Continuous Thickness Gauge for Very Fine Strip VABL 203 1E Operating Instructions

Transcription

1 Continuous Thickness Gauge for Very Fine Strip VABL 203 1E Operating Instructions 203-E2 erstellt am freigegeben am Bemerkungen Rev.01 Seiten: 28 Name: Rietdorf Name: Koenig für P03/17957

2 measuring ++ controlling ++ recording ++ automation ++ documentation Table of Content F Safety Precautions, please read carefully!... 3 Intended use of this machine... 3 Spares.3 Design and Function... 4 System... 6 Types... 7 Installation... 8 Gauge head alignment... 9 Operation Pneumatic functions Power on Pneumatic pressure Transducer balancing Zero check / Zero setting Accuracy check Nominal size and tolerance setting Measurement start Measurement end F Continuous check Trouble shooting If the gauge measures wrong If the gauge marks the strip? Maintenance Guide rollers Measurement frame Strip guide shoes Repairs Measurement cassette removal / installation Transducer removal / installation Transducer check Strip Guide Servicing Strip breaking Subject to change without prior notice 2 VABL 203/1 Operating Instructions 203-E2

3 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Safety Precautions, please read carefully! The strip processing machine must not be started until a written statement was made that the entire machine (into which the gauge is installed) is in accordance with the regulations of the EG-Maschinenrichtlinie 89/392/EWG respectively (outside Europe) in accordance with the local safety regulations. The manufacturer hereby points out, that this may include the installation of an appropriate protection device. If one is necessary, the protection device has to be made in such a way that the operator can pull the gauge on the strip and push it off the strip during the rolling process without facing any hazard by the running or by the possibly breaking strip. This manual has to be handed to the machine operator, and one copy must be permanently available to operator and service personnel. Nobody is allowed to work on or with the gauge, before he has read and understood this manual. Feel free to call the Vollmer company in case of any questions (phone ). Some parts of the gauge are pneumatically shifted. The pneumatic system should be depressurized before anybody starts to work on this gauge (as long as possible for the kind of work to be done). If the pneumatics remain under pressure, gauge parts might move unexpectedly and clamp hands or fingers. Hands or fingers may also be injured by pneumatically moving parts when they are put into the gauge during normal operation. The gauge has movable parts that are shifted back and forth along ball guides. Those parts need to be fixed, to prevent them from moving and possibly causing injuries. The gauge should be transported standing upright on its slidebase, if possible on a cart. As long as it is not firmly installed in the mill, it needs to be secured against falling over or sliding away. The gauge head might get hot. Therefore check the temperature before trying to handle the gauge head. We care about your health. Please follow the safety precautions. Especially if you have many years of professional experience, you will be a Good example for younger colleagues. Intended use of this machine This gauge is meant to be used exclusively as a fix mounted component of a strip processing machine. This gauge must be used exclusively for the measurement of cold strip between 0,01 and 0,30 mm thick and 0,1 and 3,5 mm wide. The gauge must be firmly installed in its intended position and electrically, electronically and pneumatically connected as intended by the Vollmer company. Any alteration might cause damage. Spares Please order spares referring to the part number and drawing number of the enclosed documentation drawings. To speed up our work, please do also state the Project number which is written as P-No. on the identity plate of the gauge. As this is an extremely precise gauge, it is strongly recommended to have it repaired only by staff of the Vollmer company. 203-E2 Operating Instructions VABL 203/1 3

