CGI Manual #137383 D500-31M-TFC

D500 Gage Controller
Instruction Manual
Model 31M Gage Assembly for Through-Feed Centerless Grinder
Electrical Diagrams
Options:
Intelligent Process Control - IPC
Micropeak - Dynamic Zero
Multi-Part / Multi-Dimension
Statistical Process Control - SPC
Taper
Customer: Tenneco - Monroe Mexico
CGI Job Number: 41325 A & B
Manual Number: 137383
Revision: 0.0
Issue Date: April 2018

Copyright
Copyright © 2018 Control Gaging, Inc. All rights reserved.
Information in this document is subject to change without notice. The software described in this doc-
ument is furnished under a license agreement or nondisclosure agreement. The software may be used
or copied only in accordance with the terms of those agreements. No part of this publication may be
reproduced, stored in a retrieval system, or transmitted in any form or any means electronic or mech-
anical, including photocopying and recording for any purpose other than the purchaser's personal use
without the written permission of Control Gaging, Inc.
Control Gaging, Inc.
847 Avis Drive
Ann Arbor, MI 48108
+1.734.668.6750
Fax +1.734.994.1335

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new chapters start on right (odd number) pages.
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CGI Manual #137383 Revision History

Rev. Date Revision Description By

0 18 APR 18 Original Issue. Based on 137085 TY
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6 137383
Contents
D500 Gage Controller 1
Copyright 3
CGI Manual #137383 Revision History 5
Contents 7
Chapter 1. Introduction 13
Contacting CGI 13
Warnings and Cautions: 14
Intended Use of Equipment 14
Controller Grounding 14
Hazardous Voltages 14
Guarding 15
Safety 16
Read the Manual 16
Personal Protective Equipment 16
Clear Gaging Area 16
Emergency Stopping Devices 16
Main Electrical Disconnects 17
Pneumatic Lockout Valves 17
Safety Symbols 17
Documentation Disclaimer 18
Control Gaging Supplied Components 18
New Control Gaging Components Added to Existing Systems 18
Customer Supplied Components 18
Chapter 2. System Overview 21
Introduction – D500 Gaging System for Through-Feed Centerless Grinder 21
System Summary 21
137383 7
Gage Assembly 21
D500 Gage Controller 22
Optional Software Features 24
Intelligent Process Control (IPC) Option 24
Micropeak with Dynamic Zero Option 24
Multi-Part and/or Multi-Diameter Selection Option 24
Statistical Process Control (SPC) with Data Storage and Download 25
Taper Option 25
Gage Summary 26
Model 31M Single Finger Gage 26
Chapter 3. Installation 27
Gage Controller Installation 27
Gage Controller Mounting Guidelines 27
Controller Mounting - Standard Mount 28
D500 Controller Dimensions - Standard Mount 29
Electrical Connections 30
Power Wiring 30
“Wheelslide Enable” Output Wiring 30
“Gage Enable” Input Wiring 31
Controllers and Gage Electronics - Customer Supplied 31
Converter Box Installation 31
Chapter 4. Installation Diagrams 33
D500 Connector Wiring 33
Model 31M Finger Retraction - Pneumatic Circuit Diagram 36
Chapter 5. System Component - Gage Controller 37
D500 Controller Front Panel and Keypad 37
Display Window 37
D500 Controller - Modified Interface for Microsoft® Windows® 38
Individual Key Functions: 41
8 137383
Common Tasks Using the Keypad 45
Using a Keyboard and Mouse with the D500 46
Connecting USB accessories: 46
Disconnect USB Accessories and Reboot: 46
Managing Program Files on the D500 47
Setting up for managing program files: 47
Program File Locations: 47
Updating an Existing D500 Installation 48
D500 Series Controller Specifications 50
Physical (Standard Enclosures only) 50
Power Requirements: 50
Environmental: 50
I/O Ratings: 51
D500 Rear Panel 52
D500 Operating Modes 54
AUTO Mode 54
SETUP Mode 54
FAULT Mode 55
AUTO Mode Operation and Screen Elements 56
SETUP Mode Operation and Screen Elements 60
FAULT Mode and Function Faults 64
D500 Setup Mode Pages and Parameters 66
Systems with Password Protection 67
Systems without Password Protection 68
Note Regarding Passwords 68
Zero Page 69
System Settings Page(s) 71
Gage Setup Page 78
Gage Setup Page - Details 81
137383 9
Diagnostics Page 82
Help Page 85
Optional Software Features 86
Intelligent Process Control (IPC) Option 86
Introduction 86
Trend Table 87
IPC Revisions at Software Version 1.474 89
IPC Operation and Setup – AUTO Mode Trend Page 90
IPC Operation and Setup – SETUP Mode Compensation Page 96
Example of IPC Compensation Setup and Operation 113
Micropeak Option - Overview 117
Introduction to Micropeak 117
Micropeak Method Comparison Charts 121
Micropeak AUTO Mode Page 123
Micropeak Settings Pages 124
Micropeak Settings Page - Threshold Method 127
Micropeak Settings Page - Threshold-timed Method 132
Micropeak Settings Page - Timed Method 134
Micropeak Settings Page - Threshold-Repeat Method 135
Micropeak Settings Page – Repeat Method 136
Micropeak with Dynamic Zero Option 137
Multi-Part and/or Multi-Diameter Selection Option 142
Manual Selection 143
Automatic Selection - "Internal" 143
Automatic Selection – “Remote” 144
AUTO Mode 144
SETUP Mode 147
Statistical Process Control (SPC) Option 151
Histogram Page 151
10 137383
X-Bar and R Chart Page 153
SPC Parameters Page 155
Data Storage and Output Page for Multiple Parts with same Output Fields 157
SPC Calculations 161
Taper - Option 164
Taper Option with Set Points 164
Taper Option without Set Points 165
Chapter 6. System Component - Gage Head(s) 169
Model 31M - Single Finger Gage 169
Model 31M Specifications 170
Model 31M Dimensions 171
Model 31M Adjustments 172
Pneumatic Finger Retraction 172
Contact Force 172
Overtravel Limits 173
Model 31M Gage Setup and Zeroing with D500 174
Mechanical Gage Setup 174
Model D500 Zeroing 176
Chapter 7. Maintenance 177
General Maintenance 177
Contacting Control Gaging for Assistance 177
Controllers 178
Controller Fuse Replacement 178
Controller Enclosure Cleaning 178
Controller Visual Inspections 178
Gage Heads 179
Gage Head Visual Inspections and Cleaning 179
Gage Head Troubleshooting 179
Gage Actuators 180
137383 11
Glossary 181
Index 184
12 137383
Introduction
Chapter 1. Introduction
Contacting CGI
Main Office (US)
Control Gaging, Inc.
847 Avis Drive
Ann Arbor, MI 48108
+1.734.668.6750
Fax +1.734.994.1335
www.controlgaging.com

For Telephone Email

Spare Parts +1.734.669.6589 parts@controlgaging.com
Factory Repairs +1.734.669.6589 repairs@controlgaging.com
Technical Support +1.734.669.6590 service@controlgaging.com

International Offices
Visit our website for a complete listing of International Sales offices.

Feedback
We value your input. Please send your questions and comments about our products and services,
including this documentation set, to sales@controlgaging.com. One of our knowledgeable staff will
respond to your email.
137383 13
Introduction
Warnings and Cautions:
Warning! FAILURE TO COMPLY WITH THE WARNINGS AND CAUTIONS GIVEN

BELOW MAY UNNECESSARILY COMPROMISE THE SAFETY OF THE EQUIPMENT
OPERATOR(S) AND MAY ALSO RENDER THIS EQUIPMENT OR ITS OPERATOR(S)
NON-COMPLIANT WITH REGARD TO THE SAFETY AND/OR EMC COMPATIBILITY
REQUIREMENTS OF THE EUROPEAN COMMUNITY.
Intended Use of Equipment

l All components of the gaging system must be operated within the limits set forth in the
CONTROLLER SPECIFICATIONS section of this manual.
l If this equipment is used in a manner not specified in the above cautions and other instructions
in this manual, the protection provided by the equipment may be impaired.
Controller Grounding
When Using a Grounded 3-Prong Power Chord:
l The grounded 3-prong power cord supplied with the unit is the main power
DISCONNECT DEVICE for the controller.
l The controller must not be used without a grounded power cord as specified
unless the 2-prong cord meets all other criteria defined in CONTROLLER
SPECIFICATIONS and the Protective Earth Lug is connected to Earth Ground.
When Not Using Grounded 3-Prong Power Chord:
l If a grounded power cord is not used, the Protective Earth (PE) Lug on the rear
panel of the controller, marked: must be connected to Earth Ground

using suitable GREEN/YELLOW-insulated wire before connecting any cables to
the controller, and it must remain so connected as long as any cables remain
connected to the controller.
l The PE Lug is an M4 threaded stud; Terminate the wire with a locking (internal-
tooth) ring terminal of suitable size, secured to the PE Lug with an M4 nut.
Hazardous Voltages
Warning! Hazardous voltages may be present inside the controller, even when its
power switch is OFF. If the controller's enclosure must be removed, this must be
done only by qualified and authorized personnel.
14 137383
Introduction
Warning! Exposed hazardous voltages are especially likely to be found in the

power inlet module terminals and on the circuit boards.
Warning! Unless required for troubleshooting purposes, disconnect all cables from
the controller prior to removal of the enclosure while leaving the Protective Earth
wire (if attached) connected.
Guarding
l Gages and gage actuators must be installed with adequate safety guarding in accordance with
European Directive 2006/42/EC (The Machinery Directive) before being placed into the
European market.
l These standards may require an emergency switch within one (1) meter of the moving part.
137383 15
Introduction
Safety
The gaging equipment supplied by Control Gaging typically has very little user risk. Operators should
still remain alert to surrounding conditions and be familiar with plant safety while operating machinery
to avoid potential hazards. Equipment must be maintained properly to remain safe.
Safety guidelines in this documentation are meant to be used as a supplement to your plant's safety
procedures.
Read the Manual

It is the responsibility of the customer to ensure that all personnel who will operate, maintain or clean
this equipment be trained in proper operation and machine safety.
Personal Protective Equipment

Employees must wear personal protective equipment (PPE) as dictated by your plant's regulations and
bylaws.
Ear Protection
While this gaging equipment does not reach a dangerous decibel level, it will be located in an area
which will cause hearing damage if proper ear protection is not worn. See your plant regulations for ear
protection requirements.
Eye Protection
Wear eye protection with side shields when operating this machinery. Although this gaging machinery
is not capable of producing risk to eyes, it will be located in an area or plant where potential eye haz-
ards such as grinding, cutting, sparks and chemical splash do exist.
If you wear prescription glasses, wear goggles over your glasses.
Body Protection
Do not wear loose fitting clothing or jewelry when operating equipment.
Respiratory Protection
This equipment does not emit fumes, vapors or emissions therefore, respiratory protection is not
required.
Clear Gaging Area

Make sure that all tools and master workpieces are removed from the gaging area before beginning
operation.
Emergency Stopping Devices

Know how to shut down the equipment is case of emergency. Locate E-Stops or Emergency Stop
Cables.
16 137383
Introduction
Periodically test Emergency Stopping Devices to make sure they are in good working order.
Main Electrical Disconnects

Locate main electrical disconnects before operating, repairing or cleaning machinery.
Pneumatic Lockout Valves

Locate pneumatic lockout valves (if applicable) before operating, repairing or cleaning machinery.
Safety Symbols
These symbols may be located on supplied equipment and require the appropriate cautionary or cor-
rective action described below.
Symbol Symbol Description

Protective Earth Symbol
The protective earth symbol is found adjacent to the safety ground
point/stud.
If the primary power cable does not include an earth ground, a
green/yellow wire must be connected from this terminal to earth
ground.
Fuse Symbol
Fuse label on controller rear panel. Fast blow fuses are designated with
an "F". For example, a fuse labeled F2A would be a fast blow 2 amp
fuse. Time delay fuses are designated with a "T."
For example, a fuse labeled T2A would be a 2 amp time delay fuse.
Warning Symbol
WARNING "See Manual" - Warning symbol used to call attention and
refers user to manual for explanation.
High Voltage Symbol

WARNING "High Voltage" – Hazardous voltages may be present; this
area should be accessed only by qualified and authorized personnel.
Table 1-1. Safety Symbols
137383 17
Introduction
Documentation Disclaimer
Control Gaging Supplied Components

The descriptions, procedures, safety warnings and specifications provided in this manual apply spe-
cifically to those components of the equipment supplied by Control Gaging.
For documentation regarding previously purchased Control Gaging supplied equipment, contact CGI
Customer Service.
Note: Please have specific model numbers and/or serial numbers of the equip-
ment for which you want documentation, including those same numbers for the
gage controller(s) to be used with it.
New Control Gaging Components Added to Existing Systems

If your order includes new components that will be incorporated into existing gaging systems;
Every attempt has been made to represent and update gaging system documentation as accurately as
possible but due to the age of the originally sold gaging components, it is not always possible for
manual to exactly reflect current configuration and operation sequence.
Customer Supplied Components

In addition to the inclusion of documentation covering Control Gaging supplied equipment, we make
every attempt to include information regarding interaction and the expected use of customer supplied
components (if provided to us) within the gaging operation.
If your equipment differs significantly from the example equipment described, it may be necessary for
you to write new instructions for operator use.
If you have purchased a partial system or are only replacing individual components of the complete
gaging system, see the headings below concerning customer supplied items.
Gages - Customer Supplied
If the equipment supplied by Control Gaging Inc. with this job order is limited to the gage controller,
refer to the manufacturer's original document for the measurement heads, actuators and fixtures.
In cases where previously supplied equipment included pencil-type gage probes, CGI may supply
replacement probes of the same type: see section “Gage Probe Setup with D500” for setup and use.
If customer-supplied gages are replacing Control Gaging gage

heads:
l Refer to the manufacturer’s instructions for calibration and setup.

l “Generic” instructions for a similar type of gage head may be included later in
this manual.
18 137383
Introduction
l If the system also includes fixtures or actuators originally supplied by CGI, refer
to the original documentation provided with the system.
Controllers - Customer Supplied
If the equipment supplied by Control Gaging Inc. with this job order is limited to the mechanical hard-
ware, including gage heads, actuators and/or fixtures. These items are described in separate sections
of this manual.
The electronic equipment needed to supply the signal conditioning and control logic for this applic-
ation are provided by the end-user or the machine manufacturer and are not described in this manual.
For questions regarding those items, refer to the original documentation supplied with that equipment
for operation, setup or maintenance.
Actuators, Fixtures and Parts Handling Equipment - Customer Supplied
If the equipment supplied by Control Gaging Inc. with this job order includes the gage controller and
gage heads but does not include gage actuators, fixtures or parts-moving components in the system,
refer to the original documentation supplied with that equipment for operation, setup or maintenance.
137383 19
Introduction

20 137383
System Overview
Chapter 2. System Overview
Introduction – D500 Gaging System for Through-Feed Centerless Grinder
System Summary
The gaging system described in this manual has been designed to improve and automate size control
on a through-feed centerless grinder. A Model 31M single-finger gage head is mounted to measure
the long-rod workpiece as it exits the workrest blade. The D500 Gaging Controller takes size readings
from the gage on a timed basis as the part passes between the wheels. The controller’s special Intel-
ligent Process Control software assembles the readings into subgroups, analyzes the size trend, then
provides compensation outputs to the machine to maintain size to the machine’s best capability.
This section provides a brief introduction to the gage system elements and their operation. These ele-
ments are described in full detail later in the manual.
Gage Assembly
Figure 2-1. Model 31 on Through-Feed Centerless Grinder
The gage head is mounted above the workrest so the gage contact is opposed to the blade surface as
shown in the example figure below. As the part passes between the wheels, a diameter measurement
is taken and processed by the controller. The rotation of the workpiece and the forces between the
137383 21
System Overview
wheels hold the part down onto the blade to maintain a dynamic but mechanically stable location of
the part for measurement.
The mechanical gage mounting arrangement will be similar to that shown in the next figure. If the
workrest blade is on an angle, the gage will be mounted to contact the part on that same angle. In any
case, the bracket will have a centerline adjustment screw that allows, after loosening the gage clamp
screws, the careful positioning of the gage contact horizontally until it is opposite the top of the blade.
Depending on the size range of the workpieces being ground, the mounting brackets may also have
vertical adjustment slots and clamp screws. Use these in combination with the horizontal adjust to pos-
ition the gage and contacts relative to the diameters of the different size parts.
D500 Gage Controller
Note: For a full description of the standard display components , see chapter Sys-
tem Component - Gage Controller.
The D500 Controller is a PC-based gage amplifier and controller specifically designed for high accur-
acy measurement applications in the manufacturing environment. The controller is highly con-
figurable for a wide range of applications, including multiple gage inputs, calculated measurements,
control and compensation outputs, statistical analysis and data collection, and a variety of other
optional features that expand its capability on a cost-effective basis.
Figure 2-2. D500 Gage Controller
Gage readings are displayed on a color LCD screen in a compact-sized enclosure. The screen is set up
to display real-time readings along with the status of machine inputs and size-control setpoints.
Setpoints are typically represented by a colored box on the LCD screen adjacent to the vertical or hori-
zontal bar graph of measured size. During and after the measurement cycle, setpoint indicators are
lighted to indicate the size status of the workpiece. Size values may also be communicated to a
machine controller or network via BCD or serial outputs.
22 137383
System Overview
Compensation control is based on statistical analysis of moving size trends, either by continuous aver-
aging (Averaging Compensation) or a self-improving, sigma-based analysis called Intelligent Process
Control. Compensation methods are selectable for a wide variety of machine control types.
The appearance of the display will vary depending on application.
137383 23
System Overview
Optional Software Features
Note: For further detail and set-up instructions for the optional software features
shown below, see the Optional Software Features section of the System Com-
ponent - Gage Controller chapter.
Intelligent Process Control (IPC) Option

Intelligent Process Control (IPC) is a D500 controller based option that provides sophisticated trend ana-
lysis and response software based on many years of experience in process optimization. The cal-
culations continuously refine the frequency and distance of machine compensations until they are as
small and as frequent as the observed process will allow. The result is a very narrow part size tolerance
band, as tight as the machine’s mechanical capability can produce.
For a complete description and setup information, see IPC option.
Micropeak with Dynamic Zero Option

Micropeak is a software feature used to capture a gage reading on irregular or interrupted surfaces or
on rapidly moving parts as they go through a gage station. Under these circumstances, the “live” or
“real time” gage reading is moving up and down too rapidly to use without modification. The “peak”
aspect of the feature is that it catches the extreme (usually the maximum) point of the moving gage
reading during one part or measurement cycle. Micropeak then holds on to that maximum reading
and displays it on the screen until the “live” gage reading goes through another cycle and captures a
new value.
Dynamic zeroing is used with the Micropeak function to replicate the actual process conditions where
workpieces are measured while moving relative to the gage. The dynamic zeroing process can aver-
age multiple passes on a master or on several on-size parts to provide reliable, high-accuracy zeroing
under dynamic conditions.
The Visual Profiler option is standard on all Micropeak applications.
For a complete description and setup information, see Micropeak with Dynamic Zero option.
Multi-Part and/or Multi-Diameter Selection Option

The Multi-Part Selection option allows the user to save limited configuration information (setpoints
and size zeroing offsets) and associate it with identification numbers that can be selected from a
menu. This allows quick changeover from one part or size to another, either manually by selecting
from a drop-down box, or automatically using a remote selection input from the machine or process
controller.
Note: Gage Enable Delay will restart each time a new diameter is selected, even if
there are inputs already on.
For a complete description and setup information, see Multi-Part or Multi-Diameter option.
24 137383
System Overview
Statistical Process Control (SPC) with Data Storage and Download

Statistical Process Control (SPC) data is collected in real time by the controller so it can be analyzed
according to standard techniques. A variety of user-settable parameters allow the user to configure the
display screens and calculations according to preference. Workpiece size data is collected in a data buf-
fer for each channel; the data can be downloaded conveniently to a flash drive for transfer to another
computer.
For a complete description and setup information, see SPC with Data Storage option.
Taper Option
Many gaging applications use a taper measurement as a way to determine if the diameter of a cyl-
indrical workpiece is being ground evenly and on center. This is accomplished by using at least two dia-
meter measurement points taken along the workpiece shaft. Calculation for the taper reading is
typically determined by subtracting the diameter of measurement 1 from the diameter of meas-
urement; 2. [Measurement 2] – [Measurement 1] = Taper.
For a complete description and setup information, see Taper option.
137383 25
System Overview
Gage Summary
Model 31M Single Finger Gage
Figure 2-3. Model 31M Single Finger Gage Head
The Model 31M gage is a fourth-generation gage used to precisely measure workpiece size, length,
thickness, location, height or wheel position. The gage includes finger retraction, adjustable limits for
retraction and overtravel amounts, and externally adjustable spring pressure. Every gage head is tested
to provide .5 micron repeatability to 5.15 sigma, the industry standard.
26 137383
Installation
Chapter 3. Installation
Gage Controller Installation

Proper mounting of the controller and installation of the wiring is critical to the maintainability of the
product as well as its proper function in machine control. Be sure to adhere to these instructions as well
as to plant standards and all mandated codes and directives for your region and locality.
Gage Controller Mounting Guidelines

Follow the guidelines listed below when mounting your gage controller:
l Mount the controller, preferably on a pedestal within easy view of the operator.
l Mount the controller away from the coolant spray
l Mount within range of the control cable to the machine control enclosure. Appropriate gage
and control cable lengths are customized to your installation.
l When mounting your controller, allow clearance for removal of the connectors on the rear
panel.
For electrical connections, see the Connector Wiring Diagram in the Installation Diagrams Chapter.
All wires in the control cable are color-coded and the pin designations are as shown on the diagram.
137383 27
Installation
Controller Mounting - Standard Mount

For "free standing" standard enclosure installations, follow Gage Controller Mounting Guidelines.
The gage controller should be bolted down to the platform using the existing mounting holes on the
bottom of the unit to insure that it does not move or fall.
Use the chart below to determine the thread size and quantity of the existing mounting holes on the
bottom of each gage controller. Mounting bolts are not supplied as length will be specific to install-
ation.
Controller Existing Mounting Hole - Thread Size Qty.

D500 M4 4
28 137383
Installation
D500 Controller Dimensions - Standard Mount
Figure 3-1. D500 Controller Dimensions - Standard Mount - D9053050-001
137383 29
Installation
Electrical Connections
For electrical connections, see the wiring diagram(s) in the Installation Diagrams chapter. All wires in
the control cable are color-coded and the pin designations are as shown on the diagram.
Power Wiring
3-Prong Plug
The grounded 3-prong power cord supplied with the unit is the main power DISCONNECT DEVICE for
the controller. The controller must not be used without a grounded power cord as specified unless the
2-prong cord meets all other criteria defined in section “General Controller Specifications” and the Pro-
tective Earth Lug is connected to Earth Ground as described next.
Grounding Without Using Grounded 3-Prong Plug
If the supplied 3-prong grounded power cord is not used, the Protective Earth (PE) Lug on the rear
panel of the controller, marked: must be connected to Earth Ground using suitable
GREEN/YELLOW-insulated wire before connecting any cables to the controller, and it must remain so
connected as long as any cables remain connected to the controller.
The PE Lug is an M4 threaded stud; it is recommended that the wire be terminated with a locking
(internal-tooth) ring terminal of suitable size, secured to the PE Lug with an M4 nut.
Note: The following instructions apply to a high percentage of units that include
the “Wheelslide Enable” output and “Gage Enable” input.
Alternate wiring schemes may be detailed in the Installation Diagram chapter.
“Wheelslide Enable” Output Wiring
Note: "Wheelslide Enable" may also be called “Gage in Auto” or “RUN Mode”
The “Wheelslide Enable1” output communicates to the machine control that the gage controller is
in automatic mode and ready for gage control. It can be used as a “safety switch” to prevent the cycle
from starting when the controller is in the "SETUP" mode or to shut down operation if the system, for
whatever reason (internal fault, power failure, etc.) falls out of RUN mode. In SETUP (Manual) mode,
the control point relays do not output to the machine, so a machine cycle started in SETUP mode will
not be under gage control. Machine manufacturers may alternately label their input for this signal as
“Gage in Auto” or “Run Mode”.
If this output is not wired in, the system can be used for visual gaging or “rework” without any setpoint
outputs to the machine.
1The “Wheelslide Enable” output communicates to the machine control that the gage controller is in auto-
matic mode and ready for gage control.
30 137383
Installation
Unless rework or visual gaging is performed on the machine, CGI very strongly recommends that this
output be wired as described.
Warning! Failure to connect this output to shut down grinding or feeding oper-
ations when the gage is not in control of the machine may result in damage to the
machine or production of uncontrolled bad parts.
“Gage Enable” Input Wiring
Note: "Gage Enable" may also be called “Gage Cycle Start”.
The “Gage Enable” input accepts an output (often labeled “Gage Cycle Start” in machine diagrams)
from the machine control. The gage channelmust be “enabled” for its outputs to be energized. The
input initiates the “Gage Enable Delay Timer”, which is adjustable in SETUP mode. This timer delays
the activation (or “enabling”) of the controller outputs in some applications where it is needed, as
explained below.
As an example, in an OD (outside diameter) grinder application, the gage fingers may be resting in a
closed position (gage reading below zero) until the gage is advanced and the fingers “ramp up” onto
the diameter. If the grinder control sends a “start gage cycle“ signal (the Gage Enable Input) to the
gage controller before the gage fingers are advanced fully onto the part, the setpoint outputs will
immediately be energized and the cycle will be prematurely ended. In this application, the "Gage
Enable Delay Timer" must be set to a value slightly longer than the time it takes for the gage to
advance.
Many modern machine controllers include a delay timer in their program, or the “Gage Enable Input” is
set at a different time from the beginning of gage advance. Also, in some applications, the gage fin-
gers are held open between gage cycles and will not cause the relays to energize during advance. In
such cases, the "Gage Enable Delay Timer" may need to be set to zero or to an appropriate time in
combination with the machine delay.
Controllers and Gage Electronics - Customer Supplied

Disclaimer
The equipment supplied by Control Gaging Inc. with this job order may be limited to the mechanical
hardware, including gage heads, actuators and/or fixtures. These items are described in separate sec-
tions of this manual.
The electronic equipment needed to supply the signal conditioning and control logic for this applic-
ation are provided by the end-user or the machine manufacturer, and are not described in this manual.
For questions regarding those items, refer to the original documentation supplied with that equip-
ment.
Converter Box Installation

