Figure 1: Dimensions of the UTC-4722.FPR    2

Figure 2: Parts of the UTC-4722.FPR    4

Figure 3: Front Side, Back Side and the Parts of the Machine    6

Figure 4: Main Tab    12

Figure 5: Plot Settings Tab    12

Figure 6: Parameter Settings Tab    13

Figure 7: Specimen Tab    15

Figure 8: Test Parameters Tab    16

Figure 9: Results Screen    18

Figure 10: Settings Tab    19

Figure 11: Date/Time Tab    20

Figure 12: USB Storage Tab    21

Figure 13: Unit System Tab    22

Figure 14: Language Tab    23

Figure 15: Password Tab    24

Figure 16: Calibration Tab    25

Figure 17: Gains Tab    28

Figure 18: Channels Tab    29

Figure 19: PID Screen    30

Figure 20: Auto-tuning Screen    31

Figure 21: Base Tab    32

Figure 22: Eye Bolts and Apparatus    35

Figure 23: Pieces of the Knob    35

Figure 24: Placing the Knob into its Place    36

Figure 25: Piston Assembly    38

Figure 26: Different Sizes of Distance Pieces    39

Figure 27: Combination Examples for 380 mm Vertical Clearance Models40 Figure 28: Network and Internet Settings    42

Figure 29: Changing Adaptor Options    42

Figure 30: Properties for Current Connection    43

Figure 31: Accessing IPv4 Option    43

Figure 32: Setting Correct IP    44

Figure 33: Choosing Test Type    45

Figure 34: Main Menu of the Software    46

Figure 35: Axis Settings    47

Figure 36: Device Parameters    48

Figure 37: Extraction of Box    52

Figure 38: Fuse with its Spare    52

This manual contains important information on the safe usage and maintenance  of  UTC-4722.FPR  AUTOMATIC  COMPRESSION  TESTING

MACHINE and of its related components. Please read through the manual carefully before operating the device for the first time and keep it for the future reference.

UTEST General Terms and Conditions of Sales and Delivery apply in all cases. Warranty and liability claims arising from personal injury and damage to property cannot be upheld if they are due to one or more of the following causes:

5. Unauthorized modifications to the device and its components.
6. Failure to use the instrument in accordance with its designated use and purpose which is described in this manual.
7. Failure to adhere to the sections of the manual dealing with the performance check, operation and maintenance of the instrument and its components.
8. Incorrect performance checks for operation and maintenance of the instrument and its components.
9. Damage resulting from the effects of foreign bodies, accidents, vandalism and force majeure.

The instrument is only to be used for its designated purpose as describe herein. Replace faulty components only with original replacement parts from UTEST. Accessories should only be installed or connected to the instrument if they are expressly authorized by UTEST. If other accessories are installed or connected to the instrument, then UTEST will accept no liability and the product guarantee is forfeit.

This part contains important safety instructions that the user must follow for operation and storage of UTC-4722.FPR.

9. Device should be seated on a steady base.
10. Always follow basic safety precautions when using this product to reduce risk of injury from any dangerous situations.
11. Read and understand all instructions in the documentation that comes with UTC-4722.FPR.
12. Make sure the front and rear transparent durable plexiglass guards is in place and not damaged and close position before starting to the test.
13. Observe all warnings and instructions marked on the product.
14. Before removing any covers or performing maintenance repair and service, isolate from electrical supply by removing mains plug.
15. Shut down the hydraulic power supply and discharge hydraulic pressure before disconnection of any hydraulic fluid coupling.
16. After the test, clean the upper platen, lower platen and distance pieces thoroughly with a brush and cloth and make sure that no parts remain.
17. Avoid contact with these materials if any organic or inorganic chemicals are used in the test to be performed with the equipment. Wear safety glasses, gloves and a lab coat before starting the test.

14. Oil the specifications of which are given in the instruction manuals must only be used in the ball seating and the oil tank. Do not use or mix different type oils. Otherwise, there may damage on the surface of the ball seating, which prevents the machine to load uniformly.
15. Do not change the calibration settings of the machine.
16. If the instructions given in troubleshooting cannot help to solve your problem, plug out the power cable and call UTEST technical service.
17. Do not lean the cabinet to the wall at zero distance.
18. While the test is in operation do not remove any covers or attempt to adjust any part of the machine.

WARNING: The equipment is not allowed to be operated by children or anyone under the influence of alcohol, drugs or pharmaceutical preparations. Anyone who is not familiar with this manual

must be supervised when using the equipment. Carry out the stipulated maintenance properly and at the correct time. Following completion of the maintenance tasks, perform a functional check.

