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1. 04 29 99 Model 3800 Gaging System User Manual Revision E Part Number 028585 R01 Information in this document is subject to change without notice No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical for any purpose without the express written permission of ADE Technologies except for copies made as working documents for use with ADE Technolologies supplied equipment 1996 2002 ADE Corporation All rights reserved TECHNOLOGIES 2 Model 3800 User s Guide Table of Contents Revision HISTO ec 4 1 0 ll A E 5 2 0 Setup and Getting 8 2 1 entre 8 2 2 Power Requirements 8 2 3 Probe Connection aaan a paaa aa 8 2 4 Tolerance Limits nc mean nene kx nmm cran nne caa 10 2 5 enl pee 10 3 0 Connections deeem 11 3 1 Lice 11 3 2 Connecting To The 3800 13 4 0 User 22 m 14 4 1 Front Panel Adju2. The P2 connector contains drive clock and phase information as well as power and should be bussed together from one unit to the next Power should be supplied to P2 on pins 8 11 or 21 24 See Figure 2 NOTE The P2 connector is laid out so that pins on opposite sides of the connector have the same signal This permits daisy chaining the units For example P2 14 of unit 1 could be connected to P2 1 of unit 2 Unit 2 s P2 14 could be connected to unit 3 s P2 1 etc TECHNOLOGIES Model 3800 User s Guide 13 4 0 User Adjustments 4 1 Front Panel Adjustments Calibration this is factory set and should not usually be adjusted A scale factor adjustment is available on the front panel This pot marked SF on the standard 3800 and Gain on the remote front end version allows for fine adjustments to the probe scale factor for periodic calibration The scale factor is the displacement to voltage ratio See section 5 for more details Zero A front panel pot is provided to allow fine adjustments of the output voltage offset to obtain a zero reading without having to move the probe or target The allowable range is 10 of the full scale operating range Adjustment to the Zero pot has no effect on the Scale Factor Limits not available on remote front end version Two limit pots are available for setting trip points of the and limit lines and LEDs Both limit pots may be set anywhere in the range of the probe The limi
3. able on these pins ANALOG OUT voltage will increase as distance increases while ANALOG OUT voltage will decrease as distance increases Limits P1 Pins 5 9 Limit outputs are open collector TTL compatible signals representing the state of the limit LEDs Refer to section 4 1 for more information Noise Immunity ARTN P1 Pin 3 The ARTN connection may be used to reduce noise due to non uniform grounds between the 3800 and any data collection equipment ARTN is a separate return which allows external equipment to float 0 1v from analog ground This allows the creation of a pseudodifferential connection to external monitoring equipment to prevent ground loops See Appendix A for more information on grounding 12 Model 3800 User s Guide 3 2 Connecting To The 3800 The 3800 s connection scheme has been designed to be simple and flexible The 3800 can be used as a single stand alone gage or used in an application requiring several channels When multiple channels are required the systems should be connected together synchronized Single Unit When the 3800 is used as a single channel gage power is supplied on the designated pins of P2 Outputs analog outputs and limit outputs may be obtained on P1 See Figure 1 Multiple Units The drive synchronization feature is used to eliminate probe driver differences in multiple channel applications The 3800 is designed to allow multiple units to be bussed together
4. acement displacement condition with reading reading measurement data not reported TECHNOLOGIES Model 3800 User s Guide 7 2 0 Setup and Getting Underway 2 1 Configuration The 3800 is supplied from the factory with a default configuration Any adjustments to this configuration should be made prior to installation The configurable items their default settings and instructions to change them are described in section 4 2 2 Power Requirements The 3800 must be powered with regulated 15 VDC 0 1 volts power at the power pins of P2 P2 Pin 8 or 21 15 0 25 Amp P2 Pin 9 or 22 Power Common Ground P2 Pin 10 or 23 15 VDC at 0 15 Amp Max NOTE Only one connection is required for each of the above requirements The two available pins are interconnected on the printed circuit board inside the 3800 The green front panel power LED labeled PWR will light if the power supplies are operational If this LED is not lit one or both of the power supplies may not be operational or able to supply the necessary current 2 3 Probe Connection Connect the probe to the 3800 gaging module as shown on the next page In the standard configuration the probe connector plugs directly into the front panel In the optional remote front end connection the probe connector plugs into the remote front end box and a second cable connects the remote front end to the 3800 gaging module Use care when handling probes and cab
