 to 24
hours, the TIME starts counting after the TEMPERATURE SET value has been
achieved; leave this field empty to disable the preheating time; the thermoregulation
is stopped when the TIME is elapsed;
• TEMPERATURE CONTROL SYSTEM: WATER or AIR depending on the
selection in the GENERAL SETTING screen (see chapter 4.1.11.1).
• ELAPSED TIME: display of the preheating elapsed time, numerical format, unit
HH.MM.SS, it starts counting after the temperature has reached the setup value.
• REMAINING TIME: numerical format, calculated as DURATION-ELAPSED
TIME, unit HH.MM.SS.
Rev.3 EN 55 28/06/2013
The following commands are available on this panel:

• START: when the medium used is AIR, pressing this button directly starts the
preheating phase; when the medium used is WATER, pressing this button the
machine will check the level of water in the test chamber (via the level switch) and
opens the water in electrovalve in case it is low (asking for the confirmation of the
operator before proceeding); when the test chamber is full, press again this button to
start he preheating phase.
• STOP: press this button to stop the preheating phase in progress; normally the
preheating phase will stop automatically once the set TIME is elapsed. If instead the
TIME is not set, the preheating phase will only be stopped after pressing the STOP
button.
28.06.2013 56 Rev.3 EN
4.1.7 LIST OF TESTS menu
The LIST OF TESTS menu is displayed after pressing the button on the side
command bar.
Fig. 4-12
The system saves the test data automatically at the end of the test and when the test is
stopped by the operator.
On this screen, the following buttons become available on the side command bar:
LIST OF TEST button: it shows the test archive menu (the default page)
with the list of stored tests, a field with the mixture data of the selected test
and a panel with commands perform comparison between tests (refer to
chapter 4.1.7.1).
SINGLE TEST REPORT REVIEW button: it shows full details of the
single test such as mixture data, initial test data, calculated data, graph of the
test and sample contour (see chapter 4.1.7.2).
SINGLE TEST REPORT PROCESSING button: it becomes active in the
SINGLE TEST REPORT REVIEW screen and allows performing data
processing according to Standard EN12697-22 Procedure A, Standard
EN12697-22 Procedure B and Standard AASHTO T324 (see chapter
4.1.7.2).
PRINT REPORT button: it becomes active in the SINGLE TEST REPORT
REVIEW screen and allows obtaining the hard copy of the test (see chapter
4.1.7.2).
Rev.3 EN 57 28/06/2013
EXPORT AS CSV button: it becomes active in the SINGLE TEST

REPORT REVIEW screen and allows exporting the test data in CSV format
for further elaboration (see chapter 4.1.7.2).
TEST ERASE button: to erase the single test either in the LIST OF TEST
screen and in the SINGLE TEST REPORT REVIEW screen (see chapter
4.1.7.2).
BACK TO MENU button: return to the test menu.
28.06.2013 58 Rev.3 EN
4.1.7.1 LIST OF TESTS screen
After pressing the LIST OF TESTS button on the side command bar, the system
shows the following screen.
Fig. 4-13
The field in the left half of the screen is the list of tests stored; they can be sorted by
increasing or decreasing date pressing the button DATE.
On the right half of the screen, the MIXTURES field shows the mixture data for the
selected test. Pressing the button it is possible to open directly the LIST OF
MIXTURE screen (see chapter 4.1.8).
The TEST GROUP COMPARISON field allows creating test groups, defined as
MULTIPLE TEST, required to obtain average results from data of many tests. This area
allows to:
• ADD SINGLE TEST: press this button to create a group by adding a number of
tests; the selected test are listed in the table below the buttons. Only processed tests
can be added to create a group. The tests grouped shall be processed with the same
procedure and shall be comparable (e.g. same mixture). A group can contain
maximum 6 tests.
• SAVE MULTIPLE TEST: press this button to save the group created. The system
requires naming the multiple test created.
Rev.3 EN 59 28/06/2013
• OPEN MULTIPLE TEST: press this button to access the list of MULTIPLE
TESTS (see screenshot below).
Fig. 4-14
• LIST DELETE: press this button to erase the tests belonging to a MULTIPLE
TEST.
• ELABORATE: press this button to process the multiple test, the system will show
the screen below.
Fig. 4-15
28.06.2013 60 Rev.3 EN
4.1.7.2 SINGLE TEST REPORT REVIEW screen

The SINGLE TEST REPORT REVIEW screen is displayed after pressing the button
on the side command bar.

It shows full details of the single test with the following fields:
• GENERAL DATA (calculated data),
• MIXTURE,
• INITIAL TEST DATA,
• Graph of the test,
• Sample contour.
Fig. 4-16
The button opens the panel to select the processing method.
Fig. 4-17
Rev.3 EN 61 28/06/2013
Select the method from the pull down menu and then press the button to perform
the data processing.
Available processing method are:

• EN 12697-22 Procedure A
• EN 12697-22 Procedure B
• AASHTO T324
• No processing.
Press the button to return to the sample data visualization.
The next panel allows setting of the graphs
Fig. 4-18
The button on the side command panel allows obtaining the hard copy of the test.
The button allows exporting the test data in CSV format for further elaboration.
The button allows erasing the single.
Here follows a detailed description of each method.
28.06.2013 62 Rev.3 EN
4.1.7.2.1 Data processing as per EN 12697-22 Procedure A
The deformation value to consider for the processing is the central point of the sample.
The procedure calculates the Wheel Tracking Rate (TR), processed on endurance tests up
to 1000 cycles with sampling every 100 cycles.
For each sample, the TR parameter [µm/cycle] is calculated with the following formulas:
• If at least 8 readings are available: TR = 3 r n + r n – 1 – r n – 2 – 3 r n – 3
• If there are 5 to 7 readings: TR = 5 r n – 5 r n – 2
• If there are 3 to 4 readings: TR = 10 r n – 10 r n – 1
• If there are 1 to 2 readings: TR = 15 000 / n 15
Where:
• “n” is the total number of readings sampled every 100 cycles, up to the thousand
cycle, except the initial reading (e.g. in a test with 950 cycles, the available readings
are 9);
• “r i” is the variation of the deformation between the reading on cycle “i” and the initial
value r0, in mm;
• “n 15” is the number of cycles required to get to 15mm
For tests with less than 100 cycles the “TR” value will be reported as test not valid.
Tests with more than 1000 cycles, will be processed up to the 1000 one.
Rev.3 EN 63 28/06/2013
4.1.7.2.2 Data processing as per EN 12697-22 Procedure B
The deformation value to consider in the following calculations is the average of the data
collected on 25 points equally spaced on a length of 100mm centered on the sample.
The procedure calculates the parameter Wheel Tracking Slope (WTS), ), processed on
endurance tests up to 10000 cycles with sampling at least at 5000 cycles.
In case of tests in AIR, the system will calculate the WTS parameter in [mm/103] cycles
as follows:
• WTS= (d 10000 – d 5000 )/5
Where:
• WTS is the Wheel Tracking Slope [mm/103] cycles
• d 5000 , d 10000 are the deformation values after 5000 and 10000 cycles expressed
in [mm].
If the test has a duration between 7000 and 10000 cycles, the following correction is
applied to the formula:
• WTS (d Nmax – d 5000 ) * 1000 / (N max – 5000)
Where Nmax is the duration of the test in cycles.
For tests with less than 5000 cycles, the result for “TR” value will be reported as test not
valid.
Tests with more than 10000 cycles, cycles over 10000 will not be considered.
28.06.2013 64 Rev.3 EN
4.1.7.2.3 Data processing as per AASHTO T324
The deformation value to be considered in the calculations that follow is the value
measured at the midpoint specimen.
The test parameters are to be obtained by a graphical elaboration.
Fig. 4-19
Pressing the button to start the data processing, the system will show the plot of
the deformation curve.
The plot resulting from a typical test has two phases characterized by two different
slopes.
Two dotted lines, labeled with #1 and #2 will appear on the plot and these two dottet lines
should correspond to the tangent to the two phases of the curve.
These dotted lines can be moved by the cursors on the edges.
The operator must position line #1 on the first part of the graph (initial cycles) and the
line #2 on the second part (final cycle). It the operator position the line in wrong
sequence, the elaboration will be uncorrect.
Below the graph, 3 buttons are available:

