82pilot Operating Rev 0 Us 12 Set 2001
82pilot Operating Rev 0 Us 12 Set 2001
82pilot Operating Rev 0 Us 12 Set 2001
PILOT
OPERATING MANUAL
INSTRUCTION MANUAL
PILOT pag. 2
OPERATING MANUAL
INDEX
11 CONNECTIONS ....................................................................................................................... 14
OPERATIVE MANUAL. This describes the normal operation procedures of the unit; selection of test type, input of sample data,
test, saving of test results, printing and down loading of test results to P.C. this manual is written for the operator who performs
the test.
SET-UP MANUAL. This describes the calibration procedure and the setting of fondamental machine parameters (full scale,
channel designation etc.). It is written for the technician who can access these functions using a Password.
IMPORTANT: Read these instructions carefully before accessing the calibration function of PILOT. The information contained
in this manual should be reserved for the technician only and not for the general operator. Controls declines all responsibility
for incorrect use of the calibration procedures and fondamental set up parameters.
1 GENERAL DESCRIPTION
PILOT is a microprocessor based instrument for the measurement and elaboration of applied loads of compression and flexure
load frames for tests on concrete and cement. The instrument is housed in a light weight alloy container designed to satisfy
various ergonomic aspects: it has a front panel in anti-scratch polycarbonate, with ten touch button key board and large mono-
chromatic graphical display. The rear panel houses the connectors for the connection of the PILOT to the load transducers
together with serial/parallel ports and other auxiliary ports, the mains socket with filter, fuses and mains switch.
- Ram memory with rechargeable battery back-up, with clock/calendar which functions even when the instrument is switched
off.
- Two analogical channels for connection to two pressure transducers or load cells, with resolution of 130,000 points per
channel.
- Parallel output, for connection of parallel Hewlett Packard ink jet printer.
3 MAINS FUNCTIONS
PILOT is a two channel data acquisition unit suitable for any test frames used for compression/flexure tests of concrete and
cement. It has two input channel and therefore it can be connected to two different frames (although it cannot read the two
channels simultaneously).
The functions of the PILOT is managed by its installed software, organized in various menus. The user interface consists of
a graphical display (240 x 128 pixel resolution) and a ten push button key board, of which 4 are interactive with the icons which
appear on each display. The main features of the software are as follows:
- Execution of Compression or Flexure test with input of the physical characteristics and dimensions of the sample with
selection between various forms
PILOT pag. 4
OPERATING MANUAL
- Execution of the test with automatic or manual zero and real time display of load, resistance and applied load rate
- Possibility to simultaneously display graph of load against time, load pacer and trend indicator which provides information
in real time for eventual corrections to the applied load so as this is always in conformity with reference standards
- Printout of load / time through parallel printer at the end of each test
- Display of load rate (eg. MPa/s, kg/cm2/s, psi/s, MPa/min, kg/cm2/min, psi/min) or stress rate (N/s, kg/s, lbf/s, N/min, kg/
min, lbf/min)
- Memory filing of up to 2000 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
- Memory management with display of filed tests, download of data to parallel printer through dedicated port, download of
data to PC through RS232 serial port, delete single test or reset entire memory
- Linearity 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. The PILOT process the calibration coefficient for each individual "step"
and interpolates the values in order to obtain the calibration curve of the system (machine frame + load sensor + reading
device). It is therefore possible to compensate those eventual non-linearities so to achieve a calibration in Class 1 starting
from 1% of the scale range.
4.1 Install the PILOT on the test frame using the support (supplied with separately order) and position it so that the display
can be easily read.
See figure below
4.2 Connect the mains cable ensuring that the mains supply corresponds to that shown on the identification plate of the
PILOT.
4.3 Connect the cable of load sensor of frame 1 to channel 1 (CH1). If there is a second test frame, its sensor should be
connected to channel 2 (CH2).
4.4 If available, connect the parallel printer and the PC to their relative sockets (Parallel port Printer and RS232 - see relative
chapter on has to use these ports).
4.5 When all the cables have been correctly connected, the unit may be switched on using the mains switch on the rear
panel.
PILOT pag. 5
OPERATING MANUAL
5.1 When the unit is switched on the display will show "CONTROLS" for a few seconds. After this the main menu is
displayed.
Four icons are shown on the right hand side of the display next to the F1, F2, F3 and F4 keys which activate each icon
respectively.
see
1
The function of the icons vary with the different menus.
The four icons of the main menu are the most common and are as follows:
F1 = ESCAPE (cancel): This function annuls the last command given or returns to the previous screen. The
F2 = UP arrow: This moves the arrow cursor upwards by one place each time it is pressed.
F3 = DOWN arrow: This moves the arrow cursor downwards by one place each time it is pressed.