5. below shows the jumper configurations for different phase angles 0 IN IN IN IN 22 5 IN IN IN OUT 45 IN IN OUT IN 67 5 IN IN OUT OUT 90 IN OUT IN IN 112 5 IN OUT IN OUT 135 IN OUT OUT IN 157 5 IN OUT OUT OUT 180 OUT IN IN IN 202 5 OUT IN IN OUT 225 OUT IN OUT IN 247 5 OUT IN OUT OUT 270 OUT OUT IN IN 292 5 OUT OUT IN OUT 315 OUT OUT OUT IN 337 5 OUT OUT OUT OUT default setting TECHNOLOGIES Model 3800 User s Guide 17 5 0 Calibration The 3800 gaging system s calibration may be adjusted via a front panel potentiometer This pot is labelled SF on the standard 3800 module and Gain on the 3800 module used with the optional remote front end The following procedure should be followed to calibrate the unit EQUIPMENT 1 Digital Volt Meter with 10 range Fixturing equipment capable of moving the target precisely throughout the measurement range 3 Small screwdriver to access the front panel scale factor pot NOTE Calibration is very dependent on fixturing It is important that the probe and target be parallel or calibration errors will occur PROCEDURE 1 Set the probe at near standoff so that the DVM reads 10 000 volts ANALOG OUT output 2 Move the probe or target so that the gap between them increases by the total measurement range i e for a 100 um range increase by 200um Measure according to the fixturing equipment 3 Note this voltage 4 Adjust the pot so that th
6. connecting the front end to the Gage board The probes are transducers which form a capacitor with the target surface Because the area of the formed capacitor is constant variations in capacitance are related to variations in the distance between the probe and the target surface Note that the system does not measure the absolute distance between the probe and target surface but variations from a nominal position known as the probe s Nominal Standoff This probe to target distance at the midpoint of the probe s operating range yields an output of 0 V As the target moves closer to the probe the voltage decreases At Near Standoff the smallest probe to target distance within the probe s operating range the output is 10 V At Far Standoff the greatest probe to target distance within the probe s operating range the output is 10 V Near Standoff 4Target surface here yields negative displacement Probe Nominal Standoff operating Target surface here ields positive Far Standoff _ 4displacement range 6 Model 3800 User s Guide 10 V 10 V 10 V 5V y 5V 5V 5 V 5 5 77 10 M Target further Target closer to Target outside from probe than probe than probe s operating nominal yields nominal yields range yields positive negative overrange displ
7. e reading on the DVM ANALOG OUT is 10 10 reading in step 3 2 Example If step 3 reading 9 900 V adjust pot so that DVM reads 10 050 V If step 3 reading 10 150 V adjust pot so that DVM reads 9 925 V 5 Repeat steps 1 4 to check the calibration Calibration is complete when the reading is within a desired tolerance Iteration may be necessary to precisely adjust the scale factor The scale factor may be adjusted to better than 10 mV TECHNOLOGIES 18 Model 3800 User s Guide 6 0 Range Adjustment The 3800 gaging system has a flexible architecture which will permit you to perform a full calibration of the system This will allow you to install a new probe or change ranges as needed This feature requires specialized fixturing and is usually done at the factory A description of this feature has not been included in this guide Please contact ADE Technologies for more information TECHNOLOGIES Model 3800 User s Guide 19 TECHNOLOGIES Appendix A Grounding Electrical grounding issues are important to capacitive gaging This type of transduction generally requires that the target be connected to the circuit ground of the 3800 module Target Grounding The target must be connected to the circuit ground of the gaging system The 3800 has been designed so that the probe housing is grounded An electrical connection from the probe shell or the fixture holding the probe to the target wil
8. er than its set point The LIMIT LED lights when the probe to target distance is less than its set point The limit outputs on connector P1 are TTL low less than 0 8 VDC when the LED is lit and TTL high greater than 3 5 VDC when the LED is off Default Limit Configuration The limits are factory set at the end of the probe range The LIMIT trips when the gage output ANALOG OUT is greater than 10 00 volts The LIMIT trips when the gage output is less than 10 00 volts To set the tolerance limits refer to section 4 1 2 5 Outputs Outputs are available on the designated pins of P1 and P2 ANALOG OUT P1 Pin 1 This output is the standard analog output Voltage increases with distance At Near displacement the voltage will be negative and will increase with increasing distance This voltage is relative to analog ground P1 pin 4 ANALOG OUT P1 Pin 2 Voltage decreases with distance At Near displacement the voltage will be positive and will decrease with increasing distance This voltage is relative to analog ground P1 pin 4 LIMIT P1 Pin 5 This output is TTL low when the corresponding front panel LED is lit and TTL high when the LED is off LIMIT P1 Pin 9 This output is TTL low when the corresponding front panel LED is lit and TTL high when the LED is off TECHNOLOGIES 10 Model 3800 User s Guide 3 0 3 1 Connections Pinouts The 3800 Gaging Module has two input output connectio
