ALTHEN FDK-BT Series User manual

Germany | Switzerland | Austria
ALTHEN GmbH Sensors & Controls
Dieselstr. 2
65779 Kelkheim, Deutschland
Tel: + 49 (0)6195 - 70060
[email protected]
Netherlands | Belgium | Luxembourg
ALTHEN bv Sensors & Controls
Vlietweg 17a
2266 KA Leidschendam, The Netherlands
Tel: [phone]
[email protected]
France
ALTHEN Sensors & Controls
26, avenue de la Méditerranée
34110 Frontignan, France
Tél : [phone]
[email protected]
USA | Canada
ALTHEN Inc Sensors & Controls
2375 Woodacre Drive
Oceanside CA 92056, USA
Tel: [phone]
[email protected]
Other Countries
For our international sales
partners please contact us
by email at [email protected]
www.althensensors.com
Railway FDK-BT Series
Manual
FDK-BT Series
Certified according to ISO 9001:2008
04.2017 | version 20160122 Rev 1.2

1. Safety precautions and measurement conditions ....................................................................….…......3
2. Electromagnetic compatibility.........................................................................................................….…...3
3. General information........................................................................................................................….……..3
4. Basic data and performance characteristics ......................................................................................…..3
5. Example of item designation when ordering ..........................................................................................4
6. Complete set to be supplied.........................................................................................................….…......4
7. Design ........................................................................................................................................….…………..5
7.1. Electronic gauge.................................................................................................................…..…......5
7.2. Indication device (option) ..........................................................................................................…..5
8. Operation principle ........................................................................................................................…..….....7
9. Working with the gauge and working in autonomous regime ...........................................................7
9.1. Gauge turn-on .................................................................................................................….….........7
9.2. Single measurement......................................................................................................….…...........7
9.3. Measurement with averaging .............................................................................................…........8
9.4. Gauge turn-out ..................................................................................................................….….......8
10. Indication parameters setup...................................................................................................….…...........8
10.1. Bluetooth ON/OFF...........................................................................................................….….........8
10.2. Image rotation.................................................................................................................….…..........9
10.3. Image brightness set-up ................................................................................................…............10
10.4. Millimeters-Inches -Tapes display set-up ..................................................................................10
11. Service operation modes ....................................................................................................….……...........11
11.1. Calibration conditions ....................................................................................................….….........11
11.2. Get into operational modes ...........................................................................................….…........11
11.3. Calibration of the sensor zero ..........................................................................................….........11
11.4. Calibration of the device base .............................................................................................…......12
12. Working with the gauge and PDA ...........................................................................................….…........13
12.1. Operation principle ........................................................................................................….….........13
12.2. Gauge and PDA activation ................................................................................................….….....13
12.2.1. Gauge turn-on .........................................................................................................….…….........13
12.2.2. PDA turn-on...............................................................................................................….…….......13
12.3. On-line measurement ....................................................................................................….…........14
12.4. Measurements with database maintenance..............................................................................15
12.5. Browsing the database .....................................................................................................….….....17
12.6. Saving database on flash memory card .....................................................................................17
13. PDA program setting..................................................................................................................….…......18
13.1. Selection of measurement units ..................................................................................................18
13.2. Data and Time settings....................................................................................................…..….....18
13.3. Tolerances settings ........................................................................................................….…........19
13.4. Database selection ........................................................................................................….….........20
13.5. Selection and formation of measurement scheme..................................................................20
13.5.1 Selection or removal of the measurement scheme...............................................................20
13.5.2 Formation of a new measurement scheme ............................................................................21
13.5.3 Loading of a new measurement scheme ............................................................….…...........21
13.6. New electronic gauge connection ....................................................................................….......21
13.7. Selection and changing of language and terminology ...........................................................22
13.7.1 Preparation and installation of language support file ..........................................................22
13.8. PDA software version viewing.....................................................................................................22
13.9. Deactivation........................................................................................................................….…....23
14. Working with the gauge and PC...................................................................................................…......23
14.1. Program starting ....................................................................................................................…....23
14.2. IDK-PC connection ..............................................................................................................….…...23
14.3. Measurement....................................................................................................................….…......24
15. Database maintenance software ...........................................................................................….……....24
16. Charging of built-in accumulator battery ................................................................................….…....25
17. Warranty policy.......................................................................................................................….………....25
18. Annex 1. Procedure of installation of Bluetooth connection between IDK and PC.......................25
19. Annex2.Measurementdevicesforrailwaytransport .….…………….........................….….……......30
Contents
Page 2/29

