Manual Versatil BE056C

BACK END GAUGING
SYSTEM
BE056C
Operation, Calibration and Servicing

Manual Version 1, Revision E
BE056C - BACK END GAUGING SYSTEM 1
Warning
WARNING
THIS EQUIPMENT CONTAINS HAZARDOUS MAINS
VOLTAGES, HIGH PRESSURE AIR AND POSSIBLE
CRUSHING FORCES
PLEASE FOLLOW ALL VERSATILE TECHNOLOGY

INSTRUCTIONS AND ALL HEALTH AND SAFETY
DIRECTIONS IN YOUR WORKPLACE
DO NOT DEFEAT ANY GAUGE SAFETY FEATURES OR

INTERLOCKS
DO NOT OPERATE THIS EQUIPMENT IF ANY PANELS,

SAFETY COVERS OR INTERLOCKS ARE MISSING OR
DAMAGED
INTERNAL SERVICE SHOULD BE PERFORMED BY

QUALIFIED PERSONNEL ONLY
DO NOT OBSTRUCT ANY PNEUMATIC ORIFICE WITH

ANY PART OF THE HUMAN BODY
THE POWER SUPPLY SHOULD BE PROTECTED BY AN

R.C.D (EARTH LEAKAGE) DEVICE DURING SERVICE
THIS EQUIPMENT SHOULD BE REGULARLY SUBJECTED

TO A GAUGE SAFETY TEST (REFER TO CHECKLIST IN
SAFETY SECTION)
VERSATILE TECHNOLOGY
AES098 - AUTOMATIC END SYSTEM 2
Contents
Contact Details Head Office ........................................................................................................................................ 4

Representatives ................................................................................................................................ 4
Introduction Things you should consider before starting ..................................................................... 6
Description Features of the Gauge ................................................................................................................. 7
Installation Following the correct procedure ........................................................................................... 8
Training Safety ................................................................................................................................................... 10

Operation ......................................................................................................................................... 10
Maintenance .................................................................................................................................... 10
Safety Overview .......................................................................................................................................... 11

Gauge Safety Checklist ............................................................................................................. 12
Label Checklist ............................................................................................................................... 14
In Service Safety Inspection and Electrical Safety Testing ..................................... 15
Part A: Equipment Electrical Safety Testing Proceedure ...................................... 16
Part B: Earth Resistance or Protective Earthing Test ............................................... 17
Electrical Safety Certificate ..................................................................................................... 18
Operation Measurement Explanation ...................................................................................................... 19

Familiarizing yourself with the gauge stations .............................................................. 19
Front Panel Controls .................................................................................................................. 20
Turning the gauge on ................................................................................................................ 20
Performing a test .......................................................................................................................... 21
Real World Values ...................................................................................................................... 28
Can Size Change over .............................................................................................................. 29
Height Station - Changing Drive Rollers for Different Can Sizes .................... 31
Reform Dome Scan Setup ..................................................................................................... 32
Measurement Theory for Plug Diameter ....................................................................... 34
Operation Overview ................................................................................................................. 35
Software Interface Main Screen .................................................................................................................................... 36

Main Toolbar .................................................................................................................................. 36
Main Toolbar - File ...................................................................................................................... 37
Main Toolbar - Menu ................................................................................................................ 37
Menu - Settings ............................................................................................................................. 37
Hardware Manager - RS232 .................................................................................................. 39
Hardware Manager - Ethernet ............................................................................................. 40
Hardware Manager - RTC ...................................................................................................... 41
Hardware Manager - USB ...................................................................................................... 42
AES098 - AUTOMATIC END SYSTEM 3
Hardware Manager - Probes ................................................................................................. 43

Hardware Manager - Touch Screen ................................................................................. 44
Hardware Manager - SD Card ............................................................................................. 45
Menu - Profile ................................................................................................................................ 46
Menu - Calibration ...................................................................................................................... 51
Gauge Output ............................................................................................................................... 52
Gauge Measurement Output ............................................................................................... 53
Calibration Calibration Overview ................................................................................................................ 55

When and how often should I calibrate? ....................................................................... 55
Setting Masters .............................................................................................................................. 56
Micrometer Calibration Procedure ................................................................................... 57
Calibration Record 1 .................................................................................................................. 60
Calibration Record 2 .................................................................................................................. 61
Gauge Repeatability & Introduction ..................................................................................................................................... 62

Reproducability Study Method .............................................................................................................................................. 62
(Gauge R&R) Analysis of the trial results. ..................................................................................................... 62
R&R Software ................................................................................................................................ 62
Basic GR&R Proceedure Overview ................................................................................... 63
Maintenance Routine maintenance ................................................................................................................. 64

Specific Maintenance .................................................................................................................. 67
System Voltages ............................................................................................................................ 68
Shop Air Regulator ..................................................................................................................... 69
Solenoid Maintenance ............................................................................................................... 70
Replacement of Digital Probes ............................................................................................ 70
Trouble Shooting Remedies for common difficulties ...................................................................................... 71
Specifications Technical specifications ............................................................................................................. 73
Contact Details
Contact Details
Head Office
Versatile Technology
35-37 Cleeland Road
Oakleigh South, Victoria 3167
Australia
Tel: +61 3 9548 8983
Fax: +61 3 9548 8958
Email: contact@versatiletechnology.com.au
Web: www.versatiletechnology.com.au
United Kingdom/Europe
Contact: Mr. Tim Bulman
Email: tim.bulman@tbtechnology.co.uk
Representatives
USA/Canada
Regal Metrology
4554 Popular Level Road
Louisville, KY 40213
USA
Tel: +1 502 962 3681
Fax: +1 502 805 0712

Contact: Mr. Brian Rohleder
Email: brian@regalmetrology.com
Contact Details
Japan
CKB Corporation
2-10-6 Shibuya, Shibuya-ku
Tokyo 150-0002
Japan
Tel: +81-3-(3498)-2234
Fax: +81-3-(3498)-2356
Contact: Mr Shigeru Kuramoto
Email: kuramoto@ckb.co.jp
China
Guangzhou Stolle-Denuo Machinery Co., Ltd.
No. 9 Room, No. 27, Kengtouxi Road,
Nancun Town, Panyu District,
Guangzhou City, Guangdong Province
P.C. 511400
China
Tel: +86 20 34789252
Fax: +86 20 34789254
Contact: Fenny Gong
Email: info@gz-denuo.com
South Korea
ICM Leaders Co. Ltd.
Hyundai Lakeville Rm. 416,
284, Seokchonhosu-ro, Songpa-gu