Safety features of the machine is following:

8. Maximum pressure valves to avoid machine overloading
9. Front and rear transparent durable plexiglass guards
10. Emergency stop button

10. Software controlled maximum load value
11. Piston travel limit switch

15. Do not place any heavy objects on the device.
16. Avoid any impact or rough handling that might damage the device.
17. Do not change the calibration settings of the machine
18. Do not disassemble UTC-4722.FPR.
19. Install the product in a protected location where no one can step on or trip over the power cord and in a location where the power cord cannot be damaged.

Tests can be performed by either on U-Touch Screen or on a computer with using free UTEST Software. There are several advantages of performing tests on computer with using UTEST Software, such as reporting and graphical output.

This exceptional performance enables the machines to be used for a considerable number of applications including:

19. Early age compression strength tests,
20. Flexural tests by using proper accessories,
21. Mortar (Cement) compression tests by using proper accessories,
22. Core with low diameter compression tests

For the dimensions of the UTC-4722.FPR see Figure 1.

UTC-4722.FPR Testing Machine is supplied complete with;

22. Ø 165x100 mm, Ø 165x50 mm, and 2 pieces Ø 165x30 mm distance pieces,
23. Removable transparent front-rear plexiglass guard.
24. Fixture for Centering Specimens

Table 1: Technical Specifications of UTC-4722.FPR

Parts of the machine can be seen in the Figure 2.

Table 2: Spare Parts List

Hydraulic power unit is the complex part that provides the hydraulic energy required by the system in hydraulic systems. This device can be used with other hydraulic operating equipment of the UTEST. The hydraulic unit of the UTC-4830.FPR consists of dual stage pump, motor, distribution block and oil tank.

Distribution block is used to control the oil flow direction supplied by the dual stage pump and the following hydraulic components are fitted to it:

5. Solenoid valve
6. Safety valve (maximum pressure valve)
7. Transducer
8. Low pressure gear pump
9. High pressure radial piston pump
   
10. 
    

UTC-4830.FPR U-Touch PRO Control Unit, designed to control the automatic compression/flexure testing machines for compression, flexure, splitting tensile strength tests of construction materials such as concrete, cement mortar, brick processing of data from load-cells, pressure transducers or displacement transducers.

All the operations of U-Touch PRO Control Unit are controlled from the front panel color resistive touch screen display and function keys. The unit can be configured as using for two frames or one frame with three displacement transducers. The Control Unit has easy to use menu options. It displays all menu option listings simultaneously, allowing the operator to access the required option in a seamless manner to activate the option or enter a numeric value to set the test parameters. Its specimen setting sub- menu lists different specimen types including but not limited to cube, cylinder, block, beam, beam double upper bearers, cube splitting tensile, cylinder splitting tensile, paving block splitting tensile and kerb flexure. Digital graphic display of the unit is able to draw real-time "Load vs. Time" or "Stress vs. Time" graphics. Main Features of the control unit is following:

3. 4 analog channels for load cell or pressure sensors or displacement sensors.
4. Provides load control of two separate testing frames with Closed- loop PID.
5. Support for -optionally supplied- integrated thermal printer

11. Real time display of test graph
12. Backup and recall option for device settings
13. Easy recall of embedded test parameters for different types of tests and sample sizes
14. Three different units (kN, kgf, psi)
15. Real time and adjustable date/ tim.
16. Multi-language    support    (English,    French,    Spanish,    Turkish, Russian…)
17. LAN connection for instantaneous transfer of test data to PC.
18. USB port support for transfer of test data to a flash drive.
    
19. 
    
20. In the main tab, on the left column, load, and stress is shown separately in their individual boxes in kN and MPa respectively (see Figure 4). These are the live values that come from the sensors except for the stress value. Stress value is simply the division of the live horizontal load to the area of the specimen that will be selected. Moreover, in the same column, some summary information about the upcoming test is listed (test number, status of the test, selected test speed, test type, and the specimen type).
    

In this section there are three sub-tabs in which the test type, test parameters, and the specimen shape properties are defined (see Figure 6).

Test Type: Various types of test and samples can be tested with this readout unit. Types are Compression, Tensile, and Split Tensile.

Control Mode: Two types of modes can be selected. In auto mode pace rate entered by the user is adjusted from PID system automatically after starting the test. In manual mode is used generally for calibration and load verification times. After choosing manual mode pace rate can be adjusted from the black button in front of the hydraulic unit.

Frame Selection: Two frames can be connected to UTC-4830.FPR simultaneously. The two connected frames can be connected to either a compression testing machine used for the compression test or a compression and a tensile device. In this menu, you can select the frame you have connected to the device and perform tests with the device you have selected.