1 – SAVE TANGENT LINES: to save the position of the 2 lines (inclination coefficient
and intersection point) once the manual positioning is completed. Until the line editing is
completed by saving it, no other operations are available.
2 – MODIFY TANGENT LINES: if the test is already completed and saved, it is
possible to modify it and to return to edit mode by pushing this button. Push SAVE to
complete the operation.
3 – CANCEL: To exit from elaboration page without saving.
Rev.3 EN 65 28/06/2013
The data processing defines all the parameters defined in AASHTO T324, in details:
• Stripping Inflection Point, two lines intersection point, defined by:

o Number of passes to SIP: Number of passes (each pass corresponds to two
cycles) corresponding to the X value of the intersection point
o Rut depth to SIP: Rut depth (in millimeters or inches) corresponding to the Y
value of the intersection point
• Creep slope, slope of the tangent line or first phase, defined in millimeters/pass or
inches/pass. Passes are considered (not cycles) independently from the units selected
in settings window (1 pass = 0.5 cycles);
• Strip slope, slope of the tangent line or second phase, defined in millimeters/pass or
inches/pass. Passes are considered (not cycles) independently from the units selected
in settings window (1 pass = 0.5 cycles);
• Number of passes to failure, X value of the intersection of second tangent line and
maximum allowed deformation (20mm), defined in number of passes.
When a test with elaboration to AASHTO T324 is opened, the actual tangent lines will
appear. If the existing elaboration is edited, a warning message will appear. If the
operation is confirmed, the existing calibration is cancelled and tangent lines are restored
to initial position.
4.1.7.2.4 No processing
In this case no parameter is calculated. This “processing” is used just to give the test the
status “processed” (e.g. to be able to export in CSV format).
28.06.2013 66 Rev.3 EN
4.1.8 LIST OF MIXTURES screen
The LIST OF MIXTURES screen is displayed after pressing the button on the
side command bar.
This button allows accessing the screen to manage the data of the mixtures stored into the
system.
Fig. 4-20
In the right-half of the screen, three buttons are available to INSERT, MODIFY and
DELETE mixtures.
For any of the above actions, the system requires confirmation before proceeding.
Some of the default listed mixtures cannot be erased and/or modified.
The button (BACK TO MENU) allows return to the test menu.
Rev.3 EN 67 28/06/2013
4.1.9 LIST OF PROCEDURES screen
The LIST OF PROCEDURES screen is displayed after pressing the button on

the side command bar.
This button allows accessing the screen to manage the data of the procedures stored into
the system.
Fig. 4-21
DELETE procedures.
The procedures referred to the Standards EN12697-22 method A, EN 12697-22 method B

and AASHTO T324 cannot be erased and/or modified.
28.06.2013 68 Rev.3 EN
4.1.10 LIST OF CUSTOMERS screen
The LIST OF CUSTOMERS screen is displayed after pressing the button on the
side command bar.
This button allows accessing the screen to manage the data of the customers stored into
the system.
Fig. 4-22
DELETE customers.
Rev.3 EN 69 28/06/2013
4.1.11 SETTINGS screen
The SETTING screen is displayed after pressing the button on the side command
bar.
The following buttons are available on the side command bar:
GENERAL SETTINGS button: it allows accessing a panel to set units,

default language and some other functioning parameters of the equipment.
Some of these parameters are password protected.
CALIBRATION button: it allows reviewing and performing (the latter is
password protected) the calibration of the transducers of the equipment
(displacement transducers and temperature probes).
CUSTOMIZATION LANGUAGES button: it allows customizing the
languages (e.g. add a new language by inputting the translation of the
existing text messages).
MANUAL COMMANDS button: it allows manual activation of all devices
of the machine and checking the sensors/transducers.
EVENTS LOG button: it shows the counters of the main events/devices of

the machine.
RETURN button: return to previous screen.
28.06.2013 70 Rev.3 EN
4.1.11.1 GENERAL SETTINGS screen
The GENERAL SETTING screen is displayed after pressing the button on the
side command bar of the SETTING menu.
Fig. 4-23
This panel comprises parameters that can be set by the user and parameters that are
factory set and that depend on the type/model of the equipment. The latter are protected
by a password.
Password to set the ADVANCED SETTING parameters is “userpv”.
Rev.3 EN 71 28/06/2013
Parameters in the following panel can be set by the user:
Fig. 4-24
• SETTINGS - LANGUAGE SELECTION: it allows setting the language to show on
the machine at switch ON; the language can also be changed by the pulldown menu
on the top bar (see chapter 4.1.1);
• SETTINGS – SELECTED HEATING TYPE: this field is active only for models
with double thermostatic medium; it allows selecting the thermostatic medium to
use for the test, AIR or WATER;
• SETTINGS - TEMPERATURE CONTROL: it allows selecting the position of the
temperature probe, whether fitted into the sample or into the test chamber;
• MEASUREMENT UNIT - LENGTH: selectable between mm and inches;
• MEASUREMENT UNIT - TEMPERATURE: selectable between C° and F°;
• MEASUREMENT UNIT – COUNT WHEEL TRAVEL: selectable between
CYCLES and PASSES, (1 cycle = 1 pass forward + 1 pass backward);
• FILE SAVE - AUTO SAVE FILE CSV: it allows activating the automatic data save
in CSV format at the end of the test and the path to save them. The data saved in the
CSV format will be:
o Data of each pass/cycle from 1 to 10 passes/cycles
o Data every 10 passes/cycles from 10 to 100 passes/cycles
o Data each 100 passes/cycles from 100 passes/cycles onward.
The following parameters are set in the factory and depend on the hardware configuration
of the machine; a password is requested after pressing they button ADVANCED
SETTING:
Fig. 4-25
28.06.2013 72 Rev.3 EN
• SERIAL NUMBER: serial number of the internal electronic board;

