System 1, 1A and 3 Operating Instructions

Transcription

1 12 System 1, 1A and 3 Operating Instructions Copyright by Precision Devices, Inc. 606 County Street, P.O. Box 220 Milan, Michigan PHONE: (734) FAX: (734) All rights reserved. sales@predev.com PT# 919-OP (REV A7)

2 1 RECEIVING INSPECTION COMPONENT DESCRIPTION AND USES... 2 Amplifier...2 Front of the Amplifier...2 Back of the Amplifier...2 Piloter...2 Stroke Length Adjustment...2 Linkarm...3 Linkarm Adjustment Thumbscrews...3 Tracer...4 Precision Reference Standard...4 Three Reference Areas on the Precision Reference Standard SYSTEM SET-UP... 6 Setup OPERATION AND CALIBRATION... 7 Reading the Meter...7 Selecting the proper scale...7 Interpreting the Reading...7 When Reading in Microinches (µin)...7 When Reading in Micrometers (µm)...7 Operation...7 Setup...7 Measurement...8 Calibration SKIDLESS PILOTER UNIT... 9 General Description...9 Operation CARE AND MAINTENANCE Checklist for proper operation...11 General Operating Tips and Precautions...11 Repair and Service...11 Warranty...11

3 7 ACCESSORIES Tracers...12 Skidmounts...12 Stylus...12 Linkarms...13 Linkarm Extensions TECHNICAL DATA Specifications of the System...14 Disclaimer Due to the increase of companies that provide calibration services, Precision Devices, Inc. must advise our users of the following: Precision Devices, Inc. is the manufacturer of the 12 line of surface metrology instruments and cannot be held responsible for any losses incurred relating to the validity of our units if not calibrated and certified directly by us. If you have any questions regarding this issue please feel free to call our service department at (734) ii

4 1 RECEIVING INSPECTION The Precision Devices 12 System 1, 1A and 3 with accessories were carefully packaged and inspected at the factory. Match all items to the list below, if there are any deviations, please notify us immediately: Precision Devices, Inc. 606 County Street P. O. Box 220 Milan, MI Attn.: Order Department Phone: (734) , Fax: (734) Examine the equipment for obvious transit damages which may have occurred during shipment. If the equipment is damaged notify the transportation company and file a claim for damages. 12 System 1 or 1A The standard skid-referenced system shipping package contains: Amplifier Piloter Tracer with Skidmount Assembly Linkarm Precision Reference Standard Tracer Cord Power Cord 1/4 combination wrench Instruction Manual 12 System 3 The standard skidless system shipping package contains: Amplifier Piloter with pedestal and Granite Base Tracer with Stylus Assembly Precision Reference Standard Tracer Cord Power Cord Hex wrench Instruction Manual 1

5 2 COMPONENT DESCRIPTION AND USES Amplifier Front of the Amplifier (Figure 1, Page 2) Meter The meter indicates the Ra average roughness height in Microinches or Micrometers. Cutoff Buttons There are four (4) Cutoff Selections: 0.25mm, 0.76mm, 2.54mm, and 7.62mm (0.010, 0.030, and ) for skid-referenced piloter (0.003, 0.010, and ) for skidless piloter For further information on cutoff, refer to the current ASME revised standard on surface measurement. Scale Selector Buttons There are six (6) Scale Selection Pushbuttons: 0.1, 0.3, 1, 3, 10, and 30 micrometers (3, 10, 30, 100, 300, and 1000 microinches) Microinches/Micrometer Buttons To select Microinch or Micrometer readout, simply press desired selection. Power Switch Light indicates power is on. Calibration Potentiometer The calibration Potentiometer is used for fine adjustments of the Ra reading. See Section 4, Page 8 for Calibration Procedures. Back of the Amplifier (Figure 2, Page 2) Tracer Connector This connector is the receptacle for the tracer cable. Fuse Holder/ A. C. Power Input This holder contains the 250V, 1/2A, 3AG fuse and spare fuse. A three conductor 110 volt AC Hz power cord is also provided. Auxiliary Power Outlet A three conductor 110 volt A. C. Outlet. Piloter The PDD Piloter contains a drive motor which moves the linkarm with the tracer across the surface at a constant.3 sec. (7.62mm) tracing speed. Stroke Length Adjustment The stroke length is adjustable up to 2 ½. 2