(05623) P/C
Korea (South)
Tel: +822-2642-1375
Fax: +822-2642-1376
Contact: Cindy
Email: ichem08@hotmail.com / icml004@hanmail.net
Introduction
Introduction
Things you should consider before starting
Thank you for specifying Versatile Technology equipment. All industrial equipment requires regular maintenance to
maintain the safety and performance throughout its service life. This manual will assist you in this process. We ask that
you read and consider the following.
Safety:
Your safety is a paramount concern to Versatile Technology. You will find safety notices throughout the manual.
Please read and understand at least the Operation and Safety sections of this manual before using this gauge. If
servicing or calibrating please also read and understand the Servicing Information section from this manual. Refer
to the 'Safety Test Sheet', which describes testing of the gauge safety features that should be regularly tested.
Maintenance:
Regular maintenance will ensure the gauge maintains its specified performance. Spare parts and support are available
through our office.
Calibration:
Calibration of measurement devices on the equipment ensures that measurement errors are minimized. The
calibration of the gauge should be checked at regular intervals, of no longer than one year. As part of the regular
calibration, a Safety Checklist should be completed to ensure that the safety systems on the gauge operate correctly.
Capability:
Gauge capability tests check that the equipment is capable of measuring your manufacturing process with a minimum
of variation.
Continuing Support:
Please contact us with any questions you have about the manual or equipment. Your feedback will assist us in
improving our products and result in a better service to you.
Continuous Improvement:
Due to our policy of continuous improvement, service procedures may change. Contact our office to obtain the latest
service data and information.
Please maintain contact with our office:
If the equipment is transferred or disposed of we ask that you advise our office of its new location so that we may
amend our records. This is especially important in the event we have to send a safety alert bulletin alerting you of an
unforeseen safety issue.
Thank you,
The Versatile Team
Description
Description
Features of the Gauge
This Versatile Technology built gauge is specifically designed to measure 200-211 finished cans. The following
dimensions are measured.
Finished Can Height
Finished Can Dome Depth
Plug Diameter
Flange Width
Reformed Groove Diameter
Reformed Dome Diameter
Upon completion of a test, the results are displayed on the LCD and automatically sent to the RS232 output for
seamless evaluation in any third party software.
Versatile Technology equipment is designed for ease of use and to allow quick and accurate tests. Simple one button
operation with full microprocessor control eliminates operator contact during the measurement cycle which ensures
accuracy of results. The gauge is shipped with a guaranteed accuracy and GR&R capability of better than 15% of
agreed manurfacturing tolerance.
Features of the gauge include:
Rugged construction that is easy to use.
No change parts required
Manual placement with automatic align and rotation
Selectable testmodes including Continuous TIR, Single-point and Multi-point measurement modes.
Software selectable units
Software selectable parameters
Intergral RS232 port with Mitutoyo output format communications.
Safety is of paramount importance to Versatile Technology. A comprehensive gauge safety checklist is included in this
manual which we recommend is checked regularly to ensure the continued safe operation of the gauge.
Installation
Installation
Following the correct procedure
1. Unpack the gauge. Inspect the equipment and accessories. Check against the Shipping List to ensure that all parts
have been delivered.
2. Install the gauge on a level, flat surface away from excessive moisture and vibration.
3. Connect the shop air supply to the inlet port labelled SHOP AIR. The pneumatic supply should be filtered and
non lubricated and have a pressure range of between a minimum of 600Kpa/90psi and a maximum of 900 Kpa/
130psi..
Installation
4. Connect the power lead to the connector on the gauge back panel and plug into an earthed (grounded) AC
voltage outlet. Ensure that the correct voltage has been delivered. Note the voltage on the rating plate on the
back panel. For maximum reliability a mains filter should be fitted to the mains supply to remove excessive
voltage fluctuations often found in industrial environments.
5. Connect the data cable to the RS232 / ETHERNET output located on the rear panel to an external computer.
Training
Training
Training of all people in the safe and efficient use of the gauge will ensure optimum performance. The following
training guideline is to be used in conjunction with the rest of the manual. .
Safety
Train all who come in contact with the gauge.
Safety features on the gauge.
Operation
Train all who operate the gauge.
Front Panel Controls
Performing a Test
Message Listing
Operator Routine Maintenance
Maintenance
Train Supervisory staff and Maintenance team.
Parameter Listing
Calibration
Specific Maintenance Proceedures.
Trouble Shooting Guide
Gauge Diagrams
Safety
Safety
Overview
Your safety is a major concern to all at Versatile Technology. The following steps have been taken to ensure that the
gauge is safe to use and service.
Gauge Safety Checklist

Information and a checklist to allow regular testing of gauge safety features.
Training
You will find a recommended training schedule in this manual, which covers operation and safety awareness. Please
refer to the schedule.
Feedback
Despite our best efforts, we may have missed something. If during the use of the gauge you notice any hazard that
we have not found or foreseen please immediately inform us so we can work with you to eliminate the problem on
your equipment and prevent it recurring on new equipment.
Gauge Model - Serial Number: BE056C-XXX
Inspection Performed By:
Comments:
Signed: Date:
Safety
Gauge Safety Checklist

Gauge safety features should be tested regualy to ensure correct and safe operation. we recommend quarterly
inspection of safety features using the following checklist.
If any safety feature does not operate, stop using the gauge immediately and rectify the problem. Contact Versatle
Technology for any advice and replacement parts.
Features Tasks Comments
Cabinet Check that all panels are in place and fastened with the correct
number of screws.
Electrical Safety Test Perform Electrical Safety test and record results. (Refer to the
'Electrical Safety' section of the manual.)
'Tested for Electrical Safety' adhesive label is affixed.
Earth Wire Verify Earth Wire is present and fitted between Power Supply
Module and Chassis Earth Point
Labels All labels are affixed and legible. (See Label Checklist)
Power Supply Module Supply Module Cover is in place and Mains wiring is inaccessible.
Warning labels are fitted.
Safety
Signed: Date:
Safety
Label Checklist
Labels Qty & Location Present
Calibrated, Safety Tested, Capability Trials label QTY 1 - Front upper right of display panel
CE Label (If required) QTY 1 - Front upper left of display panel
Earth point Label QTY 1 - Power supply module earth bolt

QTY 1 - Case earth bolt
Ethernet Port QTY 1 - Rear of gauge above ethernet

socket.
Gauge Model & Serial Number plate QTY 1 - Front lower right of front pane
QC Passed label QTY 1 - Power supply module
RS232 Port QTY 1 - Rear of gauge above RS232

Connector
Service Port QTY 1 - Above USB socket.
SET TO 560kPa (80psi) QTY 1 - Internal shop air regulator
SET TO 56kPa (8psi) QTY 1 - Internal precision air regulator
SHOP AIR INLET QTY 1 - Rear of gauge above mist

Set to 6-10Bar (90-145psi) seperator
Versatile Technology label QTY 1 - Front upper left of display

panel
Warning - Disconnect Supply QTY 1 - Power supply module cover
Safety
In Service Safety Inspection and Electrical Safety Testing
Purpose
In service testing is necessary for the safety of persons using the equipment. In conjunction with AS3760:2001, this
document specifies in-service safety inspection and testing protocols and criteria for the testing of Versatile
Technology Gauging equipment.
Action
Such equipment, without being dismantled, needs to be subjected to routine inspection and testing to detect obvious
damage, wear or other conditions which may render it unsafe.
Equipment identified to be faulty needs to be withdrawn from service and either Versatile Technology or qualified
personnel contacted to arrange repair or disposal.
In accordance with AS3760:2001, the equipment must be subjected to:
Visual Inspection
Protective Earthing test
Insulation Resistance test
Documentation of all tests
Frequency
We recommend protectively earthed equipment installed in a Factory or workshop be inspected every 6 months.
Safety
Part A: Equipment Electrical Safety Testing Proceedure

To ensure that a gauge does not become an electrical hazard to the operator, servicing agent or builder Versatile
Technology, an electrical safety test must be performed on the gauge prior to commissioning and a test record must
be completed and shipped to the customer.
Test Equipment Required.

