Related Manuals for Ametek Newage VERSITRON AT130-RDS
Summary of Contents for Ametek Newage VERSITRON AT130-RDS
- Page 1 Part No. MA-100 Version 4.3 Rev.04/15 ® VERSITRON Rockwell Hardness Testing System Operation Manual AT130-RDS & AT130-SRDS...
- Page 2 CAUTION! TRADEMARKS HIGH FORCES ARE OFTEN INVOLVED AMETEK is a registered trademark of WITH THE HARDNESS TESTING AMETEK, Inc. NEWAGE TESTING PROCESSES. INSTRUMENTS is a trademark of AMETEK, Inc. Other trademarks are the The machine is powered by mains supply property of their respective owners.
- Page 3 LIST OF ICONS USED IN THIS MANUAL WARNING The raised hand icon warns of a situation or condition that may lead to personal injury or death. Do not proceed until the warning is read and thoroughly understood. Warning messages are shown in bold type. DANGEROUS VOLTAGE The lightning icon warns of the presence of an uninsulated dangerous voltage within the product enclosure that might be of sufficient...
- Page 4 DECLARATION OF CONFORMITY. 4 Versitron Operation Manual...
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Page 5: Table Of Contents
TABLE OF CONTENTS 1.0 INTRODUCTION ..........6 6.0 INDIRECT CALIBRATION ........54 2.0 GENERAL SAFETY ..........7 7.0 SPECIFICATIONS ..........59 2.1 ELECTRICAL SAFETY ........8 7.1 Technical Specifications AT130-(T-Stand) ..59 7.2 T-Stand Overall Dimensions ....... 59 3.0 TEST METHOD ........... 9 7.3 Technical Specifications AT130-(N-Stand) .. -
Page 6: Introduction
1.0 INTRODUCTION The Versitron family of testers uses the most advanced mechanical and digital components of the market to make your testing as simple as possible. Due to their unique design, these testers are significantly different to install and operate than any other testers. -
Page 7: General Safety
GENERAL SAFETY General safety precautions must be followed when using this NEWAGE TESTING INSTRUMENTS product. Failure to observe precautions and warnings may result in damage to the equipment or injury to personnel. It is understood that safety rules within companies vary. If a conflict exists between the material contained in all NEWAGE TESTING INSTRUMENTS’... -
Page 8: Electrical Safety
2.1 ELECTRICAL SAFETY 1. The Versitron Test Machine has been designed to meet the requirements of BS EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control and laboratory use. 2. The user manual contains some information and warnings, which have to be followed by the user to ensure the safe operation and to keep the machine in safe condition. -
Page 9: Test Method
3.0 TEST METHOD 3.1 ASTM E18: Rockwell Hardness Testing This tester operates according to ASTM E18 standard in all particulars. It is used by virtually every large automotive, aerospace and defense manufacturer in the nation. 3.2 Top-loading and Test Surface Referencing The Versitron has two unique features: top-loading and test surface referencing. -
Page 10: Unique Benefits To Keep In Mind
3.3 Unique Benefits to Keep In Mind These features of top loading and test-surface referencing provide a number of unique benefits: Transportability - The tester does not need to be leveled before testing, nor does it need a firm foundation. This means the tester can be placed on a wheeled cart and carried to different test locations such as different furnaces in a heat treating facility. -
Page 11: Installation & Setup
INSTALLATION AND SETUP 4.1 Test Stand Installation The Versitron machines are heavy machines and great care should be taken in choosing the location where is to be installed. Ensure the bench is capable of remaining firm and stable withstanding the combined weight of the machine and any accessories supplied. - Page 12 Also included are: • Operating lever (non-automatic testers only), in crate with stand. • 3” flat anvil and clamping shield, installed on stand • Diamond indenter installed on head NOTE: Please make a careful visual inspection of all the parts made to ensure that there is no obvious transit damage.