6 THUMBSCREW A STROKE ADJUST THUMBSCREW B THUMBSCREW C Figure 3 - Piloter and Linkarm Linkarm The PDL Linkarm connects the Tracer to the PDD Piloter and is used to adjust the vertical height with respect to the surface being measured. Linkarm Adjustment Thumbscrews (Figure 3) Thumbscrew A Lowers or raises the linkarm and should be adjusted so that the tracer is level with the workpiece. Thumbscrew B Swings linkarm side-to-side, this should be adjusted so that the linkarm is at a right angle and tightened. Thumbscrew C Allows rotation of the linkarm to allow the tracer skid to seat on workpiece. CAUTION: Care should be taken after the tracer is connected to the linkarm as rough handling could damage the tracer. 3

7 Tracer The tracer is a moving coil transducer with a diamond tip stylus 10µm (.0004) radius. The transducer translates the up and down motion of the diamond tip stylus into an electrical signal. This signal is conditioned by the amplifier. Different skids can be attached to the tracer to allow for variations in work piece configurations. See Section 7, Page 12 - Accessories. Skidmounts Skidmounts provide a reference for the tracer. They are used to stabilize the stylus on the work piece. Different Skidmounts are used for different work piece configurations. SKIDMOUNT CONNECTOR SKID Figure 4 - PDK Tracer Precision Reference Standard The Precision Reference Standard is used to check the accuracy of the 12 to the tracer, and to check the condition of the tracer stylus, 10 µm (.0004) radius. The reference standard consists of three reference areas. The reference standard conforms to ASME B specifications and is traceable to the National Institute of Standards and Technology. A certification of traceability is furnished (NIST #821/251455). Your system should be calibrated to ensure that proper readings are taken. Appreciable changes in temperature or humidity may require calibration to be done. Any change in tracers, cables, linkarms, or amplifiers will require that the system be re-calibrated. Reference standards should be replaced when appreciably worn. If your system will not calibrate to the reference standard provided, your system may require service. If your system calibrates correctly on the calibration area of the reference standard, but does not get proper readings for the other areas of the reference standard, this generally indicates a problem with your tracer. Contact Precision Devices for further assistance. (Figure 5. Precision Reference Standard) Three Areas on the Precision Reference Standard - Shop Grade Calibration Area The calibration area has a Type C1 surface with a sine wave profile and is used for calibrating contact stylus instruments. The R a reading taken in this area should be within ±3µin of the rated value of the reference standard. Linearity Area This area has a Type D surface with an irregular surface. It is used to check system linearity and should not be used to calibrate the instrument. The reading taken in this area should be within ±2µin of the rated value of the reference standard. 4

8 Diamond Stylus Area The diamond stylus area, Type B2, is for checking the diamond stylus condition only. The readings taken in this area should be within the range stated on the reference standard. Measurements outside the range generally indicate wear or damage to the diamond stylus. Do not use the patch to calibrate the instrument. Notes: 1) Tolerances listed above are for the Shop Grade Reference Standard. 2) Reference Standard types are defined in ASME B

9 SYSTEM SET-UP Setup Place the 12 System equipment on a sturdy workbench isolated as much as possible from vibrating machinery and away from strong magnetic fields (transformers, generators, etc.) Assembly of the Amplifier and Piloter Install post in threaded hole at the end of the piloter ram and tighten with ¼ combination wrench supplied. Attach the linkarm to the ram post at approximately half way position as illustrated in Figure 3, Page 4. Tighten the locking thumbscrew A. Attach one end of the tracer cord (with the conductor female plug ) to the linkarm. There is only one insertion position. Tighten the threaded locking ring by hand. Attach the other end of the tracer cable (with the three pin connector) to the back of the amplifier. Tighten the locking ring. NOTE: Clip the tracer cable to the rear of the Piloter with appropriate slack to allow for linkarm movement. Remove the tracer from the tracer box. If necessary, attach the appropriate skidmount to the tracer. See the complete chart of Tracers and Skidmounts in Section 7, Page 12. Place the workpiece or precision reference standard beneath the tracer. Adjust the linkarm by using thumbscrews, A, B & C. See Figure 3, Page 4. The linkarm mounting shaft and the linkarm barrel should be adjusted to a 90 degree angle, and the barrel should be parallel to the workpiece. If necessary, mount the workpiece on a non-magnetic V block or bench vise. NOTE: When using a single skid, always lock thumbscrew C on the side of the linkarm. When using a double skid, thumbscrew C should always be loosened and both skids must be seated on the surface. CAUTION: Care must be taken in positioning the tracer, to avoid damage to the stylus. Insert the power cord into the amplifier. There is only one insertion position. Plug the amplifier and piloter into a 115V AC outlet (the piloter may be connected to convenience outlet located at the rear of the amplifier). Set the piloter stroke length to approximately 20mm (3/4 ) using the stroke adjust knob at the front of the piloter. Figure 3, Page 4. 6