Insulation and Earth Resistance Tester. Lutron DI6200 or equivalent.
Testing standards. Based on Australian Standards AS 3760:2001.
Test Procedure.
Insulation Test.
Connect the Tester as shown in the following diagram. The tester applies 500 volts and measures the resistance
between the mains circuit and the gauge earth, which is the gauge case. Record all results on Electrical Safety
Certificate
The Minimum Resistance allowed between the Active supply and case is 1 M .
Note: If the resistance is below 5 M then the gauge should be

serviced as there may be an electrical fault.
Safety
Part B: Earth Resistance or Protective Earthing Test

This check measures the resistance between the earth conductor and the external case and metal parts that may
become live due to a failure of the internal wiring. Connect the Tester as shown in the following diagram. Test with
mains switch both ON and OFF. Record all results on Electrical Safety Certificate.
If a gauge fails the electrical safety test?

In the event of a gauge failing any element of the electrical safety test the gauge should be immediately repaired. If
this is not possible it should be segregated so that it cannot be used.
Under no circumstances can a gauge be used without passing

the electrical safety test.
Safety
Electrical Safety Certificate

This is to certify that the Versatile Technology gauge listed below was tested in accordance with AS3760:2001, "In
Service Safety Inspection and Testing of Electrical Equipment" published by Standards Australia.
Refer to the Electrical Safety section for guidance in checking electrical safety.
Gauge Description
Model Serial Number
Date of Certification
1. Visual Inspection- Refer Clause 2.3.2 of AS3760:2001 p12
All mains wiring in good condition, and inaccessible during normal operation. Mains cables
properly anchored
Electrical Voltage and Fuse rating plate fitted.

Rating Plate Label Vac A Slo Blo FUSE
All electrical warning labels fitted. Flash stickers on power module.
Separate Earth stud / Earth lead longer than Active/Neutral.
All controls, safety covers, guards and safety facilities are secured and in good working order
2. Protective Earth/Resistance Test- Refer clause 2.3.3.1 of AS 3760-2001 p13
Resistance between Earth connector and exposed metal parts that may become live in the event of an internal
insulation failure. The resistance shall not exceed 1 ohm.
Test Result OHMS
3. Insulation Resistance Test. Refer clause 2.3.3.2 of AS 3760-2001 p13
Resistance between live supply conductors and exposed metal parts with a 500Vdc applied voltage. Minimum
Resistance 1 Mega ohm.
Test Result MEGA OHMS
4. Affix a signed and dated 'ELECTRICAL SAFETY' label to gauge passes in accordance with the above
specifications.
Tested By Signed
Operation
Operation
Measurement Explanation
The gauge uses a number of individual measurement stations to measure the following.
Familiarizing yourself with the gauge stations

Each gauge station can be used independantly of each other in any order. Only one gauge station can be used at any
one time.
A
B
C D
a) Station 1: Finished Can Height / Reformed Dome Depth(optional)
b) Station 2: Plug Diameter
c) Station 3: Flange Width
d) Station 4: Optional Reformed Dome Diameter or 2nd Finished Can Height Station
Operation
Front Panel Controls

A B C
D F
E
a) SETTING MASTERS: - Used to zero probes prior to measurement. Place masters here when not in use.
b) GRAPHICS DISPLAY & TOUCH SCREEN: - The display is used to view and interact with all information such as
displaying test modes, test results, and calibration screens.
c) KEYPAD: -Used to view/edit various machine operating parameters. An access code is required to edit these
parameters.
d) MASTER BUTTON(Blue): -The MASTER button is used to zero the probes for the particular can size dimension.
5 buttons one for each measurement - Finshed Can Height, Dome Depth, Plug Diameter, Flange Width & Reform.
e) MODE BUTTON(Black): - The MODE button is used to cycle through test modes between single point, multiple
point and continuous modes. Each test station has its own Mode Button (Excluding Plug Diameter and Reform)
f) START BUTTON: -The START button activates the selected test mode. Each test station has its own Start button.
g) SERVICE PORT: -Used to update software version and export test results to USB
Turning the gauge on

Turn the gauge on via the power switch located on the back panel.
The gauge will initialize and display the default run screen as shown below.
Operation
Software Version
Menu access Height changeover

setup
Save & load
Selects active profile
test files
Changes the Test
Mode on selectedSation
Performing a test
The gauge is layed out in an ituitive left to right progression of measurements. Each measurement station can be
operated independantly from one another but not at the same time.
Mastering the gauges

These gauges measure the deviation of a Can from an accurate reference master. Before any measurements are taken
the gauge MUST be mastered. This method allows the use of highly accurate measurement probes and allows a range
of sizes to be tested.
DO NOT HOLD ONTO THE MASTER WHILE MASTERING
Finished Can Height Mastering
Place the Height Master onto the gauge and push the Blue Height Master
button.
The LCD will indicate that the Height gauge has been mastered.
Operation
Reformed Dome Depth Mastering

Place the Reformed Dome Depth master onto the gauge and push the Blue
Reformed Dome Depth Master button.
The LCD will indicate that the Reformed Dome Depth gauge has been
mastered.
Remove the Master. The gauge is now ready for use.
Neck Plug Diameter Mastering

Place the Plug Diameter Master onto the gauge and push the Blue Master
button.
The LCD will indicate that the Plug Diameter gauge has been mastered.
Flange Width Mastering

Place the Flange Width master onto the gauge and push the Blue Master
button.
The LCD will indicate that the Flange Width gauge has been mastered.
Reformed Dome Diameter Mastering

Place the Reformed Dome Diameter master onto the gauge and push the
Blue Master button.
The LCD will indicate that the Reformed Dome Diameter gauge has been
mastered.
Selecting a testmode
To select a testmode, press the black Mode button. Pressing the button more than once will cycle through the
testmodes.
Operation
These gauges will measure a Can using one of the following selectable methods:
Single Point
The Can is not rotated. The gauge measures only a single point.
Multiple Point
The Can is rotated and the gauge measures a pre-selected number of points around the can. Each point is displayed
momentarily and sent via the RS 232 port.
Continuous (Total Indicator Run-out or TIR)
The Can is continuously rotated. The gauge scans and measures the entire can taking several hundred readings. The
minimum and maximum readings are displayed and sent via the RS232 port.
Starting the test
Finished Can Height & Reformed Dome Depth testing
Insert the appropriate can weight into the can to be tested
Place the Can on the footpad
Operation
Push the button labelled START.
The gauge will measure the Can using the selected measurement mode.
Upon completion of the test the results are displayed on the LCD and sent to the integral RS232 port.
NOTE: Any interference with the end during a test can cause erroneous readings. This is the reason why the
measurement procedure is automated.
Operation
Neck Plug Diameter

Place the Can over the split mandrel of the Plug Diameter gauge.
Operation
Flange Width
Place the Can on the Flange Width gauge between the datum pin and the probe.
The gauge will measure the Can using the selected measurement mode.
Operation
Reformed Dome Diameter

Insert the Can Weight into the can. Place the Can on the footpad
Operation
Real World Values

The 'Nominals' parameters in the Profile menu (Refer to System Parameters) allows the gauge to display the 'Real
World' measurement of the can.
Enter the value of the Master and the gauge will display the real world value of the Can.
Enter zero and the gauge will display results as a deviation from the master.
Operation
Can Size Change over
Height Gauge
To set the Height gauge to suit different height cans use the following procedure.
Loosen the wing knob and raise Probe holder
Place required Height Master onto footpad.
Press the height master button to extend the probe and note the probe reading on the LCD screen.
Lower the probe holder clamp down so that the probe touches the master to obtain a reading within 402
thou (100050 um) Keep pressing master to extend the probe.
Ensure that the centre line of the probe tip is on the centre line of the master
Tighten the probe holder clamp block when the probe is in position.
Operation
Remember to re-master before using.
Note: The stop collars can be set to the highest and lowest can heights in use. This will enable fast, simple height
change over between sizes.
Stop collars
Operation
Height Station - Changing Drive Rollers for Different Can Sizes

