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33-T3612 – T3613 – T3614

Proctor/CBR ASTM
Automatic Compactor

MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni COMPATTATORE PROCTOR/CBR
Instruction Manual PROCTOR/CBR COMPACTOR

Index
1. INTRODUCTION 1
1.1 Icons appearing in the manual ............................................................................................. 3
1.2 Manual revision history ....................................................................................................... 4
1.3 Symbols used ....................................................................................................................... 5
1.4 Intended use and improper use ............................................................................................ 6
1.5 Safety information ............................................................................................................... 7
1.6 Environmental risks and disposal ...................................................................................... 13
1.7 CE declaration ................................................................................................................... 14

2. DESCRIPTION 15
2.1 Identification plate ............................................................................................................. 16
2.2 Commands and controls .................................................................................................... 17
2.3 Technical specifications..................................................................................................... 18

3. INSTALLATION 19
3.1 Shipment ............................................................................................................................ 20
3.2 Unpacking and inspection.................................................................................................. 21
3.2.1 How to remove the equipment from the shipping crate ................................................. 22
3.3 Positioning of the unit and space requirements ................................................................. 24
3.4 Electrical requirements ...................................................................................................... 26
3.5 Electrical connections ........................................................................................................ 27
3.6 Removal of the transport lock............................................................................................ 28

4. USE OF THE EQUIPMENT 29


4.1 Test specifications according to Standards ........................................................................ 30
4.1.1 ASTM Standards test specifications .............................................................................. 30
4.1.2 AASHTO Standards test specifications ......................................................................... 31
4.2 Preparing the equipment .................................................................................................... 32
4.2.1 Adjusting the rammer drop height ................................................................................. 32
4.2.2 Preparing the rammer ..................................................................................................... 34
4.2.3 Installing/replacing the rammer into the compactor....................................................... 36
4.2.4 Installing the mould into the compactor ......................................................................... 39
4.3 Switching on the equipment .............................................................................................. 42
4.4 Recovery of the rammer position ...................................................................................... 44
4.5 Selecting-running a STANDARD compaction cycle ........................................................ 46
4.6 Selecting-running a CUSTOM compaction cycle ............................................................. 50

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4.7 SETUP menu .................................................................................................................... 52


4.7.1 LANGUAGE SELECT menu ........................................................................................ 53
4.7.2 DIAGNOSTIC menu ...................................................................................................... 53
4.8 Stopping the cycle via the EMERGENCY BUTTON ........................................................ 54
4.9 Switching off the unit........................................................................................................ 55

5. MAINTENANCE 56
5.1 Operator’s preventive maintenance .................................................................................. 57
5.1.1 Checking the status of the safety devices ....................................................................... 58
5.1.2 Checking the tensioning of the driving chain ................................................................. 59
5.1.3 Greasing of the transmission chain................................................................................. 59
5.2 Authorized service engineer maintenance actions ............................................................ 60

6. DIAGNOSTICS & TROUBLESHOOTING 61


6.1 Troubleshooting ................................................................................................................ 62
6.2 DIAGNOSTIC menu ........................................................................................................ 63

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

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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 operating and maintaining the equipment.
The manual may not reflect changes to the product not impacting service operations.

The automatic compactor provides a fully automatic and uniform compaction of specified
effort, thus ensuring repeatable test results and eliminating any operator fatigue during the
tests.

Conforming to ASTM D698, ASTM D1863, ASTM D1557, AASHTO T99,


AASHTO T180, AASHTO T193, this microprocessor-controlled soil compaction
tester is designed for 4" and 6" moulds. The end of each layer compaction is indicated by
a visual and acoustic signal.

The machine is supplied complete with all relevant accessories as: 50.8 mm circular face
for 4" diameter specimen and interchangeable sector face for 6" diameter specimens, and
a rammer weights (2495/4353 g) that are easily interchangeable according to the
reference standard.

The wide control display and panel are connected with a shock absorber system and can
be tilted according to user comfort.

The software gives the possibility to program customized sequences allowing the user to
set the rotation angle from 5° to 90° with 5° steps between two subsequent blows,
granting a precise and uniform blows distribution.

The rotating base has screw clamping system for the moulds locking.

Two doors, one blind frontal and one transparent lateral, ensure comfortable access to a
wide test area ad gives free view during test running.

The automatic compactor can be supplied with noise reduction cabinet (accessories to be
ordered separately).

This is a CVI-Tech product: best value drives the innovation.

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Main features of the equipment are:

• Automatic programmable compactor to Standards ASTM and AASHTO;


• Graphic display showing test progress in real time;
• Possibility to program up to 3 user defined compaction cycles and sequences;
• Rammer with both head and weights included;
• Unique rammer lifting device to guarantee correct and long life drop height;
• All safety features as protection guards and emergency button included as standard;
• Lateral transparent panel ensures free view on the compaction evolution;
• Double doors for free access to wide test area;
• Noise reduction cabinet is available (see accessories).