• PID VALUES: these are the functioning parameters of the wheel motor and of the
thermoregulations;
• SETTINGS-THERMOSTATIC MEDIUM: it is set according to the hardware
configuration of the machine as follows:
Model codes Possible setting

PV31A05, PV31A06 ONLY WATER
PV32E05, PV32E06 ONLY AIR
PV33E05, PV33E06, PV33A05,
AIR AND WATER
PV33A06, PV33B05, PV33B06
• WHEEL LIFTING TYPE: to be set as INDEPENDENT only if the independent

wheel lifting device code 4-77-PV3UP10 is mounted on the machine (to be mounted
in the factory), otherwise set it to CONTEMPORANEOUS.
Changes will take place after pressing the SAVE button and giving further confirmation.
WARNING:
Accessing to the ADVANCED CONFIGURATION parameters is allowed to
CONTROLS authorized technical personnel only. Setting the wrong configuration not
matching the hardware of the machine may damage it. CONTROLS will not be
responsible for any damage caused by improper setting of these parameters and/or
unauthorized access to this menu. Warranty will be void if this menu is used by
unauthorized personnel.
Rev.3 EN 73 28/06/2013
4.1.11.2 CALIBRATION screen
The CALIBRATION screen is displayed after pressing the button on the side
command bar of the SETTING menu.
In the calibration screen it is possible to review (default status) or to modify (password

protected, reserve to CONTROLS authorized technical personnel) the calibration of the
transducers of the machine (temperature probes, displacement transducers).
Refer to chapter 5.2.1 for further information on the CALIBRATION screen.
WARNING:
Accessing to the CALIBRATION-MODIFICATION screen is allowed to CONTROLS
28.06.2013 74 Rev.3 EN
4.1.11.3 CUSTOMIZATION LANGUAGES screen
The CUSTOMIZATION LANGUAGES screen is displayed after pressing the button
on the side command bar of the SETTING menu.
Fig. 4-26
Each message in the software can be translated into another language.

Some languages are already available as default and can be selected by means of the pull
down menu LANGUAGE in the top bar of the program.
The first column is the current selected language, while the second column the language
to customize. The language to customize is selected by the pull down menu on top of this
screen.
Once the language to modify has been selected in the pull down menu, it is possible enter
in the second column the translation of the corresponding message shown in the first
column.
At the end, press the SAVE to store the new translation.
It is also possible to add a new language by pressing the button on top of the
screen.
Rev.3 EN 75 28/06/2013
4.1.11.4 MANUAL COMMANDS screen
The MANUAL COMMANDS screen is displayed after pressing the button on the
It allows activating/de-activating the active devices of the machine (motors, heating

resistors, etc.). A lamp beside each button indicates that the relevant command has been
given and is active.
The MANUAL COMMANDS screen is reserved to CONTROLS authorized technical

personnel and is described at chapter 6.1 of the present manual.
All the above functions can be used for troubleshooting purposes.
WARNING:
Therefore damages may result in case of wrong operation (e.g. activation WATER
program.
28.06.2013 76 Rev.3 EN
4.1.11.5 EVENTS LOG screen
The EVENTS LOG screen is displayed after pressing the button on the side
Fig. 4-27
This screen shows the counters of the main events of the machine. It can be used as a
reference to perform the maintenance on the machine.
The counters cannot be zeroed.
Rev.3 EN 77 28/06/2013
4.2 Replacing the wheels

Depending on the standard in use and the type of machine, it may be necessary to mount
the proper wheel on the arm as follows:
• Stainless steel wheel for AASHTO T324
• Rubber wheel for EN12697-22.
To replace the wheel:
1. Lower the wheel arm using the MANUAL COMMANDS (see chapter 4.1.11.4);
2. Loosen the 2 fixing screws of the displacement transducer reference disk;
Fig. 4-28
3. Loosen the 3 fixing screws of the round stop plate with shaft;
Fig. 4-29
28.06.2013 78 Rev.3 EN
4. Loosen the ferrule on the other side of the wheel;
Fig. 4-30
5. Raise the arm by means of the MANUAL COMMANDS: the wheel is now free to be
removed;
Fig. 4-31
Rev.3 EN 79 28/06/2013
6. From the existing wheel remove the ferrule, the washer and the bushing, then slide
out the stop plate with shaft; also remove the 2 ball bearings
Fig. 4-32
7. Fit on the other wheel the 2 ball bearings;
Fig. 4-33
28.06.2013 80 Rev.3 EN
8. Fit on the new wheel the stop plate with shaft, the bushing, the washer and screw in a
bit the ferrule;
Fig. 4-34
9. Mount the wheel on the machine (refer to figure below to properly position all parts
involved) then tighten the 3 screws on the round stop plate;
Bushing
Ferrule Washer
Round stop plate with shaft
Fig. 4-35
Rev.3 EN 81 28/06/2013
10. Lower the arm with the MANUAL COMMANDS to secure the fixing screws of the
round stop plate;
Fig. 4-36
11. Mount the fixing plate of the displacement transducer reference disk.
Fig. 4-37
28.06.2013 82 Rev.3 EN
12. When using the rubber wheels, two additional plates (one per arm) shall be mounted
on the weights, to compensate for the lower weight of the rubber wheels themselves;
the additional plates are fixed to the weights by the eyebolts and are customized for
each arm.
Additional weight
Fig. 4-38
NOTE:
Each weight is customized for the single wheel/test position. Mounting the wrong weight
on the arm may generate a wrong load to the sample.
NOTE:
The position of the weights has been set during the calibration phase in the factory to
achieve a load of 705N. Do not change (slide) the weight holder plate. Also, the eyebolts
shall not be removed as they concur to achieve the correct load on the sample.
Do NOT loosen the screw, do NOT

change the position of the holder plate
Fig. 4-39
Rev.3 EN 83 28/06/2013
4.3 Loading the sample

The sample Is loaded into the unit with a mould.
The following types of samples can be used:

• 400 x 300 mm slab prepared with a slab compactor (it is directly housed in the
mould);
• For tests in water, 150 mm dia. Gyratory compactor samples (2 cores side-by-side)
(use the accessory code PV3/003 to place the cores in the mould);
Here follows the description of preparing a 400 x 300 mm slab sample:
1. Dismount the mould and make sure it is clean from residuals of previous samples;
Fig. 4-40
2. Measure the height of the sample;
Fig. 4-41
28.06.2013 84 Rev.3 EN
3. Position the shelf of the mould in the proper slots on the half-frame according to the
height of the slab previously measured (take into considerations that the slab shall be
aligned with the mould edge ±2 mm); in case of need, use the 10mm thick spacer
provided with the machine to achieve the required alignment;
Fig. 4-42
4. To avoid sticking of the sample, place a paper sheet on the shelf of the mould;
Fig. 4-43
Rev.3 EN 85 28/06/2013
5. Place the slab in the mould;
Fig. 4-44
6. Mount the second half-frame properly matching the slots;
Fig. 4-45
28.06.2013 86 Rev.3 EN
7. Lock the 2 latches to assemble the mould;
Fig. 4-46
8. If needed, drill a 8 mm dia. Hole in the slab through the slot in the mould frame, to
house the temperature probe;
Fig. 4-47
Rev.3 EN 87 28/06/2013
9. Place the prepared mould into the machine with the hole drilled in the slab facing the
outside; the position on the command panel side is position #1;
Fig. 4-48
10. If necessary, fit the temperature probe in the hole previously drilled (or leave it
snapped into its retainers); access the SETTING – GENERAL SETTINGS screen to
set the TEMPERATURE CONTROL option according to physical the position of
the temperature probes (see chapter 4.1.11.1);
Fig. 4-49
28.06.2013 88 Rev.3 EN
11. Center the mould in its housing using the screw heads as reference;
Fig. 4-50
12. Prepare and position the second sample mould (position #2). In case this is not
required, raise the wheel of the free position (only for machines equipped with the
single wheel lifting device code 77-PV3UP10) or place a wooden piece of proper
thickness in the empty mould;
Fig. 4-51
Rev.3 EN 89 28/06/2013
13. Install the covers over the sample moulds, properly routing the cables of the 3
temperature probes (2 probes for the sample, 1 probe of the test chamber) through
the slots in the covers.
Cables of the temperature probes
Fig. 4-52
WARNING:
28.06.2013 90 Rev.3 EN
4.4 Carry out tests in water

This chapter describes the preparation of the machine to conduct tests in water. For full
details on the functions of the DWT software program refer to chapter 4.1. For full details
on the test steps, refer to the relevant Standard.
WARNING:
sample.
WARNING:
front doors opened.
WARNING:
protection means.
1. Check that the required type of wheels is mounted on the arms, otherwise install
them (see chapter 4.2); due to the fact that the wheel surface used during the test is a
limited arch of the whole wheel circumference, in case of use of the rubber wheels
position them in order that, in the time, the wear of the rubber will be evenly
distributed;
2. Connect the tubings to the water panel, close the drain valve and open the external
water supply (loading of the water in the machine will be controlled by the
program);
Water IN
Drain valve
Water OUT
Fig. 4-53
Rev.3 EN 91 28/06/2013
3. Check in the software that it is set for test in WATER (refer to chapter 4.1.11.1); the
background of the screen will be green;
4. Prepare and load the samples as described at chapter 4.3;
WARNING:

in chapter 2.3);
6. With the PC ON (password at PC switch ON is “controls”), start the DWT software
by double-clicking the icon on the screen, and select the NEW TEST
screen by pressing the button on the side command bar, the system will
show the following screen;
Fig. 4-54
7. Input the parameters for the test, the mandatory ones on the screen will remain in red
text until a valid value has been entered; on machines equipped with the single wheel
lifting device code 77-PV3UP10, it will be possible to test one sample only, and
therefore the relevant SAMPLE # can be disabled, while for the other machines it is
mandatory to perform the test on two samples (both SAMPLE 1 and SAMPLE 2
must be ticked); as far as the “common” test parameters (right-hand part of the
screen), it is possible to load one of the stored procedures, by pressing the button
OPEN PROCEDURES and selecting from the list; for full details on the available
fields, refer to chapter 4.1.5;
28.06.2013 92 Rev.3 EN
Fig. 4-55
8. Once ready, press the button on the side command bar to start the test, the
following actions will take place:
a. If the test chamber is empty, the machine will start to load the water by
activating the water IN electrovalve (popup message on the screen) otherwise
will proceed with next step “c”;
b. Once the water reaches proper level (sensed by the level sensor in the test
chamber), the water IN electrovalve will close and the water circulation pump
starts; press button again to proceed;

c. Then the thermoregulation will start to reach the TEST TEMPERATURE set,
the functioning of the thermoregulation is monitored by 2 lamps on the
command panel:
i. TEMPERATURE CONTROL ON lamp (item #4 of figure in chapter 2.3):
when ON, indicates that the heating is enabled,
ii. HEATING STATUS lamp (item #3 of figure in chapter 2.3): the lamp
blinks while the heating resistors are active while turns OFF when the
temperature has reached the set point value;
d. Once the TEST TEMPERATURE is reached, if the DELAYED START time
was entered (e.g. Standard AASHTO T324, 30 minutes for sample
conditioning) it is counted down, otherwise proceed right away with next step;
e. The machine will start a countdown of 1 minute to make sure the temperature is
within the proper range (popup message on the screen), then the wheels will be
lowered on the samples and the carriage will start to cycle back and forth, the
next screen will be shown during the test execution;
NOTE:
At step” a” above, if the water does not start filling the test chamber, it may be needed to
trigger the water pump (e.g. in case the pump was previously completely emptied). Refer
to chapter 3.9 to perform this procedure).
Rev.3 EN 93 28/06/2013
Fig. 4-56
9. During the test, figures of all display in the upper part of the screen will be updated
continuously; also, the graph on the screen will show the behavior of the sample
during the tests;
Fig. 4-57
10. During the test, it is possible to stop it by pressing the button on the side
command bar; once pressed, the system will require a confirmation before being
applied; after stopping the test, the system will save the data gathered regardless the
test has been completed or stopped by the operator;
28.06.2013 94 Rev.3 EN
11. If the door(s) is/are open during the test, the wheel motor will stop but the
thermoregulation will keep on working; close the door(s) and press the POWER ON
push button to activate the power circuitry (item #2 of figure in chapter 2.3), the
READY lamp will turn ON (item #1 of figure in chapter 2.3). The test will restart but
its results may be affected and need to be evaluated whether to accept them or not (in
general, the Standards do not accept the results of interrupted tests);
12. The test will proceed and will end at the achievement of:
f. MAX. RUT DEPTH set, or
g. MAX. NUMBER OF CYCLES,
depending on the settings in the test parameters panel, whichever comes first;
13. At the end of the test, the wheel arm will be lifted up and the thermoregulation
turned OFF. In case the machine is equipped with the independent lifting device for
the wheels, if the end test criteria are reached on one of the two samples, the relevant
wheel will be lifted up independently and the test will proceed on the other sample
up to the achievement of the end test criteria;
14. After the end of the test, it is possible to perform the data processing (refer to chapter
4.1.7.2).
Rev.3 EN 95 28/06/2013
4.5 Carry out tests in air

This chapter describes the preparation of the machine to conduct tests in air. For full
details on the functions of the DWT software program refer to chapter 4.1. For full details
on the test steps, refer to the relevant Standard.
WARNING:
sample.
WARNING:
front doors opened.
WARNING:
protection means.
1. Check that the required type of wheels is mounted on the arms, otherwise install
them (see chapter 4.2); due to the fact that the wheel surface used during the test is a
limited arch of the whole wheel circumference, in case of use of the rubber wheels
position them in order that, in the time, the wear of the rubber will be evenly
distributed;
2. Check in the software that it is set for test in AIR (refer to chapter 4.1.11.1); the
background of the screen will be blue;
3. Prepare and load the samples as described at chapter 4.3;
WARNING:
4. Precondition the samples as required by the Standard in use.

