Gilson MC-250CS User manual

OPERATING MANUAL
Concrete Compression Testing Machines
MC-250CS, MC-300CS, MC-250CP, & MC-300CP
Rev: 08/19/2011
PHONE: [phone] P.O. Box 200, Lewis Center, Ohio 43035-0200 FAX: [phone]
740-548-7298 E-mail: [e-mail] Website: www.globalgilson.com 740-548-5314

IMPORTANT – PLEASE READ BEFORE OPERATING TESTING MACHINE
1. Inspect to see that no visual damage has occurred during shipping. If you see
any damage, contact Gilson Company, Inc. right away.
2. Check the equipment you received with your packing list.
3. It is recommended that the machine be located in an area where the atmosphere
is free from acidic or contaminating fumes, which could possibly accelerate corro-
sion to machine surfaces or electrical contacts.
4. Position the machine leaving sufficient space at the rear and sides for calibration
or service work.
5. The machine should be leveled.
6. Clean off machined surfaces that have been coated with rust preventative using
any suitable non-corroding safety solvent. Wipe machined surfaces with a clean,
oil soaked rag to minimize rusting.
7. When adding or changing oil, use only Dextron II or Dextron III automatic trans-
mission fluid.
NOTE: This machine has been operationally tested and calibrated at the factory. In
order to fully comply with the requirements stated in ASTM C 39, the compression
machine should be calibrated again “On original installation or immediately after
relocation.” Gilson does not provide calibration services directly, but can provide a
list of calibrators in your area. Contact our Technical Department at 800.444.1508
or [email protected].
WARNING!: This machine is extremely heavy and may be unstable until
properly installed. Attempting to move or reposition it without using proper
equipment and procedures may result in severe injury or death. Properly
rigged lifting equipment of sufficient capacity must be used, the load must
be secured, and lifting equipment operators must be qualified and knowl-
edgeable in the use of the equipment.
IMPORTANT – PLEASE READ BEFORE MOVING THIS MACHINE

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 1
FOREWORD......................................................................................................................... 2
1.0 INTRODUCTION .................................................................................................................. 2
1.1 Peak Load Indicator Accessories ............................................................... 2
2.0 THE KEYS & SCREEN DISPLAY ........................................................................................ 2
2.1 The <SET ENTER> Key ............................................................................. 2
2.2 The <MENU/UP ARROW> Key .................................................................. 2
2.3 The <ZERO/DOWN ARROW> Key ............................................................ 2
2.4 Peak Load Indicator & Screen Display ....................................................... 3
3.0 SETTING LOAD RESOLUTION, FULL SCALE LOAD & CALIBRATION ......................... 3
4.0 OPERATION......................................................................................................................... 3
4.1 Setting the Engineering Units ..................................................................... 4
4.2 Running a Test............................................................................................ 4
5.0 ELECTRICAL/MECHANICAL DATA ................................................................................... 4
5.1 User Connections ...................................................................................... 4
5.2 Power (DC) Input ........................................................................................ 5
5.3 Controller/Display Housing Dimensions...................................................... 5
HYDRAULIC CONTROL VALVE & HYDRAULIC PUMP SECTION ............................................. 6
6.0 HYDRAULIC CONTROL VALVE ........................................................................................ 7
6.1 Metered Advance Position .......................................................................... 7
6.2 Full/Advance Position ................................................................................. 7
6.3 Hold Position............................................................................................... 7
6.4 Retract Position........................................................................................... 7
6.5 FIGURE 1: Control Valve............................................................................ 8
6.6 Sequence of Operation ............................................................................... 8
6.7 Maintenance & Safety Precautions............................................................. 8
6.7.1 Hydraulic Pump & Flow Control Valve ........................................................ 8
6.7.2 Safety Precautions...................................................................................... 9
6.7.3 Hydraulic Fluid Level................................................................................... 9
6.7.4 How to Operate the Pump .......................................................................... 9
6.7.5 Troubleshooting ........................................................................................ 10
7.0 VALVE ASSEMBLY .............................................................................................................11
7.1 Valve Diagram .......................................................................................... 11
7.2 Valve Parts List ......................................................................................... 12
8.0 ELECTRICAL HYDRAULIC PUMP.................................................................................... 13
8.1 Pump Diagram .......................................................................................... 13
8.2 Pump Parts List......................................................................................... 14
8.3 Hydraulic Schematic Diagram................................................................... 15
8.4 Top View & Parts List................................................................................ 16
8.4.1 Bottom View & Section A-A ...................................................................... 17
8.4.2 Bottom View Parts List.............................................................................. 18
8.4.3 Motor Control Assembly & Parts List ........................................................ 19
9.0 POWER TEAM SERVICE CENTERS ............................................................................... 20
10.0 STATEMENT OF WARRANTY........................................................................................... 20
Table of Contents
Page