F4 = ENTER: This function accepts the last command given or confirms a selection made. The same function
Move the arrow cursor to the desired function and confirm to access.
6.1 Once this menu has been accessed the display will shown the selection of which channel to use (1 or 2) and the type
of test to be performed (Compression or Flexure).
If channel 2 is not connected, the choice of this channel will not be presented.
Make the desired selection and confirm so as to pass to the next screen.
The perform test menu offer the five choices described below:
6.2.1 This menu allows the operator to enter the dimensions, physical state and description of the sample. The software
provides the choice between cube, cylinder, block and other for the compression test; or beam, kerb, slab and other
for the Flexure test.
The input data is used by the PILOT in the calculation of the resistance and load gradient, this data also forms part of
the test parameters which are stored along with the test results in the test files.
The parameters to input are: the test number, the dimensions of the sample, the weight, the age of the sample in days
or hours and the load gradient to be used during the test. The area is calculated automatically and cannot be altered
directly.
6.2.3 The arrow keys allow the setting of the desired values and the ENTER key allows the operator to pass from one field
to another.
Once all the selections have been made, exit this menu by pressing the ESCAPE key. A message will appear asking
the operator to confirm the variations made to the settings, press ENTER to exit the menu and save the variations made
to the settings, or press ESCAPE to exit the menu without saving the variation made to the settings.
IMPORTANT: If this menu is exited without saving variations made to the settings, the unit will automatically use the
previous saved settings in its calculations.
PILOT pag. 7
OPERATING MANUAL
6.2.4 The flexure test menu ask for an extra two data compared to the compression test:
The distance between the bearers (L) and the load method, either two point loading on central point loading. This data
is indispensable for the calculation of the samples resistance area and hence its resistance and the load gradient.
6.2.5 When the sample to be tested does not comply with the predefined choices, select "Other" both for the compression
test or the flexure test. In this way the samples area can be inserted directly.
The Peak sensitivity value, is the value of decrease in load that the unit will consider as meaning that the sample has
failed and hence will cease acquiring further load readings for that particular test.
We suggest a value of between 15 and 30 kN for compression tests on concrete, 1 and 3 kN for flexure tests on concrete
and compression tests on cement, 0.2 and 0.5 kN for flexure tests on cement.
As a general rule the peak sensitivity value should be proportional to the failure load. In anycase it must be below the
failure load otherwise the unit will not stop automatically upon sample failure.
Use the arrow keys to set the value, press ESCAPE or ENTER to return to the previous menu.
This menu allow the graph of load against time to be shown, or not, during the test.
Use the arrow keys for selection and press ESCAPE or ENTER to return to previous menu.
With Autoprint on, a test report print via the parallel port is made automatically at the end of the test. If this function is
off, the print must be started manually be operator.
With Autostore on, a test report is stored in the PILOT memory automatically at the end of the test. If this function is
off, the test must be saved manually by the operator.
Once all the desired settings have been made, press the function key relative to Start test so as to begin the test. The
PILOT with enter the Perform test screen. 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.
It is possible to work with or without the graph.
PILOT pag. 8
OPERATING MANUAL
6.7.1 The screen of test with graph is shown below and is made up of the following components:
1 – Date
2 – Time
3 – Number of test
4 – Sample Area
5 – Applied load
6 – Unit load (resistance)
7 – Actual load gradient
8 – Trend indicator of actual load gradient with respect to theoretical load gradient
9 – Dimensions Y axis
10 – Dimensions X axis
11 – Graph Area
12 – ZERO command
13 – SAVE command
14 – NEW TEST command
15 – PRINT command
16 – Number of saved tests in memory.
1 9 2
3 16
12
5
13
6
14
7
15
8 11 10
6.7.3 When the test phase is started the screen will show the message "test running" throughout the test. The display
constantly updates the values of load and resistance in real time and gives information regarding the applied load rate
so as the operator can make necessary adjustments to the load control valve so as to maintain the required load
gradient. The load gradient is expressed in three ways:
2– Graphical representation (11) of load against 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 20%, of 200 sec. which represents 100%. The maximum possible scale
is 200% equal to 480 sec. (8 minutes).
The Y axis shows the load. At the start of the test its full scale is 20% of maximum load of the test frame being
used. The maximum scale is 100%.
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 20%). At the end of the test it is possible to zoom the two axis, the horizontal arrow cursors
are used on the X axis and the vertical arrow cursors are used on the Y axis.
PILOT pag. 9
OPERATING MANUAL
3– Display of deviation of actual load gradient (8) from the theoretical load gradient. During the test the display
shows this information with a series of symbols as described below:
6.7.4 When a sample nears failure a fall in the load gradient can be noted, and becomes zero when the load ceases to be
increased. Upon sample failure the display shows the message "End Test" and the valves of maximum load and
resistance are shown in large characters in the area of the graph as shown below:
6.7.5 To save the test in the memory press the SAVE key (F2); upon doing this you will note that the number of saved test
files will increase by one (16). It is possible to memorize up to 2000 tests, any attempt to memorize more than this
number will result in the test file not being saved. However, if the Autostore is on (see 6.5) the filing is made
automatically.