Models available are:

33-T3612
Automatic Proctor/CBR compactor for 4 and 6” dia. moulds, conforming to ASTM/
AASHTO Standards. Rammer kit included. 230 V, 50 Hz, 1 ph

33-T3613
Same as above but 220V, 60Hz, 1Ph

33-T3614
Same as above but 110V, 60Hz, 1Ph

This manual refers to units equipped with firmware version 2.04 or higher.

Fig. 1-1

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.

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

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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.

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1.2 Manual revision history

Revision/Date Change description


Rev. 1 Manual release
21st September 2015
Rev. 2 Revised explanation of the settings for the CUSTOM
18th May 2016 PROCEDURES (see chapter 4.6)

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1.3 Symbols used


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

Symbol Description

MAINS SWITCH:
O = device not connected to the mains line
I = device connected to the mains line

EMERGENCY BUTTON

Danger hand injury

Danger noise

Dangerous voltage

Conformity to the CE Directive

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1.4 Intended use and improper use


The equipment allows preparing soil samples in preparation for the Proctor and CBR tests
according to the International Standards ASTM D698, ASTM D1863, ASTM
D1557, AASHTO T99, AASHTO T180, AASHTO T193.

The equipment is designed to be used by a single operator, who is in charge of


installing/removing the rammer, loading-unloading the mould with the material to be
compacted, setting the functioning parameters and starting the compaction cycle.
During normal operation the working area of the equipment is the front one accessible
after opening the door where the housing of the mould and the lifting device of the
rammer are located, and the right-hand side where the operator’s controls and the display
are located.

The operator is responsible for switching on the machine, carrying out the operations for
which the machine was designed and manufactured, switching off the machine at the end
of the test or in the case of an emergency.

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.

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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.

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.

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.

During normal use, if the operator detects irregularities or damages, he/she should
immediately inform the authorized technical personnel.

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.

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The machine is equipped with the following devices to limit the residual risks in using it:

• EMERGENCY BUTTON that allows stopping the machine in case anomalous


conditions that may jeopardize the operator safety are encountered;

EMERGENCY BUTTON

Fig. 1-2
• Front door equipped with magnetic switch, activated by a coded magnet, that stops
the motor in case the door is open.

Magnetic switch

Fig. 1-3
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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 Noise generated by the equipment during the compaction cycle. It is
mandatory the use of proper personal protection devices (e.g. ear plugs or
ear muffs).
The area of the rammer and the mould due to the weight and the height of
fall. Follow carefully the procedures described in the present manual for the
preparation and use of the machine.
Technical personnel Above listed areas
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

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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 times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.

WARNING:
Raising and moving of the equipment must be performed by people properly trained and
equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to
follow the instructions above may endanger the personnel involved.

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

WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damages to the equipment cabinet may result. This will void the warranty terms
of the equipment.

WARNING:
Do not stand under suspended loads

WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.3), check the
maximum allowed floor load before installation.

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

WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.

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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:
Wear protection gloves to avoid injures to the hands. CONTROLS will not be held
responsible for problems arisen from not following the above recommendation.

WARNING:
Compaction cycles must always be started with mould on the turntable and soil inside it.

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:
Do not activate the compaction cycle without the mould or with the mould empty as this
may represent a residual risk for the operator and cause damages to the equipment. To
simulate a compaction cycle without soil, fill the mould with a soft material (e.g. rags).
CONTROLS will not be held responsible for damages caused to property or persons due
to the misuse of the equipment.

WARNING:
Risk of injuries to the hands due to the weight and its height of drop. Carefully
follow the procedures here after provided to prepare the equipment for the use and
wear personal protection devices (e.g. protective gloves).

WARNING:
Never operate the machine with the top cover removed. CONTROLS cannot be
considered responsible in case of injures to the operator or damages to the equipment if
the above instructions are not duly followed.

WARNING:
Make sure to select a compaction cycle compatible with the mould mounted on the
turntable. E.g. mounting a 4” mould and starting a cycle for a 6” mould, the rammer head
will roughly hit the edge of the mould thus damaging it. CONTROLS will not be held
responsible for damages caused to property or persons due to the misuse of the
equipment.

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WARNING:
The equipment generates noise during the compaction cycle. It is therefore mandatory the use of
personal protection devices (e.g. ear plugs or ear muffs).

WARNING:
In case the door is open during the execution of the compaction cycle, it is mandatory to wait the
complete stop of the moving parts before accessing the area inside the door.

WARNING:
The DIAGNOSTIC menu is reserved to CONTROLS authorized service personnel. Do not access
it unless specifically instructed and authorized by CONTROLS service department. CONTROLS
will not be held responsible for damages to the equipment and injuries to the operator in case of
unauthorized accessed.

WARNING:
In case the compaction cycle has been terminated incorrectly (e.g. by pressing the EMERGENCY
BUTTON or turning OFF the unit while the compaction was in progress) perform the procedure
explained at chapter 4.4 to reposition all the moving parts in a proper manner.

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:
Refer to qualified service organization authorized by CONTROLS to carry out the maintenance
actions described in the chapter “Authorized service engineer maintenance action”. CONTROLS
has not to be held responsible for damages to the equipment and/or injuries to personnel in case the
above is not strictly followed.

WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the service
maintenance actions described in the chapter “Diagnostic and Troubleshooting”. CONTROLS has
not to be held responsible for damages to the equipment and/or injuries to personnel in case the
above is not strictly followed.

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1.6 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

The above symbol, when attached to the equipment or to the relevant packaging, indicates
that the product must be disposed of separately from other rubbish at the end of its useful
life.

Therefore, at the end of its useful life, the owner should dispose of the product in a
suitable collection point for electrical and electronic products provided by the local
authorities.

The correct disposal of this product and the subsequent treatment encourages the
manufacture of products using re-cycled materials and limits the environmental impact of
the product caused by improper disposal.

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


regulations.

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

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

7 Ref. Description
1 Control panel
8 2 Plate for drop height adjustment
3 Rammer release toggle
4 Motor transmission chain
5 Rammer
6 Mould
7 Mould locking knobs
8 Turntable
Fig 2-1 Compactor (view with doors hidden)

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2.1 Identification plate


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

Fig 2-2

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2.2 Commands and controls


This chapter describes the commands and controls of the equipment. The description of
the functions of the keyboard is provided in chapter 4.

1 5
4

Front panel Rear panel


Fig 2-3

Ref. Description
1 Counter display
2 Keyboard
3 EMERGENCY BUTTON
4 MAINS SWITCH
5 Mains electrical supply socket

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2.3 Technical specifications

Main characteristics
Product Universal Proctor/CBR automatic compactor
Manufacturer CONTROLS Cernusco s/N (MI) Italy
ASTM D698, ASTM D1863, ASTM D1557,
Reference Standads AASHTO T99, AASHTO T180, AASHTO T193
Code version 230VAC/50Hz 33-T3612
Code version 220VAC/60Hz 33-T3613
Code version 110VAC/60Hz 33-T3614
Single-phase line voltage 110/220/230 VAC +6%, -10%
Frequency 50/60 Hz
Power 650W approx.
Method of power entry Power cable
Circular 4” (50.8 mm) head and sector face for 6”
Rammer face diameter
specimen
Rammer weight Adjustable 2495/4535 g
Rammer drop Adjustable 305 and 457 mm
Blow rate 25 blows/min approx.
Machine net weight (approx.) 130 Kg
Overall dimensions (W x D x H) 460 x 460 x 1390 mm

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

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3. INSTALLATION
The instructions indicated in this chapter enable you to perform a correct installation and
interfacing in order to grant a regular operation of the equipment.
Included are initial inspection procedure, power requirements and instructions for
installing the unit.

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

CONTROLS can supply the assistance and the necessary technical advice for pre-
installation, all the pre-installation phases are at the purchaser’s charge and must be
performed complying with the indications given below.

WARNING:
When operating with the covers open/removed and the unit is attached to the mains line,
care must be taken as high voltage is present in some parts of the unit (e.g. electrical
panel). Only authorized and qualified service technicians are allowed to open /remove
covers.

WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.

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3.1 Shipment
The equipment is normally shipped in a wooden crate having the following dimensions
and gross weight depending on the model:

Minimum
Gross
Model Overall dimensions fork lift
weight
length
T651x 240 Kg 800 x 800 x 1700 mm 1200 mm

Use a proper fork lift with minimum fork length as above indicated to raise and move the
wooden crate (see figure below).

Fig. 3-1

WARNING:
Raising and moving of the equipment must be performed by people properly trained and
equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to
follow the instructions above may endanger the personnel involved.

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

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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.

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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


T361X 130 Kg approx.

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


1. Inspect shipping crate (see NOTES above);
2. Open the shipping crate;
3. Cut and remove vacuum bag (if present) to expose the equipment;
4. The equipment must only be lifted up by the eyebolt located on the top of the
machine. Do not lift it by any other part to avoid damaging the equipment (see Fig.
3-2).

Fig. 3-2
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WARNING:
If the instructions to remove the equipment from the shipping box are not carefully
followed, damages to the equipment cabinet may result. This will void the warranty terms
of the equipment.

WARNING:
Raising and moving of the equipment must be performed by people properly trained and
equipped with suitable personal protection devices (e.g. gloves, helmet, etc.). Failure to
follow the instructions above may endanger the personnel involved.

WARNING:
Do not stand under suspended loads

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

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3.3 Positioning of the unit and space requirements

WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.3), check the
maximum allowed floor load before installation.

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

The area around the equipment must be kept free from obstacles and from
substances that may cause sliding of the personnel.

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


adequate lighting.

Parts used to build the machine and electrical/electronics component are fire-proof.
It is anyway the responsibility of the owner of the equipment to make sure that the
installation place is equipped with proper fire extinguishing systems and that the
operators have been instructed on the relevant procedures.

Use a proper mean to bring the unit to the installation place.

Place the unit in its final location, taking into account the free space around the unit: the
equipment requires at least 100 cm of clearance on the front and at least 50 cm on the 3
sides for maintenance and service purposes.

