USER`S MANUAL - A&E Gauges Ltd
Contents
1. F GAUGES LTD Vezo ELECTRONIC COLUMN GAUGE USER S MANUAL Issue no 1 April 2006 A amp E GAUGES LTD Unit 7 Redbourn Industrial Estate Redbourn Herts AL3 7LG Tel 44 0 1582 794136 Fax 44 0 1582 794463 E mail sales a egauges co uk Web www a egauges co uk CONTENTS INTRODUCTION 2 GETTING STARTED 3 Unpacking Electrical Connection Quick Start CONTROLS vis sees soe se 4 Range Switch Zero s Calibration Tolerance Probe Selector Switch CALIBRATION ees 5 Equipment Required Procedure SETTING THE PROBES 6 Procedure TOLERANCE LED s 7 Setting Procedure yez PROBE PROGRAMMING 8 Simple programming Multi gauging OUTPUTS rent iaidd 9 RS232 Oscillator connection da ds 10 MEMORY MODE Optional 11 Application examples 12 MAINTENANCE esse ese ee 13 Cleaning Fuses Warranty SPECIFICATION esse se 14 Bee ed ee Ee 15 yez Introduction The VC2000 is a single channel vertical column gauge designed for the connection of inductive probes with the standard Mercer sensitivity With single or differential measurement options one or two probes may be used in any summing or subtracting combination Units may be inter connected and probe signals mixed to provide a multi channel gauging capability The measured value is displayed on both the 100 LED bargraph and the 3 digit red LE2. Calibrate all probes as described in the Calibration section Connect all probes to their appropriate sockets as defined by the gauge programme Working in sequence set the selector switch of the first probe to All other selector switches must be set to their centre 0 positions Position the probe in the fixture with the setting master in place and lightly clamp when the display reads approximately zero Set to exactly zero using the probe zero control at the rear Do not touch the front panel zero control at this stage Repeat this procedure for all other probes ensuring that all selector switches are at centre 0 position except the one associated with the probe being set This should be at When all probes have been adjusted set all selector switches to the polarity defined by the gauge programme Finally using the front panel channel zero control set the display to read the calibrated value of the setting master Note A coarser range switch setting may be used to find the probe position before switching to a finer range for precision adjustments if this makes things easier For single probe applications set the probe in the fixture with the setting master in place and just use the front panel zero control to make any adjustment 6 yez Tolerance LED s Tolerance limits may be set so that readings outside a given range operate LED signals and additional logic signals on the rear
3. down using the same screws N B The baseplate can accept up to three columns Mount columns centrally on the baseplate using the holes provided Two larger holes are available to mount an AE6 Air Electronic Converter in this case mount the AE6 first then use the first adjacent holes for the VC2000 Electrical connection The power requirement is ANY voltage between 85 and 260 volts a c 48 60Hz NO VOLTAGE SELECTOR IS NEEDED Connect the mains lead and switch on The green tolerance LED should light and the bargraph should be somewhere on scale Quick start for simple measurement only Set the range switch to the 50 0um position Check the gauge is working by turning the zero control both ways to make the bargraph move up and down the scale If a single probe is to be used it is usual to use the A probe input but the B input may be used with equal validity Set the probe selector switch to Set the range switch to the position best suited to the working tolerance of the component Adjust the probe mechanically over the master component or reference slip gauge until the display is near to the correct value Trim to the exact size using the zero control The equipment is now set up and ready to use yez Controls Range Switch This sets the gauge magnification The choice of setting is determined by the tolerance sizes of the component to be measured The range best suited to the application is likel
4. D numeric display Traditional mechanical controls provide for quick and easy set up and adjustments Six metric measuring ranges from 5 0um to 1500um full scale are selected by rotary switch Channel zero adjustment is achieved simply and precisely by turning the recessed rotary control knob Tolerance lights are provided for quick Go No Go indication The 3 digit numeric display with 0 1um resolution gives accurate readings for standards room applications and its value is output in RS232 format for Data Logging A robust steel case gives protection in harsh workshop conditions and is smartly styled to look good in the best appointed standards room Precision bore gauging is easily achieved by connecting the AE6 Air Electronic Converter to combine the simplicity of Air Gauging with the benefits of electronics Key Features Brilliant easy to read 100 bar LED display 3 digit red LED numeric display Large Red Green Amber tolerance indication Security recessed zero control 6 Metric Ranges 5 0um to 7 5mm 2 Probe inputs easy mixing A B A B A B etc Resolution 0 1um RS232 output connect to PC Probe Mixing inter connect 2 or more gauges Wide range input voltage yez Getting Started Unpacking When the VC2000 is first unpacked the baseplate should be secured to the case as follows 1 Remove the four screws from the underside of the case 2 Attach the baseplate with the folded edges