4 measuring ++ controlling ++ recording ++ automation ++ documentation Design and Function The VABL 203/1E is designed to measure the thickness of very narrow strip on mills or on inspection lines. The gauge measures the passing material continuously and indicates the deviation of the measured values from the preset nominal size. The available measurement range depends on the individual specification. The strip may be e.g. between 0,01 and 0,3 mm (.0004" to.05") thick and 0,04 to 3,5 mm (.0015 to.15") wide. The strip passes the C-shaped thickness measurement frame with two thickness feelers measuring the strip simultaneously from the top and from the bottom. Due to strip thickness changes, the tip of the movable upper transducer ram is lifted or allowed to lower towards the fix mounted feeler below. D V M S VABL 203 / 1E: The strip passes first through the adjustable groove in the first guide roller and is then guided flat through the thickness measurement frame by ceramic covered strip guide shoes. On the outgoing side it is guided by a groove in a second guide roller. The vertical guide V carries the gauge head M with the thickness measurement cassette D. The vertical guide can be shifted across the strip in the slidebase S. For fine adjustment, the lateral gauge head position can be adjusted in a ball guide. The measurement cassette containing the guide shoes can be retracted within the gauge head, so that the guide rollers stay in position, thus allowing easy insertion of the strip. The thickness measurement frame can be traversed back and forth within the cassette, while the guide shoes remain in the "on strip" position. 4 VABL 203/1 Operating Instructions 203-E2

5 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / The measurement feeler tips are made of flat, polished diamonds, so that they do not leave any marks on the strip. The weight of the transducer ram can be balanced (i.e. reduced) pneumatically in order to the increase the life of the diamond tips. The transducer has a differential transformer at its rear end. The movable core of this transformer is connected to the measurement tip which is sliding on the strip surface. In this way any movement of the measurement tip is measured inductively. All changes within the transducer are passed to a VMF measurement amplifier. The amplifier indicates a measurement result as deviation from zero, i.e. the difference to the preset nominal size. The gauge has special, divided guide rollers in order to achieve its extreme measurement accuracy. The two parts of each roller set form a flat, width adjustable groove in the middle of each set of rollers. The strip is laterally guided by this groove. A pair of ceramic covered shoes guides the strip before and behind the measurement spot. The shoes hold the strip flat, so that the thickness is measured exactly perpendicular to the strip surface. The thickness frame is automatically pulled back to ease the insertion of a new strip into the gauge. This is while the measurement transducer tips and the flat guide shoes are pneumatically lifted off the strip. After the strip was put into the gauge, first the thickness measurement cassette moves forward into its measurement position. Then the guide shoes go down and shortly afterwards the measurement frame (C-frame) is moved forward and the feeler tips contact the strip. The gauge can be set to zero during the rolling. The guide shoes remain on strip while only the C-frame is pulled back. After the automatic zero setting, the C-frame is pushed forward again. The ram of the upper transducer (in the bottom is a fix mounted feeler) is lifted by a pneumatically operated tongue when the C-frame is shifted. It is automatically released for zero setting and when the C-frame is in measurement position. The measurement data can be used for quality control documentation according to ISO It is available at analog voltage outputs and digital interfaces of the VMF measurement amplifier. 203-E2 Operating Instructions VABL 203/1 5

6 measuring ++ controlling ++ recording ++ automation ++ documentation System The gauge is always installed with a VMF measurement amplifier. The measurement amplifier indicates the difference between measured strip thickness and selected nominal size. A separate manual (part of the documentation) describes the operation of the VMF amplifier that came with this gauge. The VMF manual is mentioned here because the text in some sections of this manual refers to it. The VMF 1000 amplifier indicates the deviation between the measured thickness and the preset nominal size. The indicator range of the analog indicator can be set to the appropriate resolution: Full deflection of the VMF needle can indicate from 1000 microns (.030 ") down to 10 microns (.0003"). Minor zero point deviations may be eliminated by means of the Master function. Another feature allows to enter Tolerance limits. Colored indicators show if the measured value is in tolerance, or below or above the limit. The optional FS4 (or FS5) nominal size selector allows to set the selected nominal values in microns or inches (depending on the application). The 5 digit FS decade switch is installed in the VMF cabinet. The VMF puts out the measurement data and for quality monitoring acc. to ISO Automatic adjustment procedures help to achieve the highest measurement accuracy at any time. The VMF 1000 is capable of processing two measurement transducer signals which add up to a measurement stroke of max. 4 mm. The controls shown left are connected to the control devices in the VMF cabinet as well as in the pneumatic cabinet. Electronic cabinet with VMF 1000 amplifier. Nominal size is set at a integrated thumb wheel decade switch and then read into the measurement electronics by pressing a button. The controls are described in detail in the related sections of this manual. 6 VABL 203/1 Operating Instructions 203-E2

