Manuale Di Istruzioni Instruction Manual: Automatic Control Console Compression Machine

2009 Series
Automatic Control Console

and
Compression Machine
MANUALE DI ISTRUZIONI
INSTRUCTION MANUAL
Manuale di Istruzioni AUTOMAX 5
Instruction Manual AUTOMAX 5
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 Safety information ............................................................................................................... 6
1.5 Environmental risks and disposal ...................................................................................... 15
2. DESCRIPTION 16
2.1 Frame ................................................................................................................................. 19
2.2 Compression platens and ball seating ................................................................................ 19
2.3 Loading cylinder assembly ................................................................................................ 19
2.4 Hydraulic unit .................................................................................................................... 19
2.5 Command and control unit ................................................................................................ 20
2.6 System block diagram........................................................................................................ 22
2.7 Connections ....................................................................................................................... 23
2.8 Identification plate ............................................................................................................. 24
2.9 Commands and controls .................................................................................................... 25
2.10 Technical specifications..................................................................................................... 26
3. INSTALLATION 29
3.1 Shipment ............................................................................................................................ 30
3.2 Unpacking and inspection.................................................................................................. 31
3.2.1 How to remove the equipment from the shipping crate ................................................. 32
3.3 Positioning of the unit and space requirements ................................................................. 34
3.4 Positioning of the display .................................................................................................. 36
3.5 Electrical requirements ...................................................................................................... 38
3.6 Electrical connections ........................................................................................................ 39
3.7 Connection of a second frame to an existing AUTOMAX compression machine ............ 41
3.7.1 Hydraulic connections.................................................................................................... 41
3.7.2 Electrical connections .................................................................................................... 43
3.8 Connection of the frame(s) to a stand-alone AUTOMAX console ................................... 45
3.8.1 Hydraulic connections.................................................................................................... 45
3.8.2 Electrical connections .................................................................................................... 48
3.9 Bleeding of the hydraulic circuit ....................................................................................... 50
Automax 5 Rev. 3 EN i 09/12/2009

Manuale di Istruzione AUTOMAX 5
4. USE OF THE EQUIPMENT 51

4.1 Switching on the equipment.............................................................................................. 52
4.2 Main menu ........................................................................................................................ 53
4.2.1 TEST RUN screen .......................................................................................................... 54
4.2.1.1 SPECIMEN DATA database ......................................................................................... 58
4.2.1.2 TEST RUN screen .......................................................................................................... 59
4.2.2 FILE MANAGER (TEST ARCHIVE) screen ............................................................... 64
4.2.3 OPTIONS menu ............................................................................................................. 66
4.2.3.1 SELECT LANGUAGE option ....................................................................................... 66
4.2.3.2 OPERATOR NAME screen ........................................................................................... 67
4.2.3.3 DATE AND TIME screen .............................................................................................. 68
4.2.3.4 TEST OPTION screen ................................................................................................... 69
4.2.4 MANUAL COMMANDS menu .................................................................................... 71
4.2.4.1 CALIBRATION menu ................................................................................................... 72
4.3 Serial port .......................................................................................................................... 73
4.3.1 Serial port setting for printer .......................................................................................... 73
4.3.2 Serial port setting for PC connection.............................................................................. 73
4.3.2.1 Use of the Hyper Terminal program .............................................................................. 74
4.3.3 USB port......................................................................................................................... 74
4.4 Carry out a test .................................................................................................................. 75
4.5 Stopping the cycle via the Emergency button ................................................................... 81
4.6 Switching off the unit........................................................................................................ 82
5. MAINTENANCE 83
5.1 Operator’s preventive maintenance .................................................................................. 85
5.1.1 Checking the status of the safety devices ....................................................................... 86
5.1.2 Checking the oil level in the tank ................................................................................... 88
5.2 Authorized service engineer maintenance actions ............................................................ 89
5.2.1 Checking the centering of the ram assembly .................................................................. 90
5.2.2 Checking the hydraulic circuit ....................................................................................... 92
5.2.3 Checking the status of distance pieces ........................................................................... 94
5.2.4 Performing the maintenance of the spherical seat .......................................................... 95
5.2.5 Checking the calibration of the load channel ................................................................. 96
5.2.5.1 Calibration verification................................................................................................... 98
5.2.5.2 Adjustment of the electronic offset .............................................................................. 100
5.2.5.3 Calibration .................................................................................................................... 101
5.2.5.3.1 Example of calibration with one coefficient................................................................. 105
5.2.5.3.2 Example of calibration with more than one coefficient................................................ 106
5.2.6 Checking the stability of the frame .............................................................................. 107
5.2.7 Replacing the oil of the hydraulic circuit ..................................................................... 109
09/12/2009 ii Automax 5 Rev.3 EN

6. DIAGNOSTICS & TROUBLESHOOTING 111

6.1 System (Hidden) menu .................................................................................................... 112
6.1.1 ADC CHANNELS SETTINGS option ........................................................................ 114
6.1.2 SERIAL NUMBER option .......................................................................................... 116
6.1.3 PID SET UP option ...................................................................................................... 117
6.1.4 MEMORY RESET option ........................................................................................... 122
6.2 Troubleshooting ............................................................................................................... 123
7. SPARE PARTS 130
8. SCHEMATICS AND DRAWINGS 137
Automax 5 Rev. 3 EN iii 09/12/2009

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
09/12/2009 iv Automax 5 Rev.3 EN

1. INTRODUCTION
NOTE:
* The present manual is updated for the product it is sold with in order to grant an adequate
reference in operating and maintaining the equipment.
The manual may not reflect changes to the product not impacting service operations.
The AUTOMAX 5 automatic compression testers represent a more sophisticated and

advanced evolution of the usual compression testers.
It features a complete automatic test cycle with closed loop digital feedback.
Once the specimen parameters have been introduced, it is sufficient to press the "Start"
button to complete the test.
The machine can be fitted with block testing platens.
Main features are:

o Automatic test cycle
o Class 1 machines starting from 10% of the full scale or from 1% of full scale as an
option
o Load/time plot and actual load rate displayed in real time
o Accurate load rate control
o High test throughput, up to about 30 tests per hour
o Connectable to a second frame
o Data download to PC
The system is mainly composed by:

o Compression/flexure frames with accessories and loading cylinder assembly (see
relevant documentation)
o Hydraulic unit
o Command and control unit with channels input for load sensors and touch screen
graphical display.
The machine must be completed with suitable distance pieces conforming to the
specimen size.
Front and rear transparent guards protect the operator from the fragments that may be
ejected by the sample under test.
The front fragment guard can be equipped with a switch that cuts off the power to the
motor when the door is open (optional device).
The hydraulic unit provides the oil to supply to load ram assembly that compresses the
sample being tested. The hydraulic unit can be fitted with a distribution block for
connection of a second frame (optional to be factory fitted); the additional frame cannot
be simultaneously controlled while the first frame is operated.
The control unit is located above the hydraulic unit and controls the functioning of the
whole equipment via a touch screen monochromatic display.
During the test phase, the user is guided by a series of messages which appear on the
display of the control panel.
Automax 5 Rev. 3 EN 1 09/12/2009

The system automatically applies the correct load rate conforming to the information
introduced via the control panel. The load rate value is continuously monitored and can
be printed in the test report when connected to PC to certify the correct load rate
application.
The device must be used in compliance with the procedures described in this manual.
Never use the device for purposes different from those herewith indicated.
This manual is applicable for units having firmware version equal to/higher than V1.12
and equipped with the emergency button.
Fig. 1-1
Please read this manual thoroughly before you start using the equipment.
NOTE:
* This manual concerns all available AUTOMAX versions, including the versions with
integrated compression frame, the versions with separate compression frame and the
stand-alone control console.
However detailed information relative to the compression/flexural frames are provided by
their relevant manuals.
09/12/2009 2 Automax 5 Rev.3 EN

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.
Automax 5 Rev. 3 EN 3 09/12/2009

1.2 Manual revision history

Revision/Date Change description
Rev. 1 New manual version release
14 April 2009
Rev. 2 • Revised description of the serial port setting for PC
07 September 2009 and printer connection;
• Typing mistakes
Rev. 3 • Implemented the emergency button;
09 December 2009 • Typing mistakes
09/12/2009 4 Automax 5 Rev.3 EN

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
Dangerous voltage
Hand injury
Conformity to the CE Directive
Automax 5 Rev. 3 EN 5 09/12/2009

1.4 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
Installation and any technical intervention must only be performed by qualified

technicians authorized by CONTROLS.
Only authorised personnel can remove the covers and/or have access to the
components under voltage.
The unit is designed to be operated by one operator that has to install the necessary
distance pieces, load-unload the sample and start the test.
The operator has to be instructed on the use of the equipment and on the related
safety rules.
During normal operation the working area of the equipment is its front part where
the operator’s controls and the display are located.
The operator is responsible of starting-up the equipment, performing the test

sequence, shutting down the equipment and eventually stopping it in case any
emergency conditions are met.
The device must be used in compliance with the procedures described in this
manual. Never use the device for purposes different from those herewith indicated
for which it has been designed.
During normal use, if the operator detects irregularities or damages, he/she should
immediately inform the authorized technical personnel.
Maintenance and service activities can only be performed by skilled authorized

technical personnel that have been properly trained on the residual risks of the
equipment.
It is responsibility of the purchaser to make sure that the operators have been
properly instructed concerning the safety issues and the residual risks related to the
equipment.
09/12/2009 6 Automax 5 Rev.3 EN

The machine is equipped with the following devices to limit the residual risks in using it:
• Max. pressure valve to avoid machine overloading.
Max pressure valve
Fig. 1-2
• Ram travel switch to prevent the excessive piston travel; when triggered it disables
the functioning of the pump motor.
Limit switch
Fig. 1-3
Automax 5 Rev. 3 EN 7 09/12/2009

• Front and rear transparent fragment guard

• Emergency button
Front fragment guard
Emergency button
Fig. 1-4
• Access panels to internal devices fixed with screws.
09/12/2009 8 Automax 5 Rev.3 EN

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 The sample during load-unloading phase into the unit, due to its weight and
sharp surfaces. Use suitable personal protection devices (e.g. gloves,
protective shoes, etc.).
The distance pieces and platens during the installation phase, due to their
weight. Use suitable personal protection devices (e.g. gloves, protective
shoes, etc.).
The area around the frame during the execution of the test, in case of test on
explosive samples and with the front and rear fragment guards not in place
The gap between the sample and the upper platen during the compression
phase, although the maximum speed is very low (max. 40mm/min)
Technical personnel Above listed areas
Area around the hydraulic tubes, due to the high pressure of the oil, in case
the tubes are damaged or not properly attached
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
Automax 5 Rev. 3 EN 9 09/12/2009

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 2.10), check the
maximum allowed floor load before installation.
09/12/2009 10 Automax 5 Rev.3 EN

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:
Due to the high pressure inside the hydraulic circuit (up to 700 bars) only tubes approved
by CONTROLS can be used. CONTROLS will not be responsible for damages to the
equipment or personnel injures in case of use of improper material and/or operations not
carried out by authorized technical 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:
If the START TEST PARAMETER value is not properly set, it will cause improper
functioning of the machine (e.g. if the value is too high the machine will not be able to
sense the failure of the sample and therefore will continue compressing the sample and
never stop).
This may result in damages to the equipment and/or danger for the operator. CONTROLS
will not be considered responsible in these events.
Automax 5 Rev. 3 EN 11 09/12/2009

WARNING:
The MANUAL COMMANDS menu is reserved to the authorised service personnel.
CONTROLS will not be responsible for any damage caused by improper setting of these
parameters. Warranty will be void if this menu is used by unauthorised personnel.
WARNING:
The INTERPOLATION menu is reserved to the authorised service personnel and should
only be entered when the calibration needs to be changed. CONTROLS will not be
responsible for any damage caused by improper setting of these parameters. Warranty
will be void if this menu is used by unauthorised personnel.
WARNING:
Be careful and use proper personal protection devices (e.g. gloves, protective shoes)
while loading/unloading samples from the test frame, due to the sample weight and sharp
surfaces.
WARNING:
while handling distance pieces and platens due to their weight.
WARNING:
Always close the front door and place the rear guard while executing the tests. Also use
proper personal protection devices (e.g. glasses) in order to avoid injures due to fragments
of samples ejected during the test (e.g. in case of test on explosive samples ).
WARNING:
Although the maximum speed of the loading piston is very low (max. 40mm/min), to
avoid injures during the compression phase, always close the front door and place the rear
guard while executing the tests. Also avoid putting hands/fingers in the gap between the
sample and the upper platen.
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.
09/12/2009 12 Automax 5 Rev.3 EN

WARNING:
Before opening/removing the covers, disconnect the mains supply to the device and wait
at least 5 minutes.
WARNING:
For continued fire protection, replace fuses with same type and rating. Also, in case of
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
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:
To avoid direct contact with the oil of the hydraulic circuit, always wear protective gloves
while performing the checking.
WARNING:
Risk of electrical shocks inside the unit. Do not touch any other components with
screwdriver and/or unprotected hands.
WARNING:
The INTERPOLATION menu should only be entered when the calibration needs to be
changed. Do not enter into this menu for any other reason. Before entering the
INTERPOLATION menu it is vital to carefully read and understand the procedure
described hereunder. If any doubts remain, contact CONTROLS service department for
further clarification.
CONTROLS will accept no responsibility for any inconvenience caused by wrongful
calibration.
Automax 5 Rev. 3 EN 13 09/12/2009

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.
WARNING:
Do not use the GENERAL MEMORY RESET function unless authorized by
CONTROLS Service department.. CONTROLS will not be held responsible for damages
to the equipment and/or injuries to personnel in case the above is not strictly followed.
WARNING:
at least 5 minute.
09/12/2009 14 Automax 5 Rev.3 EN

1.5 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.
Automax 5 Rev. 3 EN 15 09/12/2009

2. DESCRIPTION
Refer to the following figures for main components identification.
1
8
2
9
3
10
4
Fig. 2-1 AUTOMAX 5 C465X, C565X versions with integrated compression frame
Rif Description
1 Upper platen with spherical seat
2 Sample
3 Lower platen
4 Distance pieces
5 Front guard
6 Piston travel indicator
7 Control unit with touch screen display
8 Emergency button
9 “Power ON” lamp
10 Hydraulic unit
09/12/2009 16 Automax 5 Rev.3 EN

5
2
3 7
Fig. 2-2 AUTOMAX 5 C665X version with separate 4000KN compression frame
Rif Description
1 Upper platen with spherical seat
2 Front guard
3 Lower platen
4 Piston travel indicator
6 Emergency button
8 Hydraulic unit
Automax 5 Rev. 3 EN 17 09/12/2009

Fig. 2-3 AUTOMAX 5 C505X stand-alone control console
Rif Description
2 Emergency button
4 Hydraulic unit
09/12/2009 18 Automax 5 Rev.3 EN

NOTE:
* This manual concerns all available AUTOMAX versions, including the versions with
integrated compression frames, the versions with separate compression frame and the
stand-alone control console.
However detailed information relative to the compression/flexural frames are provided by
the relevant manuals.
2.1 Frame
Made of welded steel.
2.2 Compression platens and ball seating

The two compression platens are hardened and rectified.
The upper platen is fitted to a ball seating, the lower platen has marks to allow the exact
centring of samples.
2.3 Loading cylinder assembly

Made of special steel. The ram is surface hardened, rectified and lapped. The maximum
travel of the ram is indicated on the appropriate indicator. A micro-switch avoids the
expulsion of the ram in the case of incorrect use.
2.4 Hydraulic unit