Different size drive rollers are required for each different size can to be measured on the Height Station. Each set of
rollers are designed for fast change-over. See the Maintenance section of this manual (Height Station Spring Force
Diagram).
1. Loosen locking grub screws using tool provided.
2. Remove and replace rollers with correct size rollers for desired test.
3. Tighten locking grub screws on flat face of the motor shaft.
Selecting Can Sizes for TIR Measurement
1. Use the forward and back keys on the keypad to scroll through the pre-set profiles.
Editing TIR Delay Time for Individual Can Sizes
1. Use the Profile menu to edit the TIR delay time for the selected can size. See the System Parameters section of
this manual for more details.
Operation
Reform Dome Scan Setup

To ensure the correct measurement is obtained when performing a reform dome test the two scanning tips must be
setup to measure at the same height.
The height of the two scanning tips can be checked using a block of metal with a area covered in mark out blue (or
permanent marker).
Move the block across one of the scanning tips so that it scratches a line in the mark out blue.
Repeat the process with the second tip. The height of the tips can be compared using the two scrached lines.
If the height of the scanning tips is not the same, loosen the screws holding one of the tips so that its height can be
adjusted.
Once the tips are the same height, tighten the screws to make sure the tip is secure.
Operation
Once the height of the scanning tips are the same they must be set so that the scan begins higher than the groove
and the reform of the can, a tip height of 4mm can usually be used as a starting point. The scans starting location can
be adjusted by adjusting the scan height bolt.
Once the height has been set it can be verified by placing mark out blue on the base of a can and moving the can
across the scan tip to scratch a line. This will indicate where the scan will begin on the can.
Operation
Measurement Theory for Plug Diameter

The gauge measures the internal plug neck diameter of alloy cans. Using the following known parameters;
- Mandrel Diameter.
- Nominal Neck Diameter.
- Master Neck Diameter.

- Mandrel measurement force.
We are able to obtain a consistent internal plug neck diameter. The mandrel being smaller diameter than nominal is
opened up to the point where the sum of the mandrel circumference and the extra length on each side equals the
internal neck circumference. This is the ZERO point. Any deviation of the test can from this value is corrected by
2/ which is a relationship between circumference and diameter.
Eg. For 202 neck can.

(Nominal Diameter) DN = 52.40 mm
(Mandrel Diameter) DM = 52.23 mm
(Circumference Nominal) CN = 52.40 x = 164.6194

(Circumference Mandrel) CM = 52.23 x = 164.0853
Let P be the distance the split mandrel must move apart so that the distance P + P + CM = CN.
Therefore to establish the P dimension.
2P = CN - CM
= 164.6194 - 164.0853
= 0.5341
2P = 0.5341 P= 0.26705
Therefore to establish the SETTING MASTER diameter.
SETTING MASTER diameter = DM + P
= 52.23 + 0.26705 = 52.49705
NOTES:
- Ignore the effects of the can neck straightening at the split section.
- Standard measurement force - 3Kg.
Operation
Operation Overview
Step 1: Master the Gauge
Mastering Procedure for all Stations
Place the relevant master on the footpad.

Press the blue master button located at the front left of the station to be mastered.
Gauge will display 'Mastering Gauge'.
Remove master from gauge when finished.
Step 2: Select the Test Mode
Select a Test Mode
Use the 'MODE' button located at the frontright of the relevant station to toggle through to the desired test mode.
Test Mode Description
Single Point:
Measures one position on the can.
Multiple Point:
Measures and rotates the can at multiple points around the can.
Continuous TIR:
Measures over 360deg. around the can giving Max and Min readings.
Step 3: Perform the Test
Height, Dome Depth & Reform Dome Diameter Gauge Stations
Place can-weight into can to be tested and place on footpad.

Press the Green 'START' button located at the front right of the relevant station.
The gauge will perform the selected test mode and display the results on the LCD display.*
Plug Diameter & Flange Width Gauge Stations
Place can onto the relevant gauge.

Press the Green 'START' button located at the front right of the relevant station.
Gauge will perform the selected test mode and display the results on the LCD display.*
* If a computer is connected to the gauge the results will be sent via the RS232 port to the computer.
Software Interface
Software Interface
Main Screen
The main screen shows results for tests that have been completed. Results can be scroll though using the up and
down arrows on the keypad or by touching the desired result in the results table. The table can be paged though by
pressing left and right on the keypad.
All results that fall outside specified limits are shown in RED.
Software Version
Height cangeover Shows active test

setup mode for Reform Diameter
Station
Menu access Selects active profile
Save & load Shows active test

test files mode for Flange Width
Station
Indicates if System Menu is accessable Shows active test Shows active test
mode for the mode for Plug Diameter
Height Statin Station
Main Toolbar
The main toolbar allows access to the load/save, gauge options, mastering and test features.
Software Interface
Main Toolbar - File

Opens the file menu.
Load Test Results

Load previously saved test data from internal gauge memory.
Save Test Results

Save the current test data to internal gauge memory.
Export Table To USB

Save the current test data to a USB stick Test data will be saved in csv format. Only the test results will be saved,
Charts/Graphs will not be saved.
Main Toolbar - Menu

Note: You must log in as a supervisor to gain access to the main menu. The supervisor access code is 22085.
Once logged in the main menu will appear.
Menu - Settings
Opens the settings menu.
Software Interface
Settings Menu - Operational Settings

The OPERATIONAL SETTINGS screen allows editing of general gauge settings.
Units
Selects the gauge units.
Defaults
Resets gauge default parameters.
Software Interface
Hardware Manager - RS232

The RS232 hardware manager screen allows the gauge RS232 settings to be viewed, editied or tested.
Current baud rate in bps.
Change Baud Rate

Change the baud rate used by the RS232 port.
Send Test Data

Sends a test packet of data out the RS232 port using the current baud rate.
Software Interface
Hardware Manager - Ethernet

The Ethernet hardware manager screen allows the gauge ethernet settings to be viewed, editied or tested.
Ethernet IP address.
Ethernet net mask.
Ethernet transfer rate in bps.
Change IP Address
Change the IP Address used by the Gauge.
Apply Default Settings

Apply the default ethernet settings. This should also be used when the gauge is initial setup to configure the ethernet
IC.
Default Settings
IP Address: 192.168.8.201
Net Mask: 255.255.255.0
Send Test Data

Sends a test packet of data out the ethernet port.
Software Interface
Hardware Manager - RTC

The RTC hardware manager screen shows the current time and date. Days, years, minutes etc.. can be editing by
selecteing the approprate parameter.
Software Interface
Hardware Manager - USB

The USB hardware manager screen allows the gauge USB settings to be viewed. It aslo has back and restore utilities.
Type of usb device detected.
Type of driver being used by USB IC.
USB driver IC firmware version.
Update Driver From Internal Memory

Updates the firmware in the interface IC. The new firmware must be placed in the internal gauge memory first.
Contact Versatile Technology for further instructions if this isnecessary.
Export Log Files to USB

Exports logging information to storage via the USB port.
1. Plug the USB stick into SERVICE PORT of gauge.
2. Touch the Export Log Files to USB button.
Software Interface
Hardware Manager - Probes

The Probes hardware manager screen lists all the motor boards required by the gauge. The cameras operate over a
communication link. Cameras that have been detected correctly will display a camera status of Ok.
Edit ID
Manually enter the Probe ID number for the specified probe.
Get Info
Retreive probe data string from active probe. Used to validate that the gauge is able to communicate with the probe
correctly.
Re-ID All Probes

