instruction manual - ibr · converters to an ibr - column gauge c100 b100 as well as the connec-...

M e t r o l o g y

Document No. : D2F330 001Edition : June 2003 Copyright : IBR

Messtechnik GmbH & Co. KG

INSTRUCTION MANUAL

AE1 Pneumatic measurement converter

2

Instruction Manual AE1

Contents 1. Introduction

1.1 General information............................................................................................................... : 3 1.2 Measuring principle ............................................................................................................... : 3 1.3 Front panel and rear.............................................................................................................. : 3 1.4 Dimensions............................................................................................................................ : 4 1.5 Connectors round-up ............................................................................................................ : 5 1.6 Technical data....................................................................................................................... : 5

2. Getting started 2.1 Delivered items...................................................................................................................... : 6

2.2 Mounting of the measuring converter ................................................................................... : 6 2.3 Mounting the air filter and pressure regulator ....................................................................... : 6 2.3.1 Connecting to the air pressure supply without footplate ............................................. : 7 2.3.2 Connecting to the air pressure supply with footplate .................................................. : 7 2.4 Connecting the gauge heads ................................................................................................ : 8 2.5 Electrical connection ............................................................................................................. : 8 2.6 Accessories and order information ....................................................................................... : 9

3. Working with the AE1 measuring converter 3.1 First start-up ......................................................................................................................... : 10 3.2 Restrictor adjustment ........................................................................................................... : 10 3.3 Automatic gauge calibration by using the B100 / C100 ....................................................... : 12 3.4 Automatic gauge calibration by using the IBRit-da8-ae ....................................................... : 12

4. Pin assignments of connectors ................................................................................................... : 13

5. AE-FC1 connection set ................................................................................................................ : 14

6. Maintenance and care .................................................................................................................. : 14

7. Supervision of the air pressure supply ...................................................................................... : 14

8. Safety Instructions ....................................................................................................................... : 15

9. Declaration of conformity ........................................................................................................... : 16

10. Guarantee ...................................................................................................................................... : 16

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Fig. Pneumatic converter AE1

1. Introduction 1.1 General information

1.2 Measuring Principe Pneumatic measuring work contact less and can also be used under rugged operating conditions. Robust and effective measuring heads automatically clean the component during measuring. The high sensitivity allows resolutions up to 0,1µm. The design of the pneumatic converters AE1 as measuring bridge reduces the influence of external disturbances. A piezo sensor with new electronics allows highest precision and stability. The expensive use and mechanical adjustment of inductive probes as well as the narrow measuring ranges and measurement errors of membranes for pressure / stroke conversion are not longer necessary. A special restrictor at the pneumatic measuring branch allows an optimal adjustment and a minimal linearity error by the connection of different gauge heads.

1.3 Front panel and rear

Fig.: Front panel Fig.: Rear

The pneumatic converter AE1 is a pressure measuring bridge with a piezo sensor and measuring electronic with analogue voltage output. The modular design supports the cascading and the connection of 1 ... 4 AE1 measuring converters to an IBR - column gauge C100 or digital gauge B100 as well as the connection of 1 ... 8 AE1 measuring converters in conjunction with the IBRit-da8-ae to a PC. The measuring electronic of the AE1 converter in conjunction with the measuring programmes of the IBR - column gauges and digital gauges as well as the IBR – software simplify pneumatic measuring and allows automatic calibration. The constructive design allows the connection of all pneumatic air spindles, air rings, ... by minimal linearity error. Quick couplings simplify the change of gauge heads.

AE1 converter connection ( connection to B100 / C100 / IBRit-da8-ae measuring device )

Type label

Silencer

Pneum. connection Coupling DN2,7

Air pressure supply ( 2 bar / 30 psi ) Quick coupling for PU-hose 6/4 mm

Expansion connection

Restrictor

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7655

35.9

50

3221.5

11

33.7

24

45°

41

21.9

37.512.5

4015

A B

C D

21.4811.28

Thread M3 ( 4x )

25 25 2525 25252532.5

245

41

86

10

3.2

6.210.2

232.5

4366

20.3

5.7

E F

G H I J K

1.4 Dimensions

AE1 Measuring Converter

The boreholes A, B, C and D with threads of M3 allow the mechanical fastening of the measuring con-

verters. The M3 x 8 screws are delivered together with the AE1 converter. On interconnecting a row of measuring converters ( max. 4 ) the screw holes are placed at 25 mm distance from each other.