The hydraulic unit consists of:
o Tank
o pump
o motor
o valve
o distribution block.
Before describing the single components of the machine, the following definitions should
be noted:
o Useful oil volume: is the volume of oil that can be managed by the AUTOMAX
o Working oil volume: is the volume of oil required by the ram to execute the full
stroke.
The tank contains sufficient oil to feed the ram during the test. It is dimensioned to feed
all the test frames produced by CONTROLS with a capacity up to 3000 kN (standard oil
tank) or 5000 kN (bigger oil tank); in all these cases the useful oil volume of the
AUTOMAX is more than the working oil volume of the test frame.
NOTE:
* The hydraulic unit is compatible with rams of test frames manufactured by CONTROLS
up to 3000 kN (standard oil tank) or 5000 kN (bigger oil tank). Before connecting frames
of higher capacity or made by other manufacturers, ensure that the working oil volume of
the frame to be connected is less than the useful oil volume. The usable oil volume is
given in next page. In case of doubt please refer our technical service department.
Automax 5 Rev. 3 EN 19 09/12/2009

The pump is formed by two groups: the first, centrifuge, is used to give high feed at a
low pressure for the rapid approach phase of ram travel at the beginning of the test; the
second provides a low feed rate at a high pressure during the test phase.
The motor which drives the pump is of a continuous current type and is controlled by the
electronics of the system. The variation in the feed of the oil is made via the variation of
the rotation speed of the motor.
Apart from the hold valve which is not visible and not subject to regulation, the
AUTOMAX is fitted with 2 or 3 safety valves depending on whether the unit is for 1 or 2
test frames.
The regulation of the safety valves must only be made by qualified persons.
The hydraulic unit can be fitted with a distribution block for connection and non-
simultaneous control of a second frame (e.g. flexural frame or second compression
frame). The second frame option is an upgrade that must be installed in the factory by
ordering the relevant upgrade kit.
Main features of the Hydraulic unit are:

o Dual stage pump
o Centrifugal low pressure high delivery stage for rapid approach and radial multi-
piston high pressure stage for test execution
o 720 W power
o 6 litres or 9 litres (depending on the tank capacity; the latter is used in combination
with the 4000kN frame) oil capacity
o 4.0 litres or 6.5 litres (depending on the tank capacity) useful oil capacity
o 50 mm ram travel
o 40 mm/min fast approach speed.
2.5 Command and control unit

It is fitted with two input channels, thus can be fitted up to two different frames (however
the second frame cannot be used simultaneously). This unit interacts with the hydraulic
unit, transmitting commands which allow the completely automatic management of the
test cycle.
The functioning is managed by the on board software organised in menus. The interface
with the operator is via a graphic display (240 x 128 pixels resolution) and a touch screen
panel.
Main hardware features are:

o Mitsubishi M32C 32 bits processor
o 1GB Disk On Module
o Battery supported clock/calendar operating also with unit switched off
o Two analogical channels for connection of two transducers (strain-gauge load cell /
pressure transducer) with 130,000 point resolution for each channel.
o RS232 serial output, 9600/38400 baud rate, for connection to serial printer or PC.
o USB host controller.
o Analogical output for management of oil feed, 65,000 point resolution.
o Relay outputs
o Graphical mono-chromatic display, 240 x 128 pixels.
o Resistive touch screen panel.
09/12/2009 20 Automax 5 Rev.3 EN

Main features of the firmware are:

o Selectable language;
o Choice of units: kN, tonne or lb;
o System clock/calendar with possibility to input time and date;
o Input of operator name;
o Input of physical conditions and size of sample with choice between several options;
o Execution of the compression or flexure and indirect tensile test completely
automatically. The load rate is controlled by the P.I.D. closed loop system;
o Simultaneous display of load, resistance and actual applied load rate;
o Possibility to simultaneously display graph of load against time, load pacer and trend
indicator which provides information in real time of the accuracy of the applied load;
o Serial port transmission in real time, during a test, of load and time values with
maximum of 10 readings per second;
o Display of load rate (eg. N/s, kg/s, Lbf/s) or stress rate (MPa/s, kg/cm2/s, psi/s);
o Internal memory capacity of up to 1000 performed tests. Each test is identified by the
following parameters: date, time, test number, operator name, type of test, type of
sample, dimensions, area, weight, curing, load and maximum resistance;
o Memory management with display of filed tests, download of data to serial printer
through dedicated port, download of data to PC through RS232 serial port, delete
single test or reset entire memory;
o Calibration function protected by password;
o Calibration made via the touch panel;
o Linearization functions to optimise the linearity of the calibration. During the
calibration it is possible to divide the measuring range into “steps” selectable at
customer’s choice (1 to 6). The AUTOMAX System processes the calibration
coefficient for each individual “step” and interpolates the values in order to obtain the
calibration curve for the system (machine frame + load sensor + reading device). It is
therefore possible to compensate eventual non-linearity so to achieve a calibration in
Class 1 starting from 1% of the full scale range;
o Setting menu of P.I.D. parameters to allow the operator to optimise the closed loop
system.
Automax 5 Rev. 3 EN 21 09/12/2009

2.6 System block diagram
Fig. 2-4
09/12/2009 22 Automax 5 Rev.3 EN

2.7 Connections
The next figure shows the position of the connectors/ports used to connect the different
modules composing the equipment and equipment itself with external devices.
8
1
9
2
5 10
Fig. 2-5
Ref. Description
1 Control unit power cable receptacle with mains switch and line fuse
2 Pressure transducer/load cell connector channel 4 (not used)
3 Pressure transducer/load cell connector channel 3 (not used)
4 Pressure transducer/load cell connector channel 2 (for second frame)
5 Pressure transducer/load cell connector channel 1
6 Power output to control unit
7 Power cable receptacle for mains line with mains switch and line fuse
8 USB port for printer connection (HP A4 printers)
9 Serial port for PC/printer connection
10 Control unit-Hydraulic unit interconnection cable connectors
Automax 5 Rev. 3 EN 23 09/12/2009

2.8 Identification plate

The identification plate is located on the rear side of the equipment, near the power cable.
Fig. 2-6
09/12/2009 24 Automax 5 Rev.3 EN

2.9 Commands and controls

This chapter describes the commands and controls of the equipment. The operator’s
interface description and the use of the keys of the control unit is provided in chapter 4.2
of the present manual.
3 Fig. 2-7
Ref. Description
1 Keyboard and display (on front side)
2 Control unit mains switch
3 Unit mains switch
Automax 5 Rev. 3 EN 25 09/12/2009

2.10 Technical specifications
Main characteristics EN versions

Product Automatic compression tester AUTOMAX 5
Manufacturer CONTROLS Cernusco s/N (MI) Italy
Product code 230VAC version 50-C4652 50-C5652 50-C6652
Product code 110VAC version 50-C4654 50-C5654 50-C6654
Capacity 2000 kN 3000 kN 4000 kN

Single-phase line voltage 110 VAC/230 VAC +6%, -10%
Frequency 50/60 Hz
Power 750 W
Method of power entry Power cable with plug
Computer connection Serial port RS232
Platen 300 mm diam. 300 mm diam. 300 x300 mm
Ram travel 50 mm
Max vertical daylight 350 mm 350 mm 520 mm
Max horizontal daylight 310 mm 370 mm 475 mm
Fast approach speed 40 mm/min approx.
Max. working pressure 650 bar
Oil output at max. pressure 0.3 l/min approx.
Oil tank capacity (approx.) 6 litres 6 litres 9 litres
Useful oil volume (approx.) 4 litres 4 litres 6.5 litres
Working oil volume (approx.) 2 litres 3 litres 4 litres
Net weight (approx.) 890 Kg 1120 Kg 1920 Kg
Overall dimensions [mm] 938x440x1410 938x485x1460 1051x485x1701
09/12/2009 26 Automax 5 Rev.3 EN

Main characteristics ASTM versions

Product Automatic compression tester AUTOMAX 5
Product code 230VAC version 50-C3752 50-C4752
Product code 110VAC version 50-C3754 50-C4754
Capacity 1500 kN 2000 kN
Frequency 50/60 Hz
Power 750 W
Platen Diameter 165mm
Ram travel 50 mm
Max vertical daylight 350 mm
Max horizontal daylight 280 mm 310 mm
Oil capacity (approx.) 6 litres
Useful oil volume (approx.) 4 litres 4 litres
Working oil volume (approx.) 1.5 litres 2 litres
Net weight (approx.) 890 Kg 890 Kg
Overall dimensions [mm] 938x440x1410 938x440x1410
Automax 5 Rev. 3 EN 27 09/12/2009

Main characteristics stand-alone control console

Product Automatic control console AUTOMAX 5
Product code 230VAC version 50-C5052
Product code 110VAC version 50-C5054
Frequency 50/60 Hz
Power 750 W
Oil capacity (approx.) 6 litres
Useful oil volume (approx.) 4 litres
Net weight (approx.) 85 Kg
Overall dimensions [mm] 360x385x1028
Environmental conditions
Operating temperature + 10 ÷ + 40°C
Operating humidity ≤ 90%RH @ 40°C
09/12/2009 28 Automax 5 Rev.3 EN

3. INSTALLATION
The instructions indicated in this chapter enable you to perform a correct installation and
interfacing in order to grant a regular operation of the equipment.
Included are initial inspection procedure, power requirements and instructions for
installing the unit.
The information in this chapter is intended for authorized service-trained personnel.
CONTROLS can supply the assistance and the necessary technical advice for pre-
installation, all the pre-installation 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:
WARNING:
Automax 5 Rev. 3 EN 29 09/12/2009

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
C465X 995Kg 1030x880x1800mm 1200mm
C465X with block testing platens 1100Kg 1030x1180x1800mm 1200mm
C565X 1250Kg 1280x880x1800mm 1400mm
C565X with block testing platens 1350Kg 1180x1180x1800mm 1400mm
C665X 2080Kg 1280x880x1800mm 1400mm
C375X 995Kg 1030x880x1800mm 1200mm
C475X 995Kg 1030x880x1800mm 1200mm
C505X 155Kg 780x780x1300mm 1200mm
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:
WARNING:
The wooden crate is high; be careful in balancing while raising it.
09/12/2009 30 Automax 5 Rev.3 EN

3.2 Unpacking and inspection

The unit was carefully checked both mechanically and electrically before shipment; it
should be inspected for any damage that may have occurred in transit.
NOTE:
* If the shipping container or packaging material is damaged, it should be kept until the unit
has been mechanically and electrically checked.
If there is mechanical damage and/or the contents are incomplete (see the shipping list),
please notify the local CONTROLS representative.
If the shipping container is damaged or shows sign of stress, notify the carrier as well as
the CONTROLS representative. Save the shipping material for carrier’s inspection. Also
take some pictures.
Here follows the procedure for the unpacking of the equipment.
Automax 5 Rev. 3 EN 31 09/12/2009

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

C465X 870 Kg approx.
C465X with block testing platens 970 Kg approx.
C565X with block testing platens 1200 Kg approx
C505X 85 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 machine must only be lifted up by the eyebolt(s) screwed in 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
09/12/2009 32 Automax 5 Rev.3 EN

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:
WARNING:
Do not stand under suspended loads
5. Before powering on the unit, check for loose connections of cables inside the
equipment.
Automax 5 Rev. 3 EN 33 09/12/2009

3.3 Positioning of the unit and space requirements
WARNING:
Considering the weight of the equipment and the footprint (see chapter 2.10), 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.
50cm
Fig. 3-3
09/12/2009 34 Automax 5 Rev.3 EN

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 as shown in fig.
below.
Fig. 3-4
Model a mm b mm c mm
C465X 923 mm 236 mm 15 mm
C565X 993 mm 296 mm 15 mm
C665X Hydraulic unit 330 mm 312 mm 12 mm
C665X 4000KN compression frame 760 mm 385 mm 13 mm
C375X 923 mm 236 mm 15 mm
C475X 923 mm 236 mm 15 mm
C505X 330 mm 312 mm 10 mm
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.
Automax 5 Rev. 3 EN 35 09/12/2009

3.4 Positioning of the display

Depending on the lighting of the laboratory and the height of the operator, it may be
necessary to adjust the positioning of the display to ensure optimum visibility.
Proceed as follows:
1. Turn the unit OFF and unplug it from the mains power;
2. Loosen the fixing knobs of the rear panel extracting them completely;
Fig. 3-5
3. Swing the panel until it is horizontal
Fig. 3-6
09/12/2009 36 Automax 5 Rev.3 EN
4. Locate the adjustment knob on the bottom of the control unit; it is possible to
orientate the display: use one hand to hold the display, the other to loosen the knob,
adjust the display and then re-tighten the knob;
Fig. 3-7
Fig. 3-8
5. Once done, close the rear panel pushing the fixing knobs until they clip into position.
Automax 5 Rev. 3 EN 37 09/12/2009

3.5 Electrical requirements

The next table shows the electrical specifications of the equipment:
Item Specifications
Mono phase voltage 230VAC / 110VAC
+6%, -10%
Frequency 50Hz/60Hz
Maximum power 750 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.
09/12/2009 38 Automax 5 Rev.3 EN

3.6 Electrical connections

Connect the mains cable to a suitable single-phase socket/panel (see chapter 3.4).
Proceed as follows:
The sockets for electrical connection are on the rear panel of the command unit, these are
for the load sensors, serial ports, auxiliary connections and mains supply fitted with filter,
delayed fuse and switch.
1. Connect the mains cable of the control unit to the relevant socket on the main unit;
2. Connect the multi-pole cable from the main unit to the 25-pin socket on the control
unit;
3. Connect the load sensor cable relative to frame 1 to the connector CH1 (channel 1). If
present, the second frame must be connected to channel 2 (CH2). Naturally, if the
system is formed with only one frame, the second channel will not be used. It is not
possible, for example, to connect only frame 2 and not frame 1.
Control unit mains cable input
Frame 1 load sensor cable
Output for Control unit mains
Equipment mains cable

and switch (main unit)
Fig. 3-9
4. Connect the printer cable, if present, to the printer connector (serial or USB
depending on the printer type);
Automax 5 Rev. 3 EN 39 09/12/2009

5. Connect the PC serial cable, if present, to the RS232 connector (for use of the serial
ports, printer and RS232 see chapter 4.3);
Control unit
power switch
(see note below)
Multi-pole PC/printer
USB port
CH1 CH2 connector serial port
for printer
from main unit
Fig. 3-10
NOTE:
* If the test frame is fitted with a safety micro-switch for ram travel, this must be connected
to the “limit switch” socket on the rear panel of the control console. This connection is set
in the factory. If this is not connected the pump will not start. (see figure below).
Limit switch
input connector
Fig. 3-11
6. Refer to chapter 4.1 to turn ON the unit.
NOTE:
* When the machine is installed for the first time, it is recommended to leave the machine
ON for at least 8 hours so as to fully charge the internal battery. In case it get discharged,
the clock on the display will be zeroed.
09/12/2009 40 Automax 5 Rev.3 EN

3.7 Connection of a second frame to an existing

AUTOMAX compression machine
If the unit is equipped with the double-output hydraulic block (code Q0005/UP1 to be
fitted in the factory), a second frame can be controlled.
WARNING:
NOTE:
* The two frames cannot be driven simultaneously by the control unit.
3.7.1 Hydraulic connections
1. With the unit OFF and unplugged from the mains, connect the flexible tube supplied
to the valve block on the main unit and tighten properly the relevant fixing nuts;
WARNING:
Second frame
connection on the
Oil level indicator valve block
Fig. 3-12
Automax 5 Rev. 3 EN 41 09/12/2009

