Optical dimensions LASER 5872C User manual

5872C Manual Version 5_4
LASER
CHECK



Surface Roughness
Measurement Gages
OPTICA
L
DIMENSIONS
LLC
®
1 3 7 E a s t A l t o n , S u i t e B
S a n t a A n a , C A 9 2 7 0 7
P H O N E : 7 1 4 - 6 6 8 - 9 1 1 5
F A X : 7 1 4 - 6 6 8 - 9 1 1 9
i n f o @ o p t i c a l d i m e n s i on s . c o m
w w w . o p t i c a l d i m e n s i o n s . c o m
®

LASER
CHECK






, , and Optical D i m e n s i o n s
LLC

are Registered Trademarks of Optical
Dimensions, LLC. The information in this document is provided as an aid in
the Assembly, Diagnostics, and Operation of the Lasercheck Gage, Components, and Accessories and is not
to be used otherwise or reproduced without written consent of Optical Dimensions, LLC. The Lasercheck
gage is patented technology protected under US Patent Number 5,608,527.
OPTICAL DIMENSIONS
LLC
®
1 3 7 E a s t A l t o n , S u i t e B
S a n t a A n a , C A 9 2 7 0 7
P H O N E : 7 1 4 - 6 6 8 - 9 1 1 5
F A X : 7 1 4 - 6 6 8 - 9 1 1 9
i n f o @ o p t i c a l d i m e n s i o n s . c o m
w w w . op t i c a l d i m e n s i o n s . c o m
®

i
TABLE OF CONTENTS
PERFORMANCE SPECIFICATIONS ...................................................................................................... 1
S TORAGE C OMPUTER R EQUIREMENTS ......................................................................................................... 1
O THER F EATURES ....................................................................................................................................... 1
SAFETY ........................................................................................................................................................ 2
E LECTRICAL ................................................................................................................................................ 2
L ASER ......................................................................................................................................................... 2
WARRANTY ................................................................................................................................................ 3
LIMITATION OF WARRANTY............................................................................................................... 3
C USTOMS S TATEMENT FOR R ETURNING L ASERCHECK E QUIPMENT TO O PTICAL D IMENSIONS .................... 3
MAINTENANCE ......................................................................................................................................... 4
C LEANING THE W INDOW ............................................................................................................................. 4
A SSISTANCE ................................................................................................................................................ 4
INTRODUCTION TO LASERCHECK..................................................................................................... 5
O VERVIEW .................................................................................................................................................. 5
SETTING UP THE INSTRUMENT........................................................................................................... 6
U NPACKING L ASERCHECK ........................................................................................................................... 6
B ASIC C ONNECTIONS C ONTROL B OX .......................................................................................................... 6
Physical Mounting.................................................................................................................................. 7
Mounting Holes .................................................................................................................................. 7
S OFTWARE S ETUP ........................................................................................................................................ 8
To Install Lasercheck Software from Windows 98, 2000, NT, or ME .................................................... 8
BASIC OPERATION USING CONTROL BOX PUSHBUTTONS ........................................................ 9
T URNING THE S YSTEM O N ........................................................................................................................... 9
Main Screen............................................................................................................................................ 9
C ONTROL U NIT AND D ISPLAYS .................................................................................................................... 9
LCD Screen ............................................................................................................................................ 9
LCD Push Buttons .................................................................................................................................. 9
Highlighting...................................................................................................................................... 10
If Controller Does Not Respond to Pushbuttons............................................................................... 10
PERFORMING MEASUREMENTS ....................................................................................................... 11
O PERATION U SING W INDOWS S OFTWARE ................................................................................................. 11
Control Box Setup File ......................................................................................................................... 11
Initiating a Measurement ..................................................................................................................... 11
Starting Software .............................................................................................................................. 11
Entering the Setup Module ............................................................................................................... 12
Setup for Lab System........................................................................................................................ 12
Changing the Display Control of the Setup File ............................................................................... 12
M ANUAL O PERATION ................................................................................................................................ 13
Perform Measurements Module ........................................................................................................... 13
Measure Menu.................................................................................................................................. 13
Return ........................................................................................................................................... 14
Start .............................................................................................................................................. 14
Stop............................................................................................................................................... 14
Sequence....................................................................................................................................... 14
Save .............................................................................................................................................. 14

