Ametek Chandler Engineering 4207D User manual

OPERATING MANUAL
MODEL 4207D
DIGITAL COMPRESSIVE
STRENGTH TESTER
Revision M – November 2015
P/N: 89-0164
S/N: ____________
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Copyright ©2015, by Chandler Engineering Company, LLC
All rights reserved. Reproduction or use of contents in any manner is prohibited without express permission from Chandler Engineering
Company, LLC. While every precaution has been taken in the preparation of this manual, the publisher assumes no responsibility for errors or
omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein.
This publication contains the following trademarks and/or registered trademarks: AMETEK, CHANDLER ENGINEERING. These trademarks
or registered trademarks and stylized logos are all owned by AMETEK, Inc. All other company, product and service names and logos are
trademarks or service marks of their respective owners.
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TABLE OF CONTENTS T-1
Table of Contents
General Information ................................................................ P-1
Introduction............................................................................................................................ P-1
Purpose and Use................................................................................................... P-1
Description ........................................................................................................... P-1
Features and Benefits ............................................................................................................ P-1
Specifications......................................................................................................................... P-1
Safety Requirements ............................................................................................................. P-2
Safety Features....................................................................................................................... P-2
Section 1 – Installation .............................................................1-1
Unpacking the System ........................................................................................................... 1-1
Utilities Required .................................................................................................................. 1-1
Tools/Equipment Required.................................................................................................... 1-1
Connecting Power ................................................................................................................. 1-1
Connecting the Press to the Power Unit ................................................................................ 1-2
Connecting to a Data Acquisition System............................................................................. 1-2
Serial Data Connection ........................................................................................ 1-2
Section 2 - Operating Instructions ...........................................2-1
Programming the Controller.................................................................................................. 2-1
Sample Controller Program................................................................................................... 2-2
Configuring the Display ........................................................................................................ 2-3
Operating Procedure.............................................................................................................. 2-4
Interpreting the Results ......................................................................................................... 2-6
API Cement Compressive Strength Test ............................................................. 2-6
Section 3 – Maintenance...........................................................3-1
Maintenance Schedule........................................................................................................... 3-1
Filling the Oil Reservoir ........................................................................................................ 3-1
Adjusting the System Pressure ............................................................................................. 3-1
Resetting the Maximum Temperature Limit ......................................................................... 3-2
Maintaining the Press Assembly ........................................................................................... 3-3
Maintaining the Hydraulic Power Unit ................................................................................. 3-3
Adjusting the Platen Control Switch ..................................................................................... 3-3
Calibration ............................................................................................................................. 3-4
Load Cell and Display and Controller Calibration ............................................. 3-4
Controller Calibration .......................................................................................... 3-5
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T-2 TABLE OF CONTENTS
Section 4 - Troubleshooting Guide..........................................4-1
Section 5 - Replacement Parts.................................................5-1
Section 6 – Drawings and Schematics.....................................6-1

PREFACE P-1
General Information
Introduction
The Model 4207D Digital Compressive Strength Tester is a hydraulic press system that may
be used to apply known compressive loads to a sample at known rates. The maximum load is
50,000 Lbf. The Model 4207D Tester meets all the requirements for cement compressive
testing as specified in API Specification 10.
Purpose and Use
The Model 4207D Compressive Strength Tester is designed to test the compressive strength
of sample cement cubes in compliance with API Specification 10. The Model 4207D
enables the operator to achieve steady, uniform loading of the sample in order to obtain an
accurate measure of the compressive strength.
Description
The sample load schedule is programmable as a series of ramps and dwells using a controller.
The system is equipped with a digital display that retains the maximum load that causes the
failure of the sample under test.
Features and Benefits
•Programmable loading rates from 500 to 10,000 psi/min (2000 to 40,000 Lbf/min)
•Maximum load of 50,000 Lbf
•Polycarbonate safety shield with door safety interlock
•Multiple load rates/durations can be programmed as a single control operation
•Precise rate control electronic system and hydraulic pressure release valves providing
outstanding control of the loading rate
•Interface to Model 5270 Data Acquisition and Control Software (used to acquire and
plot the results)
Specifications
Power Requirements: 200-240 VAC, 50 Hz or 60 Hz
Maximum Load: 50,000 pounds-force (Lbf), 222 kN
Maximum Loading Rate: 40,000 Lbf/Minute (178 kN/min)
Maximum Load Dwell: 3 min @ 50,000 Lbf (222 kN) with initial oil temperature
below 75oF (24oC)
Maximum Oil Temperature: 175oF (60oC)
Environmental: 40-120oF (4-49oC)
95% Relative Humidity (non-condensing)