7 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Types e.g.. VABL 203 1E/VMF1000/FS5-Dek/A0/DAV/3 The abbreviations mean: VABL 203 /1E: Electronic thickness gauge for mills and strip processing lines, designed to measure very fine strip VMF 1000: Measurement amplifier VMF 1000 with analog outputs and several digital interfaces FS5 serial: Nominal size selection by a thumb wheel switch with 5 decades, usable in cennection with a VMF 1000 measurement amplifier. A0: Electronic adjustment system, which works when the thickness measurement frame is in rear position. The amplifier adjusts itself to zero. A0 is started by pressing a button. DAV: In this gauge, DAV means pneumatic transducer balancing, combined with a pneumatically operated mechanical lifting tongue, which lifts the ram of the upper transducer 3: The stroke of the slidebase is 300 mm. 203-E2 Operating Instructions VABL 203/1 7

8 measuring ++ controlling ++ recording ++ automation ++ documentation Installation When the gauge is installed into an inspection line, installation height and levelling of the gauge are derived from the inspection table. After the gauge has been removed from its position, take care to reinstall the base rectangular to the passline. In rolling mills, the gauge should be installed as described in the following sketch: W G H K U If possible, the gauge should be positioned between the roll gap (mill = W) and the deflector roll U. Base and the bracket K are so high that they lie under the strip by the "passline height" H (see data drawing in the documentation). Additional conditions are: l gauge base levelled parallel to roll axes in the mill l gauge base rectangular to the strip l gauge must be installed high enough so that the strip is safely guided in the groove of the guide rollers. Note VA It is strongly recommended to have the gauge installed by Vollmer specialists. The installation of such a high accuracy device requires to have in mind many aspects of the individual application which cannot be described in an operator's manual. Use nut VA (with lock nut) to set the height position of the gauge head. 8 VABL 203/1 Operating Instructions 203-E2

9 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Gauge head alignment HA H K The entire gauge can be shifted across the passline in the slidebase, so that the notch in the guide rollers aligns with the strip. The strip must not be laterally deflected by the guide rollers. Knob L is used to lock the gauge head with its slidebase in measurement position (front) or in service position (rear). For lateral fine adjustment, the rod H of the gauge head runs in a ball guide so that it can be easily adjusted very precisely. The position is set against a pressure spring by means of nut HA (with lock nut). DG The thickness measurement cassette is pneumatically pushed forward into measurement position. This front limit stop is formed by set screw DG. DG is correctly set, when the strip runs in the middle of the guide shoes. 203-E2 Operating Instructions VABL 203/1 9

10 measuring ++ controlling ++ recording ++ automation ++ documentation DF DU DF The thickness frame was fine-positioned within the measurement cassette during manufacturing, so that the strip runs precisely in the middle of the feeler tips. This position is set by the two set screws DF (each with a lock nut). Do not to change the position of these two set screws! The flexible pneumatic pipe DU needs to be disconnected from the thickness measurement cassette before the cassette can be removed from the gauge head. 10 VABL 203/1 Operating Instructions 203-E2