ii
Export ........................................................................................................................................... 15
A UTOMATED O PERATION .......................................................................................................................... 16
Numerous Continuous Measurements / Roll Grinding......................................................................... 16
Setting up Windows Software for External Inputs............................................................................ 16
Automatic Parameters for Automatic Start, Stop and Save Options................................................. 16
Individual Parts / Parts Inspection....................................................................................................... 18
Setting up Windows Software for External Inputs............................................................................ 18
Automatic Parameters for Automatic Start, Stop and Save Options................................................. 18
“Start” and “Stop” Sensor Wiring Inputs............................................................................................ 20
Triggering a measurement externally................................................................................................... 20
BEYOND THE BASICS ............................................................................................................................ 20
LASERCHECK ALIGNMENT PRINCIPLES AND PROCEDURES.................................................. 21
H OW D OES L ASERCHECK W ORK ?............................................................................................................. 21
A LIGNMENT ............................................................................................................................................... 22
Vertical ................................................................................................................................................. 22
Horizontal............................................................................................................................................. 23
Directional / Rotational........................................................................................................................ 23
M EASURE /H EADTEST D IALOG B OX ........................................................................................................... 24
Measure/Headtest Screen A.................................................................................................................. 24
Measure/Headtest Screen B.................................................................................................................. 25
M EASURE /A LIGN D IALOG B OX ................................................................................................................. 26
Horizontal Alignment with Measure/Headtest or Measure/Align ........................................................ 26
VERIFYING ALIGNMENT PROCEDURES ......................................................................................... 27
S ET H EAD C LOSE C ORRECT P OSITION ....................................................................................................... 27
A LIGN H ORIZONTALLY .............................................................................................................................. 27
A LIGN V ERTICALLY ................................................................................................................................... 27
V ERIFY A LIGNMENT .................................................................................................................................. 27
AIR KNIFE/SQUEEGEE ACCESSORIES ............................................................................................. 28
APPENDIX - SETUP FILES..................................................................................................................... 30
S ETUP FILE FORMAT ................................................................................................................................... 30
FILENAME........................................................................................................................................... 30
START_INPUT ..................................................................................................................................... 30
RA_UNITS ............................................................................................................................................ 30
RA_THRESHOLD ................................................................................................................................ 30
CALIBRATION ..................................................................................................................................... 30
APPENDIX - CALIBRATION PROCEDURES ..................................................................................... 31
I NSTRUCTIONS FOR USING THE S ETUP F ILE AND C ALIBRATION T EMPLATE . XLS ......................................... 31
Smooth and Rough Mode ..................................................................................................................... 31
Smooth Mode Measurements ........................................................................................................... 31
Rough Mode Measurements ............................................................................................................. 31
Calibration Spreadsheet....................................................................................................................... 31
Statistics and Accuracy......................................................................................................................... 32
Instructions for using the Setup File and Calibration Template.xls .................................................. 32
Step 1 Enter Ra Values................................................................................................................. 32
Stylus and Lasercheck Ra Values ............................................................................................. 33
Filename =................................................................................................................................ 34
Control =................................................................................................................................... 34
Units = ...................................................................................................................................... 34
Cal Type = ................................................................................................................................ 34

iii
Step 2 Mid Range ......................................................................................................................... 34
Adjust Max “X Value” / Adjust Min “X Value” ...................................................................... 34
Adjust Slope ............................................................................................................................. 35
Raise / Lower Curve ................................................................................................................. 35
Step 3 High Range........................................................................................................................ 35
Adjust Intercept ........................................................................................................................ 35
Adjust Exponential ................................................................................................................... 35
Step 4 Low Range......................................................................................................................... 35
Adjust Exponential ................................................................................................................... 36
Step 5 Review............................................................................................................................... 36
Step 6 Export Setup File............................................................................................................... 37
Export “File Transfer” or “Manual Input” Setup File............................................................... 38
Typical “File Download” Calibration Setup File...................................................................... 38
Typical “Manual Input” Calibration Setup File........................................................................ 38
Calibration Coefficients........................................................................................................ 38
Break Points.......................................................................................................................... 38
Threshold.............................................................................................................................. 39
RA_UNITS........................................................................................................................... 39
APPENDIX - INPUT AND OUTPUT PINOUTS .................................................................................... 40
I NPUT : 9-P IN F EMALE D- SUB C ONNECTOR ................................................................................................ 40
Internal Opto relay:.............................................................................................................................. 40
Trigger pins:......................................................................................................................................... 40
Power pins:........................................................................................................................................... 40
Internal Opto relay Schematic: ............................................................................................................ 40
Typical Wiring Example:...................................................................................................................... 41
1) Using Unpowered Switches for inputs:................................................................................. 41
2) Using Powered Triggering Device (e.g. Proximity Sensors) for Inputs:............................... 41
Recommended Proximity Sensor Specifications: ......................................................................... 41
O UTPUT : 9-P IN F EMALE D- SUB C ONNECTOR ............................................................................................ 42
1) Output Schematic Ra_Limit...................................................................................................... 42
a) Normal State – Surface Within Ra_Limit – in Spec ................................................................. 42
b) Surface Outside Ra_Limit – out of Spec............................................................................... 42
2) Output Schematic Analog_Out ................................................................................................. 42
a) 0-10V........................................................................................................................................ 42
b) 4-20mA................................................................................................................................. 42
APPENDIX - FILE MANAGEMENT ...................................................................................................... 44
F ILE S YSTEM W INDOW .............................................................................................................................. 44
Send Command..................................................................................................................................... 44
Receive Command ................................................................................................................................ 45
Delete Command .................................................................................................................................. 45
Reset Command .................................................................................................................................... 46
Exit Command ...................................................................................................................................... 46
S ETUP F ILES .............................................................................................................................................. 46
Creating Setup Files............................................................................................................................. 46
APPENDIX - UPGRADING CONTROLLER SOFTWARE................................................................. 47
P REPARE C ONTROLLER ............................................................................................................................. 47
P REPARE C OMPUTER ................................................................................................................................. 47
P ERFORM T RANSFER ................................................................................................................................. 47
F INISH ....................................................................................................................................................... 48

1
Performance Specifications
Measurement / Detection Method Angle resolved laser scattering
Measurement speed Single measurement in < 0.5 seconds
Measurement range 1.00 µinch to 80 µinch / 0.012 µm to 2.0 µm
Repeatability ± 3.0% of measured value
Spot size (area-measured) 5 mm X 1 mm
Environmental considerations (temperature / humidity):
Operating -10ºC to +55º C / 10% to 90% RH
Storage -40ºC to +80º C / 1% to 99% RH
Power requirements 110 VAC, 50 / 60 HZ, 2.0 Amps max.
Storage Computer Requirements
Windows 98, 2000, NT, or ME
Available serial port
Other Features
Works on any material/color (rubber, glass, steel, etc.)
RS232 Interface to upload and store data
Input Triggering: Start, Stop, and Save Measurements
User Configurable Failed Part Trigger Output
User Configurable Analog (0-10 Volt or 4-20 mA Current Loop) Output
Stored and printed items:
Roughness Plot
Date and Time
Average Ra Roughness and Standard Deviation
Minimum / Maximum Ra Roughness
ASCII Formatted File
Individual Measurement Values

2
SAFETY
Electrical
Lasercheck has been designed as a sealed and enclosed system. Voltages to operate the measurement head
are low (0 to +5 Volts) to minimize shock hazard. A power supply in the control unit converts 110/220 Volt
AC from a wall receptacle to low regulated DC voltages that power the system. High voltages are present
and they are dangerous. Lasercheck should never be run with the control unit open as it exposes operators
to hazardous voltages.
Laser
At the corner of the control unit is a labeled laser on/off switch. Turning this to the on position provides
power to the internal laser. A red LED above the switch is illuminated when the laser is operational. The
laser used in Lasercheck is a class II laser device. Class II lasers are not considered hazardous to the skin
but are considered a “chronic viewing hazard”. Users should not stare directly into the beam or directly into
the beam reflected off a smooth specular surface. The ends of the Lasercheck measurement head have
“Caution” and “Avoid Exposure” labels to remind the operator to avoid exposure to the radiation. The head
also has “Identification” and “Certification” labels. The Lasercheck control unit also has”Identification” and
“Certification” labels. Reproductions of these labels are shown below.
Caution – use of controls or adjustments or performance or procedures other than those specified herein
may result in hazardous radiation exposure.
The measurement head emits a red visible (650-nm) laser beam pulsing at a 10 to 50 Hz. Each “pulse”
contains as much as 90 microjoules of energy. Pulses can be as short as a 5 millisecond interval, with 20
microsecond rise and fall times. Maximum “peak” power can be as high as 2.0 milliwatts. Average
maximum power being emitted from the laser can be as high as 900 microwatts. Once the beam strikes the
measurement surface, the laser energy is reflected back into the Lasercheck detection system. However,
multiple reflections and stray light may exit from between the head and measurement surface and care
should be taken to avoid direct eye exposure to the radiation.
Figure 1 – Typical Laser Identification and Warning Labels
       