2. After making the hydraulic connections, check the oil level in the tank via the
transparent level indicator (the oil should be max. at half of the indicator); if
necessary refill the oil tank (refer to chapter 5 of this manual);
3. If not already done in the factory (e.g. the type/capacity of the additional frame was
communicated while ordering the double output machine), the max. pressure valve
must be adjusted:
a. Locate the 2nd frame MAX. Pressure valve;
2nd frame MAX. pressure

adjustment valve
Fig. 3-13
b. Use a 6mm Allen key to remove the cap
c. Use a flat secrew driver to turn counter-clockwise the valve to reduce the
max. pressure;
d. Adjust the valve by turning the screw clockwise until it intervenes at the full
scale of the frame;
e. Turn the screw still ¼ of turn clockwise;
f. Re-install the cap.
09/12/2009 42 Automax 5 Rev.3 EN

3.7.2 Electrical connections
1. Attach the connector of the load sensor of the second frame to the socket marked
CH2 on the rear of the control unit;
CH2
Fig. 3-14
2. If the second frame is equipped with the overtravel microswitch, it must be connected
to the relevant cable inside the control unit; loosen the fixing knobs of the rear panel
extracting them completely;
Fig. 3-15
Automax 5 Rev. 3 EN 43 09/12/2009

Fig. 3-16
4. Inside the control unit, locate the cable ending with a wire jumper, remove the wire
jumper and attach the cable coming from the piston over travel microswitch of the
second frame;
Safety interconnection wire

jumper for 2nd frame
Fig. 3-17
NOTE:
* If the AUTOMAX unit is equipped with the safety switch for the front door, the cable
above described will be already used and cannot be utilized for the connection of the
overtravel microswitch of the second frame.
5. Before using the additional frame, activate the second channel of the AUTOMAX
(refer to chapter 6.1) and perform the calibration of its load transducer (refer to
chapter 5.2.5).
09/12/2009 44 Automax 5 Rev.3 EN

3.8 Connection of the frame(s) to a stand-alone

AUTOMAX console
The stand-alone control console can supply 1 or 2 frames (upgrade kit code Q0005/UP1
must have been fitted in the factory).
WARNING:
NOTE:
* The two frames cannot be driven simultaneously by the control unit.
3.8.1 Hydraulic connections
1. With the unit OFF and unplugged from the mains, connect the flexible tube supplied
to the valve block on the main unit and tighten properly the relevant fixing nuts;
WARNING:
First frame
connection on the
valve block
Second frame
connection on the
Oil level indicator valve block
Fig. 3-18
Automax 5 Rev. 3 EN 45 09/12/2009

2. After making the hydraulic connections, check the oil level in the tank via the
transparent level indicator (the oil should be max. at half of the indicator); if
necessary refill the oil tank (refer to chapter 5 of this manual);
3. If not already done in the factory (e.g. the type/capacity of the frame(s) was/were
communicated while ordering the console), the rapid approach valve and the max.
pressure valve(s) must be adjusted:
a. Locate the rapid approach valve
Rapid approach
adjustment valve
Fig. 3-19
b. Use a 6mm Allen key to remove the cap;
c. Use a flat screw driver to turn the adjustment screw (clockwise to increase
the rapid approach speed, counter clockwise to decrease) until obtaining
approximately a speed of 40mm/min;
d. Re-install the cap;
09/12/2009 46 Automax 5 Rev.3 EN

e. Locate the MAX. Pressure valve(s);
1st frame MAX. pressure

adjustment valve
2nd frame MAX. pressure

adjustment valve
Fig. 3-20
f. Use a 6mm Allen key to remove the cap and turn counter-clockwise the valve
to reduce the max. pressure;
g. Use a flat screw driver to adjust the valve by turning the screw clockwise
until it intervenes at the full scale of the frame;
h. Turn the screw still ¼ of turn clockwise;
i. Re-install the cap.
Automax 5 Rev. 3 EN 47 09/12/2009

3.8.2 Electrical connections
1. Attach the connector of the load sensor(s), first frame to connector CH1, second
frame to connector CH2, on the rear of the control unit;
CH1 CH2
Fig. 3-21
2. If the frame is equipped with the overtravel microswitch, it must be connected to the
relevant cable inside the control unit; loosen the fixing knobs of the rear panel
extracting them completely;
Fig. 3-22
09/12/2009 48 Automax 5 Rev.3 EN

Fig. 3-23
4. Inside the control unit, locate the cable ending with a wire jumper, remove the wire
jumper and attach the cable coming from the piston over travel microswitch of the
frame;
Safety interconnection
wire jumper
Fig. 3-24
5. Before using the frame, activate and set the channel(s) of the AUTOMAX (refer to
chapter 6.1) and perform the calibration of the load transducer (refer to chapter 5.2.5).
Automax 5 Rev. 3 EN 49 09/12/2009

3.9 Bleeding of the hydraulic circuit

Before using the machine it is recommended to bleed the hydraulic circuit to remove any
air which could cause errors in load readings, proceed as follows:
WARNING:
1. Place a sample of sufficient strength between the machine platens and run in
MANUAL COMMANDS the machine until a pressure of approximately 100 N is
reached (refer to chapter 4 for instruction on how to run the machine in manual
mode);
2. With a spanner (19 or 22 mm) loosen the connector at the base of the ram cylinder
until all air bubbles have been removed. Use a clean container to collect the
discharged oil;
Fig. 3-25
3. Repeat the above actions if necessary.
09/12/2009 50 Automax 5 Rev.3 EN

4. USE OF THE EQUIPMENT

This chapter describes the operator’s interface and the execution of a test.
WARNING:
WARNING:
tools/keys. These tools and keys are for use by maintenance personnel only. Never leave
the tools and keys attached to the unit as this may endanger operator safety.
and locked.
Automax 5 Rev. 3 EN 51 09/12/2009

4.1 Switching on the equipment

1. Once all the connections have been made correctly, switch ON the unit via the power
switch on the control unit and the mains switch on the console (main unit)
NOTE:
* The power switch on the control unit can always be left ON as the activation of the whole
equipment is controlled by the mains switch on the main unit
Control unit power switch
Console mains switch (main

unit)
Fig. 4-1
2. The display shows the CONTROLS logo for a few seconds and than the main menu
appears.
Fig. 4-2
NOTE:
* When the machine is installed for the first time, it is recommended to leave the machine
ON for at least 8 hours so as to fully charge the internal battery. In case it get discharged,
the clock on the display will be zeroed.
09/12/2009 52 Automax 5 Rev.3 EN

4.2 Main menu

The main menu offers five choices:
o TEST RUN: This menu is used to perform a test to failure. It allows the choice of
channel (1 or 2), the type of the test, the type of sample with relative description and
finally to perform the test with the acquisition and elaboration of the applied load;
o FILE MANAGER: this menu allows access to the data contained in stored files;
o OPTIONS: this menu allows the setting of date, language, measurement unit,
operator name, setting of data transmission and printer;
o MANUAL COMMANDS: this menu allows manual control of the test frames for
calibration purposes and allows access to CALIBRATION menu to be used to enter
those dedicated functions for the calibration of the instrument.
o INFO: it shows a screen with general information and the version of the firmware
installed on the equipment.
The system is equipped with a touch screen display that allows activating the different
functions just touching the relevant icons on the screen.
To activate the icons on the screen use the pointer provided with the equipment or a
finger. A soft touch is enough to activate the function.
NOTE:
* Hitting the screen heavily may damage it. Never use a pen or a sharp object as damage
may result. The warranty will be void in case the screen is damaged due to improper use.
Touch the CONTROLS icon in upper-left corner on the screen to return to

previous menu.
Touch this icon to return

to previous screen
Fig. 4-3
Below the options present in the MAIN MENU are described in detail.
The CALIBRATION menu is described in chapter 5.2.5.
Automax 5 Rev. 3 EN 53 09/12/2009

4.2.1 TEST RUN screen
On the main menu press on the icon to activate the TEST RUN menu; the
following screen will appear:
Fig. 4-4
The SPECIMEN DATA screen allows the input of descriptive and dimensional
characteristics of the sample, the selection of the channel to use during the test and the
input of the test parameters.
The input data is used by the AUTOMAX 5 system in the management of the test. It is
important to input the exact data with regards to the dimensions of the sample and load
rate; this data also forms part of the test parameters which will be saved along with the
test results.
Touch on the area of the parameter to modify (the relevant field will be highlighted), use
the buttons and or touch several times the desired field to set the
parameters, use the buttons and to move among the different digits of the
alphanumeric fields.
The system allows defining up to 10 profiles of specimen for quick recall.
Each profile is associated to a number (T1 - T10) identified on the screen by the field
.
At switch ON, the system shows the last profile (TXX) used.
See chapter 4.2.1.1 for details on how to set and re-call profiles of the SPECIMEN
DATA database.
09/12/2009 54 Automax 5 Rev.3 EN

List of input parameters:
o NO TEST: a numerical value which can be between 0 and 65535;

o ID: is an alpha-numerical identification code made up of 10 characters. During input
use the right-left buttons to move the cursor and the up-down buttons to select the
characters;
o TEST TYPE: three test types are available for each active channel
(COMPRESSION, FLEXURE and INDIRECT TENSILE);
o SAMPLE TYPE: it is differentiated according to the test type selected. For
COMPRESSION tests: CUBE, CYLINDER, BLOCK or other type; for FLEXURE
test: BEAM, KERB, SLAB or other type; for INDIRECT TENSILE test:
CONCRETE, PAVER BLOCK or other type;
o SAMPLE DIMENSIONS (A, B, C): size of the sample;
o AREA: is calculated automatically and cannot be modified unless “other type” of
sample is selected;
o PEAK (Peak sensitivity): the peak sensitivity value, expressed in engineering units, is
a value corresponding to a decrease in load upon which the instrument, during a test,
considers the sample as failed and hence stops the test. The suggested values are 10 to
30 kN for compression tests on concrete, 1 to 3 kN for flexure tests on concrete or
compression tests on cement, 0.1 to 0.3 kN for flexure test on cement. As a general
rule the value must be proportional to the failure load and lower than the failure load
otherwise the machine will not stop automatically upon sample failure;
o WEIGHT: this is a numerical descriptive parameter. It can have a value between 0
and 299999;
o AGE: this is a numerical descriptive value which can be between 0 and 999. The
measurement unit can be selected between hours and days;
o TEST SPEED: this is the load gradient to be applied during the test. The units can be
selected between MPa/s and N/s (or kg/cm²*s and kg/s, psi/s and lbf/s);
For FLEXURE tests only, two extra data are added:

o DISTANCE “L” between the lower bearers;
o METHOD OF LOADING, with selection between, two point loading or central
loading depending of the number of upper bearers being used.
For in DIRECT TENSILE tests and compression tests on blocks, two extra data are
added:
o COEFFICIENTS K1 AND K2, these are explained below.
Automax 5 Rev. 3 EN 55 09/12/2009

Formulas used for COMPRESSION tests:

o CUBE AREA: side a, side b, side c. AUTOMAX 5 calculates the area using the
formula: area= a X b. The specific load is calculated by the formula F / A (F is the
load, A is the sample area);
o CYLINDER AREA: diameter d, height h. AUTOMAX 5 calculates the area using
the formula: area = (d/2)2 * π. The specific load is calculated by the formula F / A
(F is the load, A is the sample area);
o BLOCK AREA: side d, side b. AUTOMAX 5 calculates the area using the formula:
area= d X b. The specific load is calculated by the formula F / A (F is the load, A is
the sample area). Also the nominal resistance is calculated by the formula F / A * K1
* K2 (K1 and K2 input by the user);
o OTHER TYPE AREA: direct input of area value (or equivalent area value).
Formulas used for FLEXURE tests:

o SAMPLE AREA: base b, height h, length l, distance between lower bearers L, two
upper bearers. AUTOMAX 5 calculates the equivalent area using the formula (b * h²)
/ L. I The specific load is calculated by the formula F / A (F is the load, A is the
equivalent sample area);
o SAMPLE AREA: base b, height h, length l, distance between lower bearers L, one
upper bearer. AUTOMAX 5 calculates the equivalent area using the formula (2 * b *
h²) / 3 * L. The specific load is calculated by the formula F / A (F is the load, A is the
equivalent sample area);
o OTHER TYPE AREA: direct input of equivalent sample area.
Formulas used for INDIRECT TENSILE tests:

o CONCRETE SAMPLE AREA: side L, side d. AUTOMAX 5 calculates the area
using the formula: area= L X d. The specific load is calculated by the formula F / A *
K2 (F is the load, A is the sample area, K2 is input by the user). To perform this test
the machine will use a load gradient equal to the one input multiplied by K1;
o AREA PAVER BLOCK: side L, side d. AUTOMAX 5 calculates the area using the
formula: area= L X d. The specific load is calculated by the formula F / A *K1 * K2
(F is the load, A is the sample area, K1 and K2 are input by the user);
o OTHER TYPE AREA: direct input of sample area (or equivalent area). The specific
load is calculated by the formula F / A *K1 * K2 (F is the load, A is the equivalent
sample area input by the user, K1 and K2 are input by the user).
NOTE:
* When you use an input that requires the use of the coefficients K1 and K2, during the test
the value of specific load will be given together with the character “R” which indicates
the value is a nominal value.
09/12/2009 56 Automax 5 Rev.3 EN

Once all settings are done, press the CONTROLS logo on the upper-left corner of
the screen to exit from the SPECIMEN DATA menu.
Fig. 4-5
The system will require a confirmation; pressing ACCEPT, the set parameters will be
stored in the presently selected profile (see chapter 4.2.1.1); pressing ABORT, the set
parameters will not be stored and the system reverts to the previous parameters;
Fig. 4-6
At the end of this phase the system enters the COMPRESSION screen of the selected
channel (in this case only channel 1 is available).
Fig. 4-7
Automax 5 Rev. 3 EN 57 09/12/2009

4.2.1.1 SPECIMEN DATA database
To create a new profile:
1. Access the SPECIMEN DATA screen;

2. Select the desired profile TXX (XX= from 1 to 10);
3. Set the specimen data on the screen;
4. Touch the CONTROLS logo in upper-left corner of the screen;

5. Press ACCEPT to save the settings.
To recall a saved profile:
1. Access the SPECIMEN DATA screen;

2. Select the desired profile TXX (XX= from 1 to 10);
3. Touch any area on the screen to recall the parameters set for the selected profile;
4. Touch the CONTROLS logo in upper-left corner of the screen;

5. Press ACCEPT to save the settings.
09/12/2009 58 Automax 5 Rev.3 EN

4.2.1.2 TEST RUN screen

Once all the desired settings have been made, the AUTOMAX 5 will enter the test screen.
The type of test depends on the selection made in the previous screen (Compression,
flexure, Indirect tensile)
This is the main function of the unit, it allows the acquisition of the applied load of the
test frame and to make the relative calculations in real time.
The sequence of the operations relative to the failure testing of samples are managed
within this menu.
The following screen is shown and is made up of the following components:

2
3 11
12
4
5 13
6
14
7
8 10 9
Fig. 4-8
1. Date and Time
2. Record number (number of tests stored in the memory)
3. Specimen area
4. Applied load
5. Strength (resistance)
6. Test speed
7. Trend indicator of actual load rate with respect to theoretical load rate
8. Dimensions Y axis
9. Dimensions X axis
10. Graph Area
11. START TEST command
12. NEW TEST command
13. TEST RESULT MANAGEMENT command
14. Shortcut to SPECIMENT DESCRIPTION menu
Automax 5 Rev. 3 EN 59 09/12/2009