P-2 PREFACE
Serial Interface: Modbus-RTU Protocol
Hydraulic Fluid: SAE 10W30 Synthetic Oil
Shipping Dimensions: Load Frame
48” (122 cm) high x 24” (61 cm) wide x 28” (71 cm) deep
Control Cabinet
54” (138 cm) high x 28” (71 cm) wide x 30” (76 cm) deep
Net Weight: Load Frame 360 lbs (164 kg)
Control Cabinet 570 lbs (260 kg)
Safety Requirements
Note: Before attempting to operate the instrument, the operator should read and
understand this manual.
The Chandler Engineering Model 4207D Digital Compressive Strength Tester is designed for
operator safety. Any instrument that is capable of high pressures should always be operated
with CAUTION!!
To ensure safety:
•Locate the instrument in a low traffic area.
•Post signs where the instrument is being operated to warn non-operating personnel.
•Read and understand instructions before attempting instrument operation.
•Observe caution notes!
•Observe and follow the warning labels on the instrument.
•Never exceed the instrument maximum temperature ratings.
•Always disconnect main power to the instrument before attempting any repair.
•Appropriately rated fire extinguishers should be located within close proximity.
•Only trained personnel should operate the system.
•The system should never be operated while unattended.
•All personnel using the system should wear safety glasses.
•The system must be located in a safe environment.
•All safety interlocks must be operational and properly adjusted.
•The system must be properly maintained and any defective components serviced or
replaced.
Safety Features
•Door interlock switch: Prevents the operation of the system when the press door is open.
•Over temperature safety circuit: Prevents the operation of the system if the oil
temperature exceeds the specified limit.

PREFACE P-3
•Automatic system shut-down: The controller automatically terminates the active program
when the sample fails.
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P-4 PREFACE
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SECTION 1 – INSTALLATION 1-1
Section 1 – Installation
Unpacking the System
Carefully unpack the Model 4207D and all of its accessories. Visually inspect for any
damage that may have occurred during shipping. After the instrument is removed from the
shipping crate, the equipment and spare parts should be checked against the packing list to
insure that all parts have been received and none are damaged.
Remove the front cover of the instrument to remove the circuit board and spare parts that are
individually wrapped to prevent damage during shipment. Slide the circuit board into the
backplane as illustrated below; then replace the front cover.
Note: File an insurance claim with your freight carrier if damage has occurred
during shipping. Verify all parts shown on the enclosed packing list have been
received. If items are missing, please notify Chandler Engineering
immediately.
Utilities Required
Electrical: 200-240 VAC, 50 Hz or 60 Hz, depending on model.
Tools/Equipment Required
No special tools are required for the installation of the Model 4207D. Standard hand tools
are sufficient.
Connecting Power
Connect the power cord to an approved grounded receptacle in accordance with local wiring
codes. Model 4207D-60Hz is intended for use on, 200-240 VAC 60 Hz and Model 4207D-
50Hz is intended for use on, 200-240 VAC 50 Hz.

1-2 SECTION 1 – INSTALLATION
The system power switch on the front panel also serves as a circuit breaker. If the breaker
trips, correct the electrical problem then reset the breaker by cycling the switch.
Connecting the Press to the Power Unit
There are three connections between the load frame and the control cabinet, 2 hydraulic lines
and a 25-pin cable connection.
1. Connect the two hydraulic lines to the quick-connect fittings on the left side of the
control cabinet. Make certain that the hydraulic connections are fully coupled. The hose
from the bottom of the cylinder is connected to the bottom connection on the control
cabinet.
2. Connect the cable between the two 25-pin connectors located on the load frame and the
control cabinet. The cable connections are labeled with a RED circle.
3. Assemble the bottom platen and load cell in accordance with the illustration below:
Connecting to a Data Acquisition System
Serial Data Connection
The control cabinet includes a 25-pin connector on the left of the enclosure that is used for
communications with the optional Chandler Engineering Model 5270 Data Acquisition and
Control Software. The cable connections are labeled with a BLUE circle. A cable is
supplied with the unit.
Top Mandrel
Load Cell
Lower
Mandrel
Platen