              
        


   
  

CAUT
I
ON
DO NOT
STARE DIRECTLY INTO BEAM
LASER RADIATION
650 nm – 0.9 mW MAXIMUM OUTPUT
90 uJ per pulse @ 10 Hz
CLASS II LASER PRODUCT
CAUTION
LASER RADIATION
DO NOT STARE DIRECTLY INTO
BEAM
650 nm – 0.9 mW MAXIMUM OUTPUT
90 uJ per pulse @ 10 Hz
CLASS II LASER PRODUCT
O P T I C A L D I M E N S I O N S
137 East Alton, Suite B Model 5872
Santa Ana, CA 92707 Serial #
Mfg Date:
Complies with21 CFR 1040.10 and 1040.11
U.S. Patent No. 5,608,527
O P T I C A L D I M E N S I O N S
LLC
137 East Alton, Suite B Model 5872
Santa Ana, CA 92630 Serial #
Mfg Date:
Complies with 21 CFR 1040.10 and 1040.11
U.S. Patent No. 5,608,527
DO NOT STARE INTO BEAM
LASE
R
RADIA
TION
CLASS II LA
SER PRODUCT
650 nm – 0.9 mW MAXIMUM
AVERAGE OUTPUT
CAUTIO
N
AVOID EXP OSU RE
LASE R RADI ATI ON EMITTED
FROM THIS APERTURE


3
WARRANTY
Optical Dimensions, LLC certifies that the Model 5872 Lasercheck surface roughness measurement system
meets specifications. The Lasercheck system has a warranty period of 30 days, extended to one (1) year
upon receipt of full payment according to the terms specified on the invoice. This warranty is against
defects in material and workmanship. During the warranty period, Optical Dimensions will, at its option,
either repair or replace products, which prove to be defective.
LIMITATION OF WARRANTY
This warranty will not apply to defects resulting from improper or inadequate maintenance by Buyer (please
refer to Maintenance section), unauthorized modification or misuse, operation outside the environmental
specifications, improper site preparation or site maintenance, fire, flood earth movement or collapse.
Optical Dimensions shall not be liable for any direct, indirect, special, incidental or consequential damages,
whether based on contract, tort, or any other legal theory. No other warranty, whether expressed or implied,
will be valid.
For warranty service or repair, the Lasercheck system must be returned to Optical Dimensions, Santa Ana,
CA after prior authorization has been obtained from Optical Dimensions. Buyer shall prepay shipping
charges to Optical Dimensions. Optical Dimensions will pay shipping charges to return the Lasercheck
system to the Buyer.
Customs Statement for Returning Lasercheck Equipment to
Optical Dimensions
Overseas Buyers are to pay all shipping charges, taxes, and duties to Optical Dimensions. Optical
Dimensions will not pay customs and duties charges on returns. Returns must include required paperwork.
Incorrectly labeled and incorrectly prepared shipping and customs documents will result in delays to
equipment being returned to customer.
The following statement should be on all customs invoices and documents:
“The articles are manufactured in the United States. They were exported from the United States, from the
port of Los Angeles on or about (insert approximate month and year). They are being returned for (insert
the most appropriate statement below)”:
a) No charge warranty repair (or No charge warranty replacement).
c) Repair/service by manufacturer.
Also on the Air Waybill label there is usually a box for "Declared Value for Customs". If it is being
returned for a “no charge warranty”, list $O as value, AGR (American Goods Returned) in the box. Or to be
more clear "$0 - Warranty" if there is space in the box. If it is being returned for an out of warranty repair,
put $0 in that box. When we return it, $xx (the cost of the repair) will be on the paperwork. At that time,
any required duties on repair costs will be applied. On the International Waybill, mark under type of export
"RETURN" and "TEMPORARY". With that being done, it shouldn’t incur and DUTY charges but it still
may incur customs clearance fees
DO NOT put the original price of the instrument on any packing lists or shipping labels or customs
paperwork that accompanies the shipment. This can result in excessive duty charges being applied. Any
customs / duty charges will be charged to the customer.
Applying these statements, following these procedures and always using “no charge”, $0, or only the dollar
amount of the repair will help to avoid customs and duties fees being applied to the unit being returned for
repair or at least restrict customs and duties being applied to the value of the repair work or service only.