This section is provided for users who have a new Gage Controller for connection to a machine (typ-
ically of older vintage) that cannot use low-voltage solid-state inputs and outputs. In order to simplify
137383 31
Installation
the installation, Control Gaging provides a “converter box” that connects between the Gage Controller
and the machine controller using the existing cables and connectors.
A system connection diagram is also included in the converter box housing when shipped, and should
remain in the box after installation.
32 137383
Installation Diagrams
Chapter 4. Installation Diagrams

Drawings that follow will include all electrical wiring, pneumatic or hydraulic diagrams associated with
this installation.
D500 Connector Wiring

CGI Drawing Reference: A895105-004 Rev. E
Control Cable Wiring (CC1)
DB37 # I/O # Wire Color Signal Type Signal Name

18/19 --- WHT --- INPUTS COMMON (notes 2 & 4)
36/37 --- BLU --- OUTPUTS COMMON (notes 3 & 4)
28 I-1 ORG INPUT (12-24VDC) GAGE ENABLE
10 I-2 RED INPUT (12-24VDC) PART SENSOR
29 I-3 GRN INPUT (12-24VDC)
11 I-4 BLK INPUT (12-24VDC)
30 I-5 BLK/WHT/RED INPUT (12-24VDC)
12 I-6 WHT/BLK/RED INPUT (12-24VDC)
31 I-7 RED/BLK/WHT INPUT (12-24VDC)
13 I-8 ORG/BLK/WHT INPUT (12-24VDC)
9 O-1 ORG/BLK OUTPUT (12-24VDC) RUN MODE (Closed when in RUN
Mode and no faults)
27 O-2 RED/BLK OUTPUT (12-24VDC)
8 O-3 WHT/BLK OUTPUT (12-24VDC) PART NOT BAD DIVERTER OUTPUT
(Note 5)
26 O-4 BLK/WHT OUTPUT (12-24VDC)
7 O-5 BLU/BLK OUTPUT (12-24VDC) COMP IN (forward feed)
25 O-6 RED/WHT OUTPUT (12-24VDC) COMP OUT (reverse feed)
6 O-7 GRN/WHT OUTPUT (12-24VDC) BAD PART (Note 5)
24 O-8 BLU/WHT OUTPUT (12-24VDC) GOOD PART (Note 5)
5 O-9 BLK/RED OUTPUT (12-24VDC)
23 O-10 WHT/RED OUTPUT (12-24VDC)
4 O-11 ORG/RED OUTPUT (12-24VDC)
22 O-12 BLU/RED OUTPUT (12-24VDC)
3 O-13 RED/GRN OUTPUT (12-24VDC)
21 O-14 ORG/GRN OUTPUT (12-24VDC)
2 O-15 GRN/BLK/WHT OUTPUT (12-24VDC)
20 O-16 GRN/BLK OUTPUT (12-24VDC)
137383 33
Power Cable Wiring - International Colors
Wire Color Signal

Brown 100-240VAC High
Blue 100-240VAC Low
Green/Yellow Ground
NOTES:
1. CC refers to control cable, for example CC1 means Control Cable 1.
2. The machine’s 24V power supply (12V-26.4V) supplies power to the Input and Output Com-
mons. One lead connects to the INPUT COMMON, and the other lead connects to the
OUTPUT COMMON.
3. The OUTPUT COMMON is supplied to every switch and relay output on the machine. All “ON”
or “TRUE” IO wires are the same voltage as the OUTPUT COMMON. The D500’s relays are
wired like the other machine outputs so connect the D500’s OUTPUT COMMON directly to
the Machine’s OUTPUT COMMON. D500 output current <= 1/8A.
4. The INPUT COMMON returns from every input module or solenoid on the machine. All “OFF”
or “FALSE” IO wires are the same voltage as the INPUT COMMON. The D500’s inputs are wired
like all the other machine inputs so connect the D500’s INPUT COMMON directly to the
Machine’s INPUT COMMON.
5. The Good and Bad outputs (O7&8) signify the state of the last part measured. The machine can
use the Good and Bad outputs to identify good parts and use its own diverter logic, or it can let
the D500 control the diverter with the Part-Not-Bad Diverter (O3) output. A D500 controlled
diverter should be wired to divert all parts unless Part-Not Bad is active. Whenever the D500
loses power, or is taken out of Run mode, the diverter returns to the divert position, preventing
34 137383
any bad parts from proceeding down the diverter. After the D500 gages a Good Part, it waits
until the part has moved to the diverter, and energizes Part-Not-Bad, moving the diverter to
the accept parts position, to allow just this part to continue down the conveyor.
6. Rev. A (9/18/07) Corrected output numbering,
Rev. B (10/2/07) Changed diverter output text to NBP
Rev. C (10/24/07) Added Note 4
Rev. D (3/30/11) Revised Note 2-4 for clarity, added drawing.
Rev. E (7/9/12) Added Note 5, removed US Colors Power Cable wiring chart.
137383 35
Model 31M Finger Retraction - Pneumatic Circuit Diagram
Figure 4-1. Pneumatic Circuit – Model 31M Finger Retraction
For finger retraction the air supply should include a filter, a pressure regulator, and flow control valves
as shown to provide for smooth operation. Do not lubricate, since oil may collect in the cylinder.
Requirements English Metric

Incoming Air (Typical) 100 psi 700 kPa
Working Pressure 60-80 psi 400-500 kPa
Caution! Model 31M gage heads do not operate on hydraulics. Connections to

hydraulic pressure will damage the gage.
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System Component - Gage Controller
Chapter 5. System Component - Gage Controller
D500 Controller Front Panel and Keypad

The D500 Controller Front Panel contains the following components:
1. Power LED
2. Color LCD Display Window
3. Keyboard
The power LED is lighted green when the unit is powered up. All other information to the operator is
provided through the display window and all inputs from the operator to the gage controller are
provided through the keypad.
Figure 5-1. D500 Front Panel
Display Window
The color LCD screen displays the data display screens and setup pages used by the operator for oper-
ation and setup.
Note: Contents of the display window will vary considerably depending on the num-
ber of gage or calculated channels and the features included.
The software program operating the gage controller is a proprietary application running under Win-
dows® XP. It typically presents a single AUTO mode screen for normal operation. There are also a
number of separate SETUP mode “pages” that may be selected using the Menu Bar at the top of the
screen. Use of the keypad for navigation and data entry is described in the rest of this section
137383 37
D500 Controller - Modified Interface for Microsoft® Windows®
The D500 controller's keypad provides a subset of the keys normally used in a typical Microsoft® Win-
dows® interface, but still provides full navigation and use of dialog boxes without a mouse.
There are some simple “non-Windows” functions that have been added to enhance the power of the
keypad while reducing the number of keys on the panel. This sub-section provides some definitions
that clarify the most important similarities and differences between the D500 interface and the stand-
ard Windows® interface. The next sub-section describes in detail the use and function of each indi-
vidual key.
Focus
As in standard Windows®, a screen element (sometimes called a “control”) has the “focus” when it is
selected for action. The element may then be used to enter data, cause an action, etc. An element
that “has the focus” is always highlighted in some way, either by having its “shadows” deepened, its col-
ors inverted, or a dotted line around the outside or inside of the element. Since the D500 screens are
sometimes visually complex, the D500 also includes a light blue “focus pointer” triangle [ ] to
assist in locating the active element.
Figure 5-2. Focus Pointer and Menu Bar
Menu Bar
The Menu Bar displays the menu items available for selection on the Front Panel screen in either RUN
or SETUP mode. The Menu Bar is active and has the focus when there is a blue highlight on the bar,
either a square box in the upper left corner (as shown above) or one of the menu items is reverse-high-
lighted with a blue rectangle. To select the Menu Bar, press one of the [TAB] keys until a blue high-
light appears; to select an item, use the left [←] and right [→] arrow keys. Use of the Menu Bar is
described in more detail in later sections.
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“Dual-Use” Keys
Six of the keys on the keypad have two symbols, one being a number and the other being a navigation
symbol. In the SETUP mode, when a numerical data entry box is in Data Entry mode, the navigation
function of these keys is not operable – pressing the key will enter the selected number into the data
entry field. This method reduces the total number of keys on the front panel by six.
Data Entry Mode
In order to define the circumstances when the “dual-use” keys are numbers and when they are arrows
or tabs, the D500 has a special keypad mode in SETUP called Data Entry mode. For any “data entry
box” in SETUP mode where numbers are to be entered, the following sequence is used:
1. First, place the focus on the desired data entry field using the [TAB] keys. The numbers will be
reverse-highlighted, with the background dark and the numbers white as shown below.
Figure 5-3. Data Entry Box Selected
2. Press the [CLR] key to “zero out” the current value and to enter Data Entry mode. The reverse
highlight will disappear and the numbers in the box will turn red to indicate they are active.
The cursor is flashing at the right of the box.
NOTE: You can also press the [ENTER] key for Data Entry mode, but the current value
remains in place and you will need to press [CLR] anyway.
Figure 5-4. Data Entry Box in Data Entry mode
3. Enter the value desired with the number keypad. The “dual use” keys now function as numbers
only. The numbers will enter from right to left. If you make an error, press the [CLR] key again
and re-enter the value.
4. Press the [ENTER]key to load the value into memory and also leave Data Entry mode. The
navigation functions of the dual-use keys are now restored.
137383 39
Note: Except for numeric data entry, moving the focus away from a control
- typically by using a [TAB] key - automatically saves the new value to
memory. However, while you are still in Data Entry mode, pressing a [TAB]
key will enter a “7” or a “9” into the data entry box instead, and you will have
to re-enter the value. To leave a data entry box, first press [ENTER] to save
the value and to exit Data Entry mode, then press [TAB] to move away.
Windows® “Overlapping” Key Functions
Some of the standard Windows® keyboard actions include “overlapping” functions, such as when the
down arrow acts the same as the tab key. Due to the structure of Windows®, these overlaps do exist
in D500 screen navigation but because of the sometimes complex nature of the screens, the keys may
not act entirely as expected and the focus may be hard to find.
For simplest navigation in the D500, use the tab and arrow keys only for the functions described in the
next subsection, which are summarized as follows:
Tab keys: navigation from element to element
Right/left arrow keys: navigation across Menu Bar
Up/down arrow keys: selection in list boxes
Windows® “Title Bar” (Item 1)
The Title Bar (the colored bar at the very top of the program window with the program name) is not
accessible from the keypad, so the window cannot be minimized, re-sized, or closed.
Substitute and Special Use Keys

l Substitute Key: Instead of using the Space bar (which is not available) for selecting and
deselecting a check box, the “plus” [+] key adds a check and the “minus” [-] key deletes the
check.
l Special Use Key: In the Diagnostics page, pressing the [0] key toggles the state of the out-
puts
40 137383
Individual Key Functions:

Item number references in the descriptions below are to the next figure, “D500 Front Panel Layout”.
Each description identifies one or more actions that result when that key is pressed when in AUTO
mode or when in SETUP mode.
Figure 5-5. D500 Front Panel Layout
MODE Key (Item 5)

The [MODE]key toggles (alternates) between AUTO and SETUP modes.
AUTO: From AUTO, press the [MODE] key to enter SETUP mode – the leftmost item in the Menu Bar
is now “pushed in” and active.
SETUP: From SETUP, press [MODE] to enter AUTO.
TAB Keys (Items 2 and 4)

The [TAB] keys are the means to navigate from one control element to another on the screen.
AUTO and SETUP:
137383 41
Right [TAB] (dual-use with numeral 9): Moves the focus through the screen elements, based on stand-
ard Windows ® conventions and with reference to the way the elements are grouped on the screen.
Left [TAB] (dual-use with numeral 7): Moves the focus through the screen elements in the reverse dir-
ection from the right tab key. This key corresponds to shift-tab on the standard keyboard.
LEFT and RIGHT ARROW Keys (Represented by Item 12, dual use with numerals
4 and 6)
AUTO and SETUP:
Moves the focus horizontally in the Menu Bar. Press the right arrow [→] to move along the bar to the
right, press the left arrow [←] to move along the bar to the left. Press [ENTER] to select the desired
page or drop down a menu. The key action does not “wrap” from end to end – when you get to one
end of the list, use the other key to go in the opposite direction.
UP and DOWN ARROW Keys (Represented by Item 3, dual use with numerals 8
and 2)
AUTO and SETUP:
These keys step through items in a drop-down list box. A list box is used to select among pre-defined
alternatives such as “System Units” in the Settings page or “Spline Filter” in the Gage Setup page. The
key action does not “wrap” from top to bottom – when you get to one end of the list, use the other key
to go in the opposite direction.
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ESCAPE Key (Item 6)
AUTO: Closes “Gage Jogging” dialog box without saving.

SETUP: In Data entry mode, restores original value and exits Data entry mode.
Closes drop-down menus.
Closes a SETUP mode page from most elements.
CLEAR Key (Item 7)
AUTO: Clears value in “Gage Jogging” dialog box to “0”.

SETUP: Changes reverse-highlighted data entry box into Data entry mode and clears value to “0”.
Clears a value in Data entry mode to “0”.
Clears ERROR messages from the display after the error cause has been eliminated.
ENTER Key (Item 8)
AUTO: Displays selected page or dropdown menu from the Menu Bar.
If a channel’s jog buttons on screen are selected, opens “Gage Jogging” pop-up window to enter a spe-
cific jog value.
SETUP: Displays selected page or dropdown menu from the Menu Bar.
Changes highlighted data entry box into Data entry mode, retaining previous value.
Loads newly entered value (data entry box only) into memory and then drops out of Data entry mode.
Initiates action of a push button element.
Accepts a new value in a dropdown box.
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PLUS and MINUS Keys (Items 9 and 11)
AUTO: Adds positive or negative offset (jog up or jog down) for the selected gage if its jog buttons are
active (have the focus) on the screen.
SETUP: Changes sign of a numeric value entered into a data entry box.
Select a check box ([ + ] key) or deselect a check box ([ - ]key).
Increments by “1” ( + or - ) the number in a “spin control” box
ZERO Key (Item 10)
AUTO: In a numeric data entry box, enters “0”

SETUP: In a numeric data entry box, enters “0”
Energizes and de-energizes outputs in the Diagnostics Page – select the output to test, then press
“0” to energize, “0” again to de-energize.
NUMBER Keys
AUTO and SETUP:

Enter numbers into data entry box when in data entry mode.
44 137383
Common Tasks Using the Keypad

Entering Values into a “Data Entry Box"
1. Use the [TAB] keys to move the focus pointer to the desired box. The numbers will be high-
lighted in reverse color.
2. Press [CLR] to enter Data Entry mode and clear the current value to “0”. This disables the
arrow and tab functions on the number keys. The numbers in the data entry box will turn red
and the reverse background will disappear. The cursor will flash to the right in the box.
Note: You may also press [ENTER] to enter data entry mode, then press
[CLR] to set the value to “0”.
3. Enter the new value with the keypad – the numbers will move into the box from right to left.
4. If you make a mistake, press [CLR] to reset the value to “0” and start again.
5. If you want to cancel entry, press [ESC] to restore the previous value and exit Data Entry mode,
or
6. When the value is correct, press [ENTER] to load the value and exit Data Entry mode.
Note: The data entry box for “Gage Jogging” in AUTO mode comes up
automatically in Data Entry mode – the navigation keys are already disabled.
Selecting Values in a “Drop-Down List Box”
1. Use the [TAB] keys to move the focus pointer to the desired box. The list will automatically
“drop down” with the current selection highlighted in reverse color. If the list does not drop
down, just proceed to Step 2.
2. Press the UP [↑] or DOWN [↓] arrow to scroll through the available choices. Leave the
desired value visible in the box.
3. Press a [TAB] key to accept the value and move to another element in the page.
Marking a “Check Box”
1. Use the [TAB] keys to move the focus pointer to the desired box.
2. Press the [+] key to select the box; press the [-] key to deselect the box
Testing Outputs in the Diagnostic Page
1. In SETUP mode, select Diagnostics from the Menu Bar and press [ENTER].
2. Use the [TAB] keys to select the output you want to test. It will show a dotted line inside the
numbered box.
3. Press the [0] key to energize the output; press the [0] key again to de-energize it.
137383 45
Using a Keyboard and Mouse with the D500

Many D500 application programs are relatively complex, with a large number of parameter values and
settings to be entered, especially during initial setup. In such a case, it is significantly easier and faster
to use a keyboard and mouse. The keyboard and mouse are also used to manage the files on the
D500 as on any other computer (see next section.)
The keyboard/mouse interface is USB, through the capped USB connector on the rear panel. To use
both the keyboard and the mouse at the same time you need a USB hub with at least two ports. If you
want to download or upload data from a removable flash drive (thumb drive), you will need three ports.
Connecting USB accessories:

To install keyboard and mouse:
1. Plug a USB hub with at least two ports into the rear panel connector.
2. Plug both the keyboard and the mouse into the hub. The mouse pointer will appear on the
screen in 1-2 seconds.
The interaction of mouse and keyboard with Windows is now standard with the following exception:
l There is no keyboard key that functions for [CLR]:

l You can still use the D500 keypad button if desired, or the Delete or Backspace keys on the key-
board.
Disconnect USB Accessories and Reboot:

1. After using the keyboard and mouse, remove the hub from the USB port on the rear panel.
2. Reboot the D500 by turning off the power for five seconds, then turning it back on. This clears
the mouse pointer and insures the USB system is cleaned up.
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Managing Program Files on the D500

There are occasions when a user may need to update a program, upload a new configuration, or even
change the program itself because the unit is being moved to a new application. This section
describes how to manage the program files. The unit is fully Windows-based and requires only familiar
file operations used on any PC.
Setting up for managing program files:

1. Connect a USB hub with three or more ports to the USB connector (with cap) on the rear panel.
2. Plug in the mouse and keyboard – wait until step 4 to plug in the thumb drive. The mouse
pointer will appear on the screen in 1-2 seconds.
3. Close the currently running D500 program as you would close any Windows program by left-
clicking on the [X] in the upper right corner.
Note: In a few applications, the normal “close” box is grayed out – if so,
select “Help” from the menu bar and click on “Exit D500”. You will now be
on the Windows Desktop. The menu bar at the bottom is hidden, but can be
raised by pulling the mouse pointer to the bottom of the screen.
4. If you are transferring files, plug in the thumb drive to the hub.
Note: Use a “simple” thumb drive without special features that may require
installation of a driver. The D500 controller cannot support driver installation
and will have to be rebooted to clear the installation wizard that may appear.
Windows may recognize the drive’s presence and pop up the “Removable Disk (E :)” action
box. If it does, select “Open folder to view files using Windows Explorer”. If it does not, you
can run Explorer later in the normal way when needed
Note: Early versions of the D500 had only a “C:” partition, but later versions
have both “C:” and “D:” partitions. If you have an early version, the action box
will show “Removable Disk (D :).
Program File Locations:

The program files are stored in folders on D: (or C: in earlier units) as shown in the next figure. The
numbered “job” folder 33216 contains copies of all files necessary to reconstruct the software system,
but only the files in the D500 folder (highlighted) are used for running the program.
137383 47
Figure 5-6. Explorer Screen, files on D: Thumb Drive Installed
Updating an Existing D500 Installation

1. Use Windows Explorer to copy the existing “numbered folder” at the top level (example,
33216) from the D500 drive to a backup directory on the thumb drive (example,
E:\Backup\33216).
l Do not overwrite the numbered folder on the thumb drive if it has the same number.
(The example above shows that the folder on the thumb drive E: has the same number,
but the folders below indicate a new revision level “317”). Create a Backup directory as
shown.
l Copy the whole folder and all its sub-folders.
2. Delete the numbered folder you just backed up from the D500 drive, including all subfolders.
3. Copy the replacement numbered folder from the thumb drive to the D500 drive, including all
sub-folders. It may or may not have the same number.
4. Delete files individually from the D500 folder on the D500 EXCEPT the following three, if they
are there (but do not worry if they are not there):
D500.lnk
input32.dll
vars
5. With Windows Explorer, open the C: or D:\number\number.version folder (above example,
D:\33216\33216.315), select all the files, and copy them into the D500 folder.
l If you get a pop-up box warning that you are about to overwrite the “vars” file,
select NO to keep the existing file UNLESS you have been specifically directed
by a CGI software or service engineer to replace this file.
48 137383
l If the D:\D500\D500.lnk (shortcut) file does not exist:

l Right-click on \D500\D500.exe and select “Create Shortcut”.
l Right-click on the new shortcut and rename it to “D500”.
6. Test the new installation by double-clicking on the new shortcut.

l The new front panel screen should appear. If it does not, rename \D500\vars to
“vars.old” and try again. If the program does start, a new “vars” file is created that will
need all setup parameters to be re-entered.
l If it does not start or you feel you need help here, contact the Control Gaging Field
Service or Electrical Engineering department.
7. If the program started and appears to be running correctly, shut it down by clicking on the [X]
box in the upper right hand corner. Click the Windows “Start” button in the lower left corner of
the screen and select “Shut Down.” After the screen goes blank, turn off the power, remove
the USB hub and accessories, then power up again after 5 seconds to reboot.
137383 49
D500 Series Controller Specifications
Physical (Standard Enclosures only)

D500
Screen Type Standard
HWD (inches): 5.06 x 8.72 x 8.60
HWD (millimeters): 128.5 x 221.5 x 218.4
Weight (lb.): approx. 5.75
Weight (kg): approx. 2.61
IP Rating (Ingress Protection): IP54
Power Requirements:
Controller:
Power Voltage/Frequency: 100–240VAC @ 50-60Hz

Power Consumption: approx. 21W
Fuse: 5 x 20mm Time Lag 1.6 amp 250VAC
Power Cord: 18AWG with connectors: 3-pin Shroud Female (IEC-320-
C13) to 3-prong Grounded Plug Male (NEMA 5-15-P)
Environmental:
Operating Ambient Temperature Range: 10-35° C /50-95° F
Operating Ambient Humidity Range: less than 90%, non-condensing
Note: Enclosure surface temperature will normally measure 11-17 °C / 20-30 °F

higher than ambient.
50 137383
I/O Ratings:
Warning! Only connect gage inputs, digital inputs, or digital outputs to voltages
within these specifications.
Digital Inputs:
Input Voltage Range: 20-30VDC

Input Power Dissipation: D500 - approx. 0.4W max per input
D500XL - approx. 0.07W max per input
Digital Outputs:
Maximum Output Current/Voltage: 0.1 ADC @ 30 VDC per output
Gage Inputs:
Voltage: 0V to +5V
137383 51
D500 Rear Panel
Figure 5-7. D500 Controller Rear Panel
Note: The number and types of connectors may vary depending on

system configuration.
1. Control Cable Connector(s)

Control cables with mating connectors are supplied with each gage system. Your system could
have up to two control cables depending on the number of I/O required. The standard control
cable length is 5m (16 feet). Longer cables are available upon request.
Warning! Voltages may be present on the internal pins of these connectors

even when the high voltage power cable (Item 5) has been disconnected.
Only a qualified electrician should work inside this unit when the cables are
connected and enclosure cover is removed.
2. RS-232 Serial Port Connector

Male 9-Pin connector (DB-9) used for uploading and downloading program data. Also can be
configured for size data output for testing purposes.
3. Power Switch
Turns power on to the controller. When cycling power, allow 3 or 4 seconds before turning
power back on.
4. Fuse
The D500 Controller uses a 1.6 Ampere 250 V fuse.
52 137383
5. 3-Prong Plug
For use with universal-type grounded power cord. The power cord is the main power dis-
connect device for the unit.
Warning! High voltages are present on the internal side of this connector if
the power cable is connected. Only a qualified electrician should work inside
this unit when the cable is connected and the enclosure cover is removed.
6. Gage Cable Connectors

Gage cable connectors are supplied for each gage supplied with the system. Unused con-
nector openings are plugged. The standard gage cable length is 3m (10 ft); longer cables or
extension cables are available upon request.
7. Serial Number Tag
When ordering replacement parts for this controller, please have the serial number available to
ensure that the correct replacement parts are delivered.
8. Protective Earth (PE) Lug
Earth-ground connection must be used if proper grounded 3-wire cord is not used.
9. USB Port Connector
Standard USB port for uploading and downloading program and SPC data.
137383 53
D500 Operating Modes

When the D500 Controller is powered up, it displays the normal PC-based BIOS screens, then the Con-
trol Gaging logo followed by a Windows® XP® Embedded operating system screen. The D500 pro-
gram is then loaded and the AUTO mode screen for the current application is displayed.
Figure 5-8. Sample D500 AUTO Mode Screen
l The system operates in either one of two modes: AUTO or SETUP. A third FAULT mode shuts
down operation and requires corrective action.
l The mode is selected using the AUTO/SETUP toggle key on the front panel as described
in D500 Front Panel and Keypad- “Individual Key Functions”.
l There is an indicator box, usually in the upper left corner of the screen, that alternates between
green “AUTO” and red/orange “SETUP”.
AUTO Mode
AUTO mode is the default operating mode, displaying part size, process conditions, and status of
inputs and outputs while the program is managing the measurements and control inputs and outputs.
The Menu Bar is active to view the Setup Pages, but some parameters cannot be changed in RUN
Mode.
SETUP Mode
When in SETUP mode, the user can view or change operating parameters, configure some of the
screen display elements, set gage channel factors such as gain and zero, or perform diagnostic
54 137383
activities. All of the SETUP mode functions are available through the Menu Bar at the top of the
screen.
FAULT Mode
The D500 enters FAULT Mode when a serious error occurs that impairs correct action of the D500 or
that may result in damage, injury or bad parts advancing through the gage system.
Keypad operation in both modes is similar to most Microsoft® Windows® applications, but the D500
has some unique features to optimize the use of front panel space. Navigation, selection, and data
entry functions using the keypad are described in detail in section, D500 Front Panel and Keypad.
137383 55
AUTO Mode Operation and Screen Elements

l AUTO mode is the default on power up.
l When the unit is in AUTO mode, gaging is active and the D500 Controller will accept inputs
from, and provide control outputs to, the machine tool or other controller.
l The AUTO Mode screen typically displays one or two gage channels, but may vary considerably
depending on the application.
l Each channel has a group of display “elements” that includes the name of the gage channel,
the current gage reading (in numeric format and on a bar-type meter), and indicator boxes that
show the status of inputs and outputs associated with that channel.
The standard element types are identified in the figure below and described by number in the
text.
Note: Your screen may have different names or wording, or show additional
optional features. If your screen is significantly different, check the manual
for a section Application-Specific Information in the System Overview
chapter for detailed descriptions of the special items.
Figure 5-9. Typical AUTO Mode Screen Elements
1. Mode Indicator Box

