Schleibinger CDF User manual

Schleibinger Geräte
User Manual
CDF-Freeze-Thaw-Testing
Machine
Schleibinger Geräte Teubert u. Greim GmbH
Gewerbestraße 4, 84428 Buchbach
Telefon ( 8 86) 9 4 1 , Telefax ( 8 869) 9 4 14
Mobil ( 1 71) 7 32 16 7 , ( 172) 8 999 196

www. schleibinger.com , [email protected]
Contents
1 INTRODUCTION...............................................3
2 INSTALLATION AND SECURITY HINTS........4
2.1 SETUP OF THE MACHINE........................................4
2.2 INTERNET CONNECTION..........................................5
2.2.1 Chiptool...................................................6
2.2.2 CompactFlash Card................................7
2.3 PROTECTION SWITCHES AND PERSONAL SAFETY.........7
2.4 REPAIR AND MAINTENANCE.....................................8
3 PRINCIPLES OF OPERATION........................9
3.1 GENERAL............................................................9
3.2 SYSTEM OPERATION..............................................9
3.3 MECHANICAL CONSTRUCTION.................................10
3.3.1 Testing tub.............................................11
3.3.2 Circulation Unit......................................11
3.3.3 Freeze Resistance................................13
3.4 CUBE TEST.......................................................14
3.5 EY SWITCH.....................................................16
3.6 TRANSPORT OF THE CDF MACHINE.......................16
3.7 EMPTY THE COOLANT LIQUID................................16
3.8 COOLING WATER CONNECTION (OPTION).................17
4 HANDLING THE CONTROLLER...................18
4.1 INTRODUCTION....................................................18
4.2 EYBOARD AND DISPLAY......................................18
4.3 HANDLING.........................................................18
4.3.1 tart.......................................................18
4.3.2 tatus....................................................19
4.3.3 Cycle Time............................................21
4.4 SETUP..............................................................21
4.4.1 Target Value..........................................22
4.4.2 Profile Input...........................................22
4.4.3 Display..................................................24
4.4.4 Clock.....................................................25
4.5 SYSTEM MENU...................................................26
4.5.1 Manual..................................................26
4.5.2 DA Calibration.......................................27
4.5.3 Controller...............................................28
4.5.4 Probes...................................................31
4.5.5 RAM Reset............................................32
4.5.6 Misc.......................................................32
5 TECHNICAL DATA .......................................33
6 SERVICE HINTS.............................................34
6.1 MAINTENANCE CONTROLLER..................................34
6.2 VALUES FOR THE SECURITY DEVICES......................34
6.3 HELP YOURSELF................................................35
7 SCHEMATIC DRAWINGS .............................38
7.1 REFRIGERANT SCHEMATIC.....................................38
7.2 FUSES..............................................................39
8 INDE .............................................................40
CDF-Freeze Thaw- Testing Machine page 2

1 Introduction
Congratulations: You buy a sophisticated measurement system or testing the
reeze thaw resistance o concrete. This machine equipped, with the latest
generation o micro-controller and Internet technology will satis y you now and
also in the uture. This machine is engineered according to the latest standards o
security and environmental protection.
For maintenance all parts are easy accessible. The critical components are
redundant. To minimize condense water and energy loss all valves are care ully
isolated. All mechanical parts are manu actured on CNC machines, to guaranty
that all parts it in an optimal way. The tin parts are stainless or powder coated
according to medicine standards.
CDF-Freeze Thaw- Testing Machine page 3