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Page 13: Positioning Stands
4.2 Positioning the Stands, Models BT130N & BT130T The Versitron machine must be positioned such that the front can be easily accessed, the control unit and operating lever should not be obstructed and at the adequate height and reach so as to best ergonomically fitted for the end user. The Versitron machines are heavy items and cannot normally tip over. -
Page 14: Bolting The Bench Stands
4.3 Bolting the Bench Stands It is required that the Versitron machines are secured to the bench using the 4 (M12) threaded holes that must be reached from underneath the base. The templates below show the location of the 4 holes as required on the workbench for the bolts clearance. A centered hole needs to be drilled out also for clearance of the Elevating Screw. -
Page 15: Installing The Operating Lever
4.4 Installing the Operating Lever (Non-Automatic Testers) The operating lever should be slipped into the split lever casing. Tighten the thumbscrews on the casing finger-tight. Slip the operating lever assembly onto the lever spine so the lever is leaning back about 10 degrees at the resting position. -
Page 16: Installing The Test Head
4.5 Installing the Test Head All Test Heads are installed into the test stands in the same manner. They are designed for quick installation and removal. This feature facilitates scale changeover from regular to superficial Rockwell and facilitates service. Make sure the area where the Test Head sits is clean. Lower the elevating screw. Remove the clamping shield. - Page 17 Load Plate Pressure Yoke Installing the Test Head Attach all the connections at the back of the test head. They are all in labeled positions. Each connection is keyed so that only the proper male and female ends will fit. Attach the power cable and plug it into the power source. Attach the preload switch cable from the bottom of the test head.
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Page 18: Automatic Systems
The Versitron’s Control Unit uses two ceramic high breaking capacity type fuses (20mm x 5mm). The two fuses are assembled into the power entry module fuse block, as shown below. Fuse block Power Entry Module Fuses WARNING If the fuses need to be replaced, ensure to replace them using the exact same type and rating as the ones supplied by the factory (see Technical Specifications section 6.6). -
Page 19: Operation
NOTE: It is important that the tester only be used with the indenter shroud attached. CAUTION All operators must receive adequate training in basic operation before being allowed to use the machine. Additional copies of this manual are available from AMETEK Inc. 5.2 Basic Operation Indenter Shroud Head Carriage height-adjustment... -
Page 20: All Manual Or Automatic Bench Stands
4. Turn the power switch on at the back of the test head. The display will initiate with the “Splash Screen”. 5. After the “Splash Screen” flashes the Ametek and Newage logos, the display changes to show the “Test Screen”. - Page 21 Remote Shielded Foot Pedal Automatic Operation This is the complete test cycle. The operator is now ready to make another test. Proceed to the sections describing changing scales, changing indenters and other procedures and operations. Versitron Operation Manual 21...
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Page 22: Changing Scales
5.4 Changing Scales When changing scales, the indenter and the load selection both need to match the selected scale. After changing scales a mechanical load lock feature must be implemented as a secondary measure to avoid using the machine with a load outside the specification and obtaining erratic readings. -
Page 23: Changing The Hardness Scale Displayed
5.5 Changing The Hardness Scale displayed The Hardness Scale displayed can be changed from the Setup screen, when the Hardness Scale option is selected, a drop down list is shown with the appropriate scales for the measurement head. After selecting a new scale option, the user is prompted with the Indenter installation screen. -
Page 24: Changing Indenters
5.6 Changing Indenters NOTE: THE INDENTER SHROUD MUST BE SECURELY IN PLACE WHEN TESTING. The indenter area on your Versitron is different than most testers. An indenter shroud surrounds the indenter to act as a holding device for parts under load and to reference the surface position of the test specimen. - Page 25 8. The shroud and indenter area should be kept free of dirt and grease which could hamper operation. NOTE: Calibration on ball indenter scales is directly related to length of the indenter. When replacement ball indenters are required the purchase order should reference the serial number of the test head (located on chrome capstan wheel).
- Page 26 As previously indicated the load setting is changed by turning the chromed Capstan Wheel on the test head. As an approximate to the capstan wheel adjustment screen, a red line indicator on the load plate moves from one load position to another as the wheel is turned - for example from 150 kg to 100 kg on a regular Rockwell scale head or from 45 kg to 30 kg on a superficial Rockwell scale head.
- Page 27 After changing scale, it is recommended that a test block is used to verify the accuracy of the machine. Following the selection of a configuration and subsequent load adjustment, the machine will default to Verification Mode. While in verification mode and to keep verification measurements out of the test data, measurements will not be stored in your data file, will not be included in the statistics nor will be send to DataView.