This indicator displays the current functional mode (AUTO or SETUP) of the unit.
l In AUTO mode, the full measuring and process control program is running and provid-
ing outputs to the machine.
56 137383
l In SETUP mode, the menu bar and SETUP pages are accessible for entering or chan-
ging process or gage parameters, or for zeroing or calibrating gages.
2. Gage Name
This is the name of the gage channel for the associated group of display items. The name is usu-
ally assigned in the factory configuration based on information about the application or at user
request.
3. Bar Meter
The gage measurement is displayed visually using a colored bar on a bar-type meter.
In some cases, the meters have two scales, which change automatically based on current part
size:
l COARSE - for more range with less resolution
l FINE - for more resolution with less range
The scale ranges are user-configurable; see heading “Meter Scales” in the “Settings Page” sub-
section later in this chapter.
4. Gage Reading
The value displayed in this position is typically the current “real-time” gage reading. If the unit
includes the Micropeak option or is a post-process application, this value will be the last gage
reading taken, which will remain until a new reading is acquired.
5. “Jog” Buttons
When these buttons have the focus, two modes of jogging are available:
l Jog - Press the plus or minus [ + ] [ - ] keys to “jog” (apply a size offset to) the
current gage reading. The jog amount for each key press is determined by the
“Jog Increment” value described in the “Settings Page” subsection later in this
chapter.
Figure 5-10. Gage Jogging Dialog Box
l Gage Jogging - Press the [ENTER] key to bring up the “Gage Jogging” dialog
box (shown above). The box comes up in Data entry mode, so you can directly
enter the exact amount of offset you want. A minus sign can be entered at any
time by pressing the minus key [ - ]. Press [ENTER] to load the offset and close
the box.
137383 57
The dialog box also displays the total amount of offsets applied since the last
time this channel was zeroed.
6. Focus Pointer
The small, light-blue triangular arrow helps the user see the screen element that has the focus
and is active at the moment
7. Setpoint Markers
l The triangular markers next to the bar meter indicate the values of the setpoints relative
to the meter.
l The markers correspond in vertical order to the setpoint labels in the indicator boxes.
Example - In the figure showing the AUTO Mode Screen Elements, the lowest marker cor-
responds to the “Setpoint 0” setpoint, the marker above it to the “Setpoint 1” setpoint, and the
top marker to the “Setpoint 2” setpoint. The “Setpoint 3” marker is not currently visible, since
it is above the current range of the meter. The colors of the markers correspond to the color of
its associated setpoint indicator box, and both are filled with color when the output is ener-
gized.
8. Gage Enable - Indicator Box
l This indicator displays the status of the “Gage Enable” input to the D500 from the
machine controller.
l The D500 is typically wired to receive this input from the machine when the machine is
ready for the gage system to take control of the cycle.
l Until at least one channel of the D500 is “enabled”, the relay outputs for machine con-
trol are not active and the gage system will not control the machine.
l If there is no input, the indicator reads “DISABLE”, as shown for Gage 2. When the D500
first receives the input, the indicator is “hatched” (crisscrossed green lines) until the
Gage Enable Timeout period is complete; after the timeout, the indicator is fully green
and reads “ENABLE”.
Refer to heading “Enable Time” (in the System Settings Page(s) subsection later in this
chapter) for instructions on using and setting the timer.
See also the heading Gage Enable (“Gage Cycle Start”) Input Wiring and the connection dia-
gram in the Installation Diagrams chapter for information about Gage Enable wiring.
9. Setpoint - Indicator Boxes
l The “setpoints” in the system are associated with outputs used for control of the
machine.
l When the workpiece measurement matches the pre-set value of a setpoint, the indic-
ator changes from gray to an assigned color and the corresponding output to the
machine is energized.
l The names in the setpoint boxes will vary according to application or customer pref-
erence.
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l Refer to heading Setpoints described in the System Settings Page subsection later in
this chapter.
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SETUP Mode Operation and Screen Elements

l SETUP mode is used to zero gages and to adjust the software parameters that control oper-
ation of the system or configure the appearance of screens.
l When in SETUP mode, the D500 does not provide control outputs to the machine controller
(except in Diagnostic mode).
l To enter SETUP from AUTO, press the [MODE] key.

l The color of the mode indicator box will change from green in AUTO to orange indicating
SETUP as shown in the figure below.
l If the focus pointer is at another element on the screen (as shown below), the Menu Bar is not
active.
l Press one of the [TAB] keys until a blue highlight appears on the Menu Bar – it may be a
square in the left corner or on one of the menu items.
Figure 5-11. Spin Controls
To select from the menu, use the left [←] or right [→] arrow keys to move the selection
among the choices on the bar. If there is not a dropdown menu, press the [ENTER] key to dis-
play the page; if there is a dropdown, use the [↑] [↓] arrows to select, then press [ENTER].
Descriptions of the typical SETUP mode pages (Zero, Settings, Gage Setup, Diagnostics, Help)
are provided in section “Setup Mode Pages and Parameters”.
Each of the SETUP mode pages displays a combination of screen elements of the type shown
in the Typical SETUP Mode Screen Elements figure. The elements are identified in the figure
and are described by number in the following text.
Additional common elements that may appear on SETUP mode screens are described and
shown following Item 6 “Close Pushbutton”.
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Figure 5-12. Typical SETUP Mode Screen Elements
Note: All the data changes made on a SETUP mode page go into effect in
the program and are loaded into memory immediately when you press
[ENTER] (data entry boxes) or [TAB] away from the control element (all
other controls).
1. Data Entry Box

l The data entry box allows the insertion of parameter values that configure process oper-
ations (such as setpoints and timers) or gage functions (such as calibrating gain.)
l The use of the keypad in entering data has been discussed in detail under headings
Entering Values into a Data Entry Box and Data Entry Mode in section D500 Front
Panel and Keypad.
2. Pushbutton
l A button, when activated, performs an action of some kind, such as zeroing the gage
channel, setting gain, or accepting and closing a page.
l “Pushing” a button requires highlighting it with the [TAB] keys (it shows a dotted rect-
angle inside), then pressing the [ENTER] key.
l The functions of specific buttons are described under the headings for each page in the
manual. For example, the function and accompanying procedure for the “Zero” button
shown above would be under heading Zero Pushbutton in the Gage Setup Page sub-
section.
3. Display Box
l A display box shows the current value of a gage reading or a calculation derived from
other data in the system.
l Display boxes provide information needed to make decisions or assess conditions in the
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system.
l You cannot access a display box.
4. Dropdown List Box
l The dropdown list box contains a list of choices that are available for the parameter it
controls.
l The function of the parameter is described in the manual under the heading for the cor-
responding SETUP page. To access, [TAB] to the list box, then use the ↑ ↓ arrows to
highlight the desired value. [TAB] to the next element to save the value.
5. Check Box
l A check box enables or disables (by selecting or deselecting a check in the box) a dis-
play of information or the function of a feature.
l The information or feature is described in the manual under the heading for the cor-
responding SETUP page.
l To access, [TAB] to the list box, then use the [+] [-] keys to select or deselect the box.
[TAB] to the next element to save the value.
6. Close Pushbutton
Select the “Close” pushbutton and press [ENTER] to close the SETUP mode page and return
to the main AUTO screen - the focus returns to the far left item on the Menu Bar. Pressing
[ESC] will also close the page.
Figure 5-13. Spin Controls
7. Number Selection “Spin Control”

l A “Spin Control” allows the user to select from a list of numbers by pressing the “plus”
[+] or “minus” [-] keys.
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l The control may have the scroll arrows arranged horizontally or vertically but both act
the same.
l To increase the number shown in the box by an increment of “1”, press [+], and to
decrease the number press [-]. If there is a functional limit to the number that is preset
into the system, the number will simply stop advancing in that direction.
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FAULT Mode and Function Faults

If an error condition within the D500 itself is detected by the software, the D500 immediately enters
“FAULT” mode. This is called an “internal fault” and is to be distinguished from a “function fault” that is
triggered by error conditions occurring in the sequencing or operation of a gage-controlled function
(see “Function Fault” below.)
D500 Internal Fault
D500 enters FAULT Mode which includes the following:
l A pop-up box appears on the screen with a fault name or description.

l The D500 drops out of AUTO mode, dropping the “Run Mode” output (may also be called
“Gage in Auto”, “Auto Mode”, etc.). Typically this output is wired to shut down the machine
and/or gage operation.
l “Internal” faults are very uncommon but would indicate a failure of the software to run, prob-
ably as a result of a hardware failure.
The two faults listed below indicate hardware or flash disk failure:
l Internal Communication failure

l Log file open failed
In the event of a D500 internal fault, reboot the system.

If the fault remains, contact Control Gaging Factory Support.
Function Fault
“Function” faults result when specific expected conditions are not met during the operation of a
sequence or optional feature. Function faults are sometimes wired as outputs to the machine con-
troller so the machine PLC logic, rather than the gage, takes appropriate action. Function faults may,
but do not necessarily, place the D500 into “FAULT Mode”, depending on the significance of the fault
to the automatic process involved.
An example of a non-Fault-mode function fault occurs during the “Remote Zeroing” function: If the
transducer core is determined to be too far from the physical center of the coil, a “Remote Zero
Failed” fault occurs and an output to the machine stops automatic operation. After resetting the mech-
anical gage head, the fault will disappear and operation may resume.
For Function Faults:
l A pop-up box may be displayed, if there are no other outputs or indicators.

l If there is no other output (see next bullet point) a function fault may place the D500 in FAULT
Mode and display a message to indicate corrective action is needed.
l A “FAULT” output may be provided through the control cable, if shown on the connection
diagram. This output may trigger a “fault” indication requiring further action by the machine
control or by an operator
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l Function faults are documented in the context of the function or feature. For example, the
“Remote Zero Failed” fault will be described elsewhere in this chapter, section “Auto- or
Remote Zeroing Option ” if your system has that feature. Application-specific function faults
are described in section Application Specific Features typically located in the System Over-
view chapter.
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D500 Setup Mode Pages and Parameters

Operating parameters that affect the process decisions made by the controller or that change the
screen display are accessed through the menu bar in SETUP mode.
The most common standard menu items are:
l Zero – For zeroing / mastering gage(s) and calculated channels

l Settings - Process and screen configuration variables
l Gage Setup - Gage channel gain and filter settings
l Diagnostics – Tests to verify inputs and outputs
l Help – Company and program version information
Additional menu items that may appear, such as Micropeak or SPC, are "options" that are described
separately in the Optional Software Features section of this chapter. The “standard” individual
screens listed above are described in more detail in the next several pages.
Although many parameters may be viewed or changed from the Menu Bar in RUN mode, any para-
meters that could significantly affect process operation should be changed only in SETUP mode.
Some parameters that would directly affect current measurement operations cannot be changed at all
in RUN mode, such as mastering and gain setting.
To enter SETUP from AUTO mode, press the [MODE] key.
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Systems with Password Protection
Note: See subsection System Settings Page for full password information.
1. A “Login” box will appear on the screen as shown in the figure below with a data entry box for
typing in a password. Information about changing passwords is provided later in this section.
2. Enter your password, then press [ENTER].
Figure 5-14. Login Box
3. After entering the password the focus will be on the Menu Bar (there will be a blue-highlighted
box somewhere on the bar, typically a blank square in the upper left corner).
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Systems without Password Protection

1. If the focus is already on the Menu Bar a blue-highlighted box is visible, either blank in the
upper left-hand corner or on one of the menu items.
2. If not, press one of the [TAB] keys until a blue box appears on the Menu Bar.
Use the LEFT [←] or RIGHT [→] arrows to move the blue box and highlight the desired menu
item. If a dropdown menu does not extend, then press [ENTER] to display the page. If a drop-
down does appear, use the UP [↑] or DOWN [↓] arrows to select the desired page from the
dropdown, then press [ENTER] to display the page.
Figure 5-15. Dropdown Menu
Note Regarding Passwords

The following sections describe access to all parameters assuming that password protection is OFF or
with full access using the “Engineer” level login password.
See Item (11) in subsection System Settings Page for full password information.
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Zero Page
Note: The term “static zero” is used to describe zeroing when the part remains in
the gage position during zeroing. An alternative “dynamic zeroing” process is some-
times used on parts that are flowing through a gage station: the “Dynamic Zero”
menu item is included if it is appropriate for your gaging system.
The typical Zero page shown below allows the user to zero or master the appropriate gage channels
when preparing to run parts. There may be from one to eight gages, labeled by number or with spe-
cific names such as “Locator”, “Dia 1”, etc.
If your display shows an additional block of controls labeled “Dynamic Zero” below the “Static Zero”
block, refer also to section Micropeak Dynamic Zero Page in the System Components - Gage Con-
troller chapter.
Figure 5-16. D500 Zero Page
1. Size – Data Entry Box

The “Size” data entry box allows the user to enter a “non-zero” value for mastering the
channel. If your setup workpiece or master is at nominal zero, then this value should be
“0.0000”; otherwise the value needs to match the actual size of the setup master (plus or
minus) relative to nominal. In the example above, Gage 1 is already mastered to zero, while
Gage 2 will be (but has not yet been) mastered to the actual size of the non-zero master,
+0.0010.
To set a “Size” value;
a. Use the [TAB] keys to highlight the “Size” data entry box for the correct channel. The
colors of the value will be reverse-highlighted.
b. Press [CLR] to enter Data entry mode - the numbers in the box will turn red and go to
“0.0000”.
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c. Using the numeric keypad, enter a value for the master’s actual size relative to nominal.
d. Press [ENTER] again to save the value and leave Data entry mode.
2. Zero (or “Master”) Pushbutton
After the “Size” value is correct, tab to the “Zero” (sometimes labeled “Master”) pushbutton
and press it to master the gage channel. The gage “Reading” in the adjacent yellow box will
change to the “Size” value. The gage system is now set to run to the correct size.
3. Reading – Display Box
The “Reading” display box shows the current gage reading for that channel, including any pre-
vious zeroing or jogging offsets that have been applied. After zeroing, the reading will be the
same as the “Size” value.
4. Raw Reading – Display Box
The “Raw Reading” display box shows the direct reading from the gage transducer without any
zeroing or jogging offsets. This value can provide valuable trouble-shooting information if the
channel does not zero correctly.
5. Zero All - Pushbutton
Systems that have more than one gage that are typically mastered at the same time will have a
“Zero All” pushbutton. After setting all gages up correctly on the master and setting any “Size”
values needed, press this button to zero all channels at once.
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System Settings Page(s)

The D500 Controller is highly configurable, ranging from relatively simple applications to quite
complex. For applications with a small number of gages and few options, a single D500 Settings page
is available from the Menu bar. A sample is shown in the next figure with the most frequently occur-
ring parameters. These common parameters and their functions are described in this subsection with
reference to the numbers on this figure. There are additional parameters beyond number 10 that may
be available: they are numbered from 11 up and are described at the end of this section.
Figure 5-17. Single D500 Settings Page
Note: Exact labels for items shown on the screens screen may vary slightly.
Note: Item 8 can also be shown as Zero “Limits” 10 can also be shown as “Status”
Hold.
In more complex cases, selecting “Settings” from the menu bar may display a dropdown menu with a
choice of several separate pages, as shown in the figure on the next page. In these cases, the para-
meters and functions are separated into logical groups or by optional features for each page, providing
screen space as well as clarifying the relationships between the functions.
In the case shown in the Settings Dropdown Menu figure below, the common system elements are
shown on the System Settings page, including the part labels for a “multi-part selection” feature
described in a separate option section. On the Part Settings page (not shown), the gage enable timer
and the setpoint values are associated with each of the different selectable part numbers, so they are
placed logically on that page. Meter scales and other items that may differ from one gage type to
another on the same system may be located on the individual gage page.
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Note: If password protection is included in your system, and you are logged in with
supervisory rights (called “engineer” status, versus “operator” status which has lim-
ited rights), the “Settings” dropdown menu will include “Password”. The “Password”
parameter is described under 11 below.
Figure 5-18. Settings Dropdown Menu
The following descriptions apply to the “standard” elements you will find on either single or multiple
pages.
Numbered items below are from the figure Single D500 Settings Page except for item 11, which is
described with a new figure under heading 11 Password at the end of this subsection.
1. Enable Time - Data Entry Box

How to Set the Gage Enable Time:
a. Use the [TAB] keys to highlight the “Enable Time” data entry box. The colors of the
value will be reverse-highlighted as shown in the figure.
b. Press [CLR] to enter Data entry mode (the numbers in the box will turn red and go to
0.00). Using the numeric keypad, enter a value in seconds.
c. Press [ENTER] to save the value and leave Data entry mode
Overview:
This function, called the Gage Enable Delay Timer, starts when the D500 receives a signal
(Gage Enable input) from the machine controller. Until the timer “times out”, the control out-
puts from the gage system to the machine are disabled. Normally, this delay is used if the
72 137383
application requires the gage or gage fingers to advance into the measuring position at the
beginning of the machine cycle – the timer prevents gage outputs until the gage fingers are in
position and have settled onto the part for an accurate reading. Set the delay time long
enough for the gage to advance and the fingers to close onto the part. On continuous gaging
operations that use the Micropeak feature – through-feed centerless or disc grinders, rotary car-
rier disc grinders, conveyor-fed gaging systems – the gage enable timer can normally be set to
zero unless there is some kind of desired delay when the machine or gage system is powered
up.
For further detail, see heading “Gage Enable” (“Gage Cycle Start”) Input Wiring in the Install-
ation chapter and the system connection diagram, in the Installation Diagrams chapter.
2. Jog Increment – Data Entry Box
This parameter sets the amount of offset that is applied to the selected channel’s gage reading
each time its jog button has the focus and the [ + ] or [ - ] key is pressed. The effect of jog-
ging on the screen and on part size may differ depending on whether the application is post-
process or in-process and, for in-process, whether the measurement is on an internal or
external surface. If the effect of the jog is not appropriate for your application, use the “Invert
Jog” check box described next.
3. Invert Jog - Checkbox
The “invert jog” check box changes whether the “jog increment” is added to or subtracted
from the current gage reading. Select or deselect this check box if you find that the effect of
jogging is opposite of what you want. This may be needed, for example, if you move a unit
from an OD to an ID grinder, because for an OD making the part larger means removing less
stock, and on the ID it means removing more stock.
4. Meter Scales – Data Display
The Meter Scale1 parameters allow setting of the meter scale range and markings. The basic
adjustment is for the LOWER limit and the UPPER limit of each scale.
Example Meter Scale Settings:
l For an in-process application, the LOWER limit may be set at 0.0000 mm and the
UPPER limit at +0.2500 mm; if you want to see slightly below zero, you could set the
LOWER limit to –0.0100.
l For a post-process application, the LOWER limit could be set at -.050 mm and the
UPPER at +.050 mm.
In some cases, a dual-scale meter is provided. In this case, an individual scale may be con-
figured to automatically switch from a COARSE (larger range) scale to a FINE (higher resolution,
smaller range) scale depending on the current reading of the gage. In the figure “Settings
Dropdown Menu” above, two columns of parameters are available, one for the Fine scale and
one for the Coarse scale.
1The Meter Scale parameters allow setting of the meter scale range and markings.
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In most cases, there will be a set of scale parameters for each gage channel. However, in situ-
ations where the tolerances are identical across a group of several channels, a single set of
scale parameters may be used for the whole group.
5. Setpoints - Data Entry Box
A ‘setpoint’ is a pre-set dimensional value that is dynamically compared to workpiece size dur-
ing the cycle to determine when a control output should be given to the machine.
To enter Setpoints:
1. Use the [TAB] keys to highlight the desired setpoint data entry box. The colors
of the value will be reverse-highlighted.
2. Press [CLR] to enter Data entry mode (the numbers in the box will turn red and
go to 0.0000).
3. Use the numeric keypad to enter a value.
4. Press [ENTER] to save the value and leave Data entry mode.
In Process Applications
For in-process applications, the setpoints are usually labeled by number (3,2,1,0, where
“0” is “Size”), or with a description of the action or feed rate (Coarse, Fine, Spark-Out,
Micro, Size).
Post Process Applications
For post-process applications the setpoints are often labeled in pairs on opposite sides
of nominal size, such as “Over” and “Under”, “High” and “Low”, or “Approach Over” and
“Approach Under.”
The D500 is delivered with pre-set names that are either defaults or special names
requested by the customer.
6. System Units - Dropdown List

This global parameter allows selection of the units of measure used for display on the screens
and for setting of parameters.
Select the desired units from the list box using the [↑] [↓] keys, then press [ENTER.
The selection options in the dialog box are:
Selection Multiply Reading On Screen By:

mm 1.0 mm
micron 001 mm
inch 1.0 in
micro-inch 000001 in
The selection acts as a multiplier, that is, the actual value of a reading on the screen is
the reading displayed times the “Units” value you select. For example, the gage read-
ing value “.0027mm” will be displayed as “.0027” if the “Units” selection is mm, but will
be displayed as “2.7” if the selection is micron.
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7. Language Selection - Dropdown Box

When available and selected, the dropdown menu of available languages will extend.
To set the Controller's Language:
1. Using the ↑ UP or ↓ DOWN arrow keys, select the desired language.
2. Press a [TAB] key to save and move the focus.
8. Zero Limit (sometimes labeled Zero Range) - Data Entry Box

When this box is available (some older or selected units may not have this parameter), it estab-
lishes a “plus” and a “minus” limit on how far from electrical center the transducer may be in
order to accept software zeroing. It provides a safety check on the gage head’s mechanical
setup, causing a fault output (if the gage is being auto-zeroed from an outside control system)
or a failed zero attempt if being zeroed by hand. A typical value for a gage single-function
gage head is .500 mm to 1 mm, which gives a total zeroing range of 1 mm (+/-.5 mm) or 2
mm (+/- 1.0 mm) respectively.
If the current raw reading of the gage is outside of this limit, the “Zero” pushbutton on the
Zero page will be “grayed out” and inactive. Pressing it will have no effect. You will either have
to adjust the gage position or contact for the reading to be within the range, or change the
“Zero Limit” value.
On “wide-range” gages that are designed to be zeroed on multiple parts over a 12.5 mm
range, refer to a section named Wide Range Gaging. in the System Components - Gage(s)
chapter.
Note: If your system includes a “remote” or “auto” zeroing function, there
may be a second “zero range” value for the mastering operation. See section
Auto” or “Remote” Zeroing Option elsewhere in this chapter.
9. Digits Selection Spin Control – Value Selection

When this box is available (some older or selected units may not have this parameter) it allows
the user to define the number of digits in the display. The number of digits available varies
according to the selection in the “System Units” box.
Use the [+] [-] keys to scroll up or down, then press a [TAB] key to save and move the focus.
10. Setpoint Hold (sometimes labeled Status Hold) - Data Entry Box
On some systems, a parameter is provided for setting the duration of time, in seconds, that the
setpoint outputs are held energized. It is a system-wide value, that is, all of the “status-type”
setpoint outputs are energized for this same period. This does not apply to compensation out-
puts, which are controlled by their own duration timers.
11. Password – Dropdown Menu
If your system includes password protection, and you have logged into SETUP Mode using the
“Engineer” (supervisory) password, the “Passwords” item will appear on the Settings dropdown
menu as shown in the next figure. There are two password access levels (Operator and Engin-
eer) which have different functional capabilities.
Password Access Levels:
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Operator Factory Default Password: 123

This level allows changes to a limited set of parameters, typically including:
l Size jogging on front panel screen (does not require any login at all).
l Mastering or zeroing on the Zero page
Engineer Factory Default Password: 456
This level allows changes to all parameters.
Figure 5-19. “Passwords – Engineer” Page
To change the password for either the “Operator” or “Engineer” level:

a. Select “Passwords” on the dropdown menu and press [ENTER]. The Passwords –
Engineer page will appear and includes the ‘Passwords’ selection box and an adjacent
data entry box.
b. Select the level (Operator or Engineer) that you want to change from the Passwords drop
down list.
c. Type in a 3-digit numerical password between 000 and 999.
d. Press [ENTER] to lock it in to controller's memory.
e. Write the passwords (especially the Engineer-level) down and store it in a safe, retrievable
place.
Note: Although the items listed above are “typical”, Control Gaging often
provides customized password allowances at customer request depending on
specific application needs.
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If the Engineer-level password cannot be identified, contact the Control Gaging Field Service
department at +1.734.668.6750 or service@controlgaging.com to re-establish access.
12. Variables File Storage and Recovery
Note: This feature is only available for use when logged in with the Engineerpass-
word.
A feature that is available on all D500 controllers is the ability to download (for storage) and
then upload (for recovery or duplication) the “variables file” that contains all the setup data and
variable settings that currently exist in memory for a specific application. The location of the
controls for this feature depends upon the type of gaging system:
l In-process or other systems (that do not include the SPC Option section in the else-
where in this chapter): These systems will show the controls for this feature on one of
the System Settings pages as shown in the figure below.
Figure 5-20. Variables Save/Load Buttons on System Settings Page
If these buttons do appear on a System Settings page, go to section “D500 Variables File Stor-
age and Recovery” in the System Components - Gage Controller chapter for a complete
description.
l Post-process or other systems (that do include the “SPC Option” section in the else-
where in this chapter): These systems will show these controls in “Data Storage and
Output Page” described in the “SPC Option ” section, System Components - Gage
Controller chapter.
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Gage Setup Page

The Gage Setup page provides controls for calibrating gain and setting the signal filter frequency for
each channel. It also displays the current gage reading as well as the raw reading direct from the trans-
ducer (with no offset adjustments).
If the Detail check box (Item 7) is selected, additional values are displayed which will be described in
the subsection following this one.
Note: This page is used for setting the gain and filter only, not for final “zeroing” or
“mastering” before automatic operation. Instead, use the Zero Page, selected from
the Menu Bar, because it assures that all the offsets in the system are applied cor-
rectly.
Figure 5-21. Gage Setup Page
1. Set Gain - Pushbutton (Gain Calibration Procedure)

Calibrating "gain" insures that movement of the gage finger corresponds to the actual value of
displacement shown by the D500 gage reading. That is, if the gage finger moves .004” or .100
mm, the gage reading must display a change of the same amount.
Setting Gain for each gage or channel:
Follow the steps below to set the gain for each gage or channel.
Note: You will need two setup workpieces of known difference in size or a
precision shim to insert beneath the gage finger.
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a. Mechanically set up the selected gage head on the smaller of the two masters or on a
workpiece with a ground surface if using a shim.
b. Use the [TAB] keys to highlight the “Zero” button (may also be labeled “Master”) for the
channel with that gage head. Press [ENTER] – the value in the gage “Reading” box will
go to zero.
c. Verify that the “Size” box agrees with the difference between the two masters or the
thickness of the shim. If not, tab to the box and enter the correct difference with the
numeric keypad.
d. Mount the second master/workpiece or insert the shim beneath the gage contact. The
gage “Reading” box will show a new value that may or may not be correct.
e. Tab to the “Gain” button and press [ENTER]. The gage "Reading" box will now equal
the “Size” box to the left. Gain is now set.
f. Repeat Steps 1-5 for each additional channel.
2. Size - Data Entry Box