When the test phase is started the screen will show the message TEST IN PROGRESS.
Once the sample comes into contact with the upper platen/bearer a change in the noise
from the pump will be noted as the AUTOMAX 5 controls the load rate throughout the
test with its P.I.D. closed loop system. Once the system reaches equilibrium the noise will
remain constant.
Fig. 4-9
The test can be stopped at any time by pressing the button .
The display constantly updates the values of load and resistance in real time.
Fig. 4-10
During the execution of the test, the display of deviation of actual load rate (field 7 of
previous figure Fig. 4-8) from the theoretical load rate shows a series of symbols as
described below:
=== Actual load rate corresponds with theoretical load rate ± 1%
= Actual load rate = theoretical load rate ± 1...10%
– Actual load rate = theoretical load rate - 10%
–– Actual load rate = theoretical load rate – 10…25%
––– Actual load rate = theoretical load rate by more than – 25%
+ Actual load rate = theoretical load rate + 10…15%
++ Actual load rate = theoretical load rate + 15….25%
+++ Actual load rate = theoretical load rate by more than + 25%.
09/12/2009 60 Automax 5 Rev.3 EN

In this way it is possible to follow the accuracy of the machines automatic functioning. In
normal conditions the machine can keep to the set load rate within +/- 1% apart from the
very beginning and end of the test when numerous adjustments are made. If the closed
loop action needs to be improved it is possible to alter the parameters of the P.I.D.(refer
to the service department).
The central area of the screen shows the graphical representation of load versus time.
A large part of the display is dedicated to this function allowing the operator to evaluate
the progress of the test through the load against time graph. The X axis shows the time at
the start of the test its full scale is 150 sec. The maximum possible scale is 600 sec. (10
minutes).
The Y axis shows the load. At the start of the test its full scale is 50% of the capacity of
the frame.
During the test the graph is shown in real time, and the scale of the axis are optimised by
the software (autoscale function with steps of 25%).
When a sample is near the failure the noise from the pump will increase since the system
must compensate for the high sample deformation during this phase.
Upon sample failure the display shows the message TEST COMPLETED and the values
of maximum load and resistance are shown in large digits in the area of the graph as
shown below:
Fig. 4-11
At the same time the pump will stop.
Automax 5 Rev. 3 EN 61 09/12/2009

To save, print, and transmit data of the test just completed, touch the button on
the screen. The system will show the following screen
Fig. 4-12
To save the test in the memory press the button ; upon doing this you will note
that the number of saved test files will increase by one. It is possible to store up to 1000
tests, any attempt to memorize more than this number will result in the test file not being
saved.
To print a test report on a serial printer (if enabled) press the . Before doing this
check that the printer is connected to the “printer” port, it is switched ON and on line. An
example of a typical printout is given below:
AUTOMAX 5 SYSTEM
V1.XX
Serial number: 00000000
Operator : OPERATOR1
17/01/01 15:41:33
Test number: 00013
COMPRESSION CH1
Sample: CUBE
Area [ mm2]: 022500
Weight [gr]: 08238
Mat[Days: 028
Fm [ kN ]: 00311.3
Rm [N/mm2 ]: 0013.83
LR [MPa/s]: 0.500
To send the same report to a PC via the RS232 serial port press the button on the
screen.
Press the button to close this window and return to the TEST RUN screen.
09/12/2009 62 Automax 5 Rev.3 EN

To perform a new test, press the button on the screen: the graph of the previous
test will be cancelled from the display and the axis scales will return to their initial values,
the results of the previous test are cancelled and the values of load and resistance zeroed.
To change the test parameters or the sample description press the button on the
screen. Then enter in sample description menu and follow the instruction previously
provided.
When RS232 printer is not set, during the test the RS232 Serial Port continuously
transmits values of load and time (10 readings per second).
Each pair of data is transmitted so as to represent one line followed by CR (Carriage
Return).
This data can be received by a PC and subsequently elaborated to obtain, for example, a
graph of load against time. See chapter 4.3 for more information on the setting of the
serial port.
Touch the CONTROLS logo in the upper-left corner of the screen to exit from
the TEST RUN screen.
Automax 5 Rev. 3 EN 63 09/12/2009

4.2.2 FILE MANAGER (TEST ARCHIVE) screen
On the main menu press on the icon to activate the FILE MANAGER (TEST
ARCHIVE) menu; the following screen will appear:
Saved files are stored in the “Disk On Module” memory. The memory can be used to file
up to a maximum of 1000 tests (graph included).
Here below there is an example of the file management screen. The main elements are:
1 2
Fig. 4-13
1. Data area
2. Record number (position of displayed test in the memory sequence; 1 to 1000)
3. Command to select single test or the complete memory . This

selection affects the PRINT, DOWNLOAD and CANCEL functions. Press on this
icon to toggle from one condition to the other
4. Data OPTIONS command
5. To display the data of the previous stored test
6. To display the data of the next stored test.
Each test file can be shown on the display, printed on a serial printer or downloaded to a
PC through the RS232 Serial Port.
Use the buttons and to scroll through the various stored tests. Each test is
identified by as sequential position in the memory (item 2 in the above screen).
09/12/2009 64 Automax 5 Rev.3 EN

Press the button to display the available functions provided within the TEST
ARCHIVE screen.
Fig. 4-14
Press the button to cancel the test from the memory: depending on the selection
previously done (see item 3 of previous Fig. 4-13) the system will ask confirmation to
cancel the present test or the whole test memory
Fig. 4-15
Press ACCEPT to confirm or ABORT to abort this operation.
On the TEST ARCHIVE screen popup, press the button to download the
displayed test to a PC. Ensure beforehand that the PC is connected to the RS232 Serial
Port and that the PC is on line.
On the TEST ARCHIVE screen popup, press the button to print the displayed
test. Ensure beforehand that the printer is connected to the printer port, it is switched on
and on line.
On the TEST ARCHIVE screen popup, press the button to view the test graph
On the TEST ARCHIVE screen popup, press the button to exit from the popup.
the FILE MANAGER (TEST ARCHIVE) screen.
Automax 5 Rev. 3 EN 65 09/12/2009
4.2.3 OPTIONS menu
On the main menu press on the icon to activate the OPTIONS menu; the
Fig. 4-16
This menu allows the selection of language, input of name or code number of the
operator, setting of date and time, setting of test options (unit of measurement, data
printout, storage etc).
the OPTIONS screen.
4.2.3.1 SELECT LANGUAGE option
Press the button on the screen and then select the desired language.
this screen (press ACCEPT or ABORT to confirm exiting).
09/12/2009 66 Automax 5 Rev.3 EN

4.2.3.2 OPERATOR NAME screen
Press the button on the screen and to access this function.
Fig. 4-17
The operator name is one of the pieces of data that is stored in the test file.
To customize this option use the buttons and to change the characters
and the buttons and to move from one character to another.
All alphanumerical characters (in upper and lower case) are available together with a
number of symbols.
Automax 5 Rev. 3 EN 67 09/12/2009

4.2.3.3 DATE AND TIME screen
Fig. 4-18
Press the buttons and to set the parameters and the button to
select the parameter to change.
09/12/2009 68 Automax 5 Rev.3 EN

4.2.3.4 TEST OPTION screen
Fig. 4-19
Select the desired field on the screen and press the buttons and to set the
parameters.
The TEST OPTIONS screen includes the following fields:
o UNIT OF MEASURE: The firmware allows for readings to be expressed and

calculated in kN, tonnes or lb. Note that for each load measurement unit, the load rate
or stress rate may be selected. Depending on this selection the system will optimise
the display in terms of resolution and number of digits to be shown.
The firmware uses the following conversion factors:
1 kN = 0.101971 Ton
224.809 Lbf
When moving from one measuring unit to another, there is no need to re-calibrate the
instrument (provided this was previously calibrated).
o AUTO PRINT, STORE, AUTODOWN: they allow the settings for automatic
activation of print/save/transmission of data. These functions can be rendered
automatic at the end of a test using the following functions:
- AUTOPRINT: when ENABLED, activates the print function (via the
selected printer);
- AUTOSTORE: when ENABLED, activates automatic saving in the memory;
- AUTODOWN: when ENABLED, activates the transmission of the final data
at the end of the test (sample failure); when DISABLED, data transmission is
continuous in real time during the test. This, for example, allows the creation
of a graph on the PC.
Automax 5 Rev. 3 EN 69 09/12/2009

o PRINTER: select the type of printer connected:

o When USB printer is selected, the relevant data are sent via the USB port on
the rear panel of the AUTOMAX (the RS232-C port instead will transmit
data for the computer with the relevant settings). In this case it is also
possible to insert the print page heading (see chapter 6.1.2);
o When RS-232C printer is selected, the relevant data are sent via the RS232
port on the rear panel of the AUTOMAX (it will not be possible to transmist
data to a computer).
NOTE:
* To transmit data to a computer, the option PRINTER in the TEST OPTIONS menu must
be set to USB. If this proper setting is done after trials with different configurations have
been attempted, remember to switch OFF the computer and the machine in order to clean
the buffers of the computer and re-start from a “clean” situation.
o START TEST PARAMETER: this parameter, normally set to 1, is used to intervene

on this very first instant of loading before the machine follows the pre-set load
gradient.
The parameter has a multiplying effect, therefore it is sufficient to increase or

decrease it to increase or decrease the pre-load. When tests are made on samples of
large dimensions with the use of deformable capping (such as fibre boards, carton or
concrete blocks), we recommend that a value of between 5 and 10 is set.
Vice versa, a value of below 1 should be set for very small samples where a low load
gradient is being used.
WARNING:
If the START TEST PARAMETER value is not properly set, it will cause improper
functioning of the machine (e.g. if the value is too high the machine will not be able to
sense the failure of the sample and therefore will continue pressing the sample and never
stop).
This may result in damages to the equipment and/or danger for the operator. CONTROLS
will not be considered responsible in these events.
09/12/2009 70 Automax 5 Rev.3 EN

4.2.4 MANUAL COMMANDS menu
This menu allows the display of the load read by the enabled channels and to use the
machine in manual mode, that is the operator may apply the load, changing the load rate
starting from zero.
On the main menu press on the icon to activate the MANUAL COMMANDS
menu; the following screen will appear:
3
1
4
7 8 9
Fig. 4-20
This function allows the checking of the calibration of the machine by comparing the load
indicated by the display with a reference load indicator to check linearity and
repeatability (see chapter 5.2.5 of this manual for more details).
When this display is accessed the value of load of the selected channel will be shown as a
small value which corresponds to the electronic zero of the amplified signal. This value,
which must not be zero, is determined by the calibration of the hardware for the zero of
each channel.
WARNING:
The MANUAL COMMANDS menu is reserved to the authorised service personnel.
CONTROLS will not be responsible for any damage caused by improper setting of these
parameters. Warranty will be void if this menu is used by unauthorised personnel.
The main information displayed is:

1. Load reading
2. Channel selection
3. Pump START/STOP command
4. Zero function
5. Set speed to 10%
6. Button to access CALIBRATION menu
7. Load rate
8. Speed INCREASE command
9. Speed DECREASE command.
Automax 5 Rev. 3 EN 71 09/12/2009
4.2.4.1 CALIBRATION menu
Access to this menu should be made only when the calibration of the equipment requires
to be altered (e.g. after that the verification of the linearity error of the calibration has
been carried out in MANUAL COMMANDS mode).
This menu, password protected, allows the calibration to be adjusted so as to optimise the
linearity of the system (unit + load sensors + test frame). The operator can divide the full
scale of the testing unit in up to a maximum six user definable fields, this allowing the
input of up to six calibration coefficients (one for each field).
The software then automatically calculates the interpolation of these fields so as to

calculate the calibration curve of the unit over its complete range. This allows extremely
accurate calibration even at very low loads whilst using one reading scale and one load
sensor.
WARNING:
The CALIBRATION menu is reserved to the authorised service personnel and should
only be entered when the calibration needs to be changed. CONTROLS will not be
responsible for any damage caused by improper setting of these parameters. Warranty
will be void if this menu is used by unauthorised personnel.
Refer to chapter 5.2.5 for more details.
09/12/2009 72 Automax 5 Rev.3 EN

4.3 Serial port

The AUTOMAX 5 system is fitted with the following communication ports:
o Serial RS232C port for Printer (e.g. 82-P0172) or P.C. connection;
o USB port for A4 printer.
Fig. 4-21
4.3.1 Serial port setting for printer
Set the PRINTER option in the TEST OPTIONS menu to RS-232C (see chapter 4.2.3.4);
the RS-232C port on the rear panel of the AUTOMAX will be set to transmit data to a
serial printer with the following settings:
9600 baud, 8 data bit, 1 Stop bit, no parity.
All fields transmitted are ended with CR and LF. We recommend our printer 84-P0172 is
used.
4.3.2 Serial port setting for PC connection
Set the PRINTER option in the TEST OPTIONS menu to USB (see chapter 4.2.3.4). In
this case the RS-232C port on the rear panel of the AUTOMAX will be set to transmit
data to a PC with the following settings:
38400 baud, 8 data bit, 1 Stop bit, no parity.
All fields transmitted are ended with CR and LF. The data transmission protocol is
compatible with our software DataManager (code 50-C7022/SOF) used to read, process,
save and print test results. For use with C7022/SOF program, following settings must be
used: “AUTOMAX”, TYPE 1”.
In alternative our software D-Terminal (code 82-Q0800/TRM) or Hyper Terminal
(present in MS Windows®) can be used for data acquisition only.
NOTE:
* To transmit data to a computer, the option PRINTER in the TEST OPTIONS menu must
be set to USB. If this proper setting is done after trials with different configurations have
been attempted, remember to switch OFF the computer and the machine in order to clean
the buffers of the computer and re-start from a “clean” situation.
Automax 5 Rev. 3 EN 73 09/12/2009

4.3.2.1 Use of the Hyper Terminal program
We recommend that firstly the operator reads the Microsoft instruction manual regarding
this program.
If this program is not installed consult your P.C. supplier.
1. To access the Hyper Terminal on the PC click on START and then PROGRAMS ,
then ACCESSORIES and finally COMMUNICATIONS. Select the HYPER
TERMINAL folder and activate IMPORT;
2. If prompted, do not select the installation of a modem. Give a name to the connection
(e.g. AUTOMAX);
3. After this, upon the request of “Connect to...“ select the COM port used for the
connection to the AUTOMAX 5. Select between COM1, COM2... COMX (where X
is number of RS232 Serial ports available on P.C.) and confirm;
4. Input the settings as follows: 38400 bit per second, 8 data bit, no parity, 1 stop bit, no
parity. Once these have been confirmed the input screen will disappear;
5. Now the blank “Hyper Terminal” screen will appear. The PC is now ready to receive
data via the selected serial port. Any received data is displayed but is in no way filed.
To file the data it is necessary to activate the CAPTURE TEXT button. Select the
TRANSFER command and then CAPTURE;
6. Now select the folder and name in which you wish to store the data in arrival; the file
will take the extension TXT (text file) and will subsequently be opened with any text
editing file (Word, Notepad, Wordpad, Excel etc.);
7. Click on START to begin registration of data. From this moment all the data received
through the serial port are stored in the selected file in the sequence in which it
arrives;
8. To end the registration click on TRANSFER, then on CAPTURE TEXT and finally
END. All the received data is now stored in text form in the newly created file;
9. When the Hyper Terminal function is closed the operator is asked whether or not to
save the session. If the session is saved it will not be necessary to repeat the settings
described in points 3 and 4 but simply to recall the previous name (i.e. AUTOMAX).
4.3.3 USB port

