Table of Contents Page Quick Set-up Instructions 1 Theory of Operation 2 Specifications 3 TM 1003W Controls and Connections 4 1. Power Source Connector 5 2. Alarm Output Connector 5 3. Variation Detection Lamp 6 4. Defect Detection and Sensitivity Adjustment 6 5. Sensitivity Level Monitor Terminals 8 6. Recorder Output Terminals 8 7. Gain Adjustment VR 8 Calibration Instructions 9 Sensor Output Values Table 11 Optional Comparator Module 13-1 -
QUICK SET-UP INSTRUCTIONS 1. Carefully unpack the instrument and lay the contents on a table. You should have the following: A. (1) TM-1003W Surface Variation/ Flaw Detector B. (1) ± 15 VDC regulated power supply with attached DC power cable C. (1) 115 VAC power cable attached to the power supply D. (8) Connectors for monitor and recorder outputs E. (1) Alarm output interface cable 2. Attach the DC power cable to the TM-1003W 3. Attach the alarm output interface cable to the TM-1003W 4. Mount the TM-1003W on-line 5. Using a small screwdriver, adjust the sensitivity adjustment potentiometer and measure the monitor output voltage level to correspond to the defect height you want to detect, refer to the table on pages 11 and 12 for defect size and voltage relationships. Turning the potentiometer counter-clockwise increases the TM sensitivity to detect smaller defects. Conversely, a clockwise adjustment decreases the TM sensitivity to detect larger variations and ignore the smaller ones. If you are using a TM 1003W with a digital dial sensitivity adjustment, simply adjust to the desired defect size limit. The setting is in mm millimeters. Please refer to 4d for more information. NOTE: This detector has been factory calibrated, and as such, DO NOT adjust the (3) gain potentiometers. Should you have any questions, contact Takikawa at 1-888-344-0111. - 2 -
Theory of Operation When a normal object is passed through the parallel light beams, the light volume produces a null (A1-A2). When an object with a lump or bump is passed through the beams, the values A1 and A2 become unbalanced. The difference between A1 and A2 is in proportion to the size of the flaw (lump/bump). When these features exceed a preset value an alarm is output. - 3 -
SPECIFICATIONS: 1. Measuring range: 0.0008 0.350 (optical shield hole Diameter 0.314, Range can be extended to 0.410 with vibration less than ± 0.2mm) 2. Measuring area: 0.472 x 0.020 (3 axes) 3. Light source: Near-Infrared LED 720 nm 100,000 hours life expectancy 4. Light receiver element: Photo diode 5. Detector sensitivity: 0.0004 (10µm) (5µm if used with DSS processor) 6. Detection accuracy: ± 2% or less of max set value 7. Line speed: 5 ft/min 4500 ft/min 8. Recorder output: ± 50 mv/ 0.01mm 9. Alarm output:tm-1003w: Red-lamp annunciator/ relay with 0.5 sec off-delay 250V 2 amp Resistive load 250V 0.1 amp Inductive load TM-1003W-S: Red-lamp annunciator Open-collector output 0.025sec one shot. (50V max, 150mA max, PC = 100mW max) 10. Ambient temperature: -5 C - 50 C (Subject to no condensation) 11. Power source: ± 15V (± 5% or less) +0.07A, -0.02A 12. Weight: 0.8 Kg 13. Frequency:TM-1003W: 15Hz 10KHz (-3db). TM-1003W-30: 15Hz 30KHz (-3db). TM-1003W-50: 15Hz 50KHz (-3db). 14. Noise Level: ± 1.6µm ± 3µm depending on model NOTE: The optical shield is typically used for very fine wire <0.2 mm. For larger wire, the two shields may be removed. - 4 -
TM 1003W Controls and Connections Standard Model Digital Dial Model 1. Power Source Connector 2. Alarm Output Connector 3. Variation Detection Lamp 4. Alarm Sensitivity Adjustment 5. Sensitivity Level Monitor Terminals 6. Recorder Output Terminals 7. Gain Adjusting VR - 5 -
1. Power Source Connector (3 Terminal ± 15VDC Regulated Power Supply) Terminal # 1 0V (Black) 2 +15V 0.07A (White) 3 15V 0.02A (Red) NOTE: Terminal # 1 is larger than 2 and 3. 2a. Relay Alarm Output 2 Terminal Connector (Standard Model) 1 2 (250V 2A Resistance Load, 250V 0.1A Inductive Load) The relay contact closure will occur between terminals 1 and 2 for 0.5 seconds. 2b. Transistor Alarm Output (Optional) Terminal # 1 = + (White) 2 = (Black) NOTE: Terminal # 1 is larger than #2. NPN Open-Collector Transistor Maximum Current: 150mA Applied Voltage: 50VDC or less Maximum Residual Voltage: 250mV Off Delay Time: 25ms - 6 -