11 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Operation Pneumatic functions The movable elements of the gauge are driven by pneumatic cylinders. The following introduction describes the function only in form of a general overview. A more detailed description can be found in the corresponding text passages further on in this manual and in the pneumatic circuit diagrams. The controlling of the gauge is described under "Measurement start". The measurement cassette with the thickness measurement frame and the strip guide shoes can be shifted within the gauge head. Back (see photograph right) is the position for strip insertion and front is the measurement position. The guide shoes are pneumatically lifted off the strip when the cassette is in the rear position. For measurement (see photograph bottom left) the shoes are pushed together to guide the strip flat through the transducer gap. After the A0 button was pressed, the C-frame (measurement frame) is pulled back off the strip inside the cassette while the guide rollers and guide shoes remain in place (see photograph bottom right). In the rear position, the transducers are released. This is the position for the automatic zero setting (A0), where the gauge system is set to zero while the nominal size signal is ignored for the moment. The transducer ram is lifted as long as the C-frame is moved. Position for strip insert ion: Gauge head in measurement position, cassette in rear position, C-frame in rear position, guide shoes open. Measurement: The thickness measurement cassette is in front position, guide shoes are closed, C-frame is in front position, feelers are on the strip. Automatic zero setting during measurement: The C-frame is pulled back while the cassette remains in measurement position and the guide shoes remain closed. The gauge is automatically set to zero when the C-frame is in the rear position. The transducer tip is lifted when the C-frame is moved, so that the transducer tips to not touch the strip edge. 203-E2 Operating Instructions VABL 203/1 11

12 measuring ++ controlling ++ recording ++ automation ++ documentation Power on The main power supply can be switched on/off by the red/yellow switch at the side of the pneumatic cabinet. The green lamp goes on when the power is on. Another power switch at the VMF cabinet controls the power supply only of this cabinet. However, the main power needs to be on before the VMF cabinet can be switched on. Pneumatic pressure The following list shows the factory settings i.e. the default values to start with. Please note: "C-frame" is another word for "measurement frame". supply pressure = working pressure for measurement cassette forward/back 5 bar transducer lifting 4 bar transducer balancing 1 bar C-frame forward/back and guide shoes 4 bar Pressure might need to be adjusted to the individual situation. In doubt, start with 3 bar and search for improved performance by testing various values. Every moved part should travel quickly to its limit stop without hitting it unnecessary hard. Function of the pneumatic valves and pressure gauges at the inside of the pneumatic cabinet door: A B C transducer lifting transducer balancing C-frame forward/backward strip guide A B C Recommended adjustment of the working pressure for the transducer balancing: D V Adjust the valve knob V so that the pressure gauge indicates zero. Then set choke D so that the pressure gauge shows a little minus. Indication = 0 bar: no balancing Indication < 0 bar: transducer balancing active, reduced measurement load Note: If the VMF indicator shows sudden peaks to +, the measurement load has been reduced too far. 12 VABL 203/1 Operating Instructions 203-E2

13 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / The chokes were set at the factory so that the pneumatic cylinders move quickly without hitting the limit stop too hard. Altering the compressed air supply pressure might require new adjustment of the choke valves to achieve this again. Transducer balancing The ram's measurement transducer touches the strip with a load resulting from the addition of the ram's weight and the force of the measurement spring. This is as long as there is no pneumatic balancing activated. The measurement pressure may be increased or reduced pneumatically. In this gauge, the measurement pressure is pneumatically reduced, so that the measurement ram is pneumatically supported against its measurement spring. This is set by the choke valve D (see bottom left): pressure gauge indication +/- 0 bar: = no reduction pressure gauge indication -0,02 bar: = slight reduction The optimum setting for each kind of strip needs to be tested and found on site. There must be no sudden peaks in the measurement indicator, since they indicate that the measurement pressure is too low. However, it is recommended to set the measurement pressure as low as possible to achieve a long life of the measurement tips Choke valves : 1 transducer lifting device (lifter tongue forw./back) 2 strip guide open/close 3 measurement cassette forward 4 measurement cassette back 5 measurement frame (C-frame) forward/back 203-E2 Operating Instructions VABL 203/1 13