The control unit is equipped with a USB port that can be used to connect HP A4 printers
to obtain the printout of a test report in A4 format (e.g. type HP Deskjet 6940).
The printer communication protocol must be PLC 3E or PLC 3 HPA (PLC 3 GUI
protocol IS NOT COMPATIBLE).
NOTE:
* The printer must be connected and turned ON before switching ON the equipment as it
must be “seen” by the AUTOMAX during its boot phase.
See chapter 6.1.2 to set the header on the test report.
09/12/2009 74 Automax 5 Rev.3 EN

4.4 Carry out a test

The present chapter provides a quick guide for the execution of a test. Full details on the
various screens and options accessed are provided in chapter 4.2.
WARNING:
while loading/unloading samples from the test frame, due to the sample weight and sharp
surfaces.
WARNING:
while handling distance pieces and platens due to their weight.
WARNING:
Always close the front door and place the rear guard while executing the tests. Also use
proper personal protection devices (e.g. glasses) in order to avoid injures due to fragments
of samples ejected during the test (e.g. in case of test on explosive samples ).
WARNING:
Although the maximum speed of the loading piston is very low (max. 40mm/min), to
avoid injures during the compression phase, always close the front door and place the rear
guard while executing the tests. Also avoid putting hands/fingers in the gap between the
sample and the upper platen.
Automax 5 Rev. 3 EN 75 09/12/2009

Before starting any test check that:

• The test frame is free from residual of previous sample and that the surface of the
platens are clean;
• Depending on the size of the sample, use proper distance pieces to reduce the
daylight, also considering that the piston total travel is 50mm.
Fig. 4-22
1. Check that the Emergency button is released (otherwise rotates it clockwisw to

release);
2. Switch ON the machine and wait 15 minutes warm up time;
09/12/2009 76 Automax 5 Rev.3 EN

3. Place the sample in the test frame and close front door and rear guards (see previous
WARNIGS);
Fig. 4-23
4. From the main menu select the TEST RUN option;
Fig. 4-24
5. Set here all the specimen data or select a pre-stored profile (see chapter 4.2.1);
6. Once done, touch the CONTROLS logo in upper-left corner of the screen;
7. Press ACCEPT to save the settings; the system enters the TEST RUN screen;
Fig. 4-25
Automax 5 Rev. 3 EN 77 09/12/2009

8. When ready press the button on the screen to start the test (message TEST
IN PROGRESS shown on the display);
9. Once the sample comes into contact with the upper platen/bearer a change in the
noise from the pump will be noted as the AUTOMAX 5 controls the load rate
throughout the test with its P.I.D. closed loop system. Once the system reaches
equilibrium the noise will remain constant.
The display constantly updates the values of load and resistance in real time and
shows the set load rate in the lower left hand corner, whilst the actual applied load
rate is also shown on the display.
Fig. 4-26
During the execution of the test, the display of deviation of actual load rate (field 7
of previous figure Fig. 4-8) from the theoretical load rate shows a series of symbols
as described below:
=== Actual load rate corresponds with theoretical load rate ± 1%
= Actual load rate = theoretical load rate ± 1...10%
– Actual load rate = theoretical load rate - 10%
–– Actual load rate = theoretical load rate – 10…25%
––– Actual load rate = theoretical load rate by more than – 25%
+ Actual load rate = theoretical load rate + 10…15%
++ Actual load rate = theoretical load rate + 15….25%
+++ Actual load rate = theoretical load rate by more than + 25%.
In this way it is possible to follow the accuracy of the machines automatic

functioning. In normal conditions the machine can keep to the set load rate within +/-
1% apart from the very beginning and end of the test when numerous adjustments
are made. If the closed loop action needs to be improved it is possible to alter the
parameters of the P.I.D.(refer to the service department).
The central area of the screen shows the graphical representation of load versus time.
A large part of the display is dedicated to this function allowing the operator to
evaluate the progress of the test through the load against time graph. The X axis
shows the time at the start of the test its full scale is 150 sec. The maximum possible
scale is 600 sec. (10 minutes).
The Y axis shows the load. At the start of the test its full scale is 50% of the capacity
of the frame.
09/12/2009 78 Automax 5 Rev.3 EN

During the test the graph is shown in real time, and the scale of the axis are
optimised by the software (autoscale function with steps of 25%).
When a sample is near the failure the noise from the pump will increase since the
system must compensate for the high sample deformation during this phase.
Upon sample failure the display shows the message TEST COMPLETED and the
values of maximum load and resistance are shown in large digits in the area of the
graph as shown below:
Fig. 4-27
At the same time the pump will stop.
10. To save, print, and transmit data of the test just completed, touch the button
on the screen. The system will show
Fig. 4-28
11. To save the test in the memory press the button ; upon doing this you will
note that the number of saved test files will increase by one. It is possible to store up
to 1000 tests, any attempt to memorize more than this number will result in the test
file not being saved.
Automax 5 Rev. 3 EN 79 09/12/2009

12. To print a test report on a serial printer (if enabled) press the . Before doing
this check that the printer is connected to the “printer” port, it is switched ON and on
line. An example of a typical printout is given below:
AUTOMAX 5 SYSTEM
V1.XX
Serial number: 00000000
Operator : OPERATOR1
17/01/01 15:41:33
Test number: 00013
COMPRESSION CH1
Sample: CUBE
Area [ mm2]: 022500
Weight [gr]: 08238
Mat[Days: 028
Fm [ kN ]: 00311.3
Rm [N/mm2 ]: 0013.83
LR [MPa/s]: 0.500
13. To send the same report to a PC via the RS232 serial port press the button
on the screen.
14. Press the button to close this window and return to the TEST RUN screen.
09/12/2009 80 Automax 5 Rev.3 EN

4.5 Stopping the cycle via the Emergency button

In case dangerous conditions are encountered during the execution of a test cycle, it is
possible to stop the machine by pressing the EMERGENCY BUTTON.
Pressing this button will stop the movement of the piston, release the pressure of the
hydraulic circuit and turn OFF the Control unit.
The POWER ON lamp will remain ON as the mains switch of the equipment on the
console is still ON.
Releasing the emergency button (turn it clockwise) will bring the unit back to the start up
condition (MAIN MENU shown on the display).
Emergency button “Power ON” lamp
Fig. 4-29
Automax 5 Rev. 3 EN 81 09/12/2009

4.6 Switching off the unit

At the end of a test, remove residuals of the samples, and switch it OFF via the mains
switch on the console.
Leave this switch always ON

(Control unit)
Console mains switch (main

unit)
Fig. 4-30
NOTE:
* The power switch on the control unit can always be left ON as the activation of the whole
equipment is controlled by the mains switch on the main unit
09/12/2009 82 Automax 5 Rev.3 EN

5. MAINTENANCE
As with all electrical equipment, this unit must be used correctly and maintenance and
inspections must be performed at regular intervals. Such precautions will guarantee the
safe and efficient functioning of the equipment.
Periodic maintenance consists of inspections made directly by the test operator and/or by
the authorized service personnel.
Maintenance to the equipment is responsibility of the purchaser and must be performed as
stated by this chapter.
WARNING:
CONTROLS will not be responsible for maintenance and service actions performed by
unauthorized people.
WARNING:
at least 5 minutes.
WARNING:
WARNING:
tools/keys. These tools and keys are for the use of maintenance people only. Never leave
them attached to the unit as this may endanger operator safety.
and locked.
Automax 5 Rev. 3 EN 83 09/12/2009

WARNING:
WARNING:
failure, components may only be replaced by using original spare parts. It is in the
responsibility of the purchaser to ensure that fire prevention policies are properly
implemented according to the CE provisions.
WARNING:
Avoid pouring water, even accidentally, or other liquids into the device, as this could
cause short circuits. Before cleaning the device, disconnect it from the mains line.
WARNING:
09/12/2009 84 Automax 5 Rev.3 EN

5.1 Operator’s preventive maintenance

The inspections made directly by the operator are the following:
Action Who When

Check to ensure that there is no Operator Before every working session
external damage to the equipment,
which could jeopardise the safety of
use
Clean and dry platens, distance Operator At the end of each working
piece and ram from the sample session
debris
General inspection Operator Weekly
Check the status of the hydraulic Operator Weekly
tubes against leakages and damages
Check status of the safety devices: Operator Weekly
emergency button, max. pressure
valve, piston over travel switch and
relevant cable, front door and rear
transparent guard (refer to chapter
5.1.1 for their identification)
Check status and functioning of the Operator Weekly
operator's command
Check the level of the oil in the Operator Monthly
tank (see chapter 5.1.2)
Check that all label and rating Operator Monthly
plates are intact and properly
attached
Automax 5 Rev. 3 EN 85 09/12/2009

5.1.1 Checking the status of the safety devices
The machine is equipped with the following devices to limit the residual risks in using it:
• Max. pressure valve to avoid machine overloading.
Max pressure valves
Fig. 5-1
• Ram travel switch to prevent the excessive piston travel; when triggered it disables
the functioning of the pump motor.
Limit switch
Fig. 5-2
09/12/2009 86 Automax 5 Rev.3 EN
• Front and rear transparent fragment guard

• Emergency button
Front fragment guard
Emergency button
Fig. 5-3
Automax 5 Rev. 3 EN 87 09/12/2009

5.1.2 Checking the oil level in the tank
WARNING:
Check the oil level in the tank via the transparent level indicator (the oil
should be max. at half of the indicator); if necessary refill the oil tank.
Oil level indicator
Fig. 5-4
The following type of oil can be used:
Brand Type
Agip ATF Dexron
Api Apilube ATF Dexron
Chevron Chevron automatic transmission fluid
Elf Elfmatic G
Exxon Automatic transmission fluid
Fiat GI/A
Fina Dexron ATF
Gulf Automatic transmission fluid
IP Dexron fluid
Mobil ATF 220
Shell ATF Dexron II
Total Dexron
Vanguard ATF fluid DEX II
09/12/2009 88 Automax 5 Rev.3 EN

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

Checking the centering of the ram Authorized service
assembly (see chapter 5.2.1) engineer Yearly or before carrying out
Checking the hydraulic circuit (see Authorized service the calibration of the load
chapter 5.2.2) engineer channel(s) and the checking of
Checking the status of distance Authorized service the stability of the frame
pieces (see chapter 5.2.3) engineer through the force transfer test
Performing the maintenance of the Authorized service with the strain gauged column
spherical seat (see chapter 5.2.4) engineer
Checking the calibration of the load Authorized service Yearly or more frequently
channel(s) (see chapter 5.2.5) engineer depending on the quality
procedures of the laboratory
Checking the stability of the frame Authorized service Yearly or more frequently
through the force transfer test with engineer depending on the quality
the strain gauged column (see procedures of the laboratory
chapter 5.2.6)
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
Replacing the oil of the hydraulic Authorized service Every 3 years or more
circuit (see chapter 5.2.7) engineer frequently in very cold or
humid environments (where
condensation may form in the
oil tank)
WARNING:
Automax 5 Rev. 3 EN 89 09/12/2009

5.2.1 Checking the centering of the ram assembly
The proper centering of the ram assembly assures proper and uniform distribution of the
force to the sample during the execution of the compression test.
This check is normally carried out before checking the calibration of the system and
checking the stability of the frame through the force transfer test with the strain gauged
column.
This checking should also be carried out if tests on high strength concrete/explosive
samples are often carried out.
To check the centering of the ram assembly:
1. Remove the lower platen and distance pieces;
2. On the compression frame remove the cover of the ram assembly to expose its fixing
brackets;
Fig. 5-5
3. Use a straight edge and a tape measure to check the centering of the ram assembly in
all directions with respect to the columns of the compression frame;
Fig. 5-6
09/12/2009 90 Automax 5 Rev.3 EN
4. If it is not centered by more than 1mm in one or more directions, loosen the ram
fixing nuts and screws and use a rubber hammer to re-center it properly;
Fig. 5-7
5. Also check that the ram is properly positioned from a rotational point of view by
taking as reference the position of the oil supply tube with respect to the columns of
the frame on the rear of the ram;
Fig. 5-8
6. At the end firmly lock the ram assembly in place by tightening the relevant
brackets/nuts and screw.
Automax 5 Rev. 3 EN 91 09/12/2009

5.2.2 Checking the hydraulic circuit
Due to the high pressure inside the hydraulic circuit (up to 700 bars) a periodical check
on the hydraulic components is required.
WARNING:
WARNING:
Proceed as follows:
1. Remove the lower platen and distance pieces;
2. On the compression frame remove the cover of the ram assembly to expose its fixing
brackets;
Fig. 5-9
3. On the rear of the equipment check the following points for oil leakages:
o Connection point of the pressure transducer
o Input port of the oil on the ram assembly
o Both ends of the hydraulic tube and along the hydraulic tube itself
o Output of the electrovalve of the pump assembly
o On the upper surface of the oil tank where the electrovalve block is mounted
o Slot between the piston and the ram assembly;
09/12/2009 92 Automax 5 Rev.3 EN

Fig. 5-10
4. In case of oil leakages, check the single item(s) and replace the relevant gasket/O-
ring;
5. Then check the oil level in the tank (refer to chapter 5.1.2) and, if needed, re-fill the
oil tank as described in chapter 5.2.7;
6. At the end, use compressed air to clean the slot between piston and cylinder and the
base of the compression frame.
Automax 5 Rev. 3 EN 93 09/12/2009

5.2.3 Checking the status of distance pieces
To assure proper and uniform distribution of the force to the sample during the execution
of the compression test, status of distance pieces and platens must be periodically
checked.
This check is normally carried out before checking the calibration of the system and
checking the stability of the frame through the force transfer test with the strain gauged
column.
This checking should also be carried out if tests on high strength concrete/explosive
Checking the status of distance pieces requires:

o Checking that the surfaces of the distance pieces are not damaged (free of deep dents
and incisions);
o Checking the planarity of the lower and upper surface;
o Checking the status of the centering screw;
o Checking that, once the distance pieces are installed on the machine, they do not tilt
pushing them from the top.
Fig. 5-11
09/12/2009 94 Automax 5 Rev.3 EN

5.2.4 Performing the maintenance of the spherical seat
The status of the spherical seat heavily influences and determines the proper performance
of the compression machine as it must ensure proper and uniform distribution of the force
to the sample during the execution of the compression test.
The maintenance of the spherical seat is normally carried out before checking the
calibration of the system and before checking the stability of the frame through the force
transfer test with the strain gauged column.
The maintenance should also be carried out if tests on high strength concrete/explosive
Performing the maintenance on the spherical seat requires its removal from the equipment
and its complete disassembling to check and maintain its internal components.
Refer to qualified service organisation authorized by CONTROLS to perform the

maintenance on the spherical seat.
WARNING:
Automax 5 Rev. 3 EN 95 09/12/2009

5.2.5 Checking the calibration of the load channel
The load values displayed by the machine are conditioned by the calibration coefficients.
The calibration of the system must be checked periodically to ensure proper performance.
The calibration procedure here after described conform to the European standard
EN12390-4.
The main steps of the procedure can be summarized as follows:

1. Control of the calibration; if the machine is within the limits of the standard, the
procedure ends, otherwise proceed with step 2;
2. Calibration of the machine (e.g. adjustment of the force measurement device of the
machine);
3. New control of the calibration (repeat step 1).
Steps 2 and 3 above are required if the machine is not within the limits indicated by the
standards.
Step 1 above consists of:

o Application of several levels of force (at least 5) ranging from 20% to 100% of the
full scale of the machine;
o For each level of force, compare the force measured by the compression machine (the
“indicated force”) with the force measured by a calibrated force measurement device
(the “true force”)
For class 1 machine the requirement of EN12390-4 are the following:

o Relative accuracy error within the range ±1%;
o Relative repeatability error within the range ±1%;
o Relative zero error within the range ±0,2%.
The same procedure can also be applied for equipment complying with the ASTM C39
standard, that requires an accuracy ±1% for any value displayed within the verified
loading range and the provision to display true 0 reading at 0 load.
09/12/2009 96 Automax 5 Rev.3 EN