9. l provide the necessary ground If this is not possible a wire may be run from the 3800 module directly to the target A grounding point has been established on the rear panel of the 3800 between the P1 and P2 connectors A ground wire may be attached there with a 4 40 screw and toothed washer NOTE Do not use a screw which protrudes more than 25mm 1 inch into the 3800 module as it may short to an internal component Chassis Ground The chassis of the 3800 gaging module is always capacitively coupled to Analog Ground A jumper has been provided W46 which will explicitly ground the chassis The default configuration is with the jumper in place This will connect the case to ground directly For some applications it may be desirable to remove this jumper to improve noise performance or remove ground loops caused by the fixtured position of the 3800 module If this jumper is removed do not use the external grounding point as target ground Analog Return The ARTN connection P1 3 may be used to reduce noise due to non uniform grounds between the 3800 and any data collection equipment ARTN is a separate return which allows external equipment to float 0 1V from analog ground This allows the creation of a pseudo differential connection to external monitoring equipment to prevent ground loops 20 Model 3800 User s Guide
10. les DO NOT PULL ON THE PROBE CABLE S The probe cable and its connectors must not be cut spliced or disassembled NOTE The target MUST be at the same potential as analog ground The housing of most models of probes are grounded via the probe cable In cases electrically attaching the target to the probe shell will result in a well grounded target In addition a ground point has been provided on the rear panel of the gaging module A 4 40 threaded hole has been placed between P1 and P2 for grounding purposes NOTE Do not use a screw which protrudes more than 25mm 1 inch into the 3800 module as it may short to an internal component See Appendix A for more information on grounding TECHNOLOGIES 8 Model 3800 User s Guide probe EN 5800 probe cable Standard Probe Connection extension cable remote front end probe cable probe o 0 JJ Oo onn B 5800 TECHNOLOGIES IM Probe Connection For Optional Remote Front Ends TECHNOLOGIES Model 3800 User s Guide 9 2 4 Tolerance Limits not available with remote front end option Two limit adjustments are supplied to indicate a gage reading outside of an expected value The limits may be set to any point in the gage s operating range 10 Volts The LIMIT LED lights when the probe to target distance is great
11. ns P1 and P2 P1 is a 9 pin male D subminiature connector and P2 is a 25 pin female D subminiature connector The connectors are designed so that multiple units may be synchronized using a bus type arrangement on P2 The connectors have the following pinouts P1 9 Pin D Female P2 25 Pin Male Analog Out Analog Out ARTN Analog Return Analog Ground Limit Qo Clock Clock Not Digital Ground Phase Phase Not Digital Ground NC 415 VDC Power Common 10 15 VDC 11 NC 12 NC 13 NC no connection ouo NC NC NC Limit Clock Clock Not Digital Ground Phase Phase Not Digital Ground NC 415 VDC Power Common 15 VDC NC NC p TECHNOLOGIES Model 3800 User s Guide 11 TECHNOLOGIES These connections can be grouped into the following categories Drive Synchronization P2 Pins 1 2 3 4 5 6 14 15 16 17 18 19 Drive synchronization is useful when more than one 3800 is being used in a particular application Drive synchronization eliminates noise caused by frequency differences between probe drives See section 4 for more information Power P2 Pins 8 9 10 Power to the board is supplied by these pins Power requirements are 15 VDC at 250 mA and 15VDC at 150 mA Both supplies must be regulated Displacement Outputs P1 Pins 1 2 The analog displacement signal is avail
12. on the P1 and P2 connector end Then slide the bottom plate off Jumper Settings Defaults are starred Bandwidth The 3800 may be set to one of four bandwidths Use the following table to determine the jumper settings Bandwidth W6 W7 w8 w 5 kHz IN OUT IN OUT 1 kHz OUT OUT OUT OUT 100 Hz IN IN IN IN 10 Hz OUT IN OUT IN default setting gt TECHNOLOGIES Model 3800 User s Guide 15 Drive Synchronization Drive synchronization is a method of phase locking the probe drives of two or more 3800 units to prevent any probe to probe interactions Refer to Figure 2 for the proper electrical connections for multiple units Configuration W45 Master OUT Slave IN default setting NOTE A slave will not operate without the master unit connected and powered Output Scaling The analog output level of the 3800 is configurable The standard Chassis GND TECHNOLOGIES 16 Model 3800 User s Guide output is 10 volts for the entire probe range Shown is a table of other common output voltages that are available W1 W5 set the scale factor while W10 is an offset jumper for configuration of bipolar unipolar output Confiquration W1 W3 W4 W5 W10 10 V Bipolar IN OUT IN OUT IN IN 5 V Bipolar IN IN IN IN IN IN 010 10 V Unipolar IN IN IN IN IN OUT default setting NOTE The voltage on ANALOG OUT will be the negative of ANALOG OUT If you want a negative unipolar output set