2 Installation and Security Hints
2.1 Setup of the Machine
The ground loor should withstand a pressure o 300 kg/m². Air cooled machines
should be installed in rooms not smaller then 200 m³.. This rooms should have a
good air exchange, to keep the room temperature below 28°C. Also or water
cooled machines , according to DIN EN 378-1 the room volume should be at
least 8 m³ , i with leak cooling gas comes into the atmosphere.
I the distance between the backside o the machine and the wall is below 50cm,
you should change the per orated cover to the ront side to ensure a ree
circulation or the air ( or air cooled machines)
Be sure that the machine stands horizontal. Please check this by a level at the
cooling bath. I necessary the machine may be setup by the our adjustable eet.
The horizontal deviation should be not higher then 1-2 mm/m.
This machine is constructed according to DIN EN 378-1class A. This means it is
allowed to run this machine in a room where people are sleeping, disabled
persons are working, or a lot o not instructed people are present. So there are no
special requirements in the training o the people working with, or nearby the
machine.
As cooling liquid a mix o 45 % tap water and 55 % glycol coolant is used. This
according to the European water protection standard level 0 . There are no special
requirements or environmental or water protection.
The re rigerant is
R507 (or R404A). This
re rigerants are ree o
FCKW. They are not
reducing the ozone
shield in the
atmosphere.
Compared with CO2
(GWP = 1,0) R507
has a high potential
or global warming
(GWP = 3800). This
act requires a care ul
handling with the
re rigerant. Service
and repair jobs at the
CDF-Freeze Thaw- Testing Machine page 4
0,4m 0,4 m
0,5 m
abe llänge3 m
Schleibinger Geräte 0,8m
2,25m
Opti onalüh lwasser
Vor- /Rücklauf
Luftein lass nicht v erstell en

at the cooling machine are allowed only or well trained and special educated
persons. Pleas contact our service center or urther questions.
The lubricant o the cooling machine has not be changed during the li etime o the
machine. The oil is classi ied at water dangerous class =1. There are no special
oil protection requirements necessary, because the machine automatically stopp i
there is a leakage in system.
The CDF/CIF-machine has a mains connection with a 3x32A/400V/50Hz CEE
connector. As circuit protection 3x32A are necessary.
The environmental conditions should be at 10 to 28 °C at maximum 65 % relative
humidity. I the humidity is higher there may be more condense water at some
machine parts. Below 10°C s special winter-controller should be ordered with the
machine. For temperatures over 28°C an additional water cooling is necessary.
Opening the lid o the cooling bath is only allowed when the bath temperature is
near the room temperature. We strongly recommend water-proo isolation
protection gloves. Contact to the cooling bath may cause reezing the skin,
ingers, or the hand.
2.2 Internet Connection
The CDF testing machine rom Schleibinger is equipped (option) with an internet
inter ace. So you may easy integrate the machine in your laboratory network or in
the world-wide-net. You can contact the CDF machine as easy as any other web-
site. Also you may use the telnet or FTP service.
The WEB server integrated in the CDF machine displays the the temperature data
as well as the actual temperature and some status in ormation.
To contact the CDF machine input the IP address o the CDF machine in your
web-browser so tware. For example :
http://192.168.1.40
The CDF machine need a ix IP address.
CDF-Freeze Thaw- Testing Machine page 5

2.2.1 Chiptool
To change this, start the so tware chiptool.exe delivered with the CDF machine on
your PC. This PC must be connected to the same network then the CDF machine.
Choose the menu point
Chip -Find in the chiptool
so tware. I everything is
well connected the CDF
machine will be
displayed. Then select
the machine and change
the IP address and the
network address
according to you local
network requirements.
Be sure that your PC and
the CDF machine are in
the same IP namespace, otherwise you may have to con igure also the Netmask.
You may also access the CDF machine with the chiptool File Trans er Protocol
"FTP Client" in the menu "Tools":
User is tp, password is tp.
Change the Drive to B: in the right column. All measurement data are in the
subdirectory :
B:\httpd\htdocs\daten
CDF-Freeze Thaw- Testing Machine page 6

