OPERATING INSTRUCTIONS FOR DIGITAL
COMPRESSION TESTING MACHINE CAPACITY 2000KN
OPERATING INSTRUCTIONS FOR DIGITAL
COMPRESSION TESTING MACHINE CAPACITY 2000KN
INTRODUCTION: The ultimate consideration in concrete
structural design is an attainment of desired Strength Tests conducted on
sample pieces ensure the concrete is in accordance with given specification. The large capacity Compression Testing
Machine prove in valuable in large construction sites like, Dam, Bridges,
Airstrips, River Valley Project, Large Mines and Research Laboratories. They can be used for testing cubes up to
150mm x 150mm and 150mm long cylinders and also very high strength specimen of
a smaller capacity. The machine
generally confirms to IS-516, B.S.S. 1610, 1881 and various other international
standards.
LOADING UNIT : (Load
Frame) It consists of a steel cross head and machined steel base with four
tension rods connecting the base and the cross head and firmly tightened by
means of nuts. The machine is covered
three sides with wire mesh door in front and wire mesh fixed shelves in right
and left side. The Hydraulic Jack
(Piston Cylinder) of 2000KN capacity is fixed on the base. The upper platen has a self aligning action
and is attached to a block protruding from the cross head. The lower platen rests on the jack ram and
positioned centrally with the help of a centering pin. Loading is accomplished by the upward
movement of the lower platen. The lower
and the upper platen of the machine are hardened and ground. Markings are provided on lower platen to keep
the specimen centrally and coaxially with the hydraulic jack. A dust cover is provided on the jack to
prevent any dust penetrating into cylinder of the jack.
Three spacer with centre locating pins are provided to the
inserted in between the lower platen and hydraulic jack reduce the excessive
gap between the two platens when small specimens are to be tested. The centering pin also prevents the platen
slipping out of the assembly while loading or failure of sample.
PUMPING UNIT: Digital pumping unit motorized in an elegant
console wired for 220v. Single phase
50 Hz power supply. Two plungers
with reciprocating motion operate to pump oil.
The plungers are operated by cam activated by motor. A oil reservoir has a total cap of 5 ltr
(approx.) and is sent with a full charge of multigrade oil of grade 20/40. A transparent tube oil level indicator is
provided on the tank. A load Indicator
of Four Digit LED display is fitted on the panel with facility of overload cut
off. The load indicator is calibrated by
certified Proving Ring. A pressure release valve is provided to start loading
when open the oil will return to the pump even when pump are pumping. A slow fast knob a flow adjustment valve is
provided to adjust rate of flow. A clock
wire rotation increases flow and thereby rate of loading and anticlockwise,
position allows no flow of oil from pump.
A power on switch and power off switch is provided to start stop the
machine. An indicator lamp is provided
to indicate that power has gone into the unit.
The loading unit assembly is connected to the console with the help of pipe.
Setting and Assembly:
Unpack the boxes with base down. The
columns and pumping unit console are sent in separate boxes. Fix both the load frame and pumping unit
module on a level ground. Foundation is
not essential. If the machine is to be permanently fixed, the load frame can be
fitted on to 6” slab and bolted. Connect
the load frame to the pumping console using rubber hose pipe provided. Connect the load frame to the pumping console
using rubber hose pipe provided. Connect
console to 220 volts single phase 50Hz A.C. supply. The red indicator lamp glows showing the
console has received power supply.
Ø
Switch on the Digital Indicator
Ø
Press the zero button and the peak button to
enter the peak hold mode.
Ø
Close the release valve
Ø
Place the cube into Load frame to test ON the
lower platen with suitable spacers and closed the wire mesh door for safety
precaution.
Ø
Switch on the machine pump to start apply load
on cube.
Ø
Adjust the slow/fast knob for proper rate of
loading.
Ø
Peak valve is stored in the memory as soon as
the specimen is broken/crushed. Switch
off the machine and release the pressure with help of release valve. Allow the piston to come down. Open the wire mesh door and remove the broken
specimen. Clean the platen and place the
next cube and start the above process again.
Reset the peak button to bring the digital back to zero.
MAINTENANCE:
Ø
The machine should always keep clean.
Ø
The platens and all other unpainted parts should
be greased when not in use to prevent rusting.
Ø
The Oil level in the pump should be maintained
between the oil indication level.
Ø
In no case the pump should be operated when
there is no oil in the pump or the oil level is below the lower mark.
Ø
Hydraulic oil Servo System 526 of Indian Oil
Corporation is filled in the mach. This
Oil or any equivalent oil only should be used.
Ø
When oil starts leaking from the jack cylinder
piston the seal should be replaced.
Ø
The oil in the system should be changed half
yearly as a normal practice but this period can be increased and decreased
according to the use of the machine.
Ø
Over tightening the pressure release valve
should be avoided. It should be kept a
couple of turns unscrewed this is not being used.
Ø
Care should be taken not to take out the ram
more than 50mm (maximum limit)
Ø
The machine should never be over loaded beyond
its capacity.
WARNING
THE TRAVEL
OF THE PISTON NOT MORE THAN 25MM TO AVOID PERMANENT DAMAGE TO THE MACHINE
CONVERSION
1 KGF = 9.80665 Newton
1KN = 101.971 kgf
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