10 4 OPERATION AND CALIBRATION Reading the Meter Selecting the proper scale The reading should fall within the mid-range of the meter rather than the extreme ends. For example, if the value is 20 microiches, the proper scale to use would be the 30 scale. If the value is 90 microinches, the correct scale would be the 300 scale, etc. Interpreting the Reading The 12 amplifier features a highly damped meter which minimizes needle fluctuations. However, you will, on occasion, encounter a non-uniform surface roughness which will cause the needle to vary somewhat. The ASME Standard states that you should read where the needle tends to dwell, disregarding the highs and lows. If the surface has a scratch or flaw, the needle will surge upwards. Disregard this also, as a scratch or flaw is not considered to be part of the surface roughness. When Reading in Microinches (µin) With the push-button set at 3, read 10 as 1µin, 20 as 2µin, etc. With the push-button set at 30, read 10 as 10µin, 20 as 20µin, etc. With the push-button set at 300, read 10 as 100µin, 20 as 200µin, etc. NOTE: THE ABOVE SCALES ARE COLOR CODED IN BLACK ON THE METER. With the push-button set at 10, read 2 as 2µin., 4 as 4µin., etc. With the push-button set at 1, read 2 as 0.2µm., 4 as 0.4µm., etc. With the push-button set at 1000, read 20 as 200µin., 40 as 400µin., etc. NOTE: THE ABOVE SCALES ARE COLOR CODED IN RED ON THE METER. When Reading in Micrometers (µm) With the push-button set at 0.1, read 2 as 0.02µm., 4 as 0.04µm., etc. With the push-button set at 1, read 2 as 0.2µm., 4 as 0.4µm., etc. With the push-button set at 10, read 2 as 2µm., 4 as 4µm., etc. NOTE: THE ABOVE SCALES ARE COLOR CODED IN RED ON THE METER With the push-button set at 0.3, read 10 as 0.1µm., 20 as 0.2µm., etc. With the push-button set at 3, read 10 as 1µm, 20 as 2µm., etc. With the push-button set at 30, read 10 as 10µm., 20 as 20µm., etc. NOTE: THE ABOVE SCALES ARE COLOR CODED IN BLACK ON THE METER. NOTE: The figure at which the push-button is set indicates the full scale reading of the meter in Microinches or Micrometers. Operation Setup Ensure that the 12 has been calibrated. If not, calibrate the unit before taking any measurements. 7

11 Set the piloter enable switch to OFF. Position the workpiece under the tracer, with the tracer level and parallel to it. Select the desired cutoff and scale. Measurement Set the piloter enable switch to ON, and observe the meter. The reading should fall within the mid-range of the meter for the desired value rather than the extreme ends. If needed, adjust the scale selector until the needle is midranged. Observe and interpret the meter in accordance with the previous section, Reading the Meter. Calibration To assure the 12 is working properly, it should be checked periodically with the Precision Reference Standard. Set the Amplifier controls as follows: 1 µin./µm. button at µin. 2. scale selector button at cutoff selector button at Place the precision reference standard beneath the tracer so the tracer is on the center of the CALIBRATION area. The tracer should move across the area in the direction of the arrows. Set the piloter enable switch to ON, making sure the tracer stylus is contained in the rectangular patch area. The reading should be within ±0.076µm (±3µin) of the rated value of the reference standard. If the reading is not in this range, adjust the calibration screw on the front of the amplifier with a standard screwdriver and take another reading. NOTE: Adjust Calibration using only the CALIBRATION area. Neither of the other areas is suitable for calibrating the instrument. To check the integrity of the amplifier and tracer once the system has been calibrated with the CALIBRATION area, take one reading in the LINEARITY area and another in the STYLUS CHECK area. Make both of these measurements with the scale selector button set to the 30 scale. The LINEARITY patch reading should lie within ±0.05µm (±2µin) of the rated value of the reference standard, if not the amplifier and/or tracer may require servicing. Contact Precision Devices, Inc. for service. The reading from the STYLUS CHECK patch should lie within the range stated on the reference standard. If not, the diamond tip may be worn or damaged. Contact Precision Devices for repair or replacement of the stylus. NOTE: Check the instrument calibration first, then the linearity and diamond stylus condition. NOTE: When reading in Micrometers, the scale setting should be 10µm for the calibration area and 1µm for the linearity and stylus check areas. If the results are not in the proper limits the following procedures should be checked: A. Cutoff selector should be 0.030, scale selector should be 300 for calibration and 30 for linearity and stylus checks. B. Tracer should be level with the workpiece. C. The precision reference standard should be read in the direction of the arrows. D. The tracer cable should be clipped with enough slack to allow free travel. E. The diamond stylus should have free movement in the skidmount. F. Make sure the selected cutoff and scale buttons are fully depressed. 8