All program iles in:
B:\httpd\cgi-bin.
For advanced users: As super user you may also have an access to the machine
via Telnet:
User is tel, password is tel.
In the telnet window a command line terminal will be opened. Here you may use
most o the usual DAS commands. Press help Enter i you are in doubt. Give the
command closetelnet to close the connection.
2.2.2 CompactFlash Card
You may also read the data iles
rom the built in CF card.
Switch o the machine. Open the
electrical cabinet. On the le t side
you will see the electronic.
Remove the card.
All measurement data are in the
subdirectory :
B:\httpd\htdocs\daten
All program iles in:
B:\httpd\cgi-bin
2.3 Protection S itches and Personal Safety
The machine is equipped with the ollowing sa ety and security components. This
components are adjusted by Schleibinger, Its not allowed to change the settings.
(6.2 ):
•Over-temperature protection or the heating unit (70 °C)
•Level indicator or the bath and the liquid bu er.
•A sa ety switching device or limiting the high pressure or the compressor
•A sa ety switching device or limiting the low pressure or the compressor
CDF-Freeze Thaw- Testing Machine page 7
CF Card

Changing the setup of the security devices is not allowed.
Any manipulation will lead to a total warranty loss!
Pleas ollow care ully all standards and laws or personal protection. Also ollow
the DIN EN 378-1 and DIN EN 378-2 standards.
The owner o the machine has to supply personal protection equipment, specially
security gloves and security eye glasses or all people working with the machine.
2.4 Repair and Maintenance
The ollowing jobs may be done by the user:
Maintenance quarterly yearly
Check the rost resistance o the
cooling liquid, at least at -38 - -45 °C
or density @ 20°C 1.072 – 1.075
g/cm3. Using a re ractometer is
recommended
X
Checking the coolant level in the bath.
Stop the machine and level checking
with specimen containers mounted.
X
Cleaning all components outside.
Cleaning the tin plates o the heat
exchanger. Removing concrete loss
or sand out o the bath.
X
Following jobs are recommended but not necessary:
Maintenance yearly
Checking the bath temperature probe X
Calibration o the bath probe at
-20°, 0°, 20°C
X
Checking the compressor heater X
Checking the magnetic valves X
Changing the backup battery o the controller X
i necessary, latest
a er 4 years
Repair jobs should be done only by quali ied persons
Please call Schleibinger or special questions.
CDF-Freeze Thaw- Testing Machine page 8

3 Principles of Operation
3.1 General
The CDF reeze-thaw testing machine is developed ollowing the CDF standards
o RILEM-(Materials and Structures (1996) Vol 29 (193), pp 523-528), the RILEM
CIF standard and prEN 12390-9. The main advantage o thees standards is the
very good reproducibility o the measurement results. The specimen containers
are hanging in an coolant liquid. So you get a constant temperature distribution, a
ast temperature balance and temperature gradient right to tested specimen
sur ace. Due to the low thermal resistance the temperature deviations are very
small.
BetonLuftPrüfflüssigkeitühlflüssigkeit
Kühl lüssigkeit = coolant liquid; Prü lüssigkeit = test luid, water or water with
salt; Lu t = air; Beton = concrete
Also the cube test according to prEN 12390-9 may be run (option) by the CDF
machine. In opposite to air cooled test chambers, the cube test cycle may be
shortened rom 24h to 12h. This cuts testing time and costs dramatically..
3.2 System Operation
The CDF machine is a bath o circulation coolant liquid. In the bath stainless steel
containers are mounted. The concrete specimen is placed on three small spacers
in the middle o this containers. Each container is illed with some amount o water
or water/ salt solution. The coolant liquid, and so the specimen, are rozen and
thawed in a well de ined temperature cycle.
The re erence temperature is measured at the bottom o the container. Be shure
that minimum one container is in contact with the probe.
CDF-Freeze Thaw- Testing Machine page 9

Z e mpera turz y klus
-2 0
-1 5
-1 0
-5
0
5
1 0
1 5
2 0
0 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2
T
e
m
p
e
r
a
t
u
r
h
The coolant liquid is circulated by pump 1. In the circulation a electrical heater is
mounted. For cooling a dosage o cooler liquid, cooled in a special bu er
container, is added by two magnetic valves. The coolant in the bu er is pumped
in a 2nd circulation through the evaporator, which is cooled to -38°C by the
compressor, back to the bu er. The bu er-temperature is always below the
temperature in the main circulation. The compressor is cooled by air, water or
water + air.
Ä L T E
B a d
S p e i c h e r
P u m p e 2
P u m p e 1
H e i z u n g
V e r d a m p f e r
M a g n e t v e n t i l e
Kälte = cool re rigerant; Verdamp er = evaporator; Pumpe = pump;
Magnetventile = magnetic valves; Bad = bath; Speicher = bu er, Heizung =
heater
3.3 Mechanical construction
The CDF machine is a ready to run test chamber. It is based on three main
components:
•Test-bath
•Re rigerating installation
CDF-Freeze Thaw- Testing Machine page 10