To check the calibration of the load channels, the MANUAL COMMANDS screen must
be accessed from the system MAIN MENU by pressing on the button ; the
3
1
4
7 8 9
Fig. 5-12
The main information displayed is:
1. Load reading
2. Channel selection
3. Pump START/STOP command
4. Zero function
5. Set speed to 10%
6. Button to access CALIBRATION menu
7. Load rate
8. Speed INCREASE command
9. Speed DECREASE command.
The load values are conditioned by the calibration coefficients.
When the AUTOMAX 5 is supplied with a Compression/Flexure frame(s) it is factory

calibrated and no calibration is necessary at the time of installation (see Calibration
Certificate supplied with the machine).
If instead the unit is supplied separately, is to be connected to another test frame or a

different load sensor, then the preliminary operation of calibration of the zero must be
made (see chapter 5.2.5.1).
Automax 5 Rev. 3 EN 97 09/12/2009

5.2.5.1 Calibration verification
To verify the calibration the unit should be left switched on for at least 15 minutes to
allow the thermal equilibrium of the electronic components. Then proceed as follows:
1. From the main menu press the button to select the MANUAL COMMANDS menu;
Fig. 5-13
2. Correctly place the reference instrument (e.g. load cell) between the compression
platens of the test machine. Check that the free vertical span is approximately
between 5 and 25 mm, use suitable distance pieces if necessary;
3. Select the channel which you wish to verify the calibration;
4. When ready press the button . The pump will start immediately and the ram of
the test machine will start to rise. During this phase, before the load cell is subjected
to load, zero the load reading by pressing the button . At the same time the
load rate shown on the display will go from 0% to that corresponding to the rapid
approach, normally 20-30% unless otherwise set by the manufacturer;
NOTE:
* The load rate may have values between 0 and 100%, corresponding to the minimum and
maximum load rates respectively.
09/12/2009 98 Automax 5 Rev.3 EN

5. When the load cell is close to the upper platen of the compression machine it is
recommended that the load rate is decreased so as to not apply a shock load to the
cell. To do this press and keep pressed the button ; an immediate fall in the
noise level from the pump and a fall in the load rate will be noticed. Vice versa to
increase the load rate press the button . The button when pressed, will
immediately set the load rate at 10%, this is very useful when one must quickly pass
from the rapid approach speed to a much lower speed;
6. Once the load cell is under load, a moderate speed should be used, making
adjustments with the arrow buttons as described above. By taking the load rate close
to zero it is possible to stop the load increase and maintain an almost constant
pressure. The value of the applied load is updated in real time on the display. To
interrupt the load application press : the pump will stop and the ram will
return to its initial position. Before checking the calibration the machine should be
taken to its maximum capacity 3 or 4 times so as to obtain a stabilised signal from the
load sensors. After this check the readings given by the AUTOMAX 5 system against
that of the reference load cell. Normally this is done at values of 10%, 15%, 20%,
40%, 60%, 80% and 100% of the full scale of the compression machine. It is also
possible to check the calibration at lower loads if the compression machine has been
so calibrated;
7. If the percentage deviation is higher than permitted tolerances, the unit should be re-
calibrated by changing the calibration coefficient so as to obtain the best possible
linearity. To do this the interpolation menu should be accessed. After this the manual
mode will be entered and the above mentioned procedure repeated so as to check the
new calibration.
Automax 5 Rev. 3 EN 99 09/12/2009

5.2.5.2 Adjustment of the electronic offset
The above procedure concerns the verification of the calibration assuming that the initial
calibration has already been made. However, to set the zero in the case of fitting the unit
to a new test frame or changing the load sensor, it is necessary to adjust a trimmer as
described below:
1. Remove the rear panel of the AUTOMAX 5 control unit (unscrew the two rear
screws and three upper screws);
2. Connect the load sensor/s and switch on the instrument. Enter MANUAL
COMMANDS menu function by pressing the button on the MAIN MENU

screen and await a few seconds for the displayed values to stabilise;
3. When the machine under consideration is not under load it should indicate between
1/1000th and 1/100th of the full scale (e.g. for 2000 kN machine, the zero must be
between 2 and 20 kN);
4. To adjust the zero channel 1 act on trimmer P1 and likewise for channel 2 trimmer
P2. For this operation use a small screw driver and act with extreme care so as not to
damage the components;
WARNING:
Risk of electrical shocks inside the unit. Do not touch any other components with
screwdriver and/or unprotected hands.
5. Once the adjustment has been made, reinstall the rear panel and proceed with the
calibration procedure described in paragraphs 5.2.5.2 and 5.2.5.3.
P2 P1
Fig. 5-14
09/12/2009 100 Automax 5 Rev.3 EN

5.2.5.3 Calibration
Access to this menu should be made after that to the MANUAL COMMANDS and
verification of the linearity error of the calibration.
This menu allows the calibration to be adjusted so as to optimise the linearity of the
system (unit + load sensors + test frame). The operator can divide the full scale of the
testing unit in up to a maximum six user definable fields, this allowing the input of up to
six calibration coefficients (one for each field). The software then automatically foresee
the interpolation of these fields so as to calculate the calibration curve of the unit over its
complete range. This allows extremely accurate calibration even at very low loads whilst
using one reading scale and one load sensor.
WARNING:
The CALIBRATION menu should only be entered when the calibration needs to be
changed. Do not enter into this menu for any other reason. Before entering the
CALIBRATION menu it is vital to carefully read and understand the procedure
described hereunder. If any doubts remain, contact CONTROLS service department for
further clarification.
CONTROLS will accept no responsibility for any inconvenience caused by wrongful
calibration.
1. On the MANUAL COMMANDS screen select the channel to calibrate;
2. From the MANUAL COMMANDS press the button to activate the

CALIBRATION screen; the system will ask for a password;
Fig. 5-15
3. Input the password using the buttons . The password is 00101 and it
cannot be changed. Next press the button to confirm;
Automax 5 Rev. 3 EN 101 09/12/2009

4. The CALIBRATION MENU will appear (see below). Before describing this menu
and its functions, it is important to fully describe the calibration procedure;
Fig. 5-16
5. Before entering the CALIBRATION MENU the operations described in chapter

5.2.5.1 must be made. In particular the values shown by the AUTOMAX 5 compared
to various reference loads should be noted. The applied loads should remain within
the calibrated measurement range of the test frame, normally from 10% or 20% up to
100% of the full scale.
The aim of the calibration is to obtain class 1 classification of the frame within this
measurement range. However, it may be necessary to extend this accuracy to lower
loads in which case it will be necessary to use a reference load cell of appropriate
capacity and accuracy. The recorded readings, that is the values displayed by the
AUTOMAX 5 at known reference loads, will be used for the interpolation, thus these
should be recorded on a piece of paper showing reference load against load read on
AUTOMAX 5.
On the basis of these readings and the general linearity of the system determine the
range you wish to calibrate. AUTOMAX 5 system allows the calibration to be made
on up to 6 points which are then automatically interpolated by the unit to compensate
for any non linearity of the system (i.e. the test frame, AUTOMAX 5 and load
sensor).
If the system is sufficient linear and the measurement range is from 10-20% to full
scale it is sufficient to use one calibration point, normally between 40 and 50% of
the full scale. This calibration is of the linear type, that is it is based on a single
calibration coefficient with no interpolation. This is the easiest and quickest
calibration method and is the standard method which is normally used.
If class 1 calibration must be reached at particularly low loads, it is necessary to

make more readings above all at the beginning of the measurement range. Normally
readings are made at 1%, 3%, 5%, 10% and 50-70%.
Particular operator experience or needs may lead to the use of other measurement
values.
If the system linearity is not acceptable within the field 10% to 100% full scale, we
recommend the following values, 10%, 20%, 60%, 100%. Particular operator
experience or needs may lead be the use of other values.
09/12/2009 102 Automax 5 Rev.3 EN

6. After accessing the CALIBRATION menu of the desired channel the screen will
show the values relative to the last calibration made (if such a calibration has been
made) or a default value of 1. The first column on the left represents the reference
load value, the second column shows the value given by the AUTOMAX 5 system
and the third column shows the calibration coefficient.
Fig. 5-17
7. At this point insert the pairs of values previously recorded. Start with the lowest value
and finish with the highest. For each step insert first the theoretical value (column 1)
and then the value shown by the display of the AUTOMAX 5 system at this load
(column 2). The software will calculate the corresponding calibration coefficient
(column 3).
Use the buttons and to set the values and press on the field to be
changed to allow entering the values (the selected field will be highlighted). Those
steps which are not used must be completed with values of 0 so as the calibration
coefficient is 1.
NOTE:
* Once a value has been confirmed it cannot be changed. Therefore take care not to
introduce incorrect values.
8. Once all the values have been entered press the button to save the new
calibration: the system will ask for a confirmation;
Fig. 5-18
Automax 5 Rev. 3 EN 103 09/12/2009

9. Pressing the ACCEPT button the system will store the new calibration, while
pressing ABORT the system will keep the existing calibration;
10. If instead the existing calibration must be completely cancelled (e.g. after replacing
the pressure transducer and therefore completely different coefficient values might be
expected), press the button ; the system will ask confirmation before erasing
the calibration;
Fig. 5-19
NOTE:
* DO NOT ENTER THE CALIBRATION MENU WITHOUT FIRSTLY
VERIFYING THE CALIBRATION IN THE MANUAL MODE. The AUTOMAX 5
system has calculated the new calibration coefficients and thus modified the gain of
the system. If the CALIBRATION MENU is entered, and even if the same data is re-
inserted, its effect on the calibration will be completely different because they will
act upon the new calibration coefficients.
11. Once done, touch the CONTROLS logo in upper-left corner of the screen to
return to the MANUAL COMMANDS screen.
09/12/2009 104 Automax 5 Rev.3 EN

5.2.5.3.1 Example of calibration with one coefficient
As an example we show the calibration of a 2000 kN machine which had already been
previously calibrated.
1. Enter the MANUAL COMMANDS screen and select the channel relative to the 2000
kN machine;
2. After having placed a 2000 kN reference load cell in the test frame make at least three
load/unload cycles;
3. Next read the load displayed by the AUTOMAX 5 system when the reference load
cell shows 1000 kN let us assume a value of 1013.4 kN;
4. Access the CALIBRATION screen: the display, for example, shows the follow
values:
REF. LOAD ACTUAL COEFF
1000.0 725.4 +1.3785
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
5. The cursor is on 1000. Since we made a reading on this value select the next field on
the right (second column). The cursor is on 725.4; press the buttons and
to set the value to 1013.4.

6. Make sure that all the successive values are set at zero so as not to effect the
calibration. At the end of the operation the table will read as follows:
1000.0 1013.4 +1.3785
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
0000.0 0000.0 +1.0000
7. Press the button and press ACCEPT to store the new calibration and return to
the manual mode and again verify the new AUTOMAX 5 system read-out with the
reference load cell. Naturally the new readings will be different because the
calibration coefficient has been altered.
NOTE:
* When the interpolation menu is entered again, column 2 does not show the inserted value,
but rather a value calculated by the software. Therefore do not worry if the table does not
show the previously inserted values. The only significant values are the calibration
coefficients which are calculated upon exit of the menu once the table has been
completed.
Automax 5 Rev. 3 EN 105 09/12/2009

5.2.5.3.2 Example of calibration with more than one coefficient
As an example we show the calibration of a 2000 kN machine which had been previously
calibrated with five coefficients.
1. Enter the MANUAL COMMANDS mode and select the channel relative to the 2000
kN test frame;
2. After having placed a 2000 kN reference load cell in the test frame make at least three
load/unload cycles and then read the loads displayed by the AUTOMAX 5 system at
the values 20, 60, 100, 200 and 1200 kN read on the reference load cell. Lets assume
we record values of 21.1, 61.3, 102.4, 204.1, 1221.5 kN;
3. Access the CALIBRATION screen. The display, for example, shows the following
values:
0020.0 0014.5 +1.3785
0060.0 0043.6 +1.3785
0100.0 0072.7 +1.3785
0200.0 0145.4 +1.3785
1200.0 0872.7 +1.3785
0000.0 0000.0 +1.0000
4. The cursor is on 0020.0. Since we made a reading on this value we move to the
second column. The cursor is on 0014.5;
5. Select this field and press the buttons and to set the value to 0021.1;
6. Select the next field in column one (0060.0) and set 0061.3 instead of 0043.6 in
column 2. Repeat this procedure for the subsequent values. The last series will be
zero so as not to have any influence on the calibration. At the end of this operation
the table will show:
0020.0 0021.1 +1.3785
0060.0 0061.3 +1.3785
0100.0 0102.4 +1.3785
0200.0 0204.1 +1.3785
1200.0 1221.5 +1.3785
0000.0 0000.0 +1.0000
7. Press the button and press ACCEPT to store the new calibration and return to
the manual mode and again verify the new AUTOMAX 5 system read-out with the
reference load cell. Naturally the new readings will be different because the
calibration coefficient has been altered.
NOTE:
* When the interpolation menu is entered again, column 2 does not show the inserted value,
but rather a value calculated by the software. Therefore do not worry if the table does not
show the previously inserted values. The only significant values are the calibration
coefficients which are calculated upon exit of the menu once the table has been
completed.
09/12/2009 106 Automax 5 Rev.3 EN

5.2.6 Checking the stability of the frame
The proper application of the load to the sample can be tested through the force transfer
test carried out with the strain gauged column.
This testing procedure conforms to the European standard EN12390-4.
This test checks the performance of the compression machine under loading and the
uniformity of the force transferred from the machine to the sample.
The cylindrical Strain Gauged Column simulates the concrete sample and can measure
the stress transferred along the wall of the sample.
The Strain Gauged Column can read the applied force through 4 independent Wheastone
bridges located peripherally along the wall of the cylinder. A dedicated electronic unit
switches and independently balances each bridge, simultaneously displays the 4 bridges
and has an accuracy within the limits ±0,1% or 5µm strain.
A dedicated 150mm square stainless steel plate allows proper positioning of the Strain
Gauged Column during the tests.
Fig. 5-20
The above picture shows the Strain Gauged Column code 82-E0105/1,the force transfer
digital tester code 82-P0804/E and the printer code 82-P0172 that can be used to carry out
the Force transfer test.
Automax 5 Rev. 3 EN 107 09/12/2009

The Force Transfer Test allows checking the behaviour of the machine in order for it to
provide accurate force values and to crush the sample “regularly” as shown below
Fig. 5-21
If instead the machine crushes samples as shown in the next drawings, it may not be
applying the load uniformly and this can be discovered by means of the Force Transfer
Test.
Fig. 5-22

checking of the compression machine as described in this chapter.
WARNING:
09/12/2009 108 Automax 5 Rev.3 EN

5.2.7 Replacing the oil of the hydraulic circuit
WARNING:
Periodically the oil of the hydraulic circuit must be completely replaced.
1. Discharge the old oil via the drainage screw (size 18mm spanner);
Drainage screw
(view from below)
Fig. 5-23
Automax 5 Rev. 3 EN 109 09/12/2009