14 measuring ++ controlling ++ recording ++ automation ++ documentation Zero check / Zero setting The "out of / in position" switch is used to move the measurement cassette forward (in position = measurement position) or backwards (rear position = strip insertion position). The switch "C-frame forw./backw." is used to shift the thickness measurement frame inside the measurement cassette. The transducers are automatically lifted while the thickness frame inside the cassette is moved. The guide shoes are operated by the switch "Strip guide open/ close". This switch needs to be set to "open" before the measurement cassette is moved. The automatic zero setting procedure (A0) can be performed even during a measurement by pressing the "Zero adjust" button. This starts the diamond lifting and moves the thickness frame off the strip while cassette remains in position and the guide shoes remain closed. Once the frame is in the rear position (monitored by a limit switch), the DAV releases the transducer so that the measurement tips touch each other. Then the nominal size signal is automatically ignored for a moment while the VMF measurement amplifier is automatically set to zero. After that the thickness frame returns into the measurement position and then the nominal size signal input into the VMF is enabled again. To check the zero setting, the switch "C-frame forw./backw." can be operated several times to operate the diamond lifting device. The VMF indicator must always return to zero. Otherwise, the gauge needs to be checked. 14 VABL 203/1 Operating Instructions 203-E2

15 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Accuracy check If the gauge zero is OK, gauge accuracy can be checked by a slip gauge or a master. This test should be performed regularly, in case of tight tolerances several times a day. The thickness frame must be in measurement position for that test, because the system will set it automatically to zero when it is in the rear position. When inserting a slip gauge between the transducer tips, make sure that it is exactly levelled in order to avoid measurement errors. Ideally, the digital indicator should show the exact thickness of the slip gauge. Deviations from that value must be considerably smaller than the tolerance of the measured strip material. Nominal size and tolerance setting After the gauge was set to zero, set the new nominal size at the FS5 thumb wheels. Then press "nominal size setting" to read the new value into the measurement electronics. After the desired strip thickness, e.g. 200 µm, was read in as nominal size and the measured strip is 201µm thick, the measurement amplifier indicates +1µm. 203-E2 Operating Instructions VABL 203/1 15

16 measuring ++ controlling ++ recording ++ automation ++ documentation If the desired strip thickness, e.g. 200 µm, was read in as nominal size and the measured strip is 201µm thick, the measurement amplifier indicates +1µm. Tolerance limits can be entered by the keys of the VMF. They are then monitored by the integrated electronic classifier (see also VMF manual): Key F2 or or etc. Action press 1 x press several times until 'up TOL' (upper tolerance limit) is indicated press 1 x > PLUS or MINUS sign flashing press to change sign to PLUS press 1 x > 1. digit flashing press to set 1. digit press 1 x > 2. digit flashing After the last digit of the upper tolerance limit was set, continue with the lower tolerance limit: F2 press several times until 'low TOL' (lower tolerance limit) is indicated press 1 x > indication flashing press 1 x > PLUS or MINUS sign flashing or press to change sign to MINUS press 1 x > 1. digit flashing or press to set 1. digit press 1 x > 2. digit flashing etc. When both tolerances are set to the selected value, press the RESULT key in order to read the new values into the VMF storage and simultaneously to switch back the amplifier to standard operation mode The new tolerance limits will be erased when the amplifier is switched off. This is because the original tolerance limits in the amplifier are stored for safety reasons. When the amplifier is switched on, the old values will come up again (see separate VMF manual for details about alteration of the permanently stored data). Measurement start First open the guide shoes, then move the measurement cassette backward. Now insert the strip and adjust the notch size of the guide rollers and check the gauge head position and the position of the measurement cassette. The following describes the procedure step by step (see pictures next page): l move measurement cassette back (out of position) l open the guide shoes (strip guide open) l move the measurement frame back (C-frame back) l insert the strip into the gauge 16 VABL 203/1 Operating Instructions 203-E2