Run automatic probe identification sequence to identify each probe.
Software Interface
Hardware Manager - Touch Screen

Press the Calibrate Touch Screen button to enter the touch screen calibration.
Once in the TOUCH SCREEN CALIBRATION screen follow the prompts on the screen to calibrate the screen.
Touching in the blank area of the screen will display a blue dot onscreen to indicate the position that was detected.
If the dot does not align with the region pressed, press 1 on the keypad to carry out a custome calibration and follow
the prompts on screen.
Software Interface
Hardware Manager - SD Card

The SD Card hardware manager screen provides the details for the current SD Card. Information is given for storage
space. Provisions are supplied for freeing space by deleting Test, History and Screen Shot files
Software Interface
Menu - Profile
The Profile screen allows the users to create new profiles or adjust properties of current profiles. A profile defines
the way a can will be tested and how the results will be displayed.
Profile - Add
Allows the user to add a new can profile.
Profile - Delete
Allows the user to delete an exsisting can profile.
Profile - Rename
Allows the user to rename an exsisting can profile.
Profile - Copy
Allows the user to copy an exsisting can profile.
Software Interface
Profile Menu - Measurement Screen

Allows the user to edit the selected can profile master setting values.
Nominal
Set the Heigh, Dome, Plug , Flange, Reform and Groove nominal vaules.
Height and dome should match the values on the masters used for current profile. Thinwall / Mid-wall and Thickwall
/ Top-wall values should be left as zero.
Lower
Set lower tolerance for selected profile. Any values below the selected value will be highlighted in RED.
Upper
Set upper tolerance for selected profile. Any values above the selected value will be highlighted in RED.
Offset
Value to be added to measurement.
Software Interface
Profile Menu - Height Screen

Allows the user to edit the selected can profiles Height station settings.
MP Points
Set the number of points to be measured in multi-point mode.
MP Delay
Set the time the motor rotates the can between points in multi-point mode.
TIR Delay
Set the time the motor rotates to get the can to complete one full revolution.
Software Interface
Profile Menu - Flange Width Screen

Allows the user to edit the selected can profiles Flange Width station settings.
MP Points
Set the number of points to be measured in multi-point mode.
MP Delay
Set the time the motor rotates the can between points in multi-point mode.
TIR Delay
Set the time the motor rotates to get the can to complete one full revolution.
Software Interface
Settings Menu - Diagnostics

The diagnostics screen is used for troubleshooting problems and making adjustments to the gauge.
Probe Bars Diagnostic

Commands
Output Input
Banks Banks
Probe Bars
The probe bars show the current readings for probe and quadrature.
Touch on the bar to zero the reading.
Inputs Banks
Shows the status of all the inputs connected to the gauge.
Output Banks
Shows the status of the outputs available on the gauge.

Use the left and right arrow keys on the keyboard to scroll though the output banks. The current bank is hi-lighted
in red. Use 1-8 on the keypad to toggle the respective output of the selected bank on/off.
Diagnostic Commands
The gauge provides a number of command to help with diagnosing problems and calibration.
Software Interface
Menu - Calibration
Use the Calibration screen to test the gauge calibration. The calibration showns live probe readings.
Use left and right buttons on the keypad or screen to select between Height, Plug, Flange and Reform stations. Press
the probe bar to zero the reading.
All screeens contain the following buttons.

[1] Extends probes - Extends all probes on selected test station
[2]Retract Probes - Retracts all probes on selected test station
[3]Load Sample/Master - Loads a sample or master on selected test station

[4]Unload Sample/Master - Unloads a sample or master on selected test station
[5]Rotate Motors On - Turns Rotate motors on the selected test station (Plug station does not use this button)
(Reform Station)[5]Reform Down - Moves the reform tips down.

[6]Rotate Motors Off - Turns Rotate motors off the selected test station (Plug station does not use this button)
(Reform Station) [6]Reform Up - Moves the reform tips up back to its home position.
Software Interface
Gauge Output
The gauge can output results via RS232 or ethernet. Results are output after every sample has been completed.
RS 232 Output Specifications

RS232 serial output from the gauge that emulates Mitutoyo serial equipment. Only the measured results are output
over RS232. The ASCII serial output from the gauge has a fixed width of 13 characters.
eg. 01A+ 175.5[CR]
Char 1 - Gauge ID number [0]
Char 2 - Reading numeric tag [1]

1 - Height, 2 - Dome Depth, 3 - Plug Diameter 4 - Flange Width, 5 - Reform Probe 1, 6 - Reform Probe 2.
Char 3 - Constant [A]
Char 4 - Sign [+]

Char 5 to 12 - Measurement [ 175.5]
Char 13 - Terminating character [CR]
Baud Rate - 9600, Data Bits - 8, Stop Bits - 1, Parity - None
Ethernet Output Specifications

Ethernet output from the gauge follows the VT data processor specification. Data is output with comma separation.
Test parameters and results are output after each sample is completed. The fields are all variable width.
Height Station
<Height>, <Test Mode>, <[n]>, <DomeDepth>, <HeightValue1>, <HeightValue2>, <HeightValue[n]>, <Profile>,
<LineFeed(ASCII 10)>
Plug Diameter Station

<Plug>, <Test Mode>, <[1]>, <Plug>, <Profile>, <LineFeed(ASCII 10)>
Flange Width Station

<Flange>, <Test Mode>, <[n]>, <FlangeValue1>, <FlangeValue2>, <FlangeValue[n]>, <Profile>, <LineFeed(ASCII 10)>
Reform Diameter Station

<Reform>, <Test Mode>, <[1]>, <GrooveDiamter>, <ReformDiameter>,<Profile>, <LineFeed(ASCII 10)>
Software Interface
Gauge Measurement Output

Below is a list of all the testmodes listing the number of results sent via the RS232 port and the order of results sent
at the end of the test.
Dome Depth / Height Gauge Measurement Output
Single Point Test Mode
2 Values.
Dome Depth + Height.
Multipoint Test Mode
Send All Parameter set ON.
Various amount of values depending on number of multiple points selected.
Dome Depth + (Height results sent out after each measurement is made).
E.g. 4 point measurement results in a total of 5 readings being sent.

Send All parameter OFF.
3 Values.
Dome Depth + Maximum Height + Minimum Height.
Continuous Test Mode
3 Values.
Dome Depth + Maximum Height + Minimum Height.
Plug Diameter
1Values.
Plug diameter.
Flange width

1 Values.
Flange Width.
Multipoint Test Mode

Send All Parameter set ON.
Various amount of values depending on number of multiple points selected.
Flange Width.
E.g. 5 point measurement results in a total of 5 readings being sent.
Send All parameter OFF.
Software Interface
2 Values.
Maximum Flange Width + Minimum Flange Width.
Continuous Test Mode
2 Values.
Maximum Flange Width + Minimum Flange Width.
Reform Dome Diameter
Reform Scan
2 Values
Groove Diameter + Reform Diameter
Calibration
Calibration
Calibration Overview
All gauges used for the purpose of process control and acceptance inspections should be regularly tested to ensure
they are accurate, within calibration and capable of measuring the process.
Ensure that all equipment used to calibrate the gauges has been laboratory calibrated and its certification is traceable
to national measurement standards.
Setting Master Inspection and Calibration

The setting masters are critical to the accuracy of the equipment because the gauge compares the cans against the
setting master. Setting masters are generally checked by a laboratory with suitable dimension testing systems for jigs,
gauges and fixtures.
Inspection and Servicing

The gauge should be cleaned and inspected for worn or defective parts. Any rework should be completed prior to
the calibration and GR&R study. Refer to the Maintenance section in this Manual for complete details on inspection,
rework and spare parts.
Measurement Probe Calibration

Gauge probes are checked against known calibration devices such as micrometers or slip gauges. The measurements
are recorded and compared against the recommended limits of accuracy and linearity.
Calibration Report and Sticker

At the completion of the calibration the results should be studied to ensure all parts of the gauge operate within
specifications and a calibration sticker applied to the gauge indicating when the next calibration is due. Calibration
reports should be filed for future reference. Calibration of the gauge should be conducted annually.
Gauge Repeatability and Reproducibility Study (GR&R)

All measurement gauges have some variation. It is important to measure this variation to ensure that it is only a small
percentage of the manufacturing tolerance being measured. The Gauge R&R study ensures that the gauging system
is capable of controlling the manufacturing process.
When and how often should I calibrate?