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 2
FOREWORD
Classic and Classic Plus Peak Load Indicators are
designed and constructed with great care in every phase
of assembly. To ensure reliability, both the mechanical
and electrical components have been built with the best
available materials. This section of the manual provides
description and instruction on the operation and mainte-
nance of the mechanical, electrical and software com-
ponents.
HOW TO USE THIS MANUAL
This manual is intended to outline the capabilities, oper-
ation and maintenance of the Classic and Classic Plus
Peak Load Indicators, as well as the hydraulic sys-
tem and load frame. Maintenance procedures specified
herein should be followed. Please read and understand
this manual and become familiar with the operation of
your test machine prior to operating.
TECHNICAL SUPPORT
If a problem should occur with your testing machine:
1) Check that all external inputs are properly connected.
2) Call Gilson Company, Inc. Technical Support line at
800.444.1508 (8AM - 5PM EST) Monday - Friday.
1.0 INTRODUCTION
The Classic and Classic Plus Peak Load Indicators
are designed for materials testing machines. Features
include an Auto-Test-Reset mode for hands free opera-
tion, automatic sample break detection and three points
of calibration for maximum accuracy, which exceeds
ASTM E 4. Load rate indication is also offered on the
Classic Plus model.
Classic and Classic Plus Peak Load Indicators are
ideal for:
• FlexuralBeamTesting
• ConcreteCylinderTesting
•CementCubeTesting
•RemoteOn-SiteTesting
•QualityControl
Features:
•DisplayLiveLoadandPeakLoadnumerically.
•SelectengineeringunitsofLb,N,KN,andKg.
•Threesoftwareprogrammablecalibrationpoints
with password protection (No need to turn a poten-
tiometer to adjust calibration.). Accuracy exceeds
ASTM E4.
•Auto-Test-Resetautomatically“readies”the indica-
tor for the start of the next test without requiring
operator interaction.
•ClassicPlusmodelhasloadrateindicationinforce
units per second.
•1x16LCDwith0.38inhighcharacters.
•Three-keytactilekeypad.
1.1 Peak Load Indicator Accessories
•1,0002,5005,00010,000psipressuretransducers
with cables pre-wired for the Indicator.
• Loadcellsofvariouscapacities.
2.0 THE KEYS & SCREEN DISPLAY
2.1 The <SET ENTER> Key
•Changesengineeringunits(KN,KG,LB,N)
• Accepts/assignsthevalueinadataentryfieldtothat
field.
2.2 The <MENU/UP ARROW> Key
•Selectsthecalibrationmenuforsettingloadresolu-
tion (RES), full scale (FS) load and calibration.
•Increasesthevalueofanumericdigit.
2.3 The <ZERO/DOWN ARROW> Key
NOTE: Record the previous test result prior to
pressing ZERO, or it will be lost.
•Definesanewzeroload.
•PlacestheIndicatorTestStatusinReadyMode.
•Clearsouttheprevioustestresultsfromthetestbuf-
fer and initializes the indicator for the next test.
•Decreasesthevalueofanumericdigit.