5. Hold TIR GND 8 Pin 1 Analogue signal 1 000 v Full Scale Pin 2 Analogue Ov return Pin 3 Output goes high when amber LED lights Pin 4 Output goes high when red LED lights Pin 5 Output goes high when amber or red LED lights Pin 6 5v at 10mA max Pin 7 5v at 10mA max Pin 8 Digital ground Pin 9 Probe A signal use for Probe mixing Pin 10 Probe B signal use for Probe mixing Pin 11 input use for Probe mixing Pin 12 input use for Probe mixing Pin 13 TIR Optional connect to Ov to activate Pin 14 Reset connect to Ov to reset TIR Pin 15 Hold connect to Ov to hold reading TIR only 10 yez Memory Mode optional The gauge and Probe s should be set up in the normal mode before enabling Memory Mode Refer to the Calibration and Setting the Probes sections for the procedures Memory mode is activated by connecting SK1 pin 8 to pin 13 This is achieved automatically by connecting the remote reset run hold switch box to SK1 Should the gauge parameters need to be verified at any stage normal mode is enabled by unplugging the remote switch box Memory options HOLD freezes the display in its position at the moment the switch is operated TIR calculated from max min Biasing the toggle switch to Reset sets the display to zero then by rotating or moving the part the gauge memorises the highest and lowest probe deflection and the d
6. eric 100 bar LED 3 Digit LED 2 of range 0 1um 1pm 1Bar or 1 of analogue signal gt 0 05 reading 1 count Single or Differential 5 0 15 0 50 0 150 0 500 1500 6 way rotary switch on front panel Channel gt 125um by front panel 10 turn control Probe gt 100um by rear panel multi turn control Each input can be individually calibrated by recessed control at rear Range 10 of nominal Probe 2 x 5 pin 240 DIN screw retained Data 9 pin D socket SK1 15 pin D socket Mains Switched Fused IEC power inlet 2 input channels A B Impedance 10KQ 2 Sensitivity 50mV V mm 3 position slide switch on rear panel or any multiple by resistor via SK1 Voltage 1 2V rms nominal Frequency 5 0KHz no load Current 25mA 14 Tolerance display Outputs Environmental Mechanical Electromagnetic Conformity v 1 April 06 yez By LED indication O S amber SIZE green U S red Setting Range Any point on scale no crossover Setting Accuracy lt 0 01 full scale with care RS232 via 9 way D socket Probe signals via SK1 Analogue via SK1 Tolerance via SK1 1 TTL standard load DC power 5V at 10mA Storage 10 C to 70 C Working 0 C to 40 C Humidity 10 95 non condensing Enclosure 2mm Mild Steel Painted Size 384 h x 130 d x 44 w Weight 2 85 Kg EN61326 1998 Class A EN61010 1 2001
7. isplay moves up the scale to indicate the difference between the two values Maximum biasing the toggle switch to Reset updates the display to read the current probe position then by rotating or moving the part the gauge memorises the maximum probe deflection and the display moves up the scale to indicate this value Minimum biasing the toggle switch to Reset updates the display to read the current probe position then by rotating or moving the part the gauge memorises the minimum probe deflection and the display moves down the scale to indicate this value Mean calculated from Y max min Biasing the toggle switch to Reset updates the display to the current probe position then by rotating or moving the part the gauge memorises the highest and lowest probe deflections and the display moves up and down to indicate half the sum of the highest and the lowest values Note It is possible that a component being gauged for any feature other than TIR is put into the fixture at its extreme value No display change will result from rotation in this case If this happens it is not a fault with the gauge the component should be rotated through 90 and the sequence restarted Soil yez Application examples for different Memory Functions HOLD used to retain a reading at a particular point in a gauging process or until a feature not to be gauged has passed the Probe tips TIR simplifies the gauging of
8. ly used for external measurements thickness for example Use minus settings for gap or bore measurements yez Calibration Equipment Required lt is recommended to use a gauge stand and gauge blocks but other calibration standards may be used A ranging device calibrated step drum micrometer or a setting master device for use in its gauging fixture is suitable in many cases Care must always be taken to account for all sources of error When both the A and B Probe inputs are used together in summing or differential modes each must be calibrated independently Ensure that only the probe to be calibrated is selected by means of its selector switch The other selector switch must be in the centre 0 position The gauge is supplied factory calibrated to the specification however periodic verification is advised and certain procedures require re calibration Although the manufacturing tolerance of probe sensitivity is better than 1 this may not be sufficiently accurate for some users The following procedure allows precise calibration and therefore a probe should be identified with its own input Procedure Select the range required and set both probe selector switches at the rear to their centre 0 positions Choose two gauge blocks slip gauges of known precision and place them on the platen of a suitable gauge stand For best results the gauge blocks should span at least 75 of the chosen range This e
