Optical dimensions LASER CHECK 6212A User manual

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
LASER
CHECK

Surface Roughness
Measurement Gages
™
6212A Manual Version 14.56

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™

LASER
CHECK

Operations and Specification Manual for the
Lasercheck 6212A System
Revision 14.56
© Optical Dimensions
and Optical D i m e n s i o n s are Registered Trademarks of Optical
Dimensions. 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.
The Lasercheck gage is patented technology protected under US Patent Number 5,608,527.

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
Contents
Operations and Specification Manual for the .......................................................................................................................i
Lasercheck 6212A System .....................................................................................................................................................i
Revision 14.56 .......................................................................................................................................................................... i
© Optical Dimensions .............................................................................................................................................................. i
PERFORMANCE SPECIFICATIONS..........................................................................................................................................1
Other Features.........................................................................................................................................................................1
SAFETY.................................................................................................................................................................................2
Electrical ..................................................................................................................................................................................2
Laser ........................................................................................................................................................................................2
WARRANTY OVERVIEW .......................................................................................................................................................3
LIMITATION OF WARRANTY .................................................................................................................................................... 3
Contact Optical Dimensions customer service for shipping instructions: ................................................................................3
MAINTENANCE ....................................................................................................................................................................4
Cleaning the Windows.............................................................................................................................................................4
Assistance................................................................................................................................................................................4
INTRODUCTION TO LASERCHECK .........................................................................................................................................5
Overview.................................................................................................................................................................................. 5
Setting up the Instrument....................................................................................................................................................6
Unpacking Lasercheck ............................................................................................................................................................. 6
Basic Connections Control Box ................................................................................................................................................ 7
Physical Mounting ...................................................................................................................................................................8
Mounting/Fixturing Lasercheck .......................................................................................................................................... 8
Software Setup ........................................................................................................................................................................9

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
To Install Lasercheck Software............................................................................................................................................9
Basic Operation Using Control Box Pushbuttons................................................................................................................10
Turning the System On ..........................................................................................................................................................10
Main Screen ......................................................................................................................................................................10
Control Unit and Displays ......................................................................................................................................................10
LCD Screen ........................................................................................................................................................................ 10
LCD Push Buttons..............................................................................................................................................................11
Highlighting ....................................................................................................................................................................... 11
If Controller Does Not Respond to Pushbuttons .......................................................................................................... 12
Performing Manual Measurements ......................................................................................................................................13
Choose a Setup File........................................................................................................................................................... 13
Measure Window with Results ......................................................................................................................................... 13
Saving a Measurement .....................................................................................................................................................13
File Management ..................................................................................................................................................................14
File System Window..........................................................................................................................................................14
Send Command.................................................................................................................................................................14
Preparing Windows Software to receive files ..............................................................................................................14
Sending Measurement Data from the Lasercheck Controller ......................................................................................15
Receive Command ............................................................................................................................................................15
File Naming...................................................................................................................................................................15
Preparing Control Box to receive files ..........................................................................................................................15
Sending Setup Data with the Windows Software.........................................................................................................16
New Cal Command............................................................................................................................................................16
Delete Command ..............................................................................................................................................................16
Reset Command................................................................................................................................................................17

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
Exit Command...................................................................................................................................................................17
Data Files:.............................................................................................................................................................................. 18
Sample Data File ...............................................................................................................................................................18
Advanced Operations ........................................................................................................................................................19
Operation Using Windows Software .....................................................................................................................................19
Control Box Setup .............................................................................................................................................................19
Starting Windows Software ..............................................................................................................................................19
Entering the Setup Module............................................................................................................................................... 19
Setup Options ...................................................................................................................................................................20
Select the Communications Port ..................................................................................................................................20
Select Automation Types.............................................................................................................................................. 21
Setup for Lab System ...............................................................................................................................................21
Setup for Continuous Measurements / Roll Grinding ..............................................................................................21
Set up for Individual Parts / Parts Inspection........................................................................................................... 22
Create New Lasercheck Windows Setup Files ..............................................................................................................22
Controller Setup Files ...............................................................................................................................................24
Creating Controller Setup Files ................................................................................................................................24
Open Lasercheck Windows Setup Files ........................................................................................................................ 24
Automatic.................................................................................................................................................................26
Save Parameters ......................................................................................................................................................26
Software Manual Operation .............................................................................................................................................28
Perform Measurements Module ..................................................................................................................................28
Measure Menu......................................................................................................................................................... 30
Start .....................................................................................................................................................................31
Stop......................................................................................................................................................................31

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
Sequence .............................................................................................................................................................31
Save......................................................................................................................................................................31
Export...................................................................................................................................................................32
Return ..................................................................................................................................................................32
Automated Operation.......................................................................................................................................................32
“Start” and “Stop” Sensor Wiring Inputs......................................................................................................................34
Appendix A –Lasercheck Alignment Principles and Procedures.........................................................................................35
How Does Lasercheck Work? ................................................................................................................................................ 35
Alignment .............................................................................................................................................................................. 36
Vertical..............................................................................................................................................................................36
Vertical Alignment Base plate ......................................................................................................................................37
Horizontal ......................................................................................................................................................................... 38
Cylindrical Surface Measurement Alignment Fixture ...................................................................................................39
Bore ID Surface Measurement Alignment Fixture........................................................................................................ 40
Directional / Rotational..................................................................................................................................................... 40
Custom Shapes and Fixturing ................................................................................................................................................41
3-Dimensional Shapes.......................................................................................................................................................41
Small Surfaces ...................................................................................................................................................................42
Measure/Headtest Dialog Box .............................................................................................................................................. 43
Measure/Headtest Screen A .............................................................................................................................................43
Measure/Headtest Screen B .............................................................................................................................................44
Measure/Align Dialog Box..................................................................................................................................................... 45
Horizontal Alignment with Measure/Align .......................................................................................................................45
Verifying Alignment Procedures ........................................................................................................................................46
Set Head Close Correct Position ............................................................................................................................................46