•Electrical cabinet and controller unit
Prü wanne = testing – tub; Temperierbad = testing-bath; Kätespeicher = cooling
bu er; Kälteanlage = re rigerant equipment; Aggregate, Pumpen, Ventile Heizung
= valves, pumps, heating unit
3.3.1 Testing tub
The testing tub is well isolated and made o stainless steel. Also the lid is well
isolated to avoid thermal loss. In the testing bath the cooling liquid is circulation to
ensure a balanced thermal distribution. The gastro norm specimen containers are
hanging in the cooling bath. Below the bath the coolant bu er is mounted.
3.3.2 Circulation Unit
CDF-Freeze Thaw- Testing Machine page 11

This part o the machine contains the units or heating, cooling and pumping the
coolant. All components are easily accessible. Please remove the cover tins i
necessary. Take is on one side rom the bottom, and draw it with a small jerk out
o the spring clips.
For mounting the cover again set the small pins in the wholes o the spring-clips.
Then ix it with some strong pushes on the edges o the tin. Do never push on the
middle o the cover, otherwise it may be bended.
3.3.2.1 First Filling of the Cooling liquid
The volume or the cooling liquid is about 100l.
First Time you thin down the glycol coolant with 40 % o water, so that the reeze
protection ist -45°C.
I you ill all the coolant in the testing-tub the additional liquid comes over into the
bu er and the valves.
CDF-Freeze Thaw- Testing Machine page 12

Fill the bath up, until the optimal level in the bu er is reached.
You can check this at the indicator outside the testing – bath. In the irst time,
some air bubbles may leave in the tube o the indicator. You can blow into the
tube until the right liquid level is shown.
Be sure that the machine is balanced.
Switch on pump 1 and pumpt 2 using the manual menu in the system menu.
Maybe you have to switch on and o the pumps several times until the circulation
is constant and all air is removed rom the tubes and valves.
Check the level again i all specimen containers are mounted.
Never run the pumps without liquid. Be sure that no air is sucked by the pumps or
a longer time.
3.3.3 Freeze Resistance
o the coolant (glycol-tap water mix)
CDF-Freeze Thaw- Testing Machine page 13

Adjust the reeze resistance o the coolant to at least -40 °C maximum -50°C.
The density at a temperature o 20 °C must be between 1.072 to 1.075 g/cm3 .
To push up the glycol concentration o the coolant, replace the amount o coolant
listed below, by pure glycol.
Measured
reeze re-
sistance, °C
Density
g/cm³
relation
glycol /
water
Replace
volume / l
-20 1.051 35/65 18
-25 1.058 40/60 14
-30 1.065 45/55 9
-35 1.070 53/47 7
-40 1.075 55/45 0
The temperature o the bath is most o the time below the room temperature.
There ore the the coolant is diluted by condense water, specially i the lid is open.
Also during the specimen handling water may be added to the coolant.
We recommend a re ractometer or easy checking the density o the coolant
liquid.
3.4 Cube Test
Also the cube test according to prEN 12390-9 may be run (option) by the CDF
machine. In opposite to air cooled test chambers, the cube test cycle may be
shortened rom 24h to 12h. This cuts testing time and costs dramatically.
CDF-Freeze Thaw- Testing Machine page 14
Skala ETHYLENE GLYCOL
there you see a freeze protection of
about -36 °C