13. per for configuration of bipolar unipolar output changed to W10 from W12 added assembly drawing of Model 3800 housing and parts list Figure 4 1 0 Overview The 3800 OEM gaging module is a non contact capacitive dimensional gaging system designed for maximum flexibility combined with ease of use Capacitive transduction converts variations in a probe to target distance into an electrical signal The system consists of the following items 1 3800 electronics module 2 spare jumpers 3 probe and cable 4 optional remote front end electronics module and extension cable The remote front end option allows gaging in applications with excessive noise and applications which require long distances i e more than 10 feet between the probe and the 3800 electronics module A4 TECHNOLOGIES Model 3800 User s Guide 5 1 3 TECHNOLOGIES Probes The patented measurement probes which are included with the 3800 may be selected from a vast variety of available models which vary in diameter and operating range Use extreme care when handling the probes and especially try to avoid scratching the sensor Each probe has been calibrated for use with a particular Gage board and MUST be used with that Gage board to ensure accurate operation Most probes have a ten foot cable which connects to the Gage board Probes with remote front ends have a cable connecting the probe to the front end and an additional 30 foot cable
14. stments eese 14 4 2 Configuration Adjustments 15 5 0 Galibiatio eR Hm 18 6 0 Range Adjustment eie 19 Appendix A Grounding 20 Figure T 21 aediles 22 jc c 23 FIGUE p 24 DZ TECHNOLOGIES Model 3800 User s Guide 3 Revision History rev date description of change X5 04 05 93 A 07 29 93 B 05 13 96 03 07 97 D 02 13 98 E 04 29 99 gt TECHNOLOGIES 4 Model 3800 User s Guide preliminary release corrected bandwidth jumper settings section 4 2 for 5 kHz and 10 kHz corrected output scaling jumper settings 4 2 so last jumper is W10 not W11 corrected Figure 1 to show proper power were previously reversed remote front end support 1 0 2 3 2 4 4 1 5 0 new illustrations ECO 6252 corrected reversed MSB LSB designations in Appendix A Figure 3 ECO 6710 corrected output scaling jumper settings 4 2 so last jumper is W12 ECO 7242 corrected explanation of Far Standoff in section 1 3 corrected explanation of when LIMIT and LIMIT LED s become lit reversed reversed LIMIT and LIMIT in Outputs and Pinouts sections P1 pins 7 and 20 replaced with pins 5 and 9 offset jum
15. ts are set by adjusting the probe to target distance until the trip point voltage is obtained The limit pot is then turned so that the trip point equals the probe voltage This is defined as the point at which the LED changes state ON to OFF or vice versa LIMIT LED LIMIT LED POWER LED ZERO Standard Model 3800 Remote Front End P Version TECHNOLOGIES 14 Model 3800 User s Guide 4 2 Configuration Adjustments The 3800 has features enabling you to adjust electrical parameters of the internal printed circuit board to suit your application These parameters are listed below along with the default settings set at the factory Confiqurable Function Default Configuration if applicable Master Slave Master Single unit operation Drive Phase 0 Degrees Output Scaling 10 volts for probe range Bandwidth 1 kHz Chassis GND Enable Grounded See Appendix A Gain Setting Adjusted at factory see Section 6 Linearity Setting Adjusted at factory see Section 6 Front End Gain Adjusted at factory see Section 6 NOTE Probe range is a function of the last three items listed above These jumpers are set at the factory for a specific range refer to the data sheet which was included with the 3800 Refer also to section 6 Descriptions of individual parameters follow If any configurable items need to be changed refer to Figure 3 to locate the position of the jumpers on the PCB Board Jumper Access Remove the four screws
16. up the jumpers as in case 3 above and use the ANALOG OUT output This will give you a 0 to 10 V swing A jumper has been provided allowing the chassis of the 3800 to be either grounded or ungrounded See appendix A for more grounding information Configuration W46 Chassis Grounded IN Chassis Ungrounded OUT default setting Drive Phase When more than one 3800 is used one master unit with several slave units the phase of the probe drives may be set to an appropriate angle with respect to the master This patented feature allows for the gaging of poorly grounded targets using two or more probes To choose the proper phase angle determine the phase angle spacing P by dividing 360 by the number of probes that are gaging the same target The first probe should have a phase of 0 The second probe should have a phase as close to 2P as possible The third probe s phase should be as close to 3P as possible etc Here are some examples 1 If all probes are independent a phase angle of zero is recommended on all boards default setting 2 If two probes are used the first board should be set to 0 and the second set to 180 3 Ifthree probes are used the first board should be set to 0 the second set to 112 5 and the third set to 247 5 4 If four probes are used the first board should be set to 0 the second set to 90 the third set to 180 and the fourth set to 270 NOTE The master must be set to 0 degress The chart
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