AXIAL LOAD

GAUGE

JC010C

Operation, Calibration & Servicing

Manual Version 1, Revision A.
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Warning

WARNING
THIS EQUIPMENT CONTAINS HAZARDOUS MAINS
VOLTAGES AND POSSIBLE CRUSHING FORCES

PLEASE FOLLOW ALL VERSATILE TECHNOLOGY

INSTRUCTIONS AND ALL HEALTH AND SAFETY
DIRECTIONS IN YOUR WORKPLACE

DO NOT DEFEAT ANY GAUGE SAFETY FEATURES OR

INTERLOCKS

DO NOT OPERATE THIS EQUIPMENT IF ANY PANELS,

SAFETY COVERS OR INTERLOCKS ARE MISSING OR
DAMAGED

INTERNAL SERVICE SHOULD BE PERFORMED BY

QUALIFIED PERSONNEL ONLY

THE POWER SUPPLY SHOULD BE PROTECTED BY AN

R.C.D (EARTH LEAKAGE) DEVICE DURING SERVICE

THIS EQUIPMENT SHOULD BE REGULARLY SUBJECTED

TO A GAUGE SAFETY TEST (REFER TO CHECKLIST IN
SAFETY SECTION)

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Contents

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

Representatives ................................................................................................................................ 4

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

Training Safety ...................................................................................................................................................... 7

Operation ............................................................................................................................................ 7
Maintenance ....................................................................................................................................... 7

Safety Overview ............................................................................................................................................. 8

Gauge Safety Checklist ................................................................................................................ 9
In Service Safety Inspection and Electrical Safety Testing ..................................... 11
Equipment Electrical Safety Testing Proceedure ....................................................... 12
Part B: Earth Resistance or Protective Earthing Test ............................................... 13
Electrical Safety Certificate ..................................................................................................... 14

Operation Front Panel Controls .................................................................................................................. 15

Measuring a can ............................................................................................................................ 16
Profiles ................................................................................................................................................ 16

System Parameters System Access ............................................................................................................................... 17

Parameter Listing .......................................................................................................................... 18
Serial Parameters ......................................................................................................................... 18

Calibration Calibration Overview ................................................................................................................ 19

Calibration Procedure ............................................................................................................... 20

Maintenance Routine maintenance ................................................................................................................. 21

General Maintenance ................................................................................................................. 22
JC010 Assembly Diagram ....................................................................................................... 24

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Contact Details

Contact Details
Head Office

Versatile Technology
35 Cleeland Rd

Oakleigh South, Victoria 3167

Australia

Tel: +61 3 9548 8983

Fax: +61 3 9548 8958

Email: contact@versatiletechnology.com.au

Web: www.versatiletechnology.com.au

United Kingdom/Europe
Contact: Mr. Tim Bulman

Email: tim.bulman@tbtechnology.co.uk

Representatives

USA/Canada

Regal Metrology

4554 Popular Level Road

Louisville, KY 40213

USA

Tel: +1 502 968 7993

Fax: +1 502 968 3275

Email: brohleder@regal-ind.com

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Contact Details

China

Guangzhou Stolle-Denuo Machinery Co., Ltd.

First Floor - Building E

Shibei Industrial Estate, No. 5 Anping Rd,

Dashi Town, Guangzhou

China

Tel: +86 20 34789252

Email: info@gz-denuo.com

South Korea
ICM Leaders Co. Ltd.
#2111-2, HYUNDAI 41 TOWER BLDG, 917-9

MOKDONG, YANGCHEON GU, 158-723

Korea (South)

Tel: +822-2642-1375~6

Fax: +822-2642-2218

Contact: Lisa

Email: ichem08@hotmail.com

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Introduction

Introduction
Things you should consider before starting
Thank you for specifying Versatile Technology equipment. All industrial equipment requires regular maintenance to
maintain the safety and performance throughout its service life. This manual will assist you in this process. We ask that
you read and consider the following.

Safety:
Your safety is a paramount concern to Versatile Technology. You will find safety notices throughout the manual.
Please read and understand at least the “Operation” and “Safety” sections of this manual before using this gauge. If
servicing or calibrating please also read and understand the “Servicing Information” section from this manual. Refer
to the 'Safety Test Sheet', which describes testing of the gauge safety features that should be regularly tested.

Maintenance:
Regular maintenance will ensure the gauge maintains its specified performance. Spare parts and support are available
through our office.