Footplate for 1 ... 4 AE1 measuring converter The boreholes E and F are used to mount the footplate to the measuring fixtures, measuring machines etc..

Two screws M6 x 10 are delivered with the footplate. The boreholes G, H, I and J are used for air pressure supply of the separate AE1 - measuring converters. The delivery includes 3 seal caps for the use of incomplete equipped footplates. The connection K is used for the connection of filtered and on 2 bar / 30 psi regulated air pressure.

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1.5 Connectors round-up ( all accessories are shown )

1.6 Technical data

Mechanical characteristics Case Aluminium and plastic sides

Dimension W x H x D / Weight 50 x 41 x 76 mm / ca. 150 g

Electrical characteristics Power supply ( of IBRit.-da8-ae / B100 / C100 ) +5V / 8 ... 12mA

Output voltage 2V / bar

Connectors Power supply connection 9-pin Sub-D male connector

Air pressure supply connection Quick coupling for PU hose 6/4mm Air pressure supply of the AE - FC1 4 - 8 bar / 60 - 120 psi

Air pressure supply of the AE1 2 bar / 30 psi ( filtered air < 5µm ) Outlet of measuring air Coupling DN2,7

Connection of gauge head Nipple DN2,7 for PU hose 6/4 mm

Measuring parameters Measuring principle Differential pressure measuring with Piezo sensors

Pneumatic measuring range ( depends on the measuring head )

... ±80 µm / ... ±0,003 INCH

Environmental conditions Working temperature range 0...45°C Storage temperature range -30...+80°C

Type of protection IP 50 ( CEI / IEC 529 )

Electromagnetic compatibility ( EMC ) Electromagnetic compatibility ( EMC ) Generation of armful interference according to EN50081-2

Resistance to armful interference according to EN50082-2

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2. Getting started 2.1 Delivered items

Pneumatic measuring converter AE1 incl. the nipple for the gauge head ( hose connection 6/4 mm ), 4 screws M3x8 for mounting and instruction manual. Further accessories : AE-FC1 connection set, footplate for 1...4 AE1-converter etc,. as listed on the delivery note. Please, check the delivery for completeness and save the packaging for future use.

2.2 Mounting of the measuring converter The measuring converter can be mounted on the footplate or directly to the measuring fixture, machine etc. The footplate can be mounted with two screws M6x10 to the measuring fixture or machine. !!! Attention : The screw must not rise more than 8mm into the AE1 case.

2.3 Mounting the air filter and pressure regulator

To mount the filter and the pressure regulator a mounting kit is supplied together with the AE-FC1.

The kit consists of a wall bracket and a nut to fasten the filter / regulator to the bracket. Attention : For keeping condense water away from the AE1 measuring converters the air filter and

pressure regulator should be mounted below the AE1 converters.

Bracket

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2.3.1 Connecting to the air pressure supply without footplate

Mounting instructions : 1. Cut the PU hose ( 6/4 mm ) to the recommended length according to the picture showing the

connection of the AE1 converters. 2. Connect the PU hose pieces according to the picture and the number of your converters to the plastic

T-components. !!! Push the hose pieces to the T - components as far as they have to go.

3. Blow through the connected hose piece so that no dirt can reach the AE1- measuring converter. 4. Push the hose pieces onto the quick couplings of the AE1 air inlets and secure with nuts.

!!! Tighten nuts only by hand. 5. Cut the remaining PU hose ( 6/4 mm ) to the necessary length to connect the AE1 converter to the

filter / pressure regulator. Push the PU hose piece onto the plastic T-component and then on the quick coupling of the outlet from the filter / regulator. !!! Tighten nuts only by hand.

6. After this the connection to the air pressure supply is carried out. !!! Check in advance that the air pressure is in the range of 4-8 bar ( 60-120 psi ). The connection is done with a DN7,2 coupling. The coupling is the interface to your air pressure supply and allows the connection of pressure hoses with a 9 mm internal diameter.