The “Size” box sets the amount of difference between the two setup masters or the thickness
of the shim you are using.
a. Use the [TAB] keys to highlight the “Size” box for the gage channel desired.
b. Press the [CLR] key to zero out the number and enter Data entry mode.
c. Press [ENTER] to exit Data entry mode and save the value.
3. Zero (or “Master”) - Pushbutton

Zeroing (or Mastering) a Workpiece:
a. Select the “Zero” (or “Master”) button by pressing the left or right [TAB] keys until the
button for the gage channel desired is highlighted.
b. Press [ENTER] to zero. The gage “Reading” in the first column will change to zero – the
“Raw Reading” value will not change.
Before zeroing, a master workpiece must be mounted in the measuring position and the gage
head physically “set up” on it (see the full procedure under Set Gain Pushbutton above) Refer
to other sections of this manual for gage head setup procedures.
4. “Reading” - Display Box

The value displayed in this box is the current gage reading for this channel including all the off-
sets or adjustments that have been applied since the last time it was zeroed. Size offsets
include previous zeroing offsets plus any jog offsets that have been applied.
5. Spline Frequency1 - Dropdown List
To set the signal filtering frequency:
1The frequency selected sets an electronic filter that is used to smooth out fluctuations in the gage signal
that occur when measuring over interrupted or uneven surfaces such as splines, gears, etc. It can also
used to stabilize the gage signal by minimizing the effects of environmental “noise” from machine vibra-
tions or background electrical interference.
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a. Use the [TAB] keys to highlight the “Spline Freq” list box.
b. Press the ↑ UP or ↓ DOWN arrow keys to highlight the value desired.
c. Press [ENTER] to select.
The frequency selected sets an electronic filter that is used to smooth out fluctuations in the
gage signal that occur when measuring over interrupted or uneven surfaces such as splines,
gears, etc. It can also be used to stabilize the gage signal by minimizing the effects of envir-
onmental “noise” from machine vibrations or background electrical interference.
The values in the list box represent filter frequency in “Hz” (cycles per second) ranging from .2
to 200 in the list.
As an example, when the filter is set at 50 Hz, the filter is designed to remove any fluctuations
or “waves” in the gage signal that are happening faster than 50 times per second. But because
of the filtering action, it also takes about 1/50 (.02) second for a change in the incoming gage
signal to be fully reflected in the gage reading in the controller. If the filter is set to 2 Hz, more
wave frequencies are removed (everything faster than 2 cycles per second) and it takes ½ (.5)
second for the gage reading to reflect the change in measurement. The lower the value, the
more stable the reading, but the slower the response to size changes. The higher the value the
faster the gage will respond to change, but with possible loss of signal stability depending on
the application and environment.
For most normal gage applications, including Micropeak when used on long straight parts, a fil-
ter setting of 5 Hz is used as the default. For measuring high-frequency, regular interruptions
such as splines or gears, the typical setting is 2 Hz. When Micropeak is used for capturing read-
ings on shorter moving parts, the typical setting is 50 Hz. For applications that require
Micropeak to select only one or two samples on a rapidly moving or curved part, the filter fre-
quency may need to be even higher.
6. “Raw Reading” - Display Box
The value displayed in this box is the current gage reading for this channel excluding any off-
sets or adjustments that have been applied since the last time it was zeroed. This value is use-
ful on some applications for mechanical setup or for troubleshooting, since it displays the
physical position of the transducer inside the gage head.
7. “Details” - Check Box
The Details check box provides access to additional information about the gage channels when
it is marked.
To mark it, use the [TAB]keys to select it, then press the [+] key to add the check mark or the
[-] key remove it.
When the box is checked, the page will appear as shown and described in the next sub-section.
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Gage Setup Page - Details

The Details check box displays two additional values for each channel: “% Full Scale” and “Gain”.
These values may be used for diagnostics or troubleshooting under direction of Control Gaging per-
sonnel.
Figure 5-22. Gage Setup Page with “Details” Checkbox
1. % Full Scale
This value shows the percentage of the full scale raw transducer range that the current reading
is using. This value can be used to determine if the gage finger or transducer are shifted or are
in an unusable position.
2. Gain
This value shows the gain factor (a multiplier) that has been set in software. It can indicate that
gain is outside of normal bounds, indicating that it needs to be reset or that there may be a
transducer failure.
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Diagnostics Page
The Diagnostics (or Digital I/O) page is used to verify that the gage controller’s keypad is func-
tioning and that the inputs and outputs are working correctly. The page contains a grid of the available
inputs and outputs as shown below, as well as a display box for performing the keypad test.
Figure 5-23. Diagnostics Dropdown Menu
Note: In some newer systems, if the Main Menu bar is full and the Profile page is
included in the system, the Diagnostics page described here is found in the “Dia-
gnostics” drop-down menu and is named the Digital I/O page.
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Figure 5-24. Sample Diagnostics Page
Keypad Test
To test the keypad:

After opening the window, press the right [TAB] key to select the “Key” box, which initially has a white
background.
To perform a keypad test:
1. Press [ENTER].

l The background will turn light blue and the word displayed will change to “ENT” as long
as you hold the key in. (If you press [ENTER] again, you will drop out of Keypad Test
Mode – see second paragraph following.)
2. Press any other key (except AUTO/SETUP, which does not respond the same) to display the
number, symbol, or abbreviation on the key. If the word “Key” remains in the box even though
you are pushing the button, that key has failed.
l The AUTO/SETUP key will toggle the Front Panel screen display between red SETUP
and green AUTO during the key test. The word “Key” will remain in the box.
l The controller is in Keypad Test Mode as long as the box background is light blue.
3. Press [ENTER] again at any time to exit the keypad test – the background will change back to
white and the word “Key” will remain.
4. Press [TAB] to continue to the I/O test described below.
Outputs
Output numbers are identified on the Connection Diagram in the “InsDiagrams” Chapter.
General instructions for testing outputs are included on the screen:

TAB-Select: Use the [TAB] keys to move through the output numbers.
0 – Toggle: Use the zero [0] key to toggle the output on or off.
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ESC – Exit: Press [ESC] to exit and close the Diagnostics page.
Note: If there are two or more I/O boards shown on the Diagnostics page, continue
to tab to the last of the Board 1 outputs, then press [TAB] twice to move to Board 2,
Output 1.
Select an output to test from the grid by using the [TAB] keys. The currently selected box has a
dashed rectangle inside the box rectangle (Output 2 in the Sample Diagnostics Page figure).
To energize an output:
1. Press the [0] zero key and the box will turn green. The output can then be
checked at the output connector or at the connection inside the machine panel.
2. Press the [0] key again to de-energize the output. As many outputs as desired
can be energized at the same time.
Inputs
Input numbers are identified on the Connection Diagram located in the Installation Diagrams
chapter.
Manually supply an input on the appropriate lines and observe the input grid. When an input is valid,
the appropriate box will turn green. If the light does not turn green, it may be necessary to determine
whether the failure is in the machine (there is no output), in the connections (broken or improperly
connected wire), or in the gage controller (input board or internal wiring).
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Help Page
Select the Help menu item and press [ENTER], then press [ENTER] again to display the "About" box.
The box contains the program name and version number, the unit serial number, signal processor firm-
ware version, and the Control Gaging copyright. To close the box, press [ENTER] or [ESC].
Figure 5-25. Sample Help/About Box
Take notice of the number in the column to the right of “D500 Panel": This is the configuration num-
ber (on units shipped after 12 March 2009) that specifically defines the exact software and con-
figuration of your unit. The configuration number in the sample box above is “36447.444:1”.
Note: Please have your controller's panel number (configuration number) available
when contacting Control Gaging for assistance to ensure accuracy and expediency
in solving your problem.
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Optional Software Features

This system includes the following optional software features:
Intelligent Process Control (IPC) Option
Note: The following sections describing the IPC include improvements made to
parameter names and functions starting with software revision level 1.474 (open
“Help|About” on the menu bar to check your unit.)
Note: Previous IPC users: see subsection IPC Revisions at Version 1.474 later in
this section for changes; use the manuals provided with the earlier systems for
information about them.
Introduction
The IPC software option provided in the D500 controller provides a sophisticated, self-improving
method for reducing the variation of size output until it achieves the best capability of the machine.
The AUTO Mode Trend Page, shown in the figure below, is the heart of the D500 when using the IPC
software. The page shows a real-time X-bar and R chart with unique display features that make the
size trend, the actions of the gage system, and the response of the machine all “visible” to the user.
See the next section “IPC Operation and Setup – AUTO Mode Trend Chart” for a full description of the
chart.
Figure 5-26. Sample Trend Chart
The IPC uses four specialized techniques in combination to refine the machine’s output:
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These techniques give the D500 controller the capability to adjust the aggressiveness with which it
approaches the mean, depending on the capability of the process including the quality of the
compensator. An accurate compensator for instance will be able to compensate more often in smaller
increments, while a less accurate compensator will need to move less often and have allowance for lar-
ger or less consistent increments.
Another factor that can affect the aggressiveness of settings is the ability of the gage to accurately
measure the parts. Factors such as part geometry, flow rate, undercuts, and stability in the fixture as
well as uncontrolled dirt or vibration can affect the gage system’s ability to accurately measure the
parts. As gage accuracy is decreased, the aggressiveness must also be decreased. Likewise, as the
factors reducing the ability of the gage to measure true size are removed, the aggressiveness can be
increased.
Trend Table
To configure aggressiveness, a “Trend Table” is set up as shown in the next figure. A Trend Limit is the
number of consecutive subgroup average “plots” that must occur in or beyond a specific Trend Zone
in order to initiate a compensation move. The farther from nominal, the fewer subgroups are required,
but as part size approaches zero, more subgroups are needed. This causes a fast approach toward nom-
inal when a process is starting up, but when the process is closer to nominal, it minimizes the amount
of “hunting” and over-compensations that will occur.
Figure 5-27. Trend Chart and Trend Table
The “Trend Zones” are defined statistically by calculating a new sigma value each time a new lot is
completed. The screen displays the chart with the calculated values of +/-3 sigma at the upper and
lower limits. (Intermediate dotted lines have been added in the above figure to make the zones easier
to see – on D500 screens after October 2013 the zones have different colored backgrounds). A para-
meter for “Starting Sigma” is used to pre-set the +/-3 sigma chart limit for the first lot, before a sigma
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value based on actual part readings has been calculated. The “Over Spec” and “Under Spec” zones
are established by the “Over” and “Under” setpoints used to define a “bad part.”
In the example shown above, five consecutive subgroups have occurred in the Over 1 Sigma zone.
(The “Trend Limit” for Over 1 Sigma is “5”, as shown in the default trend table on the right.) The
square yellow “box” around the green subgroup average “diamond” indicates that a compensation
move is needed. Using a proportional compensator, the amount of compensation that the gage
requests is performed by the machine to bring the size very near zero, as shown by the subgroup that
follows.
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IPC Revisions at Software Version 1.474
Note: If you have not used the D500 with IPC in previous versions, you can pro-
ceed to next sub-section.
The purpose of the revisions is to improve the overall function of the IPC based on experience as well
as making it easier to understand. The IPC sections that follow include this update. The changes and
their effects are summarized below:
“Process Center”
The new term “process center” has two new functions:

l Defines the desired finished size of the workpiece, which may be at a non-zero value.
In previous versions the desired finish size was fixed at ”zero” so the screen markings
sometimes did not correspond to the user’s actual dimensions.
l Defines the permanent center of the Trend Chart screen. In previous versions the cen-
ter of the screen has been set either at the “target” or at the calculated statistical pro-
cess center (X-double bar), both of which resulted in confusion.
“Deadband In”, “Deadband Out”
The previous parameters, “Min In” and “Min Out” are replaced by the new values “Deadband
In” and “Deadband Out”, a change which includes both a name change and an improvement in
function:
l The name “Deadband” makes it much clearer that these values define the inner and
outer limits of a range within which no compensation is allowed, even if the IPC cal-
culations call for it.
l The “deadband” values are now relative to the “process center” rather than relative to
the “target” value. This provides improved and more understandable control of the sys-
tem.
“Comp Target”
l This is a new name for the parameter previously called “Target”; however, the function
remains identical. The name makes it clearer that this is the desired end point of a com-
pensation move and is independent of the desired workpiece size, which is now called
the “Process Center” as defined above.
l This parameter now appears on the Compensation page as well as the Trend page. On
the Compensation page it is displayed in the “Compensation Group” so during setup it
is easy to see the relationship between the “Process Center” and the “Comp Target”.
Changing the value in either place changes it in both.
For an example of the relationships among these three items in a process situation, see section
“Example of Compensation Setup and Operation” later in this chapter.
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IPC Operation and Setup – AUTO Mode Trend Page

The AUTO Mode Trend Page shows a real-time X-bar and R chart with unique display features that
make the size trend, the actions of the gage system, and the response of the machine all “visible” to
the user. In AUTO mode, the operator can disable compensation from this screen during setup, and
also “jog” part size for fine adjustments to the target.
The trend chart, as well as the actions of the four methods described in the previous section, is con-
figurable through parameters that can be changed in SETUP mode on the Compensation Page, to be
described later.
The trend chart is accessed from the Menu Bar by highlighting the Trend menu item and pressing the
[ENTER] key. The page displays the following chart, display boxes, and controls.
Figure 5-28. Trend Page in SETUP Mode
1. A - Process Center
This value is the desired size around which you want the process to run, and is maintained at
the vertical centerline of the chart screen. In most cases this value will be “zero” (which is the
default setting on the Compensation setup page and shown in the figure) but if your desired
size is a non-zero value, or if your tolerance limits are not centered around zero, you may set
this value as needed to keep it on the center of the screen.
1. B - Trend Chart “Sigma” Limits

These values are the +/-3 Sigma limits used by the trend chart to determine when and how
much to compensate the machine. They are always displayed equally above and below the pro-
cess center. Normally these values are calculated from the last completed lot of run-time read-
ings taken by the gage, but a “starting value” can be set at the beginning of a run for an empty
chart.
See manual section IPC Operation and Setup – SETUP Mode Compensation Page under the
heading 1. Trend Comp” Control Group.
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The trend zones are lightly colored: from process center +/-1 sigma is light green, from +/-1
sigma to +/-2 sigma is light yellow, from +/-2 sigma to +/-3 sigma is light blue, and beyond
the tolerance zones are light red.
2. Clear Trend - Pushbutton
To clear the current trend chart and restart the calculations, press the button.
3. Skip Count - Display Box

The trend chart can be pre-set to ignore a specified number of parts (if any) between the cut-
ting tool and the gage that have been unaffected by the last compensation (for example, parts
between the wheels and the gage on a through-feed centerless or disc grinder). This pre-
vents initiating a new compensation based on measuring parts that were made prior to the com-
pensation move.
The “Skip Count” value is set on the SETUP mode Compensation Page. The number in the
box counts down to display the number of parts yet to be measured before the gage system
begins again to accumulate readings into trend subgroups. When the box displays “0” the IPC
begins a new subgroup.
The Skip Counter does not begin counting down until the compensation output to the
machine is complete – for example, in a pulse compensation machine where three pulses are
sent, the count does not start until all three pulses have been sent.
4. Comp Amt - Display Box
This box displays the amount of compensation that was calculated by the gage controller as
necessary to bring the parts to target size. It is the same value as the last subgroup average that
met the requirements of the Trend Table to initiate a compensation move. The actual com-
pensation made by the machine may be slightly different, depending on the type of pro-
portional compensation and Maximum and Minimum limits set in the “Compensation Sizes”
portion of the SETUP mode Compensation Page. The sign of the value indicates whether the
unit comped “in” (+) because the part was larger than zero, or “out” (-) because the part was
smaller than zero.
5. Limiter Amt - Display Box
See section “IPC Operation and Setup – SETUP Mode Compensation Page” under heading
“Analogic Limiter Control Group” for a discussion of how the Analogic Limiter operates.
This box displays the size value that was added to the current subgroup for the last gage read-
ing:
l If the Analogic Limiter has no limits enabled, or if the reading is within the preset ana-
logic limits, it will show the same as the Current Part Reading display box.
l If the reading was “cut off” by the limiter, it will show the “limited” value that was used
instead of the gaged “current part reading” value.
6. Micropeak Samples/Time Indicator
The indicator provides information about how the Micropeak feature “saw” the last part meas-
ured, and is comprised of two parts. The number on the left of the ‘/’ represents the total num-
ber of samples taken during the sampling period; the number on the right of the ‘/’ represents
the amount of time over which the samples were taken.
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See subsection “Micropeak AUTO Mode Page” in the Micropeak option section of the
“System Components ” chapter.
7. Current Part Reading - Display Box
This box shows the value of the gage reading determined by the Micropeak function on the
last part measured.
8. ”Jog” - Buttons
When these buttons have the focus, two modes of jogging (adjusting size) are available:
l Press the plus or minus [ + ][ - ] keys to “jog” (apply a size offset to) to the current gage
reading. The jog amount for each keypress is determined by the “Jog Increment” value
set on the SETUP mode Settings Page.
l Press the [ENTER] key to bring up a “Gage Jogging” dialog box. The box comes up in
data entry mode, so you can directly enter the exact amount of offset you want. A
minus sign can be entered at any time by pressing the minus key [ - ]. Press [ENTER] to
load the offset and close the box.
9. Comp On - Check Box
The “Comp On” checkbox should always be unmarked when the D500 is running in AUTO
mode (so you can observe the process) while you are setting up the machine at the beginning
of a run. If not, gage compensation outputs from the D500 may interfere with the manual
changes you are making to bring the machine toward size. When the machine is running good
parts and the gage has been dynamically zeroed, mark the box to place the gage system in con-
trol of the process.
10. Comp Target – Data Entry Box
This value allows the user to adjust the size value that the compensation calculations use as the
“target” of a compensation move. The default value is the “process center” (set on the Com-
pensation page). However since the calculated compensation amounts would drive gaged size
toward the process center but never beyond it (calculated comp amount is always “not-to-
exceed” the last subgroup average), the actual average part size value produced will tend to be
slightly higher than the desired process center.
The “0.0000” value for Comp Target thus results in a size pattern that will tend to be slightly
above the “process center” by an average amount proportional to the resolution of the comp
increments that the machine can make. In order to cause the size pattern to be centered
around the process center, you can enter an amount in this data entry box to shift the “target”
that the compensations are aimed at. For example, if your desired process center is “0.0000”
and the trend chars tends to run about .000040”/.001mm above zero), enter a value of
-.000040 or -.001mm to shift the compensation target downward by that amount relative to
the process center.
11. X-Bar and R Plot Markers - green or red diamond for X-bar, vertical bar for R
As the process proceeds, the average and range values are displayed as “plots” on the Trend
page. Each plot consists of a diamond and a vertical bar as described below.
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A new diamond marker is displayed on the graph when the first reading of a new subgroup is
taken. The diamond will represent the part size of that individual part only. When the second
reading in the group is taken, the diamond will display at the position of the average of the two
readings. As further readings are added, the subgroup average represents the current average
of the readings taken so far. When the group is filled, the next reading will plot a new dia-
mond.
When the diamond in the plot is green, the subgroup average is in the “good” size range, that
is, between the <OVERSIZE> and <UNDERSIZE> setpoints displayed on the main AUTO mode
screen (your setpoints may have different names.) If the diamond is red, the average is beyond
one of these setpoints.
After the second reading is taken, the current range is calculated and displayed as a vertical bar
with a small horizontal “cap” at the largest reading and another at the smallest reading. Until
the subgroup is filled, the range line will change according to the values of the readings thus
far.
The plots may look very different from one another depending on how large the range is and
whether the readings are “grouped” at one end or the other. For example, if the range is very
small, the range bar may be completely hidden by the diamond. Or if most of the readings are
at the low end of a large range, the diamond may be at the bottom of a more lengthy range
bar. A variety of plots are shown on the example chart.
12. Compensation Marker – Yellow Square
A small yellow square surrounding the subgroup average diamond indicates that the controller
has provided a compensation output to the machine. When a plot with the square is displayed,
the Comp Amt display box will show the amount and direction of the compensation requested.
Compensation outputs can be of two kinds:
l Pulse – A closure-type output will cause the machine to move a specified “step”
amount per pulse according to the machine mechanics or program. When proportional
compensation is used, the D500 will calculate how many pulses are needed to achieve
the required compensation amount.
l Numeric – Machines that can read RS232 or BCD numeric outputs are sent the actual
calculated amount of compensation needed and the machine will respond as closely as
its program will allow to that amount based on its own capability.
13. Analogic Indicator Arrow
If the Analogic Limiter feature is active and a reading has been limited by this feature, an arrow
will appear at the top (positive limiting) or at the bottom (negative limiting) of the range bar,
replacing the horizontal “cap” representing the largest or smallest part. The average and range
of the subgroup displayed in the plot have been calculated using the limited value, not the
actual value of the reading – the actual reading is not displayed but its size direction is indic-
ated by the arrow.
To understand the Analogic Limiting function, see the next subsection “Compensation Page”
under heading “Analogic Limiter Control Group.”
14. Skip Count Indicator “X”
15. Skip Count Indicator "X"
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l When a chart “plot” includes gage readings made during the “Skip Count” number of
parts after a compensation move has been called for, that plot is completely ignored in
calculating the trend.
l This plot does not represent a normal “subgroup” in that it may include some parts that
are measured during the compensation move and at least one part from the “Skip
Count”; it may include more parts than the normal subgroup if there are many parts in
the skip count, and will include all the parts in the skip count.
l Item 14 shows a plot with its calculated range and with an “X” in the average position. It
is not necessarily the case that all readings in this group were in the skip count.
l Item 15 shows a plot where all of the readings in the subgroup were in the Skip Count,
the subgroup was ignored in trending, and all readings were exactly the same size
(since no range is displayed).
l The subgroup following Item 15 is similar to Item 14, where some but not necessarily all
of the readings were part of the skip count, there was a range of sizes in the subgroup,
and the subgroup was ignored in calculating trend.
16. First Column
After a subgroup is calculated, the entire graph indexes to the left. If a new reading has not
been taken, the first column will be empty, with no marker. This example shows the first read-
ing after a subgroup is started – the average of the subgroup is calculated each time a part is
added to a subgroup, so the average of one part is the size of that particular part. If the second
part were exactly the same, the marker would not change, but if it were different, the marker
would then show a range marking.
17. Edge of Chart Indicators
The three indicators in the circle occur when items are off-scale at the top (as shown) or at the
bottom of the chart. From left to right:
l Red “bad part” marker: When a part outside of spec limits is measured, the indicator dia-
mond is RED instead of GREEN. This particular subgroup shows the red bad-part dia-
mond (with an arrow to edge of chart) indicating there was a bad part in the subgroup
that was probably off the chart, and that the subgroup was limited by the analogic lim-
iting setting. There were apparently a significant number of parts at the lower end of
the range in the subgroup to place the red marker near the bottom of the range.
l A single bad part (or a subgroup with no range) that is off the scale will show a red half-
diamond.
l A single “skip count” part (or skip count subgroup with no range) that is off the scale
will show a half “X”.
18. Dress Count Indicator with Compensation Marker – “X” in a yellow square
Note: The Dress Count feature is optional and may not be included in your
system. If the “Dress Count” label and data entry box do not appear on the
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Compensation page (normally just above or just below the “Skip Count” label
and box, see next figure), then this indicator will not appear on your system.
When the “Dress Count” feature is included in the system and is active, a compensation output
is sent to the machine for each part in the count (see Item 15 in subsection “Additional
Features”Control Group at the end of the next section “IPC Setup and Operation – SETUP
Mode Compensation Page”.) If dress count is set to “1”, there will be an “X” (indicating the
value is not included in any compensation subgroup) in a yellow box (indicating that a comp
output has been sent), with no range (left item in the #18 circle). If the count is set to “2” or
higher, there may be a range displayed as the count is fulfilled (right item in the #18 circle);
when the count is complete, a normal subgroup will begin to accumulate.
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IPC Operation and Setup – SETUP Mode Compensation Page

The SETUP Mode Compensation Page is the location for all of the trend chart and compensation con-
trol parameters. These parameters configure the statistical calculations and the methods of determ-
ining the size of each compensation move for the machine.
Figure 5-29. Compensation Page – Parameters Numbered
This figure is reproduced for reference with each later group subsection to help identify the para-
meters by number.
To aid in the description and understanding of this very full page of parameters, the controls on the
page are organized into four groups as listed below -- each “Control Group” (except the last, “Addi-
tional Features”) includes related functions best understood together.
l “Trend Comp” Control Group (Items 1-5)

l “Analogic Limiter” Control Group (Items 6-9)
l “Compensation” Control Group (Items 10-14)
l “Additional Features” Control Group (Items 15 & 16)
“Trend Comp” Control Group (Items 1-5)
The dotted lines at the top and bottom of the Trend Chart are the +/-3 Sigma values calculated based
on the last full lot of measurements. The Trend Chart always displays plot marks based on calculations
from part measurements, except in cases where the measurement reading has been modified by the
Analogic Limiter, described later.
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This group includes the critical parameters for setting the Trend Limits for each Trend Zone (see Item
3). The Trend Limits are the values in the Trend Table (shown below) that determine when a com-
pensation move is called for in a given Trend Zone. When the specified consecutive number of sub-
group averages (“plots” on the graph) are in or beyond that trend zone, a compensation move toward
the “comp target” will be initiated.
A subgroup average plot that falls farther away from center than a given zone is considered to be
included in that zone.
For example, a plot in the “Over 2 Sigma” zone also falls in the “Over 1 Sigma” zone and in the “Over
Zero” zone. Thus, using the default Trend Limits shown in the table, three plots in the “Over 1 Sigma”
zone and two plots in the “Over 2 Sigma” zone will complete the limit of “5” for “Over 1 Sigma” and
initiate a comp.
Trend Zone Trend Limit