Also consider that mains connection is achieved through the mains cable socket on the
rear side of the equipment cabinet.

The unit requires adequate air circulation around it to assure proper cooling of the internal
devices.

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The machine must be fixed to the floor using expandable fixing bolts (see drawings
below for drilling positions).

Fig. 3-3

To ensure that the compactor works correctly and that abnormal wear is avoided, the
machine must be perfectly vertical, this can be adjusted with metal shims placed at the
anchorage points.

The compactor can also be mounted inside a soundproof cabinet. In this


case, it is possible to remove the control unit from the compactor frame and,
thanks to the cable length, fix it outside the soundproof cabinet. The extra
cables are housed inside the machine, remove its rear panel to expose them
and cut the cable ties to extend them.

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

WARNING:
If the equipment is brought from a cold environment into a heated room, condensation on
and in the unit can constitute a danger and lead to malfunctioning of the unit when
started. Wait to connect and operate the unit until it is at room temperature.

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3.4 Electrical requirements


The next table shows the electrical specifications of the equipment:

Item Specifications
Mono phase voltage 110VAC/220/230VAC
+6%, -10%
Frequency 50Hz/60Hz
Maximum power 650 W

The equipment shall be connected to a proper earth system, the efficiency of which shall
be checked by qualified personnel. Earth shall be via the power cable, as specified above.

WARNING:
The general grounding must comply with the rules in force; a wrong quality of the
grounding could be dangerous for the operator’s safety and cause bad function of the
electrical devices.

The power supply line shall be equipped with a safety device (breaker and ground fault
switch) properly sized with respect to the electrical specifications provided above.

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3.5 Electrical connections


Connect the mains cable to a suitable single-phase socket/panel (see chapter 3.4).

Then connect the female plug of the power cord to the socket located on the rear of the
control panel.

Power cord receptacle

Fig. 3-4

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3.6 Removal of the transport lock


The rammer is shipped inside its housing hold on the bottom by a wooden piece.
To remove the wooden piece:
1. Lift a bit and hold the rammer in order to make free the wooden piece.
2. Press the elbow outward and release the rammer making sure it is hold in position
3. Remove the wooden piece.

Fig. 3-5

WARNING:
Wear protection gloves to avoid injures to the hands. CONTROLS will not be held
responsible for problems arisen from not following the above recommendation.

WARNING:
Compaction cycles must always be started with mould on the turntable and soil inside it.

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4. USE OF THE EQUIPMENT


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

WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.

WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/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:
Do not activate the compaction cycle without the mould or with the mould empty as this
may represent a residual risk for the operator and cause damages to the equipment. To
simulate a compaction cycle without soil, fill the mould with a soft material (e.g. rags).
CONTROLS will not be held responsible for damages caused to property or persons due
to the misuse of the equipment.

WARNING:
Compaction cycles must always be started with mould on the turntable and soil inside it.

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4.1 Test specifications according to Standards


The following tables shows the test details depending on the most common International
Standards. Tests are implemented into the machine according to these specifications.
Make reference to the following information when setting up the machine for a cycle.

4.1.1 ASTM Standards test specifications

Standard ASTM D698 ASTM D1557 ASTM D1883


101.6 (4 inches), 152.4 (6 101.6 (4 inches), 152.4 (6 as ASTM D698 and
Mould(s) diameter [mm]
inches) inches) ASTM D1557
2.495 4.536
as ASTM D698 and
Rammer weight [kg] (rammer head can be circular (rammer head can be
ASTM D1557
or sector) circular or sector)
Method A or Method B Method A or Method B
Procedure name to Bearing ratio at optimum
(depends on the sample (depends on the sample
Standard water content
particle size) particle size)
Mould diameter [mm] 101.6 (4 inches) 101.6 (4 inches)
Rammer weight [kg] As ASTM D698 or ASTM
2.495 circular 4.536 circular
and type D 1557 with mould dia.
Drop height [mm] 304.8 457.2 152.4 only (Method C)
Procedure Number of layers 3 5
#1 25 with possibility to
change number of blows
Blows per layer 25 25
per layer (typical values:
10, 25, 56)
Outer drop to achieve a gap Outer drop to achieve a gap
As ASTM D698 or ASTM
between rammer head and between rammer head and
Pattern D 1557 with mould dia.
mould wall of 2.5 +/-0.8mm. mould wall of 2.5 +/-0.8mm.
152.4 only (Method C)
30° rotation after each blow 30° rotation after each blow
Procedure name to Method C (with circular Method C (with circular Bearing ratio for a range
Standard rammer head) rammer head) of water contents
Mould diameter [mm] 152.4 (6 inches) 152.4 (6 inches) Use CBR mould
Rammer weight [kg]
2.495 circular 4.536 circular As ASTM D698 or ASTM
and type
D 1557 with mould dia.
Drop height [mm] 304.8 457.2
152.4 only (Method C)
Procedure Number of layers 3 5
#2 25 or 56 with possibility to
change number of blows
Blows per layer 56 56
per layer (typical values:
10, 25, 56
As ASTM D698 or ASTM
Pattern Variable drop axis Variable drop axis D 1557 with mould dia.
152.4 only (Method C)
Procedure name to Method C (with sector Method C (with sector
---
Standard rammer head) rammer head)
Mould diameter [mm] 152.4 (6 inches) 152.4 (6 inches) ---
Rammer weight [kg]
2.495, sector head 4.536, sector head ---
and type
Procedure Drop height [mm] 304.8 457.2 ---
#3 Number of layers 3 5 ---
Blows per layer 56 56 ---
Outer drop to achieve a gap Outer drop to achieve a gap
between rammer head and between rammer head and
Pattern ---
mould wall of 2.5 +/-0.8mm. mould wall of 2.5 +/-0.8mm.
30° rotation after each blow 30° rotation after each blow