9. panel connector SK1 This procedure may be carried out with the probes disconnected if it is more convenient All tolerance settings are related to the gauge signal and not directly to the dimension being measured This allows the setter to change to a finer range switch setting to make the zero control cover the desired scale points if this makes setting easier All controls must be restored to the working positions before gauging can be resumed Red Green and Amber LED s can be set to indicate any out of tolerance condition as follows AMBER indicates a plus reading GREEN indicates within tolerance RED indicates a minus reading Note following the normal convention RED indicates a scrap condition and AMBER a rectifiable condition this is only valid when gauging external dimensions With the Probe Selector Switch set to minus for gauging internal dimensions the RED LED for example still indicates a minus reading but a minus bore has plus material and could be rectified Setting Procedure Both controls operate by moving the tolerance point up the scale with clockwise rotation and down the scale with anti clockwise rotation 1 Initially turn the left or negative control more than 10 turns anti clockwise and the right or positive control more than 10 turns clockwise 2 Using the front panel Zero Control set the bargraph to the lower tolerance position 3 Turn the left hand control clock
10. r front or rear panels as any ingress could cause electrical failure Liquids entering the enclosure will invalidate the warranty Changing the fuses the main fuses may blow during use due to power surges etc Should this occur it is important to isolate the incoming power by disconnecting the power lead before any attempt is made to open the fuse drawer To access the fuses pinch the tabs at each end of the drawer inwards before pulling it out Identify which fuse s has blown and replace with type T250mA 20 x 5mm Warranty The quality of this instrument is guaranteed for a period of twelve months from the date of delivery This guarantee covers all material and manufacturing defects Liability is confined to repair or should we deem it necessary replacing or crediting the goods The following are not covered by the guarantee Damage due to incorrect handling or operation Failure to observe the operating instructions Attempts by any un authorised personel to open or repair the instrument Should you detect an irregularity of any kind please contact your agent in the first instance Specification Power System Display Resolution Accuracy Measurement Ranges um Range selection Zero Adjustment Calibration Connectors Probe Inputs Probe Mix Probe Drive yez Voltage 85 260 V a c Current gt 0 25A Frequency 48 62 Hz Fuse 2 x T250mA 20mm x 5mm Bargraph Num
11. run out concentricity parallelism ovality taper and face squareness e g gives twice the eccentricity of a single diameter of a component rotated on fixed centres under a single probe Concentricity of two diameters on a component using two probes in differential A B Maximum used to measure the max diameter of a component rotated under a single probe or rotated about a fixed centre between two diametrical probes Both applications use probes in the positive mode A or A B Minimum can be used to record the smallest bore size of a component a bearing outer shell for example Use two probes in the minus mode A B Mean can be related to the circumference of a near circular element This measure is useful in gauging a thin ring component that is required to fit into an outer sleeve Other options Auto Zero this is not a memory feature as above but for use in normal mode The memory circuit is used to reset the gauge to read zero before the next gauging sequence Auto Datum as for Auto Zero but the memory circuit is used to reset the gauge to a preset value determined by the setting of a control yez Maintenance In general very little maintenance is required There are no internal or external components for the user to service Cleaning when necessary this should be done with a soft lint free cloth moistened with mild detergent and water only Do not apply liquids directly to eithe