3. Variation Detection Lamp Will be illuminated at each detection for 0.5 sec for the standard relay model. 4a. Defect Detection and Sensitivity Adjustment The TM-1003W is a high-speed defect detector, which utilizes a continuous sensing method for repeatable and cost effective detection of defects as small as 10 µm on wire and fiber. 5 µm defect detection is possible using our TM DSS defect analysis system. A dual parallel Photo- optic slit technique combined with Infrared light source is used to measure rapid light volume changes created when a sudden change in product diameter occurs. This diameter change is caused by the flaw, bump, neck down, color skip, etc. The light volume received is converted to a Real time analog signal, which is then analyzed through a differential circuit. The actual throughput speed is limited by the design of the circuits used, i.e. light modulation and filtering techniques. However, 5 µm defects can be characterized at speed greater than 15 m/sec. The sketch below illustrates how a defect may appear as it passes through the TM defect detectors two parallel photo- optic slits. And although the defect height may be the same, the actual light volume received can be different due to defect size characteristics. As such allowances should be made to adjust the TM sensitivity lower for these variations. Fig A. Fig B. Fig C. In figure A the defect creates a shadow that takes up the entire photo- optic slit. The defect is detected as a 0.5 mm high defect. In figure B the defect is detected as a 0.25 mm high defect. In figure C the defect is detected as a 0.125 mm high defect. Using the above comparison, it is suggested that the TM 1003W s sensitivity be set to the lowest possible setting (without false triggering) for very small defect detection on small diameter wire and optical fibers. - 7 -
4b. Calculating Defect Size for Proper Sensitivity Adjustment 1. The formula for calculating a defect size which is smaller than the TM 0.5mm optical slit width shall be: Length (mm) x Width (mm) 0.5mm 2. Deviated Projection: When the point of the projection (Defect) leans by a certain degree against the emitted beam direction, as shown below, the detected height becomes smaller than the actual one. To prevent from misdetection, the actual variation width (height) shall be calculated using the following formula: h= ½ φ (cos α - 1) + Hcos α For such application, detection by multi-direction shall be required. 4c. Alarm Sensitivity Adjustment (Standard Model) 1. Determine the size of the variation/flaw you wish to detect. 2. Attach a digital multimeter (DMM) to the sensitivity level monitor terminals. 3. Adjust the sensitivity potentiometer to change the voltage level at the monitor output to be in proportion to the defect size. (0.05V/ ± 0.01mm) To increase the sensitivity to detect smaller defects turn the potentiometer counter clockwise. To decrease the sensitivity to only detect larger variations turn the potentiometer clockwise. - 8 -
4d. Alarm Sensitivity Adjustment (Digital Dial Model) To set the sensitivity on the digital dial model set the dial display to the defect to detect from 20 to 999 µm. Example to detect a defect 0.04 mm set the dial to 040. 5. Sensitivity Level Monitor Terminals Monitor with a DMM that has an impedance of 1 MΩ or more for alarm sensitivity adjustment. (Does not apply to Digital dial models.) 6. Recorder Output Terminals Output Impedance = 100 Ohms ± 50mV/ uneven 0.0004 ±01V max. 7. Gain Adjusting VR The TM 1003W has been calibrated at the factory and should require a calibration check at yearly intervals to ensure optimum performance. DAS Distribution Inc. provides this annual service as part of a 17-point inspection test. (See Test Certificate on Page 16) Takikawa also offers an optional calibration gage kit (P/N: TMG 05) for this purpose, should the user wish to check the linearity of the recorder output only. - 9 -
Calibration Instructions 1. Remove the detection area protection covers and clean the emitter/ receiver lenses with alcohol and a lint free cotton cloth, or optical glass cleaner. Ensure that there is no left over residue on the lens. 2. Re attach the protection covers and attach the 0.5 mm gage pin (P/N: TMG 05) to the TM 1003W center detecting area. 3. Attach an oscilloscope or high-speed analog processor to the number 1 recorder output terminals. 4. Press the cable trigger button and note that the 0.5mm gage pin moves horizontally through the center portion of the detecting area. The in and out movement of the pin must be done quickly (within 0.5 sec. or less) to accurately simulate a 0.5mm defect. 5. While moving the gage pin in and out monitor the output reading on the oscilloscope. A 0.5mm defect should produce an output pulse of 2.5V. 6. Adjust the number 1 gain potentiometer so that the output pulse is within ±0.1V of 2.5V. Note that when the gage pin is retracted there will be a dent signal. Disregard this signal. Calibration is done with the gage pin projection only. 7. Repeat the above steps for recorder outputs 2 and 3 using their respective gain potentiometers. - 10 -