Over Spec 2
Over 3 Sigma 3
Over 2 Sigma 4
Over 1 Sigma 5
Over Zero 7
Under Zero 7
Under 1 Sigma 5
Under 2 Sigma 4
Under 3 Sigma 3
Under Spec 2
Table 5-1. Default Trend Table
Note: A “0” value for a Trend Limit makes that trend zone inactive. A com-
pensation move will not occur until the limit at the next farthest Trend Zone is sat-
isfied.
If part size as controlled by the gage tends to “hunt” or create a “saw-tooth” pattern on the trend chart,
the trend limits may be too small or the compensator increments (depending on the type of com-
pensator) may be too large relative to the stability of the process. In other words, the setup is too
aggressive. In such cases, experiment by increasing the trend limits to reduce the frequency of com-
pensations and/or check to see if the compensator increments can be reduced.
If it takes a long time for the gage to narrow the control limits and achieve a tight pattern around zero,
the trend limit values may be too high. Decrease the limits slightly in the intermediate zones to see if
increased aggressiveness will stabilize the process sooner without “hunting”.
Note: The chart values for all the Trend Zones except “Over Spec” and “Under Spec”
are based on sigma values recalculated at the end of each lot from the measurement
data. The Trend Zones for “Over Spec” and “Under Spec” are not shown on the Trend
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Chart, but will cause compensations based on the Trend Limits set for them. The
value for “Over Spec” and “Under Spec” Trend Zones are established by the “<Over>”
and “<Under>” setpoint values that define a “bad part”. For adjusting these setpoint
values (which may have different names in your configuration), see manual section
“D500 Setup Mode Pages and Parameters” under the heading “Settings Page”.
Figure 5-30. Compensation Page – “Trend Comp” Group (1 – 5)
1. Subgroup size
This value is the number of individual part readings that are averaged in each subgroup, which
is then plotted on the Trend Chart. A typical number for long to medium-length parts is 2 or 3;
for very short parts higher numbers can be much higher, depending on how long you want to
wait for a lot to accumulate.
2. Subgroups per lot
A “lot” consists of the number of readings calculated by multiplying the Subgroups per lot by
the Subgroup Size. For example, a Lot Size of 40 and a Subgroup Size of 3 yields a lot with 120
readings. (If parts are flowing at one per second, it will be two minutes between lots.) The con-
trol limits are recalculated and displayed when a “lot” is completed.
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Figure 5-31. Trend Zone and Trend Limit Parameters
3. Trend Zone - Dropdown Box

Trend Limit - Data Entry Box
Select the Trend Zone for which you want to set the Trend Limit from the dropdown box. Then
enter the number of consecutive subgroups outside that zone that will initiate a compensation
move.
4. Sigma Limit - Dropdown Box and Data Entry Box
These parameters set how “coarse” or “fine” the Trend Chart limits can become as they are
recalculated. Set these values based on experience with your process and to display the res-
olution you want to see on the screen.
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Figure 5-32. Sigma Limit Parameters
Note: If you have a known process and you do not want the screen chart to
change its range/resolution each time the sigma is recalculated, set both Min
Sigma and Max Sigma to the same value. Under these circumstances you
can typically also set the Start Sigma the same.
Min Sigma
This value is the smallest value for +/-3 sigma that will be displayed on the chart. Even if the
actual calculated value of +/-3 sigma is smaller than this, the Minimum Chart Limit is displayed
instead.
Max Sigma
This value is the largest value for +/-3 sigma that will be displayed on the chart. Even if the
actual calculated value of +/-3 sigma is larger than this, the Maximum Chart Limit is displayed
instead.
Start Sigma
This is the chart limit that is displayed after all data in the system has been erased or the “Clear
Trend” pushbutton has been pressed. The closer the Start Limit is set to the actual process cap-
ability limits, the quicker the process will stabilize and run at peak capability. Setting the Start
Limit below, or finer, than the actual capability of the process will cause the system to “chase”
size or overcompensate for the first lot. If an estimate of actual limits is not available, use the
Maximum Sigma you expect to need.
5. Process Center/Comp Target Dropdown and Data Entry Box
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From the dropdown box, select the parameter you wish to enter or change. Then enter the
desired value into the data entry box.
Figure 5-33. Process Center and Comp Target Parameters
“Process Center”
The term “process center” has two functions:
a. Typically defines the desired finished size of the workpiece, which may be at a non-zero
value.
b. Defines the permanent center of the Trend Chart screen.
The process center is very often zero (0.0000) which is the default value. If your process or tol-
erance define a non-zero value (such as -0.0002), enter that value in the data box.
Note: Be sure the OVER and UNDER limits, set on the Part Settings page,
are set correctly in reference to the process center. For example, if your part
is dimensioned as -0.0002 +/-0.0010 and the process center is set at-0.0002,
the OVER limit should be at +0.0008 and the UNDER limit at -0.0002, the
OVER limit should be at +0.0008 and the UNDER limit at -0.0012.
“Comp Target”
After a process becomes stable, it usually displays a kind of “sawtooth” pattern on the Trend
page, with the parts drifting slowly larger in size due to wheel wear, then at a certain point
(called by the gage controller) a compensation move causes the part size to move downward.
The IPC process with its self-narrowing limits is designed to minimize the magnitude of this pat-
tern, but does not eliminate it entirely.
The “comp target”:
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l Is the desired end point of a compensation move and is independent of the desired
workpiece size, which is called the “Process Center” as defined above.
l Appears on the Trend page (the data entry box is active even when in AUTO mode) as
well as the Compensation page. Changing the value in either place changes it in both.
The comp target parameter allows you to set the end-point of a compensation move to
wherever you want relative to the desired process center. If you are trying to run to the sys-
tem’s tightest capability, this can be set at one-half of the “step in size” below process center.
(Step in Size is the amount your compensator moves when it receives a single “comp in” signal
from the gage - see the Compensation Sizes group later in this section). Under these best cir-
cumstances, when your process is stable, the part size will increase to ½ step size larger than
process center, the gage will call for a compensation move, the compensator will move a dis-
tance of one step, and size will decrease to minus ½ step size. Under these circumstances the
“sawtooth” will be at its absolute smallest possible magnitude.
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Analogic Limiter Control Group (Items 6-9)
“Analogic Limiting” sets limits on how much change the D500 will recognize between two con-
secutive part readings. This method is used to prevent false or erroneous readings from affecting the
sub-group averages and causing false compensations. The rationale and technique of the method are
described below, followed by a description of the parameters that can be set to configure it.
Figure 5-34. Compensation Page – “Analogic Limiter” Group (6 – 9)
Dynamic gaging of parts as they exit a machine tool is often subject to conditions that can cause false
or erroneous gage readings. In particular, grinding swarf or chips on the part surface, “bumping” of
parts as they contact each other in the fixture, or “bouncing” of gage contacts due to part impact or
vibration are all possible causes of occasional false readings. Fortunately, machining processes such as
throughfeed centerless grinding are extremely stable when they are under control. This allows the
gage controller to “know” that some readings are very likely to be false and should not be responded
to with machine compensation. For example, when a throughfeed centerless grinder is operating
smoothly and under control, it is virtually impossible for an individual part in the parts stream to be
more than a very small amount larger than the parts around it.
6. Limit Over - Checkbox and Data Entry Box

If Analogic Limiting is enabled, this is the maximum amount a gage reading can be larger than
the previous gage reading to be included in the Trend Chart subgroup average. If it is larger,
the size value put into the subgroup will be the previous size value plus this “Limit Over” value.
Unmark the checkbox to disable this feature.
7. Limit Under - Checkbox and Data Entry Box
If Analogic Limiting is enabled, this is the minimum amount a gage reading can be smaller than
the previous gage reading to be included in the Trend Chart subgroup average. If it is smaller,
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the size value put into the subgroup will be the previous size value minus this “Limit Under”
value. Unmark the checkbox to disable this feature.
8. Tolerance
This value applies to the priming count set with the next parameter – please read that descrip-
tion first. This tolerance is a limit on the part-to-part variation that is tracked when the priming
count is being filled. If a reading is farther than this value from the previous reading, the current
subgroup is discarded and the priming count is restarted.
This assures that the process is reasonably stable before the analogic limiter function is
enabled.
This tolerance is normally set somewhat wider than the analogic limits to assure the priming
count is filled, but not so wide as to allow the limiter to start functioning when the process is
not stabilized.
If this tolerance is too tight for the process, or the process is actually not under control to within
the desired tolerance, then the priming count number of consecutive parts may never be filled.
If it is not filled, the Analogic Limiter will have no effect: there will be no arrows on the range
bars indicating limiting has occurred, and the values in the “Limiter Amt” display box and the
“Size” display box (just above it on the Trend page) will always be the same.
9. Priming Count
When a new Trend Chart is started after pressing the Clear Trend button, or when the system is
remastered, there will not be a valid gage reading in memory as a basis for the Analogic
Limiter. So the limiting feature does not commence operation until a small group (“Priming
Size” value) of new part readings is taken. This first “priming” group is averaged and used as
the “previous gage reading” for the first analogic limiting comparison. This method stabilizes
the operation of analogic limiting at the beginning of a run.
A reasonable initial setting for priming count is 3 to 5.
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Compensation Control Group (Items 10-14)
Note: In a few applications the D500 may be purposely configured with restricted
access to some parameter values or selections, so some items below may not
appear.
A specific case is when the compensation type, not included in dropdown box item (10), is “numeric
output”. If your screen shows “Comp Action” where “Compensation Sizes” appears below, look for sec-
tion “Numeric Output of Compensation Amount Option” elsewhere in the options chapter.
In combination with the Trend Table and the self-narrowing control limits described above, setup of
the compensation mechanism is critical to achieving optimal control of the machining process. The
D500 is programmed to work with several different types of machine compensators, and provides a
number of setup parameters specific to each type. Careful setting and “tuning” of both the Com-
pensation parameters and the Trend Table values can result in a system that produces workpiece tol-
erances to the machine’s best capability.
Figure 5-35. Compensation Page – “Compensation” Group (10 – 14)
10. Times
Pulse On Time
This parameter establishes the length of time an output pulse is maintained. This value
depends upon the input requirements of the machine controller, and should be established by
an electrician, by reference to the machine documentation, or by testing the machine require-
ments.
Pulse Off Time
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This parameter establishes the length of time between output pulses. This value depends
upon the input requirements of the machine controller and the mechanical responsiveness of
the machine itself. This value should be established by an electrician, by reference to the
machine documentation, or by close observation of the amount of time the machine needs to
mechanically complete an incremental move and be ready for the next one.
The Pulse Off Time forces a delay between pulses that is most likely to be needed when using
the Proportional Pulse compensation method on older machines. If pulses come faster to the
machine than it can complete them, required compensation increments may be lost.
11. Compensation Type
Note: If your screen shows “Comp Action” where “Compensation Sizes”
appears on the screen, this means the compensation type, not included in
dropdown box Item (10), is “numeric output”. Look for section “Numeric Out-
put of Compensation Amount Option” elsewhere in this chapter and skip to
subsection “Additional Features Control Group (Items 15-16)”.
There are three types of compensation that may be selected from the drop-down box. For use
with the IPC, only a proportional method of compensation provides the appropriate control.
If the machine tool has a fixed compensation increment, such as in “single step” compensation,
its responsiveness to size changes is limited to that increment. Proportional compensation
logic in the gage system, however, can evaluate the actual deviation from size and provide the
number of increments needed to bring the part size back to nominal. This allows the incre-
ment on the machine and the compensation limit in the gage to be set quite small for “fine”
control, but also allows for a “coarse” response (by moving several increments at once) if a lar-
ger size change occurs. Machines that have the capability described in both single-step and
dual-step compensation can be set up for proportional compensation by using multiple pulses.
A proportional compensation action (one or several pulses, depending on the value of the aver-
age) is initiated at the end of a subgroup calculation, subject to additional settings that limit min-
imum and maximum compensation amounts.
In all cases, compensating OUT depends on whether the machine has a bi-directional comper.
If not, all the related items (Step Out, Maximum Out, etc.) have no effect.
Single step - This method is in most cases not used with the IPC.
Note: Under some circumstances, selecting this method within the IPC
module may be desired to continue non IPC operation as performed with
earlier model gage controllers. If used this way, however, many of the adapt-
ive features of the IPC will be lost: contact Control Gaging Technical Support
at the numbers on page 2 of this manual if you need assistance in setup using
the full IPC system.
If Single step is selected, slide movement is produced in one direction (or two if the machine
has a bi-directional compensator) by one-shot pulses, resulting in a fixed amount of
106 137383
movement. These pulses are initiated by a simple comparator limit (see Item 12 Com-
pensation Sizes, below) – when the group average exceeds the preset limit (step in or step out
size), a pulse is sent to the corresponding machine input. The amount of movement is set in
the machine compensator, either mechanically or electronically.
Dual step - This method is in most cases not used with the IPC.
module may be desired to continue non-IPC operation as performed with
earlier model gage controllers. If used this way, however, many of the adapt-
ive features of the IPC will be lost: contact Control Gaging Technical Support
at the numbers on page 2 of this manual if you need assistance in setup using
the full IPC system.
If Dual step is selected, the system has two comparator limits on the gage and two inputs on
the machine for slide movement in each direction, a “Fine” and a “Coarse” increment (see Item
12 Compensation Sizes, below). A.”Coarse” compensation output is initiated when the
“Coarse” comparator setting (larger than the “Fine” comparator setting) is exceeded, and
causes a larger amount of movement than “Fine” as set up in the machine compensator. This
allows the machine to respond more rapidly when farther from size while allowing for smaller
steps when closer to size.
Proportional pulse – This method takes full advantage of all IPC features.
Proportional slide movement is produced by pulsing the appropriate output (IN or OUT) the
number of times needed to produce the amount of movement called for by the D500
calculations. The total compensation amount is determined by the last subgroup’s average cal-
culation relative to the “Process Center”, and the number of pulses is calculated (in order to
move to the Comp Target) based on the step size per increment (of the machine slide)
entered into the “Step in” and “Step out” parameters described below. The number of pulses
is calculated to move as close to, but not to exceed, the Comp Target.
12. Compensation Sizes
Note: If your screen shows “Comp Action” where “Compensation Sizes”
appears on the screen, this means the compensation type, not included in
dropdown box item (10), is “numeric output”. Look for section “Numeric Out-
put of Compensation Amount Option” elsewhere in this chapter.
Single Step Compensation Type - This method is in most cases not used with the IPC.
module may be desired to continue operation as performed with earlier
model gage controllers. If used this way, however, many of the adaptive fea-
tures of the IPC will be lost: contact Control Gaging Technical Support at the
numbers on page 2 of this manual if you need assistance in setup using the
full IPC system.
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Step In
Step Out
These values define the limits that initiate a compensation output. If the sub-group average is
farther from zero than this value, a single pulse will be applied to one of the two (In or Out) out-
put lines. This value is set to the amount of mechanical compensation that occurs when the
machine is pulsed in that direction. The Step in and Step out sizes may need to be set at dif-
ferent values depending upon machine capability or process characteristics.
Dual Step Compensation Type - This method is in most cases not used with the IPC.
module may be desired to continue operation as performed with earlier
model gage controllers. If used this way, however, many of the adaptive fea-
tures of the IPC will be lost: contact Control Gaging Technical Support at the
numbers on page 2 of this manual if you need assistance in setup using the
full IPC system.
Fine In
Fine Out
Coarse In
Coarse Out
Each of these values defines a limit that initiates a specified compensation output. If the sub-
group average is farther from zero than one of these values, a single pulse of that size (Fine or
Coarse) will be applied to its corresponding output line. This value is set to the amount of
mechanical compensation that occurs when the machine is pulsed (Fine or Coarse) in that
direction. The “in” and “out” sizes for each may need to be set at different values depending
upon machine capability or process characteristics.
Proportional Pulse Compensation Type– This method takes full advantage of all IPC features
Step In
Step Out
These values tell for the D500 controller how much actual mechanical slide movement occurs
with each compensation pulse in the specified direction. These increments are determined
from machine settings, either by the machine’s controller software or mechanical adjustment.
On older machines it may be necessary to confirm the increments by mounting an indicator or
probe, then manually pulsing the compensator several times, and dividing the slide movement
by the number of pulses. Based on this setting, the software calculates how many pulses are
needed to accomplish the proportional move requested – the number of pulses equals the dis-
tance from zero divided by the step size, rounding downward so as not to exceed the reques-
ted amount. The Step in and Step out sizes may need to be set at different values depending
upon machine capability.
Deadband In
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Deadband Out
These limits create a “deadband” or “neutral zone” around your process center where no
machine compensations will occur. If the IPC calculations call for a compensation move after a
series of subgroups satisfies one of the trend table values, but the last subgroup is inside the
deadband, the signal to the machine is suppressed and no compensation occurs.
A machine that can only compensate inward uses only “Deadband in”, which is the upper limit
of the zone; a machine with two-way compensation will also use “Deadband out”. (On older
machines with less accurate comp mechanisms, it is common to set the “Deadband out”
farther from the process center than the “deadband in” because the actual amount of com-
pensation per step may be larger or less reliable – the wheel wear already tends to move size in
the correct direction if the part is somewhat undersize, so unless it is significantly undersize, it
is often safer to let the process bring it back to size.)
The deadband limits gives you additional control over the process. For tightest tolerance con-
trol, the deadband values can be set to about the size of the smallest physical increment that
the machine controller or mechanical compensator can accomplish. If this fine control is unne-
cessary, set the values to create a distribution of sizes that fulfills your required Cpk but does
not result in over-frequent compensations at small increments that may affect wheel wear or
other process factors.
Maximum In
Maximum Out
The “Maximum” values are the largest total compensation allowed for any individual move.
They can be set to an amount based on previous experience with the process as a maximum,
or at a safety limit to prevent a “runaway” condition that might occur if a gage or machine com-
ponent is malfunctioning.
13. Skip Count

This parameter specifies how many part readings to ignore after a compensation move is per-
formed before starting to apply the compensation logic again. These are the parts in the “part
stream” that were not affected by the compensation move. Most common examples are:
l Throughfeed centerless or disc grinder – these are the parts in the guides that have
exited the wheels but not yet gone through the gage.
l Post-process gage station where parts are handled into one or more intermediate pos-
itions before actually being measured.
By skipping these part readings, the gage will not provide another compensation before the
effect of the last compensation can be measured.
This value should be set to at least the number of parts between the cutting tool and the gage.
The Skip Counter does not begin counting down until the compensation output to the
machine is complete – for example, in a pulse compensation throughfeed grinder where three
pulses may be sent, the count does not start until all three pulses are completed. However,
depending on mechanical machine response time (especially on older machines) if may be a
good idea to increase this value slightly for assurance.
NOTE 1: The parts that are “skipped” by the system show up on the chart only in the range of
the “Comp Box” subgroup that initiated the compensation move. In other words, the range for
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the yellow box may be quite large, since all the measurements preceding the completion of
the compensation move (which may be getting smaller gradually if there are several com-
pensation pulses) are included in it.
NOTE 2: Although the “skipped” parts do not show up in subgroup plots on the Trend Screen,
they are still all measured, recorded in the SPC data, classified for Over, Under, or Good out-
puts, and activate the diverter(s) if appropriate.
If there are no parts “staged” or in line between the machine and the gage (for example, a dis-
crete-parts application such as an ID grinder or post-process system that can measure and com-
plete a comp before the following part is processed), set this value to “0” for immediate
response.
14. Response Limit

This parameter establishes a maximum consecutive number of compensation outputs in one
direction (over multiple moves) that is allowed without the gage reporting a group average
within its “target window” - that is, if average part size has not been moved close to nominal.
The “target window” is defined for each compensation type as follows:
Single Step – This method is not used with the IPC.
Dual Step – This method is not used with the IPC.
Proportional Pulse – the range between values Over 1 sigma and Under 1 sigma
If the response limit number of outputs occurs before a subgroup average falls within the target
window, the error is generated on message the s and the gage controller, if so wired, will turn
off automatic operation of the machine.
The error message displayed on the screen is “Comp failed to respond within limits”.
This error indicates that either the machine is not responding to the gage or there is some kind
of a measuring error. The feature is disabled if the check box is not marked.
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“Additional Features” Control Group (Items 15 – 16)
Note: The following items may not appear on your screen. They are included only
with specific application types or option features.
Figure 5-36. Compensation Page – “Compensation” Group (15 – 16)
15. Dress Count
Note: This item is optional and may not appear on the screen in your sys-
tem.
In some applications, for example ID grinding with CBN wheels, the grinding process changes
so rapidly after wheel dressing that trend compensation cannot respond. At completion of the
dress cycle the machine provides the “Dress” input. If a number is entered into this box then
for the “dress count” number of parts
l Trend comp is “inhibited”
l The compensation amount is set equal to the size of each part measured, so a virtually
immediate response is made
l The analogic “Priming Count” is reset on each part
l If available on the Front Panel Screen, an indicator box will show “Dress” with a yellow
background; otherwise the box will show blank grey
l On the Trend Page, an “X” will be displayed within a yellow box; if the dress count is set
to more than “1”, the marker may also show a range.
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When the “dress count” is fulfilled:

l Trend comp is reactivated and begins to collect a new subgroup
l Analogic “Priming Count” begins
Although this method could possibly be used with pulse-type compensation systems, the most
common use is with numeric compensation output so the machine can respond directly to the
specified amount. If your system uses numeric compensation there will be a section elsewhere
in the "System Components" Chapter named “Numeric Output of Compensation Amount
Option”.
16. Part Selection Dropdown
This item is optional and may not appear on the screen in your system.
If your system includes the multi-part or multi-diameter selection feature, this box allows you
to select the part number to observe or to set the appropriate parameters. Be sure this box dis-
plays the correct part number when you are changing values. See section “Multi-part and/or
Multi-diameter Selection Option” in the System Components - Gage Controller Chapter.
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Example of IPC Compensation Setup and Operation
Figure 5-37. Example Trend Chart
The IPC is a very capable system, but operates based on several interacting principles and includes a
large variety of parameters to understand and set. Now that you have at least an idea of the types of
factors involved, this section provides an example trend chart with some parameters specified and
some configuration details explained so you can get a better sense of how it actually works.
The figure above displays a somewhat exaggerated view of several types of size trends and the
response that the IPC makes based on specific parameter settings. This screen is an example only –
these parameter settings may be very unlike the appropriate ones for your process. Always feel free to
contact the CGI Field Service department (Technical Support information on page 2 of this manual).
They will attempt to assist you on the phone or you may arrange a visit to your plant to assist in a thor-
ough review of your process setup.
The limited set of parameter settings that are visible in the action of this chart are listed below to help
in the explanation.
Note: It is much clearer to look at this chart on the computer or print the page in
color, since the trend zone coloring is not clearly visible when printed in black and
white.
Parameters for Example Trend Chart
The Item numbers in the column prior to the parameter name correspond to the numbered descrip-
tions in the previous section “IPC Operation and Setup – SETUP Mode Compensation Page”.
Item Page Parameter Name Readings