12. tting The basis for the calculation of the programming resistor value is Ratio 1 1 use 4K99 0 5 Metal Film resistor Ratio 1 2 use 10K0 0 5 Metal Film resistor Ratio 2 1 use 2K49 0 5 Metal Film resistor When the ratio is not a whole number To increase sensitivity divide 5K by the decimal value To decrease sensitivity multiply 5K by the decimal value Example To increase sensitivity by 1 354 5 1 354 3 69 resistor 3K69 To decrease sensitivity by 2 5 5 x 2 5 12 5 resistor 12K5 Note It may be necessary to combine two resistors in series or parallel to achieve the required value yez Outputs RS232 Transmitted data TXD is the value of the 3 Digit Display exactly as seen with leading zeros suppressed GND DTR TXD RXD NC 5 4 3 2 1 Data transmission is continuous in the following format BAUD RATE 9600 STOP BITS 1 START BITS 8 PARITY NONE FLOW CONTROL NONE Oscillator connection When two or more units are used together it is essential to synchronise the oscillator signals to prevent Probes used in close proximity causing interference to the display Link the jack socket from one gauge to the O socket of the next for synchronization O yez Outputs SK7 Analogue Out 1 9 Probe A Out Analogue Ov 2 10 Probe B Out Oversize TTL 3 11 Probe In Undersize TTL 4 12 Probe In Tolerance TTL 5 13 TIR 5v 6 14 Reset TIR 5v 7 15
13. wise until the RED LED just switches on 4 Check the position by slowly turning the zero control so that the change over point may be observed 4 Set the bargraph to the upper tolerance position 5 Turn the right hand control anti clockwise until the AMBER LED just switches on 6 Check the position using the zero control Note if both the amber and red LED s are lit together the tolerance controls have been crossed over This is easily rectified by turning the controls as described above 1 yez Probe Programming Mixing Simple programming of up to two probes is possible for each column by use of the selector switches at the rear For ratios other than 1 1 self programme using the programming connections at SK1 as follows Example 0 5A 2B Connect a 10K resistor between SK1 pin9 and pin11 Connect a 2K49 resistor between SK1 pin10 and pin11 Multi gauging The gauging of multi dimensional components frequently entails the combining of outputs from two or more probes The precise combination of outputs expressed as a formula will depend on the type of measurement required e g squareness concentricity straightness etc Programming is achieved through a combination of selector switch settings and or linked leads through SK1 programming connections as follows Pin 9 Probe A Out Pin 11 Input Pin 10 Probe B Out Pin 12 Input Note Probe output is always ve irrespective of polarity switch se
14. xample uses the 150 0um range but the method used extends to all other ranges Gauge blocks 200um 0 200mm apart in size are chosen Switch on the gauge and set the display to zero using the front panel zero control 2 Set the A input selector switch at the rear to 3 Set the display to zero using the probe zero control at the rear 4 Plug the probe into the A socket 5 Fit the probe into the stand over the lower gauge block and mechanically adjust so that the gauge reads as close as possible to 100 0um 6 Set to exactly 100 0um using the front panel zero control 7 Move to the higher gauge block and note the new reading Any error is a deviation from 100 0um shown by the display 8 If adjustment is necessary note the reading and trim out half the error with the calibration control at the rear and the rest of the error with the zero control 9 Return to the lower gauge block and repeat the procedure if necessary The B input is calibrated in the same way as above but using the B controls yez Setting the Probes Where two or more probes are used in combination to measure a single feature it is necessary for each probe to be set at its optimum electrical position Probes should be positioned over a test component or setting master to give a zero reading or some other reading determined by the components actual size Procedure 1 2 3 4 5 6 7 8
15. y to give the expected span of readings over at least 70 of the scale Avoid using spans close to zero make the best use of the scale length 6 settings are available 5 0um 15 0um 50 0um 150 0um 500um 1500um Zero Controls Channel Zero is a 10 turn control located on the front panel and is recessed to prevent accidental movement This control introduces an adjustable offset to the gauge reading A and B Probe Zeros are located at the rear and provide offset adjustment to the probe signal This control must be used when adjustment is necessary in multi gauging mode when more than one probe is being used Calibration Controls Separate A and B controls are located at the rear and are used to provide fine adjustment of sensitivity to match the displayed value exactly to the size of the master component Tolerance Controls High and Low setting controls are located on the front panel and are used to set the Red Green and Green Amber changeover points at the desired scale position Probe Selector Switch A three position switch located at the rear used to select a Probe input and determine its polarity The switch is marked plus 0 neutral and minus Selecting causes the gauge to read upward in a positive direction for inward movement of the probe tip Conversely selecting causes the gauge to read downward in a negative direction for inward movement of the probe tip Plus setting is normal
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