6.7.6 To print a test report on a parallel printer press the PRINT key (F4). Before doing this check that the printer is connected
to the "printer" port, it is switched on and on line. However, if the Autoprint is on (see 6.5) the print out is made
automatically.
6.7.7 Press the NEW key (F3) if a new test is to be made. The graph 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. Restart from point 6.7.2 if the sample description remains the same (e.g. dimensions).
6.7.8 To change the test parameters or the sample description press the ESC key to return to the previous menu.
Then enter in sample description menu and follow the instruction described in 6.2. After this proceed as per point 6.6.
PILOT pag. 10
OPERATING MANUAL
6.8.1 The screen display of a test without graph is given below. It is composed of the following:
1 – Date
2 – time
3 – Descriptive data of the test and sample
4 – Applied load
5 – Unit load (resistance)
6 – Actual load gradient
7 – PRINT command
8 – NEW test command
9 – SAVE command
10 – ZERO command
11 – Number of test files saved in memory
1 11
10
3
9
4
8
5
6 7
6.8.3 When the test phase is started the screen will show the values of load, resistance and load gradient in real time, so that
the operator can make necessary adjustments to the load control valve in order to maintain the required load gradient.
6.8.4 When a sample nears failure a fall in the load gradient can be noted and becomes zero when the load ceases to
increase. Upon sample failure the display shows the values of maximum load and resistance.
6.8.5 To save the test in the memory press the SAVE key (F2); upon doing this you will note that the number of saved test
files will increase by one (11). It is possible to memorize up to 2000 tests, any attempt to memorize more than this
number will result in the test file not being saved. However, if the Autostore is on (see 6.5) the filing is made
automatically.
6.8.6 To print a test report on a parallel printer press the PRINT key (F4). Before doing this check that the printer is connected
to the "parallel" port, it is switched on and on line. However, if the Autoprint is on (see 6.5) the print out is made
automatically.
6.8.7 Press NEW key (F3) to make a new test. The values of load and resistance are zeroed. Restart from point 6.8.2 unless
the sample description must be altered (e.g. dimensions).
6.8.8 To change the test parameters or the sample description press the ESC key to return to the previous menu.
Then enter in sample description menu and follow the instruction described in 6.2. After this proceed as per point 6.6.
PILOT pag. 11
OPERATING MANUAL
7 FILE MANAGEMENT
7.1 Saved files are stored in the system RAM memory. This system has a battery back-up which ensures the data is
maintained even when the unit is switched off. The memory can be used to file up to a maximum of 2000 tests.
7.2 Below is an example of the file management screen. The main elements are:
1 – Area data
2 – Position of displayed test in memory sequence (1 to 2000)
3 – Command to select single test or the complete memory
4 – CANCEL command
5 – DOWNLOAD to a PC command
6 – PRINT command
7.3 Each test file can be shown on the display of the PILOT; printed on a parallel printer connected to the parallel port;
downloaded to a PC through the RS232 Serial Port.
7.4 Using the vertical arrow cursors ( and ) it is possible to scroll through the various tests. Each test is identified
by as sequential position in the memory (2), the test results, Sample data and Test data.
7.5 Press the Print key (F1) to print the displayed test. Ensure beforehand that the printer is connected to the Parallel port,
it is switched on and on line.
7.6 Press key download to a PC (F2) 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.
7.7 Press the Cancel key to cancel the displayed test from the memory. The display will ask the operator to confirm the
cancellation. Press ENT to confirm or ESC to abort this operation.
7.8 It is possible to select all the filed tests simultaneously and this print, download or cancel them all together. Press F4
to activate this function, its icon will change so as to represent many files.
Now the Print, download and cancel commands will effect all the files stored in the memory.
7.10 Press ESC to exit the file management menu and return to the main menu.
PILOT pag. 12
OPERATING MANUAL
8 OPTIONS MENU
8.1 The options menu allows the selection of language, setting of date and time, selection of measurement units and input
of name or code number of the operator, upload/download of system set-up parameters.
8.2 Language selection: use the vertical arrows ( and ) to select between English and Spanish. Press ENT to
confirm.
8.3 Setting time: use the vertical arrows ( and ) to select the time. Press ENT to pass from one digit to another and
ESC at the end of the input to return to the previous menu.
8.4 Selection of measurement units: The PILOT software allows for readings to be read and calculated in kN, N, kg, tonnes
or lb. the alternative choices are shown in the screen below. The first column on the left indicates the measurement
unit of the load, the second that of the load gradient, the third that of the sample dimensions.
