LTC Laser MicroMap LP-4210F Manual

Laser MicroMap  Inspection System
Operating Procedure
For LP-4210F
Systems
Revised 17 Dec 2010
6742 185TH AVE. NE, SUITE 300 REDMOND WASHINGTON, USA 98052 425-885-0607 WWW.LASER-NDT.COM

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TABLE OF CONTENTS
TABLE OF CONTENTS.................................................................................................................................................1
LASER SAFETY ..........................................................................................................................................................3
INTRODUCTION..........................................................................................................................................................4
Overview..............................................................................................................................................................4
System Configuration..........................................................................................................................................4
LP-4210F™ Data Acquisition Instrument ...........................................................................................................5
Delivery System....................................................................................................................................................7
LaserViewer™ 2010 Software .............................................................................................................................7
SYSTEM SETUP ..........................................................................................................................................................8
SYSTEM SETTINGS.....................................................................................................................................................9
Laser Power.........................................................................................................................................................9
Automatic.............................................................................................................................................................9
Fixed ....................................................................................................................................................................9
Laser Intensity.....................................................................................................................................................9
Gain .....................................................................................................................................................................9
Null......................................................................................................................................................................9
OPENING AND SAVING WORKSPACES......................................................................................................................10
Opening a Different Workspace .......................................................................................................................10
Saving a Workspace..........................................................................................................................................10
MOTOR AND AXIS CONTROL ...................................................................................................................................11
Driving Motors..................................................................................................................................................11
Moving to a Specified Location ........................................................................................................................11
Stopping Motors ................................................................................................................................................11
Setting Encoder Values.....................................................................................................................................11
SYSTEM CALIBRATION ............................................................................................................................................12
Initializing a Calibration Scan .........................................................................................................................12
If the Calibration Verification Process Passes.................................................................................................12
If the Calibration Process Fails........................................................................................................................13
Calibration Troubleshooting.............................................................................................................................14
SCANNING OPERATION............................................................................................................................................15
Setting the Scan Parameters.............................................................................................................................15
Advanced Scan Parameters................................................................................................................................15
Initializing a Scan .............................................................................................................................................16
VIEWING AND ANALYZING DATA............................................................................................................................17
Viewing Profile Data.........................................................................................................................................17
Opening Data Files............................................................................................................................................17
Data File Header ...............................................................................................................................................17
Color Plot Display .............................................................................................................................................18
Color Palette......................................................................................................................................................19
Changing the Magnification ..............................................................................................................................19
Viewing in 1:1 Aspect Ratio...............................................................................................................................20
Displaying Cross-Sectional Auxiliary Windows ................................................................................................20
Displaying Annotations......................................................................................................................................20
Viewing LaserVideo™ (LVI) Data ...................................................................................................................21
Data Analysis.....................................................................................................................................................22
Applying Processors to a Scan Data File ..........................................................................................................22
Processors..........................................................................................................................................................23
Reading Data Values .........................................................................................................................................25
Making point-to-point measurements.................................................................................................................25
Calculating Area/Diameter Statistics.................................................................................................................25
Viewing Cross Sectional Data...........................................................................................................................26
Selecting the Viewing Position...........................................................................................................................26
Selecting the Reference Radius ..........................................................................................................................27
Measuring the Radius/Diameter ........................................................................................................................27
Measuring Pit Depth..........................................................................................................................................27
Printing and Saving Data .................................................................................................................................28

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Saving Processed Data ......................................................................................................................................28
Saving Text Files................................................................................................................................................29
Saving Bitmaps...................................................................................................................................................29
Printing ..............................................................................................................................................................29
USB KEY POWER ISSUE ..........................................................................................................................................30
Resolution ..........................................................................................................................................................30
QUICK REFERENCE SHEET.......................................................................................................................................31
TROUBLESHOOTING.................................................................................................................................................32
Laser..................................................................................................................................................................32
Motors................................................................................................................................................................32
Data ...................................................................................................................................................................33
Software.............................................................................................................................................................34

