Metrologic M20-EPS User manual

METROLOG CONTROLES DE MEDIÇÃO LTDA
RUA SETE DE SETEMBRO,2656 –CENTRO –SÃO CARLOS –SP –BRASIL
TEL:[phone]
WWW.METROLOG.NET –[e-mail]
Fusion Strength Tester
M20-EPS
User Guide

Metrolog M20-EPS
User guide / Technical document (CE)
Version 2.3
Compatible with Metrolog Fusion Tester M20-EPS firmware v2.1 b0002+

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Safety Information
1. Read all manual before using this equipment.
2. Turn it off before cleaning; use only slightly wet cloth for cleaning.
3. Do not install it close to heavy machinery with exposed running liquids.
4. Do not install it over irregular surfaces.
5. Do not install it near strong heat sources.
6. Please check proper supply voltage before connecting to an AC outlet. If
proper voltage not available please contact technical personnel.
7. To install or remove a connector hold firmly by its body. Never pull or apply
force by the cable.
8. This equipment is supplied with a three pin power cable. The third pin,
ground connection, must be properly connected. Do not damage the cable
or try to force the cable into an incompatible outlet.
9. Except when described on this manual, do not try to repair this equipment.
Opening it without the proper training and knowledge can lead to electrical
accidents. Please inquire Metrolog about troubleshooting and preventive
maintenance.
10. The equipment uses a pressurized needle to take measurements. Improper
use of the instrument can result in serious injury. Carefully review the
guidelines in section 2. Equipment placement and safety information.

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11. Unplug the equipment and send it for repairs if one of these situations
occur:
A. Cables were damaged or show burning/melting marks;
B. It was exposed or submersed in liquid;
C. It was exposed to the weather/rain;
D. It does not perform as described on this manual;
E. Damage to its enclosure was detected due to accidental fall or
misuse.
CAUTION
RISK OF ELECTRICAL SHOCK
DO NOT OPEN
WARNING: TO AVOID EXPOSURE TO ELECTRICAL SHOCK DO NOT
REMOVE OR OPEN THE EQUIPMENT ENCLOSURE.
INSIDE THE DEVICE THERE IS NOT ANY COMPONENTS THAT CAN BE
REPLACED OR REPAIRED BY THE USER. REPAIRS MUST BE
CONDUCTED ONLY BY QUALIFIED TECHNICIANS.
CAUTION
RISK OF INJURY DUE TO
PIERCING COMPONENT
WARNING: THE EQUIPMENT USES A PRESSURIZED NEEDLE TO TAKE
MEASUREMENTS. THE GUIDELINES PRESENTED IN THIS MANUAL MUST
BE CAREFULLY OBSERVED BEFORE USING THE EQUIPMENT, UNDER
THE RISK OF SERIOUS INJURY.

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Warranty
This equipment has a warranty of 6 months from the invoice expedition date. During
this period it may be repaired without any part or labor costs.
This warranty will be void if detected damage results of misused, fall, mechanical
shock, incorrect cable connection, use by untrained personal, fire, floods or other
accidents.
Only Metrolog’s technical personnel will be eligible for analyzing any repair requests
and void warranty, if applicable.
All warranty repairs will be conduct at Metrolog laboratory. Customer is responsible
for shipment costs.
Information on this manual is subject to change without prior notice.

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EMC DECLARATION, REGULATIONS AND SAFETY
INFORMATION
Electrical Safety Checks
This unit is designed to comply with EN 61010-1 "Safety requirements for electrical
equipment for measurement, control and laboratory use". The specification complies with
the EU Directive 2014/35/EU and BR regulations NR-12 concerning low voltage electrical
safety.
This unit was checked for electrical safety during final quality checks, prior to
dispatch.
If the user wishes to carry out his own PAT tests (or similar standard test), the
following points must be followed:
•This Safety Class 1 apparatus has a PCB fixed low fuse rating (<3A), and a low
current rated power connection cable.
•It is recommended that when carrying out an earth bond test (EN 61010-1,
Section 6), the test current of 25A should not be applied for more than six
seconds.
•In general it is not recommended that high voltage (e.g. 1.5kV) insulation tests
are carried out (EN 61010-1, Section 6). This could cause damage to
suppresser components in the power supply.
EMC Compliance
This unit is designed to comply with EN61326-1 "EMC requirements for electrical
measurement equipment" and ABNT NBR IEC 61000-4-3:2022 "EMC compatibility”
For full EMC compliance, when automation signals are used, only shielded multi-core
cables should be used for connection to this unit; the cable shield to be terminated by
means of a short "pig-tail".
The metal rear panel should be used as a ground connection for all cable shields.
The panel is internally connected to the supply earth wire that must be connected to a
reliable ground. Cable shields to be earthed at only one end and routed away from any
obviously powerful sources of electrical noise, e.g. electric motors, relays, solenoids and
electrically noisy cables.