Decimal Point: Decimal Point is used for adjusting the number of digits after decimal point for load, stress and other channel values.

Start speed: It is not recommended to change this value by the user. It defines the approach speed of the piston to the sample. The desired speed of the test is multiplied by the percentage written here. The device proceeds with the obtained speed until loading onto the specimen begins. When the device starts to apply a load to the specimen, the selected test speed enters the circuit. These two stages are controlled by a dual stage pump. After the piston touches the specimen, the radial piston pump is activated.

Max load: One of the safety features of the machine that stops the motor to prevent over loading. The max load value must be selected 10% of the max capacity of the frame to make calibration at max capacity value.

Failure threshold: Below this value no failure will be detected by the machine. At the start of the test, there may be small fluctuations in the load reading due to micro-cracks or electrical noise and this option can be used to enable the machine to continue the test even when load decreases below this value. For example, if this value is set as 3 kN and if load decreases 50% for half a second at 2 kN machine will continue the test. In the same situation if this value is set as 1 kN, machine will stop the test.

Zero Suppression: This option defines the value below which readings are filtered. Below 1% capacity of the load cell, machine can only read electrical noise. Instead of visualizing electrical noise, machine will filter these values as 0 and displays a stable value.

Break percentage: This value defines the break detection algorithm of the machine. In real time, the machine constantly takes the current reading value and compares it to the maximum value reached during the test. When the ratio of current value to maximum value reaches this value defined by the user, test will be stopped. For example, if this value is 10% and the peak stress is 400 kPa. The test will be terminated when the stress value falls to 360kPa. (400 x 10% = 40; 400 – 40 = 360)

Pace Rate: Test speed for tests can be adjusted in this box. There are two different test speed unit. First one is kN/s and the other one is MPa/s.

Device can be adjusted for both test speed. For example, you enter a speed with MPa/s unit, device automatically convert this value to kN/s.

Record Raw Data: Raw data during the test can be recorded with desired intervals to the internal memory of the touchscreen. Please note this function uses internal memory of the machine and logs should be dumped to flash drive very often if this function is checked with low intervals.

Settings tab contains the company, date/time, USB storage, language, and password. All of the sub-tabs is explained in the following section (see Figure 10).

In the company screen, on the left side UTEST logo and the contact information of UTEST is displayed. With the box on the right side, theme selection for the screen is possible.

By using the box placed on the right side of the screen; year, month, day, hour, minute, and second values can be input and then by pressing the “SET” button, date and time settings are done (see Figure 11).

There are two boxes in the screen under “USB STORAGE” tab (see Figure 12). The first box is used in data transfer from the memory of the control unit to a usb stick. By touching the Refresh button the current memory status can be displayed in percentage. The Clean Storage deletes the recorded test results (both txt and excel files) and clears the memory.

When the Unit System is changed, PID settings must be made again. For example, when switching from kN to lbf, the speed of the device is not at the desired setting. PID values need to be reconstructed. How to change PID values is explained in section 3.5.3.

WARNING: The Calibration menu is reserved to the authorized service personnel and should only be entered when the

calibration needs to be changed. UTEST will not be responsible for any damage caused by improper setting of these parameters. Warranty will be void if this menu is used by unauthorized personnel.

These values are located under the value column. The first value must be zero. Since values getting from pressure transducer are transformed to the load values, second calibration point must be selected around 50-100 kN. Other calibration points can be set by increasing the value as 10% or 20% of the maximum load capacity of the machine.

First adjust the pace rate value to zero by rotating the Pace Rate & Calibration adjusting knob (Potantiometer) located rigt side of the U- TouchPRO Screen to counter clockwise position.

To start getting Raw-Values, start the calibration operation by placing the load cell between the upper plate and distance pieces of the compression press. After that press start button. While the machine is running, import the first calibration point value before the upper platen touch but not apply load to the loadcell. After that rotate the Pace Rate & Calibration adjusting knob to the clockwise direction slowly. Then, after reaching the actual data written for P2, press the "get raw" key and save the millivolts value by the transducer. Then continue to rotate the Pace Rate & Calibration button, and when it reaches the second value (P3), press "get raw" as for the first value. When the value in the Real-Value column is matched with the value you read from the load cell placed in between the plates do the same process until completing raw-values to import at all calibration points. When all calibration points are calibrated press Stop Button to unload the machine. Press Save To Memory to save changes for calibration.

Verification of the Calibration: Since load measurement system verifications are required for International Standards, verification must be performed by an expert engineer whose tools are approved for verification.