TMG-05 Gage Unit - 11 -
Sensor Output Values Defect size Output inches Meters Millimeters Microns Voltage 0.040000 0.001016 1.016000 1016.00 5.079997 0.039000 0.0009906 0.990600 990.60 4.952997 0.038000 0.0009652 0.965200 965.20 4.825997 0.037000 0.0009398 0.939800 939.80 4.698997 0.036000 0.0009144 0.914400 914.40 4.571998 0.035000 0.0008890 0.889000 889.00 4.444998 0.034000 0.0008636 0.863600 863.60 4.317998 0.033000 0.0008382 0.838200 838.20 4.190998 0.032000 0.0008128 0.812800 812.80 4.063998 0.031000 0.0007874 0.787400 787.40 3.936998 0.030000 0.0007620 0.762000 762.00 3.809998 0.029000 0.0007366 0.736600 736.60 3.682998 0.028000 0.0007112 0.711200 711.20 3.555998 0.027000 0.0006858 0.685800 685.80 3.428998 0.026000 0.0006604 0.660400 660.40 3.301998 0.025000 0.0006350 0.635000 635.00 3.174998 0.024000 0.0006096 0.609600 609.60 3.047998 0.023000 0.0005842 0.584200 584.20 2.920998 0.022000 0.0005588 0.558800 558.80 2.793998 0.021000 0.0005334 0.533400 533.40 2.666999 0.020000 0.0005080 0.508000 508.00 2.539999 0.019000 0.0004826 0.482600 482.60 2.412999 0.018000 0.0004572 0.457200 457.20 2.285999 0.017000 0.0004318 0.431800 431.80 2.158999 0.016000 0.0004064 0.406400 406.40 2.031999 0.015000 0.0003810 0.381000 381.00 1.904999 0.014000 0.0003556 0.355600 355.60 1.777999 0.013000 0.0003302 0.330200 330.20 1.650999 0.012000 0.0003048 0.304800 304.80 1.523999 0.011000 0.0002794 0.279400 279.40 1.396999 0.010900 0.0002769 0.276860 276.86 1.384299 0.010800 0.0002743 0.274320 274.32 1.371599 0.010700 0.0002718 0.271780 271.78 1.358899 0.010600 0.0002692 0.269240 269.24 1.346199 0.010500 0.0002667 0.266700 266.70 1.333499 0.010400 0.0002642 0.264160 264.16 1.320799 0.010300 0.0002616 0.261620 261.62 1.308099 0.010200 0.0002591 0.259080 259.08 1.295399 0.010100 0.0002565 0.256540 256.54 1.282699 0.010000 0.0002540 0.254000 254.00 1.269999 0.009900 0.0002515 0.251460 251.46 1.257299 0.009800 0.0002489 0.248920 248.92 1.244599 0.009700 0.0002464 0.246380 246.38 1.231899 0.009600 0.0002438 0.243840 243.84 1.219199-12 -
Defect size Output inches Meters Millimeters Microns Voltage 0.009500 0.0002413 0.241300 241.30 1.206499 0.009400 0.0002388 0.238760 238.76 1.193799 0.009300 0.0002362 0.236220 236.22 1.181099 0.009200 0.0002337 0.233680 233.68 1.168399 0.009100 0.0002311 0.231140 231.14 1.155699 0.009000 0.0002286 0.228600 228.60 1.142999 0.008000 0.0002032 0.203200 203.20 1.015999 0.007000 0.0001778 0.177800 177.80 0.889000 0.006000 0.0001524 0.152400 152.40 0.762000 0.005000 0.000127 0.127000 127.00 0.635000 0.004000 0.0001016 0.101600 101.60 0.508000 0.003000 0.0000762 0.076200 76.20 0.381000 0.002000 0.0000508 0.050800 50.80 0.254000 0.001000 0.0000254 0.025400 25.40 0.127000 0.000900 2.286E-05 0.022860 22.86 0.114300 0.000800 2.032E-05 0.020320 20.32 0.101600 0.000700 1.778E-05 0.017780 17.78 0.088900 0.000600 1.524E-05 0.015240 15.24 0.076200 0.000500 0.0000127 0.012700 12.70 0.063500 0.000400 1.016E-05 0.010160 10.16 0.050800 0.000300 7.62E-06 0.007620 7.62 0.038100 0.000200 5.08E-06 0.005080 5.08 0.025400 0.000100 2.54E-06 0.002540 2.54 0.012700 0.000090 2.286E-06 0.002286 2.29 0.011430-13 -
Optional Comparator Module Function: This module is used if two different size defects need to be detected. The module mounts on the side of the TM 1003W and plugs in to the monitor terminal and recorder output terminals. Specifications Input: L Output: 4ch (3ch for variations, 1ch for monitor. 0 ~ ± 10V, ± 0.05V/ ± 0.01mm Red lamp lighting and relay connector Output = 0.05 sec one shot per detection. (250V 2A Resistance load, 250V 0.1A Inductive load) Monitor: Alarm level voltage monitor terminal for small variation = ± 0.05V/ 0.01mm. Alarm level voltage monitor terminal for large variation = ± 0.05V/ 0.01mm. L Alarm setting: 15 turn potentiometer Power: + 15V 0.03A - 15V 0.01A DC power, with ripple Voltage of 3mVp-p or less. - 14 -
Installation 1. Remove 2 screws from TM 1003W (Refer to drawing on proceeding page.). 2. Plug the Comparator module into the Level monitor and recorder output terminals. Secure the module to the TM 1003W with the two screws removed in step 1. 3. Attach the power and relay cobles to the TM unit and the comparator module. 4. Set the voltage for the smaller variation by using a Digital Multimeter in the Lo terminal and adjusting the Potentiometer on the TM 1003W. 5. Switch the meter to the Hi terminals and set the voltage for the larger variation by adjusting the potentiometer on the comparator module. - 15 -