SECTION 2 – OPERATING INSTRUCTIONS 2-1
Section 2 - Operating Instructions
Before operating the 4207D it is necessary to be familiar with the press controller and load
indicator features and controls.
Programming the Controller
The Model 7052 controller used with the 4207D system features user defined segment
programming (8 segments maximum). Using these segments, sample load ramp and dwell
segments are defined.
Controller Feature Description of Feature
Output 1 or 2:
N
ot active.
Upper Readout
(Process Value) Displays the current value of the sample load. This
value must be multiplied by 10 to indicate pounds-
force (Lbf).
Lower Readout or
(Setpoint Value) Indicates the current set point value. Indicates alarm
condition in the event of an alarm.
Remote Communication Indicates remote communication if the system is
equipped with this option.
Auto/Manual Button Changes the mode of the controller from Automatic
to Manual. When the controller is not being used,
place the controller in Manual mode and verify that
the lower readout displays Off.
Run/Hold Button Used to Run, Hold, or Terminate a program. Press
once to Run the program. Press again to Hold the
program. Press for over 3 seconds to terminate the
program.
Pa
g
e B
u
tton Used to page through the various menus in the
controller.
Scroll Button: Used to scroll through the parameter settings within a
menu page.
Up/Down Buttons: Used to change the value of a parameter. Press and
hold the button for rapid changes to a value.
Setpoint 2
N
ot use
d

2-2 SECTION 2 – OPERATING INSTRUCTIONS
Configuring the controller to perform a sample load program involves defining a series of
ramp and dwell segments.
Once the program exists, the program is executed by pressing the Run button. To suspend
the program the Run/Hold button may be pressed briefly (Hold light illuminates) and
restarted by pressing the Run/Hold button again.
To terminate the program, the Run/Hold button is pressed until the Run light is Off. Press
the Auto/Man button to place the controller in manual mode.
Use the following procedure to define and run a program:
1. Turn the system On.
2. Press the Page button until the Prog menu appears.
3. Press the Scroll button until the Segment number 1 is displayed (SEG.n with the set
point value reading 1 indicates segment number 1)
4. Press the Scroll button twice.
5. Enter the segment type (tYPE). Use the Up/Down buttons to enter a ramp time (rmP.t)
type.
6. Press the Scroll button.
7. Enter the target setpoint (tGt). This is the desired load at the end of the ramp, expressed
in units of Lbf/10.
8. Press the Scroll button.
9. Continue the process of defining remaining segments. The maximum number of
segments is 8.
10. The final segment type has a type End.
11. Press the Run/Hold button to start the program.
12. To stop the program, hold the Run/Hold button until the Run light turns Off.
Sample Controller Program
The following table provides the API Specification 10 programs for the controller.
Note: The indicated value on the controller and display must be multiplied by 10 for
the force in pounds-force (Lbf).

SECTION 2 – OPERATING INSTRUCTIONS 2-3
Segment
Number Segment Type Value, Lbf/10 Time, min Comment
1 Ramp Time 15 0.5 This is used to load the sample.
2 Dwell 0.5
3 Ramp Time 4800
3.00 or 12.00 API Spec 10A Ramp rates of 16,000 Lbf/min or 4,000 Lbf/min.
4 End Rset Ends the program once the setpoint is
reached.
Configuring the Display
The display indicates the sample load in units of Pounds-Force (Lbf ) and stores the
maximum value. The display may be configured for other units of force by rescaling the
display and controller. Contact Chandler Engineering for instructions if the display must be
rescaled.
Note that the value displayed by the controller must be multiplied by 10 to obtain Lbf. The
display indicates in units of Lbf directly.
The display provides the peak value to the 5270 Data Acquisition software every 1 second
using the serial communication port.
Note: The scaled peak value is available at Modbus register 133 (2:133f). To reset
the peak value, 5270 must be configured to transmit a 0 to Modbus register
133 (2:133f) when a test is started. This is accomplished using the Start
Sequence option in the instrument Test Profile definition. The device address
and register (2:133f) must be configured in the Advanced option for the Lbf
load signal.
Note: The display calibration is based on the calibration certificate provided with the
load cell and the excitation voltage (+10Vdc). If the instrument must be
recalibrated, an independent load cell must be loaded into the press and used
to validate the output of the load cell in the instrument. Any changes to the
Page
Scroll