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4.1.2 AASHTO Standards test specifications

Standard AASHTO T99 AASHTO T180 AASHTO T193


101.6 (4 inches) 101.6 (4 inches)
Mould(s) diameter [mm] 152.4 (6 inches)
152.4 (6 inches) 152.4 (6 inches)
2.495 (rammer head can be 4.536 (rammer head can be As AASHTO T99 and
Rammer weight [kg]
circular or sector) circular or sector) AASHTO T180
Method A or Method C Method A or Method C
Procedure name Bearing ratio at optimum
(depends on the sample (depends on the sample
to Standard water contents
particle size) particle size)
Mould diameter
101.6 (4 inches) 101.6 (4 inches)
[mm]
As AASHTO T99 and
Rammer weight
Procedure Circular Circular AASHTO T180 with 152.4
[kg] and type
#1 mould
Drop height [mm] 305 457
Number of layers 3 5
25 with possibility to
Blows per layer 25 25 change (typical values
10, 30, 56, 65)
Pattern Uniformly distributed Uniformly distributed Not defined
Method B or Method D Method B or Method D
Procedure name Bearing ratio at optimum
(depends on the sample (depends on the sample
to Standard water contents
particle size) particle size)
Mould diameter
152.4 (6 inches) 152.4 (6 inches) Use CBR mould
[mm]
Rammer weight
Procedure Circular Circular As AASHTO T99 and
[kg] and type
#2 AASHTO T180 with 152.4
Drop height [mm] 305 457
mould
Number of layers 3 5
25 with possibility to
Blows per layer 56 56 change (typical values
10, 30, 56, 65)
Pattern Uniformly distributed Uniformly distributed Not dfined
Procedure name
--- --- ---
to Standard
Mould diameter
--- --- ---
[mm]
Procedure Rammer weight
--- --- ---
#3 [kg] and type
Drop height [mm] --- --- ---
Number of layers --- --- ---
Blows per layer --- --- ---
Pattern --- --- ---

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4.2 Preparing the equipment


This chapter describes how to prepare, set and install the rammer and how to install and
fix the mould into the machine.

4.2.1 Adjusting the rammer drop height

Depending on the test (Standard) to carry out, the drop height con be: 300 mm, 305 mm,
450 mm, 457 mm.

Refer to chapter 4.1 to see the different combinations according to the test (Standard).

The drop height is determined by the position of two plates on the rammer housing bars.
The following picture shows the 4 positions indicated by 4 notches.

457 mm
450 mm

305 mm
300 mm

Fig 4-1

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Position the plates to the required drop height and tighten them through the holes that
become visible (see examples below).

Fixing holes
Fixing holes

457 mm 450 mm
Fig 4-2

Repeat the same on the other bar.

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4.2.2 Preparing the rammer

Depending on the test (Standard) to carry out, the rammer can be set for different weights
and head diameters as follows:
• Weight: 2.49, 4.53 Kg
• Head: 50.8 mm diameter for 4” mould or sector face for 6” mould.

Refer to chapter 4.1 to see the different combinations according to the test (Standard).

Aluminum mass (2.5 Kg approx. in total)

Steal mass (4.5 Kg approx. in total)

Fig 4-3

To change the mass and the head of the rammer:

1. Loosen the 4 fixing grub screws.

Fig 4-4

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2. Slide out head and mass.

Fig 4-5

3. Fit the other mass and the required head on it.

Fig 4-6

4. Once done tighten the 4 grub screws.

5. Refer to chapter Errore. L'origine riferimento non è stata trovata. to set the
different drop heights.

NOTE:
The rammer weight can be fine tuned, according to the Standard in use, adding/removing
small spheres inside the rammer.

Fig 4-7
Little spheres

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4.2.3 Installing/replacing the rammer into the compactor

WARNING:
Risk of injuries to the hands due to the weight and its height of drop. Carefully
follow the procedures here after provided to prepare the equipment for the use and
wear personal protection devices (e.g. protective gloves).

The rammer is fitted into the compactor from the top side.
1. With the unit OFF open the front doors and remove the top cover by undoing the 2
relevant fixing screws.

Fig 4-8
2. Make sure the rammer release toggle is in its inner position otherwise push it so.

Fig 4-9
3. Slide in the rammer from the top of the compactor with its rack facing towards the
back side of the rammer housing, holding it from the bottom (head).