in chapter 2.3);
28.06.2013 96 Rev.3 EN
6. With the PC ON (password at PC switch ON is “controls”), start the DWT software
by double-clicking the icon on the screen; the computer senses that the
thermoregulation is active and therefore de-activate all commands but the
PREHEATING FUNCTION button on the side command bar, the following

panel will open;
Fig. 4-58
7. Check that the TEMPERATURE SET is the desired one and waiting for the
reaching of the temperature stabilization;
8. Exit from the PREHEATING FUNCTION panel by pressing the button

on the panel itself, the preheating phase will continue in background;
Rev.3 EN 97 28/06/2013
9. Select the NEW TEST screen by pressing the button on the side command
bar, the system will show the following screen;
Fig. 4-59
10. Input the parameters for the test, the mandatory ones on the screen will remain in red
text until a valid value has been entered; on machines equipped with the single wheel
lifting device code 77-PV3UP10, it will be possible to test one sample only, and
therefore the relevant SAMPLE # can be disabled, while for the other machines it is
mandatory to perform the test on two samples (both SAMPLE 1 and SAMPLE 2
must be ticked); as far as the “common” test parameters (right-hand part of the
screen), it is possible to load one of the stored procedures, by pressing the button
OPEN PROCEDURES and selecting from the list; for full details on the available
fields, refer to chapter 4.1.5;
Fig. 4-60
28.06.2013 98 Rev.3 EN
11. Once ready, press the button on the side command bar to start the test, the
following actions will take place:
a. The thermoregulation will continue until reaching the TEST TEMPERATURE
set,
b. Once the TEST TEMPERATURE is reached, if the DELAYED START time
was entered it is counted down, otherwise proceed right away with next step;
c. The machine will start a countdown of 1 minute to make sure the temperature is
within the proper range (popup message on the screen), then the wheels will be
lowered on the samples and the carriage will start to cycle back and forth, the
next screen will be shown during the test execution;
Fig. 4-61
12. During the test, figures of all display in the upper part of the screen will be updated
continuously; also, the graph on the screen will show the behavior of the sample
during the tests;
Fig. 4-62
Rev.3 EN 99 28/06/2013
13. During the test, it is possible to stop it by pressing the button on the side
command bar; once pressed, the system will require a confirmation before being
applied; after stopping the test, the system will save the data gathered regardless the
test has been completed or stopped by the operator;
14. If the door(s) is/are open during the test, the wheel motor will stop but the
thermoregulation will keep on working; close the door(s) and press the POWER ON
push button to activate the power circuitry (item #2 of figure in chapter 2.3), the
READY lamp will turn ON (item #1 of figure in chapter 2.3). The test will restart but
its results may be affected and need to be evaluated whether to accept them or not (in
general, the Standards do not accept the results of interrupted tests);
15. The test will proceed to and will end at the achievement of:
a. MAX.RUT DEPTH set, or
b. MAX. NUMBER OF CYCLES,
depending on the settings in the test parameters panel, whichever comes first;
16. At the end of the test, the wheel arm will be lifted up and the thermoregulation
turned OFF. In case the machine is equipped with the independent lifting device for
the wheels, if the end test criteria are reached on one of the two samples, the relevant
wheel will be lifted up independently and the test will proceed on the other sample
up to the achievement of the end test criteria;
17. After the end of the test, it is possible to perform the data processing (refer to chapter
4.1.7.2).
28.06.2013 100 Rev.3 EN

4.6 Stopping the machine via the emergency button

In case dangerous conditions are encountered during the execution of the process, it is
possible to stop the machine by pressing the EMERGENCY BUTTON. The machine is
equipped with two EMERGENCY BUTTONS, one per side.
EMERGENCY BUTTON
Fig. 4-63
Activation of the EMERGENCY BUTTON deactivates the power circuitry of the

machine thus disabling the movement of the wheel arms, the heating resistors (both air
and water depending on the model), water pump and air circulation motor.
The communication with the PC remains active.
The tests in progress and the samples are lost.
After clearing the reason for the emergency, release the button by turning it clockwise
and press the POWER ON push button to re-activate the power circuitry (item #2 of
figure in chapter 2.3 of the present manual).
Rev.3 EN 101 28/06/2013

4.7 Switching OFF the machine

At the end of the test session check that:
• The wheel arm returned to the upper position;
• The wheels are not in contact with the sample or with any other part of the
equipment;
Remove the sample moulds and clean the test chamber from the residuals of the test just
carried out.
If the machine will not be used for more than a couple of days, drain the water from the
test chamber (connect a tube to the water OUT fitting and open the drain valve; valve and
fitting are located on the left-hand panel of the machine).
Water drain valve Water OUT fitting
Fig. 4-64
De-activate the equipment by acting on its mains switch.
MAINS SWITCH
Fig. 4-65
28.06.2013 102 Rev.3 EN

5. MAINTENANCE
As with all electrical equipment, this unit must be used correctly and maintenance and
inspections must be performed at regular intervals. Such precautions will guarantee the
safe and efficient functioning of the equipment.
Periodic maintenance consists of inspections made directly by the test operator and/or by
the authorized service personnel.
Maintenance to the equipment is responsibility of the purchaser and must be performed as
stated by this chapter.
WARNING:
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
at least 5 minutes.
WARNING:
WARNING:
tools/keys. These tools and keys are for the use of maintenance people only. Never leave
them attached to the unit as this may endanger operator safety.
and locked.
WARNING:
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 electronic compartment
of the device, as this could cause short circuits. Before cleaning the device, disconnect it
from the mains line.
Rev.3 EN 103 28/06/2013

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
With the machine at ambient Operator Before every working session
temperature, use a vacuum cleaner
to remove sample residuals, making
sure not to damage the
internal devices of the chamber, the
temperature sensors, the
linear transducer and the level
sensor of the water.
With the machine at ambient Operator Before every working session
temperature, check that the wheels
rotate freely and position them in
order that, in the time, the wear
of the rubber will be evenly
distributed.
General inspection Operator Weekly
Check status and functioning of the Operator Weekly
safety devices (safety
switches on the doors, emergency
button, mains switch), the
operator's command and command
lights
Check that all label and rating Operator Weekly
plates are intact and properly
Attached
28.06.2013 104 Rev.3 EN

5.2 Authorised 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

Lubrication and checking of the Authorised service Yearly or more frequently
tensioning of the wheel arm crank engineer depending on the workload
chain (see chapter 5.2.1)
Greasing of the ball bearings of the Authorised service Yearly or more frequently
wheel arm crank shaft (see chapter engineer depending on the workload
5.2.2)
Status of the internal and external Authorised service Yearly
cables wear and tear and fastenings engineer
Grounding of all the accessible Authorised service Yearly
conductive parts engineer
Checking of displacement Authorised service Yearly or depending on the
transducers and temperature probes engineer quality system in place
calibration (refer to chapter 5.2.3)
Rev.3 EN 105 28/06/2013

5.2.1 Lubrication and checking of the tensioning of the wheel arm crank chain
To lubricate the chain of the wheel arm crank assembly, use a spry oil specific for
transmission chains.
To access the transmission chain remove the right hand side panel of the machine.
Chain
Fig. 5-1
28.06.2013 106 Rev.3 EN