2-4 SECTION 2 – OPERATING INSTRUCTIONS
calibration values must be configured in the display and controller (CONFIG
– IP menus).
The display is configured to display the current value. To display the peak value, press the
UP or DOWN arrow, the peak value will display for 2 seconds then revert to the current
value.
The load cell used in the instrument is rated for 0 – 50,000 Lbf. The load cell output is not
exactly 0.000 mV due to the mass of the platen. The display is adjusted to display 0 Lbf
using the Offset option. This value is set by the factory but may require periodic
adjustments:
•Press Scroll one time until OFS.1 is displayed.
•Press UP or DOWN arrow to change the value. Adjust the value until the main display
indicates 0 Lbf.
•Press Scroll two times to return to the main display.
Although the 5270 software resets the peak value in the display when a new test starts, the
user may manually reset the stored peak using the following procedure:
•Press Scroll two times until RES.L is displayed.
•Press UP or DOWN arrow two times to select YES. The display will flash.
•Press Scroll one time to return to the main display.
Operating Procedure
1. Turn the system On.
2. If required, push the cylinder control switch, located to the right of the power switch, to
the Down position to lower the platen. This will lower the platen to provide adequate
clearance for the sample.
3. Turn the cylinder control switch to the Off position.
4. The platen has an engraved square that will approximately match the size of the sample
block. Place the sample within the center of this square. It is critical that the sample be
centered on the platen. Leave approximately ¼” of clearance between the sample and the
top platen.
5. Close the door on the press assembly.
6. Reset the peak value stored in the display by pressing the Scroll button until RES.L is
displayed. Press Up or Down arrow two times to select YES. The display will flash.
Press the Scroll button to return to the main display.
Note: The 5270 DACS software will automatically reset the peak value stored by the
display when a data acquisition test is started.

SECTION 2 – OPERATING INSTRUCTIONS 2-5
7. If using a data acquisition system, start the program.
8. Confirm the controller is idle and in manual (MAN) mode by performing the steps below.
a. Press and hold the RUN/HOLD button for three seconds or longer. This will reset
and idle the controller. The RUN and HOLD indicators will extinguish.
b. Press the AUTO/MAN button to switch from automatic (AUTO) mode to manual
(MAN) mode. The MAN indicator will illuminate.
9. Select the proper ramp time in segment three (Seg.n 3) of the controller program to match
the rate desired. Additionally, select the target pounds-force value in segment three
(Seg.n 3), if the desired value is different than 48000 Lbf. DO NOT change any other
segment values.
To change the Seg.n 3 values;
a. Press the Page button until the Prog menu appears.
b. Press the Scroll button until the Segment number 3 is displayed (Seg.n 3).
c. Press the Scroll button.
d. Enter the segment type (tYPE). Use the Up/Down buttons to enter a ramp time
(rmP.t) type.
e. Press the Scroll button twice.
f. Enter the target setpoint (tGt). This is the 48000 at 4800 of the ramp, expressed in
units of Lbf/10. (For example, 48000 Lbf = 4800)
g. Press the Scroll button to display duration parameter (dur).
h. Enter the dur time (min) using the up button.
i. Press the Page button 4 times to exit.
Note: For low compressive strength samples 8.0-12.0 min is the recommended
duration. For high compressive strength samples 2.0-3.0 min is the
recommended duration.
10. Place the press direction control switch in the UP position.
11. Increase the controller output to 1.0% by pressing the UP arrow button. The press will
rise, contact the upper platen and stop. The press will then hold in an idle position for
20-30 seconds.
12. While the press is in idle decrease the controller output to 0.0% by press the DOWN
arrow button.
13. Wait for the press to engage the hydraulics. An audible change in pump rate will be
heard.
14. Place the controller in automatic (AUTO) mode. By pressing the AUTO/MAN button
The AUTO indicator will illuminate.
15. Start the program using the steps below.