Calibration:
Calibration of measurement devices on the equipment ensures that measurement errors are minimized. The
calibration of the gauge should be checked at regular intervals, of no longer than one year. As part of the regular
calibration, a Safety Checklist should be completed to ensure that the safety systems on the gauge operate correctly.

Capability:
Gauge capability tests check that the equipment is capable of measuring your manufacturing process with a minimum
of variation.

Continuing Support:
Please contact us with any questions you have about the manual or equipment. Your feedback will assist us in
improving our products and result in a better service to you.

Continuous Improvement:
Due to our policy of continuous improvement, service procedures may change. Contact our office to obtain the latest
service data and information.

Please maintain contact with our office:

If the equipment is transferred or disposed of we ask that you advise our office of its new location so that we may
amend our records. This is especially important in the event we have to send a safety alert bulletin alerting you of an
unforeseen safety issue.

Thank you,

The Versatile Team

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Training

Training
Training of all people in the safe and efficient use of the gauge will ensure optimum performance. The following
training guideline is to be used in conjunction with the rest of this manual. .

Safety

Train all who come in contact with the gauge

• Demonstrate powering up/down the gauge. Demonstrate removal of Mains Power.

• All safety features on the gauge.

Operation

Train all who operate the gauge.

• Front Panel Controls

• Measuring a Can

• Message Listing

• Routine Maintenance

Maintenance

Train Supervisory staff and Maintenance team.

• Parameter Listing

• Calibration

• Specific Maintenance Proceedures.

• Trouble Shooting Guide

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Safety

Safety
Overview
Your safety is a paramount concern to all at Versatile Technology. Operator and maintenance safety has been
considered throughout all the design and manurfacturing process. The following steps have been taken to ensure that
the gauge is safe to use and service.

Gauge Safety Checklist

Information and a checklist to allow regular testing of gauge safety features.

Training
You will find a recommended training schedule for all staff in this manual. which includes operation and safety
awareness.

Feedback
Despite our best efforts, we may have missed something. If during the use of the gauge you notice any hazard that
we have not found or foreseen, please immediately inform us so we can work with you to eliminate the problem on
your equipment and prevent it recurring on new equipment.

Gauge Model - Serial Number:

Inspection Performed By:

Comments:

Signed: Date:

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Safety

Gauge Safety Checklist

Gauge safety features should be tested regularly to ensure correct and safe operation. we recommend quarterly
inspection of safety features using the following checklist.
If any safety feature does not operate, stop using the gauge immediately and rectify the problem. Contact Versatile
Technology for any advice and replacement parts

Features Tasks Comments

Cabinet Check that all panels are in place and fastened with the correct
number of screws.

Power Supply Module Supply Module Cover is in place and Mains wiring is inaccessible.
Warning labels are fitted.

Electrical Safety Test Perform Electrical Safety test and record results. (Refer to the
'Electrical Safety' section of the manual.)
'Tested for Electrical Safety' adhesive label is affixed.

Door Interlocks Opening front door during normal gauge operation causes
gauge to stop as per emergency stop activation.
With door open the gauge does not start and the LCD alerts
the user.
Test only operates when front door is fully closed and latched.

Emergency Stop During normal gauge operation press the emergency stop but-
ton.
Test immediately stops and the LCD alerts the user.
All gauge movement ceases instantly.

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Safety

Features Tasks Comments

Window The Polycarbonate Safety Panel is not excessively scratched and

is tightly inside the rubber seal.

Labels All labels are affixed and legible

Label Checklist

Labels Qty & Location Present

Gauge Model & Serial Number plate 1 off Inside Test Cabnet RHS

Safety, Calibration, Capability Label 1 off Lower RHS Front of Gauge

Warning - Disconnect Supply 2 off Power supply module (top)

Earth point Sticker 1 off Power supply module

1 off Case earth point

CE Sticker (If applicable) 1 off Front Lower RHS

RS232 Port 1 off Rear of Gauge

Service Port 1 off Front RHS next to USB port

Ethernet Port 1 off Rear of Gauge next to Ethernet port

DO NOT DEFEAT INTERLOCK 1 off Inside case next to interlock

12.0VDC 1 off Next to VMS02

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Safety

In Service Safety Inspection and Electrical Safety Testing

Purpose
In service testing is necessary for the safety of persons using the equipment. In conjunction with AS3760:2001, this
document specifies in-service safety inspection and testing protocols and criteria for the testing of Versatile
Technology Gauging equipment.