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Page 28: Load Lock
5.8 Load Lock As a preventive measure, a load lock feature is provided. This mechanical option prevents the operator from using the machine with a load outside the predetermined specification. Once the load setting and adjustment has been completed, secure the Calibration Lock to the head upper shell notch. -
Page 29: Clamping Shield Operation
Clamping Shield Operation: Large Parts The use of the clamping shield is optional. When performing calibration and testing on small parts, it is advisable to remove the clamping shield. The clamping shield is useful to eliminate fixturing of large parts that overhang the anvil. -
Page 30: Checking Vee Anvil Alignment
5.10 Checking Vee Anvil Alignment (for Testing Rounds) When round parts have to be tested, the alignment of the indenter tip with the specimen has to be nearly perfect. Securely tighten the height locking knob on the head carriage. Tighten (only by hand) the anvil plate knob. Insert small Vee anvil. - Page 31 Head Carriage Height-Adjustment Knob Locking Nut (left side) Locking Knob T-Stand Vee Anvil adjustment: side-to-side Front-to-Back centering is adjusted by the set screw and nut underneath the anvil stage. Elevating Screw Adjustment Screw & Lock Nut T-Stand Vee Anvil adjustment: front-to-back (underside view) Loosen anvil plate knob.
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Page 32: N-Stand; Vee Anvil Adjustment
5.12 N-Stand; Vee Anvil Adjustment Slide front of stand over the edge of the work table. Be careful not to allow the tester to tip over. If alignment is out, adjustment is performed by loosening three [3] set screws under the elevating screw on the underside of the stand. A large ring holds the adjustment position when secured by three screws. -
Page 33: Testing Without Anvil Stage
5.15 Testing Without Anvil Stage, BT130T Stands The anvil stage with elevating screw may be removed to increase the test stand capacity to its maximum. Snap in clamping shield to protect indenter. Lower anvil about 2” (5 cm) from indenter. Loosen anvil plate screw. - Page 34 Conditions Necessary for Reliable Test Results Test load must be properly set. Indenter and its shroud must be properly screwed in. The indenter must correspond with test load for appropriate Rockwell scale (see Section 8.1). Clamping Shield should be snapped in place when testing large parts or removed for testing small parts.
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Page 35: User Interface (Ui) Control Unit
Power up the Control Unit from the power switch located on the back of the console. When the Control Unit is powered up, the initial “splash screen” first flash the Ametek logo, followed by the Newage hardness testing logo, along with the firmware version and the machine serial number. -
Page 36: Basic Operation
5.19 Basic Operation The Versitron U.I. consists of a column of function tabs on the left side of the screen that are used to navigate to the main portions: Test Screen, Statistics Screen, Files Screen and Setup Screen. The Power tab option at the bottom closes and shuts down the machine. -
Page 37: Test Screen
5.20 Test Screen The Test Screen displays after the “splash” screen and is the primary measurement screen for the Versitron. When a hardness measurement is performed, both the hardness scale and hardness reading are displayed on this screen. If tolerances have been stablished; a tolerance limit range indicator will be displayed also. -
Page 38: Statistics Screen
5.21 Statistics Screen The Statistics screen displays basic statistics from a current part. All of the measurements must be made using the same scale. The displayed statistics are: Count, Average, Std. Deviation, Max and Min. If High and/or Low Tolerances are entered, the number (up to 100) of “Pass” measurements and “Fail”... - Page 39 When the erroneous measurement needs to be removed, go to the Statistics Screen and select the Delete Last button. The measurement will be removed and all statistics recalculated. Versitron Operation Manual 39...
- Page 40 To see the statistics for the entire set of parts click the Dataset tab. If the statistics for a batch of parts for which multiple measurements were made are being displayed, the “pooled” Average and Standard Deviation for the measurements is presented, along with the overall Max and Min, the High and Low Tolerance, the number of measured Parts, the number of Pass/Fail measurements and the history of the Averages.
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Page 41: File Screen
5.22 File Screen The File Screen allows stored files on the machine’s computer to be copied to an external USB drive. The USB drive must be plugged into the USB A connector at the bottom of the console (it must be inserted after start-up, as the USB is the default boot drive and if present the application will not load). - Page 42 The function will be confirmed by an Export complete prompt screen, hit OK to continue. 42 Versitron Operation Manual...