Trend Comp Group
1 Subgroup size 3
2 Subgroups per lot (120 total parts per lot)
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3 Over 2 sigma 3
3 Over 1 sigma 4
3 Over zero 5
3 Under zero 5
3 Under 1 sigma 4
3 Under 2 sigma 3
4 Start sigma 0.0150 (sets first lot values to +/- 0.0150)
5 Process Center 0.0000
5 Comp Target -0.0040
Compensation Group
11 Compensation type Proportional Pulse
12 Step In size 0.0010
12 Dead Band In size 0.0030
12 Step out size 0.0030
12 Deadband out size 0.0050
13 Skip Count 6
Description of Compensation Process on Example Chart
Starting conditions and explanations:
l The process center is set at zero for simplicity, but it can be set at a non-zero value if your pro-
cess or tolerances require.
l The Comp Target is shown as a red line with long dashes (which will not appear on your screen)
and is shown with an arrow indicating where the value is entered on the Trend page.
l The deadband values are set relative to the process center as shown on the chart, and the “no
comp zone’ (between +0.003 and -0.005) is shown with dashed lines (which will not appear on
your screen).
l The chart moves from right to left – the latest “plot” (subgroup average, shown as a green dia-
mond) is at the far right edge, the earliest at the far left.
l This is the first lot after beginning a run. The machine has been set up and is running parts giv-
ing subgroup averages around +0.0060 when the Comp On checkbox was checked to turn on
the IPC. The range of the screen in this example was set at +/- 0.0150 by setting the “Start
Sigma” value to 0.
1. The first three plots on the far left of the chart are all in the yellow +1 sigma range. Since the
trend limit for +1 sigma is set at Item 3the IPC calls for a compensation move, labeled Item 1,
with a box around the green diamond.
2. After the compensation move is initiated, the plot marker labeled that follows has the fol-
lowing unusual characteristics:
l The symbol indicating the average of this plot is an “X” rather than a diamond, indic-
ating that this plot includes parts measured during the “skip count” (see Item 13 in pre-
vious section.) A plot with an “X” (see also after comp plots Item 4 and Item 6) is
completely ignored in the trend calculations.
114 137383
l The “X” marker does not represent a “subgroup” as such: it includes all the parts
from the beginning of the comp move until the skip count is complete. In this
example, there may be four parts measured during the comp move on and six
parts in the skip count for a total of ten.
l The vertical “range bar” for this plot is quite long, since this subgroup includes
parts from the beginning of the comp move until after it is complete, including
the “skip count”, as the wheel moved inward to its new position. The “skip count”
measurements are not shown anywhere else on the trend chart, but the individual
part measurements of those parts are included in the SPC data and, if out of spec,
will be flagged as bad parts and diverted if required.
3. The part size gradually increases over the next few subgroups, as the wheel wears, until there
are five consecutive plots in the green “over zero” trend zone. Since the trend limit setting for
the “over zero” zone is 5, the IPC calculates that a compensation move is called for (green dia-
mond labeled Item 3 on the chart). However, since the value of this plot is less than the dead-
band in value (+0.003), the compensation output to the machine is suppressed and not sent.
The trend plot counter continues to increase while the plots remain in the “over zero” zone.
4. Part size continues to gradually increase with plots in the green “above zero” trend zone. Once
the plot size exceeds the “deadband in” limit, the conditions for a comp are met (the trend
counter is already above 5), so a signal is sent to the machine (labeled Item 4), moving the
wheel as many pulses as needed to bring the part size down to the comp target. The plot that
follows is also an “X” type plot with a large range as described in paragraph 2 above.
5. Following compensation Item 4 is a series of plots where the part is getting smaller (for
whatever reason). At this point there are three plots in the “under zero” zone plus three more
plots in the “under 1 sigma zone”. Since plots in “over 1 sigma” also count in “over zero sigma”
count, the requirement of trend limit (5) is sufficient to cause a compensation move. In addi-
tion, the subgroup average (-0.0061) is outside of the deadband out limit, which would nor-
mally allow the compensation move to occur at Item 5.
However, the comp target (-0.0040) is too close to the current subgroup average; it is only
0.0020 from the plot and the step out increment is (0.0030) - an outward compensation would
go farther than the target and overcompensate. So this comp output is also suppressed. (See
Item 11 Compensation Type in section “IPC Operation and Setup – SETUP Mode Com-
pensation Page” earlier in this chapter.)
The same type of limitation occurs if the step in size is larger than the distance from the plot
average to the comp target. It will simply ignore that condition until the distance is equal to or
larger than the step in size.
6. After plot Item 5 the counters for both “under zero” and “under 1 sigma” continue to increase
and continue to meet requirements for a compensation move, but each time it is suppressed
as described in paragraph 4 above. Finally the subgroup average of plot Item 6 (-0.0072)
exceeds the step out size (0.0032 > 0.0030) from the comp target and a compensation move is
initiated, resulting in size returning near the comp target.
7. After compensation Item 6 moves the trend line close to the comp target again, the trend line
moves gradually upward as the wheel wears, resulting in another suppressed comp at Item 7
because it is within the deadband (see paragraph 2 in this list, above). Compensations will
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continue to be suppressed while the trend limit is full until the subgroup plot average is above
the deadband in limit.
The up-and-down range of the “sawtooth” is automatically reduced over time as the recal-
culated "sigmas” get smaller. However, it will never get smaller than the width of the dead-
band since compensations called for within the deadband will be suppressed.
If you want to further improve system responsiveness, two types of adjustments can be made:
a. The deadband can be reduced experimentally toward the process center, which will allow
the IPC to tighten the spread of part sizes,
a. The trend limits (number of consecutive plots in each sigma zone that trigger a comp)
can be reduced, which will cause the system to respond sooner in each zone.
If the machine compensation system is very accurate and step in size small, it is possible to set
the deadband values to zero to take full advantage of the IPC self-narrowing capacity. In that
case the comp target can be set slightly below process center (the tightest possible value
would be ½ the step insize) – in this configuration the part size will grow to ½ step size above
zero, will then count subgroups to meet the “over zero sigma” trend limit, and comp a full step
back down slightly below process center toward comp target.
This degree of fineness may not be achievable in any given application due to the machine
step accuracy, the rate or consistency of wheel wear, response to dress cycles, etc. But the vari-
ous parameters can be adjusted individually in small increments to experimentally seek out the
best configuration for your process.
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Micropeak Option - Overview
Introduction to Micropeak
Micropeak is a software feature used to capture a gage reading on irregular or interrupted surfaces or
on rapidly moving parts as they go through a gage station. The “peak” aspect of the feature is that it
catches and holds on to the extreme (usually the maximum) point of the moving gage reading. As an
example, think of a ball thrown up in the air: the ball rises in a curve until it reaches a maximum height,
then continues in a curve back to the ground. If the “live” gage reading is thought of as measuring the
height of the curve through its entire travel, the function of the Micropeak feature is to “capture” the
height of the ball at its maximum, just before it begins to fall back down. It then holds on to that max-
imum reading and displays it on the screen until the “live” gage reading goes through another rising/-
falling cycle and Micropeak captures the next peak.
The setup pages and parameters described in this section allow the user to set up and tune the way
Micropeak works to capture a peak reading. The way these are used depends on the shape of the part
surface, the speed of part movement, and the mechanical design of the gage contacts and fixtures.
For most Micropeak systems a Control Gaging service engineer is on-site during the initial installation
and setup, and will determine the best configuration for the application and the specific parts being
measured.
Micropeak1 Definitions:
l Sampling2 – The software is continually taking data “samples” from the raw voltage signal that
is coming from the gage transducer. These samples are quick “snapshots” taken in little “time
slices” at the sampling speed of the system, usually more than 2000 Hertz or 2000 samples per
second. These samples are the data points that are processed by the Micropeak software into a
gage reading displayed on the screen. The figure in the next sub-section provides a graphic
view of the sampling process.
l Peak3 – The “peak” is the extreme value of the gage reading as it rises or falls on the surface of
the part. The specific term “peak” is used when the system is seeking a maximum reading; the
term “valley” is used when the system is seeking the minimum reading (for example on the
base circle of a camshaft.) By far most applications use “maximum” values, so the descriptions
that follow will assume that “peak” means maximum unless otherwise stated.
l Group Size4 – There are several Micropeak ‘methods’ of calculating what the actual “peak”
1Micropeak is a software feature used to capture a gage reading on irregular or interrupted surfaces or on
rapidly moving parts as they go through a gage station. The “peak” aspect of the feature is that it catches
and holds on to the extreme (usually the maximum) point of the moving gage reading
2The software is continually taking data “samples” from the raw voltage signal that is coming from the
gage transducer. These samples are the data points that are processed by the Micropeak software into a
gage reading displayed on the screen.
3The “peak” is the extreme value of the gage reading as it rises or falls on the surface of the part. The spe-
cific term “peak” is used when the system is seeking a maximum reading; the term “valley” is used when
the system is seeking the minimum reading (for example on the base circle of a camshaft.)
4There are several Micropeak ‘methods’ of calculating what the actual “peak” value is from the hundreds
or thousands of data points collected in the “sample”.
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value is from the hundreds or thousands of data points collected in the “sample”. But in all
methods the “group size” is a way for the user to define how many data points are to be used:
l The smaller the group size, the closer to the actual peak sample the value will be, but the
larger the group size, the more stable and repeatable the value will be by averaging out
the “noise” from mechanical and electronic variability in the system.
There is always a balance between getting the ‘true’ peak and a ‘repeatable’ peak when setting
the group size value. See the first figure and description in the following heading,
“Threshold–based Micropeak ” for further detail on group size.
There are two basic methods for taking Micropeak readings:

l Threshold-based
l Time-based
These two methods can be combined in some instances to provide even more flexibility for differing
part types. The combination methods, described briefly after the basic methods, are covered in more
detail later when describing different Micropeak method setup pages.
Threshold-Based Micropeak
The Threshold-based method uses the rising and falling of the gage finger(s) to determine when to
start and stop taking samples. The Threshold parameter on the Settings page is set at a value below
the minimum process size of the workpiece, typically between .1mm and .3mm (.004” - .012”) below
nominal. As a workpiece approaches the gage, the fingers are reading below the threshold, so data is
not being sampled. When the gage finger(s) rise onto the part, the reading crosses the threshold and
triggers the sampling period. Sampling continues until the size reading falls below the threshold again
(the gage finger falls off the trailing edge of the part). The Micropeak software then picks out the
highest individual sample (or an average of a group of the highest samples, determined by the para-
meter “Group Size”) and displays that value as the “peak” reading.
When the next part (or lobe or gear tooth, etc.) contacts the finger(s) and the gage reading goes above
the threshold, the controller begins collecting samples again, calculates the peak reading, and displays
it on the screen when the fingers fall off. This process continues as the finger(s) rise and fall, with the
last peak reading displayed and held on the screen until the next reading is determined.
The next figure provides a view of the Micropeak sampling process using the threshold method.
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Figure 5-38. Threshold-based Sampling Process for One Peak Reading
If the group size is set for 5 or fewer, the resultant peak reading will be the same as the five maximum
data samples 31-35. If the group size is set for 10, the resultant peak reading will be the average of
the five highest readings plus the next five lower readings (four to the right, samples 36-39, one to the
left, sample 30).
Common applications of the threshold method include measuring workpieces as they pass individually
through a gage station, often in or behind a disc or through-feed centerless grinder or on a conveyor.
It may also be used in-process to capture decreasing size on a rotating workpiece with large inter-
ruptions during grinding, such as the flutes of a reamer or gun-drill. Likewise, a minimum peak, or “val-
ley”, is measured when checking the base circle of a rotating cam lobe during grind.
Time-Based Micropeak
In the basic “Time-based” method, the “trigger” for starting the sampling period is a switched input to
the gage controller. The input can be a proximity switch that “sees” a part in the measuring position or
any other kind of switch input.
The sampling period ends when the amount of time set in the “Sample Time” parameter has elapsed
after the trigger is received. The method for calculating the “peak” from the samples is otherwise
exactly the same as in the Threshold method described above.
This approach might be used on a large valve spool with multiple grooves or on a compressor plate
with multiple or randomly-spaced holes. The gage will measure across the top of each of the separate
surfaces over the whole length of the part, giving one reading at the end of the “sample time”. This
method avoids the threshold interrupting/restarting the Micropeak process on each gap and giving
multiple readings on the same part.
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Threshold-Timed Micropeak
The two methods described above may also be mixed in the “Threshold-timed” method, which uses
the threshold as the initial trigger, but then uses the sample timer to end the sampling. The method
will be described later in subsection “Micropeak Settings Page - Threshold-timed Method”.
Threshold-Repeat Micropeak
The “threshold-repeat” method is initially triggered by the threshold, but repeats based on sample
time. This method differs from the threshold-timed method in that it does not require another rise to
threshold to restart sampling – the next sample starts immediately after the previous sampling time
has expired. This method is often used on parts such as piston pins or bearings when used with a TF1,
TF2, or TFN gage fixture. These fixtures do not separate the parts, so if there are no chamfers or under-
cuts, the gage cannot distinguish one part from another. In this circumstance, once the threshold is
exceeded, a timer causes each subsequent reading to be taken. The timer can be set to closely match
the time for one part to pass through the gage in order to approximate a reading-to-part cor-
respondence if needed.
Repeat Micropeak
This method begins the “repeat” timer as soon as the gage system is “enabled”, not depending on
either the threshold or a switch input. The timer then runs continuously, providing a new reading
when the sample timer elapses, starting a new sample immediately, and repeating indefinitely until
the gage system is disabled.
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Micropeak Method Comparison Charts

The two tables on the following pages compare the functions (types of “trigger” and method of “end
sampling”) and typical applications for each of the Micropeak methods.
In the table below, italicized words are parameters that are settable or selectable on the Micropeak Set-
tings page corresponding to the specific method.
Micropeak Start Sampling “Trigger”(in all cases End Sampling

Method gage enable input is received and
enable timer has elapsed)
Threshold Gage signal rises above threshold Gage signal falls below threshold
Timed Switch input Sample time elapsed
Threshold- First reading: signal rises above threshold Complete Sample checkbox is not
repeat checked:
Subsequent readings:
if signal is still above threshold when sample Gage signal falls below threshold or
time elapsed - end of sample time Sample time elapsed
if not above threshold when sample time Complete Sample is checked:
sample time elapses, signal rises above Sample time elapsed
threshold
Threshold- First reading: signal rises above threshold Part duration elapsed
timed
Subsequent readings: signal rises (or
remains) above threshold
Repeat First reading: gage enable timer elapsed Sample time elapsed
Subsequent reading: end of previous
sample time
Figure 5-39. Micropeak Method Functional Comparison
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Method Application Type Workpiece Type

Threshold In-process OD Plunge Grinding Parts with small number of flutes or large
diameters with interruptions or peaks:
Reamers, oval pistons, shafts with large %
interruption;
In-process surface grinding Parts in consistent position under path of
gage for consistent time on part
Throughfeed centerless grind with in-line Hydraulic pistons and valves, shafts with
gaging undercuts; almost any part where parts
are separated or have interruptions as
they go through the gage
Throughfeed or plunge disc grind with in- Almost any part type where parts are sep-
line or in-process gaging, includes surface arated or have interruptions as they go
grinders beneath the gage contact
Timed Post-process gaging station where part- Vary, not frequently used
present uses switch input
Threshold - Throughfeed centerless with in-line Piston pins, solid shafts with minimal or
Repeat gaging where there are no surface inter- no chamfers, very long solid shafts
ruptions and gage “sees” what looks like a
continuous or very long part
Threshold- Throughfeed centerless, disc or inspection Hydraulic pistons and valves, shafts with
timed machine where parts are separated undercuts; almost any part where parts
through the gage and also have inter- have interruptions along the length.
ruptions, but it is desired to discriminate
from part-to-part (rather than surface-to-
surface) in order to count parts, collect
SPC data, etc.
Repeat In-process OD plunge grinding Parts with small number of flutes or large
diameters with interruptions or peaks:
Reamers, oval pistons, shafts with large %
interruption
In-process surface grinding Non-symmetrical parts or random shapes

with widely variable holes and spaces
Figure 5-40. Micropeak Method Application Types
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Micropeak AUTO Mode Page

The AUTO Mode page (the window labeled “D500 Front Panel”) for a system with Micropeak has one
additional feature, the “Micropeak Samples/Time Indicator”, as shown in the figure below. The indic-
ator is comprised of two parts. The number on the left of the ‘/’ represents the total number of
samples taken during the data collection process for that cycle; the number on the right of the ‘/’ rep-
resents the amount of time over which the samples were taken. In the case shown below, the system
was taking samples at nominal speed (1000 Hz), so the number of samples corresponds to the number
of milliseconds of sampling time. (In some applications, the sampling speed may be set to a different
value.) These numbers can be helpful in understanding the measuring process and in setting some of
the parameters described in the next section.
Figure 5-41. Micropeak Indicator on AUTO Mode Page
The Micropeak function only operates when the gage system is ENABLED, that is, the gage enable
input is being received from the machine controller.
See the Installation Chapter, Section Mounting and Wiring the Gage Controller for a description
of the wiring and use of the gage enable input.
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Micropeak Settings Pages

In some applications where only one of the Micropeak methods is useful, the Micropeak settings are
found on a single D500 Settings page that includes all the settings for the entire gage system, includ-
ing a single set of Micropeak parameters (identified 1-7), as shown in the figure below.
Figure 5-42. Micropeak Settings on Main D500 Settings Page
In more complex configurations, there may be a drop-down menu for Settings on the main Menu Bar
from which a separate Micropeak Settings page can be selected. This page in turn may include its own
dropdown selection box with a choice of several different Micropeak methods, each with its own set of
parameters, as shown in the next figure.
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Figure 5-43. Separate Micropeak Settings Page with Methods Selection Dropdown Box
Note the “Use Micropeak” checkbox at the top of the frame. In some in-process control applications, a
gage channel may need to be used both with and without Micropeak because different kinds of parts
are processed on the same machine; by un-checking the box (all the Micropeak parameters will dis-
appear) the channel is returned to non-peak “live” operation such as used in an in-process plunge
grind. If there are two channels with checkboxes, they can be set up independently, one with and one
without Micropeak functioning. This feature is described in Section “In-process Micropeak Option”,
which, if it applies to your application, will be immediately in front of this section.
The Micropeak Settings page in turn may have several choices of Micropeak methods available from
the dropdown box, each of which will be described separately below. Some D500 Controller con-
figurations may not include all available methods if they are not useful to the specific application.
Many of the parameters described are used in more than one method, but each will be described only
for the first settings page where it is used. Simply refer back to the description on the earlier page
using the circled number that appears on the figure as a reference.
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Figure 5-44. Micropeak Settings Page with Methods Dropdown
126 137383
Micropeak Settings Page - Threshold Method
Figure 5-45. Micropeak Settings Page - Threshold Method
1. Threshold
Enter a numerical value for the level of the gage reading that will “trigger” the Micropeak data-
sampling cycle.
There are two general guidelines:
a. The Threshold must be set at a value below the size of the smallest workpiece that would
normally come through the gage system. If a part comes through the gage that reads
lower than the threshold, the gage reading will not rise high enough to “trigger” the data
sampling and the part will pass through without being detected or measured.
Note: An additional option, Extreme Undersize Checking may be

included in your system to protect against this situation when incoming
parts may be way too small.
b. The Threshold must be closer to zero than the amount of “overtravel” set on the gage
fingers. Overtravel limits are used on some gage applications to reduce the amount of
impact and “bounce” that occurs when parts make contact with the gage fingers. If the
threshold is set farther from zero than the overtravel amount, the gage reading will always
be triggering the Micropeak and it will not cycle on and off to collect data. Look for a
manual section name that includes “overtravel” to determine if your system uses over-
travel and how it is set.
2. Group Size
During the sampling period, the unit collects data samples at a high rate. When the sampling
period is complete, the unit calculates the “peak” gage reading as an average of the highest
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samples (or the “valley” as an average of the lowest samples) that are collected in the sampling
“group”. The number of samples averaged to create the gage reading is determined by the
“Group Size” parameter.
The group size can be set at a value of “1”, which means that the single highest sample will be
used as the “peak” reading. A small group size of 1 to 5 may be appropriate when the meas-
ured surface is curved or extremely short, and the gage finger will be physically on the max-
imum point for only an instant. However, more stable and accurate results are usually achieved
by taking a larger number of samples and averaging them. This is particularly true on straight or
flat surfaces (straight shaft diameters or flat disc-ground parts). In these cases, it is recom-
mended to take an average of as large a number of readings as possible. If, for example, the
gage fingers are on the measured surface for a full second, the unit will have collected 1000
samples at the standard sampling rate. If the Group Size is set to 500, a very large number of
samples will be averaged and a more repeatable result is likely.
Group Size Detailed Examples:
Referring to the figure “Threshold-based Sampling Process for One Peak Reading”, the
sampling has begun at timeslice “0” (off to the left) and stopped at about 80 (off to the right).
The “digitized gage signal” shows the samples that should be considered in calculating the
peak reading, the peak area being from about 28 to 60.
l If Group Size is set to “1”, the highest value is any of samples 31 to 35, about .0035mm.
l If Group Size is set from 2 to 5, the peak value will be the same since the five highest
readings are all of the same value.
l If Group Size is set to 10, the calculated value will be the average of the 10 samples
including 31-35 and 49-53, or about .0034.
l If the “Group Size” is set to 50, the samples will include many readings from the rising
and falling of the gage signal on the part, and the average will be a false number that
does not reflect the peak size correctly.
A practical way to determine how many total samples are available on each reading is to
observe the “Micropeak Samples/Time Indicator” (see figure “Micropeak Indicator on AUTO
Mode Page” above) when the system is running parts. Based on the various timing and
threshold parameters that are set, the left-hand number of the indicator will display the num-
ber of samples that were taken on the last reading. By observing several readings (there may
be some differences between parts or surfaces) you can determine a “typical” number of
samples as a basis for determining your group size.
Note that you should never use 100% of the available samples as the Group Size. This is
because there are always some false samples at the beginning and end of the threshold cycle,
and on interruptions the samples at the edges of holes or grooves may not be valid either.
Group Size “Rules of Thumb”:
l Longer parts with continuous surfaces lasting 1 second or more; take about ½ the avail-
able samples.
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l Short lands or fast-moving parts, measuring for less than ½ second; reduce the per-
centage of the total readings taken as the “time-on-part” decreases, because the pro-
portion of false readings increases with shorter sample time.
l When measuring parts where the gage rises and falls along the curve of the surface
(rather than across the square-cornered end), use 1 or 2 samples if they are moving fast
or the diameter is very small. Try to increase it if the part has a large diameter or is mov-
ing/rotating slowly.
l A way to verify if the gage is reading the “full” size of the part rather than including the
rising and falling samples, is to compare the dynamic Micropeak reading in AUTO to
either the static reading (part static reading maximum point) or to the dynamic
Micropeak reading with a group size of 1. If there is a significant difference, reduce the
group size until the difference levels off. There will always be some differences
between these readings, but it should not be a large amount.
Group Size Considerations for In-Process Applications
Group size setting for diameter applications may be more critical than most surface grinders
due to the high rate of workpiece revolution, small amount of contact time, and the high rate
of stock removal. See subsection “Verifying Sufficient ‘Full-Size’ Readings” in the previous sec-
tion “In-Process Micropeak Option” for ways to verify the validity of group size.
Diameter Applications
A practical starting value for “Group Size” for most workpieces is “5”.
The group size can be set at a value of “1”, which means that the single highest sample will be
used as the “peak” reading. A small group size of 2 to 5 may be appropriate when gage fingers
will be physically on the maximum point for .1 second or less. A larger number of samples will
tend to give a more stable average, but it is critical that the “group size” include only samples
taken when the contacts are riding on the full diameter.
Surface Grind Applications
If the pure “Threshold” method is used as described in this subsection, the “Group Size” must
be small enough to avoid false undersize readings on the smallest/shortest land that the con-
tacts will ride on - if lands are small, it is safer to use the “Threshold-Timed” method. This
method works fine if the parts are of the same shape and are mounted in a circle to pass under
the contact consistently with the same amount of surface,
3. Throw Outs
The “Throw Outs” parameter is also called “spike suppression”, and allows you to discard a spe-
cified number of the very highest (or, for “valley”, the very lowest) samples taken. This feature
is normally used if there is a danger of the gage finger “bouncing” when the workpiece first
enters under the gage contact, or if there are other kinds of vibration or contamination. This
value must be set at least 1 less than the Group Size to leave at least 1 sample to be used for
the peak value.
If there is little likelihood of “spikes” in your system, this value may be set at zero. Setting this
value is usually a matter of testing for the results of any given value under run-time conditions,
that is, if a “test” value gives more consistent readings closer to actual size than a different
value.
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4. Starting Clip Time

The two “Clip Time” parameters allow for ignoring or excluding portions of the sampled data at
the beginning and end of the total length of the workpiece. The “Starting Clip Time” value
excludes all the data points from the moment the gage signal exceeds the threshold until the
set time expires.
This feature can be used:
l To ignore bounce or part/fixture misalignment that may occur when a part enters a fix-
ture and then “settles in”.
l To ignore sections with a looser tolerance than the area being controlled.
l In conjunction with “Ending Clip Time”, to select a single portion of the workpiece to be
measured.
An example of fixture “settling” is shown in the next figure, where an unexpected rise in size is
seen at both the entering and exiting of the part (but separate inspection does not show such a
size difference.)
5. Ending Clip Time

The “Ending Clip Time” excludes all the data points in the specified time period backwards
from the end of the sampling period. This feature can be used to ignore bounce or part/fixture
misalignment that may occur when a part leaves a fixture, or if parts have sections with a looser
tolerance than the area that is being controlled, or simply if the center of a surface - excluding
the ends - is being measured. See the next figure.
130 137383
Figure 5-46. Clip Times
6. Peak or Valley
The “Peak” or “Valley” selection box defines the type of “peak” to be captured: for “peak”, it is
the maximum reading, for “valley”, it is the minimum reading. In the figure “Threshold-based
Sampling Process for One Peak Reading” the value desired is a “peak”, while in figure “Clip
Times” above the value measured is a “valley”.
7. Duration
This value is used in conjunction with the Sampling Time timer to ignore portions of the part at
the trailing end. For example, if an individual part has holes or undercuts that will trigger read-
ings over five seconds, but only the first three seconds are of interest, set the duration timer for
5.1 and the sampling time for 3. The controller will take samples for 3 seconds, but the dur-
ation timer will prevent the gage from starting another measuring cycle before the 5.1 seconds
has elapsed, even if the gage contacts rise above the threshold several times.
If the duration time is set smaller than sampling time, it is ignored. If not being used, set it to
zero.
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Micropeak Settings Page - Threshold-timed Method

This method uses the threshold to begin the data sampling as described just above, but uses a timer to
end the sampling instead of the threshold. This method might be used where only a portion of a long
part is critical, or where there may be slots or interruptions over the measured section but you do want
to ignore the holes or spaces to get a reading based on samples across the whole length.
Figure 5-47. Micropeak Settings Page – Threshold-timed Method
8. Sample Time
This value determines how long the unit will collect samples after a “trigger” has occurred to
start the Micropeak cycle. In this application, the trigger for starting the sampling timer is the
gage finger rising above the threshold. But instead of the sampling period ending when the
gage falls below the threshold again, the end of the cycle occurs after the period defined by
“Sample Time”.
An example for using this combination is a circular compressor plate being measured for thick-
ness behind a through-feed disc grinder. The plate contains a number of irregularly shaped
and spaced holes. This surface would cause a pure threshold-based method to take a varying
number of unevenly-spaced readings across the surface of each individual part, since the
threshold would start a new reading every time the gage contact fell into and rose out of a
hole. By setting the “Sample time” value long enough to cover the full length of the part, the
gage will collect samples across the entire surface of the workpiece (including the holes) and
take an average of the highest readings across all the raised portions of the surface. (The holes
will be excluded because they are low readings.) After the timer times out, the threshold “trig-
ger” becomes active again, so when the finger rises up on the next part, a new measuring cycle
is started.
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In this example, the “Group Size” should be set low enough to ignore the low readings that
were taken across the holes. For example, if the holes represent about 30% of the surface,
then about 70% of the data samples are valid. The “Group Size” should be no more than half
of that, or 25% to 35% of available samples.
Note: If the gage contact is still up on the surface of the part (has not fallen
off the final edge) when the timer elapses, a new Micropeak cycle will start
immediately (since the threshold is “made”). Normally when “Sampling
Time” is used in this manner, the amount of time set on the timer should be
enough that the entire length of the part has passed through the gage before
the timer times out. Then when the gage rises again on the next part, it will
begin a new measuring cycle. There are other circumstances where this is
not the case – see the Duration timer below for an example.
Sample Time Considerations for In-process Applications

With Sample Time, after the process is enabled (and if used, the Threshold is exceeded), the
D500 Controller takes samples over the specified time period, calculates the maximum reading
from the number of samples in the “Group Size” parameter, updates the display and setpoint
status, then continues to repeat the cycle until the cycle ends.
To set the “Sample Time” value, enter the amount of time in seconds over which the reading is
to be taken.
Diameter Applications
For diameters, when the RPM of the workhead is known it is easy to calculate the sampling
time. Because a two-finger gage will “see” the maximum workpiece size two times per revolu-
tion, calculate the value as:
For example, 120 RPM (2 revolutions per second) gives 60/120, then divide by two again to
yield .25 seconds as the sample time. It is essential that the time period allows both contacts to
pass over the maximum diameter at least once, so set the value to no less than the calculated
value and preferably slightly more to account for inaccuracies. In the example, use a value of .3
seconds.
Surface Grind Applications
For flat parts on surface grinders, the time must be long enough to get enough samples on the
full part surface to create a good average. If you estimate that the grinder table is 20% covered
with workpiece grind surface along the path of the gage finger, and you set the sample time for
5 seconds, you should get approximately 1 second total of full-size reading samples, or 1000
samples. That would allow you to set the group size at as much as 400 - 500 to get a solid read-
ing every five seconds. Adjust the times and samples up or down depending on rate of grind,
rotation speed of table, and also the stability of the readings you are getting relative to the tol-
erance under those varying combinations.
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Micropeak Settings Page - Timed Method

The timed method for Micropeak begins its sampling period when Gage Enable times out –
please review subsection “Time-based Micropeak” near the beginning of this “Micropeak
Option” section. In this method, the “trigger” that starts the sampling process (review “Sample
Time” earlier) is a switch input, sometimes initiated by a gage-handling controller or possibly a
“part present” proximity switch. Sometimes the “gage enable” is connected in software to this
input, so the machine “gage enable input” is used.
All of the parameters on the page have already been described above – “Threshold” and “End-
ing Clip Time” are not available.
Figure 5-48. Micropeak Settings Page – Timed Method
“Starting Clip Time” is available for this feature and the timer is started when Gage Enable
times out. Unless there are unusual circumstances that would require “clipping” (such as an
odd shape discontinuous surface), just set it at “0” and set the switch position or PLC timer to ini-
tiate sampling when desired.
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Micropeak Settings Page - Threshold-Repeat Method

The “threshold-repeat” method for Micropeak begins its first sampling period when the
threshold is exceeded – please review subsection “Threshold-based Micropeak” near the begin-
ning of this “Micropeak Option” section.
As default, if the “Complete Sample” checkbox is not marked, the first sample is then taken
when the “sample time” period has elapsed OR when the reading falls below threshold. If the
reading is above threshold, the next sample is started immediately; if not, the system waits until
the threshold is exceeded to start a new sample.
The “Complete Sample” checkbox, if marked, requires the D500 Controller to wait through the
complete sampling time before it can start a new sample, regardless of the threshold. Using
this feature, the sampling time can be set for a longer time that may include several ups and
downs of the gage finger above and below the threshold. When the final reading is calculated,
the group size will be selected from all of the data taken during that time period.
All of the parameters on the page have already been described above – “Starting Clip Time”
and “Ending Clip Time” are not available.
Figure 5-49. Micropeak Settings Page – Threshold-repeat Method
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Micropeak Settings Page – Repeat Method

The “Repeat” method is the simplest of the group and depends only on repetition of the
sampling timer. Once the “gage enable input” is received and the delay has timed out, the sys-
tem starts taking its first sample. Thereafter, when the sample time has elapsed a new reading
is calculated and a new sample is begun immediately.
When using this method it may be necessary to use the “Extreme Undersize Checking” feature
or another method to make sure that when parts are not passing under the gage finger that the
continuous undersize outputs that will result are ignored by either the D500 controller or the
machine. This may be done by a “part present” switch that disables the gage when no parts are
present or some other system logic.
Figure 5-50. Micropeak Settings Page – Repeat Method
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Micropeak with Dynamic Zero Option

Dynamic Zeroing is a method to master or zero the Micropeak Option when the gaging process
includes many kinds of variables, such as rate of speed or rotation, surface finish, coolant flow, gage
contact shape, sharp or rounded shape of workpiece edges, and so on. This dynamic procedure zeroes
the system with the part or gage moving along with the other process factors influencing the meas-
urements as they would “in real life”, giving a more realistic result that requires less adjustment later.
Dynamic zeroing is most often used for flow-through post-process applications like disc, centerless,
inspection machines or dynamic checkpoint gages where the parts are moving through the gage
without stopping. In some post-process fixturing applications, the part or gage may move relative to
each other, and a Micropeak reading is taken. It may also be used for in-process applications if the
“Static-zero-and-jog” method is found to be inaccurate on that application.
Note: Dynamic zeroing can be performed automatically using an input from a

machine or robot controller rather than having the operator press the “Start” and
“Accept” buttons. If your system has this feature, set up the parameters described in
this section, then refer to the next section “Remote Dynamic Zeroing Option” (if not
included, the feature is not available) for additional setup instructions.
The preferred way to use dynamic zeroing is with “on-size” parts flowing through the gage. For this
scenario, the gage system has already been set up on a static part, and the machine system (such as a
through-feed center-less grinder or a rotary disc grinder) has been set up and adjusted to be pro-
ducing on-size workpieces. As “on-size” workpieces flow through the gage, the “Dynamic Zero” pro-
cess will take a series of readings on the parts and then determine an average value from the readings.
This value is considered “zero” and the gage controller will be offset to show zero for that size. If the
parts being measured are slightly different from nominal, after zeroing simply “jog” the value to rep-
resent the actual size.
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Figure 5-51. Dynamic Zero Page
Dynamic zeroing can also be performed by passing a master workpiece through the gage (or passing
the gage over the master) multiple times, simulating some of the aspects of the process. This
approach is used when robotic, fixtured, or remote dynamic zeroing is used.
Note: With the Micropeak Option, the controls for mastering/zeroing in the “static”
mode are located on the Dynamic Zero page. The page is labeled “Zero” on the
menu bar, and there may be a dropdown selection box if there are multiple gages
for zeroing.
Dynamic Zero Page
Refer to figure “Dynamic Zero Page” above.