12 5 SKIDLESS PILOTER UNIT General Description The PDP-4 Piloter is a precision traversing unit for skidless roughness measurements. The unit is specially designed to be used with a PDG skidless tracer. A granite base is used to provide vibration isolation between the workpiece and the operation environment. The unit is designed with height adjustment features to accommodate many different workpiece configurations. If required, the unit can be detached from the granite base and mounted on special test fixtures. Operation Place the amplifier and skidless piloter on a sturdy workbench isolated as much as possible from vibrating machinery and away from strong magnetic fields. Vibration isolation pads may be used to minimize floor vibration, but are not furnished with the instrument. Remove the PDG tracer from the box, slide it into the tracer holder. Tighten the tracer locking knob so the tracer is secure in the holder. With the tracer installed, slide the tracer holder into the piloter opening until it reaches the stop, and tighten the locking knob securely. (see Figure 6, Page 10). While amplifier is OFF, connect the tracer cable to the amplifier and connector of the tracer. Tighten the locking rings on both ends of the cable. Place the tracer cable in the retention clip on the front of the piloter approximately as shown in Figure 6, Page 10. Place a workpiece under the tracer (use the calibration patch if this is the first time you are using the instrument). The surface to be measured must be parallel to the direction of travel (horizontal). If necessary loosen the tracer locking knob and raise the tracer to accommodate the workpiece. Loosen the tracer locking knob and lower the tracer until the stylus is about 1/16 above the workpiece, tighten the tracer locking knob. Also check the vertical position of the stylus and adjust the tracer holder if necessary. The stylus should be aligned with the direction of travel. Turn the amplifier ON and select the appropriate cutoff, set the scale selection to 3µin/0.1µm. NOTE: The PDP-4 piloter travels at 0.1 in/sec versus 0.3 in/sec for a standard piloter, therefore a cutoff template with the proper cutoff settings should be placed on the amplifier. 9

13 While watching the display, lower the tracer by slowly rotating the tracer height adjust knob counter-clockwise until the display reading begins to jump. Advance the height adjust knob 4 more divisions and choose the proper scale selection according to your workpiece. CAUTION: The stylus tip is fragile. Be careful not to crash the stylus into the workpiece when making the height adjustment. NOTE: Each time a new workpiece is positioned, the height of the tracer must be adjusted using the height adjust knob. HOLE PLUG TRACER CORD RETENTION CLIP STROKE ADJUST KNOB TRACER HOLDER LOCKING KNOB HEIGHT ADJUST KNOB TRACER HOLDER TRACER LOCKING KNOB Figure 6 - Skidless Piloter Unit 10

14 6 CARE AND MAINTENANCE Checklist for proper operation General Operating Tips and Precautions To make sure the 12 is working properly, check it periodically with the Precision Reference Standard. Wipe parts to remove dirt and oil before making a measurement. The most easily damaged component is the tracer. Use care in handling. Do not drop the diamond stylus on the workpiece. If the piloter has been exposed to temperatures below 40 degrees F. it may act sluggish. If so, allow it to remain at room temperature for minutes before using. Do not use magnetic fixtures. Do not demagnetize the tracer. Make sure the movement of the tracer is parallel to the workpiece. Repair and Service Do not attempt to repair any of the 12 components. In most cases special tools and test equipment are required. Send items for repair to the address listed below. Best method of shipment is United Parcel Service. Warranty Precision Devices, Inc. 606 County Street Milan, MI Attn.: Service Department Phone: (734) Fax: (734) The 12 system is warranted against defects in material and workmanship for a period of one (1) year from date of shipment. If there is evidence of tampering the warranty will be void. 11