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Measuring instruments (MID) Compliance
Although the M20-EPS meter is a measuring device, is not directly covered by the
Directive 2014/32/EU " Measuring Instruments Directive (MID)" and other country
specific measuring instruments calibration standards.
The procedure that the equipment performs, based on an empirical study and
correlation with the usual "break and count" method, is to anchor the weldability index in
2 absolute masters: complete flow blockage (100% welded) and free flow (theoretical
null welded). These two absolute masters are embedded into the equipment design and
are used as the basis of the calibration process available in the equipment.
As an objective evaluation criterion, the strength index allows technical EPS parts to
be quickly categorized according to criteria previously defined by the user. Pilot parts are
typically subjected to mechanical stiffness tests, compression capacity, among other
analyses, have their local strength index evaluated and minimum limits are established
for subsequent batch approval / disapproval. The certification must occur in the usual
engineering tests and subsequent correlation applied to the equipment's measurements.
Consult section 3. Basic measurement principles for details.
Pressure equipment and piercing Injury Safety Notes
In the absence of specific regulations regarding the use of air pressured needles
associated with industrial devices, Directive 2010/32/EU "Prevention from sharp injuries
in the hospital and healthcare sector", BR standard NBR NR-32, Directive 2014/68/EU
"Pressure equipment”, and BR standard NBR NR-13 have guidelines that can be
adapted and applied to identify and prevent accidents related to the handling and use of
the AG20 air pressurized needles. Please review the guidelines presented in section 2.4
– Safety guidelines while using the AG20 before using the M20-EPS.

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Summary
I. TECHNICAL SPECIFICATIONS ................................................................................................................................... 7
1. PANEL AND CONNECTORS....................................................................................................................................... 8
2. EQUIPMENT PLACEMENT AND SAFETY INFORMATION ................................................................................. 11
2.1 –INSTRUCTION AND SITE SELECTION ........................................................................................................................ 11
2.2 –COMPRESSED AIR SUPPLY ..................................................................................................................................... 12
2.3 –AG20 MEASUREMENT NEEDLE INSTALLATION ........................................................................................................ 13
2.4 –SAFETY GUIDELINES WHILE USING THE AG20........................................................................................................ 14
2.5 –REGULATIONS AND INJURIES PREVENTION ............................................................................................................. 15
3. BASIC MEASUREMENT PRINCIPLES .................................................................................................................... 18
3.1 –MEASUREMENT OF FUSION STRENGTH INDEX ........................................................................................................ 18
3.2 –CALIBRATION ROUTINE........................................................................................................................................... 19
3.3 –MEASUREMENT ROUTINE ....................................................................................................................................... 20
3.4 –DEEP MEASURING ................................................................................................................................................. 21
3.4.1 – Creation of guide holes.............................................................................................................................. 22
3.5 –STATISTICAL ANALYSIS........................................................................................................................................... 23
3.6 –TOLERANCE LIMITS ................................................................................................................................................ 24
3.7 –NEEDLE CLEAN UP AND AIR BLOCKAGE .................................................................................................................. 25
4 – DIGITAL I/O INTERFACES ...................................................................................................................................... 26
4.1 –USB/RS232 COMMUNICATION INTERFACE............................................................................................................. 26
4.1.1 – Connecting to a computer or data logger................................................................................................ 26
4.1.2 – Standard ASCII Protocol ........................................................................................................................... 27
4.1.3 – M20 Communication protocol ................................................................................................................... 28
4.2 –DIGITAL PARALLEL INTERFACE ............................................................................................................................... 30
4.2.1 – Digital interfaces working modes.............................................................................................................. 33
4.2.2 – PE-10 switch setup (optional component)............................................................................................... 36
5. DATA LOGGER ........................................................................................................................................................... 37
5.1 –INTEGRATED DATA LOGGER ................................................................................................................................... 37
5.2 –DATA LOGGER SETUP AND USE.............................................................................................................................. 38
5.2.1 – Sample acquisition ..................................................................................................................................... 38
5.2.2 – Transmission of acquired data ................................................................................................................. 38
6. SPECIAL PROCEDURES........................................................................................................................................... 40
6.1 –USER PARAMETERS FACTORY RESET..................................................................................................................... 40
6.2 –SECURITY RESTRICTIONS UNLOCK ......................................................................................................................... 41
6.3 –FIRMWARE UPDATE ................................................................................................................................................ 42
7. INTERNAL PARAMETERS AND ROUTINES REFERENCE................................................................................. 43