17 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / l open the groove in the guide rollers wide enough for the new strip (increase groove width by turning the two wheels BF anticlockwise) l set the groove in the guide rollers so that the strip runs free: turn the two set wheels BF clockwise until the groove sides just touch the strip edges, then turn back for one gradation line. The strip edges must not permanently touch the sides of the groove. l close the strip guide BF Use the wheels BF to set the width of the groove in the guide rollers. l move the C-frame forward; the DAV will then release the transducer ram so that it is lowered onto the strip. Check, if the strip passes the gauge exactly in the middle of the guide shoes. PD SD l Check the guide shoes for correct pressure: The guide shoes are pneumatically pressed down onto the strip. The limit stop must be set so that the strip is pressed only very little, so that it can be pulled through the gauge by hand without The set screw SD forms the bottom limit stop for the upper strip guide shoe. The detecting any resistance. pneumatic cylinder PD lifts the upper shoe while the measurement cassette is moved. The gap between the guide shoes should be 0.05 mm (.002") bigger than the strip thickness, so that the strip will not wear out the shoe and make grooves into the guide pads. Such grooves might result in measurement errors. They may not be deeper than 1/3 of the measured material's thickness. Use the knurled screw SD to adjust the gap between the strip guide shoes. l adjust the measurement pressure (see page 13, transducer balancing) l for zero setting press "Zero adjust", repeat this at any time during the measurement if required 203-E2 Operating Instructions VABL 203/1 17

18 measuring ++ controlling ++ recording ++ automation ++ documentation l perform the measurement Measurement end l Finish every measurement before the strip end passes through the gauge. This means at least to move the C-frame back and to open the guide shoes. Continuous check In between the service intervals, it is recommended to check the gauge regularly: Compressed air supply: Check for correct pressure (see page 12). DAV: The thickness indicator needle must be deflected to plus when the thickness frame is moved Guide Rollers: Check for easy rotation and clean surface Strip Guide Shoes: Check for worn out grooves 18 VABL 203/1 Operating Instructions 203-E2

19 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Trouble shooting If the gauge measures wrong l Transducer dirty? In a very dirty environment, the ram of the transducers sometimes gets too sticky, so that it does not shut completely. If the gauge is then set to zero, the indication of a following measurement is too low. After cleaning, the transducer ram should slide easy in its bushing or bearing for a long period of time. ð increase cleaning frequency l Transducer clamped too hard? If the clamp screws in the C-frame are clamped too hard, they possibly distort the transducer housing which increases the friction in the ram guiding. ð loosen the clamp screw and re-tighten it with moderate force l Oil in the flexible cable protection hose? Although the oil does not damage the transducer, it increases the friction of the ram guide bushing or ball bearing. In that case the transducers cannot continuously keep contact to a vibrating strip surface. The measurement then indicates "too thick". Much oil in the protection hose does additionally choke the transducer balancing. ð Drain the oil from the hose by opening the drain screw in the white plastic DAV connector (see extra DAV instruction). Clean the transducer and possibly improve the quality of the supplied compressed air. l Gauge zero not constant? If the screws, which connect the measurement ram with the guide ram, are not tight, the measurement ram might move against the guide ram. If, for example, DAV was activated or material was placed between the transducers and then removed, the zero point changes. The indication is incorrect even if the symmetry is correct. ð Fasten the grub screws in the guide ram (see transducer manual) l Indication wrong? If the transducer or the fix mounted measurement feeler pin in the C- frame are clamped not tight enough, they might move in their bore. Gauge zero is then shifted too. l Additional check for gauges with decade switch (type FS5): If a new transducer was installed, the adjustment of the measurement amplifier to the nominal size selector has to be checked by a slip gauge. Set the gauge to 0 and insert a 100 or 200 µm (.004" resp..008") slip gauge. Then set the decade switch to the respective value and check, if the gauge measures zero. If not, ð adjust the VMF to the nominal size selector (see VMF 1000 manual) l Indication too large? If the strip has worn out the guide shoes, it might not be held flat any 203-E2 Operating Instructions VABL 203/1 19

20 measuring ++ controlling ++ recording ++ automation ++ documentation more because the outer sections of the guide shoes are contacting each other, while the strip runs through the worn out groove. ð replace guide shoes If the gauge marks the strip? l measurement tips with small cracks? If hit too hard, the diamond in the measurement tips might get tiny cracks, which are hardly visible. Sometimes such crackles mark the strip ð replace the measurement tip l tip broken out? In case of strip breaking the tips might break out of the measurement tips. ð replace the measurement tip l Roller blocked? ð Replace roller. If the roller surface is not damaged, replace only the bearings. 20 VABL 203/1 Operating Instructions 203-E2