Action
Such equipment, without being dismantled, needs to be subjected to routine inspection and testing to detect
obvious damage, wear or other conditions which may render it unsafe.
Equipment identified to be faulty needs to be withdrawn from service and either Versatile Technology or qualified
personnel contacted to arrange repair or disposal.

In accordance with AS3760:2001, the equipment must be subjected to:

• Visual Inspection

• Protective Earthing test

• Insulation Resistance test

• Documentation of all tests

Frequency
We recommend protectively earthed equipment installed in a factory or workshop be inspected every 6 months.

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Safety

Equipment Electrical Safety Testing Proceedure

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

Test Equipment Required.

Insulation and Earth Resistance Tester. Lutron DI6200 or equivalent.
Testing standards. Based on Australian Standards AS 3760:2001.

Test Procedure.

Part A: Insulation Test.

Connect the Tester as shown in the following diagram. The tester applies 500 volts and measures the resistance
between the mains circuit and the gauge earth, which is the gauge case. Record all results on Electrical Safety
Certificate

The Minimum Resistance allowed between the Active supply and case is 1 M .

Note: If the resistance is below 5 M then the gauge should be

serviced as there may be an electrical fault.

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Safety

Part B: Earth Resistance or Protective Earthing Test

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

If a gauge fails the electrical safety test?

In the event of a gauge failing any element of the electrical safety test the gauge should be immediately repaired. If
this is not possible it should be segregated so that it cannot be used.

Under no circumstances can a gauge be used without passing

the electrical safety test.

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Safety

Electrical Safety Certificate

This is to certify that the Versatile Technology gauge listed below was tested in accordance with AS3760:2001, "In
Service Safety Inspection and Testing of Electrical Equipment" published by Standards Australia.

Refer to the Electrical Safety section for guidance in checking electrical safety.

Gauge Description AXIAL LOAD GAUGE

Model Serial Number JC010C-XXX

Date of Certification

1. Visual Inspection- Refer Clause 2.3.2 of AS3760:2001 p12

All mains wiring in good condition, and inaccessible during normal operation. Mains cables
properly anchored
Electrical Voltage and Fuse rating plate fitted.

Rating Plate Label 100-250 Vac 3.15 A Slo Blo FUSE

All electrical warning labels fitted. Flash stickers on power module.

Separate Earth stud / Earth lead longer than Active/Neutral.

All controls, safety covers, guards and safety facilities are secured and in good working
order

2. Protective Earth/Resistance Test- Refer clause 2.3.3.1 of AS 3760-2001 p13

Resistance between Earth connector and exposed metal parts that may become live in the event of an internal
insulation failure. The resistance shall not exceed 1 ohm.

Test Result OHMS

3. Insulation Resistance Test. Refer clause 2.3.3.2 of AS 3760-2001 p13

Resistance between live supply conductors and exposed metal parts with a 500Vdc applied voltage. Minimum
Resistance 1 Mega ohm.

Test Result MEGA OHMS

4. Affix a signed and dated 'ELECTRICAL SAFETY' label to gauge passes in accordance with the above
specifications.

Tested By Signed

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Operation

Operation
Front Panel Controls

H
B

G E

F
C
A: LCD Display and Touch Screen
The display is used to show the status of the gauge such as test modes, test results, calibration screens and interlock
status. The display also incorporates a touch screen which allows the user to view/edit various machine operating
parameters.

B: Keypad
The keypad is used to view/edit various machine operating parameters. An access code is required to edit these
parameters.

C: Start Button
This activates the test mode.

D: Profile Button
Use this button to cycle through individual profiles.

E: Emergency Stop Button

Push to stop current test and disable all movement. Pull Emergency Stop button to release.

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Operation

On release the display will announce that the test has been stopped and no data is sent to the serial port.

F: Adjustable feet
Used to level gauge during installation

G: Safety Door
High impact polycarbonate interlocked safety door

H: Measurement Load Cell

250Kg Force Load cell

I: Service Port
Usb port used to save and load test results, setting and firmware. Alsoused to update the gauge code.

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Operation

Main Screen

C
F
D

A:Test Graph
Displays live infomation of current test or previous selected test. Graph axis can either be Force vs Time or Force vs
Distance

B:Test Results
Displays previous test results, shows type, profile name, force and distance. Use the up and down arrows to view
other test. Test results are cleared if not saved when the gauge is turned off.

C:Current Profile
Shows the current profile selected, press to cycle through profiles.