4
MAINTENANCE
Lasercheck has been designed and assembled by skilled and experienced engineers and technicians. All
components used in the system operate well within their rated specifications to ensure long life and
reliability of the Lasercheck system. Electronics, lasers, and detectors are all solid-state devices and should
not need to be serviced or maintained by the user.
The controller housing is made from impact-resistant ABS and is colored black. The housing is not
waterproof, but it can be subjected to moderate rain or splash without harm.
The laser head is made of machined aluminum and plastic and all electronics and optics are secured and
sealed within the head. The head is rugged enough to withstand handling that might be normally
encountered in manufacturing shop floor gage operation. The head is also water resistant and can be
subjected to moderate rain or splash without harm.
Boards and electronics used in the system are static sensitive and easily damaged by mishandling. The
Lasercheck housing and electronics are well grounded. The head is sealed at all seams and holes to protect
components from external contaminants. The user should not open the measurement head. If opened without
prior authorization by Optical Dimensions, the warranty provided by Optical Dimensions will be void.
Cleaning the Window
The internal optics and electronics are cleaned during assembly and kept within the sealed head. The
outside windows at the bottom of the Lasercheck head will be exposed to outside contaminants and should
be cleaned at least weekly with more frequent cleanings in very dirty environments. Dust and light visible
films will not affect Lasercheck performance on rougher surfaces, but on very smooth surfaces (1 to 2
µinches or smoother), even light films and dust can affect performance and should be cleaned off
frequently.
The windows are rugged, but care needs to be taken to not scratch them during operation or cleaning. They
should only be cleaned with ethanol, methanol, or a glass cleaner and a soft, clean paper towel, tissue, or Q-
tip.
Assistance
Optical Dimensions, LLC
137 East Alton, Suite B
Santa Ana, CA 92707
Tel: [phone]
Fax: [phone]
Email: [email protected]

5
INTRODUCTION TO LASERCHECK
Overview
Lasercheck is designed to perform high speed, accurate, non-contact measurements of surface roughness. A
built in visible laser diode emits a laser beam from the bottom of the gage illuminating the surface beneath
it. After striking the surface, the laser light is reflected and scattered back into the Lasercheck detection
system. The overall intensity and distribution of the reflected and scattered light is measured, digitized by
Lasercheck electronics, and then Ra roughness is calculated for the illuminated area. This Ra value is then
displayed on the LCD screen of the Lasercheck control unit. The Lasercheck Windows display and control
software can be used to display the real time Ra values in graphical and numeric format along with
statistical parameters.
Lasercheck has been designed for a nominal height standoff of 1.055 inch ±0.01 inches from the
measurement surface. Motions and vibrations within that tolerance range are monitored continuously and
reflectance and scatter distribution are normalized and corrected during every measurement cycle to ensure
accurate results. Surfaces are positioned 1.055 inches below the gage allowing non-contact measurements of
the surface to be made.
Measurements can be performed by manual pushbutton operation, or continuous high-speed measurements
controlled by Windows software, or fully automated high speed on-line measurements triggered by external
signals and the Windows software. At the end of a measurement sequence, the user is provided options for
performing additional measurements, saving the current measurements or exiting the measurement
sequence. When measurements are saved an ASCII file format can be created for reading into a variety of
spreadsheet and analysis software packages.