21 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Maintenance This thickness gauge does not need much maintenance. Only the pads on the guide shoes and - after a very long time of operation - the measurement tips and the guide rollers are subject to wear. From time to time the gauge should be cleaned in order to prevent movable parts from becoming blocked by dirt deposits. The following points should be checked regularly, even if the measurement results are correct: Guide rollers l Clearance? The rollers have to move freely. They should have only little axial clearance. Blocking rolls mark the strip. ð Replace defective rollers l Deposits on the surface? Some strip materials leave deposits on the rollers. They cannot run smooth on the strip and might mark the strip. ð replace rollers (have them reworked, if possible) Measurement frame l Easy movable? The measurement frame might get stuck because of major dirt deposits in the gauge mechanics. The C-frame need to be movable by hand (only for about.004" ) when easily pushed back/forth at the cable guide of the transducer. It is OK if the frame is not blocked. Otherwise, ð Clean the gauge, and have it readjusted afterwards Strip guide shoes l Grooves? If the guide shoes are pressed onto the strip too hard, the strip might wear out the guide shoes and produce deep grooves in the ceramic pads. If a groove is deeper than 1/3 of the smallest measured strip thickness, ð replace guide shoes 203-E2 Operating Instructions VABL 203/1 21

22 measuring ++ controlling ++ recording ++ automation ++ documentation Repairs Measurement cassette removal / installation The measurement cassette needs to be removed for transducer service. To remove the measurement cassette (photo right): - depressurize the pneumatics of the gauge - disconnect the flexible pipe DU (see page 10) at the front of the cassette. To avoid unintentional swapping, it is recommended to mark the flexible pipes before more than one is disconnected. Then disconnect the two pipes 1 and 2 (see photograph page 13). - remove side cover PD (four screws) - measure, how far the guide rod FS protrudes beyond the clamping piece KS or mark it, to allow an easy re-installation into the same position. - remove the lock nut (see arrow) from the end of the rod of the pneumatic cylinder PN and then screw the rod out of the rear panel R - loosen the two clamp screws KL, pull the clamping piece KS together with the cylinder PN off the guide rod FS and put the parts onto the vertical guide block V V PD 22 VABL 203/1 Operating Instructions 203-E2

23 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / KS PN FS KL R - Pull the measurement cassette D towards the front side. Once the rods are pulled off their ball guides lift it at the front side and simultaneously tilt it back, so that it can be lifted over the guide rollers towards the left. Put the cassette in its original orientation on the bench beside the gauge. - The installation is done in the reverse way. Finally check the measurement position of the cassette and readjust it if necessary as described under "Gauge head alignment". 203-E2 Operating Instructions VABL 203/1 23

24 measuring ++ controlling ++ recording ++ automation ++ documentation Transducer removal / installation The transducer needs to be removed from the gauge only if the ram got sticky or if it marks the strip even after the tip was wiped clean in the gauge. Transducer service is described in a separate manual that came with the entire documentation. Transducer removal: - remove the clear plastic cover - loosen the clamp screw KT and pull the transducer MT out towards the top while supporting the measurement frame with the other hand - mark the rotational orientation of the fix mounted measurement feeler in the bottom clamp of the C-frame. This is required to allow the reinstallation in the same orientation (only important if the measurement diamond is not flat but a rounded edge which has to stand rectangular to the strip. Loosen the clamp screw KM and pull the feeler pin out of its clamp hole towards the bottom. Transducer installation After the transducer was cleaned or after the measurement tip was replaced, it needs to be repositioned most exactly in the measurement frame. If there is one, the dog screw for the rotational fixing of the transducer ram, needs to point parallel (not across) the passing strip. If only one item, the transducer or the fix mounted feeler pin, was removed at a time, the remaining item can be used to guide the removed part back into the old position. The transducer needs to be connected to the VMF amplifier. The removed item is then inserted into its clamp hole in the C- frame and slowly pushed against the remaining item. Clamp it in a position where the VMF indicator (in the 10µm range) is as close to zero as possible. Then set the gauge to zero. If both items were removed, first install the fix mounted feeler pin: - depressurize the pneumatics in the measurement cassette - pull the ram lifter TH forward, so that the lifter tongue (see arrow) is in the center of the two clamp holes in the C-frame. In this position, the bottom side of the tongue forms the measurement basis, that is the reference level for the positioning of the transducer and the feeler pin in the C-frame. - insert the feeler pin from below into its clamp hole and push it up until it just touches the tongue. Check (if the diamond is edge shaped) if the edge stands rectangular to the strip. Then let go of the lifter tongue. - Now connect the transducer to the VMF and insert it into the upper clamp hole. Push it down until it meets the feeler pin. Clamp it (not too hard) where the VMF (in the 10µm or.0003" range) indicates as close to zero as possible - Set the gauge to zero to eliminate minor deviation (at the VMF, press and directly afterwards the key F1) 24 VABL 203/1 Operating Instructions 203-E2