D:File
Allows the user to save/load results to internal memory and export data to USB.

E:Menu
Allows the user to access and edit Profiles, Settings, Calibration and Diagnostics screens. An access code is required
to access this menu. Please refer to System Parameters section of this manual for more information.

F:Log Out
Allows the user to log out from supervisor access to the system parameters.

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Operation

Measuring a can
Ensure the can locator is seated correctly. A locating spigot ensures that it is centered and will not move during testing.

Select the desired Profile by pressing the ‘PROFILE’ button on Gauge or Screen to select desired profile. The platten
will move to the pre-set location.
Place the appropriated Neck Adapter onto the can ensuring that it is properly inserted. (I.e. all the way to the flange)

With the Neck adapter fitted, place the can on the locator.

Start the test by pressing the ‘START’ button.

The can is now crushed until a collapse or failure is detected.

The waveform graph is displayed and peak force is captured and displayed. above the graph (large text size). Note
the result will pass to the table when a new can is tested. (Newest at the top, oldest at the bottom)

A result highlighted as Red indictes out of specification. A result highlighted as Green indicates within specification.
Lower and upper tolerances can be edited in the Profile menu.

Profiles

A B
C

E G

A: Profile List
Allows Profiles setting to be edited.

B: Current Profile
Shows the current Profile selected to be edited.

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Operation

C: Tolerances and Offsets

Allows the user to set the lower and upper Tolerances for current Profile, the force at which in/out of specification
is determined. Any values above or below will be displayed in red on the main screen. Offset allow a value to be
added to the measurement.

D: Test Parameters

Dip ‘Kg’ - The internal microprocessor monitors the force until a drop in force greater than a specified amount is
observed. The following picture represents the ‘drop in force’ or ‘dip’ detection method used.

The drop in force used to detect the collapse point is software selectable.
By adjusting this parameter the gauge can filter out force anomalies that may otherwise constitute a failure.

Start Threshold - The force at which the microprocessor begins to “look” for a dip value.

Can Heigh “mm” - The distance from the home postion to the top of the can. The value is automatically calcu-
lated by pressing the setup button.

E: Edit Options

Add - Allows the user to add a new can profile.

Delete - Allows the user to delete an exsisting can profile.

Rename - Allows the user to rename an exsisting can profile.

Duplicate - Allows the user to copy an exsisting can profile.

F: Setup
Allows the user to setup the Height postion of the top of the can to the home position of the measurement load cell
for the current Profile. Follow screen prompt to setup Height position.

G: Exit
Exits the Profile menu and saves all changes.

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System Parameters

System Parameters
System Access
The Access Code must be entered to view or edit any of the system parameters.

Your Access Code is: 22085

This is provided to allow the supervisor access to the system parameters. It is not intended for every day use by
operators as incorrect parameter selection may render the gauge inaccurate or inoperable.

To remove System Access press LOG OUT button at the bottom of the main screen.

The Access Code is fixed within the gauge memory and cannot be altered from the factory setting.

All parameters are stored in RAM andretained when power is removed.

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System Parameters

Parameter Listing
The following is a list of all gauge internal software parameters.
Factory settings are listed in the Default column. These values may have been adjusted to suit individual customer
needs prior to leaving the factory.

Changes made to the parameter settings should be recorded for future reference

Serial Parameters
The factory set RS232 serial output from the gauge emulates Mitutoyo serial equipment. The baud rate may be
selected from 1200 baud to 9600.

Baud Rate Selectable 1200 - 9600 Baud

Data Bits 8

Stop Bits 1

Parity N

Serial Output Data Format

The ASCII serial output from the gauge has a fixed width of 13 characters. It conforms to the Mitutoyo format.

Char 1 Device ID number 0

Selectable between 0 & 9.
(See “Parameter Listing” on page 16)

Char 2 Reading numeric tag. 1

Crush Reading is tagged [1]

Char 3 Constant A

Char 4 Sign +

Char 5-12 Measurement 25.5

Char 6 Terminating Character CR

Ethernet
The ethernet output is used to output data to the Versatile Data Processor software. The Data Processor software
is configured to accept the gauge output and create data files on the factory network for collection by an SPC
program.

Axial Load Gauge Measurement Output

The gauge outputs two reading:

• Peak force

• Distance

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Calibration

Calibration
Calibration Overview
All gauges used for the purpose of process control and acceptance inspections should be regularly tested to ensure
they are accurate, within calibration and capable of measuring the process.

