Professional Documents
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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
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
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.
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.
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).
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.
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.
Symbol Description
MAINS SWITCH:
O = device not connected to the mains line
I = device connected to the mains line
EMERGENCY BUTTON
Danger noise
Dangerous voltage
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.
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.
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.
The machine is equipped with the following devices to limit the residual risks in using it:
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
18/05/2016 8 33-T361X - Rev. 2 EN
Manuale di Istruzioni COMPATTATORE PROCTOR/CBR
Instruction Manual PROCTOR/CBR COMPACTOR
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.
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.
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.
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.
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.
1.7 CE declaration
This page shows a copy of the CE declaration. The original is supplied with the
equipment as a separate document.
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)
Fig 2-2
1 5
4
Ref. Description
1 Counter display
2 Keyboard
3 EMERGENCY BUTTON
4 MAINS SWITCH
5 Mains electrical supply socket
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
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.
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.
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.
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.
The following table shows the net weight of the different models of the equipment:
Fig. 3-2
18/05/2016 22 33-T361X - Rev. 2 EN
Manuale di Istruzioni COMPATTATORE PROCTOR/CBR
Instruction Manual PROCTOR/CBR COMPACTOR
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.
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.3), check the
maximum allowed floor load before installation.
The area around the equipment must be kept free from obstacles and from
substances that may cause sliding of the personnel.
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.
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.
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.
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.
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.
Then connect the female plug of the power cord to the socket located on the rear of the
control panel.
Fig. 3-4
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.
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.
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
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
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).
Fig 4-3
Fig 4-4
Fig 4-5
Fig 4-6
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
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).
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.
6. Close the front doors (the transparent one first) and lock the handle.
Fig 4-12
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.
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
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.
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
Fig 4-18
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
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
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
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.
Fig 4-24
Select the desired option by means of the buttons and and press
to confirm.
Fig 4-25
Select the desired option by means of the buttons and and press
to confirm
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
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
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.
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
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).
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
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.
To access the SETUP menu, press and hold the button at switch ON, the
system will show the following screen.
Fig 4-36
Use the buttons and to select the desired option and the button
to access it.
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
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.
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.
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.
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.
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
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
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.
4. Run the machine for a few cycles making sure the chain is greased in all parts.
The following table lists the maintenance actions and the relevant timing:
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:
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.
6.1 Troubleshooting
The following error codes may appear on the display in case anomalous confitions are
encountered during the use of the equipment.
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
Fig. 6-2
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.
Notes:
Notes: