ThreadChecker Universal
Contents
1. 06457 www kamansensors com or 860 632 4442 Page 12 of 13 ThreadChecker Specifications ELECTRICAL INPUT Voltage 15 VDC to 30 VDC reverse polarity protected Current 50 to 100 mA ANALOG OUTPUT Current short circuit protected Impedance 50 ohms Voltage 0 10 VDC SWITCHED OUTPUT Opto Isolated Load Current 80 mA maximum AC or DC Load Voltage 30V rms 42 4V peak On Resistance 1 ohms minimum 8 ohms maximum Switch Point Hysteresis see application variations SAMPLING FREQUENCY gt 5 KHz ENVIRONMENTAL ENCLOSURE RATINGS Sensor IP 67 Electronics IP 67 OPERATING TEMPERATURE RANGE Sensor and cable 32 F to 158 F 0C to 70 C Electronics 32 F to 131 F 0 C to 55 C STORAGE TEMPERATURE RANGE Sensor and cable 40 F to 185 F 40 C to 85 C Electronics 40 F to 158 F 40 C to 70 C Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 13 of 132. bad thread need to be detected there are a couple of things that will help First when teaching the sensor use an example of the bad thread a partially threaded part Next make sure to use as large a sensor as possible This results in better resolution And finally minimize temperature changes even with the specified 05 C temperature compensation a 20C change will result in a 196 shift Allow the system to warm up to operating temperature before calibrating A full warm up usually takes about 15 minutes but usually 5 minutes is adequate Make sure the sensor connector is screwed on tight Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 10 of 13 Electronics Mounting Instructions Mounting the ThreadChecker electronics module can be done using the two holes in the enclosure and an M 4 or 6 32 screw see below The DIN mount attachment can also be used to allow mounting on a DIN rail Positioning the electronics module so that it is not the low point in the cable will keep liquids from running down the cable and into the electronics Take care to route the sensor cable to avoid crushing or crimping it during use Damage to the sensor cable may affect the desired set points and overall operation of the electronics Teach button LED 23 12 7 E 5
3. it will read 7 5V on the unthreaded hole and 2 5V on the threaded hole For small diameter sensors in large diameter holes there ends up being a substantial amount of gain on the analog output and so it may appear to be noisy Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 6 of 13 The LED s There are two bi color LED s on the system The power LED labeled PWR displays whether the system is running or has a fault The status LED labeled THREAD displays the limit output and can flash at different calibration points The function of the status LED in the Thread Checker is to indicate the state of the switched output In compatibility mode the status LED output mirrors the switch state When the LED is off the switch output is pulled to ground When the LED is on the output is open In standard Window comparator mode the status LED functionality is NOT affected by the limit inversion and will continue to operate with green indicating a good or threaded hole red indicating a bad or non threaded hole and off as no target POWER LED Green System is running with no faults Red Solid red on the power LED means that it does not recognize the sensor or it is disconnected If the sensor is connected and this condition p
4. window or level comparator inversion of limit available to user e Low power consumption ThreadChecker Unit The ThreadChecker system consists of two subassemblies the sensor with integrated cable and the signal conditioning electronics module with power and output cable The ThreadChecker electronics uses a standard 24AWG cable to bring 15 Vdc to 30 Vdc into the electronics and provide outputs for the analog voltage and switch functions Theory of Operation The ThreadChecker system is an eddy current system The sensor coil is resonated and the amount of impedance change in the output is measured by the electronics The proximity of the target to the sensor coil will cause the sensor coil to change impedance The signal is then processed and filtered to obtain an analog voltage proportional to the target position or displacement Cable Connections and Power I O Cable Color Chart Wire Color Signal O BROWN Vin 15 30vdc BLUE WHITE SWITCHED OUTPUT BLACK Vout 0 10v Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 3 of 13 Electronics The ThreadChecker electronics has one switch and two LEDs visible in the enclosure to provide various setup and status functions The power led indicates that power is applied and everything is functi
5. ThreadChecker Universal Noncontact Thread Detection System User s Manual Kaman Aerospace Corporation Kaman Precision Products Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Copyright 2008 PART NO 860510 001A Last Revised 6 8 11 Page 1 of 13 This apparatus when installed and operated per the manufacturer s recommendations conforms with the protection requirements of EC Council Directive 89 336 EEC on the approximation of the laws of the member states relating to Electromagnetic Compatibility Please refer to the Declaration of Conformity or contact Kaman Precision Products for details Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 2 of 13 ThreadChecker Universal Kaman s ThreadChecker Measuring System is a noncontact linear proximity measuring system This low cost easy to use system makes precision static and dynamic measurements of the presence or absence of a thread Features Summary Advantages e Easy to Use Universal Electronics for All Sensor Types and Target Types Built in Self Test Small size for efficient system integration less than 4 cubic inches 80cc Flexible packaging and performance Several sensor options Flexible Switched Output Options
6. bration sequence 1 2 Connect the sensor and power source to the electronics Allow the system to warm up for a minimum of 5 minutes With the sensor in air i e not in a hole or near any conductive material press and hold the Teach button until the Thread LED blinks fast then release more than 1 second but less than 10 seconds the Thread LED should blink slowly Position the sensor tip in the threaded hole and momentarily press the Teach button The Status LED will blink fast Position the sensor in an unthreaded or bad hole and momentarily press the Teach button The LED should be solid red indicating no threads present The system is now calibrated and ready for use Since the switch point is half way between these 2 points you can teach these in reverse order bad then good if desired Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 5 of 13 The Switched output This is an opto coupled solid state relay While the switched output can handle a substantial amount of voltage amp current see specifications it is not infinite Connect external devices accordingly There are two modes of operation for the switched output Window comparator and compatibility level comparator mode You can easily switch between the two modes by hol
7. ding down the button on power up It will remember the last mode it was set up for the next time you power on The ON polarity of the switch can also be inverted Operation is as follows Standard Window Comparator Mode In standard mode it is a window comparator The switch will be closed to ground when it detects a threaded or good hole Otherwise the switch will be open Compatibility Level comparator Mode In compatibility mode the switch is open when detecting no thread and closed to ground when it detects a thread or open air Inverting the Switch Polarity The polarity of this output can be inverted in either mode so that the open and closed stated are reversed To do this after the unit is powered on press and hold the teach button on the unit for more than 10 seconds To re invert the output press and hold the teach button for more than 10 seconds after the unit has been powered on Note that in compatibility mode the status led mirrors the opto isolated switch state The Analog Output The analog output will read a 5V difference between the threaded and unthreaded holes after calibration The air i e no target value will always be the highest voltage and will be at or near saturation 10V The direction of the output depends on the sensor and target type but typically for aluminum targets the system will read 7 5V on the threaded hole and 2 5V on the unthreaded hole while for magnetic or ferrous target
8. ents may damage electronics module sensor or power I O cable Clean the unit with a damp cloth EMI Performance The ThreadChecker conforms with the applicable standards of Council Directive for Generic for Light Industrial and Commercial Use Under some EMI environments at specific frequencies the ThreadChecker unit may experience a change in output voltage In general when exposed to those environments covered by the EMC directive the user can expect less than 596 deviation of output Contact Kaman for specific data or for recommended solutions if you experience problems with the ThreadChecker Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 4 of 13 Operation of the ThreadChecker Wire colors amp pin out The wire colors and typical connection diagram are as follows Brown 15 30 Vde input ThreadChecker White Electronics Module Black 0 10 Vdc output Switched output pic Blue Ground Teach sequence Before the system is first used it must have the teach sequence run In order to do this you must have a representative threaded and non threaded hole The system can be easily calibrated to any new sensor designed for the ThreadChecker as well as for most hole thread configurations with a simple cali
9. ersists after a teach then the electronics does not recognize the sensor and it may be faulty Red Flashing Fast The system has a fault calibration error power input too low etc Most likely calibration error with points too close together Yellow The system is being calibrated or the button is pushed Off System has no power or is otherwise faulty Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 7 of 13 Dwell time and Frequency When the sensor is being inserted into a hole there is a certain period of ambiguity at partial insertion To avoid switching on this ambiguity a form of derivative is used to determine whether the sensor is in motion or is at the measurement point The system will effectively delay of approximately 10 20 milliseconds after it stops moving before it recognizes the values for the limits the analog output does not do this and is continuous If this delay is too short for the application it can be adjusted at the factory If the delay is a problem for the application and there is another method of determining when a reading is valid then the delay can be turned off by holding down the button for more than 10 seconds during power up until the led turns on It can be toggled back on by the same method Posit
10. i6 Eh 2X 38 0 92 0 50 TH 15 46 79 2 3 me im bw in this view 5 3 Is Sensor I O cable 4 6 0 18 diameter X 71 l o t 0 28 49 ag UU 0 14 Optional DIN rail mount 70 2 8 included All dimensions in mm inches Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 11 of 13 Thread Sensor Specifications 2 mm Sensor M5x0 8 Thread i 7 0 27 eG 30 4 1 20 62 0 08 Hole sizes Model Part 3mm 5mm 5 10 2mm 855641 303 4 mm 6 mm 10 mm Sensors A B E v En dios 95 4 4 0 Hole sizes Model Part A B 6mm 7mm 12 5 16 4mm 855641 602 M8x1 4 0 0 16 8mm 10mm 3 8 1 2 6mm 855641 802 M8x1 5 8 0 23 12mm 14mm 9 16 3 4 10mm 855641 1202M12x1 9 5 0 38 External Thread Sensors A M usse Stud sizes Model Part A B C 4mm 6mm 6 10 6mm 855800 605 M18x2 5 31 8 1 25 8 0 0 31 8mm 10mm 12 3 8 8mm 855800 805 M24x3 38 1 1 50 11 9 0 47 Copyright 2008 PART NO 860510 001A Last Revised 6 8 11 Kaman Aerospace Corporation Kaman Precision Products Measuring amp Memory Systems 217 Smith Street Middletown CT
11. ioning Mounting the sensor Ideally the sensor should be just slightly smaller than and centered in the untapped hole The surface of the sensor tip should be at mid depth Larger For holes that are much larger than the sensor the mounting can be offset so that the sensor is near the threaded edge While this will be able to detect the presence or absence of a thread there are a couple of limitations First only a small section of the tapped hole is being tested Second generally the signal strength is lower This results in lower resolution Smaller For holes that are smaller than the sensor the sensor can be mounted near the surface of the material and measure down into the hole The main limitation here is that there is a limited depth that the sensor can detect threads near the max range of the sensor There is also a limitation on very small holes where the diameter of the hole is less than half the diameter of the sensor Copyright 2008 Kaman Aerospace Corporation PART NO 860510 001A Kaman Precision Products Last Revised 6 8 11 Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 8 of 13 Push Button Switch Operation and User Configuration Switch Operation Result Holding the button down for longer than one second The status light starts blinking On release it acquires the air readings for all frequencies The next step is to put the senso
12. onal if it is green Red or flashing red on the power LED indicates a problem The thread or status LED indicates the presence or absence of a thread or teach status see application information The ThreadChecker electronics and sensors utilize SMA type coaxial connectors female on the electronics and male on the sensor cable Four probe configurations for detecting internal threads are currently available from 2mm to 10mm and two probe configurations for detecting external threads are available more configurations are created regularly check with Kaman sales for current configurations The sensor must be attached snugly finger tight to the electronics assembly for the unit to function properly Adjustment and Calibration The ThreadChecker requires calibration to the users configuration before use NOTE solid red on the power LED means that it does not recognize the sensor or the sensor is disconnected If the sensor is connected and this condition persists after a teach then the electronics does not recognize the sensor and it may be faulty The switched output can be adjusted using the teach modes See application information for more details Switched Output Operation The ThreadChecker s switched output is a simple on off switch The switch can be adjusted to trip anywhere along the sensor range using application teach modes Cleaning The ThreadChecker is designed to have limited operation while immersed in liquids Some solv
13. r in a threaded hole and press the button again On release the system will acquire a set of calibration data for all frequencies for the threaded hole The last step is to put the sensor in a non threaded hole and press the button again On release the system will acquire data for all frequencies for the non threaded hole optimize the sensor frequency and modality and set the limits Holding switch down during power up for Holding switch down during power up for more than 10 seconds Holding switch down for longer than 10 seconds until the status light stops blinking Toggles between window comparator and level less than 10 seconds comparator Status LED will turn yellow and when the switch is released it will toggle the Dwell Enable i e whether or not you are using the derivative to check the limits Limits are inverted Copyright 2008 PART NO 860510 001A Last Revised 6 8 11 Kaman Aerospace Corporation Kaman Precision Products Measuring amp Memory Systems 217 Smith Street Middletown CT 06457 www kamansensors com or 860 632 4442 Page 9 of 13 Troubleshooting No LED s are on Check power input Make sure power input is correct polarity and connected to right wires Ifyou can verifiy that the proper voltage is across the power input pins 15 to 30V on the brown wire the blue wire connected to ground then contact the factory Power LED is red all of the time Make sure senso
14. r is connected and is tight lf sensor is connected do a teach function If after the teach the power LED is solid red then the sensor is probably bad contact the factory If after the teach the power LED is flashing red there may not be enough output from the sensor for the holes or the sensor is bad Power LED is flashing red Make sure power input is between 15 and 30VDC Make sure the ambient temperature around the electronics is lt 55C Ifitis red after you do a teach it is likely there is not enough output difference between the threaded and non threaded holes You may need a different sensor or see the section on System not resolving thread no thread correctly Make sure sensor connector is screwed on tight before a teach Status LED never goes to red when there is no threaded hole Doa teach to make sure that it has a good calibration t may be that the switch was held down during power up inadvertently hold the switch down on power up and release it when powered up to put it back into Window comparator mode System not resolving thread no thread correctly The difference between a thread and a no thread condition usually produces a large signal difference approx 20 of the sensor range There are cases though where this may be a smaller percentage A partially threaded hole may produce 1 10 the signal difference resulting in just a 296 signal difference In cases where smaller differences in good
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