Ensure that all equipment used to calibrate the gauge has been laboratory calibrated and its certification is traceable
to national measurement standards.

Calibration Report and Sticker

At the completion of the calibration the results should be studied to ensure all parts of the gauge operate within
specifications. A ‘calibrated’ sticker is applied to the gauge indicating when the next calibration is due. Calibration
reports should be filed for future reference.

When and how often should I calibrate?

Calibration of the gauge should be conducted annually. It is recommended calibration be checked when the gauge is
first commissioned, when any repair work has been performed that would affect calibration or if test results are
suspect.

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Calibration

Calibration Procedure

A
B

A: Load Cell Reading

Displays the force applied to the load cell.

B: Gain Value
Allows manual adjustment of the Gain, use the up and down arrows on the keypad or the touch screen buttons to
adjust.

C: Offset Value
Allows manual adjustment of the Load cell offset, use the left and right arrows on the keypad or the touch screen
buttons to adjust.

D: Load Cell Control

Allows the user to move the load cell up and down for calibration. Press the

E: Options

• Defult - Sets the Gain and Offset to gauge defualt.

• Unit - Changes the Units between Kgs & N.

• Auto Offset - Automatically sets the Offset value when no load is applied to the load cell

• Auto Gain - Automatically sets the Gain Value.

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Calibration

Calibration Procedure
The following procedure is straightforward, however the procedure should be carefully followed to avoid damage to
the gauge and personal injury.

1. Open the Left Hand Side Service panel.

2. Enter the access code to gain internal system access.

3. Enter the calibration menu by pressing Menu -> Calibrate.

4. Remove the can locator and place the reference load cell directly in the centre of the axial load platen.

IF YOU ARE NOT USING THE VERSATILE TECHNOLOGY

FC070 FORCE CALIBRATOR PLACE A RESILIENT BLOCK
BETWEEN THE LOAD CELLS - I.E. RUBBER
5. Zero the force transducer by pushing the force reading ‘Lable A’ on the screen.

6. Press Auto Offset (Lable ‘E’) to automatically set the offset.

7. ZERO the display of the reference gauge.

8. Press the ‘Down Fast’ button to lower the upper platen. When the platen touches the load cell block,
CAREFULLY watch the reference display to ensure the full scale is not exceeded.

IF A FORCE OVER 250KG IS APPLIED DAMAGE TO THE

LOAD CELL MAY RESULT
REMEMBER FULL SCALE = 250KG
9. Repeat pressing ‘Down’ allowing the force to approximately reach the nominal crush point (150Kg) on the
reference load cell.

10. Press Auto Gain, follow screen prompts and enter the reading the reference load cell.

11. Press ‘Crush Home’ to return platen to its home position.

12. Once complete, vary the range of force on the load cell and check for non-linearity. ie 50, 100, 200kg, etc. If
there is an error over 2.5 Kg, adjustment will be necessary. Repeat steps 7-11 until satisfactory.

13. To exit calibration mode and save settings press the 'ESC' key.

Note: To manually adjust the Force, when no load is applied to the load cell adjust the offset with the Left and Right
keys so the force reads ‘0.0’. Jog the platen down to 150Kgs on the reference load cell, use the Up and Down keys
to alter the reading to match the reference load cell.

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Maintenance

Maintenance
Routine maintenance

Cleaning
The Axial Load gauge is extremely hard wearing and does not require daily maintenace other than keeping the test
area clean from dirt and grime. As required clean the gauge using a soft cloth moistened with non-corrosive oil such
as WD-40.

Operator Feedback
Ask the operators to describe any difficulties using the gauge and note all concerns.

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Maintenance

General Maintenance

Changing the Fuse

The power supply module supplies all low voltage power to the gauge and is located on the rear panel.

1. Disconnect the mains power cable.

2. Remove the fuse cage with a flat blade screw driverver.

3. Replace the ‘blown’ fuse with new fuse.

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Maintenance

Replacing Relays
Use the following guide to replace worn or faulty relays.

1. Cut the cable tie holding the relay in position.

2. Carefully remove the relay with your fingers.

3. Fit new relay ensuring the pin layout is correct. Replace relays with the same type or equivalent.

Note: The cable tie is used as a holding device during shipping. It is not necessary to replace this upon fitting a new
relay.

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Maintenance

JC010 Assembly Diagram

VERSATILE TECHNOLOGY