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Page 43: Setup Screen
5.23 Setup Screen The Setup Screen provides access to the functions required for selecting test parameters. Many of these parameters are optional. The test machine should always start up ready to test using the most recently set configuration (if applicable). From the Setup Screen, the user is allowed to enter a New configuration test, Select, Edit, Rename or Delete an existing configuration. -
Page 44: Hardness Scale
a. Hardness Scale The Hardness Scale selection defaults to the current setting, with a drop down list to select a different scale. The drop down list will only show the hardness scales appropriate for the installed measurement hardware (Regular Rockwell or Superficial.) If the Hardness Scale is changed, a series of screens will walk the user through the required physical changes to the machine. -
Page 45: Measurement To Average
c. Measurements to Average This function allows the user to set the number of test measurements to average per individual specimen, with plus “+” and minus “-” icons to adjust the count from 1 to 100 measurements. When multiple measurements are selected, an average will be displayed following the final measurement. -
Page 46: Conversion
Tolerance keypad e. Conversion The Conversion selection is made with a drop down list of scales appropriate to the selected Hardness Scale only (see ASTM E18-14, pg. 25-27). 46 Versitron Operation Manual... -
Page 47: Roundness
Ø f. Roundness ( Ø The Roundness ( ) selection defaults to the current setting with a drop down list to allow selection in 1/8” increments (listing associated mm measurement) from 1/4” to either 1” or 1 ½” as appropriate for the selected hardness scale (see ASTM E18-14, pg. -
Page 48: Advanced Settings
5.24 Advanced Settings Selecting the Advanced function, prompts the Advanced Settings screen which allows the user to enable Minimum Thickness, Verification Mode, Set Date & Time, view machine specific information and access the Technician screen. 48 Versitron Operation Manual... - Page 49 The Minimum Thickness function is On/Off selectable. When enabled, it uses the minimum thickness value for a corresponding hardness in the respective scale. See Minimum Thickness reference chart in section 10.2. The Verification Mode function allows the user to take measurements while keeping those results out of the valid test data.
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Page 50: Technician Screen
5.25 Technician Screen The technician screen is password protected and it requires a “Technician” password to be accessed (see section 5.9). It allows the technician to select Hardness Scale, to Adjust measurements and set Indirect Calibration or Restore Factory Calibration settings. The Adjustment function allows the technician to make corrections to a measurement up to +/- 2.0 counts in 0.2 increments. - Page 51 An asterisk will display on the Test Screen by the reading value when this function is enabled. Adjustment enabled icon The Indirect Calibration option allows a qualified technician to indirectly calibrate the equipment by establishing a new profile set of data points per a specific hardness scale, indenter type or machine (both) using a multi set of scale hardness reference blocks.
- Page 52 52 Versitron Operation Manual...
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Page 53: User Settings
5.26 User Settings Some functions are password protected and they require either a “Supervisor” or “Technician” password to be accessed. See previous sections for directions of these functions. Function Operator Supervisor Technician Look at Statistics Delete last measurement Export Data Turn DataView On/Off Select previously created configuration... -
Page 54: Indirect Calibration
6.0 INDIRECT CALIBRATION The Indirect Calibration should not be revised on a routine basis. The process consists of three optional indirect calibration levels: Machine level, Indenter level and Hardness Scale level. The Machine calibration level is the broadest and more extensive method as it incorporates both the indenter and the hardness scale approaches, it requires a minimum of three different reference blocks per hardness scale range and it’s recommended to take a minimum of three readings per reference... - Page 55 Check the applicable calibration level, for Indenter and Hardness Scale calibration, the technician needs to select an indenter type or a hardness scale from the drop down list of options. After making the appropriate choice click Select, an empty New Reference Readings data grid will appear to the right of the screen, with two option tabs;...
- Page 56 Click on the Add tab will prompt the Add a New Reading screen, choose the hardness scale you are interested in calibrating first from the drop down list of hardness scale options. Tap on the Reference Hardness box, at the prompted keypad, type the test block hardness reference value stamped on the test block and hit Enter.