To change over to the cube test, a higher
liquid level in the bath is recommended.
To get this, an additional outlet can be
ixed.
Please don´t orget to put the ilter over
the outlet.
Put in most o the specimen containers
and ill in additional coolant liquid.
Check the liquid level at the level indicator
right in ront o the instrument.
CDF-Freeze Thaw- Testing Machine page 15

The heating unit can run with a power o 2
kW or 6 kW. For the cube test 6 kW is
required.
Select Setup -->Systemmenu -->
Controler --> Bath --> VDZkr.
Key in "1" or 6 kw heating power.
3.5 Key S itch
You can lock the instrument against
unauthorized use. I you switch the key
switch o the touch screen is locked
during operation.
Please note that it is not locked or setup
input.
3.6 Transport of the CDF Machine
Empty the coolant rom the bath and the bu er, i you like to transport the CDF
machine. Li t the machine only at the rame below the bath, never at the coper
plates or the electrical cabinet. The cover plates should be ixed additionally, or be
transported separately.
I no transport at enviromental temperatures over 0°C is possible, empty also the
water rom heat exchanger to avoid a rost damage.
3.7 Empty the Coolant Liquid
Connect a hose to the emptying valve. Keep the liquid running in some prepared
container (ca. 100l) Remove the run over valves in the testing bath, to be sure that
all coolant will run out the bath.
CDF-Freeze Thaw- Testing Machine page 16

3.8 Cooling Water Connection (option)
I you have installed this option the machine may be supplied by cooling water by
two 1/2“ hoses. Please beware o the water direction (in / out) One o the cover
plates has holes or the hoses.
We recommend to install in your laboratory a pressure and a volume meter in the
input and output valves.
The di erence pressure between input and output should be between 0,5..10 bar.
Adjust the volume controller, that only water is running when the compressor runs,
no cooling air is available, or the room temperature is over 28°C. To reduce the
room heating by the machine turn on the volume controller to level 3. I no room
heating is allowed, the an might be switched o by a service man.
CDF-Freeze Thaw- Testing Machine page 17
water input
Water output

4 Handling the Controller
4.1 Introduction
This part o the user manual describes all eatures you may handle by the touch
screen o the controller. The controller is mounted on the le t side o the electrical
cabinet.
4.2 Keyboard and Display
The user inter ace is a modern colored touchscreen.
I you setup some parameters virtual buttons are displayed on the screen. During
the test run, you may stop the machine by touching any place on the screen (i the
keyboard key-switch is on)
4.3 Handling
A ter switching on the machine at the yellow-red switch, or some seconds you will
see a greeting screen with date and time o the so tware release, then the main
menu will appear.
4.3.1 Start
The main switch o the machine should be on at least one hour, be ore you start a
test-run. Ther ore the compressor is preheated, the lubricant inside is getting luid,
and the cooling gas is separated rom the oil. Otherwise a over pressure error may
CDF-Freeze Thaw- Testing Machine page 18

occur and the machine will be automatically stopped again. I you are sure that
the compressor is warm enough, you may cancel this warning by pressing
Continue
The machine starts with de ined cycle clock. The cycle time is battery back-upped
when the machine was switched o . The cycle time may be set in the appropriate
menu. With the CDF test 28 cycles a 24h are run. You may also activate other
cycles. I the last cycle is over, the temperature will be kept constant at 20°C. So i
you start a new test-run, you have to reset the number o cycles and the cycle
time.
ATTENTION The machine is protected against automatic
restart when the mains was off. For restart you have to
press the start utton.
If you want to restart automatically you may activate the
automatic restart at System-Menu --> Div. --> Restart.
The temperature pro ile and the number o cycles may be reprogrammed in the
System-Menu, Pro ile-Input. The CDF pro ile is activated by de ault.
4.3.2 Status
Status give an in o o all machine units as well about all temperatures. The graphic
o the last 24h temperatures will be implemented in the next so tware release.
CDF-Freeze Thaw- Testing Machine page 19

I a security protection switch is on, it is shown in this menu by an inverse button
The actual temperatures are shown in the screen below:
CDF-Freeze Thaw- Testing Machine page 20