USER'S MANUAL - A&E Gauges Ltd
Contents
1. 4 Fig 2 The AE6 with air filter regulator monogauge assy FINAL SETTING AIR RING amp OPEN JET CALIPER GAUGES 11 111 1v vi vil Connect the probe to the A plus socket or check that where appropriate the correct polarity has been programmed Insert the MINUS setting plug into the air ring Unscrew the control Fig 2 5 marked M until the display reads the SET minus value marked on the setting plug Replace the minus plug with the PLUS setting plug NOTE it is unlikely that the reading will correspond exactly with the calibrated SET minus value to adjust proceed as follows AIR RINGS for STANDARD measuring range adjust to the SET plus value using the gauge unit ZERO control AIR RINGS for LONG measuring range adjust to the SET plus value using the transducer unmarked zero control Fig 2 5 Replace the MINUS plug and using the transducer control marked M overcorrect by 3 to 4 times the amount of error Repeat this procedure until the correct setting is achieved ensuring that adjustments are made as follows With the MINUS plug in the Air Ring use the transducer MAG control marked M With the PLUS plug in the Air Ring For2. GAUGES LTD THE AE6 AIR ELECTRONIC TRANSDUCER USER S MANUAL Issue no 5 Feb 2005 A amp E GAUGES LTD Unit 7 Redbourn Industrial Estate Redbourn Hertfordshire 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 1 1 THE A amp E GAUGES A E 6 ELECTRONIC TRANSDUCER SECTION 1 INTRODUCTION GENERAL DESCRIPTION The A amp E Gauges A E 6 Air Electronic Transducer permits the use of air gauge measuring heads such as air plug or air ring gauges with a variety of A amp E Gauges Electronic Units In addition to providing very high magnification the simplicity of air gauge measuring heads is combined with electronics to provide benefits such as high accuracy tolerance indication differential and match gauging and SPC Statistical Process Control Precision at high magnification is ensured by restricting the standard measuring range to a maximum of 0 015mm 0 0005 in There is a special measuring range of up to 0 050mm 0 002 in For very special applications longer measuring ranges are possible A amp E Gauges Technical Dept will be pleased to advise on receipt of a detailed requirement Two versions are available with a differing connection for the measuring head and are designated as follows A E 6 Part No 96100 005 Standard version with bayonet connection A E 6F Part No 96100 007 Fixture version with G1 4 BSP Parallel co
3. Standard Range plugs use the gauge unit ZERO control For Long Range Plugs use the Transducer unmarked zero control NOTE When used with MICROLINE zero is adjusted using the special auto zero procedure SPECIAL NOTE WHEN USING ANALOGUE UNITS It may be convenient when setting to switch to a longer range lower magnification final adjustment for the zero setting must be made at the correct range to be used when gauging For this reason a zero Setting Gauge may be necessary in addition to the Plus and Minus Gauges 3 0 3 1 3 2 SECTION Ill MATCH GAUGING INTRODUCTION Match gauging is the term used to describe equipment designed to measure the difference in size or fit between matching components shafts and bores The fit may be classified as clearance interference or transition EQUIPMENT USED 1 Any Gauge Unit in the 122 or two column Electroline series may be used ii The bore is measured with an air plug gauge and the A E6 transducer the shaft may be measured with a comparator and probe or an electronic calliper iii Two calibrated setting rings are required to range the air plug a third ring made to the mean size of the component matches a mean size plug used to set thecomparator or caliper MATCH GAUGING WITH 122 SERIES GAUGE UNITS The method consists of measuring the bore with the A channel the shaft with the B channel and by combining the two r
4. Current BS ISO approval requires regular maintenance and traceable calibration of all gauges and test equipment used in a manufacturing process A amp E Gauges Ltd offers comprehensive service and calibration facilities for all its products In line with current British Standard and ISO requirements we recommend that any gauge is serviced at least once a year Some quality procedures require more frequent equipment servicing and re calibration A amp E Gauges gauging references are fully traceable to National Standards Conformity and calibration certificates are available if required Full service support is provided for all air gauging products and on site service contracts for larger users are strongly recommended The Service Department will be pleased to provide full details of service rates and contract terms Contact The Service Department A amp E GAUGES LTD Unit 7 Redbourn Industrial Estate Redbourn Herts AL3 7LG 44 0 1582 793528 44 0 1582 794463 sales a eqauges co uk www a egauges co uk