2. Collect the old oil and dispose it in accordance with the local
regulations;
3. Refill the tank (6 litres or 9 litres approx. depending on the tank

capacity) with the oil type shown in next table;
Brand Type
Agip ATF Dexron
Api Apilube ATF Dexron
Chevron Chevron automatic transmission fluid
Elf Elfmatic G
Exxon Automatic transmission fluid
Fiat GI/A
Fina Dexron ATF
Gulf Automatic transmission fluid
IP Dexron fluid
Mobil ATF 220
Shell ATF Dexron II
Total Dexron
Vanguard ATF fluid DEX II
4. Let the pump run and check oil level in the tank via the transparent level
indicator (the oil should be max. at half of the indicator);
Oil refil port
Oil level indicator
Fig. 5-24
5. Top up if necessary.
09/12/2009 110 Automax 5 Rev.3 EN

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.
Depending on the problem encountered, the troubleshooting is carried out by dividing the
system into functional blocks. During this phase, refer to the system block diagram of
chapter 2.6 of the present manual.
WARNING:
at least 5 minute.
WARNING:
them attached to the unit as this may endanger operator safety. After performing
maintenance/repair, make sure that all covers/doors are properly closed and locked.
WARNING:
WARNING:
Automax 5 Rev. 3 EN 111 09/12/2009

6.1 System (Hidden) menu

This menu allows setting a number of functioning parameters of the system and
performing procedures reserved to CONTROLS authorized service organisation.
WARNING:
To enter the SYSTEM (HIDDEN) MENU:
1. Switch the system OFF;
2. Touch the display in any point with a finger, switch ON the machine and
release the finger from the display after 10 seconds approx; the
following screen will be shown
Fig. 6-1
09/12/2009 112 Automax 5 Rev.3 EN

3. Use the buttons and to enter password 00202 and
confirm it pressing the button . The system will show the

following screen:
Fig. 6-2
4. The following options are available in the SYSTEM MENU:

• ADC CHANNELS SETTINGS
• SERIAL NUMBER
• PID SET UP
• MEMORY RESET.
The following pages describe the above mentioned options.
Automax 5 Rev. 3 EN 113 09/12/2009

6.1.1 ADC CHANNELS SETTINGS option
It allows setting into the AUTOMAX 5 control unit the working parameters
of the frame connected.
Fig. 6-3
For each channel, frame CAPACITY, PRELOAD and APPROACH

parameters can be entered.
To select a field, touch the relevant area on the display and use the buttons
and to set the parameter value.
NOTE:
*
Buttons and present on the screen are not active.
The following table shows the parameters set up for CONTROLS frames.
Frame type Capacity [kN] Preload [kN] Approach[%]

Concrete compression 4000 kN 4000 20 35
Cement compression 250 kN 250 1 15
Cement flexure 15 kN 15 0,05 10
Concrete flexure 100 kN 100 0,25 15
Concrete flexure 150 kN 150 0,25 15
Concrete flexure 300 kN 250 1 15
NOTE:
* The ADC CHANNELS SETTINGS parameter are factory set in case the
AUTOMAX 5 is sold as a machine already equipped with relevant frame.
09/12/2009 114 Automax 5 Rev.3 EN

Once done, touch the CONTROLS logo in upper-left corner of the

screen and press the ACCEPT button to save the changes and return to the
SYSTEM MENU screen.
Automax 5 Rev. 3 EN 115 09/12/2009

6.1.2 SERIAL NUMBER option
This screen allows entering:

• The unit serial number: it is normally set during the manufacturing of the
unit and does not need to be changed unless the MEMORY RESET
function has been activated (see chapter 6.1.4);
• The headers of the A4 format test report that can be obtained through the
use of a HP printer that can be connected to the USB port of the control
unit (see chapter 4.3.3).
Fig. 6-4
To set the different fields, touch the relevant area on the screen and use buttons
and to set the alphanumeric characters, use the buttons and to

move from one digit to another.
Once done, touch the CONTROLS logo in upper-left corner of the

screen and press the ACCEPT button to save the changes and return to the
SYSTEM MENU screen.
09/12/2009 116 Automax 5 Rev.3 EN

6.1.3 PID SET UP option
This function allows accessing to the screen used to set the coefficients of the PID
control (Proportional, Integral, Derivate) which manages the performance of the
automatic test guaranteeing uniform application of set load rate by appropriately piloting
the oil flow. It is also possible to find the control parameters for the initial part of the test,
that is just after the pre-load.
All the parameters are separated for each channel.
Once this option is entered, the system shows the following screen:
Fig. 6-5
Here follows a description of the parameters and logic of the working of the servo control
system.
NOTE:
* The P. UNDERSHOOT parameter shown in the screen above is reserved. Do not modify
its setting.
The constants of proportional, integral and derivates are fundamental parameters of the
software mathematics of the servo-control unit. In this respect we feel it useful to give a
brief introduction on the functioning logic of the servo-control of the AUTOMAX 5
system.
The logic is as follows: each time a load gradient is requested to be made, in reality the
machine is asked to act so that some variables (output or controlled variables) follow a
certain pattern by acting appropriately on other variables (input or control variables).
The relationship between control variables and controlled variables is nothing more than
a mathematical model which makes each controlled variable correspond to a respective
control variable.
Automax 5 Rev. 3 EN 117 09/12/2009

For the AUTOMAX 5, an hydraulic servo-controlled system, is illustrated in the

following chart:
Fig. 6-6
Thanks to the closed loop system, when the test machine is asked to perform a load ramp
with certain characteristics, the oil flow is controlled and corrected continuously (several
times per second) so as to respect those characteristics (particularly load rate) as best as
possible.
The accuracy of the control and hence the respect of the imposed load rate depends on a
number of inter-related factors:
• The soundness of the close loop logarithm;
• The speed of the system (data acquisition, elaboration and consequential intervention
etc.);
• The type of test; the type of test and sample also has an effect on the working of the
closed loop. For example a load rate controlled test on a weak sample could result in
the machine to be required to increase the oil flow in order to respect the load rate at a
pace faster than the whole system can perform. In this case it would be almost
impossible to respect the test speed and the real load rate would be less than the
theoretical one requested. This is a very extreme example, but it could occur.
Thus, whilst it is possible to intervene on the system (by CONTROLS) to optimise the
performance and on the type of test (by the operator) so as to avoid any critical points in
the test, it is also possible to intervene on the close loop logarithm so as to optimise
its performance.
The close loop used by CONTROLS is the PID type which has three variables that can be
freely set to alter the functioning.
Proportional closed loop constant K proportional:

Used to amplify the small errors between real and theoretical values (both positive and
negative) measured by the machine continuously so as to decide how to modify the oil
feed (increase or decrease) so as to near the theoretical load. The error is in effect the
main key that pilots the behaviour of the machine. If the real load rate is above the
theoretical one, the oil feed must be reduced and vice-versa. When this error has a certain
sign, after a few acquisitions and corrections with the same sign, normally the error will
change sign and the corrections will be with the opposite sign.
09/12/2009 118 Automax 5 Rev.3 EN

Thus the curve of the real load is always close to the theoretical one but never exactly
superimposed, it moves above and below it in cycles. The size of this oscillation can be
reduced by adjusting the K proportional constant. Indeed amplifying the error
proportionally the changing of the sign of the error will occur in a shorter time.
Theoretically, increasing K proportional infinitely the real and theoretical load graph
should coincide, however, above a certain threshold which depends upon the specific set
up of the test, amplifying the error produces resonate oscillations and instability instead
of increased precision.
Integrative closed loop constant K integral:

Is used to maintain the history of the test, that is what has happened just before that
moment in time. Allows the proportional amplification of the integral sum of the
differences (The errors) that have been read moment by moment between the theoretical
curve and the real curve cancelling those constant errors always of the same sign which
cannot be eliminated with the use of K proportional only. Also in this case there is a
maximum threshold value which should not be surpassed.
Derivative closed loop constant K derivative:

Is used to compensate systems with very long time constants. Allows the “smoothing” the
size of the oscillations to bring the system more quickly to the reference values. Also in
this case there is a maximum threshold value which should not be surpassed to avoid the
system being extremely instable or even out of control.
These parameters are factory set so as to optimise the system and thus do not need to be
altered by the operator. However, should it be felt necessary to alter the parameters for
particular user need, please contact CONTROLS Service Department for
further details.
After the PID parameters, on the screen the two control parameters which act at the first
part of the test are shown. These are:
• SET UP DELIVERY (%) which is the oil feed percentage (with respect to rapid
approach feed rate) which the system will apply for a certain time after the pre-load,
that is after the threshold load set in the system menu. This time is expressed in the
following parameter.
• SET UP TIME [s] is the time in seconds that the oil feed SET UP DELIVERY (%)
will be applied.
Before giving a complete description of the interaction logic of the control parameters,
we must introduce the final two parameters of the SYSTEM MENU, that is:
• Preload, is the threshold load above which at the beginning of the test during the
rapid approach (open loop) the PID controls intervene to give closed loop servo-
control. From this point onwards the oil flow is piloted so as to maintain the pre-set
load rate;
• Rapid approach, expresses the oil feed rate, with respect to the maximum, which the
system must apply during the rapid approach, that is from the start of the test to the
pre-load threshold. This parameter, together with the mechanics of the pump,
determines the speed that the ram rises when not subjected to load.
Automax 5 Rev. 3 EN 119 09/12/2009

The functioning logic of the AUTOMAX 5 system is as follows:

at the start of the automatic test the pump feeds the test frame ram the amount of oil
determined by the rapid approach parameter.
The ram will rise so as to close the free span and bring the sample into contact with the
upper platen. The pump continues to operate in this way until the set pre-load threshold
has been reached.
At this point the pump immediately changes speed so as to supply the set oil delivery (%)
for a set up time (s); this phase, which normally last for 3 or 4 seconds, allows the system
to stabilise itself and be ready for the servo-control without harsh variations of load and
oil feed.
Indeed, after this phase the control system enters a closed loop phase where the PID logic
elaborates, several times a second, the necessary instructions so as to maintain the pre-set
load rate and pilots the pump accordingly.
The servo-control remains active until the end of the test.
The system is calibrated by the manufacturer so as to optimise its performance in terms of

load rate control. However, certain tests may require the factory set parameters to be
modified. This is the case for failure tests on very weak or highly deformable samples
(e.g. concrete block with soft-board capping), or tests on very small samples with
extremely slow load rate (e.g. tests on cement samples using a 2000 kN or 3000 kN test
frame).
In the first case, to compensate for the high deformation at the beginning of the test it is
sufficient to increase the pre-load, even 5 to 7 times the factory set value. The idea is to
achieve the major part of the deformation during the rapid approach phase when the oil
feed is high.
In the second case, the opposite should be done, reducing the pre-load by 1/3 to ¼ and oil
delivery (%). The aim is to achieve a notable reduction of oil feed as soon as the sample
comes in contact with the upper platen and start the servo-control at a very low speed.
NOTE:
* After the test, re-set the parameters to their factory set values. Contact CONTROLS
Service Department if you have any doubts.
The above two examples illustrate extreme cases, for standard tests the system can be
used with its factory settings.
To select a field, touch the relevant area on the display and use the buttons
and to set the parameter value.
NOTE:
*
Buttons and present on the screen are not active.
09/12/2009 120 Automax 5 Rev.3 EN

The following table shows the parameters set up for CONTROLS frames.
Frame type and code K K K Set up Set up

Proportional Integrative Derivative time delivery
Concrete compression 4000 kN 25 25 20 3 35
Cement compression 250 kN 50 40 30 3 15
Cement flexure 15 kN 155 250 105 1 10
Concrete flexure 100 kN 70 60 55 2 15
NOTE:
* The PID SET UP parameters are factory set in case the AUTOMAX 5 is
sold as a machine already equipped with relevant frame.
Once done, touch the CONTROLS logo in upper-left corner of the screen and
press the ACCEPT button to save the changes and return to the SYSTEM MENU screen.
Automax 5 Rev. 3 EN 121 09/12/2009

6.1.4 MEMORY RESET option
The MEMORY RESET option allows erasing the whole system memory
including, calibration coefficients, full scale, language selection, measurement units, etc.
and the test data stored in the memory card.
It can be used to completely reset the system in case of system memory corruption.
WARNING:
Do not use the MEMORY RESET function unless authorized by CONTROLS Service
department. CONTROLS will not be held responsible for damages to the equipment
and/or injuries to personnel in case the above is not strictly followed.
Once this function is activated, the system will show the following screen;
Fig. 6-7
A double confirmation is requested before erasing the memory;
Fig. 6-8
After performing the MEMORY RESET all working parameters of the

equipment must be re-entered.
09/12/2009 122 Automax 5 Rev.3 EN

6.2 Troubleshooting
The following general considerations have to be taken into account when replacing the
boards of the Control unit:
• If the SIGNAL CONDITIONING BOARD has to be replaced (item 5 of chapter 7)
the calibration of the system must be checked/carried out as this board influences it
(see chapter 5.2.5);
• If the CPU board has to be replaced (item 7 of chapter 7), before removing it from the
machine save the present calibration data (see chapter 5.2.5.3 to access the
CALIBRATION MENU); then enter the calibration data in the new CPU board.
The following table provides a list of possible causes and checks in case a faulty
condition is encountered:
Type of fault Actions

The equipment does not turn • Check that mains supply voltage matches the functioning mains
ON (POWER ON lamp OFF) voltage of the equipment (see data on the machine plate);
• Check mains power supply line and proper plugging of mains
power cable (See Fig. 6-9);
• Check Mains switch 1QS1; replace it if necessary (See Fig. 6-9
and item 1of chapter 7);
• Check line fuse 1FU1; replace it if necessary (See Fig. 6-9 and
items 10 and 11 of chapter 7);
• Check POWER ON lamp 1HL1 and replace it if necessary (see
Fig. 6-15 and item 30 of chapter 7);
The equipment does not turn • Check that the Emergency button 1SB1 is not pressed (in case
ON (red LED on motor drive release it);
board OFF, green LED on • Check the emergency button and relevant contacts 1SB1 and
+24V power supply OFF, replace them if necessary (see Fig. 7-3 and items 28 and 29 of
display of control unit blank) chapter 7);
even though the POWER ON • Check that all cables within the control unit and the hydraulic
lamp is lit unit are properly attached (See schematics in chapter 8);
• Check console line filter 1FT1 (voltage at input and output);
replace it if necessary (See Fig. 6-10 and item 12 of chapter 7).
The control unit does not turn • Check the power cord of the control unit (its male side plugs
ON even though the into the main unit, its female side plugs into the control unit);
equipment turns ON (display (See Fig. 6-9);
of control unit is blank • Check that the mains switch of the control unit 1QS2 is turned
although the Power ON lamp ON (See Fig. 6-9);
is lit, the red LED on motor • Check line fuse of the control unit 1FU2; replace it if necessary
drive board is ON and the (Item 2 of chapter 7);
green LED on +24V power • Check that all cables within the control unit are properly attached
supply is ON) (see schematics in chapter 8);
• Check the output voltage (+12VCC) of the power supply of the
control unit 1GD2 (see Fig. 6-14, item 3 of chapter 7) and
replace it if necessary.
Automax 5 Rev. 3 EN 123 09/12/2009