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
Align Horizontally ..................................................................................................................................................................46
Align Vertically ......................................................................................................................................................................46
Verify Alignment.................................................................................................................................................................... 46
Appendix B –Mounting/Fixturing Lasercheck....................................................................................................................47
Existing Mounting Holes on Lasercheck Sensor.....................................................................................................................48
Appendix C - Setup Files.....................................................................................................................................................49
Setup file format.................................................................................................................................................................... 49
RECEIVE_NAME.................................................................................................................................................................49
FILENAME..........................................................................................................................................................................49
START_INPUT .................................................................................................................................................................... 49
MEAS ............................................................................................................................................................................49
SERIAL ...........................................................................................................................................................................49
EXTERNAL1 ...................................................................................................................................................................49
RA_UNITS ..........................................................................................................................................................................49
RA_LIMITS .........................................................................................................................................................................50
ANALOG_OUTPUT.............................................................................................................................................................50
LOW_ANALOG .............................................................................................................................................................. 50
HIGH_ANALOG ............................................................................................................................................................. 50
Jumper Settings for Setting Analog Output to 4-20 mA or 0-10 V ...........................................................................50
RA_THRESHOLD ................................................................................................................................................................ 50
CAL_TYPE ..........................................................................................................................................................................50
CALIBRATION ....................................................................................................................................................................50
Default.set setup files............................................................................................................................................................50
Appendix D - Calibration Procedures .................................................................................................................................51
Theory - Measurement and Calibration ................................................................................................................................ 51

OPTICAL DIMENSIONS™
2973 Harbor Blvd, #665, Costa Mesa, CA 92626
Phone: [phone]
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 . o p t i c a l - d i m e n s i o n s . c o m
™
Measurement of Roughness.............................................................................................................................................51
Requirement for Calibration of Lasercheck to Specific Machining Operation..................................................................52
Base Calibration .................................................................................................................................................................... 53
Overview of Calibration Process............................................................................................................................................53
Appendix E –Input and Output Pinouts.............................................................................................................................54
Input: 9-Pin Female D-sub Connector....................................................................................................................................54
Internal Opto relay:........................................................................................................................................................... 54
Trigger pins: ...................................................................................................................................................................... 54
Power pins: .......................................................................................................................................................................54
Internal Opto relay Schematic: .........................................................................................................................................55
Typical Wiring Example:....................................................................................................................................................55
1) Using Unpowered Switches for inputs:................................................................................................................55
2) Using Powered Triggering Device (e.g. Proximity Sensors) for Inputs:................................................................ 56
Recommended Proximity Sensor Specifications: ..................................................................................................... 56
Output: 9-Pin Female D-sub Connector.................................................................................................................................57
1) Output Schematic Ra_Limit......................................................................................................................................57
a) Normal State –Surface Within Ra_Limit –in Spec ..............................................................................................57
b) Surface Outside Ra_Limit –out of Spec...............................................................................................................57
2) Output Schematic Analog_Out ................................................................................................................................ 58
a) 0-10V....................................................................................................................................................................58
b) 4-20mA ................................................................................................................................................................58

6212A Manual Version 14.56.docx
Page 1 of 58
PERFORMANCE SPECIFICATIONS
Measurement / Detection Method
Angle resolved laser scattering
Measurement speed
Single measurement in < 0.5 seconds
Measurement range
0.5 µinch to 40 µinch / 0.0125 µm to 1.0 µm
Repeatability
± 3.0% of measured value
Spot size (area-measured)
5 mm X 1 mm
Environmental considerations (temperature / humidity):
Operating
-10º C to +55º C / 10% to 90% RH
Storage
-40º C to +80º C / 1% to 99% RH
Power requirements
110 / 220 VAC, 50 / 60 Hz
Other Features
Factory Calibrated to Ra Ground Surface Standards
Works on any material/color (rubber, glass, steel, etc.)
RS232 Interface Option
Stored items:
All Roughness Values
Date and Time
Average Ra Roughness and Standard Deviation
Minimum / Maximum Ra Roughness
CSV text Formatted File

6212A Manual Version 14.56.docx
Page 2 of 58
SAFETY
Electrical
Lasercheck has been designed as a sealed and enclosed system. Voltages to operate the measurement sensor
are low (0 to +5 Volts) to minimize shock hazard.
Laser
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 sensor have “Caution”
and “Avoid Exposure” labels to remind the operator to avoid exposure to the radiation. The sensor 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 sensor 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 sensor and measurement surface and care should be taken to avoid direct eye
exposure to the radiation.
Typical Laser Identification and Warning Labels
Optical Dimensions
2973 Harbor Blvd #665
Costa Mesa, CA 92626
Mfg Date:
Serial #
Complies with 21 CFR
1040.10 and 1040.11
U.S. Patent No. 5,608,527
Model 6212
TM
CAUTION
DO NOT STARE INTO BEAM
LASER RADIATION
CLASS II LASER PRODUCT
650 nm –0.9 mW MAXIMUM
AVERAGE OUTPUT
AVOID EXPOSURE
Laser Radiation Emitted
From This Aperture