- Page 57 Click the Apply tab will prompt the Capstan Wheel Adjustment screen, adjust the capstan wheel to the optimum load position and when ready click Done. The Add a New Reading screen is now ready for the first measurement to be executed.
- Page 58 When the final measurement is completed click the Add tab to add another reading using a different reference block, enter the new reference block value and repeat the previous process to achieve a second set of readings under the new scale range. A third reference block scale range must be used for a third set of readings for a minimum of nine readings (at least three for each reference block scale range).
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Page 59: Specifications
7.0 SPECIFICATIONS 7.1 TECHNICAL SPECIFICATIONS BT130 (T-Stands) The T-Stand is the most versatile and utilizes the top-loading feature to its maximum. There are two vertical adjustments; one for elevating screw testing and one which moves the entire head holder along two columns for use when the anvil stage is removed. -
Page 60: Technical Specifications At130-(N-Stand)
7.3 TECHNICAL SPECIFICATIONS BT130 (N-Stands) Frame Construction Cast Iron Vertical Capacity 208mm (8.2in) Horizontal Capacity 198mm (7.8in) Throat Depth 219mm (8.7in) Approximate Weight 63.5kg (140lb) 7.4 N-Stand OVERALL DIMENSIONS BT130N Max. Height 32.0 Max. Width 16.2 Max. Depth 22.5 Base Height Max. -
Page 61: Test Head Technical Specifications
7.5 TECHNICAL SPECIFICATIONS BT130R & BT130S Test Heads Displayed Hardness Resolution 0.1 Rockwell Supply Voltage 115 or 230+/-10%VAC Supply Frequency 50-60Hz Power Rating 230VAC @3.15A Fuses (2) T3A15H250V(3.15ASlow Blow Ceramic) Weight of Test Head 8kg (18lb) BT130R tests in Regular Rockwell scales with full loads of 60, 100 and 150 Kg with a preload of 10 Kg. -
Page 62: Test Head Overall Dimensions
7.6 Test Head OVERALL DIMENSIONS BT130R & BT130RS Control Unit Height Control Unit Width Control Unit Depth Head Width Head Height 62 Versitron Operation Manual... -
Page 63: Dataview Output Specifications
7.7 DataView Output Specifications USB Type B (located on back of the console). The following is the format of the DataView output of test values: ######:bbbHHHHHSSSSSbTT where: ### = The sequence number b = blank space HHHHH = The hardness result SSSSS = The scale ID TT = The tolerance indicator (High, Low, Ok) ... -
Page 64: Standard Accessories
7.8 Standard Accessories These accessories and parts are included in the accessory kit provided with each test head. Diamond indenter for Regular or Superficial scale (normally installed on test head, not in kit). 1/16” ball indenter Test blocks Calibration lock Pin wrenches USB Device Driver install CD (for connection to external PC). - Page 65 AT/5321 Shortened clamping shield (for Motorized) AT/5322 Anvil adapter to fit 3/4” diameter anvil posts AT/5401 Normal indenter shroud AT/5402 Enclosed indenter shroud AT/5404 Fully enclosed pointed nose indenter shroud for tapered diamond AT/5405 1.7” enclosed pointed nose indenter shroud AT/5411 4”...
- Page 66 Indenter Shroud Dimensions Clamping Shield Dimensions 66 Versitron Operation Manual...
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Page 67: Maintenance & Troubleshooting
8.0 MAINTENANCE & TROUBLESHOOTING 8.1 Maintenance Procedures The Versitron needs no regularly scheduled maintenance other than calibration. For highest accuracy; anvils, indenters and indenter shrouds should be checked for damage and dirt on an occasional basis or when changed. The Vee anvil alignment should also be checked regularly especially before testing small diameter rounds. -
Page 68: Troubleshooting Checklist
8.5 Troubleshooting Checklist Symptom Problem Check/Remedy Low readings on test Bad test Block. Try a different test block. block Bad Indenter. Substitute new Indenter or switch from diamond indenter to ball or vice versa and check calibration on appropriate test block. Loose Indenter or Shroud. - Page 69 Symptom Problem Check/Remedy High reading on part. Metal too soft to support Look at test impression to see if the Shroud makes foot print. Indenter Shroud (especially when testing inside diameters). Test specimen does not Test on test block (see Section 8.2). meet minimum thickness requirements.