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I. Technical Specifications
Readout
Bargraph - 101 multicolor leds (256,5 mm total length);
High contrast OLED display
2 lines, 16 characters per line;
6 auxiliary multicolor leds;
Side scale indication (bargraph top, central and base) with 3
numeric digits each.
Keyboard
Membrane keyboard with tactile and sound feedback,
composed by 15 keys (5 user programmable keys), for easy
parameter setup software use.
Readout
stabilization 133ms typical, with programmable digital filters.
Update rate
Bargraph: 16,6 ms;
LCD Display: 216 ms;
Digital output: 10 ms.
Tolerance limits Up to 3 configurable tolerance limits.
Zero adjustment

Automatic during calibration routine.
Display % readout, sample size, average and standard deviation.
Outputs
RS232: standard serial output for interface with
microcomputers, data collectors or automation equipment
(standard ASCII format);
USB (Universal Serial Bus);
10-bit I/O for interface with PLCs or other automation
equipment.
Sensor input 
Quick-fit pneumatic port for measurement needle (6mm OD
hose)
Compressed air
supply

Line pressure: 40 to 110 psi (2.7 to 10.2 bar)
Output pressure: 10 psi (0,75 bar), internally regulated
Typical flow: 1.25 cfm (35 l/min)
Power supply
90~240 VAC, 50-60Hz (5 VA) auto range.
Operational
temperature
Maximum: 45ºC
Minimum: 0ºC
Protection class
IP50
Weight
(base unit)
4.6 kg

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1. Panel and connectors
This section details each indicator, key and connectors available on the equipment
panels. Optional items, when available, are individually identified below.
Picture 1 – Frontal and rear panel of Metrolog M20-EPS Fusion Tester
















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OLED Display – 2 lines, 16 alphanumeric characters per line. Main textual
information and digital readout display.
Key : allow quick selection of readout information displayed in the LCD
during measurement process.
Bargraph:101 segment bar capable of displaying percentual information in
graphical form (multicolor points/segments).
Scale Displays:7 segment digits used to identify the bargraph scale. Top,
center and base indications.
Keyboard : set of 5 programmable
keys used to access
frequently required routines. (For configuration, access System parameters,
option Special keys (F1 thru F5)).
Main keyboard: Functions based on context:
During measurement mode:
Access calibration routine.
Needle clean up. If pressed during 3s, stops the air flow (standby mode).
Switch between available setups.
No function.
Enters configuration mode.
Discards last sample. If pressed during 3s, restarts data acquisition.
Trigger data transmission to the USB/RS232 ports.
During setup mode:
No function.
Zero set while editing numeric/alphanumeric field or revert to a standard
value.
Move between characters while editing numeric/alphanumeric field.
Menu navigation and character selection
while editing
numeric/alphanumeric field.
Access menu option or accept data entry (returning to menu navigation).
Return to parent menu (while in menu navigation) or discard data entry
(returning to menu navigation).
No function.
Auxiliary indication:user configurable leds to display tolerance overrun. (For
setup, access menu System parameters, option Auxiliary indication).

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Frontal pneumatic quick-fit: measurement needle port.
Digital I/O connector:DB25F connector with 10-bit input and 10-bit output
signal for integration with external hardware.
Identification label:model, serial number and basic power supply requirement
information.
Solenoid valves connector.
USB Interface:standard USB connector (type A) compatible with computers,
data collectors and PLCs. Allow data acquisition and remote command.
RS232 Interface:standard RS232C connector (DB9F) compatible with
computers, data collectors and PLCs. Allow data acquisition and remote
command.
On/Off switch.
Power cord outlet (standard 3-pin cable connection).
Compressed air inlet.