5.2.2 Greasing of the ball bearings of the wheel arm crank shaft
Use a push gun to grease the ball bearings of the wheel arm crank shaft, through the
relevant nipples. Use silicon grease.
To access the ball bearings remove the right hand side panel of the machine.
Nipple
Nipple
Fig. 5-2
Rev.3 EN 107 28/06/2013

5.2.3 CALIBRATION screen
The CALIBRATION screen is displayed after pressing the button on the side
Fig. 5-3
In the calibration screen it is possible to review (default status) or to modify (password

protected, reserve to CONTROLS authorized technical personnel) the calibration of the
transducers of the machine (temperature probes, displacement transducers).
WARNING:
Accessing to the CALIBRATION-MOFIFICATION screen is allowed to CONTROLS
The following buttons are available in the review mode (default one):
28.06.2013 108 Rev.3 EN

Press this button to access the CALIBRATION-

MODIFICATION mode; a password is requested to proceed.
SELECT TRANSDUCER Pulldown menu, to select the transducer to review/calibrate.
To print a report of the present calibration.
To export the present calibration in a CSV file.

To create a backup file of the calibration of the selected
transducer. This file can be used to import the calibration into the
unit, through the button , not active in

the review mode.
To return to the SETTINGS menu bar.
The central area of the screen includes:
• On the left side: Calibration table of the selected transducer with a column for the
values in bit and a column with the calibrated value in the relevant unit (it cannot be
modified in the review mode);
• In the center: Calibration graph;
• On the right side: data of the selected transducer (they cannot be modified in the
review mode).
The 2 displays show the value in bit and unit of the selected transducer. The value in unit
is subject to the calibration factor. The value can be zeroed by pressing the button
. This is a hold-release type button (when hold function is active, it becomes

highlighted in red).
In general, the units follow the selection made in the GENERAL SETTINGS screen (see
chapter 4.1.11.1).
Rev.3 EN 109 28/06/2013

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.
WARNING:
at least 5 minute.
WARNING:
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:
28.06.2013 110 Rev.3 EN

6.1 MANUAL COMMANDS screen
The MANUAL COMMANDS screen is displayed after pressing the button on the
Fig. 6-1
It allows activating/de-activating the active devices of the machine (motors, heating

resistors, etc.). A lamp beside each button indicates that the relevant command has been
given and is active.
Here follows some limitations:

• The movement commands are disabled with the doors open;
• Some commands will not take place if specific conditions are met (e.g. lowering the
wheel arm will not take place in case the arm is already fully down);
• Commands available depend on the model/type of machine (air, water, both).
Rev.3 EN 111 28/06/2013

The TRANSDUCER READING field displays the present readings of

temperature probes and displacement transducers.
The SENSOR STATUS field shows present status of microswitches and

EMERGENCY BUTTON.
It is also possible to set the SPEED to achieve with the wheel arm motor
once the relevant activation button is pressed and to read the actual speed via
its magnet sensor.
The CONNECTION STATUS lamp monitors the communication between

machine and PC (lamp ON means communication in place).
All the above functions can be used for troubleshooting purposes.
WARNING:
Therefore damages may result in case of wrong operation (e.g. activation of the WATER
program.
28.06.2013 112 Rev.3 EN

6.2 Troubleshooting
The following table provides a list of possible causes and checks in case a faulty
condition is encountered (for component identification refer to the schematics of chapter
7):
# Type of fault Action
1 The machine does not turn ON • Check the power cord;
(MAINS ON led remains OFF) • Check the external protection devices of the electrical
circuit laboratory distribution (fuses, breaker, etc.);
• Check that the MAINS SWITCH is turned ON;
• Check the status of the MAINS SWITCH 1QS1 and
replace if necessary;
• Check fuse 1QU2 and replace if necessary;
• Check +24V 2.5A power supply 1GD2 and replace if
necessary;
• Check led 2HL2 and its resistor 2R1 and replace if
necessary.
2 Pressing the POWER ON push • Check that the EMERGENCY BUTTONS are not pressed
button the power circuitry are not and release if necessary;
activated and the relevant lamp • Check that the doors are not open and close if necessary;
remains OFF • Check the EMERGENCY BUTTONS contacts 2SB1 and
2SB2 and replace if necessary;
• Check the magnetic sensor of the doors 2S1 and 2S2 and
• Press the POWER ON pushbutton 2SB3 and replace if
necessary;
• Check relay 2KA1 and replace if necessary.
3 The heating resistors do not heat • Check as per previous point #2;
up • Check relay 2KA3 and replace if necessary;
• Check fuses 7QU1, 7QU2, 7QU3 for water
thermoregulation and fuses 8QI1, 8QU2, 8QU3 for air
thermoregulation and replace if necessary;
• Check thermal switch 3S1 for water thermoregulation and
3S2 for air thermoregulation and replace if necessary;
• Check contactor 3KM1 for water thermoregulation and
3KM2 for air thermoregulation and replace if necessary;
• Check static relays 3KS1, 3KS2, 3KS3 for water
thermoregulation and 3KS4, 3KS5, 3KS6 for air
• Check heating resistors 7EH1, 7EH2 , 7EH3 for water
thermoregulation and 8EH1, 8EH2, 8EH3 for air
• Check the electronic control board and replace if necessary.
Rev.3 EN 113 28/06/2013


4 The air blower does not operate • Check as per previous point #2;
• Check fuses 9QU1, 9QU2, 9QU3 and replace if
necessary;
• Check contactor 4KM1 and replace if necessary;
• Check blower motor 9M1 and replace if necessary;
• Check the electronic control board and replace if
necessary.
5 The wheels arm motor does not • Check as per previous point #2;
operate • Check fuses 9QU4, 9QU5 and replace if necessary;
• Check that there are not mechanical jams and the
status/tensioning of the transmission chain;
• Check contactor 4KM2 and replace if necessary;
• Check replay 2KA2 and replace if necessary;
• Check motor driver 9U1 and replace if necessary;
• Check cycle counter magnetic sensor 11PC1 and replace
if necessary;
• Check the wheels arm motor 9M1 and replace if
necessary;
necessary.
6 The water does not flow into the • Check the water connection and supply;
unit • Check as per previous point #2;
• Check fuses 10QU1 and replace if necessary;
• Check status of the water level sensor 11SL1 and replace
if necessary;
• Check relay 4KA1 and replace if necessary;
• Check water electrovalve 10YV1 and replace if
necessary;
necessary.
7 The water circulation pump does • Check as per previous point #2;
not operate • Check fuses 9QU6 and replace if necessary;
• Check relay 4KA2 and replace if necessary;
• Check pump motor 9MS2 and replace if necessary;
necessary.
8 The wheel arm does not move • Check as per previous point #2;
either UP or DOWN • Check fuses 1QU3 and replace if necessary;
• Check +24V 10A power supply 1GD3 and replace if
necessary;
• Check relays 4KA3, 4KA4 and replace if necessary;
• Check the lower position magnetic sensor 11S1 and
• Check the wheel arm UP/DOWN motor 5MD2 and
necessary.
28.06.2013 114 Rev.3 EN