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Laser Safety
The LP sensor system contains a Class IIIa laser: a visible, red laser diode with a
wavelength between 630-660nm and a maximum output power of 4.5mW. When used
according to these procedures, this product operates as a Class II laser product. The LP
data acquisition instrument is equipped with a SmartLaser™ mode that causes the laser
to turn on and off, with a maximum pulse length of 1.6ms and a frequency of 1Hz, when
a sample is not in range. The laser will only operate continuously when the sensor
detects a surface in range.
When the system is scanning inside closed-end tubes, LTC may setup the
LaserViewer™ workspace so that SmartLaser™ turns off during a scan of the sample,
and then automatically turns back on after the scan is ended. Scans should only be
performed when the sensor is inside a test sample or the provided calibration ring. This
procedure is required to operate as a Class II laser product.
No routine maintenance for the sensor needs to occur beyond keeping the system
generally clean. If fingerprints or other contamination are on the laser or photodetector
windows, make sure the system is off, then clean with an alcohol-based lens cleaner
and a lens cloth/tissue. For any other maintenance or service questions, contact LTC.
CAUTION
Use of controls or adjustments or performance of procedures other than those
specified herein may result in hazardous radiation exposure.
The sensor warning and ID/certification labels are located on the sensor.
Manufactured by: Model: DD-XXXX
Laser Techniques, LLC Serial #: LP-S-XXXX
Redmond, WA USA Mfd. Dec. 2008
Complies with USFDA 21CFR1040.10
<1mW @ 630-660nm
LASER APERTURE LABEL
AVOID EXPOSURE- Laser radiation is
emitted from this aperture.
ID/CERTIFICATION LABEL
SENSOR WARNING LABEL

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Introduction
Overview
This manual is intended to provide the reader an introduction to the basic theory and application
of laser-based profilometry. It also includes specific instructions for the setup and operation of
the Laser MicroMap™ laser profilometry system (LP system).
The LP probe sensor employs the principle of optical triangulation using a 630 –680nm
wavelength visible diode laser. When operated in AUTO mode the LP system meets the Class II
requirements as set forth in FDA - 21 CFR 1040.10. In TEST mode (intended for maintenance
only) the system is classified as a Class IIIa laser product.
Although this document is intended to provide sufficient instructions for the operation and use of
the LP system, on-site training is advised to augment the information contained herein.
System Configuration
The Field-Grade Laser MicroMap™ system is typically comprised of three elements: the LP-
4210F™ data acquisition and control instrument (which also houses the motor control unit), a
sensor, and a sensor delivery unit. In addition, all inspection systems have a calibration fixture
that is either external to the system or integrated into the sensor delivery unit. The following is a
brief description of each of the basic elements of a system. For more information regarding each
element for a specific application, refer to the Addendum that is provided with each system.

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LP-4210F™ Data Acquisition Instrument
The LP-4210F™ provides controls for all motion of the sensor, laser power control, analog
signal processing, and data acquisition and analysis capabilities.
Front Panel Controls
POWER –A red LED that indicates power ON/OFF.
LASER –An indicator light that illuminates yellow when the sensor control board is powered
and red when the laser is emitting light.
SENSOR –A two-position, key-lockable switch that controls the laser diode with OFF and ON
settings. In the OFF state, there is no power to the sensor control board. Use this setting when
plugging or unplugging the sensor from the LP-4210F™ unit.In the ON state, the sensor control
board is powered up, and the laser can be nulled and turned on using LaserViewer™ software.
MOTOR POWER –The LP-4210F™ houses a Motor Control Unit (MCU). This unit is often
custom-configured according to the client’s application. The Motor Power switch turns
ON/OFF the MCU. The switch will illuminate red when the MCU is ON. To prevent moving
the sensor accidentally, turn the MCU OFF when not driving the motors or scanning.
USB –Two USB 2.0 ports.
Figure 1. LP-4210F™ Front Panel