15 7 ACCESSORIES Tracers Standard Tracers PDK For skid referenced systems, less skidmount PDM For skid referenced systems, less skidmount PDB Skid Type for I.D. s as small as 5/8 (16mm) to depth of 3 (76mm) PDC Skid Type for I.D. s as small as 1/4 (6.3mm) to a depth of 3 (76mm) or 6 (152mm) PDF Skid Type for I.D. s as small as 3/8 (9.5mm) to a depth of 3 (76mm) Skidmounts Standard Skidmounts for PDK Tracer SMT, 3.2mm (1/8 ) I.D. & O.D. to flat SML, 12.7mm (1/2 ) I.D. to flat SMM, 9.5mm (3/8 ) O.D. to flat SMV, 12.7mm (1/2 ) I.D. to flat, for 2.54mm (0.100 ) Cutoff SMW, 9.5mm (3/8 ) O.D. to flat for 2.54mm (0.100 ) Cutoff SMQ Adapter, (required for SML. SMM, SMV, & SMW Skidmounts) SML-1, 12.7mm (1/2 ) I.D. to flat* SMM-1 9.5mm (3/8 ) O.D. to flat* SMV-1, 12.7mm (1/2 ) I.D. to flat for 2.54mm (0.100 ) Cutoff* SMW-1, 9.5mm (3/8 ) O.D. to flat for 2.54mm (0.100 ) Cutoff* * Adapter not requried. Standard Skidmounts for PDM Tracer SMA, 19mm (3/4 ) O.D. and 46mm (1 13/16 ) I.D. to flat SMB, 9.5mm (3/8 ) O.D. to flat SMD, 3.2mm (1/8 ) O.D. to 12.7 (1/2 ) O.D. only SME, 19mm (3/4 ) O.D. to flat, for sideways tracing SMA-1, 19mm (3/4 ) O.D. and 46mm (1 13/16 ) I.D. to flat for 2.54mm (0.100 ) & 7.62mm (0.300 ) Cutoffs SMB-1, 9.5mm (3/8 ) O.D. to flat for 2.54mm (0.100 ) Cutoff Mounting Skidmounts to Tracers To attach a skidmount to a PDK tracer, see Figure 7, Page 12. When tightening the screws, align the skidmount to insure that the diamond stylus has free movement. To attach a skidmount to a PDM tracer, see Figure 8, Page 13. Stylus Standard Stylus: 10µm (.0004 ) Radius per ASME B Standard 12

16 Holding Screw SMT Skidmount Figure 7 - Mounting a Skidmount on a PDK Tracer Skidmount Skid Holding Screw Figure 8 - PDM Tracer with Skidmount Installed Linkarms PDL-5 Lite-Touch Linkarm Linkarm Extensions PDE-1, 228 mm (9 ) extension for PDL PDE-2, 305mm (12 ) extension for PDL PDE-3, 458mm (18 ) extension for PDL 13

17 8 TECHNICAL DATA Specifications of the System Cutoff Values: Tracing Speed: , 0.762, 2.54, 7.62 mm (0.010, 0.030, 0.100, in) for standard piloter 0.076, 0.254, 0.762, 2.54 mm (0.003, 0.010, 0.030, in) for skidless piloter 7.62 mm/sec, 0.3 in/sec (skid-referenced) 2.54 mm/sec, 0.1 in/sec (skidless) Detector: Detecting method: Velocity Stylus material: Diamond Stylus tip radius: 10 µm (.0004 in) Stylus force: 0.016N (1.6gf) or less Power Supply: Temperature Range: Relative Humidity: 110VAC 50/60 Hz Operation 10 to 30 C Storage 0 to 40 C 10-90% non-condensing Dimensions: W x H x L WT. Amplifier 279 mm 171 mm 267 mm 3.75 kg (11 in 6 3/4 in 10 1/2 in) (8 1/4 lbs) Piloter 114 mm 102 mm 216 mm 3.2 kg (4 1/2 in 4 in 8 1/2 in (7 lbs) Skidless Motor 146 mm 121 mm 235 mm (4.5 kg) Drive (5 3/4 in 4 3/4 in 9 1/4 in) (10 lbs) Readouts: Reference Standard: Overall System Accuracy: Dynamic Range: 3 X 5 Analog Meter Calibration Patch - Traceable to NIST +/- 2% of full scale reading 5000 µin. total peak to valley 14