Initially every 6 months for 2 years. Thereafter every 12 months.
Calibration
Setting Masters
Inspect the setting masters for damage. Small marks or burrs on the edges of the measuring faces should be carefully
removed. Note that damage on the measurement faces should be inspected and removed under guidance from a
tool maker specialising in setting jigs and gauges. The manufacturing tolerances on the masters are +/- 3 micron (+/-
0.000125 inch). If the damage cannot be reworked the master should be replaced.
Carefully pack and ship the masters to the calibration laboratory and request a certificate traceable to international
standards.
Instruct the laboratory to measure the master and supply a report with the dimension measurements on a certificate
that is traceable to national standards.
Compare the certificate measurements with the dimension engraved on each master to decide if the master is
acceptable to be put back into production.
Recommended maximum error:
Front End: Less than +/-5 micron variation (+/- 0.0002 Inch)
Back End: Less than +/-7.5 micron variation (+/- 0.0003 inch)
The backend masters can have larger variations because the manufacturing specifications on the finished can are larger
than the trimmed can.
Calibration
Micrometer Calibration Procedure

A certified calibration micrometer may be used to check the accuracy and linearity of the probes.
An adaptor is used so that the probe can be held steady against the micrometer.
WHEN CALIBRATING USING THE MICROMETER

ALWAYS USE A BALL POINT PROBE TIP
From the menu select Gauge and then select Calibrate to display the probe real-time measurement. Use the
forward and back keys to scroll between probe readings.
Insert the probe into the micrometer adapter and tighten the clamping screw lightly when the tip contacts the
anvil of the micrometer. Ensure the thimble of the micrometer is adjusted back far enough to allow the full range
of the probe to be calibrated.
Finished Can Height, Reformed Dome Depth & Reformed Dome Diameter stations: Adjust micrometer thimble
to obtain a 1000um (40thou) reading on the gauge LCD display.
Plug Diameter & Flange Width stations: Adjust micrometer thimble to obtain a 2000um (80thou) reading on the
gauge LCD display.
Zero the micrometer.
Calibration
Adjust the micrometer to various points either side of zero noting the values on the micrometer compared to
that on the gauge LCD display
Avoid Backlash: When performing the calibration always adjust the micrometer from the same direction to elim-
inate errors due to backlash in the micrometer.
Calibration
Probe Re-Installation Procedure.
Place the appropriate master on the gauge. The master is the 'zero datum'.
From the Gauge menu select Calibrate. Use the forward and back keys to select the station being worked on.
Finished Can Height, Reformed Dome Depth & Reformed Dome Diameter stations: Push the probe against the
master and observe the gauge display as it approaches 1000um (40thou). This is the mid point of the probe.
Plug Diameter & Flange Width stations: Push the probe against the master and observe the gauge display as it
approaches 1000um (40thou). This is the mid point of the probe.
Lock the probe clamp when the probe is at the mid point +/- 20um (1thou).
Avoid Probe Damage: Where a probe is secured with a grub screw, be careful not to over tighten as too much
direct pressure on the probe may break it.
Calibration
Calibration Record 1
This certificate is to certify that the gauge listed below was calibrated and found to perform to within the specifications
of Versatile Technology Pty. Ltd.
GAUGE DESCRIPTION Back End Gauging System - Finished Can Height / Finished Can
Dome Depth / Reformed Dome Diameter
MODEL/SERIAL NUMBER
DATE OF CALIBRATION
CALIBRATION EXPECTED GAUGE

TEST RESULT ERROR
STANDARD DISPLAY
1000um / 40thou / ____ 2000um / 80thou / ____
750um / 30thou / ____ 1750um / 70thou / ____
500um / 20thou / ____ 1500um / 60thou / ____
250um / 10thou / ____ 1250um / 50thou / ____
100um / 4thou / ____ 1100um / 44thou / ____
0um / 0thou / ____ 1000um / 40thou / ____
-100um / -4thou / ____ 900um / 36thou / ____
-250um / -10thou / ____ 750um / 30thou / ____
-500um / -20thou / ____ 500um / 20thou / ____
-750um / -30thou / ____ 250um / 10thou / ____
-1000um / -40thou / ____ 0um / 0thou / ____
The equipment used to perform this calibration is traceable to Australian Standards.
CALIBRATION UNITS: um / thou MAXIMUM ALLOWABLE ERROR: +/-10um / 0.4thou
Calibration Standard Certificate Number
Digimatic Micrometer
Serial No:
COMMENTS/ACCEPTABILITY
TESTED BY: SIGNED:
Calibration
Calibration Record 2
This certificate is to certify that the gauge listed below was calibrated and found to perform to within the specifications
of Versatile Technology Pty. Ltd.
GAUGE DESCRIPTION Back End Gauging System - Plug Diameter / Flange Width
MODEL/SERIAL NUMBER
DATE OF CALIBRATION
CALIBRATION EXPECTED GAUGE

TEST RESULT ERROR
STANDARD DISPLAY
1000um / 40thou / ____ 3000um / 120thou / ____
750um / 30thou / ____ 2750um / 110thou / ____
500um / 20thou / ____ 2500um / 100thou / ____
250um / 10thou / ____ 2250um / 90thou / ____
100um / 4thou / ____ 2100um / 84thou / ____
0um / 0thou / ____ 2000um / 80thou / ____
-100um / -4thou / ____ 1900um / 76thou / ____
-250um / -10thou / ____ 1750um / 70thou / ____
-500um / -20thou / ____ 1500um / 60thou / ____
-750um / -30thou / ____ 1250um / 50thou / ____
-1000um / -40thou / ____ 1000um / 40thou / ____
The equipment used to perform this calibration is traceable to Australian Standards.
CALIBRATION UNITS: um / thou MAXIMUM ALLOWABLE ERROR: +/-10um / 0.4thou
Calibration Standard Certificate Number
Digimatic Micrometer
Serial No:
COMMENTS/ACCEPTABILITY
TESTED BY: SIGNED:
Gauge Repeatability & Reproducability Study (Gauge R&R)
Gauge Repeatability & Reproducability Study

(Gauge R&R)
Introduction
Gauge R&R studies are designed to be preformed on non-destructive measurement testing equipment.
The purpose is to determine the suitability of a gauge or gauging system to measure a particular process. A common
industry method (and used by Versatile) to determine this, is to conduct a gauge repeatability and reproducibility
study where:
Repeatability: Equipment Variation (E.V.)

Is the variability of the measurements obtained by one person while measuring the same item repeatedly.
Reproducibility: Appraiser Variation (A.V.)

Is the variability of the measurement system caused by differences in operator behaviour.
Method
In order to quantify both these components of gauge variation it is necessary to have three operators to preform the
trial. Samples should be taken from standard production and the operators tests each sample three times. Therefore
a total of nine tests are completed per sample for a total of 90 tests to complete a Gauge R&R.
Ensure that the test samples are undamaged and clean of foreign matter and are clearly labled 1 to 10. Since most
samples vary in size at different positions it is necessary to mark each one to ensure measurements are taken in the
same place each time.
Analysis of the trial results.

Below 10%: Excellent -The gauge is capable of measuring and controlling the process.
10 - 15%: Good -The gauge is capable of measuring the process.
15 - 25%: Marginal -Confirm required tolerances. If results are deemed acceptable, the gauge should be monitored
and the GR&R repeated at regular intervals to ensure gauge does not deteriate.
Above 25%: Not capable: The gauge is not capable of controlling your process. Confirm tolerances required and
investigate reasons for variation.
R&R Software
GR&R software is available from Versatile Technology that automatically extracts the readings from the gauge and
calculates the GR&R value. Please contact Versatile Technology or visit our website at
www.versatiletechnology.com.au for more information.7
Gauge Repeatability & Reproducability Study (Gauge R&R)
Basic GR&R Proceedure Overview
Can Preparation.
Select 10 undamaged finished cans off the line. Avoid Cans with creases or imperfections.
Use a felt tip pen to label the cans 1 to 10 and mark a line on each can near the top and bottom.
Gauge Preparation.
Carefully clean around each probe with a clean cloth. Check that all areas of can contact are clean.
Select Single Point or Continuous test mode.
Mastering.
Master the gauge before commencing the trial.
At no point during the trial should the gauge be mastered again.
Can placement.
Place the can on the gauge with the can weight inserted.
Align the can in the same position each time (ie line up the bearing, etc).
Testing
Press the START button.
For the Height/Dome Depth station, use the "F" key on the keypad to toggle the display between Height and Dome
Depth readings.
Test can number one through to ten to complete Trial 1. Repeat this process for Trial 2 & Trial 3.
Operator B and Operator C will then perform the same procedure.
Maintenance
Maintenance
Routine maintenance
Cleaning
Clean the gauge using a soft cloth moistened with non-corrosive oil such as WD-40 or CRC. Pay particular attention
to the probe tips.
The 'Routine Maintenance Overview' sheet that appears later in this section may be copied and displayed with the
gauge.
Operator Feedback
Ask the operators to describe any difficulties using the gauge and note all concerns.
Drain Mist Seperator

Inspect the Mist Seperator located on the rear panel every week and drain all liquid if required.
Push upwards on the pin on the bottom of the Mist Seperator to allow liquid to drain out.
Height Gauge
Clean the base plate. Check for grooves or wear. Replace the base plate or resurface on a grinder if a groove can be
felt with your fingernail.
FOOTPAD
WEAR GROOVES
HOLDING SCREW
Maintenance
Clean the flat probe tip and check it for wear. Replace the tip if any groove can be felt.. Ensure that the tip is tight.
PROBE TIP
CONTACT FACE
WEAR GROOVE
Enamel buildup from the finished can sometimes makes the rollers slippery. Clean the rollers to ensure that the can
rotates smoothly and fully.
DRIVING ROLLER
CLEAN KNURL
Dome Depth Gauge

Clean the area around the probe tip and ensure the tip is tight.
Plug Diameter Gauge
MANDREL SECTORS
REMOVE ANY BUILD UP FROM CORNERS OF MANDREL
ENSURE PROBE TIP IS TIGHT
PROBE
Maintenance
Flange Width Gauge

Clean inside the groove of the driving rollers.
Ensure that the rollers are tightly secured to the motors
Clean inside the groove of the locating roller. Check that the roller rotates freely.
DRIVING ROLLERS
CLEAN INSIDE GROOVE
Clean the flat probe tip and check it for wear. Replace the tip if any groove can be felt.. Ensure that the tip is tight.
PROBE TIP
CONTACT FACE
WEAR GROOVE
Reform Dome Diamter

The Reform Dome Diameter Gauge requires very little maintenance.
Inspect the Datum pins for damage.
Check that the Datum pins are firmly secured in the bearing blocks.
Check that the two locating bearings rotate freely.
Remove any build up found on the datum pins or locating bearings.
Ensure that all bearing blocks move very freely.

Check that the probe tips are tight.
Maintenance
Specific Maintenance
Changing the Fuse

The power supply module supplies all low voltage power to the gauge and is located on the rear panel.
1. Disconnect the mains power cable.
2. Remove the fuse cage with a flat blade screw driver.
3. Replace the worn fuse with new.
Maintenance
System Voltages
The following table lists all major internal system voltages
Wire colour convention
WIRE COLOUR VOLTAGE
RED +12VDC
BLACK -12VDC
GREEN RETURN
GREY +24VDC
YELLOW +24VDC PROTECTED
ORANGE +5VDC
Power Supply Terminal Strip (From Left to Right)
REF POWER
1 +24VDC
2 RETURN
3 +24VDC
4 RETURN
5 +12VDC
6 -12VDC
7 RETURN
8 +5VDC
9 RETURN
10 (UNUSED
11 (UNUSED)
12 (UNUSED)
V2 Microprocessor Board: +12VDC (RED), RETURN (GREEN)
RLY030 Relay Board +24VDC (RED/GREEN), RETURN (RED/BLACK)
Maintenance
Shop Air Regulator

The Shop Air regulator should be set to 560kPa (80psi).
Rotate the adjusting knob clockwise to increase pressure
Rotate the adjusting knob anti-clockwise to decrease pressure.
Once pressure is set push down on the knob to lock it in position.
Maintenance
Solenoid Maintenance
Manual Over-ride
The solenoids may be manually driven to check their operation. This makes fault finding easier to help determine if
the fault is electrical or mechanical.
Press the orange (or blue) button with a small pointed instrument to activate the solenoid.
Replacement of Digital Probes
1. Turn the power and the air to the gauge off.
2. Open the gauge by removing the 3 holding screws and raise test station carefully
3. Remove probe from probe holder.
4. Remove airline from the probe.
5. Remove the Digital probe that is going to be replaced by releasing the retaining clip.
6. Place the new Digital Probe Body onto the mounting block and secure with retaining clip.
7. Reconnect airline to probe.
8. Replace the probe into probe holder.
9. Reapply the power and air to the gauge. The gauge will automatically find the probe's ID Number.
10. Follow probe set-up procedure. Once the probe has been set-up push the Master button to master the gauge.
Trouble Shooting
Trouble Shooting
Remedies for common difficulties
No Symptom Remedy
1. Gauge Dead, no display, no movement. Check power outlet. Ensure mains connector is pushed home in inlet connector on
back panel of gauge.
Check fuse. Remove mains cable from power and use a small screwdriver to remove
the fuse clip. Insert a new fuse of correct rating.
Check Shop Air Supply pressure is 6-10 Bar (90-145psi)
Check that the internal regulator dials are indicating correct pressure.
Check that the pressure is arriving at the cylinder.s/probes
2. No display. Open gauge case, use voltmeter to check microprocessor voltages (+/-12VDC) both
at the microprocessor and terminal strip connectors.
3. Display ok, no movement Open gauge case, use voltmeter to check voltages on power module connector
located on the front of the module.+ 24VDC +/- 1V Relay/Motor supply.
4. Power supply voltages incorrect This can be due to either power supply failure or an external fault pulling the supply
down. Check by disconnecting the power module connector and rechecking the sup-
ply voltages. If the voltages are still incorrect, replace the power supply module.If the
voltages are now OK, check for shorts. Follow the circuit diagrams and selectively
remove circuit sections of the gauge and reconnect the power module connector until
the short can be found. Repair or replace the faulty module as required.
5. Display ok, power supply ok, air ok, still Open gauge case. Watch the relays on the relay PCB and press a start button. Sev-
no movement eral relays should activate, if they don't, ensure all connectors are pushed home firmly
especially on the microprocessor boards. Replace if neccessary.
6. Display ok, Gauge functions ok gauge Remaster the gauges and recheck you have problems.
gives suspect readings. During mastering check that the zero values displayed are close to zero. If not the
probes may need to be re-set. Follow the probe setup proceedure in this manual.
Ensure the probes are held firmly in place and not going to slip.
Enter the gauge access code on the keypad. Follow the parameters section of this
manual and write down all of the internal parameters as some may have been changed
from the factory default settings. Follow the instructions and reset the gauge to factory
defaults. Check the operation of the gauge. Now enter the access code and re-enter
any changed parameters. The internal microprocessor refers to the EPROM for factory
default parameters. Changed parameters are held in battery backed RAM. On occa-
sions this battery-backed ram can be corrupted by excessive voltage spikes during
lightning storms or plant start-ups.
Ensure that measurement stations are setup correctly, refer to the gauge station
setup diagrams.
Check internal air regulators and ensure that they are set to the marked pressures.
Loose tips. A loose tip can give confusing, varying errors. Check that all tips on the
measurement probes are tight.
Worn tips. Grooves in tips mean errors. If you can feel the slightest mark, replace the
tip.
Worn measurement surfaces. Check the surfaces on the height gauge plates, replace
or resurface (surface-grind) as required.
Split or holed rubber boots on the measurement probes resulting in loss of air and
low force. Replace as required.
Ensure smooth movement of components.
7. Gauge ok, no data output Check the Serial Link