1. Safety precautions and measurement conditions
· The metering accuracy depends greatly on the wheel surface quality. There-
fore it is necessary to carry out the check and presorting of the wheel surface
roughness and flaws before measuring the diameter.
· Prior to place the gauge onto the wheel there is a need to clean the wheel
parts that contact with gauge ball bearings, side supports and measuring tip,
of the mud.
· At arranging the gauge, do not allow hitting its supports on the wheel and any
measuring tip side hitting
· At arranging the gauge, do not apply strong forcing in the direction of the
measuring tip movement. It can result in the gauge sag, that will bring about
the uncertain metering result
· It is necessary to inspect the gauge supports periodically and to cleanse them
· To save the battery power the display extinguishes if there were no buttons
pressings for 60 seconds, at that only blinking dot is shown. Pressing any but-
ton just turns on the display and does not act in any other way in this case.
2. Electromagnetic compatibility
The gauge has been developed for use in industry and meets the requirements of the
following standards:
· EN 55022:2006 Information Technology Equipment. Radio disturbance
characteristics. Limits and methods of measurement.
· EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards.
Immunity for industrial environments.
· EN 61326-1:2006 Electrical Equipment for Measurement, Control, and Laboratory
Use. EMC Requirements. General requirements.
3. General information
Electronic gauge is designed for measuring wheel rolling circle diameter (amount of
wear) of railway, metro and tram in the course of checkup, examination, repair and
formation of wheel sets. Measurements are made directly on rolling stock without
wheelset roll-out.
4. Basic data and performance characteristics
Name of parameter Value
Measurement range, mm 400…1400 or on request
Measurement error, mm ±0.2
Indication discreteness 0.1mm, 0.01mm * or 0.01 inch **
Position of measurement, S, mm On request
Distance between axes of ball bearings (base), mm
and measurement range, mm
122±0.5(400…750mm)or
200±0.5(400…950mm)or
250±0.5(600…1400mm)or
300±0.5(720…1400mm)
Display build-in, LED
Operating temperature, 0C -5…+55
Power supply – built-in rechargeable battery two AAA 1,2V
The number of measurements that can be taken before battery recharge is
not less than 1000
Weight, kg 0,5
Page 3/29

5. Example of item designation when ordering
FDK-S/B-MIN/MAX-X-BT
Symbol Description
S Position of measurement, mm
B Base, mm
MIN Bottom of measuring range, mm
MAX Up of measuring range, mm
X Positionofindication.A – Indicationisatthesideofsidesupports(figureA),B
– Indicationisatoppositeside(figureB)
BT Bluetooth presence*
* The gauge with Bluetooth can work in autonomous regime and together with FDRF303 PDA or PC, with
measurements saving in database.
Example: FDK-70/250-850/1260-A-BT. Position of measurement – 70 mm; base of the
gauge – 250 mm; bottom of measuring range – 850 mm; up of measuring range – 1260
mm; position of indication – A, BT – Bluetooth presence .
Fig. A Fig. B
6. Complete set to be supplied
Name Quantity Weight, kg
Wheel diameter measuring gauge FDK series 1 piece 0,5
Charger 1 piece 0,2
FDRF303 – PDA (option) 1 piece 0,4
Charging device 5V 3.0A for PDA (option)
Manual 1 piece
Case 1 piece
Database management system (CD)
Calibration tools (option) on request
Flat block FDRF510.11.000 (fig.4) -
Reference wheel block for calibrating FDRF510.11.850 (fig.5) -
Page 4/29

7. Design
7.1. Electronic gauge
The gages with bases of 200, 250 and 300 mm are shown on the Figure 1, the gage
with base of 122 mm – on Figure 1.1. Electronic gauge contains two ball supports to
place the gauge onto the roll surface, two side magnet supports to base the gauge to
the wheel edge and a measuring tip.
There are a digital numeric display and control buttons on the front panel of the
gauge.“Charge”connectorforchargingdeviceconnection and Bluetooth indication
LED are situated on the top panel of the gauge.
Figure 1
Figure 1.1
7.2. Indication device (option)
PDA is designed for control of the laser scanning module, data reception from the
scanning module, indication of measurement results, parameter input and data
storage.
Page 5 /29

Figure 2
Fig. 2 indicates:
(1) Turn-on button
(2) Charging indication, red/blue LED
(3) Connector to PC USB-port or charging device
(4) Flash memory card connector
(5) Stylus
(6) Bluetooth antenna
Overall dimensions of PDA are shown in figure 3.
Figure 3
Page 6/29

