Optical dimensions Lasercheck 6212C 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
™
6212C Manual Version 15_22 Rev 07-19

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
™
Operations and Specification Manual for the
Lasercheck 6212C System
Manual Revision 15.22 Rev 07-19
© 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.

LASER
CHECK


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 6212C System .....................................................................................................................................................i
Manual Revision 15.22 Rev 07-19 ............................................................................................................................................ 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....................................................................................................................................................................7
J1 and J2 Communication Connections ..............................................................................................................................7
J3 and J4 Power Connections..............................................................................................................................................8
J7 IO (Input / Output) Connections.....................................................................................................................................8
Basic Operation ...................................................................................................................................................................9
Software Setup ........................................................................................................................................................................9
To Install Lasercheck Software from Windows...................................................................................................................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
™
Running the System using Lasercheck Windows Software.................................................................................................9
Comm. port Baud rate....................................................................................................................................................9
Turn on Lasercheck Windows Software .......................................................................................................................10
Set Comm Port on computer........................................................................................................................................10
Review or Create Lasercheck Setup Files on computer................................................................................................11
Perform Measurements ...............................................................................................................................................12
Physical Mounting .................................................................................................................................................................15
Manual Operation.............................................................................................................................................................15
Automated Operation.......................................................................................................................................................15
Numerous Continuous Measurements ........................................................................................................................16
Individual Parts / Parts Inspection................................................................................................................................17
Positioning Prox Sensors on Conveyor for Automated Inspection ..........................................................................17
Setup and Alignment.............................................................................................................................................................18
Message Type 15 ..............................................................................................................................................................18
Sample Setup and Alignment Aid from Message Type 15............................................................................................18
Performing Roughness Measurements .................................................................................................................................20
Message Type 02 ..............................................................................................................................................................20
Rough and Smooth Ra Value ........................................................................................................................................20
Common Error Codes ...................................................................................................................................................20
Max Detector................................................................................................................................................................20
Recommended Tests and Diagnostics ..............................................................................................................................20
Negative Ra Value.........................................................................................................................................................20
Low sum_voltages and “lv” Error Code ........................................................................................................................20
Appendix A –Lasercheck Alignment Principles and Procedures.........................................................................................22
How Does Lasercheck Work? ................................................................................................................................................22
Alignment ..............................................................................................................................................................................23
Vertical..............................................................................................................................................................................23
Vertical Alignment Base plate ......................................................................................................................................24
Horizontal .........................................................................................................................................................................25
Cylindrical Surface Measurement Alignment Fixture...................................................................................................26
Bore ID Surface Measurement Alignment Fixture........................................................................................................27
Directional / Rotational.....................................................................................................................................................27
Custom Shapes and Fixturing ................................................................................................................................................28
3-Dimensional Shapes.......................................................................................................................................................28
Small Surfaces...................................................................................................................................................................29
Checking Alignment Using the Lasercheck Diagnostics Option...........................................................................................30
1) Prepare Software to Receive Alignment Measurement...........................................................................................30