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Fig 4-10
4. Holding the rammer from the bottom at mid height (its head should not protrude the
rammer housing), push the rammer release toggle in its outer position: this will hold
the rammer in position. If not hold, repeat this action.

Fig 4-11
5. Re-install the cover on top of the compactor.

WARNING:
Never operate the machine with the top cover removed. CONTROLS cannot be
considered responsible in case of injures to the operator or damages to the equipment if
the above instructions are not duly followed.

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6. Close the front doors (the transparent one first) and lock the handle.

Fig 4-12

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4.2.4 Installing the mould into the compactor

Depending on the test (Standard) to carry out, the mould can have 4 diameters: 100 mm,
150 mm, 4”, 6”.

Refer to chapter 4.1 to see the different combinations according to the test (Standard).

Before placing the mould on the turntable make sure the rammer has been fitted and that
it is lifted up.

1. See the thickness of the base plate of the mould in order to adjust the number of
washers of the clamping plates.

Whashers

Fig 4-13

This it to make sure the mould is properly secured to the turn table once the two
knobs are tightened.

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2. Note the centering recessed hole on the bottom of the mould base plate, to match the
screw head on the turntable.

Recessed hole

Screw head

Fig 4-14
3. Place the mould on the turntable, well centered and then tighten the 2 knobs.

Fig 4-15

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4. Check that both clamps act on the mould base and are not in touch with the turntable
(there should still be some gap).

Gap

Fig 4-16

5. The machine is now ready to perform the compaction cycle. Close both doors (first
the transparent one) and lock the handle. Refer to the next chapters to set a
compaction cycle and run it.

WARNING:
Do not activate the compaction cycle without the mould or with the mould empty as this
may represent a residual risk for the operator and cause damages to the equipment. To
simulate a compaction cycle without soil, fill the mould with a soft material (e.g. rags).
CONTROLS will not be held responsible for damages caused to property or persons due
to the misuse of the equipment.

WARNING:
Make sure to select a compaction cycle compatible with the mould mounted on the
turntable. E.g. mounting a 4” mould and starting a cycle for a 6” mould, the rammer head
will roughly hit the edge of the mould thus damaging it. CONTROLS will not be held
responsible for damages caused to property or persons due to the misuse of the
equipment.

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4.3 Switching on the equipment


1. Make sure the EMERGENCY BUTTON is released otherwise turn it clock-wise.

2. Turn the MAINS SWITCH located near the power cord socket to position I.

3. Once the unit has been turned ON, the display shows the company logo followed an
information screen with the version of the firmware installed.

MAINS SWITCH

Front panel Rear panel


Fig 4-17

Fig 4-18

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4. Afterwards the unit will ask whether the rammer is in its starting position (e.g. its
head is not touching the bottom of the mould).

Fig 4-19

5. In this case close the door and press the button, otherwise press the button

in order to home the rammer, the system will show the following screen
and the red LED will be ON.

Fig 4-20

6. This screen allows selecting the type of compaction to perform according to the
different international standards.

WARNING:
The equipment generates noise during the compaction cycle. It is therefore mandatory the
use of personal protection devices (e.g. ear plugs or ear muffs).

NOTE:
ASTM/AASHTO compactor can be easily converted to compact 100 mm dia specimens
conforming to EN using a 50 mm dia tamping face available on request and adjusting the
weight and the drop height of the hammer

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4.4 Recovery of the rammer position


In case the unit has been turned OFF when the compaction cycle wasn’t completed
correctly or the EMERGECY BUTTON has been pressed during a cycle or it is unknown
how the machine was deactivated, perform the following recovery procedure to position
all moving parts in a proper manner.

1. Make sure that:


a. The rammer is mounted on the unit
b. A 6“ mould is present on the turntable
c. The mould is filled with soil otherwise put some rags in it.

2. Make sure the EMERGENCY BUTTON is released otherwise turn it clock-wise.

3. Turn the MAINS SWITCH located near the power cord socket to position I.

4. Once the unit has been turned ON, the display shows the company logo followed an
information screen with the version of the firmware installed.

Fig 4-21

5. Afterwards the unit will ask whether the rammer is in its starting.

Fig 4-22

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6. Press the button in order to home the rammer: the system will drop the
rammer, then collect it. The following screen will be shown at the end of this
sequence and the red LED will be ON.

Fig 4-23

7. The machine is now ready to proceed with activities.

NOTE:
The above procedure has normally to be carried out in case the unit has been turned OFF
when the compaction cycle wasn’t completed correctly or the EMERGECY BUTTON
has been pressed during a cycle or it is unknown how the machine was deactivated.

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4.5 Selecting-running a STANDARD compaction cycle


The system allows setting the compaction cycle according to the most common reference
standards. Refer to chapter 4.1 for full details on the test setup. Also, rammer drop height
and weight will need to be set accordingly (see chapter 4.2).
Once selected, the compaction cycle will proceed automatically and the operator will be
instructed on the different phases with clear messages on the screen.
It is also possible to store and recall up to 6 CUSTOM PROCEDURES to be configured
and saved into the system memory by the operator (see chapter 4.6).