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 3
Classic model displays live load while specimen is un-
der test and peak load when sample break is detected.
Classic Plus model displays live load plus load rate
while specimen is under test and peak load when sam-
ple break is detected.
2.4 Peak Load Indicator & Screen Display
3.0 SETTING LOAD RESOLUTION,
FULL SCALE LOAD & CALIBRATION
A LOAD CELL IS REQUIRED FOR CALIBRATION
CALIBRATION MUST BE PERFORMED
BY A CERTIFIED CALIBRATION TECHNICIAN
1) Press the <MENU> key from the Live Screen. The
screen display changes to: RES:
2) Use the UP and DOWN ARROW keys to change the
first place in the resolution.
3) Press <ENTER> once to set the place.
4) Repeat steps 2-3 until all places in the number are
defined. Then press <ENTER> to set the resolution.
“FS” should now appear on the screen. NOTE: Full
Scale load is used only to define start test threshold,
which is set to 0.5% of full scale.
5) Use the UP and DOWN ARROW keys to change the
first place in full scale.
6) Press <ENTER> once to set the place.
7) Repeat steps 5-6 until all places in the full scale number
are defined. Then press <ENTER> to set full scale.
The screen will now read “MENU)CAL ENT)ESC”.
Press <ENTER> to exit to the Live Screen or <MENU>
to proceed to calibration.
NOTE: The Peak Load Indicator requires three cal-
ibration points. All three-calibration points MUST
be used. The first calibration point should be set at
zero load, the second calibration point at low load
(5% of full scale load) and the third calibration point
at or near full scale load.
Calibration is password protected. At this point you will
need to enter the password.
8) After entering the password successfully the screen
will read “ENT) Set PT1”. Unload the machine and
press <ENTER> to set the zero load calibration
point.
9) The screen will now read “ENT) Set PT2”. Load
the machine to the second calibration point then
press <ENTER>. Note the load value for the sec-
ond calibration point.
10) The screen will now read “ENT) Set PT3”. Con-
tinue loading the machine to the third calibration
point then press <ENTER>. Note the load value for
the last calibration point.
11) The screen will now read “PT1:”. Enter a value of
zero for the first calibration point.
12) The screen will now read “PT2:”. Enter the load
value for the second calibration point. Remember
that the UP/DOWN ARROW keys change place
values just like for full scale load.
13) The screen will now read “PT3:”. Enter the load
value for the last calibration point. Remember that
the UP/DOWN ARROW keys change place values
just like for full scale load.
Calibration is complete. You are now ready to verify the
load readings.
4.0 OPERATION
NOTE: To fully comply with ASTM requirements,
the unit must be calibrated by a qualified calibration
service prior to running any tests. See Section 3.0
for the calibration procedure.

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 4
Figure 5.1.1
DI Peak Load Indicator Rear Connection Panel
4.1 Setting the Engineering Units
Press the <ENTER> key from the Live Screen. The four
possible values for engineering units are KN, KG, LB,
and N.
4.2 Running a Test
There are two modes, manual and hands free, available
for running a test. Under manual mode, the operator
presses <ZERO> prior to each test to remove any tare
weight. With hands free mode, the operator zeros the
load once prior to running a batch of samples. Then three
seconds after the completion of the previous test, the In-
5.0 ELECTRICAL/MECHANICAL DATA
dicator begins waiting for the load to exceed the thresh-
old (0.5% of Full Scale), which signals the beginning of
the next test. During a test, the Indicator will continue
monitoring for peak load until the live load falls below
50% of peak load. Once the live load drops below 50%
of peak, the test ends and the peak load will be displayed
on the screen. The peak will remain on the screen until
a) <ZERO> is pressed or b) a new test is started.
NOTE: Before <ZERO>ing the load make sure that
the piston is floated and the loading platen is close
to the specimen.
5.1 User Connections
Load Channel Connections
Analog-Load Input
pins 9 & 10 (+Exc & AGND)
10 Vdc (5Vdc optional)
Analog Inputs:
pins 1 & 2 (+/- IN)
Input Range: 4.2 mv/v Standard
Contact factory for other input range options.
Connect all shields to chassis. Cable end requires a DB15 male.
DB15 Female
Figure 5.1.2

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 5
5.2 Power (DC) Input
The Peak Load Indicator requires 12-15Vdc unregulated
input voltage. A voltage adapter is supplied with the ma-
chine.
5.3 Controller/Display Housing Dimensions
REAR
VIEW
3.18
2.35
150°