Gain values of each channel can be arranged by using this menu. First box is for gain control and it is used to arrange gain values of channels. Second box (GAINS) in the middle shows the present gain values for each channel. The last box (RAW DATA) displays the live raw data of channels to check the saturation. (see Figure 17). As an information the gain options of some sensors are given in the Table 3.

Figure 17: Gains Tab Table 3: Gain Options of Some Sensors

NOTE: Gains of each channel is optimized according to the sensors supplied with UTEST as ex-factory. Gain menu is only for the use of UTEST Technical Service Staff. Unauthorized

changes may result in wrong test results or even damaged sensors and mechanical parts of the device and the device will be out of warranty.

Channel selection is made from the upper left part of the screen. There are three channel options (Channel 2, Channel 3 and Channel 4); for load cell, horizontal and vertical displacement transducers, and pressure transducer. By using this channels any of the device connected to the UTC 4830.FPR can be calibrated or data can be recorded or tests can be done for connected devices. For example, two different type of machine can be connected to the UTC 4830.FPR at the same time using different channels. To do so, simply connect the socket of the machine to the socket of the channels of the UTC 4830.FPR. If two different machines are connected to the UTC 4830.FPR, these devices can be controlled separately as channel 3 and channel 4 from choosing device that want to be controlled the frame selection section.

Depending on the structure of each specimen, the behaviour under load is different and these specimens must first be introduced to the UTC- 4830.FPR. Taking this difference into account, the PID values (Kp, Kd and Ki values) must be calculated and written in their place on the PID screen. This calculation is performed by Auto-tuning. First, the shape information of the sample is selected from the Coefficient screen (eg. CUBE). After that First Speed, Second Speed and Switch Time values are entered in Autotuning screen. These are the default values and are 20%, 50% and 15 respectively. The First Speed is the speed at which the machine starts to compress itself to pick up the specimen and then the machine applies the load at the Second Speed and recognizes the sample. As a result of this operation, it calculates the Kp, Kd and Ki values of that sample, these values should be written in their places on the Coefficient screen and press the SAVE button.

NOTE: These values (Kp, Kd and Ki values for each type of specimen) of each sample are entered as default by UTEST.

Files: Files transferred by UTEST technical service personnel can be loaded to the machine using this tab.

Base: IP and theme selections, frame selections can be made on this tab. Theme changes the visual display of the touchscreen. The IP, SM, and GW values written in Figure are the current values set by UTEST. Do not change these values. (see Figure 21).

Table 4: UTC-4722.FPR Electrical Connection Properties

Main electricity line must be free from instabilities and repetitive power cuts for both the extended life of the device and the continuity of testing. Therefore, make sure that the mains supply is well grounded. If the power cuts are frequent or the grounding is not well enough, the use of an uninterruptible power supply (UPS) is recommended.

Make sure that the device is placed in a clean and dry surrounding. Direct contact of the device with the sunlight should be avoided. A conditioned room for example, will comply the above conditions and will result in best operational performance and measurement results. Device should be well

accessible from the front and the sides for connections, testing and maintenance.

In order to prevent inaccurate test results, the ground should be rigid enough to minimize vibrations or shocks. If there are any other testing equipment or a source that creates vibrations on the floor, UTC-4722.FPR should be placed maximum possible distance to that source. Surface of the ground should be horizontal and smooth enough so that the horizontal and vertical alignment of the device are not shifted.

NOTE: If remote assistance will be required from the UTEST Technical Service Department, the room should have an internet access.

You can use the 2 eye bolts on the top when carrying the device.

Read the requirements of the standard to be applied before starting the test. Prepare all the materials needed to perform the test. First, plug the power cord into the back of the hydraulic unit, then plug it into the power outlet. Then turn on the power switch by pressing the on / off button. Second, open the plexiglass guard and place the distance pieces according

to the size of the specimen. You are going to place distance pieces in order to ensure that they are firmly attached to each other. Examples of how the distance pieces are selected according to the sample size can be seen in the Figure 27. Then place the concrete sample in the middle of the bottom plate. Close the plexiglass guard and lock the door securely.

After that go to parameter tab be sure that auto control mode is selected. Once the machine has been prepared (after the autocontrol mode selection checking) the only required operations are;

1. Choosing test type under “Test Type” Menu

2. Entering dimensions of the specimen under the “Specimen Menu”

4. Setting test parameters, including pace rate (only required when the specimen type is changed).
5. Pressing the START button on the control unit.

The machine automatically starts the rapid approach, when the specimen touches the upper platen the rapid approach is ended and starts loading at the pace rate that selected by user and stops once the specimen fails and automatically saves the test parameters and test results.