Fig 4-24

Select the desired option by means of the buttons and and press

to confirm.

Depending on the STANDARD selected, different PROCEDURES and mould


DIAMETERS can be selected

Fig 4-25

Select the desired option by means of the buttons and and press

to confirm

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Once the compaction cycle has been set, the system shows the following screen.

Fig 4-26

Press and hold the button to position the turntable as needed and/or the button

to continue with the test setup. A summarizing screen with all info will be
displayed.

Fig 4-27

Press button to initiate the compaction cycle; the red led will turn OFF while
the green led will turn ON.

Fig 4-28

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At the end of any layer, the machine stops running and ask the operator to add the soil
(both leds will be blinking in the meantime).

Fig 4-29

Open the door, add the soil layer in the mould, close the doors then press to re-
start.
During the compaction, it is possible to stop the running cycle by pressing the button

; the system will show the following screen, the green led will turn OFF and the
red led will turn ON.

Fig 4-30

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The same happens in case the door is open during the compaction cycle.

WARNING:
In case the door is open during the execution of the compaction cycle, it is mandatory to
wait the complete stop of the moving parts before accessing the area inside the door.

Press the button to resume the compaction. The red led will turn OFF and the
green one turn ON

At the end of the compaction cycle the rammer is homed (raised half-way with its
housing on the right side), the leds will blink and the following screen is shown.

Fig 4-31

Press the button to return to the STANDARD selection screen and proceed with
the next steps.

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4.6 Selecting-running a CUSTOM compaction cycle


In addition to the Standard compaction cycles, the system allows setting and running up
to 40 customized compaction cycles.

Select the option CUSTOM PROCEDURE on the main screen. Press the button

to access it.

Fig 4-32

Select the procedure to run and/or edit by means of the buttons and

and press to confirm.

Fig 4-33

Press to initiate the cycle according to the procedure already set (refer to the
description of the STANDARD cycle for the intermediate steps).

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Pressing the button instead, allows setting up the cycle.

Fig 4-34
Fields available are:
• LAYER NO: number of layers of the compaction cycle;
• ST: step number of the layer;
• NO: number of blows for the selected step of the layer;
• ANG: amount of rotation in degrees (minimum shift is 5 degrees).

Press to edit the first step of the layer and again to move among the

different fields, then to set the figures. Once done, press to


set up the parameters of the second step of the layer (02 will appear under the ST column,
to indicate that you are now entering the parameters of the second step of the layer) and

so on. At the end, press the button to confirm the whole cycle and store it.

Fig 4-35
Now it is possible to run the cycle as previously explained.

NOTE:
Make sure all fields of the steps after the last one set are empty.

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4.7 SETUP menu

To access the SETUP menu, press and hold the button at switch ON, the
system will show the following screen.

Fig 4-36

The SETUP menu allows to:


• LANGUAGE SELECT: allows setting the language of the messages shown on the
display
• DIAGNOSTIC: allows checking the main devices of the equipment

Use the buttons and to select the desired option and the button

to access it.

Here follows a description of the different options available.

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4.7.1 LANGUAGE SELECT menu

The following screen is shown after selecting the CHANGE HEIGHT option of the
SETUP menu.

Fig 4-37

Use the buttons and to select the desired option and the button

to confirm the selection and return to the DIAGNOSTIC menu.

Press the button to proceed and return to the MAIN MENU.

4.7.2 DIAGNOSTIC menu

Refer to chapter 6.2.

WARNING:
The DIAGNOSTIC menu is reserved to CONTROLS authorized service personnel. Do
not access it unless specifically instructed and authorized by CONTROLS service
department. CONTROLS will not be held responsible for damages to the equipment and
injuries to the operator in case of unauthorized accessed.

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4.8 Stopping the cycle via the EMERGENCY BUTTON


The control panel is fitted with an EMERGENCY BUTTON.

In case of danger for the operator or the machine itself, the EMERGENCY BUTTON
should be pressed immediately. This will turn OFF the whole equipment thus stopping
the movements.

EMERGENCY
BUTTON

Fig 4-38

After clearing the reason for the emergency situation, the EMERGENCY BUTTON can
be released by turning it clockwise and the machine will re-with the usual start up
procedure.

WARNING:
In case the door is open during the execution of the compaction cycle, it is mandatory to
wait the complete stop of the moving parts before accessing the area inside the door.

WARNING:
In case the compaction cycle has been terminated incorrectly (e.g. by pressing the
EMERGENCY BUTTON or turning OFF the unit while the compaction was in progress)
perform the procedure explained at chapter 4.4 to reposition all the moving parts in a
proper manner.

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4.9 Switching off the unit


Never turn OFF the unit while the cycle is running, let it get to the end or stop it by

pressing the button.

WARNING:
In case the compaction cycle has been terminated incorrectly (e.g. by pressing the
EMERGENCY BUTTON or turning OFF the unit while the compaction was in progress)
perform the procedure explained at chapter 4.4 to reposition all the moving parts in a
proper manner.