2-6 SECTION 2 – OPERATING INSTRUCTIONS
a. Press the RUN/HOLD button. The RUN indicator will illuminate.
b. The program will increase the applied force to 150 Lbf (15 x 10) clamping force in 30
seconds.
c. The program will hold the 150 Lbf clamp force for another 30 seconds.
d. The program will begin applying the chosen rate of force.
16. The sample will crush at its peak compressive strength.
17. When the sample fails, the controller will automatically terminate the program and
remain in the standby state. The message “4rat” will flash indicating a “rate of change”
alarm has occurred.
If a sample fails gradually, without a sudden fracture, the controller may not
automatically terminate the program. In this case, the operator must manually stop the
program by pressing and holding the RUN button for three seconds or longer. In the
event that the operator manually stops the program the peak value is not stored on the
display.
To stop the press manually:
a. Place the press direction control switch in the OFF position. This will stop the press
from rising.
b. Reset the controller by pressing and holding the RUN/HOLD for three seconds or
longer. This will reset and idle the controller. The RUN and HOLD indicators will
extinguish.
c. Press the AUTO/MAN to switch from automatic (AUTO) mode to manual (MAN)
mode. The MAN indicator will illuminate.
18. Reset the rate alarm on the controller by pressing PAGE and SCROLL together.
19. Place the press direction control switch in the DOWN position to lower the platen for
cleaning.
20. Place the press direction control switch in the OFF position.
21. Open the safety door, dispose of the sample.
22. Clean both the upper and lower platens.
Interpreting the Results
API Cement Compressive Strength Test
To calculate the compressive strength of a sample, the peak load at which failure occurred
must be determined. The peak value is obtained from the display or from graphical data (if a
data acquisition system is used). The peak value is divided by the sample cross-sectional
area to obtain the compressive strength using the following equation:

SECTION 2 – OPERATING INSTRUCTIONS 2-7
AreaonalCrossSectiSample LoadMaximum
StrengtheCompressiv =
If a standard ASTM cement cube is used, the cross-sectional area is 4.0 in2(2 inch x 2 inch
cube). To obtain the Compressive Strength in psi, divide the Maximum Load value by 4.0.

2-8 SECTION 2 – OPERATING INSTRUCTIONS
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SECTION 3 – MAINTENANCE 3-1
Section 3 – Maintenance
Maintenance Schedule
MAINTENANCE SCHEDULE
Model 4207D Digital Compressive Strength Tester
COMPONENT EACH TEST MONTHLY 3 MONTHS 6 MONTHS ANNUAL
Oil Check Level Every two years,
change the oil
System Pressure Check the system
pressure, adjust
to 2600 psi
Press Assembly
(See procedure
below)
Perform
maintenance
checks below
Hydraulic Power
Unit (See
procedure below)
Perform
maintenance
checks below
High Temperature
Limiting Circuit Verify operation
Platen Control
Switch Adjust as needed
Load Cell Calibrate
This maintenance schedule applies to normal usage of two tests per day. Detailed procedures for these operations are
contained in your manual.
Filling the Oil Reservoir
The system reservoir will not require refilling unless the oil is
drained or a leak occurs. The oil should be changed every two
years. To fill the reservoir, use the following procedure:
1. Remove the reservoir fill cap.
2. Fill the reservoir using 10W30 synthetic oil. Verify that
the oil is not contaminated. Do not reuse old oil.
3. Fill the reservoir until the oil level is mid-range on the
sight gauge onthe front of the reservoir.
Adjusting the System Pressure
The system pressure must be set to a value greater than the maximum pressure required by
the system to create the anticipated loads. Use the following procedure to adjust the system
pressure:
Gauge
Reservoir fill cap

3-2 SECTION 3 – MAINTENANCE
Note: The system pressure will decrease as the oil temperature increases. For this
reason, adjust the system pressure when the oil temperature is at or near room
temperature.
1. Verify that the system temperature is below 80°F (27°C).
2. Turn the system On.
3. Place the cylinder control switch in the Up position.
4. Locate the relief valve adjustment and the system pressure
gauge.
5. Adjust the relief valve until the system pressure gauge
equals 2,600 ±200 psig.
6. Place the cylinder control switch in the Off position.
7. Tighten the relief valve lock nut.
Resetting the Maximum Temperature Limit
This system is equipped with a circuit that disables the hydraulic power unit if the oil
temperature exceeds 70°C. The circuit must be manually reset for continued operation of the
system.
To reset the temperature limit, press the red reset button located on the right panel.
Use the following procedure to adjust the maximum temperature limit:
1. Turn the system Off.
2. Remove the back panel from the power unit.
3. Locate the temperature limit circuit board located on the left side of the enclosure
(viewed from the rear).
4. Locate the calibrated dial on the circuit board. Adjust the knob to a value of 70°C.
5. To reset the temperature circuit, press the Red reset button located on the right panel.
6. To test the circuit, turn the system On then adjust the temperature set point below the oil
temperature. Verify that the relay opens and an LED illuminates. Adjust the set point
and press the Reset button.
Relief Valve Adjustment
Gauge