Compression Platens and Ball Seating:  The two compression platens; Upper Platen and Lower Platen. There are marks on the lower platen to center samples properly. The upper platen is fitted to a ball seating. The ball seating is filled with oil number 10.

Loading Cylinder Assembly: The piston placed into the frame moves only up at vertical direction. The frame has a single acting upstroking loading cylinder assembly (see Figure 25). The diameter of piston changes with respect to the capacity. There is a low friction coaxial PTFE seal between the cylinder and the piston fitted to the cylinder.

Distance Pieces: Depending on test specimen, it is possible to adjust the vertical clearance between the lower and the upper platens by using distance pieces. Ø165x30 mm, 50 mm and 100 mm distance pieces are given with UTC-4601.FPR.

The distance pieces must be placed in between the lower platen and the piston. During this process, the surface area of piston and the distance pieces must be free from dust. Any deterioration on the piston surface will cause non-homogenous loading and other parts to get deteriorated. Distance pieces must be placed underneath of the lower platen.

There are some recommended distance pieces for these machines. Please check Figure 27 for combination examples for 340 mm vertical clearance models UTC-4601.FPR. Please consult UTEST for different size distance piece applications.

NOTE: Maximum piston movement is 50 mm. After 50 mm movement, the piston touches to the limit switch fitted on the frame and thus stops the motor, so depending on the size of the

specimen, the distance between the upper and lower platen should be decreased by placing the correct distance pieces.

Establish the connection between Hydraulic Power Pack and the computer using the cable provided. Plug the end of the cable into the ethernet port on the back of the hydraulic power pack. Plug the other end of the cable into the port of your computer.

To establish the connection, make sure the IP of your computer is set to 192.168.1.176. The IP of the digital display unit should be left as default. You can refer to the following figures to change your computer’s IP to 192.168.1.176.

First, as shown in Figure 28, right click on the "Network” and select “Open Network and Internet Settings”.

Run the software using the application (*.exe) file. When the software is launched users will be greeted with software main menu as shown in Figure 33. On this interface different type of tests will be displayed.

After selecting the test to be done with the device from this menu, the main interface of the software will appear. The features of the menus in this interface are described below.

This menu is password protective menu. To open this menu password which is 88378 should be entered from password menu. There are 3 different sub- menu options under this menu.

You can change the unit of parameters such as stress, pressure that will be used for the test you will perform under the Unit System Menu, the first of which is. Under the Axis Settings Menu, you can make changes for the values on the x-axis and y-axis of the graph where the test is observed instantly. For example, under this menu, you can increase or decrease the dimensions of the graph by changing the values such as maximum stress and maximum time. The third menu is the Device Parameters Menu.

The values found under this menu are the interface with the same values as those found under the Test Parameter Tab menu of U-Touch PRO. You can learn what these values mean by reading section 3.1.3. At the same time, under this menu, if 2 different test bodies are connected to your hydraulic unit (for example, a bending and compression body), you can select the body you will test and make the test type under this menu. In the Main Menu Setting user can be choose test types that is appeared when software is launched (see Figure 33). With this menu, you can only see the tests you will do with the device and gain an easier use.

In this screen under the password tab, the admin password box is displayed. Entering the password activates the Settings Menu (Password is 88378).

NOTE: While choosing a test name for the test file please only use English characters and make sure save path, i.e. folder names for the save path also contains only English characters.

After creating a new test file from File Menu, prepare the device and the specimen for the test. This procedure is same with procedure described in section 5. After that enter the dimensions and the test rate from the software at the right side of the interface. After that under Device Parameters Menu choose frame and test type and enter load speed. Then

press SEND and SAVE buttons. Come to the main screen and press play button on left-bottom of the screen to start the test. Once a test is finished other tests of the same set can be performed by changing sample. To get the results of the test, if you want to get Report in the bottom right corner of the main screen or only the graph report, the report can be obtained by pressing the Graph Report tabs in the same place.

WARNING: It is important to care that the unit must be switched off and the main cable must be removed before starting any

maintenance for user’s safety.

All safety devices must be functional at all times. Damaged protective covers or devices must be replaced as soon as possible. When safety components are replaced, the protective devices are to be properly attached and tested.

We recommend that the device is cleaned of any particles and dust from the scattered specimen after the test with a damp cloth and brush to avoid incrustations which could damage the paint work.

As with all electrical equipment, machine must be used correctly and maintenance and examination must be performed at regular periods. Such precautions will guarantee the safe and sufficient functioning of the equipment.

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