At the end of the working session switch the equipment OFF via the MAINS SWITCH
located on the rear side of the control panel.

MAINS SWITCH

Fig 4-39

Refer to the chapter MAINTENANCE (refer to chapter 5) for proper machine clearing
and preparation for the next working session.

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

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

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

WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.

WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/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.
After performing maintenance/repair, make sure that all covers/doors are properly closed
and locked.

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.

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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 jeopardize the safety
of use
Clean mould and turntable from Operator At the end of each working
residual of soil session
Check visually the status and the Operator Weekly
tensioning of the chain (refer to
chapter 5.1.2; if necessary, refer to
the authorized technical personnel
to carry out the necessary
adjustment)
General inspection Operator Weekly
Check status of the safety devices: Operator Weekly
EMERGENCY BUTTON, door
and relevant magnetic switch (refer
to chapter 5.1.1 for their
identification)
Check status and functioning of the Operator Weekly
operator's command
Check that all label and rating Operator Monthly
plates are intact and properly
attached
Grease the transmission chain (see Operator Monthly
chapter 5.1.3)

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5.1.1 Checking the status of the safety devices


• EMERGENCY BUTTON that allows stopping the machine in case anomalous
conditions that may jeopardize the operator safety are encountered;

EMERGENCY BUTTON

Fig. 5-1
• Front door equipped with magnetic switch, activated by a coded magnet, that stops
the motor in case the door is open.

Magnetic switch

Fig. 5-2

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5.1.2 Checking the tensioning of the driving chain

With the machine OFF and unplugged from the mains electricity supply, check the
tensioning of the chain: pressing it with a finger it should move approximately 4 to 5 mm.

Fig. 5-3

5.1.3 Greasing of the transmission chain

1. Turn OFF the machine and unplug it from the mains electricity supply.

2. Use a cloth damped with solvent to clean thoroughly the chain from residual
of soils.

3. Use a light grease for transmission chain to lubricate.

4. Run the machine for a few cycles making sure the chain is greased in all parts.

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5.2 Authorized service engineer maintenance actions


In addition to the maintenance actions performed by the operator, the performance of the
equipment is checked and, if necessary corrected, during the maintenance activities
performed by the authorized service engineer, in accordance with the indications
provided in the present manual.

The following table lists the maintenance actions and the relevant timing:

Action Who When


Status of the internal and external Authorized service Yearly
cables wear and tear and fastenings engineer
Grounding of all the accessible Authorized service Yearly
conductive parts engineer

WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the
maintenance actions described in the chapter “Authorized service engineer maintenance
action”. CONTROLS has not to be held responsible for damages to the equipment and/or
injuries to personnel in case the above is not strictly followed.

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

WARNING:
Covers/doors can only be removed/opened by maintenance people, by using relevant
tools/buttons. These tools and buttons are for the use of maintenance people only. Never
leave them attached to the unit as this may endanger operator safety. After performing
maintenance/repair, make sure that all covers/doors are properly closed and locked.

WARNING:
All safety devices must be functional at all times. Damaged protective covers or devices
must be replaced immediately. When safety components are replaced, the protective
devices are to be properly attached and tested. Any manipulation of the safety devices
endangers the operating personnel.

WARNING:
Refer to qualified service organization authorized by CONTROLS to carry out the service
maintenance actions described in the chapter “Diagnostic and Troubleshooting”.
CONTROLS has not to be held responsible for damages to the equipment and/or injuries
to personnel in case the above is not strictly followed.

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6.1 Troubleshooting
The following error codes may appear on the display in case anomalous confitions are
encountered during the use of the equipment.

Error code Actions

The cycle counter is not triggered in a given time


window. Check for possible mechanical jams, status
of the cycle counter magnetic switch, wiring inside
the machine. Refer to authorized service personnel

The turntable motor encoder is not sensing rotation in


a given time window. Check that the mould clamps
are not interfering with the rotation of the turntable.
Check for any mechanical jam, status of the turntable
motor encoder, wiring inside the machine. Refer to
authorized service personnel

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6.2 DIAGNOSTIC menu

WARNING:
The DIAGNOSTIC menu is reserved to CONTROLS authorized service personnel. Do
not access it unless specifically instructed and authorized by CONTROLS service
department. CONTROLS will not be held responsible for damages to the equipment and
injuries to the operator in case of unauthorized accessed.

The DIAGNOSTIC option is part of the SETUP menu that can be accessed by pressing

and holding the button at switch ON, the system will show the following
screen.

Fig. 6-1

Use the buttons and to select it and the button activate.

Fig. 6-2

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Use the buttons and to select the desired option and the button

activate it.

Selecting the LIFTING option and holding the button will activate the rammer
motor. The counter will be updated every complete turn, when the magnetic sensor is
triggered.

Selecting the ROTATION option and holding the button will activate the
turntable motor. The counter on the screen will be activated every 5° of rotation.

The main electronic board is equipped with LEDs that monitor the status of the different
sensors related to the counters above mentioned. These can be used for troubleshooting
purposes.

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Notes:

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Notes:

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