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2. Equipment placement and safety information
2.1 – Instruction and site selection
The Metrolog M20-EPS fusion tester has a robust case, designed for continuous floor
shop use; however, some simple guidelines should be followed to reduce maintenances:
•Place the equipment base over a flat and leveled surface.
•Avoid places with Strong vibration.
•Keep it away from liquids and strong magnetic fields.
•If possible secure the equipment base over the working bench (use available holes on
the base, as shown in Picture 2).
•Attach the solenoid valves cable to the upper back connector, as shown in Picture 3,
highlight A.
•Connect the equipment to a power outlet using the supplied power cord, as shown in
Picture 3, highlight B. The M20-EPS accept power supply from 90~240VAC, 50~60Hz
sinusoidal, without any additional setup. Make sure the ground connection is properly
connected to the power cord center pin.
Picture 2 – Securing equipment on
working bench
Picture 3 – Solenoid valves cable
connection and power cord connection.
IMPORTANT NOTE:
Special care must be taken before connecting the equipment to external
devices. Always use shielded cabled and EMI suppressor no minimize
interferences.

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2.2 – Compressed air supply
The M20-EPS requires compressed air supply to work. The connect must the made
using the back quick-fit connection (6mm OD hose), as shown below. Inlet air pressure
must be between 40 and 110 psi (2.7 to 10.2 bars).
Picture 4 – Compressed air
inlet port connection
Picture 5 – Measurement needle
connection port (DO NOT connect
to the compressed air network)
WARNING:
Apply clean and low humidity compressed air. Contamination by water
and/or oil will cause equipment malfunction. A 5µm particulate filter,
followed by a 0.01µm coalescent filter is recommended to remove any
residual contamination that may be present in the compressed air line;
Air filters are recommended;
NEVER use air lubrication system in the air supply;
Make sure all air connection is secure and leak-free.
For safety reasons, an emergency button for blocking the
compressed air supply must be available to the operator. Review the
safety guidelines described in this manual.

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2.3 – AG20 measurement needle installation
To install or replace the AG20-20 or AG20-50 needle, follow the steps
•Unpacking the AG20 needle, keeping protective cap;
•Connect the supplied hose to the AG20 quick fitting;
•Connect the other hose end to the M20-EPS Measurement needle connection
port, as highlighted below as D;
•Remove the AG20 cover cap with care and place the needle in the resting pad,
as highlighted below as E;
•Please note the quick fit connection highlighted below as Cis intended for the
compressed air supply
•Review the safety guidelines on this document before use.
Picture 6 – Installing AG20 measurement needle
The installation of the long needles (AG20-100 to AG20-1000) should be done
in a similar way. Check the safety and usage guidelines for long needles in sections 2.4
– Safety guidelines while using the AG20 and 3.4 – Deep Measuring before starting to
use them.

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2.4 – Safety guidelines while using the AG20
AG20 needles can be handled safely if a few basic precautions are taken:
•Always wear personal protective equipment, in particular gloves, safety goggles
and ear protection
•For the short-needle AG20 models (AG20-20 and AG20-50, 20mm and 50mm
respectively), the needle should always remain in the resting pad of the
equipment when:
- The equipment is not in use
- Before starting the calibration process
- Before using the needle cleaning function
•For the long-needle AG20 models (AG20-100 to AG20-1000) it is necessary to
install a special resting cradle, designed according to the customer's structure.
Manual use of the long needles is not recommended due to the danger of
moving a long piercing object. In these applications it is highly recommended
that the needle be incorporated into an automated insertion system. See section
3.4 – Deep Measuring for details.
For storage, always keep the protective cap over the needle.

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2.5 – Regulations and injuries prevention
Although designed for use on industrial shop floor and laboratories, the M20-EPS
meter employs the AG20 measuring needles as a penetration mechanism to inspect
inside the EPS parts.
The AG20 needles have highly sharp points that can cause serious or even fatal
accidents if not used properly.
In the absence of specific regulations regarding the use of air pressured needles
associated with industrial equipment, Directive 2010/32/EU "Prevention from sharp
injuries in the hospital and healthcare sector", BR standard NBR NR-32, Directive
2014/68/EU "Pressure equipment”, and BR standard NBR NR-13 have guidelines that
can be applied to identify and prevent accidents related to the handling and use of AG20
needles.
Based on these directives, the risk associated with the use of AG20 needles is known,
so the following guidelines must evaluated:
Assess the risk:
•Decide who might be harmed and how
•Check the work environment and working conditions and identify factors which
could increase the risk of a sharps injury, such as overcrowded conditions,
fatigue and poor ergonomics
Select appropriate controls and implement them. In particular:
Safety-engineered protection mechanisms
Since eliminating the use of the needle is not possible, the Regulations require that
where there is a risk of exposure to injury, the sharps must incorporate safety-
engineered protection mechanisms designed to prevents or minimize the risk of
accidental injury.
The M20-EPS includes a needle stand that should always be used when the
equipment is not in use or during the calibration and needle cleaning processes.
The creation of special guides, according to the part geometry and the regions to
be inspected, is also recommended, especially when using needles longer than
50mm.
Personal protective equipment
The Regulations require the employer to provide suitable personal protective
equipment for the employee at risk where there is a risk of injury from the use of
sharps. Protective gloves should be worn to minimize the risk of accidental puncture
during needle handling. It is worth noting that safety goggles and ear protectors
should be part of the personal protective equipment.