2.3.2 Connecting to the air pressure supply with footplate

The pressure connection at the footplate is simply done by pushing the hoses into the bores. If necessary remove before the seal caps.

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2.4 Connecting gauge heads

In order to connect the pneumatic gauge heads the AE1 converter is delivered inclusive a DN2,7 nipple suitable for a PU hose 6/4 mm. The PU hoses of the measuring heads are pressed onto the nipples and fastened with nuts. !!! Tighten the nuts only by hand. Fit all gauge heads with PU hoses and DN2,7 nipples and connect them to the AE1 converters. To save compressed air the gauge heads should be parked in a bore ( for example in a rejected part ). !!! Connect air pressure supply by mounting the coupling DN7,2 then set the pressure regulator at 2 bar / 30 psi.

2.5 Electrical Connection Electrical connection of AE1 converters to B100 digital displays, C100 column gauges or IBRit-da8-ae is done with a shielded 1:1 connection cable. The connection cable is contained in the assembly kit supplied with the AE-FC1. 1. Switch off the B100 / C100 gauge before you connect the connection cable. 2. Check out which type of measuring module is installed in the B100 / C100 measuring device. a) B/C100-ind2 A maximum of 2 AE1 converters can be connected. ( The inputs A & B are already reserved for inductive probes ) b) B/C100-ana4 A maximum of 4 AE1 converters can be connected.

3. The IBRit-da8-ae gauge allows the connection of 4 AE1 - measuring converters to each of

the two Sub - D female connectors. 4. First of all make sure that only the maximum allowed number of AE1 converters is connected. Connect then the connection cable to the Sub-D male connector of the AE1 module. 5. Connect the connection cable to the Sub - D female connector of the measuring module or to one of the two Sub - D female connectors of the IBRit-da8-ae.

Secure the connectors with the screws. Only a fixed connection guarantees a certain contact

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Measuring module B/C100-ana4

Measuring module B/C100-ind2 ( You can connect at maximum 2 AE1 measuring converters ) AE1 - Measuring Converters

Connection cable

Figure : Measuring modules B/C100-ind2 / ana4 and AE1 - measuring converter Figure : IBRit-da8-ae and AE1 - measuring converters

2.6 Accessories and order information

Description Article number

AE1 Pneumatic measuring converter with analogue voltage output F330 001 Nipple for gauge head hose connection ( hose 4/6 mm ), 4 mounting screws M3 x 8 and instruction manual AE-FC1 Connection kit for 1...4 AE1 pneumatic measuring converters F330 010 Connection cable, coupling for air pressure connection, air filter, bracket, regulator and T-connectors with 3 m pneumatic hose AE1-FP Footplate for 1...4 AE1 pneumatic measuring converters with 3 seal caps F330 020 for free connection places. AE1-Adapt Adapter cable to connect several B100 / C100 gauges to one AE1 - bus F330 030

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3. Working with the AE1 measuring converter 3.1 First start-up υ 1. Mount footplate, air filter with pressure regulator.

υ 2. Mount all PU hoses and connect gauge heads. υ 3. Connect air pressure and set pressure regulator at 2 bar / 30psi. υ 4. Electrical connection of AE1 converters to B100 / C100 or IBRit-da8-ae gauges. ( Detailed information for 1 .. 4 you will find in chapter 2 of this instruction manual. )

υ Connection to B100 / C100 gauges

Your next step will be to program the gauge B100 or C100 for your measuring task. Check that in the Setup menu of the gauge the option "Automatic gauge calibration" with 2 masters is switched on (on) and that in the programming menu "Set Master value(s)" the masters for automatic calibration have been set. !!! Please see also chapter 3 of the B100 / C100 instruction manuals.

υ Calibration of the gauge ( B100 / C100 ) !!! Please see also chapter 3.3 of this instruction manual.

υ Connection to IBRit-da8-ae measuring boxes !!! For programming of the measuring boxes please see chapter 6 of the IBRit-da8-ae instruction manual. The gauge and the AE1 converter are now ready for operation. Note : By measuring an inner diameter ( bore ) the coefficients should have a negative sign.

