48-D0515/A

Aggregate
impact test machine

MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
 Aggregate impact test machine

Warning

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 permis-
sion 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 damages 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.

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Index Pag.
1. INTRODUCTION 4

2. DESCRIPTION 11

3. TECHNICAL SPECIFICATION 11

4. OPERATING INSTRUCTIONS 12

5. MAINTENANCE 14

6. OPERATOR’S PREVENTIVE MAINTENANCE 14

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1. INTRODUCTION

NOTE: The present manual is updated for the product it is sold with in order to grant an adequate reference in opera-
ting and maintaining the equipment. The manual may not reflect changes to the product not impacting service opera-
tions.

Used to determine the aggregate impact value (AIV) which provides a relative measure of the resistance of an aggregate
to sudden shock or impact. The machine is robustly designed , made from steel protected against corrosion. Fit with a
counter to check the number of blows delivered to the sample. Supplied complete with two cylindrical measures (to BS
and NF) and tamping rod.

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.

In this manual and on the equipment itself, apart from the symbols indicated on the control panel, also the following icons
are used:

Description:

Hand injury

Use Protection gloves

Use protection glasses

Use protection shoese

Conformity to the CE Directive

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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 a correct use and the warnings related to use of the equipment.

CONTROLS has 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.

Installation and any technical intervention must only be performed by qualified technicians authorized by CONTROLS.
Only the authorised personnel can remove the covers and/or have access to the components under voltage.

The operator has to be instructed on the use of the equipment and on the related safety rules.

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 for which it has been designed.
The operator has to be instructed on the use of the equipment and on the related safety rules.

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 line operators and maintenance engineers have been properly instructed
concerning the safety issues and the residual risks related to the equipment.

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Here follows a list of all WARNINGs

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:
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:
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.

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Identification plate

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.

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.

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WARNING:
Considering the weight of the equipment and the footprint 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.

The machine must be sited on a strong, level, plane surface block or floor of high-grade concrete at least 450 mm thick. Depending
on the height of the operators, it may be more convenient to lay the required depth of concrete with its top surface flush with the
floor. When casting the concrete, provision must be made for setting into it the base.
If the machine is to be floor mounted, a heavy steel plate, larger than the base may be cast into the concrete.
The base must rest steadily on this, without any rocking or need for wedging during operation.

A part from the size of the device, the following conditions must be respected:

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.

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.

The machine is supplied fully assembled and only requires checking over, mounting and lubrication. Before mounting onto the
concrete plinth, or floor, make sure that the surface is horizontal, plane and smooth.

WARNING:
When handling the machine during assembly, make sure the hammer is in a safe position: with the locking pin (fig. 1 ) securely
fixed in place.

Fig. 1

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Detail

Locking Pin rest position

Locking Pin holding hammer

Fig. 2

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Rischi ambientali e smaltimento
INFORMAZIONI AGLI UTENTI
Ai sensi dell’art. 13 del Decreto Legislativo 25
luglio 2005, n. 151"Attuazione delle Direttive
2002/95/CE, 2002/96/CE e 2003/108/CE, relative
alla riduzione dell'uso di sostanze pericolose nelle
apparecchiature elettriche ed elettroniche, nonché
allo smaltimento dei rifiuti"
Il simbolo del cassonetto barrato riportato sull’ap-
parecchiatura o sulla sua confezione indica che il
prodotto alla fine della propria vita utile deve esse-
re raccolto separatamente dagli altri rifiuti.
Pertanto, l’utente dovrà conferire l’apparecchiatu-
ra, giunta a fine vita, agli idonei centri di raccolta
differenziata dei rifiuti elettronici ed elettrotecnici,
predisposti dalle amministrazioni locali, oppure
riconsegnarla al produttore/rivenditore contro l’ac-
quisto di una nuova.
L’adeguata raccolta differenziata del rifiuto e le
successive operazioni di trattamento, recupero e
smaltimento, favoriscono la produzione di apparec-
chiature con materiali riciclati e limitano gli effetti
negativi sull’ambiente causati da una gestione
impropria.
Lo smaltimento abusivo del prodotto da parte
dell’utente comporta l’applicazione delle sanzioni
amministrative previste dalla normativa vigente.
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Aggregate impact test machine
Environmental risks and disposal
INFORMATION TO THE OWNER
OF THE EQUIPMENT
In accordance with article 13 of Decree num-
ber 151 dated 25 July 2005 “Implementation of
Directive 2002/95/CE, 2002/96/CE and 2003/108/
CE, relative to the reduction in use of dangerous
materials in electrical and electronic products and
product disposal”.
The above symbol when shown on the product or
on its packing indicates that the product must be
disposed of separately from other rubbish at the
end of its useful life.
Therefore, at the end of its useful life, the user
should dispose of the product in a suitable col-
lection point for electrical and electronic products
provided by the local authorities, or alternatively
return to the original producer in exchange for a
newly purchased product.
The correct disposal of this product and the
subsequent treatment encourages the manufacture
of products using re-cycling materials and limits
the environmental impact of the product caused by
improper disposal.
Improper disposal of the product is subject to pe-
nalties foreseen by local regulations.
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2. DESCRIPTION

