Hardware
Designed and built by Forney, the CA-0399 RetroPak converts your manual machine to an automatic machine.
Forney RetroPak™ is an automatic control system that easily retrofits to most manual testing machines. The CA-0399 series of drive and control packages are specifically designed for testing a variety of materials in compression and flexure on machine frames with larger cylinder diameters. Additional pump flow and reservoir size have been incorporated into the design in anticipation of large hydraulic piston and a variety of accessories. It allows seamless conversion of a manual machine to fully automatic and arrives pre-wired and pre-assembled making installation and connection quick and simple. RetroPak is the easiest way to upgrade a testing machine to fully automatic operation. It’s also the only one that works with ForneyVault.
WHAT’S INCLUDED
ForneyLink TA-1258 touchscreen HMI, hydraulic pump and Automatic (VFD) control system. The entire system is integrated into a single console, allowing for easy field retrofit of existing manual compression testing machines. Comes assembled.
Console Design
The console consists of a welded frame with removable side and end covers to allow access to two areas: an electronic control chamber, housing a variable frequency drive, power supplies, and additional electrical equipment to control the load frame; and a hydraulic power chamber housing the pump, valves, and other necessary equipment.
Convert to Easy Automatic Testing
The Forney automatic control system provides fully automatic, “one touch” testing for many construction material test specimens Push one button and the machine performs the complete test, including piston retract. Accurately controls the rate of load at the desired setting, thus no question about meeting ASTM (or other) specifications and ensuring repeatable results. Frees the operator to do other tasks while testing is in process.
Easy to Install
Installation work consists of the removal of the existing hydraulic power pack and digital readout, along with the pressure transducer, hoses, and any other miscellaneous wiring.
The new system is connected via a single hose to the compression machine and then plugged into a standard electrical outlet (available for 110V to 240V). No further field modifications are required, except, at the customer’s request, or to incorporate non-standard features such as over-travel limit switches or specialized testing protocols.
The system works with most compression testing machines and is especially suited to machines utilizing 5,000 to 10,000 psi hydraulic operating pressures.
Hydraulic
The hydraulic unit is supplied as a complete, fully integrated assembly. The console houses the pumping system, consisting of a submerged, vertically mounted radial piston pump, in-line coupled with a supercharged/rapid advance pump. Appropriate valves for safety relief and pressure discharge are mounted on top of the reservoir, which is mounted inside the bottom of the console.
The system utilizes a variable frequency drive to adjust motor speed and therefore pump output to coincide with programmed demand per the test set up. This provides the most efficient hydraulic power arrangement as only the amount of flow needed is developed. Excess oil is not generated, and does not therefore require discharge over the relief valve. This minimizes heat and greatly extends hydraulic system longevity.
An optional proportional valve for controlled piston retract required by code for Modulus of Elasticity and Poisson’s Ratio tests is available.
The ForneyLink human machine interface (HMI), hydraulic unit, E-Stop, and dump valve are directly connected to the unit. Single unit design permits easy installation and provides portability without disassembling of hydraulic or electrical components.
Electrical
A PC-based system utilizes a variable frequency drive to control the hydraulic pump motor. This maximizes efficiency – only running the pump at speeds necessary to achieve the desired pressure. This energy-efficient approach dramatically reduces heat build-up in the hydraulic system and greatly extends hydraulic component life.
Here are the main components of the system:
- Variable frequency drive (VFD)
- Windows-based touchscreen human machine interface (HMI)
- Pressure transducer that provides pressure feedback
- E-stop PB
- Limit switch
- Solenoid-operated dump valve
Single phase current is required. The operational system is available in a number of configurations – 110V/220V single phase, 50/60Hz. Other electrics are available upon request
Safety Features
Several safety features are incorporated to protect both operator and testing machine:
- Maximum Capacity Protection: A high-pressure safety relief value protects the hydraulic circuit and load frame from exceeding maximum capacity.
- Overextension Protection: A piston over-extension limit switch system protects against piston extension beyond maximum travel.
Software
Easy Automatic Testing
Push one button and the machine performs the complete test, including piston retract. Accurately controls the rate of load at the desired setting, thus no question about meeting ASTM (or other) specifications and ensuring repeatable results. Frees the operator to do other tasks while testing is in process.
Digital Control System
Setup of testing protocol, real-time display of test data, and post-test data transfer is accomplished through the ForneyLink touchscreen HMI. The operator can navigate options for:
- Test Run
- Test Setup
- Machine Setup
- Calibration
- Reporting and Data Transfer
- Diagnostics
Provides simultaneous display of force, stress, and rate of load and displays a real-time graph of Load vs. Time, or Stress vs. Strain. Standard functionality includes data collection by the ForneyLink HMI for printing and transfer. Data from optional extensometer and compressometer displacement transducers are also collected by the HMI. This data is captured with the same timestamp as the load data.
CMT Software Integration
Seamless Integration with ForneyVault® CMT Software
Connected machines work in tandem with ForneyVault to streamline critical workflows before and after every test—enhancing accuracy, efficiency, and compliance throughout the testing process.
Pre-Test Intelligence
Before testing begins, integrated machines automatically:
-
Verify specimen identity through barcode scanning for accurate tracking
-
Run Smart Checks using preloaded sample data to confirm specimen size, type, date, and expected strength
-
Validate specimen geometry to ensure conformance
-
Calculate preload settings based on actual or expected strength, improving consistency
Post-Test Automation
Once testing is complete, the system delivers immediate, actionable results:
-
Generates detailed XY plots for each test
-
Automatically transfers data to LIMS, quality control systems, or other connected software platforms
-
Issue automated alerts for early breaks, low or outlier results, overdue tests, and completed sets—helping you manage compliance, scheduling, and reporting with confidence.
-
Enables intelligent workflows for streamlined reporting, review, and approval processes
Remote Support
With a user-provided Internet connection (either Wi-Fi or Ethernet), the RetroPak system offers real-time online support from the Forney Support Team, covering basic settings and test setup, as well as advanced troubleshooting, fault finding, and software updates.
We offer unlimited Remote Technical Support for all Forney Testing Machines during the two-year warranty period.
For ForneyVault® subscribers, post-warranty remote technical support fees are waived for the life of your subscription.
Please refer any special requirements to a Forney sales representative.
* Specifications are subject to change without notice.