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 6
HYDRAULIC CONTROL VALVE
&
HYDRAULIC PUMP SECTION

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 7
6.0 HYDRAULIC CONTROL VALVE
6.1 Metered Advance Position
Placing Control Handle No.1 (see Figure 1) into the me-
tered advance position allows the operator to adjust the
rate of loading through the use of Control Knob No. 2.
The adjustment for increasing the rate of loading is to
turn Knob No. 2 counter-clockwise. To decrease the rate
of loading, turn the Knob No. 2 clockwise. CAUTION:
Do not over-tighten Control Knob No. 2.
When testing concrete cylinders, the rate of loading
must conform to ASTM C 39 specifications. For a hy-
draulically operated testing machine, the load must be
applied at a constant rate within the range of 20 to 50
psi/sec. Knob No. 2 controls the rate of loading. For 6in
(150mm) diameter concrete cylinders, the loading rate
should be 565—1,413 lbs/sec., or 34,000—84,000 lbs/
min. For 4in (100mm) dia. cylinders, the rate would be
251—629 lbs/sec. or 15,060—37,710 lbs/min.
For Load Indicators with no rate of load display, a read-
ing of 10,000 lbs. on 10 seconds is a good average and
is easily set through the use of Control Knob No. 2 and
a watch with a second hand.
6.2 Full/Advance Position
Placing Control Handle No. 1 into the rapid advance
position causes the piston to advance rapidly at an un-
controlled rate. This is normally used for pre-loading a
specimen or rapidly advancing the piston to reduce the
daylight opening between the specimen and the platen.
CAUTION: When pre-loading a specimen, watch the
machine’s load indicator to prevent overloading, or
premature failure of the specimen may occur.
WARNING!:DO NOT ALLOW THE MACHINE TO
TRAVEL BEYOND THE MAXIMUM PISTON STROKE
TAG LOCATED ON THE FRONT OF THE LOAD
FRAME. OVEREXTENDING THE HYDRAULIC RAM
MAY RESULT IN DAMAGE TO THE SEALS AND
WILL CAUSE THE UNCONTROLLED RELEASE OF
HYDRAULIC FLUID UNDER PRESSURE.
6.3 Hold Position
Placing Control Handle No. 1 into the hold position (see
Figure 1) stops the loading of the specimen and holds
the pressure on the specimen at that point.
6.4 Retract position
Placing Control Handle No. 1 into the retract position re-
leases all pressure in the hydraulic cylinder allowing the
piston to retract to it’s start position. It is not necessary to
retract the piston fully between tests. A daylight opening
that will allow the specimen to be inserted and removed
is all that is required.
NOTE: During continuous operation of the machine,
the Flow Control Valve will go through a significant
temperature rise. This is not a cause for alarm, as
the temperature rise will not affect the operation of
the testing machine.

Gilson Company, Inc. Concrete Compression Testing Machines: MC-250CS, MC-300CS, MC-250CP & MC-300CP
Page 8
6.6 Sequence of Operation
1. With Pump Motor switched off, carefully center
specimen in testing machine.
2. Turn Control Knob No. 2 clockwise to a snug posi-
tion. Never over tighten. (If Knob No. 2 has already
been adjusted as in section 6.1, this step may be
skipped until a specimen of different size is tested.
3. Position Valve Control Handle No. 1 to a “metered
advance” position.
4. Switch on pump motor.
5. If a preload of the specimen is desired, position
Valve Control Handle No. 1 to “full advance”. Cau-
tion is required to avoid overload or failure of
the specimen.
6. Watch the display closely. When the desired pre-
load has been attained, move the Valve Control
Handle No. 1 to the “metered position”.
7. To increase the rate of loading, turn Control Knob
No. 2 counter-clockwise. To decrease the rate of
loading, turn Control Knob No. 2 clockwise.
8. To hold pressure at any desired point, position Valve
Control Handle No. 1 to the “hold” position.
9. To release pressure so that the platen will return af-
ter a test has been completed, position Valve Con-
trol Handle No. 1 to the “retract” position.
10. For repetitive testing of identical specimens, Control
Knob No. 2 can be preset with a stopwatch, then
locked in position by tightening the thumbscrew lo-
cated beneath the knob.
6.7 Maintenance & Safety Precautions
6.7.1 Hydraulic Pump & Flow Control Valve
This two-stage hydraulic pump incorporates precision
design and engineering features. Peak efficiency for ei-
ther continuous or intermittent operation is assured at
the full range of pressures up to 10,000 psi. You will
have uninterrupted, trouble-free service if you keep it
clean and free of dust.
6.5 Figure 1: Control Valve
CONTROL VALVE
Figure 1