3.2 Restrictor adjustment

Only an optimal restrictor adjustment guaranties a minimal linearity error !

For the adaptation of a wide range of pneumatic gauge heads and for the minimization of the linearity error the AE1 has a restrictor. The default setting of the restrictor is for gauge heads with jet diameters of 0,8 mm - 1 mm. On gauge heads with smaller or bigger jets and very small or very big gaps respectively the AE1 measuring converter could be optimised by the restrictor. By the use of 3 masters the restrictor allows to adjust the linearity error at all 3 masters to zero. For the adjustment of the restrictor please see the following description and schedule.

Restrictor for the adaptation of different gauge heads and linearity adjustment

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Restrictor adjustment with 2 masters To get by relative small or big jet diameters good measuring results a restrictor adjustment is recommended. For the adjustment close the restrictor completely ( turn right ) then open ( turn left ) it according to the table.

Jet size Measuring range Restrictor opening

< 1,0 mm < 50 µm 1 turn left > 1,0 mm < 25 µm 2 turns left > 1,0 mm > 25 µm 3 turns left

Note : The restrictor adjustments mentioned in the table are rough guiding values for standard measuring heads and guaranties no optimal adjustment. Improved restrictor adjustment on B100 / C100 – Gauges 1. The B100 / C100 gauge must be set into Measuring mode. If it is not set to Measuring mode, please

press the PRG/CAL key to leave the Programming mode. 2. Press the and keys for more than 3 seconds until the luminous displays MIN, MAX, TIR and

MEAN or Gauge 1…4 start flashing and confirm the Adjustment mode. When this mode is active the gauges switches all factors and offsets automatically off and displays the true measuring value of the measuring converter. If "SECUrE" appears in the numeric display the keypad is locked. Refer to Setup menu "Automatic adjustment" ( "0-triG." → Adb. on/oFF set to "on" ).

3. Change the restrictor adjustment till the display values of the MIN and MAX Master are laying symmetrically around 0. ( that means both have the same absolute value )

Example : Display on MAX Master = 0.4573 Display on MIN Master = - 0.4600

4. When the restrictor has been adjusted, press the ENTER key to exit the Adjustment mode. The message Load appears in the numeric display and all coefficients of the inputs are loaded once again. The offset values cannot be retrieved. It is therefore necessary to perform a Gauge calibration before starting work.

Restrictor adjustment with 3 masters 1. Close the restrictor ( turn right ) and open it for 1 turn left. 2. Do an automatic gauge calibration. ( Please see chapter 3.3 of this manual ) 3. Measure the middle master and compare the measuring value with the master size. υ If the measuring value and master size are identical the restrictor is optimal adjusted. υ If the measuring value is different to the master size the restrictor adjustment has to be

changed. For this leave the gauge head inside the master and change the restrictor adjustment till the measuring value is equal to the master size.

4. After changing the adjustment of the restrictor repeat the points 2. and 3. until the difference between measuring value and master size is nearly zero.

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3.3 Automatic gauge calibration by using the B100 / C100 : Start by placing one of the masters in the fixture ( air spindle, air ring... ) and make sure that the gauge ( B100 / C100 ) is in Measuring mode. If not, press the PRG/CAL key to exit the Programming mode. The Setup menu AutoCA of the gauge ( B100 / C100 ) must be set to On in order to perform the automatic gauge calibration.

Automatic calibration is started by pressing the and keys simultaneously. In the numeric display the message 'CAL.' and the Measured value are flashing alternately.

Place now the 2nd master in the measuring fixture and press the and keys again. The gauge will now carry out the calibration automatically and will take the second master value in the display.

"SECUrE" in the numeric display indicates that the keypad is locked. Refer to the SETUP menu for

"Automatic adjustment” ( "0-triG" → Adb. on/oFF must be set to "on" ). Automatic gauge calibration can also be triggered by the foot switch or via an external contact, under

condition that "Auto Zero by Trigger" is enabled in the Setup menu ( "0-triG" → Adt. on/oFF set to "on").