25 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / KT MT MB KM TH Thickness measurement cassette (removed from the gauge head). 203-E2 Operating Instructions VABL 203/1 25

26 measuring ++ controlling ++ recording ++ automation ++ documentation Transducer check This manual describes only some quick checks of the transducer. Details for service and repair are in the transducer service manual in the documentation. l Ram easy movable? The transducer ram must be easy to be pushed in and spring back immediately. l Measurement tips worn? To achieve accurate measurement results, the measurement tip of the thickness transducer needs to be flat, and the edge of the feeler pin needs to be straight without notches or cracks. Depending on the application, the lower feeler pin may be a flat diamond instead of an edge. If a diamond is worn or damaged: ð Replace it l Cracks in the measurement tips? May cause incorrect measurement results and might mark the strip ð Replace it l Broken out measurement tips? (after strip breaking or when the strip end has passed through the gauge) ð Replace it 26 VABL 203/1 Operating Instructions 203-E2

27 FRIEDRICH VOLLMER Feinmeßgerätebau GMBH, D Hagen, Verbandsstraße 60, ) / 507-0, Fax.. / Strip Guide Servicing To replace the guide shoes: Check, if the ceramic pads of the guide shoes are worn. If they have visible groves, check the depth of the grooves. Measurement can be continued, if the grooves are no deeper than 1/3 of the strip that is measured in this gauge. Deeper grooves require a replacement of the guide shoes. Guide shoe removal and installation: - remove the clear plastic cover from the side of the measurement cassette - loosen clamp screw KD - pull the clamping piece KO up for about 10 mm (approx..4") so that the two guide rods come out of the upper guide shoe DO - carefully (not to damage the transducer tip) take the guide shoe DO out towards the front of the cassette. - remove the two screws from the front side of the lower guide shoe DU - remove the shoe DU carefully towards the front of the cassette - first reinstall the lower guide shoe, be careful not to touch the feeler pin and the transducer ram (if they are installed in the gauge). - put the upper shoe on top of the lower shoe, lift it slightly at the front and insert the guide rods by pushing down the clamp KO. Clamp the guide rods in the guide shoe by tightening the screw KD. The rods should be flush with the bottom side of the upper guide shoe, they must not protrude from guide shoe. - readjust the position of the upper guide shoe (see page 17) KO KD DO DU 203-E2 Operating Instructions VABL 203/1 27

28 measuring ++ controlling ++ recording ++ automation ++ documentation Strip breaking Check the gauge zero after each strip breaking. If it has not changed, measurement can continue immediately. This high precision gauge might be misadjusted if a breaking strip hit sensitive parts. If the gauge zero has shifted for a minor amount, set the measurement amplifier to zero. Then check a the gauge with a slip gauge (extra, available from Vollmer). If the result is all right, measurement can go on. If the measurement does not indicate the exact thickness of the sample, check the entire gauge. Take special care of the measurement tips, the easy movement of the transducer ram and the alignment of the clamp holes in the C- frame. It is recommended to call the Vollmer company for service if the reason for the measurement error remains unclear. 28 VABL 203/1 Operating Instructions 203-E2