Setup Parameters
1. Tolerance
This value defines a “window” that excludes a reading from the averaging process if it is farther
away (either positive or negative) than this amount from the previous reading. This process
“homes in” on a value that ignores fliers or other kinds of errors during the averaging process.
This number should be an estimate of the highest acceptable level of variation from part to part
reading (repeatability) that the measuring process might be expected to produce.
2. Passes Required
Enter a number that will provide an effective average of part readings to insure accuracy – as a
guideline, start with 5 unless the parts are very long (use a smaller number) or very short (use a
larger number). This value is the number of consecutive readings that are required (starting
the count over whenever a part is out of “tolerance”) to establish the average that is used as the
“dynamic zero”.
Pushbuttons
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3. Start
This pushbutton starts the Dynamic Zeroing process after the parameters have been entered.
After pushing the button, parts going through the gage will begin counting in the “Done” dis-
play box. See also the description of the “Done” display box below.
4. Accept
Once a valid “Average” value is determined, unless there are indications of serious problems
(for example, the “Done” box is at a very large number, indicating many parts outside the tol-
erance), press the “Accept” pushbutton to load the average as the new Dynamic Zero. When
that occurs, the “Dynamic Offset” box will show green with the same value as the “Average”
was before, indicating the amount of offset between the original static zero and the new
dynamic zero. The “Average” value will now change to “0.0000” and stay green as the new
dynamic zero.
Displayed Values
5. Samples/Time
The indicator is comprised of two parts. The number on the left of the ‘/’ represents the total
number of samples taken during the sampling period; the number on the right of the ‘/’ rep-
resents the amount of time over which the samples were taken. When the process is inactive,
the numbers are zero.
6. Reading
This is the reading just taken on a part or master during the dynamic mastering process. This
display box will have a yellow background.
7. Dynamic Offset
This display box shows the amount of difference between the static zero previously established
and the new zero established by the dynamic zeroing process. This number will turn green and
be valid after the “Accept” pushbutton is selected. Until then, the background will be pink and
the value will not be valid.
8. Average
This number is the current average of the consecutive valid (that is, not outside of tolerance)
readings taken so far during dynamic zeroing.
9. Done
This box displays the number of parts measured so far. It may grow larger than the “Passes
Required” number if any part measured is outside the tolerance, because the averaging sub-
group will start over from the count of ‘1’.
For example, if the “Passes Required” value is ‘5’ and the gage takes ‘3’ valid readings then ‘1’
out of tolerance, the “Done” value will be ‘4’ but the “Average” value will be invalid because
the count will be starting over. If all 5 of the next readings are valid, the “Average” box will turn
green and be “0.000” and the “Done” box will show 9.
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Dynamic Zeroing Procedure

NOTE 1: In applications with the “Compensation Verification Option”, there will be two gages on the
dynamic zeroing page as shown in the next figure. Only the diameter gage can be zeroed
dynamically. For zeroing the Comp Verification Probe, see section “Compensation Verification Option
with CVU” elsewhere in this chapter.
Figure 5-52. Dynamic Zero Page with Comp Verification
Before Dynamic Zeroing:
l “Static zero” the gage on a master or master workpiece in the gage. On some systems, some
kind of “mountable” substitute master or “finger-centering master” may be provided – you can
use this for static zeroing if it is too difficult to position a work piece to do so.
l If your master workpiece is not to exact nominal, enter the deviation in the “Size” box in the
“Static Zero” frame or page. This assures that the dynamic zero set in the controller will be
adjusted for the actual size of the mastering workpiece.
l Enter values in the “Tolerance” and the “Passes Required” data entry boxes. See the previous
subsection “Dynamic Zero Page” for descriptions of each parameter and display element.
l If you are mastering on parts as they are being ground, set up the machine and run on-size
parts
l If you are mastering on a master or on-size workpiece, have the part ready to feed through mul-
tiple times
NOTE 2: In applications with the “Remote Dynamic Zeroing Option”, the “Start” and “Accept” func-
tions described below are performed by the machine controller or internally to the D500 Controller.
However, you can read the following to understand how the system works. Also see the section fol-
lowing this one, “Remote Dynamic Zeroing Option”.
To dynamic zero the gage system:
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1. Press the ‘Start” pushbutton to begin.

As parts are measured:
a. The “Reading” display shows each measurement (yellow) based on the previously set
static zero.
b. The “Average” display shows the current average value (yellow) of the readings.
c. The “Done” display counts all the parts measured, including the out of tolerance ones (yel-
low).
d. The “Dyn. Offset” value does not change from its previous value and will have a pink back-
ground to indicate it is not valid.
2. The process continues until the “Passes Required” number of parts has been measured
consecutively. It then considers the “Average” value to be valid. If any part reading is out of
“Tolerance”, the count starts over. The “Done” box will continue to count all parts measured.
3. When a valid average is established, the “Average” display turns green. This number rep-
resents the amount of difference between the “static zero” and the “dynamic zero”.
4. If the “Average” value seems reasonable (that is, not a large amount different from the static
zero) and the “Done” value is not extremely large (which would indicate poor repeatability
from part-to-part), go to Step 5. Either of these conditions may require that you adjust
Micropeak parameters or check for loose or unaligned fixturing elements to improve the accur-
acy of the gage.
5. To complete the process, press the “Accept” pushbutton:

a. The “Average” display will go to “0.0000”.
b. The value of the “Dyn. Offset” box will take the previous value of the “Average” display
and turn green.
Dynamic zeroing is complete.
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Multi-Part and/or Multi-Diameter Selection Option
Note: Control Engineer - Electrician - Field Service

The active diameter is selected either by unary or binary input. The Gage Enable
Delay will restart each time a new diameter is selected, even if there are inputs
already on.
Binary Example: If Input 1 is on and timed out and the setpoint outputs are on, turn-
ing on Input 2 while Input 1 is still on (selecting Diameter 3) will cause the setpoint
outputs to turn off and the Gage Enable Delay to restart for Diameter 3.
Unary Example: In the unary method, the user must turn on just one input. The
response to multiple gage enables being turned on is not supported.
The D500 may be configured with several options that allow the user to save specific configuration
data (setpoint values and size zeroing offsets) and associate the data with identification labels for later
selection.
This allows quick changeover from one part or size to another in one of the following ways:
1. Manually by selecting from a drop-down box.

2. Automatically:
l Using logic and data “internal” to the D500 controller itself.
l Using a “remote selection input” from the machine or process controller.
3. Both manually and automatically- for example, the part selection may be made manually by
the operator, but the diameter selection automatically.
The option may appear in one of three possible forms, which are provided based on the requirements
of the application:
1. Multi-Part Selection

2. Multi-Diameter Selection
3. Multi-Part/Multi-Diameter Selection
Note: The term “diameter” may actually be used for any workpiece feature. Dia-
meters are by far, the most common.
The principles of all three versions are the same, that is, a specific set of operating parameters can be
assigned to a specific processing or measuring operation. The difference between the first two ver-
sions is the difference between selecting different workpieces (multi-part) and selecting specific dia-
meters on a workpiece (multi-diameter). The third option is a combination of both functions, resulting
in a specific set of stored parameters for each combination of workpiece and diameter/feature.
If one of these options is available, it is identifiable on several screens either as labels that change
according to the selected part, diameter, or both, or selection boxes to assign parameter values to
each part or each diameter, or both.
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Figure 5-53. Manual Selection Dropdown Box
Manual Selection
In some systems, the selection of part or diameter is made by the operator directly from the Front
Panel screen using the Part/Diameter Selection dropdown box.
In SETUP mode, tab to the selection box and press the either the up or down arrow [↑] [↓] key to dis-
play the dropdown list. Using those keys, highlight the desired number, then press [ENTER], [ESC] or
[TAB] to close the box. The part label (in this case “Part 12”) is displayed immediately on the screen
when its line is highlighted in the box.
The manner in which part or diameter/feature numbers (or names) are used to label screen displays
(meters or size display boxes, setpoints, etc.) are common to all selection types and are described in
more detail later in this chapter.
Automatic Selection - "Internal"

Special applications may include logic that uses no external input at all, either from the operator or
from the machine control. One example is a camshaft application where the machine is capable of
mechanically handling and programmatically grinding a variety of different part numbers that may
enter the machine randomly. In this case a gage is added to the system to measure an “Identification
Ring” on the part whose diameter falls within one of several preset ranges that correspond to different
part numbers. When the range is determined by the gage, the D500 automatically selects the cor-
responding part number for its own control parameters, and also sends a part selection output to the
machine to inform it which grinding program to use.
The features of any “internal” automatic selection method will be described in more detail in the
“Application-specific Information” section in the “System Overview” chapter of the manual. Unless
described otherwise in that section, the functions of all data entry boxes, dropdown selection boxes,
and screen display boxes for “internal” selection are identical to those that apply to all types as
described in the balance of this chapter.
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Automatic Selection – “Remote”

In the case of “remote” automatic selection by the machine controller or other switch input, the selec-
tion interface is detailed in the connection diagram in the “Diagrams” Chapter. Selection inputs are
typically named “cycle select”, “part select”, “diameter select”, or similar depending on machine
builder terminology. When selection is done remotely, there may be no means to provide manual
selection for parts or diameters, so some setup and zeroing functions may require use of the machine
control console.
These features are described in the following subsections generally apply to all forms of selection
unless otherwise identified.
AUTO Mode
AUTO Mode Screen
The AUTO mode screen shown in the next figure provides an example of labels that change according
to the selected part and diameter. In this somewhat complex case, there are two gage channels that
are labeled Left and Right above their columns of setpoint indicators. Each of the two gage channels
can be assigned to Part 1 through Part 4 by a remote selection input, and, for each part selected, Dia-
meter 1 through Diameter 4 can also be assigned. The Part number and Diameter number selected
for each channel is indicated by labels above the gage reading and bar meter.
Figure 5-54. AUTO Mode Screen, Multi-Part/Multi-Diameter
If only the Part Selection or Diameter Selection option were available, only one of the labels would be
present, as shown in the following example.
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Figure 5-55. AUTO Mode Screen, Multi-Part Only
Another labeling scheme (shown circled in the next figure) includes the idea of part “families” and
could be called “Multi-Family/Multi-Part”. In the case shown below, a part family is identified (“SUN”)
and a specific part number in that family is shown below (87601). This approach operates similarly to
Multi-Part/Multi-Diameter.
Figure 5-56. Multi-Family/Multi-Part
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Auto Mode Jogging
Adjusting size or “jogging” on a multi-part or multi-diameter system is identical to the normal method
with the exception that the “Gage Jogging” dialog box includes drop-down selection boxes for access
to all combinations in the system.
For example, the screen shown below results from pressing [ENTER] with the Right gage jog function
selected (note the marker triangle next to the +/- jog box for Diameter 4). The current part/diameter
combination values are already highlighted, so to jog the current channel, just [TAB] twice to high-
light the “Jog amount” box and enter the value as usual. However, if you want to jog any other com-
bination of part and diameter for that channel, you may select from the drop-down boxes first, then
enter a value. The jog will be applied to the size value for the selected part/diameter and will affect
size the next time that combination is selected in AUTO mode.
Figure 5-57. Multi-Part/Multi-Diameter Jogging
On applications where a single gage head controls size for multiple diameters during the same cycle,
jogging the gage to account for temperature or size drift needs to apply to all diameters in the cycle.
In that case an “All Dia.” entry appears in the drop-down as shown below.
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Figure 5-58. “All Dia.” Jog
SETUP Mode
Settings Page
On the Settings Page, setpoints that can be assigned to a part, diameter, or part/diameter combination
will either be listed in rows (if there are a small number of choices) or will be displayed below drop-
down list boxes that allow selection of the available combinations. The figure below shows a relatively
complex situation with two gage channels (each with 8 setpoints) and the same type of 4-part, 4-dia-
meter drop-down boxes used in the Auto Mode Jogging Box above.
A variation on a two-level scheme is for parts in “families”. In that case, there are also two drop-down
boxes: the “family” identifies the type of part (Example: “Sun” gear or “Pinion” gear), and the second
dropdown allows selection of the specific part number within that family. This scheme is set up in the
same manner is described below.
To set the values of the setpoints for a gage channel, first select the Part number and the Diameter
number for that channel. After loading or changing values, [TAB] to any other location to save the
new readings.
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Figure 5-59. Multi-Part/Multi-Diameter Settings Page
Note that in the case of the “Right” gage above, the names in the drop-down box have been cus-
tomized for a specific application. In some applications the part or feature names are specified by the
customer and loaded into the system at the factory (or during installation) by a CGI software or service
engineer. In other applications, there may be a data entry dropdown box on one of the Settings pages,
providing a space for the customer to enter or change the names on site as described next.
In the case of a “Multi-Family” application, a dropdown box on the settings page will display the list of
family names to select from. Once selected, the names that appear in the Part Labels panel will be
available only for that family.
Figure 5-60. Multi-Family Labels
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Changing Part Labels
Figure 5-61. System Settings Page with Part Labels
If one of the Settings pages has a “Part Labels” group as shown in the next figure, you may change the
part/diameter names displayed in the system. To do so, you must connect a keyboard and mouse –
see Section “Using a Keyboard and Mouse with the D500” earlier in this chapter for further details.
By default, the first four part indexes (if applicable) are generically named Part 1 up to Part 4 . The gen-
eric placeholder names can be changed by the user based on individual requirements (i.e., Cam 1,
Journal 6, Part CG6666, etc.). In addition to the generic placeholder part names, the system allows for
adding as many additional names as required until the limit, determined during the quote/system
order, is reached.
Note: The maximum quantity of allowable part names is determined during the
quote/system order process and cannot be expanded once the configuration is in
the field.
The “Index” box indicates the sequence of the part labels stored, and if “automatic selection” is used,
the index numbers correspond to the value of the input from the machine controller (see connection
diagram) that will select the part name entered in the corresponding “Label” box.
Note: If you enter a “null” name in the “Label” box, the corresponding index pos-
ition will disappear from a manual selection dropdown box. For example, if you no
longer use a particular part name and you want to eliminate it from the selection
dropdown, erase the name in the “Label” box and it will no longer appear.
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Note: If you erase the label on a system that uses automatic selection, the remote
input for that index number will still select it, but no label will appear to identify the
selection on any page. If you erase a label on automatic systems, be sure the
machine controller is no longer programmed to request it.
Zeroing Page
In the example below, the Part label is shown on the zeroing screen in SETUP mode to identify the
part (currently selected by the machine control input or from the Front Panel selection box) being zer-
oed.
Figure 5-62. Multi-Part Zeroing Page
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Statistical Process Control (SPC) Option

The Statistical Process Control (SPC) Option includes four pages selected from the Menu Bar in either
AUTO or SETUP modes.
These pages are:
l Histogram – displays distribution of current part data

l X bar R – displays X-Bar and R charts for current data
l SPC – displays SPC calculations and setup parameters
l Data – for storage of data or selection of data for output to another device
All four pages can be re-configured in RUN or SETUP mode and calculations and charts will be imme-
diately recalculated and displayed. Navigation on the pages and the types of controls for parameter
entry are the same as previously described for other menu pages.
The “Close” pushbutton on each screen saves the parameters, if changed, to the flash disk.
Histogram Page
The Histogram provides a running display of the distribution of measured sizes.
Figure 5-63. Histogram Page
1. Histogram
The histogram displays a graph consisting of bar segments that represent the percentage of the
part measurements that fall into the partition categories. The percentage values are shown
across the bottom of the graph. Example: The segment that coincides with the X-Double Bar
value (-.00101) represents about 12% of the total number of parts currently stored in the his-
togram data buffer.
2. Histogram Reading Counter
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The right-hand value indicates how many part readings are stored in the chart buffer; the left-
hand value indicates how many of the part readings in the buffer are shown on the graph. The
example shown in the figure above indicates there are 5 readings in the buffer that are outside
the range of the graph and cannot be seen.
3. Samples
This value determines how many part readings are used in constructing the histogram. The
range of available values is 1 to 300 readings. If this value is set to 300, the last 300 gage read-
ings are displayed on the chart. When the chart memory buffer has reached this number, it will
be the number displayed in the right-hand portion of the “Histogram Reading Counter” in the
upper right-hand corner of the histogram page.
4. Partitions
This setting determines the number of bars displayed on the histogram. The available range is
1 to 30. The number of histogram segments is used in combination with the Upper and Lower
Limits to define the width of the segments in terms of part dimension. For example, if the
Upper and Lower Limits are set at +/-.001” respectively, and the number of segments is 20,
each segment will contain parts within a .0001” range.
5. Upper Limit
This value sets the upper size limit on the vertical axis for the histogram.
6. Lower Limit
This value sets the lower size limit on the vertical axis for the histogram.
7. Include Bad
When this box is checked, the data includes all parts measured, including any out-of-spec
parts. If “bad” parts have been physically removed from the lot and you want the screen to dis-
play the lot statistics without them, uncheck this box.
8. Part/Diameter/Source Selection Boxes
If the system has multiple parts, multiple diameters on a single part, or multiple sources for
parts, these selection boxes allow the user to choose which data to display on the chart.
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X-Bar and R Chart Page

The X-Bar and R Chart page displays a running statistical analysis of measurement data. The charts dis-
play the most recent data and plot new points as they are received. If there is data in memory and the
unit is powered up or switched to RUN mode from SETUP, the graph is re-plotted using the most
recent data.
Figure 5-64. X-Bar and R Chart Screen
1. X-Bar Chart
The X-Bar Chart displays a graph of the subgroup averages plotted against the “grand average”
(X-Double Bar) and the Upper and Lower Control Limits calculated on the last full lot. The
series of numbers below the X-Bar chart (0 to 130 in the figure above) is the number of sub-
groups displayed. The chart axes and subgroup/lot sizes are adjustable using the data entry
boxes on the right side of the screen (and described below.)
2. Range Chart
The Range Chart displays a graph of the subgroup ranges plotted against the Average Range
(R-bar) and the control limits calculated on the last full lot. The subgroup numbers are dis-
played on a line above the chart (using the number of points 0 to 130 in the figure above.)
Range chart parameters are changeable using the data entry boxes on the right side of the
screen and described below.
3. Reading Counter
This value is the total number of individual gage readings that are represented on the chart.
The horizontal scale of the graph on the same line represents the number of subgroups shown
on the chart.
4. X-bar Upper Limit
This value sets the upper limit on the X-bar (upper) portion of the X-bar & R Chart.
5. X-bar Lower Limit
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This value sets the lower limit on the X-bar (upper) portion of the X-bar & R Chart.
6. R Upper Limit
This value sets the upper limit on the Range (lower) portion of the X-bar & R Chart.
7. Horizontal Scale
The horizontal scale of the X-bar & R chart is defined by the number of pixels for each sub-
group plotted on the chart. Use a beginning value of four to get a sense of the scale. Smaller
numbers provide more points on the chart; larger numbers provide fewer.
If the system has multiple parts, multiple diameters on a single part or multiple sources for
parts, these selection boxes allow the user to choose which data to display on the chart.
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SPC Parameters Page

The Parameters page allows entry of the fundamental parameters used for statistical calculations (sub-
group and lot sizes, specification limits) and also displays the calculations performed on the data from
the last completed lot. If there is not enough data to complete the first lot, the calculations are
replaced by a “?”.
Figure 5-65. SPC Parameters Page
1. Parts per Subgroup

This value is the number of individual part readings that are averaged in each subgroup, then
plotted on the X-bar and R chart or used in calculations. The range of available subgroup sizes
is 1 – 15. If “1” is selected, the SPC functions will be operating on each individual part reading
rather than subgroup averages.
2. Subgroups per Lot
This value is the number of subgroups in a “lot”. The statistical calculations such as standard
deviation and upper and lower control limits are calculated based on the size of the lot. The
range of available lot sizes is 5 to 100. A typical lot size of 40 with a subgroup size of 5 would
yield a lot that contained a total of 200 gage readings.
3. USL
The USL is the Upper Specification Limit of the workpiece being measured. A part larger than
the USL is considered to be a bad part. This value is used in the statistical calculations of cap-
ability indexes.
4. LSL
The LSL is the “Lower Specification Limit” of the workpiece being measured. A part smaller
than the “LSL” is considered to be a bad part. This value is used in the statistical calculations of
capability indexes.
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If the system has multiple parts, multiple diameters on a single part or multiple sources for
parts, these selection boxes allow the user to choose which data to display on the page.
6. Calculated Statistics
This area of the page includes the standard SPC calculations for process control. The cal-
culations are listed in the Appendix at the end of the manual in section “SPC Parameter Cal-
culations”.
7. Include Bad Parts (optional)
When this box is checked, the data includes all parts measured including any out-of-spec parts.
If “bad” parts have been physically removed from the lot and you want the screen to display the
lot statistics without them, uncheck this box.
8. Parts Stored
This is the total number of parts - for the selected combination of part/diameter/source (see
Item 5) currently selected - that are currently in storage. This includes all parts, including “bad”
parts.
9. Parts Included
The number must be at least as large as one full lot (parts/subgroup x subgroups per lot) for cal-
culations to be made. If “Include Bad Parts” box is checked, ` number will include parts that are
bad in the calculation, otherwise, they are excluded. If the number is between lot sizes, the
actual calculations will be made upon the latest parts that make a full lot or multiple of full lots.
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Data Storage and Output Page for Multiple Parts with same Output Fields
The Data Storage page allows the user to download and erase data that has been collected in flashdisk
memory. Size data is stored independently for each measurement channel, including calculated chan-
nels such as taper. An example of data file format (with all output fields in the following figure
checked) is shown later in this subsection.
Figure 5-66. Data Storage Page
1. Output Fields
This group of check boxes allow the user to select the specific data desired, including the meas-
urement channels, the calculated channels (such as “Taper”), identifying information such as
date/time and record number and the source of the data by part number, machine number,
etc. On the sample page, all fields except “Record Number” will be downloaded.
2. Good Part
The “Good Part” check box, when marked, creates a final column containing “True” or “False”
for each measurement in the listing relative to the setpoints as configured.
3. Send Data Pushbutton
After selecting the desired check boxes and output method (See 4 below), press the “Send
Data” push button to download the data.
4. Output Port Selection Box
This selection box provides two choices:
COM2
Connect a PC with communications software to the 9-pin RS232 connector on the rear panel.
Make sure the serial port parameters on both the sending unit (the gage controller) and the
receiving unit (PC) is set to the same values, and that the PC software is ready to receive. The
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default serial port parameters for the D500 controller are 9600, N, 8, 1. Press the “Send Data”
pushbutton to begin download.
File
Connect a flash memory storage device into the USB connector on the rear panel. Press the
“Send Data” pushbutton to begin download. The name of the file will be “snXXXXX_YY.csv”
where XXXXX is the unit’s serial number and YY is the next consecutive number depending on
how many data files already exist. For example, filename “sn15057_9” is the ninth data file in
memory on serial number 15057.
The extension “.csv” means “comma separated values”, or may also be described as a “comma
delimited” file. It is a simple text file with commas between each field. The “.csv” extension
and format are easily recognized by external programs such as MS Excel for importing.
Note: The previously used “.dat” extension was not as easily recognized
and sometimes required additional manipulation. However, the format of
the file has not changed – previous .dat files may be renamed to .csv and will
be processed correctly. The change was made on 25 Feb 09.)
After erasing, the numbers start over again, but files with the same names may be dis-
tinguished by the date and time they are downloaded.
The format of the file is in columns in the order checked off on the Output Fields selection
panel. Unchecked items are skipped. The file may be imported into Excel, selecting “Delim-
ited” format and selecting both “Space” and “Comma” as delimiters (uncheck all others.)
The following is a short segment of a raw text file where the fields from the above figure were
all checked for download.
Date & Time Record Part Name Gage 1 Gage 2 Taper Good Part
Number
01/15/2008 10:30:15, 1, AN4576, .069125, .069120, -.00005, FALSE
01/15/2008 10:30:15, 2, AN4576, .069117, .069121, .00004, TRUE
01/15/2008 10:30:16, 3, AN4576, .069111, .069112, +.00001, TRUE
01/15/2008 10:30:17, 4, AN4576, .069119, .069125, +.00006, TRUE
01/15/2008 10:30:18, 5, AN4576, .069116, .069117, +.00001, FALSE
01/15/2008 10:30:18, 6, AN4576, .069120, .069119, -.00002, FALSE
01/15/2008 10:30:19, 7, AN4576, .069121, .069119, -.00002, TRUE
01/15/2008 10:30:20, 8, AN4576, .069119, .069116, -.00003, FALSE
5. Erase Data Pushbutton