3.4 Automatic gauge calibration by using the IBRit-da8-ae :

The gauge calibration depends on the used measuring programme. IBR - measuring programmes are : ComGage, IBREXDLL, IBR_CAL, ITEC !!! Please see the according instruction manuals

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4. Pin assignments of the connectors

Wiring principle of the AE1 measuring converters

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5. AE-FC1 connection set

1. Nipple of pressure connector for 9mm hose 2. Filter / pressure regulator ( 0 - 4 bar ) 3. Wall bracket 4. Nut 5. T - hose connectors ( 3 pcs. ) 6. PU - hose 6/4 ( 3 m ) 7. 1:1 shielded connection cable 2 m

6. Maintenance and care

Service weekly monthly Empty filter from condensed water. By filters with automatic emptying it is not necessary.

●

Check system and hoses to thightness. ●

7. Supervision of the air pressure supply

For supervise the air pressure supply we recommend the use of a pressure switch, which triggers alarm when the pressure gets below the minimum pressure of 4 bar. A stabile pressure supply is base for good measuring results. It is important to supervise especially by automatic measuring systems the pressure supply. The supervision of the pressure supply is independent to the IBR - pneumatic and measuring elements.

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8. Safety Instructions

The present instrument is state-of-the-art design and complies with the current safety standards. It is nevertheless mandatory to observe the following instructions in order to prevent personal injuries or accidental death of staffmembers and other persons.

1. All operators must read the present instructions and this manual very carefully before starting

operation.

2. The instrument may be used only in errorless technical condition. Disruptions which may be a danger to operational safety must be removed immediately.

3. The device may be used only as stated in these instructions. The manual must be kept near at

hand at the place of operation.

4. Before connecting the device to the power outlet, make sure that the voltage indicated on the label corresponds to the voltage of the local power net. If this is not the case, the device should under no circumstances be connected to the power outlet.

5. The instrument must be connected to the power supply through a properly grounded safety socket.

Extension cables, where required, must comply with the VDE safety standards.

6. Any modification and procedures concerning the instrument are permitted only with the prior written consent of IBR Messtechnik GmbH & Co. KG and must be carried out by competent staff. Opening the case or tampering with the device without prior permission will lead to the loss of the guarantee and free the producer from all liabilities. Before opening the instrument, make sure to effectively cut the power supply, e.g. by disconnecting the power cable.

7. Before cleaning, disconnect the instrument from the power supply. No liquids should ever be

allowed to leak inside the instrument. Strictly avoid the use of cleaners that attack plastic.

8. Replace faulty fuses only with fuses of identical amperage and current characteristics following the instructions given in this manual.

9. Corporate guidelines and safety regulations enforced by the industrial trade associations for the

prevention of industrial accidents must be strictly observed. Make sure to consult the safety officer at your company.

10. Do not operate the instrument in an environment containing explosive gases, because an electric

spark can cause an explosion.

We reserve the right to change the design and technical data contained in our documentation without notifying our customers. IBR is not obliged to notify changes of the products to previous buyers. IBRit is a registered trademark of IBR. All parts of this document must not be reproduced without written permission from IBR.

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9. Declaration of conformity Thank you very much for your confidence in purchasing this product. We herewith certify that it was manufactured and inspected in our works.

We declare under our sole responsibility that this product is in conformity with technical data as specified in this instruction manual.

On addition, we certify that the measuring equipment used to check this product refers to national master standards. The trace ability of measuring values is guaranteed by our Quality Assurance.

10. Guarantee The quality of this instrument is guaranteed for a period of 12 months from the date of delivery. This guarantee covers all materials and manufacturing defects. Our liability is confined to repair, or should we deem it necessary, replacing or crediting the goods. The following are not covered by the guarantee :

υ Damages due to incorrect handling, υ Disregard of operating instructions, υ Tampering by unauthorised staff, υ Attempts by any unauthorised person to repair the instrument.

In no case any consequences are covered by the guarantee which are connected either directly or indirectly to the instrument or its use. Notice : If returning the instrument under guarantee please use the original packaging.

Should you detect an irregularity of any kind, please contact one of our authorised distributors or our Service department. D-36166 Haunetal, 05.03.2002 I B R Messtechnik GmbH & Co. KG

A. Schneider Quality Assurance Manager

instruction manual - ibr · converters to an ibr - column gauge c100 b100 as well as the connec-...

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