9 The single wheel lifting device • Check as per previous point #2;
does not operate • Check fuses 1QU3 and replace if necessary;
• Check +24V 10A power supply 1GD3 and replace if
necessary;
• Check relay 4KA5 (for wheel #1) or 4KA6 (for wheel
#2) and replace if necessary;
• Check motor 5MD2 (for wheel #1) or 5MD3 (for wheel
#2) and replace if necessary;
necessary.
10 The wheel carriage cycles are not • Check optical sensor 11SQ1 and replace if necessary;
counted • Check the electronic control board and replace if
necessary.
11 The reading of the displacement • Check for proper positioning and fixing of the
transducer(s) is not correct displacement transducer(s);
• Check displacement transducer 6RP1 (for wheel #1) or
6RP2 (for wheel #2) and replace if necessary;
necessary.
12 The machine does not • Check for proper connection of the USB cable;
communicate with the PC • Check that the software program is properly
installed/set;
necessary.
Rev.3 EN 115 28/06/2013

6.3 Carriage motor driver setting parameters

This chapter lists the parameters to be set into the motor driver assembly (component 9U1
on the electrical diagram). These may be necessary in case the motor driver needs to be
replaced.
The procedure to enter these parameters into the motor driver assembly is explained in
the relevant manual provided with the equipment.
Function Setting
01 00.5
02 00.5
03 000
04 000
05 001
06 70.0
07 20.0
08 10.0
09 06.0
10 001
11 001
12 005
13 00.0
14 000
15 00.0
16 01.5
17 08.0
18 100
19 002
20 005
21 003
22 000
23 000
24 003
25 000
26 20.0
27 30.0
28 000
29 02.3
28.06.2013 116 Rev.3 EN

7. SPARE PART
This chapter contains the list of spare parts. For each item, the following information is
provided:
• CONTROLS order code
• Item description
• Quantity in the unit
Orders for spare parts have to be addressed to CONTROLS representatives.

When ordering spare parts, please provide code number, serial number, year of
manufacture and any other useful information of the unit involved.
WARNING:
at least 5 minute.
WARNING:
them attached to the unit as this may endanger operator safety.
and locked.
WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
WARNING:
failure, components may only be replaced by using original spare parts.
NOTE:
Spare part list here after provided refer to the more equipped machine versions (WATER
and AIR testing). Single test type machine versions (only WATER or only AIR) will not
have some of the listed components.
NOTE:
The same component with its reference number are shown in different drawings of the
following pages.
Rev.3 EN 117 28/06/2013

Codice Q.tà in una

ricambio/ macchina/
Ref. Descrizione Description
Spare part Q.ty in one
code unit
1 68-PV33/R01 Sensore ottico Optical sensor 1

2 68-PV33/R02 Trasduttore di spostamento LDT LDT displacement transducer 2
3 68-PV33/R03 Riduttore Gear box 1
4 68-PV33/R04 Motore braccio ruote Wheel arm motor 1
5 68-PV33/R05 Sensore induttivo conta-cicli Cycle counter inductive sensor 1
Microswitch posizione braccio
6 68-PV33/R06 Wheel arm position microswitch 2
ruota
7 68-PV33/R07 Ruota in gomma completa Rubber wheel assy 2
7 68-PV33/R08 Ruota in acciaio Steel wheel 2
8 68-PV33/R09 Elettrovalvola ingresso acqua Water inlet electrovalve 1
9 68-PV33/R10 Martinetto braccio ruote Wheel arm jack 1
10 68-PV33/R11 Pompa acqua 50 Hz Water pump 50 Hz 1
10 68-PV33/R12 Pompa acqua 60 Hz Water pump 60 Hz 1
11 68-PV33/R13 Ventilatore Air blower 1
Resistenza riscaldamento aria
12 68-PV33/R14 Air heating resistor 1200W 3
1200W
13 68-PV33/R15 Termostato aria Air thermal switch 1
14 68-PV33/R16 Termostato acqua Water thermal switch 1
Resistenza riscaldamento acqua
15 68-PV33/R17 Water heating resistor 1500W 3
1500W
16 68-PV33/R18 Sensore di livello acqua Water level sensor 1
17 68-PV33/R19 Inverter motore Motor driver 1
18 68-PV33/R20 Relay statico Static relay 6
19 68-PV33/R21 Teleruttore Contactor 4
20 68-PV33/R22 Relay 24VDC Relay 24VDC 9
21 68-PV33/R23 Alimentatore 24VDC 4A Power supply 24VDC 4A 1
22 68-PV33/R24 Alimentatore 24VDC 10A Power supply 24VDC 10A 1
Sensore magnetico di sicurezza
23 68-PV33/R25 Door magnetic safety switch 2
porte
24 68-PV33/R26 Interruttore principale Mains switch 1
25 68-PV33/R27 Pulsante emergenza Emergency button 2
26 68-PV33/R28 Contatto normale NC NC contact 2
27 68-PV33/R29 Catena di trasmissione Transmission chain 1
28 68-PV33/R30 Scheda elettronica Electronic board 1
29 68-PV33/R31 Alimentatore 5VDC, +/-15VDC Power 5VDC, +/-15VDC 1
30 68-PV33/R32 Lampada Bulb 3
31 68-PV33/R33 Pulsante verde Green push button 1
33 68-PV33/R35 Contatto normale NA NO contact 5
34 68-PV33/R36 LED bianco White LED 1
35 68-PV33/R37 LED verde Green LED 1
28.06.2013 118 Rev.3 EN

Codice Q.tà in una

ricambio/ macchina/
Ref. Descrizione Description
Spare part Q.ty in one
code unit
36 68-PV33/R38 LED rosso Red LED 1
37 68-PV33/R39 Sensore temperatura Temperature probe 2
68-PV33/R40 Fusibile 5x20 3AT Fuse 5x20 3AT 1
See 68-PV33/R41 Fusibile 5x20 2AT Fuse 5x20 2AT 3
NOTE
68-PV33/R42 Fusibile 5x20 4AT Fuse 5x20 4AT 3
below
68-PV33/R43 Fusibile 10,3 x 38 8A Fuse 10,3 x 38 8A 6
NOTE:
For fuse identification refer to the electrical diagram of chapter 8 and labeling on the
electrical panel.
Rev.3 EN 119 28/06/2013

2
1
27
Fig. 7-1 Wheel movement carriage components
28.06.2013 120 Rev.3 EN

27
9 4
8 10
Fig. 7-2 Water thermoregulation components
Rev.3 EN 121 28/06/2013

27
13
11
12
Fig. 7-3 Air thermoregulation components
28.06.2013 122 Rev.3 EN

2 1 2
27
Fig. 7-4 Impression measuring system components
Rev.3 EN 123 28/06/2013

14
37
15
18
15
16
37
Fig. 7-5 Test chamber components
28.06.2013 124 Rev.3 EN

19
18
17
19
20
20
21
22
Fig. 7-6 Electrical panel components
Rev.3 EN 125 28/06/2013

34
30 30
35
31
30
33 36
23
25 26 33
24
28
29
Fig. 7-7 Commands and electronic components
28.06.2013 126 Rev.3 EN

8. SCHEMATICS AND DRAWINGS

1. Electrical diagram 400VAC version (11 sheets)
2. Electrical diagram 220VAC version (11 sheets)
3. Electrical panel layout
4. Electrical panel component identification
NOTE:
Schematics here after provided refer to the more equipped machine versions (WATER
and AIR testing). Single test type machine versions (only WATER or only AIR) will not
have some of the listed components.
Rev.3 EN 127 28/06/2013

Electrical diagram 400VAC version – Sheet 1 of 11
28.06.2013 128 Rev.3 EN

Rev.3 EN 129 28/06/2013

28.06.2013 130 Rev.3 EN

Rev.3 EN 131 28/06/2013

28.06.2013 132 Rev.3 EN

Rev.3 EN 133 28/06/2013

28.06.2013 134 Rev.3 EN

Rev.3 EN 135 28/06/2013

28.06.2013 136 Rev.3 EN

Rev.3 EN 137 28/06/2013

28.06.2013 138 Rev.3 EN

Rev.3 EN 139 28/06/2013

28.06.2013 140 Rev.3 EN

Rev.3 EN 141 28/06/2013

28.06.2013 142 Rev.3 EN

Rev.3 EN 143 28/06/2013

28.06.2013 144 Rev.3 EN

Rev.3 EN 145 28/06/2013

28.06.2013 146 Rev.3 EN

Rev.3 EN 147 28/06/2013

28.06.2013 148 Rev.3 EN

Rev.3 EN 149 28/06/2013

28.06.2013 150 Rev.3 EN

ELECTRICAL COMPONENTS LEGENDA
1QS1 Mains switch

1GD1 +5V,+15V,-15V power supply (for electronic board and sensors)
1GD2 +24V 2,5A power supply (commands power supply)
1GD3 +24V 10A power supply (wheel UP/DOWN power supply)
1QU1 +5V,+15V,-15V power supply fuses (2A)
1QU2 +24V 2,5A power supply fuses (2A)
1QU3 +24V 10A power supply fuses (4A)
2SB1 Emergency button #1
2SB2 Emergency button #2
2S1 Door magnetic switch #1
2S2 Door magnetic switch #2
2SB3 POWER ON push button
2KA1 POWER ON (power circuitry) relay
2KA2 Carriage movement enable relay
2KA3 Heating resistors enable relay
2SH1 TEMPERATURE CONTROL ON lamp
2HL1 HEATING STATUS lamp
2HL5 READY lamp
2R1 2HL2 led resistor
2HL2 MAINS ON led (white)
2HL3 CPU RUNNING led (green)
2HL4 WARNING led (red)
3S1 Water thermal switch
3KM1 Water heating resistor contactor
3KS1-2-3 Water heating resistor static relays
3S2 Air thermal switch
3KM2 Air heating resistor contactor
3KS4-5-6 Air heating resistor static relays
4KM1 Air blower contactor
4KM2 Emergency line contactor
4KA1 Water IN electrovalve relay
4KA2 Water pump relay
4KA3 Wheel arm UP relay
4KA4 Wheel arm DOWN relay
4KA5 Independent lifting device UP/DOWN relay for wheel 1
4KA6 Independent lifting device UP/DOWN relay for wheel 2
5MD1 Wheel arm UP/DOWN motor
5MD2 Independent lifting device UP/DOWN motor for wheel 1
5MD3 Independent lifting device UP/DOWN motor for wheel 2
6RP1 Displacement transducer wheel 1
6RP2 Displacement transducer wheel 2
Rev.3 EN 151 28/06/2013

ELECTRICAL COMPONENTS LEGENDA
7QU1-2-3 Water heating resistors fuses (8A)

7EH1-2-3 Water heating resistors
8QU1-2-3 Air heating resistors fuses (8A)
8EH1-2-3 Air heating resistors
9QU1-2-3 Air blower fuses (4A)
9M1 Air blower motor
9QU4-5 Carriage movement fuses (4A)
9U1 Carriage motor driver
9M2 Carriage motor
9QU6 Water pump motor fuse (3A)
9MS2 Water pump motor
10QU1 Water IN electrovalve fuse (1A)
10YV1 Water IN electrovalve
11SL1 Water level switch
11PC1 Cycle counter magnetic sensor
11S1 Wheel arm DOWN magnetic sensor
Wheel carriage center position optical sensor (to trigger reading of
11SQ1
the displacement transducers)
28.06.2013 152 Rev.3 EN

Notes:
Rev.3 EN 153 28/06/2013

Notes:
28.06.2013 154 Rev.3 EN

77-Wheel Tracker - Rev 3 - EN - 28 - 06 - 2013

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PAVELAB

Wet & Dry

4. USE OF THE EQUIPMENT 45

6. DIAGNOSTICS & TROUBLESHOOTING 110

7. SPARE PART 117

8. SCHEMATICS AND DRAWINGS 127

Rev.3 EN iii 28/06/2013

This Manual is published by CONTROLS.

Test in 77-PV31A05, PV31A06

Main features of the machines are:

• Meets or exceed AASHTO or EN standards depending on the model

The following models are available:

PAVELAB, UNIVERSAL AASHTO/EN DOUBLE WHEEL TRACKER

Air and Water conditioned specimens

PAVELAB, DOUBLE WHEEL TRACKER, EN VERSION

Air conditioned specimens

Air and Water conditioned specimens

PAVELAB, HAMBURG TYPE DOUBLE WHEEL TRACKER

Standard Water conditioning specimens version

Air and Water conditioned specimens version

1.1 Icons appearing in the manual

1.2 Manual revision history

Revision/Date Change description

1.3 Symbols used

Emergency stop switch

Conformity to the CE Directive

1.4 Intended use and improper use

1.5 Safety information

CONTROLS will not to be held responsible for:

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

Installation and any technical intervention must only be performed by qualified

Personnel Area with residual risks

1.6 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

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

Loaded wheel system

Wheel tracking carriage

Temperature control system

Impression measurement system

The machine stops automatically opening the protection.

Air temperature overheating protection system.

Motor protection and other standard safety applications.

Fig. 2-1 Wheel movement carriage components

Fig. 2-2 Water thermoregulation components

Fig. 2-3 Air thermoregulation components

Fig. 2-4 Impression measuring system components

Fig. 2-5 Test chamber components

2.2 Identification plate

2.3 Commands and controls

2.4 Technical specifications

Reference standard AASHTO/ EN EN AASHTO AASHTO EN

The information in this chapter is intended for authorized service-trained personnel.

3.2 Unpacking and inspection

Here follows the procedure for the unpacking of the equipment

3.2.1 How to remove the equipment from the shipping crate

Model Net weight

Follow the instructions below to remove it from the shipping crate:

2. Open the shipping crate;

3.3 Positioning of the unit and space requirements

The unit must be placed on a flat and level surface.

It is responsibility of the purchaser to provide an installation place with

Spirit level position to check leveling orthogonally

Spirit level position to check leveling parallely