This button will delete all data from the flashdisk. Be sure you want to do this, since there is no
way to recover the data. If unsure, download the data first so you will be able to review it later.
6. Write Header Checkbox
158 137383
If the box is checked, the labels of the checked output fields will be printed across the top of
the output file.
7. Use Local Time Checkbox
Time/date is printed in “military” (24 hour) format. If the box is checked, the date/time used
will be from the local time set in the D500 Controller’s MS Windows settings; if not checked,
the date/time will be Greenwich Mean Time (GMT).
8. Variables
These buttons are used to save or restore the “variables” file that contains all of the con-
figuration information stored in the D500 Controller for this specific application plus all of the
variables settings that have been entered through the keypad. If you need help with this oper-
ation, contact Control Gaging at the number or address for Technical Support on page 2 of this
manual.
The files are transferred to and from a flashdrive plugged into the USB port on the rear panel.
The flashdrive used must not require that any special software be loaded for using it.
l Save: Insert an appropriate flashdrive in the USB port and press the SAVE button. A file
with a name in the following format will be created on the drive:
Cfg331232CA.443_4.vars
This file can be used to restore settings in the event of a corrupted file, to save settings
for possible later use, or to transfer settings to another identical D500 application that
may be installed elsewhere in the plant.
Figure 5-67. Help|About Box
Note: The numbers in the file correspond to the numbers displayed

on the “D500 Panel:” line of the HELP|ABOUT box displayed from the
Menu Bar (the “:” in the number on the panel is not acceptable in a
filename and is replaced by “_”).
l Load: Insert an appropriate flash drive in the USB port that has a filename at the
top level that matches the configuration and version numbers shown in the
HELP|ABOUT box. No other file name will be accepted. Press the “Load” button
to upload the file.
In the event of a failure, one of the following messages may be displayed:
137383 159
Figure 5-68. Variable Files
The most likely cause for either type of failure is a flash drive that requires proprietary software
to run or there is no flash drive present. A “load” operation will fail if the file name does not
match the unit requirements. Contact CGI Technical Support if needed.
9. Part Selection Dropdown
When a controller includes the “Multi-Part Option”, use this menu to select the part or parts for
data download The dropdown menu includes selections for “All Parts” (all recorded parts will be
downloaded) or for every individual part name/number set up on the System Settings page
(only the selected part’s data will download. See also section Multi-Diameter and/or Multi-
Part Selection Option in the elsewhere in this chapter.
When “All Parts” is chosen and the “Select for All” checkbox is not checked, none of the “Out-
put Fields” are visible in the left-hand panel on the page.
10. Select for All

This checkbox appears only if the part selection dropdown setting Item 9 is “All Parts”. If this is
the case, when you check it, the specific “Output Fields” (see Item 1) will appear in the panel to
the left of the screen. You can then check individual fields for the download. If so, the data
download for each part will have only the checked fields included.
11. File per Part

This checkbox appears only if the part selection dropdown setting Item 9 is “All Parts”.
l Unchecked – The data for all part numbers/names are downloaded in a single file.
l Checked – A separate file for each part number/name will be created.
160 137383
SPC Calculations
The following are the SPC Parameters calculated and displayed by the gaging controller. Variables and
constants used in the calculations are defined below and the formulas for calculation are included on
the following page.
Unless otherwise noted, these parameters are calculated over the last (lot size * sub-group size) of
parts stored in memory.
137383 161
Table of Constants
Table of Constants
n A2 D3 D4
2 1.880 0.000 3.268
3 1.023 0.000 2.574
4 0.729 0.000 2.282
5 0.577 0.000 2.114
6 0.483 0.000 2.004
7 0.419 0.076 1.924
8 0.373 0.136 1.864
9 0.337 0.184 1.816
10 0.308 0.223 1.777
11 0.285 0.256 1.744
12 0.266 0.284 1.717
13 0.249 0.308 1.692
14 0.235 0.329 1.671
15 0.223 0.348 1.652
Figure 5-69. Variables and Constants in SPC Parameter Calculations
162 137383
Formulas for SPC Calculations
Figure 5-70. Formulas for SPC Calculations
137383 163
Taper - Option
Many gaging applications use a taper measurement as a way to determine if the diameter of a cyl-
indrical workpiece is being ground evenly and on center. This is accomplished by using at least two dia-
meter measurement points taken along the workpiece shaft. Calculation for the taper reading is
typically determined by subtracting the diameter of measurement 1 from the diameter of meas-
urement; 2.
[Measurement 2] – [Measurement 1] = Taper
Taper Option with Set Points

The Taper value box, set point indicators and bar graph are typically located at the bottom of the Front
Panel screen. The taper bar graph and set point indicator boxes will give the operator the part taper
status at a glance using a color coding. The appropriate indicator box, located above the graph, as well
as the bar graph, will light up in color if the predetermined set point values are reached during the
measurement cycle.
The graph and set points indicator boxes will change color as follows:
l -3 and +3 boxes will turn red

l -2 and +2 boxes will turn yellow
l -1 and +1 boxes will turn blue
l OK box will turn green
Figure 5-71. Taper Display Area - Bad Part
164 137383
Figure 5-72. Taper Setting Page with Set Points
Taper Option without Set Points

The Taper value box, set point indicators and bar graph are typically located at the bottom of the Front
Panel screen. The taper bar graph will give the operator the part taper status at a glance using a color
coding. The bar graph will turn green if the part is within the predetermined set point range during the
measurement cycle. The "Good" part indicator box will turn green.
Figure 5-73. Taper Display - Good Part
137383 165
The bar graph will turn red if the part is outside of the allowable set point range during the meas-
urement cycle. The "Bad" part indicator box will turn red.
Figure 5-74. Taper Display - Bad Part
The allowable part specification ranges (Over/Under) are entered on the Taper Settings screen. If your
system includes the Multi-Part option, select the appropriate part from the dropdown menu.
Figure 5-75. Taper Setting Page
166 137383
To Enter the Taper Set Point Range

1. In the SETUP Mode, select the Taper Settings screen.
2. If your controller configuration includes the Multi-Part option, select the desired part from the
dropdown menu.
3. Highlight the Setpoint data entry box.
4. Using the keypad, enter the value of each setpoint into the boxes, pressing [ENTER] after
each entry to lock in the value.
5. Close the Taper Settings screen.
The entered setpoint values will now correspond with the setpoint indicator boxes located on the bot-
tom of the Front Panel screen.
The entered allowable part values (Over / Under ) will now will correspond with the setpoint arrows loc-
ated on the bottom of the Front Panel screen.
137383 167

168 137383
System Component - Gage Head(s)
Chapter 6. System Component - Gage Head(s)
Model 31M - Single Finger Gage

The Model 31M gage is a laboratory-precise, heavy-duty gage head used to measure workpiece size,
length, thickness, location, height or wheel position in abusive industrial environments. The position
of the gage finger is converted to a proportional voltage by a linear variable displacement transducer
(LVDT) within the gage housing. The gage connects to an electronic gage controller which powers the
LVDT and processes its output voltage to generate useful size or position information.
The Model 31M replaces the CGI Model 31 and 30 gage heads with an improved retraction mech-
anism and stainless steel body, and incorporates other fourth-generation precision and construction
features. All adjustments are externally accessible with simple, available tools.
Note: When replacing an earlier Model 30 or 31 gage head with a Model 31M,
note that the mounting hole spacing is identical, but the 31M is designed for use
with metric mounting screws. The counter-bore on the existing brackets may need
to be increased slightly to accommodate the larger head of the metric screw.
Figure 6-1. Model 31M with Adjustments
137383 169
Model 31M Specifications

Contact Pressure: 85-120 grams (3.0-4.2 oz.) at finger tip
Clutch Breakaway Force: 2.7-3.2 kg (6-7 lbs.) at finger tip
Measuring Repeatability: .0005mm (000020")
Finger Retract Pneumatic Pressure: (Do not use hydraulics)
Minimum 415 kPa, 60 PSI
Maximum 690kPa, 100 PSI
Recommended 415-550 kPa, 60-80 PSI
Caution! Do not open the gage for repair – contact the factory!!
A Model 31M Gage may be filled with a viscous damping fluid - if so, the Serial Num-
ber Tag will be marked “Fluid filled: YES”. Fluid filled gages have all the air evac-
uated from the gage body during manufacture.
170 137383
Model 31M Dimensions
137383 171
Model 31M Adjustments
Pneumatic Finger Retraction

A pneumatic ram is integrated into the rear of the gage for applications that require that the gage fin-
ger retract from the workpiece between gaging cycles.
Note: The Model 31M defaults to the retracted position using an internal spring,
when there is no air pressure on the input port. When air pressure is applied to the
gage retract mechanism, the retract spring is compressed and the finger is allowed
to move into contact with the workpiece.
Air Retract Connections
If air retract is used, the plastic cap on the barbed vent fitting on the rear of the gage must be
removed. If the gage is in a dirty or wet environment, a vent line (2.5mm ID) should be connected to
the fitting with its open end outside the machine.
The air supply should include a filter, a pressure regulator, and flow control valves to provide for
smooth operation. It is highly recommended to provide flow controls in both directions, which
provides the ability to control both the retraction and the advance closing speed. Do not lubricate,
since oil may collect in the retraction cylinder and prevent operation. See the pneumatic diagram in
the “Installation” section.
Setting Retraction Amount
The retraction amount is always relative to the position the finger was set up to. Therefore, the finger
must be set up on a workpiece prior to adjusting the retraction. The retraction amount will remain con-
stant on future setups regardless of part size.
The amount of finger retraction can be adjusted by turning the square post near the back of the gage
head using a 6mm/.25” open-end wrench or a small rod or Allen wrench through the hole. Turning
the head clockwise (toward the “0” mark on the gage body” will reduce retraction amount, turning
counter-clockwise will increase it.
After adjusting retraction, always dry cycle the machine and gage or otherwise verify that there are no
interferences that will damage the finger or gage during automatic operation.
Contact Force
The contact force can be adjusted by turning the slotted adjuster on the side of the gage. Turning in
the direction of the arrow increases the force. Recommended force is 90 grams measured at the tip of
the finger after setup on a workpiece, but lighter forces may be used for some dynamic situations and
heavier forces may be required for applications with heavy coolant flow or mechanical vibration. The
gage retract mechanism must be released (apply air pressure) when checking or adjusting this setting.
Do not loosen the clamp screw when adjusting, or the spring may unwind.
172 137383
Overtravel Limits
Overtravel limits are used to reduce the “interference” between the tip of a gage contact and the sur-
face of a workpiece. They are normally used on applications where the parts are moving through a
gage station (on a conveyor or other automation) and are being measured dynamically. The overtravel
limits insure that the fingers “ramp” smoothly onto and off of the workpiece, minimizing bounce or
impact that could affect accuracy, and reducing wear to the contact’s leading edge.
Figure 6-2. Overtravel
Setting Overtravel Amount
Most applications do not require overtravel adjustment setting, and the head should be oriented so its
mark is aligned with the “slash” mark on the case. This position allows the finger its full travel.
The overtravel amount is always relative to the position the finger was set up to. Therefore, the finger
must be set up on a workpiece prior to adjusting the overtravel. The overtravel amount will remain rel-
atively constant on all setups with minor variations due to setup force and deflections.
The overtravel limit adjustment head is a square head with hole located between the setup lever and
the contact force adjustment screw. Use a 6mm/.25” open-end wrench or a small rod or Allen wrench
through the hole to turn the head; if it does not turn easily, loosen the clamp screw slightly, but be sure
to retighten in firmly.
To set the overtravel limits:
1. Set up the gage on a workpiece (see setup instructions elsewhere in manual)
2. Zero the gage channel on the controller.
3. Remove the part from beneath the gage finger.
4. Loosen the set screw that locks the retraction limit adjustment head and turn the adjustment
head. The slash mark on the gage housing is full overtravel, that is, the limit is “out of the way”.
The head can be turned all the way around without damaging the gage.
As you turn the adjustment head the gage finger and the controller meter will move. If you
want .25mm/.010” overtravel, turn the adjustment head until the gage controller reads - .25m-
m/-.010".
5. With the overtravel limit adjusted, retighten the retraction limit clamp screw.
137383 173
Model 31M Gage Setup and Zeroing with D500

Follow the procedure below to set up and zero the single-finger gage Model 31M with the D500
Controller.
Mechanical Gage Setup
Note: Gage orientation on your system may differ, as well as whether or not an
actuator or finger retraction is supplied. Likewise, the surface may be flat and the
contact may be rounded or pointed. Or the measured surface may be internal (such
as an ID) rather than external (such as the OD in the example below), but the basic
instructions apply in all cases.
Figure 6-3. Single-Finger Gage Setup
174 137383
1. Pull the Setup Lever into the SETUP position and hold it. Open the gage finger wider than the
dimension of the part to be measured. - simply pull on the finger to slip it through the res-
istance of the clutch. (A)
Release the Setup Lever. If the finger is still too close in to load the workpiece, pull it back
farther.
2. Mount an on-size workpiece or master in the gage fixture or machine.
3. Advance the gage toward the part (if the system includes an actuator) and/or release the finger
retraction (if provided).
4. While holding the setup lever in the SETUP position, slip the finger through the clutch action
and toward the part until it contacts the surface. (B) Now ease the setup lever into the RUN
position - do not let it “snap”.
5. Retract the actuator and/or finger, then advance and retract half a dozen times to "settle in"
the gage. (C) Simulate operating conditions if possible – for example run coolant and rotate
the workpiece.
137383 175
Model D500 Zeroing
1. Press the [MODE] key on the front panel to enter SETUP mode. The “focus” will move to
the SETUP menu bar at the top of the screen. (The Zero menu item will appear “pushed in”.)
Figure 6-4. Zero Page

2. Press [ENTER] to display a Zero page similar to the one below. The value in the “Reading” dis-
play box for the gage you are zeroing (in this example, Gage 1) will not be zero.
3. Use the [TAB] keys to highlight the “Zero” pushbutton and press [ENTER]. The “Reading” dis-
play box will now go to zero.
4. If the application has more gages, or there is a Gage (1+2) configuration, the channels will be
labeled to identify them.
For additional information about zeroing and for mastering to a non-zero size (such as channel 2 in the
above figure) see section “D500 Setup Mode Pages and Parameters” under heading “Zero Page”.
176 137383
Maintenance
Chapter 7. Maintenance
General Maintenance
The gage system components are all designed for use on machine tools in the factory environment,
and minimum general maintenance is required. However, the following periodic checks may prevent
premature failure from unusual exposure or wear.
Contacting Control Gaging for Assistance

Many repair or maintenance problems may be resolved quickly by contacting CGI Service Department
at the following link: Contact CGI
Note: Please have your model and serial numbers for any gage controllers or gage
heads available when contacting Control Gaging to ensure accuracy in troubleshoot-
ing your equipment. There is also a “CGI Job Number” on the cover page of this
manual that provides a means to identify the equipment.
Note: In addition to the identifying numbers listed above, please have the con-
figuration number from the Help/About screen (on D500 Controller units shipped
after 12 March 2009) available when contacting CGI. The configuration number in
the box below is “32421B.098”.
Figure 7-1. Help/About Box
137383 177
Maintenance
Controllers
Controller Fuse Replacement

The controller fuse is located on the rear of the controller in a rectangular black holder which is incor-
porated into the power switch and cord housing..
Figure 7-2. Controller Fuse Location
Fuse Removal:
1. Insert two small screwdriver tips into the slots at top and bottom of the fuse holder.
2. Pry inward on both and the fuse block will pop out.
3. See the chart below for the correct replacement fuse for your controller.
Controller CGI Part Number Fuse Size Amp

D500 809000 5 x 20 mm 1.6 amp 250V Time Delay
Note: Do not use hard tools such as screwdriver tips to press buttons on the front
panel. The membrane will eventually wear through and the switches will fail.
Controller Enclosure Cleaning

l Wipe exterior of enclosure periodically with a cloth and mild detergent.
l Internal components should not be washed. Return to CGI for cleaning.
Controller Visual Inspections

l Inspect the interior of the controller enclosure periodically to make sure that there are no
traces of coolant present.
l If it is determined that coolant is entering the enclosure, relocate, mount inside another enclos-
ure or cover it to reduce exposure.
l Inspect cabling regularly to ensure that it is not being abraded during daily use. This is par-
ticularly important with the gage head cable, which should be tied up inside the machine to pre-
vent rubbing during actuator cycling.
178 137383
Maintenance
Troubleshooting the Input/Output (I/O) interface of the D500 Controller is aided by use
of the “Diagnostics Page.
Gage Heads
CGI gage heads have been designed to measure accurately and consistently for years under the most
demanding factory conditions. The gage heads are thoroughly sealed against coolant and are made
entirely of stainless steel to resist corrosion.
Gage Head Visual Inspections and Cleaning

The following tasks should be performed regularly to eliminate the most common
causes of failure:
1. Clean all chips and Swarf1 accumulation from the external moving parts, par-
ticularly between the gage fingers and the gage body. This material may harden
and prevent free motion of the gaging fingers, thus reducing accuracy. Inspect
and remove material from this area before it hardens.
2. Check the gage head cable periodically to ensure that it is not being abraded
during daily use. The cable should be tied up inside the machine to prevent rub-
bing and wear during actuator movement.
Gage Head Troubleshooting

There are many factors in the gaging system environment that can cause measuring
errors that appear to be gage head problems, but are not.
When diagnosing problems, consider the following:
l Check that gage fingers are tight on the shafts and gage contacts are tight on
the fingers.
l Check that all brackets and gage mounts are firmly tightened.
l If a spare gage head of the same type and in good working order is available,
switch the gage heads to see if the problem goes away.
l If a spare gage controller of the same type and in good working order is avail-
able, switch the gaging controller with another to further isolate the problem.
l Check operation of any actuators or cylinders in the system. Accumulation of dirt
on locating surfaces, loss of actuator pressure, or mechanical interference with
actuator movement can all cause erratic measurement.
Note: Gage heads should be opened for repair only by qualified

technicians. To maintain coolant resistance, gaskets and seals are nor-
mally replaced whenever they are removed. Contact your distributor
for the availability of repair kits.
1Fine chips or filings of metal material produced by a machining operation.
137383 179
Maintenance
Note: If the serial number tag on your gage has the “Fluid Filled”
box checked, the gage is filled with a high-grade silicone damping
fluid. Fluid-filled gages are used to measure interrupted surface work-
pieces, but they can also measure smooth surface parts. All air has
been evacuated from the gage through use of special vacuum equip-
ment. DO NOT OPEN Fluid Filled gages – return them to the factory
for repair if needed.
Gage head adjustments, such as spring pressure, overtravel limits, etc., are normally
described later in this chapter, but may be in the “Gage Descriptions” chapter for some
gage heads.
Gage Actuators
Actuators are also built for use in the factory environment, but accuracy can be affected if chips or
Swarf1 accumulate in the “seats” around piston rods or in rotating joints.
l Insure that proper operating pressure is maintained. If motion of an actuator seems erratic, too
fast, or too slow, check that the pressure setting is correct according to the product spe-
cifications. Also check flow controls that may have been inadvertently changed or become
plugged.
l Periodically check these areas and flush or clean by hand as needed.
l Periodically inspect hydraulic or pneumatic connections and lines for leaks.
1Fine chips or filings of metal material produced by a machining operation.
180 137383
G
Glossary
Group Size
There are several Micropeak ‘meth-
A ods’ of calculating what the actual
“peak” value is from the hundreds or
Averaging thousands of data points collected in
the “sample”.
Averaging is a Micropeak function
that calculates a workpiece size based
on a “group” of data samples taken H
by the gage. The size and location of
this “group” on the part can be con- Hook
figured multiple ways by the user.
Hook is the commonly used name for
a calculation of taper between the
C first gage point (GP 1) near the bot-
tom of the bore and a measurement
Clipping made even lower in the part (in a
measurement region labeled
Clipping is a function of Micropeak
UNDERCUT) that includes an area
which allows excluding samples for
where grinding wheel breakdown can
specified times at the beginning and
be observed. “Hook” occurs when
end of the sampling period for each
the diameter nearest the corner of the
part.
undercut is undersize due to wheel
wear,
F
L
Fixed Roller
This is a componant of the TFD24 LVDT
Gaging System - The term “fixed
Linear Variable Displacement Trans-
roller” is used for rollers man-
former The LVDT converts a position
ufactured for a specific part size.
or linear displacement from a mech-
anical reference (zero, or null pos-
ition) into a proportional electrical
137383 181
signal containing phase (for dir- S
ection) and amplitude (for distance)
information. Sampling
The software is continually taking
M data “samples” from the raw voltage
signal that is coming from the gage
Meter Scale transducer. These samples are the
data points that are processed by the
The Meter Scale parameters allow set-
Micropeak software into a gage read-
ting of the meter scale range and
ing displayed on the screen.
markings.
Slice Time
Micropeak
Slice Time is a optional feature in
Micropeak is a software feature used
Micropeak which refers to defining
to capture a gage reading on irreg-
size readings only in specified sec-
ular or interrupted surfaces or on rap-
tions along the length of a part.
idly moving parts as they go through
These readings may focus on specific
a gage station. The “peak” aspect of
high-tolerance portions of the part or
the feature is that it catches and
they can be used to calculate taper,
holds on to the extreme (usually the
hourglass, or barrel shapes.
maximum) point of the moving gage
reading
Spline Frequency
P The frequency selected sets an elec-
tronic filter that is used to smooth
Peak out fluctuations in the gage signal
that occur when measuring over inter-
The “peak” is the extreme value of the rupted or uneven surfaces such as
gage reading as it rises or falls on the splines, gears, etc. It can also used to
surface of the part. The specific term stabilize the gage signal by min-
“peak” is used when the system is imizing the effects of environmental
seeking a maximum reading; the term “noise” from machine vibrations or
“valley” is used when the system is background electrical interference.
seeking the minimum reading (for
example on the base circle of a cam-
shaft.)
182 137383
W
Swarf
Fine chips or filings of metal material Wheelslide Enable
produced by a machining operation.
The “Wheelslide Enable” output com-
municates to the machine control
T that the gage controller is in auto-
matic mode and ready for gage con-
Taper trol.
The difference between any one dia-

meter measurement region and
another.
Threshold-Based
"Threshold Based" is a version of the
Micropeak software, which uses the
rapid rising and falling of the gage
contacts on the part’s edges to know
when to collect data samples.
VFP
The Virtual Front Panel or VFP Option
uses “remote control” software that
runs as a “window” on the machine’s
host computer and communicates
with a standard D100 unit mounted
out of sight in the machine panel.
137383 183
Index
184 137383

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D500 Gage Controller

Customer: Tenneco - Monroe Mexico

CGI Job Number: 41325 A & B

Manual Number: 137383

Issue Date: April 2018

Rev. Date Revision Description By

For Telephone Email

Warnings and Cautions:

Warning! FAILURE TO COMPLY WITH THE WARNINGS AND CAUTIONS GIVEN

Intended Use of Equipment

When Not Using Grounded 3-Prong Power Chord:

panel of the controller, marked: must be connected to Earth Ground

Warning! Exposed hazardous voltages are especially likely to be found in the

Read the Manual

Personal Protective Equipment

Do not wear loose fitting clothing or jewelry when operating equipment.

Clear Gaging Area

Emergency Stopping Devices

Main Electrical Disconnects

Pneumatic Lockout Valves

Symbol Symbol Description

High Voltage Symbol

Table 1-1. Safety Symbols

Control Gaging Supplied Components

New Control Gaging Components Added to Existing Systems

Customer Supplied Components

Gages - Customer Supplied

If customer-supplied gages are replacing Control Gaging gage

l Refer to the manufacturer’s instructions for calibration and setup.

Controllers - Customer Supplied

Actuators, Fixtures and Parts Handling Equipment - Customer Supplied

This page intentionally left blank to ensure that

Chapter 2. System Overview

Introduction – D500 Gaging System for Through-Feed Centerless Grinder

Figure 2-1. Model 31 on Through-Feed Centerless Grinder

D500 Gage Controller

Figure 2-2. D500 Gage Controller

Optional Software Features

Intelligent Process Control (IPC) Option

Micropeak with Dynamic Zero Option

Multi-Part and/or Multi-Diameter Selection Option

Statistical Process Control (SPC) with Data Storage and Download

Model 31M Single Finger Gage

Figure 2-3. Model 31M Single Finger Gage Head

Gage Controller Installation

Gage Controller Mounting Guidelines

Controller Mounting - Standard Mount

Controller Existing Mounting Hole - Thread Size Qty.

D500 Controller Dimensions - Standard Mount

Figure 3-1. D500 Controller Dimensions - Standard Mount - D9053050-001

Grounding Without Using Grounded 3-Prong Plug

“Wheelslide Enable” Output Wiring

“Gage Enable” Input Wiring

Note: "Gage Enable" may also be called “Gage Cycle Start”.

Controllers and Gage Electronics - Customer Supplied

Converter Box Installation

Chapter 4. Installation Diagrams

D500 Connector Wiring

Control Cable Wiring (CC1)

DB37 # I/O # Wire Color Signal Type Signal Name

Power Cable Wiring - International Colors

Wire Color Signal

Model 31M Finger Retraction - Pneumatic Circuit Diagram

Figure 4-1. Pneumatic Circuit – Model 31M Finger Retraction