The control unit turns on but • Open the rear panel of the control unit and check that all
the display remains interconnection cables between the CPU board 1SC1 and the
completely blank Display board 1SC3 are well attached (See Fig. 6-14);
• Check that the backlight cable of the display is well attached
(normally this cable has pink colour); (See Fig. 6-14);
• Check/replace the touch screen display board 1SC3 (See item 4
of chapter 7);
• On the CPU board check that the 3 green LEDs are on (power
supply voltages present) and that the red LED blinks
(microprocessor running), otherwise replace the CPU board
1SC1 (see Fig. 6-14 and item 7 of chapter 7)
The control unit turns on but • Open the rear panel of the control unit and check that all
the touch screen does not interconnection cables between the CPU board 1SC1 and the
accept commands from the Display board 1SC3 are well attached (See Fig. 6-14);
operator • Replace the touch screen display 1SC3 (See item 4 of chapter 7);
• Replace the CPU board 1SC1 (See item 7 of chapter 7).
The pump motor does not • Check that the red led on the motor drive board 1SC2 is ON;
operate otherwise check the fuses of the motor drive board (See Fig.
6-13);
• Check that the green LED on the motor drive board 1SC2 is ON
when the motor should be running; otherwise check (See Fig.
6-13):
1. Piston over travel switch 1IP2 and relevant interconnection
(See Fig. 6-11);
2. Wire short circuit jumper on 2nd frame safety cable (See
Fig. 6-10);
3. Door safety switch (or safety on 2nd frame) 1IP1 and
relevant interconnection (See Fig. 6-12);
4. Interconnection cable between control unit and machine
(See Fig. 6-9);
5. Signal at pin 9-10 of the Motor drive board 1SC2 terminal
block; (with all safety switches closed and the motor
enabled to run, it should read 0 ohm);
6. Voltage between pin 14-15 of the Motor drive board 1SC2;
it should be between 0-10V according to the motor speed
set on the control unit (0V=0%; 10V=100% speed); if
voltage is not present, check the CPU board 1SC1 of the
control unit;
7. Check power supply voltage to the motor at pin 3-4 of the
Motor drive board 1SC2 terminal block (see the table on
Fig. 6-13 for voltage readings/adjustment); if the voltage is
absent/wrong, replace the motor drive board 1SC2 or the
motor 1MD1;
The oil discharge electrovalve • Check that the green LED on the +24V power supply 1GD1 is
does not operate on (See Fig. 6-9);
• Check input and output voltage on the +24V power supply 1GD1
• Check the interconnection cable between control unit and
machine (See Fig. 6-9);
• Replace the electrovalve 1YV1 and/or 1YV2 (see items 22 and 3
of chapter 7);
• Replace the +24V power supply 1GD1 (See item 13 of chapter
7).
09/12/2009 124 Automax 5 Rev.3 EN


The load values on the display • Check that the load transducer cable is properly connected to the
are always zero, or always full control unit (see chapter 3 and items 25 and 26 of chapter 7);
scale, or unstable • Check that cable and connectors are not damaged;
• Check the status of the transducer;
• Check/replace the Signal conditioning board (See item 5 of
chapter 7).
The load values on the display • Check the system calibration (See chapter 5.2.5)
are not accurate
The machine does not crush • Refer to chapter 5.2.6.
the sample correctly
The machine does not stop • Check that the load transducer cable is properly connected to the
after crushing the sample (it control unit (See chapter 3.6)
keeps on running until it is • The START TEST PARAMETERS is not properly set (See
stopped manually) chapter 4.2.3.4)
The machine does not stop • Immediately after turning ON the unit, go to the MANUAL
after crushing the sample (it COMMANDS menu and check that the readings of the load
keeps on running until it is value on the display is not fix to 0; in such case adjust the
stopped manually) electronic offset of the load channel (see chapter 5.2.5.2);
afterwards perform the calibration of the load channel (see
chapter 5.2.5);
• If the load value remains 0 for a certain time after switching ON
and then shows a correct electronic offset value (approx. 1% of
the frame full scale), it means that the ADC circuit on the signal
conditioning board (it takes too long to start working); replace
the signal conditioning board (see item 5 of chapter 7) and
perform the calibration of the load channels (see chapter 5.2.5).
The printer connected to the • Check that proper serial cable is used (CONTROLS code 82-
serial port does not print or P0172/1)
does not print correctly • Check the status of the serial cable and replace if necessary (use
CONTROLS code 82-P0172/1);
• Check proper connection of the serial cable on both sides
(AUTOMAX control unit side and printer side);
• Check proper setting of the communication parameters on the
printer (see chapter 4.3 of the present manual and the manual of
the printer).
The computer connected to the • Check the status of the connection cable between AUTOMAX
serial port does not receive control unit and PC serial port, that it is properly attached on
data or does not receive them both sides and that it is of the “Pin-to-pin” type;
correctly • Check the setting of the serial port on the PC (see chapter 4.3 of
the present manual and the manual of the PC and
communication software in use).
The clock on the display is • The internal battery got discharged (e.g. the unit has been left
zeroed. unplugged from the mains supply for a long period of time):
connect the unit to the mains supply and leave it on for at least 8
hours to allow the internal battery to fully recharge
Automax 5 Rev. 3 EN 125 09/12/2009

Control unit
mains switch
Control unit power cable

Control unit
line fuse
Mains power cable
Interconnection cable
Line fuse
Fig. 6-9
+24V power supply
Safety interconnection wire

jumper for 2nd frame
Motor drive board
Line filter
Fig. 6-10
09/12/2009 126 Automax 5 Rev.3 EN

Safety over travel switch
Fig. 6-11
Door switch
Fig. 6-12
Automax 5 Rev. 3 EN 127 09/12/2009

Adjust MAX motor speed

Red LED
Green LED
DOT NOT TOUCH
Adjust MIN motor speed
Vout on pin 3-4 Vout on pin 3-4 POT. To adjust(if needed)

Speed % set on (motor behaviour) (motor behaviour) DO NOT TOUCH OTHER
Control unit 230VAC machine 110VAC machine POTS.
2% Motor starts turning Motor starts turning Nm
50% 85VCC 45VCC N.A.
100% 170VCC 90VCC NM
Fig. 6-13
Touch screen CPU board

display
Relay board
12VCC SM
power
supply
Signal
conditioning
board
Fig. 6-14
09/12/2009 128 Automax 5 Rev.3 EN

Power ON lamp
Emergency button
Fig. 6-15
Automax 5 Rev. 3 EN 129 09/12/2009

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

When ordering spare parts, please provide code number, serial number, year of
manufacture and any other useful information of the unit involved.
The following general considerations have to be taken into account when replacing the
boards of the Control unit:
• If the SIGNAL CONDITIONING BOARD has to be replaced (item 5 of chapter 7)
the calibration of the system must be checked/carried out as this board influences it
(see chapter 5.2.5);
• If the CPU board has to be replaced (item 7 of chapter 7), before removing it from the
machine save the present calibration data (see chapter 5.2.5.3 to access the
CALIBRATION MENU); then enter the calibration data in the new CPU board.
WARNING:
at least 5 minute.
WARNING:
them attached to the unit as this may endanger operator safety.
and locked.
WARNING:
WARNING:
failure, components may only be replaced by using original spare parts.
09/12/2009 130 Automax 5 Rev.3 EN

Q.tà in una
Codice ricambio/ macchina/
Ref. Descrizione Description
Spare part code Q.ty in one
unit
1 68-Q0502/R07 Interruttore unità di comando Control unit mains switch 1
Fusibile unità di comando Fuse control unit 1,25AT
2 68-Q0502/R08 1,25AT (scatola di 10 pezzi) (pack of 10 pieces)
1
Alimentatore 12VCC switching Control unit 12VCC switch
3 68-C5052/R02 1
per unità di comando mode power supply
4 68-C5052/R01 Display touch screen Touch screen display 1
Scheda condizionamento
5 68-C5052/R03 segnale
Signal conditioning board 1
6 68-C5052/R04 Scheda relay Relay board 1
7 68-C5052/R05 Scheda CPU Automax Automax CPU board 1
8 68-C5012/R03 Cavo interconnessione 25 poli 25-poli interconnection cable 1
9 68-Q0502/R09 Interruttore console Console mains switch 1
Fusibile console 230VAC Fuse console 230VAC 6,3AT
10 68-C5012/R15 6,3AT (scatola di 10 pezzi) (pack of 10 pieces)
1
Fusibile console 110VAC Fuse console 110VAC 10AT
11 68-C5012/R16 10AT (scatola di 10 pezzi) (pack of 10 pieces)
1
12 68-C5012/R10 Filtro di linea per console Line filter for console 1
13 68-C5012/R01 Alimentatore 24 VCC Power supply 24VCC 1
Scheda azionamento motore
14 68-C5012/R11 230VAC
Motor driver board 230VAC 1
Scheda azionamento motore
15 68-C5012/R17 110VAC
Motor driver board 110VAC 1
16 68-C5012/R12 Gruppo pompa Pump assembly 1
Pump assembly high delivery
17 68-C5012/R18 Gruppo pompa maggiorato 1
version
18 68-C5012/R13 Guarnizione pompa Pump gasket 1
19 68-C5012/R07 Motore pompa 230VAC Pump motor 230VAC 1
20 68-C5012/R19 Motore pompa 110VAC Pump motor 110VAC 1
21 68-C5012/R08 Olio ATF ATF oil 6-9 Lt.
Single output block
22 68-C5012/R04 Elettrovalvola blocco singolo
electrovalve
1
Double output block
23 68-C5012/R20 Elettrovalvola blocco doppio
electrovalve
2
24 68-C3100/R07 Tubo connessione idraulica Hydraulic connection tube 1-2
25 P0354 Trasduttore pressione 700Bar Pressure transducer 700Bar 1
26 P0354/ELT Cavo trasduttore pressione Pressure transducer cable 1
Micro-switch extra-corsa Piston overtravel
27 68-C5012/R14 pistone microswitch
1
28 68-C5012/R24 Pulsante di emergenza Emergency button 1
29 68-C5012/R25 Contatto pulsante emergenza Emergency button contact 2
30 68-C5012/R26 Lampada “Power ON” “Power ON” lamp 1
Automax 5 Rev. 3 EN 131 09/12/2009

8
9
10 11
Fig. 7-1
7
4
Fig. 7-2
09/12/2009 132 Automax 5 Rev.3 EN

29
13
14
15
12
Fig. 7-3
23
24
Fig. 7-4
Automax 5 Rev. 3 EN 133 09/12/2009
16
17
Fig. 7-5
19
20
22
18
Fig. 7-6
09/12/2009 134 Automax 5 Rev.3 EN

27
26
25
Fig. 7-7
18
Fig. 7-8
Automax 5 Rev. 3 EN 135 09/12/2009

30
28
Fig. 7-9
09/12/2009 136 Automax 5 Rev.3 EN

8. SCHEMATICS AND DRAWINGS

1. Control board (CPU) layout
2. Electrical diagram 230VAC version
3. Electrical diagram 110VAC version
4. Components identification
5. Load sensor cable pinout
6. Power unit-Control unit interconnection cable
Automax 5 Rev. 3 EN 137 09/12/2009

09/12/2009 138 Automax 5 Rev.3 EN

Automax 5 Rev. 3 EN 139 09/12/2009

09/12/2009 140 Automax 5 Rev.3 EN

ELECTRICAL COMPONENTS IDENTIFICATION
COMPONENT
COMPONENT DESCRIPTION
NAME
CONSOLE FUSE 6,3AT (230VAC VERSION)
1FU1
CONSOLE FUSE10AT (110VAC VERSION)
1FU2 CONTROL UNIT FUSE 1,25AT
1GD1 SWITCH MODE POWER SUPPLY 24VCC 2,5A
1IP1 DOOR MAGNETIC SWITCH
1IP2 PISTON OVERTRAVEL SWITCH
1MD1 PUMP MOTOR CC
1QS1 MAINS SWITCH
1QS2 SWITCH CONTROL CONSOLE
1SC2 MOTOR DRIVE BOARD
1FT1 LINE FILTER
1SC1 CONTROL UNIT CPU BOARD
1SC3 CONTROL BOARD LCD TOUCH PANEL
1GD2 SWITCH MODE POWER SUPPLY 12VCC
1YV1 ELECTROVALVE FRAME #1
1YV2 ELECTROVALVE FRAME #2
1SB1 EMERGENCY BUTTON CONTACT
1HL1 POWER ON LAMP
Automax 5 Rev. 3 EN 141 09/12/2009

09/12/2009 142 Automax 5 Rev.3 EN

25-PIN MALE CONNECTOR

POWER UNIT – CONTROL UNIT INTERCONNECTION CABLE
PIN TO PIN CONNECTION
25-PIN FEMALE CONNECTOR
Automax 5 Rev. 3 EN 143 09/12/2009

Notes:
09/12/2009 144 Automax 5 Rev.3 EN

Notes:
Automax 5 Rev. 3 EN 145 09/12/2009

Notes:
09/12/2009 146 Automax 5 Rev.3 EN

Manuale Di Istruzioni Instruction Manual: Automatic Control Console Compression Machine

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2009 Series

Automatic Control Console

Automax 5 Rev. 3 EN i 09/12/2009

4. USE OF THE EQUIPMENT 51

09/12/2009 ii Automax 5 Rev.3 EN

6. DIAGNOSTICS & TROUBLESHOOTING 111

7. SPARE PARTS 130

8. SCHEMATICS AND DRAWINGS 137

Automax 5 Rev. 3 EN iii 09/12/2009

This Manual is published by CONTROLS.

09/12/2009 iv Automax 5 Rev.3 EN

The AUTOMAX 5 automatic compression testers represent a more sophisticated and

Main features are:

The system is mainly composed by:

Automax 5 Rev. 3 EN 1 09/12/2009

09/12/2009 2 Automax 5 Rev.3 EN

1.1 Icons appearing in the manual

Automax 5 Rev. 3 EN 3 09/12/2009

1.2 Manual revision history

09/12/2009 4 Automax 5 Rev.3 EN

1.3 Symbols used

Conformity to the CE Directive

Automax 5 Rev. 3 EN 5 09/12/2009

1.4 Safety information

CONTROLS will not to be held responsible for:

Installation and any technical intervention must only be performed by qualified

The operator is responsible of starting-up the equipment, performing the test

Maintenance and service activities can only be performed by skilled authorized

09/12/2009 6 Automax 5 Rev.3 EN

Max pressure valve

Automax 5 Rev. 3 EN 7 09/12/2009

• Front and rear transparent fragment guard

Front fragment guard

• Access panels to internal devices fixed with screws.

09/12/2009 8 Automax 5 Rev.3 EN

Personnel Area with residual risks

Automax 5 Rev. 3 EN 9 09/12/2009

09/12/2009 10 Automax 5 Rev.3 EN

Automax 5 Rev. 3 EN 11 09/12/2009

09/12/2009 12 Automax 5 Rev.3 EN

Automax 5 Rev. 3 EN 13 09/12/2009

09/12/2009 14 Automax 5 Rev.3 EN

1.5 Environmental risks and disposal

INFORMATION TO THE OWNER OF THE EQUIPMENT

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

Automax 5 Rev. 3 EN 15 09/12/2009

09/12/2009 16 Automax 5 Rev.3 EN

Automax 5 Rev. 3 EN 17 09/12/2009

Fig. 2-3 AUTOMAX 5 C505X stand-alone control console

09/12/2009 18 Automax 5 Rev.3 EN

2.2 Compression platens and ball seating

2.3 Loading cylinder assembly

2.4 Hydraulic unit

Automax 5 Rev. 3 EN 19 09/12/2009

Main features of the Hydraulic unit are:

2.5 Command and control unit

Main hardware features are:

09/12/2009 20 Automax 5 Rev.3 EN

Main features of the firmware are:

Automax 5 Rev. 3 EN 21 09/12/2009

2.6 System block diagram

09/12/2009 22 Automax 5 Rev.3 EN

Automax 5 Rev. 3 EN 23 09/12/2009