Check the RS232 connection.
8. Height Gauge Check tip tightness and surface condition.

Check probe rubber boot is not damaged
Check baseplate condition. Resurface if required.
Ensure that the probe holder is set the maximum 2mm (0.08") of travel which is the
probes linear measurement region. Follow the setup procedure.
Trouble Shooting
No Symptom Remedy
9. Plug Neck Ensure tip is tight.

Follow setup diagram and check 3 KG or 6.6 Lb opening force as well as sectors are
aligned.
Ensure that the sectors are opening smoothly but firmly.
If fitted, ensure that the can flange is supported by a support ring if measuring on the
upper diameter of the split sectors.
Check that the correction factor has been included during calibration.
10. Flange Width Check tightness and condition of tip.

Check tightness and surface condition of datum cylinder.
Clean can flange roller grooves to ensure smooth rotation of the can flange.
Ensure probe rubber boot is not damaged and probe moves forward positively.
Check that the front roller and probe housing move very freely without any stiffness
or obstruction. This is critical to the correct operation of the gauge. Suspect jammed
airline or wires or dirty linear bearings. Follow the setup procedure for this station.
11. Reform Dome Diameter Check condition and height of measurement pins. Refer to the setup diagram.
Ensure that the pins move smoothly without obstruction. Suspect fouled airlines or
wires or dirty linear bearings.
Check condition of probe rubber boots. Replace as required.
Check ball bearings on measurement station for smooth rotation. Replace as
required.
Specifications
Specifications
Technical specifications
Gauge Model BE056C - BACK END GAUGING SYSTEM
Capacity Height: 50cl to 500cl

Plug Diameter: 202, 204, 206. (200 on application)
Flange Width: 200 to 209
Resolution 1.0um (0.0001)
Accuracy Better than +/- 1% full scale

Probe Accuracy +/- 10um (0.0004)
Master Accuracy +/- 5um (0.0002)
Tolerance Height: +/- 150um (0.006)

Dome Depth: +/-100um (0.004)
Plug Diameter: +/- 100um (0.004)
Flange Width: +/-150um (0.006)
Reform Diameter: +/-100um (0.004)
Test Cycle Time Under 1 minute
Units Software selectable - mm/inches
Data Output RS232 (Mitutoyo Output Format)
Safety Fully enclosed cabinet
Display 320x240 TFT Backlit
Dimentions 620mm (25) W x 400mm (16) H x 650mm (26) D approx.
Weight 60kg (130bs) net approx.

90kg (220lbs) packed approx.
Requirement Electrical Supply: Single Phase 100-250VAC Filtered Power

Filtered Shop Air: 600kPa (90psi) approx.

Manual Versatil BE056C

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BACK END GAUGING

Operation, Calibration and Servicing

PLEASE FOLLOW ALL VERSATILE TECHNOLOGY

DO NOT DEFEAT ANY GAUGE SAFETY FEATURES OR

DO NOT OPERATE THIS EQUIPMENT IF ANY PANELS,

INTERNAL SERVICE SHOULD BE PERFORMED BY

DO NOT OBSTRUCT ANY PNEUMATIC ORIFICE WITH

THE POWER SUPPLY SHOULD BE PROTECTED BY AN

THIS EQUIPMENT SHOULD BE REGULARLY SUBJECTED

Contact Details Head Office ........................................................................................................................................ 4

Introduction Things you should consider before starting ..................................................................... 6

Description Features of the Gauge ................................................................................................................. 7

Installation Following the correct procedure ........................................................................................... 8

Training Safety ................................................................................................................................................... 10

Safety Overview .......................................................................................................................................... 11

Operation Measurement Explanation ...................................................................................................... 19

Software Interface Main Screen .................................................................................................................................... 36

Hardware Manager - Probes ................................................................................................. 43

Calibration Calibration Overview ................................................................................................................ 55

Gauge Repeatability & Introduction ..................................................................................................................................... 62

Maintenance Routine maintenance ................................................................................................................. 64

Trouble Shooting Remedies for common difficulties ...................................................................................... 71

Specifications Technical specifications ............................................................................................................. 73

Oakleigh South, Victoria 3167

Tel: +61 3 9548 8983

Fax: +61 3 9548 8958

4554 Popular Level Road

Tel: +1 502 962 3681

Fax: +1 502 805 0712

Guangzhou Stolle-Denuo Machinery Co., Ltd.

No. 9 Room, No. 27, Kengtouxi Road,

Nancun Town, Panyu District,

Guangzhou City, Guangdong Province

Tel: +86 20 34789252

Fax: +86 20 34789254

Contact: Fenny Gong

ICM Leaders Co. Ltd.

Hyundai Lakeville Rm. 416,

284, Seokchonhosu-ro, Songpa-gu

Email: ichem08@hotmail.com / icml004@hanmail.net

Please maintain contact with our office:

The Versatile Team

Finished Can Height

Finished Can Dome Depth

Reformed Groove Diameter

Reformed Dome Diameter

Rugged construction that is easy to use.

No change parts required

Manual placement with automatic align and rotation

Software selectable units

Software selectable parameters

Intergral RS232 port with Mitutoyo output format communications.

Train all who come in contact with the gauge.

Safety features on the gauge.

Train all who operate the gauge.

Front Panel Controls

Operator Routine Maintenance

Train Supervisory staff and Maintenance team.

Specific Maintenance Proceedures.

Trouble Shooting Guide

Gauge Safety Checklist

Gauge Model - Serial Number: BE056C-XXX

Inspection Performed By:

Gauge Safety Checklist