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Rear Panel Controls
MOTOR FUSE 2.5AMP –The MCU uses a 2.5A time delay fuse.
MOTOR and SENSOR –The Linear Motor Cable and Sensor Cable attach to these connectors.
EXT MONITOR –An external VGA monitor may be plugged into this connector. When using
an external monitor, the image quality on the internal monitor may degrade significantly.
ETHERNET –A Category 5e Ethernet port for the data acquisition system.
USB –Two USB 2.0 ports.
100-240VAC (50/60Hz) FUSE 4AMP –The power supply is rated for 100-240VAC (50/60Hz),
and will automatically detect the voltage input level at the power module. LP-4210F™is
provided with a 4A fused rocker-type momentary power switch.
Motor Control Unit
The LP-4210F™ system is provided with an internal Motor Control Unit. This unit is custom-
configured according to each customer’s application, and is not accessible by the customer.
Figure 2. LP-4210F™ Back Panel

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Delivery System
The LP system may include a sensor delivery system. This unit is often custom-configured
according to each client’s application. The attached Addendum contains provides a detailed
description of the delivery system, if included.
LaserViewer™ 2010 Software
To open LaserViewer™2010, double-click on the LaserViewer™ 2010 icon on the desktop, or
choose Programs, LTC, LaserViewer ™2010 from the Start Menu.
LaserViewer™ 2010 will not operate if the software key is not attached to one of the USB ports
on the LP-4210F™ before starting the software.
If LaserViewer™ 2010 is started without the software key, the program must be closed, then re-
opened after the key is in place.

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System Setup
Important
All instruments in the system should be plugged into the same circuit to insure a common
ground.
Always confirm that the power is OFF to all instruments, including the Motor Controller
Unit, before attaching or detaching cables.
When attaching or detaching cables only grasp the outer ring of the connector. DO NOT
grasp and rotate the main body of the connector.
1. Attach all cables and the sensor as shown in the Addendum.
2. Confirm that the LP-4210F™ is plugged into a fused and surge-protected power source
that provides 100 –240 VAC at 50 to 60 Hz.
3. Confirm that the SENSOR key switch and the MOTOR POWER switch are in the OFF
position.
4. Ensure that the LaserViewer™USB Key is in a USB port.
5. Turn the LP-4210F™ ON, and double-click the LaserViewer icon on the desktop.
6. Click the System Setup tab.
7. Verify that the workspace name is correct. If not, click the Open Workspace button and
click on the correct workspace for the application (Figure 3).
8. Turn the SENSOR key switch on for at least 5 minutes before proceeding with
calibration. This allows the internal electronics to warm up and will minimize any
temperature-related drift in calibration.
Figure 3. System Setup Tab

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System Settings
Open the System Settings window from the System Setup tab (Figure 3).
Note: The default settings are recommended. The System Settings window is intended
primarily for test purposes.
Laser Power
Automatic
This is the default setting. In Automatic mode, the laser is under control of an embedded laser
driver that is housed in the sensor module. In this mode the system employs Automatic Gain
Control (AGC), and the laser output will vary between 10% and 90% of full rated power,
depending on the surface reflectivity of the target.
Fixed
Fixed mode is Manual Gain Control (MGC). In Fixed mode the Laser Intensity buttons control
the laser output power, and the Gain buttons control the amplification (gain) of the normalized
analog voltage signal from the sensor.
Laser Intensity
The Laser Intensity buttons control the laser output power in Fixed mode. The Low, Med, and
High settings typically correspond to 20%, 50% and 100% of full rated power, respectively. The
precise laser power output for each setting is set by the manufacturer.
Gain
The Gain buttons control the amplification (gain) of the normalized analog voltage signal from
the sensor. Each interval of Gain (1, 2, 5, 10, 20, 50, 100) is the factor by which the LVI signal
increases.
Null
The Null button is used to balance the amplifier offsets for individual sensors. This button is
used primarily for testing, as the sensor will auto-null before scans.
Figure 4. System Settings