8. Operation principle
Themeasurementofthediameterisperformedaccordingtothe“threepoints”
technique, without the complete wheel coverage. The measurement method is based
on the diameter calculation by the known length of the segment chord (the distance
between the ball bearings centers), which is obtained at placing the gauge onto the
wheel.
The suggita of the segment is measured by means of the displacement converter.
Video presentation is available on request.
9. Working with the gauge and working in autonomous
regime
9.1. Gauge turn-on
Press Red buttontoturnonthepower.Thedisplayshows“ErrP”message if the
accumulator battery voltage became lower then the control level. In this case the short-
term work is possible after pressing any key.
9.2. Single measurement
To perform measurement, it is necessary to:
· turn the power on (press Red button). Thedisplayshows“- - - - -”;
· place the gauge onto the wheel;
· make sure the ball supports are tight against the roll surface and side sup-
ports are adjacent to the edge of the wheel;
· press Green button.
· in a 1 second the display will show the value of the wheel diameter.
For viewing the result of measurement with indication discreteness of 0.01mm (it
is accessible only in a mode of direct indication) it is necessary to press Blue button,
thus displayed result will be shifted to the left on one digit. Next pressing Blue button will
lead to return of indication to a starting position:
Page 7/29

9.3. Measurement with averaging
The program of the wheel diameter calculation contains an averaging algorithm that
allows eliminating the surface defects influence on the diameter measuring result.
All the results of metering, performed after the Red button pressing, are averaged.
The measurement is meant to be Green button pressing.
To carry out measurements it is necessary to
· turn the power on (press Red button).Thedisplayshows“- - - - -”;
· place the gauge onto the wheel
· make sure the ball supports are tight against the roll surface and side sup-
ports are adjacent to the edge of the wheel;
· press Green button;
· display shows the value of pressing counter “n x”,where x– quantity of av-
eraged values;
· in a 1 second display shows an average value over the set of metering (over
the quantity of Green button pressings)
· move the gauge to a new position and repeat the measuring.
(The total quantity of measurements averaged in this way can run up to 9999.)
· Press Red button to reset averaging result at switching to another wheel.
For viewing the result of measurement with indication discreteness 0.01mm (it is
accessible only in a mode of direct indication) it is necessary to press Blue button, thus
displayed result will be shifted to the left on one digit. Next pressing Blue button will
lead to return of indication to a starting position.
9.4. Gauge turn-out
The gauge turn-out occurs automatically. The display extinguishes if there were no
buttons pressings for 60 seconds, at that only blinking dot is shown. If there were no
button pressings for 4 more minutes, the gauge is turned out completely. You can
turn the gauge off by long pressing Red button (more then 3 sec.).
10. Indication parameters setup
10.1. Bluetooth ON/OFF
To switch Bluetooth ON it is necessary to:
· turn the power on
· press Blue button and keep it pressed for more than three seconds
· displaywillshow“bt On”
· to turn Bluetooth off press Green button.Displaywillshow“bt OF”
Page 8/29

· to save the changed parameters press Red button. The display shows
“SAUE”message,pressthe Green button to confirm saving and Red button
to cancel saving of the changed parameters
10.2. Image rotation
To rotate the image it is necessary to:
· turn the power on (press Red button);
· press Blue button and keep it pressed for more than three seconds;
· display will show "bt On" or "bt OF";
· press Blue buttonagain. Displaywillshow“Up”
· by the pressing of Green buttonturnovertheimage:themessage“Up”will
be turned over 1800;
· to save the changed parameters press Red button. The display shows
“SAUE”message,pressthe Green button to confirm saving and Red to can-
cel saving of the changed parameters;
Image rotation function allows observing the result in the way comfortable for the
operator regardless of the gauge placement direction.
Page 9/29

Notes:
- indication discreteness of 0.01mm is accessible only in a mode of direct indication;
- the separation point is indicated at the top side of the screen in the reverse indication
regime.
10.3. Image brightness set-up
To change the display brightness it is necessary to:
· turn the power on (press Red button).;
· press Blue button and keep it pressed for more than three seconds;
· display will show "bt On" or "bt OF";
· press Blue button again until “brt X”messageappearsonthedisplay;
· choose the necessary brightness value by Green button pressings;
· to save the changed parameters press Red buttonthedisplayshows“SAUE”
message, press the Green button to confirm saving and Red to cancel saving
of the changed parameters;
At brightness choosing one should take into account that increased brightness
enhances power consumption and decreases the period till battery recharge moment.
10.4. Millimeters-Inches -Tapes display set-up
To change the mode it is necessary to:
· turn the power on (press Red button).;
· press Blue button and keep it pressed for more than three seconds;
· display will show "bt On" or "bt OF";
· press Blue buttonagainuntiltheeither“SI”or“Inch” or“Tape” message
appearsonthedisplay.“SI” – measuringresultswillbeshowninmm,“Inch” –
measuring results will be shown in inches; “Tape” – measuring results will be
shown in tapes.
· choose the necessary value by Green button pressings;
Page 1 0/29