Before selecting the measuring unit of the load it is necessary to set the base time by which the PILOT will evaluate
the speed of the displayed test. This can be selected between seconds and minutes.
Note that for each load measurement unit, the load gradient or resistance gradient may be selected.
Upon the basis of the above selection, the PILOT will optimize the display in terms of resolution and number of digits
to be shown.
The software is based on the following conversion facrors:
1 kN = 0.101971 Ton
224.809 Lbf
When moving from one measuring unit to another, there is no need re-calibrate the instrument (provided this was
previously calibrated).
8.5 Input of operator name: The operator name is one of the pieces of data that is stored in the test file. To personalise this
option use the vertical arrows ( and ) to change the characters and the horizontal arrows ( and ) to move
from one character to another. All alphanumerical characters (in upper and lower case) are available together with a
number of symbols. At the end of operator name input press ENT to return to the previous menu.
9 MANUAL MODE
This menu allows the display of the load values of the two channels. This permits to appreciate the calibration of the instrument
by comparing it to a master calibration device and thus allowing the evaluation of linearity and repeability errors.
Detailed instructions on this specific menu and those related to the calibration are included in the separate section of the
Instruction Manual.
PILOT is fitted with two Serial Ports, the Printer Port is dedicated to a Serial Printer whilst the RS232 Port to a P.C.
10.1 The printer port transmits with 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-P0171 is used.
10.2 The RS232 Serial port transmits with the following settings: 38400 baud, 8 data bit, 1 Stop bit, no parity. All fields
transmitted are ended with CR and LF. To receive the data in the P.C. we recommend the use of the “Hyper Terminal”
program present on Windows 95 and subsequent versions.
10.3.1 We recommend that firstly the operator reads the microsoft instruction manual regarding this program.
To access the Hyper Terminal click on “Start” and then “Programs”, then “Accessories” and finally
“Communications”. Select the Hyper Terminal folder and activate.Important: If this program is not installed
consult your P.C. supplier in merit.
10.3.2 If prompted, do not select the installation of a modem. Give a name to the connection (e.g. Digimax).
10.3.3 After this, upon the request of “Connect to...“ select the com port used for the connection to the PILOT. Select
between COM1, COM2... COMX (where X is number of RS232 Serial ports available on P.C.) and confirm.
10.3.4 Input the settings as follows: 38400 bit per second, 8 data bit, no parity, 1 stop bit, no flowcontrol. Once these
havw been confirmed the input screen will disappear.
10.3.5 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.
10.3.6 To file the data it is necessary to activate the “Capture text” key. Select the transfer command and then catch.
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 accessable from any text editing file (Word, Notepad, Wordpad, Excel
etc.).
10.3.7 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.
10.3.8 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.
10.3.9 When the Hyper Terminal function is closed the operator is asked whether or not be necessary to repeat the
settings described in point 10.3.3 and 10.3.4 but simlpy to recall the previous name (i.e. PILOT).
PILOT pag. 14
OPERATING MANUAL
11 CONNECTIONS
PARALLEL
RESET CIRCUIT
PROCESSOR
RAM SYSTEM
ADDRESSES
BACK UP
KEY BOARD
MANUALE D'ISTRUZIONI
INSTRUCTION MANUAL
NOTE
MANUALE D'ISTRUZIONI
INSTRUCTION MANUAL
Italy
CONTROLS S.r.l.
6, Via Aosta
I-20063 Cernusco s/N. (MI) Italy
Tel. +39-0292184.1
Facsimile +39-0292103333
E-Mail: [email protected]
Web Site: www.controls.it
France
Controls S.à r.l.
Zone Artisanale
68130 Walheim, FRANCE
tel. +33-03 89 402655
facsimile +33-03 89 402645
E-Mail: [email protected]
Mexico
Equipos de Ensaye Controls S.a. De C.V.
Rio Churubusco N°. 27, Col. Portales
C.P. 03300, Mexico, D.F.
Tel. +52-55 56726186
Facsimile +52-55 55393229
E-Mail: [email protected]
Spain
Equipos de Ensayo Controls S.a.
Poligono industrial arboledas
C/Sabina, Nave 5, Manzana D
45200 - Illescas (Toledo), ESPAÑA
Tel: +34-902 180843 (4 lineas)
Facsimile: +34-902 180846
E-Mail: [email protected]
Web Site: www.eecontrols.es
United Kingdom
Controls Testing Equipment Ltd
Controls House
Icknield Way
Tring, Hertfordshire HP23 4JX - U.K.
Tel. +44-1442 828311
Facsimile +44-1442 828466
E-Mail: [email protected]
Web Site: www.controlstesting.co.uk