This is a hand-operated impact device used to obtain the Aggregate Impact Value, which is an empirical measure of crushing
strength of aggregates (closely related to the Aggregate Crushing Value).
The machine is essentially a heavy cylindrical hammer, which is raised and allowed to fall a fixed distance, a number of
times, onto single-size aggregate, thus crushing it. The Aggregate Impact Value is calculated from the amount of fine material
produced by crushing.

3. TECHNICAL SPECIFICATION

Weight of hammer: 13,990 kg ± 10 g

Diameter of hammer: 100 mm
Depth of drop, adjustable 380 (BS) to 400 (NF) mm
Outer cup dimensions:
Ø 102 mm, H = 52 mm (NF), H = 50 (BS) mm

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4. OPERATING INSTRUCTIONS

NOTE:
Before starting a test, check that the hammer, hammer flanges, guide bars, cup recess and release mechanisms are
clean and lightly lubricated, and the hammer safely secured.

a) Preparation test portion and specimens:

Take a representative sample of aggregate and prepare it according to the specification
of BS.812:112 and NF P 18-574.

The apparatus 48-D0515/A is supplied complete with two different cups:

- the outer cup with internal diameter of 102 mm is rigidly fixed at the centre of the base
- the inner cup with internal diameter of 75 mm

The inner cup is used only for sampling purposes as described in BS.812:112
The outer cup is used for testing purposes. It is the container in which the aggregates have to be poured from
the inner cup before testing.

b) Adjustment of hammer drop:

Remove the safety bar and lower the hammer gently until it rests on the surface of the aggregate.
Mark on one of the guide rods the position of the lower edge of one of the hammer flanges.
(This can be done conveniently by taping a long strip of paper vertically onto the rod, just out of the way of the flange,
and marking with a pencil). Then slowly raise the hammer while a second operator marks on the paper the height
reached by the flange when the release mechanism operates and the hammer falls onto the aggregate.
The distance between the marks should be 380 +/- 5 mm for BS 812 or and 400 mm +/- 5 for NF P18-574. If it is
not, the discrepancy should be noted. Then loosen the locknut on the catch release rod projecting above the hammer
assembly (use a 19 mm spanner) and adjust by this amount. Retighten the locknut.
Repeat the procedure on a fresh sample of aggregate and check that the drop is within the specified limits.
Once adjusted and tightened correctly, the adjustments can be left untouched during subsequent work, except for
normal maintenance, providing regular periodic checks for height drop are made.

NOTE:
It may also be necessary to adjust the blow counter activation screw at this point. Please check that each blow results in
the counter increasing by 1. If not adjust the screw accordingly. The spring activation arm on the counter is however usually
able to compensate for this.

c) Crushing the specimens:

Set the blow-counter to zero then a fresh specimen obtained and tamped into the cup and with the machine properly
adjusted, deliver 15 hammer blows to the aggregate in the cup. Lift and secure the hammer with the safety bar, and
remove the cup.
Do not dig out the crushed aggregate, but remove by beating on the outside of the cup with a hard rubber mallet,
soft wooden block etc., and thus dislodge.

d) Test procedures
Follow the test procedures as explained in BS 812:112 for the 48-D0515 apparatus and as explained in
NF P 18 - 574 for 48 D0515/F apparatus.

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Details

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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 the responsibility of the purchaser and must be performed as stated by this chapter.
Failing to perform the recommended maintenance actions or maintenance performed by unauthorized people can void the warranty.

WARNING:
Failing to perform the recommended maintenance actions or maintenance performed by unauthorized people can void the warranty.
CONTROLS will not be responsible for maintenance and service actions performed by unauthorized people.

6. OPERATOR’S PREVENTIVE MAINTENANCE

The inspections made directly by the operator are the following:

Action Who When

Check to ensure that there is no external damage to the equipment, which Before
Operator
could jeopardise the safety of use. every working session

General inspection. Operator Weekly

Clean periodically the frame with a suitable product. Operator Weekly

Keep the machine clean, paying particular attention to the cup recess, catch
mechanism and guide rods. Check tightness of all securing nuts etc. at regular
intervals. Lubricate all moving parts, and the guide rods, with ordinary lubricating Operator Monthly
oil (grease tends to build up an abrasive sludge).

Check that all label and rating plates are intact and properly attached. Operator Monthly

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Note:

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