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Policies and procedures
The employer must have in place policies and procedures which take account of
the findings of the risk assessment and the control measures which are in place to
prevent or reduce the risk of sharps injuries. Policies should be reviewed at regular
intervals to ensure that they continue to be effective and up to date.
Information and awareness-raising
Providing health and safety information is a requirement. The Regulations build on
this requirement by ensuring that the information provided to employees includes
those matters listed below:
•Potential risks to health:
Severe Physical Injury
Improper use of compressed air can cause serious injuries, including loss of
vision, ruptured eardrums, and internal bleeding. In addition, a blast of air can
penetrate cuts and abrasions on the skin, inflating flesh and causing intense
pain or more serious injury.
Air Embolism
When compressed air penetrates the circulatory system, it can lead to the
formation of air bubbles that block blood circulation in the vessels. This
condition, known as an air embolism, is a medical emergency and can be fatal.
Particle Projection
Even at low pressures, compressed air can throw particles of metals or other
solid materials at extremely high velocities, turning them into dangerous
projectiles that can cause injury to the eyes and face.
Contamination by impurities
Compressed air can carry impurities such as particles of oil, grease and other
harmful substances. These impurities can be introduced into the skin or eyes,
increasing the risk of infection and illness.
•Precautions to prevent exposure;
•The steps to be taken by employees in the case of accidents and incidents;
•Guidance on existing legislation relating to the protection of employees at work
from the risks to health and safety from sharps;
•The importance of recording accidents and incidents involving sharps.

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Training:
The Regulations require the employer to provide training relating to risks from sharps
to employees who are exposed to the risks. The Regulations build on this requirement
by ensuring that the training provided includes those matters:
•The correct use of the device and associated sharps protection mechanisms;
•Preventive measures in accordance with the procedures in the workplace;
•Incident reporting and response procedures and their importance; and
•The measures to be taken in the case of injuries. This should include first aid
measures to be taken and where to seek any immediate further assistance.
Training must be repeated at regular intervals.
Reporting
The Regulations place a duty on employees to report to their employer or immediate
supervisor any accident or incident involving an exposure to the risk of injuries from
sharps.
This will ensure that an injured employee can receive the appropriate care and the
incident can be investigated with a view to preventing recurrence.
Review the local legislation requirements on this matter.
Response and follow up
The Regulations require the employer to have in place policies and procedures to be
followed in the event of sharps injury at work. They should include the immediate first
aid response, the arrangements in place for the care of the injured employee and the
reporting and investigation procedures.
The employer must investigate the reported accident or incident and take any
necessary remedial action to prevent recurrence. The purpose of the investigation
should be to establish whether the employer’s existing controls are adequate. It
should look at underlying causes as well as the immediate factors that led to the
incident

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3. Basic measurement principles
3.1 – Measurement of fusion strength index
The fusion strength index of expanded polystyrene (EPS) parts and other low density
expanded thermoplastics represents a localized percent of cells (or pearls) that
effectively fused to the adjacent cells. This index is function of several expansion process
variables, as well part geometry. Local cellular anisotropy also contributes to small
variation of this index. The fusion strength index can be used as an indirect measurement
of manufacture process parameters, allowing better comprehension of
dependence/Independence and correlation to specific quality control criteria.
As an objective criteria, the fusion strength index allow technical EPS parts to be
quickly categorized based on customer quality criteria. Prototype parts are usually
subjected to mechanical stiffness tests, compression capabilities, among other
laboratorial tests, and local fusion strength indexes are defined for later use on
approval/reproval of manufactured batches.
The M20-EPS measurement column uses an air to electronic principle to detect and
evaluate the fusion strength index of low density expanded thermoplastics. State of the
art signal conditioning and processing results in high measurement, stability, repeatability
and accuracy.
The measurement column uses two reference points (free air scape and total air
blockage) for calibration and measurement. During the measurement process the
measurement needle is inserted into the part body and a small air flux constriction is
detected. This change in the air flow is due the material cellular structure and represents
a value from 0% (minimal/null restriction) and 100% (maximum/blockage restriction).
Technical EPS parts usually show local fusion strength index over 60%.