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
™
2) Prepare Sample and Fixture .....................................................................................................................................30
3) Perform Measurement.............................................................................................................................................30
4) Save Measurement Data for Input to Lasercheck Align Graph.xls Spreadsheet ......................................................31
5) Graphing the Lasercheck Data Measurements in Excel Spreadsheet ......................................................................31
5) Determining Alignment using the Lasercheck Alignment Graph Excel Spreadsheet ...............................................32
Vertical Alignment....................................................................................................................................................32
Horizontal Alignment ...............................................................................................................................................32
Notes to Using the Lasercheck Diagnostics Option for Alignment...............................................................................33
Vertical Alignment....................................................................................................................................................33
Horizontal Alignment ...............................................................................................................................................34
Recommended Alignment Diagnostics..................................................................................................................................34
Verifying Alignment Procedures .......................................................................................................................................34
Set Head Close to Correct Position...............................................................................................................................34
Align Horizontally .........................................................................................................................................................34
Align Vertically..............................................................................................................................................................34
Verify Alignment...........................................................................................................................................................35
Appendix B –Mounting/Fixturing Lasercheck....................................................................................................................36
Existing Mounting Holes on Lasercheck Sensor.....................................................................................................................37
Appendix C - Calibration Procedures..................................................................................................................................38
Theory - Measurement and Calibration ................................................................................................................................38
Measurement of Roughness.............................................................................................................................................38
Requirement for Calibration of Lasercheck to Specific Machining Operation..................................................................39
Base Calibration ....................................................................................................................................................................40
Overview of Calibration Process............................................................................................................................................40
Appendix D –Communication Protocol .............................................................................................................................41
Message Types: .....................................................................................................................................................................42
@02 Request Ra Value......................................................................................................................................................42
Response Details: .........................................................................................................................................................42
@03 Request Ra Value......................................................................................................................................................43
Response Details: .........................................................................................................................................................44
@04#<cr-lf> Specular Values Request ..............................................................................................................................45
@05 Request Ra Value......................................................................................................................................................45
Response Details: .........................................................................................................................................................46
@07<cr-lf> Set/Query Failed Part Operation...................................................................................................................46
Set xx subfunctions.......................................................................................................................................................47
@10#<cr-lf> Laser on Voltages: used to request just laser on voltages. Only for testing purposes................................47
@11#<cr-lf> Convert Light & subtract Dark, correct and send processed voltages .........................................................47

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
™
@15<cr-lf> Combine Cmd 11, 02, and 04 .........................................................................................................................48
@20,xx#<cr-lf>, Set/Query baud rate...............................................................................................................................48
@21#<cr-lf>, Query Revision Number..............................................................................................................................48
@22,xx,vvv#<cr-lf> Set/Query Configuration Values........................................................................................................49
Set Values .....................................................................................................................................................................49
Query Values ................................................................................................................................................................49
@23,xxxxx#<cr-lf>, Set/Query Head Serial Number .........................................................................................................50
@26,b,xxx.xxV#<cr-lf>, Set/Query resistor values............................................................................................................50
@29,xx,vv.vv#<cr-lf> Set/Query Ra Calibration Values ....................................................................................................51
Appendix E –Wiring and Dimensions American and Metric Versions ................................................................................52

6212C Manual Version 15_22 Rev 07-19.docx
Page 1 of 53
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
7 to 18 VDC
Other Features
Factory Calibrated to Ra Ground Surface Standards
Works on any material/color (rubber, glass, steel, etc.)
ASCII format Serial Communication via RS232 Interface
Ability for external triggering / remote control

6212C Manual Version 15_22 Rev 07-19.docx
Page 2 of 53
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
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

6212C Manual Version 15_22 Rev 07-19.docx
Page 3 of 53
WARRANTY OVERVIEW
Optical Dimensions certifies that the Lasercheck surface roughness measurement system meets specifications.
The Lasercheck system has a warranty period of one (1) year from date of first usage. 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. For detailed warranty information, refer to second page
of this manual.
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.
For warranty service or repair, the Lasercheck system must be returned to Optical Dimensions, after prior
Return Material Authorization Number (RMA #) has been obtained. Buyer shall prepay shipping charges to
Optical Dimensions. The return shipment should be labeled with the RMA #.
Contact Optical Dimensions customer service for shipping instructions:
OPTICAL DIMENSIONS
2973 Harbor Blvd, #665
Costa Mesa, CA 92626
Phone: [phone]
Email: [e-mail]

6212C Manual Version 15_22 Rev 07-19.docx
Page 4 of 53
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 by non-
authorized personnel, the warranty provided by Optical Dimensions will be void.
Cleaning the Windows
The internal optics and electronics are cleaned during assembly and kept within the sealed sensor. The internal
windows at the bottom of the Lasercheck sensor cover and protect the internal sensors and laser source. They
will be exposed to outside contaminants and in very dirty environments should be cleaned at least weekly.
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
Contact your nearest Optical Dimensions office.