5. A minus socket For air rings insert into the A plus socket Note On 122 series gauge units the B Channel may be used if preferred The polarity on the Microline is included as part of the gauge program 2 3 SETTING THE GAUGE UNIT ii iii Check that the Gauge Unit is correctly calibrated in accordance with the instructions appropriate to the Unit Note Ifthe Transducer probe is used for this purpose note the different sensitivity ratios 490 is 1 1 1 e 1 0 mm reads 1 0 mm 493 is 1 3 1 e 0 9 mm reads 0 3mm 495 is 1 2 1 e 1 0 mm reads 0 5mm Set the zero control to mid travel Select the range given in column 4 of Table 1 Section 2 1 note the following a Electroline 80 87 series range is selected by means of an interchangeable plug Ensure that the appropriate Range Plugs are available for both Setting and Gauging b Microline it may be necessary to temporarily reprogram sensitivity for L Low Sensitivity for the purpose of setting the Transducer in some cases a separate transducer Channel is provided Check with the instructions supplied with the equipment c 155 Units only check that the slider switch at the rear of the Unit is set at the NORMAL up position 2 4 2 5 2 6 SETTING THE TRANSDUCER 1 Lightly clamp the probe in the Transducer until the gauge meter reads the approximate value of dimension A in Table 1 Column 4 Note The reading should b
6. AUGES 1 Connect the probe to the A minus socket or check that where appropriate the correct polarity has been programmed 11 Place the PLUS setting ring on to the air plug 111 Unscrew the control Fig 2 5 marked M until the display reads the SET value marked on the setting ring Always remove the hexagon key from the control between adjustments otherwise spurious measurements may be encountered iv Replace the PLUS setting ring with the MINUS setting ring NOTE it is unlikely that the reading will correspond exactly with the calibrated SET value to adjust proceed as follows v Air plugs for STANDARD measuring range adjust to the SET minus value using the gauge unit ZERO control Air plugs for LONG measuring range adjust to the SET minus value using the transducer unmarked zero control Fig 2 5 vi Replace the PLUS ring and using the transducer control marked M over correct by 3 to 4 times the amount of error vii Repeat this procedure until the correct setting is achieved ensuring that adjustments are made as follows With the PLUS Ring on the plug use the transducer control marked M With the MINUS Ring on the plug For standard range plugs use the gauge unit ZERO control For long range 495 490 plugs use the transducer unmarked zero control PU
7. ECE ELECTRONIC PROBE ZERO CONTROL DIAPHRAGM 1 2 Fig 1 Operating principle of the AE6 air electronic transducer PHYSICAL DATA Dimensions Weight Air supply Air consumption Electronic probe Standard version Special version Accuracy Measuring range Standard Special see Fig 3 1 4 kg nett 4 8 bar 70psi gauge min 1 3 litres min 0 5 scfm Type 493 Type 495 0 5 um 0 00002 0 015 mm 0 0005 0 050 mm 0 0020 This figure is based on the use of a measuring head with two 1 5mm jets 1 3 1 4 TRANSDUCER GAUGE UNIT COMPATIBILITY The A E 6 Transducer can be used with any of the current range of A amp E approved electronic gauge units in addition some of the older obsolete 155 Series may also be used The Gauge Units comprising these systems are as follows IBR Mercer 122 series EL80 83 87 90 EL300 EL400 EL500 etc Tesa PROBE GAUGE UNIT COMBINATION The following table summarises the type of probe which must be fitted to the Transducer when used with a particular Gauge Unit For details see Section II GAUGE TYPE PROBE TYPE Standard Special Application Application 122 Series EL80 83 87 90 EL300 493 495 EL400 EL500 Microline 490 490 Used with divisors programmed into Microline 2 0 2 1 SECTION ll SETTING INSTRUCTIONS INSTALLATION Connect the Filter Regulator Bracket and the Transducer to the main air supp
8. e plus for Air Plugs and minus for Air rings when match gauging see Section lll 11 Securely clamp the probe with both screws but do not over tighten 111 Set the gauge meter reading to the exact value for dimension A using the zero control of the gauge unit Microline has a special auto zero procedure refer to the appropriate manual MASTER SETTING GAUGES When using air gauge measuring heads air plugs and air rings etc it is necessary to range the indicating equipment to suit the measuring head This is done using two Setting gauges master rings for air plugs and master plugs for air rings For some applications a third zero gauge may be required Standard setting gauges are made PLUS and MINUS from the nominal size to be measured they are calibrated in temperature controlled conditions and are marked with the mean zero size and a SET or SET value EXAMPLE a PLUS setting ring may be marked 12 700 mm 0 0117mm or 0 5000 in 0 00046in FINAL SETTING PRELIMINARY 1 Turn the air supply ON Fig 2 1 11 Check that the monogauge Fig 2 3 registers between or within 1 5 mm of the red lines iii Screw both transducer control s Fig 2 5 right in clockwise IMPORTANT NOTE The zero control unmarked is only required when long range measuring heads are used iv Set the range of the gauge unit to suit the range of the gauge head to be used 2 7 FINAL SETTING AIR PLUG G
9. eadings the A B setting will give their difference i Before connecting any probes to the gauge unit use the A and B controls to set both channels to read zero ii Set the 122 Unit as described in its own manual and set the air plug and transducer as described in Section Il of this manual Following the procedure described the transducer probe will be fitted to the A minus A socket iii Connect the probe from the comparator or caliper to the B minus B socket iv Set the comparator caliper closely to zero but note that because the probe is connected to give minus polarity all deviations must be reversed EXAMPLE A setting plug calibrated 0 002mm must be set to give a reading of 0 002mm i e to the right of zero This is necessary to achieve the correct polarity at the A B matching setting v With the mean size setting ring on the Air Plug and the setting plug in position in the comparator caliper turn to the A B setting and check that the meter reads the difference between the two masters Any small error should be corrected by re checking the setting of Air Plug and comparator caliper CLEARANCE will be indicated as plus to the right of zero INTERFERENCE will be indicated as minus to the left of zero NOTE If it is required only to check the actual size of the shaft it is important to remember that polarity is reversed where a batch of shafts is to be measured pr
10. ior to matching It may be more convenient to transfer the probe connector to B and reset Title AE6 TRANSDUCER DIMENSIONAL DETAILS Zero fitted to all THIS VIEW SHOWS josi a but not used in 0521 FIXTURE VERSION CO ea i i i MAS E Sta applications MAY 96100 007 4 Probe BED 4 EN Smm A F clamp MAX SPENE 12 0 l CEJ hex socket SOENS SSO 20 0 Se MAX O 40 0 a i C 21 0 CD My G1 4 BSP PARALLEL THREAD FIXTURE 31 0 9 SUPPLY HOSE VERSION ONLY e 75 9 E o SEPEN A 3 U rino PRUBE 493 0 015mm BAYONET ADAPTOR 499 0 050mm Y 99 2 220 0 28 0 21 0 16 0 j THIS VIEW SHOWS ee A es 96 0 A A OOS em STANDARD VERSION 10 2 12 0 96100 005 Flg S 10 SERVICE Your gauging and inspection procedures are a critical part of your production process and their integrity is vital to your business Regular maintenance and calibration of this air gauge will ensure continuity of its usefulness assure accuracy of measurement and prolong its service life Time and production losses through unplanned repairs will be minimised
11. ly as illustrated in Fig 2 Make sure that all connections are air tight Purge filters by opening drain taps Fig 2 2 and turning on the air supply Close drain taps and check that the pointer of the pressure gauge Fig 2 3 is between the two scale marks IMPORTANT The filters must be drained daily and the bowls washed occasionally with soap and water NEVER USE SOLVENTS See Air Filter Regulator Bracket AFRB instruction sheet PROBE GAUGE UNIT GAUGE HEAD COMBINATION It is absolutely essential that the correct probe appropriate to the gauge unit is used Details are given in the following Table columns 2 to 4 It is essential that the correct measuring head air plug or air ring is used the markings detailed in column 2 of table 1 are marked on the gauge plug adaptor 1 2 3 4 Application Probe Type Sensitivity Dimension A mm inch Standard de 13 0 095 mm 0 0037 Long Range IM 0 285 mm 0 0112 Deep Jet e 1 2 0 142 mm 0 0056 Table 1 Transducer Probe data 2 2 CONNECTING THE PROBE The Transducer is normally supplied with the probe assembled if it is not fitted proceed as follows i ii iii iv Shut off the air supply using tap Fig 2 1 Section 2 7 Wait until the air is completely emptied from the system Insert the probe into the Transducer and lightly clamp the screws Insert the probe connector into the gauge unit as follow For air plugs insert into the
12. nnection Two MS clearance holes are provided on the body of the transducer for securing it to a bench or fixture multiple transducers can be secured to each other OPERATING PRINCIPLE Fig 1 Compressed air at a minimum gauge pressure of 4 8 bar 70 psi is filtered and regulated externally to a gauge pressure of 2 96 bar 43 0 psi before entering the transducer through the magnification control to one side of a diaphragm sensitive to minute changes in pressure Air flows to atmosphere through one or more jets in the gauge measuring head and variations in pressure against the diaphragm result from variations in the clearance between the measuring head and the work piece The movement of the diaphragm is detected by an electronic probe and indicated by the gauge unit Probes of differing sensitivity are used for differing applications full details of Probe Gauge Unit are given in section 1 4 The zero control on the gauge unit and the magnification control on the transducer are used to calibrate the system using suitable masters The zero control on the transducer is only used in special applications and can be blanked off to prevent tampering IMPORTANT The transducer must be used with a suitable air filter and pressure regulator and we recommend our Air filter regulator monogauge unit Ref No 95050 641 AIR PLUG CONTROLLED PRESSURE AIR SUPPLY MAGNIFICATION CONTROL TO GAUGE IN WORK PI
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