- Page 70 Symptom Problem Check/Remedy Erratic readings. Part not clamped tight Check for movement or looseness of specimen and check for enough (if using clamping adequate tightening of elevating. shield with large parts). No display No power to test head. Check cord and power supply, check fuse and check switch Flickering display Fuse blown.
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Page 71: Versitron Factory Service & Shipping Instructions
9.0 VERSITRON FACTORY SERVICE & SHIPPING INSTRUCTIONS MAKE CERTAIN YOUR INSTRUMENT NEEDS TO BE SERVICED: Test Stands: Usually, broken parts on the test stand portion of your Versitron can be installed at your plant by your maintenance personnel or Newage representative. Call Newage Customer Service Department if you need assistance. - Page 72 NOTE: Newage policy for warranty repairs is for customer to pay shipping to Newage. Newage will pay charges for shipment back to customer. Shipping Test Stands Test stands must be crated or bolted to a skid (there are four M12 threaded holes on the underside of the stand) and protected with cardboard or similar.
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Page 73: Reference Tables, Astm E18
10.0 REFERENCE TABLES, ASTM E18 10.1 Rockwell Scale Reference Table Scale Indenter Major Dial Typical Application of Scales Symbol Load Figures, 1/16-in. (1.588mm) ball 100 Copper alloys, soft steels, aluminum alloys, malleable iron, etc. Steel, hard cast irons, pearlitic malleable iron, titanium, deep diamond Black case hardened steel and other materials harder than B 100. -
Page 74: Round Correction
10.3 Round Correction Chart reprinted from ASTM Handbook 74 Versitron Operation Manual... -
Page 75: Hardness Conversion Chart, Rockwell C Hardness Range
10.4 Hardness Conversion Chart, Rockwell C Hardness Range Hardness values in brackets are outside the range recommended for Brinell testing in ASTM E-10. The above table is from ASTM E-110 except values for E-scale and Tensile Strength which are not from or according to ASTM Standards. Versitron Operation Manual 75... -
Page 76: Hardness Conversion Chart, Rockwell B Hardness Range
10.5 Hardness Conversion Chart, Rockwell B Hardness Range Chart reprinted from ASTM Handbook 76 Versitron Operation Manual... -
Page 77: Test Blocks Hardness Ranges (Indirect Verification)
10.6 Test Blocks Hardness Ranges (Indirect Verification) Maximum Allowable repeatability and Error of Testing Machines for Ranges of Standardized Test Blocks Maximum Maximum Range of Standardized Repeatability, R Error, E Test Blocks (HR units) (HR units) < 70 ± 1.0 $ 70 and <... -
Page 78: Appendix A: Motor Drive Options
APPENDIX A: AT130-MT2 (-N or –T) Electric Motor Drive Option This tester uses an electric motor assembly, mounted to the top of the stand, to apply test loads. After installing the test head, connect the cables from the motor assembly to the back of the tester readout unit. -
Page 79: Automatic Head-Height Adjustment Option
APPENDIX B: AT130-MT4 (T-Stand) Automatic Head-Height Adjustment Option Testers supplied with a motorized head height adjustment option can move the top of the tester and test head up or down automatically to accommodate testing on parts that vary greatly in size. The control box has 4 controls 1. -
Page 80: Calibration & Service Support
APPENDIX C: Calibration & Service Support Newage Testing Instrument’s sales and service staff and our associates have the capability to support hardness testing needs anywhere in the world. Additionally, Newage Versitron ® test heads can be shipped to our Pennsylvania location for factory service. -
Page 81: Warranty
ONE YEAR LIMITED WARRANTY Should Newage Testing Instruments, Inc. equipment require service, we will repair or replace, at our option, any part or product which upon examination by a Newage service technician, shows to be defective in material or workmanship. Excluded from this warranty are any parts that are to be replaced as part of normal product operation, such as indenters, test blocks, and indenter shrouds. - Page 82 Tel +49 0 2159 9136 70 • apie@ametek.de AMETEK Singapore Pvt. Ltd. (Singapore) Tel +65 484 2388 • aspl@ametek.com.sg Information in this document is subject to change without notice. ©2011 by AMETEK, Inc., www.ametek.com. All rights reserved 82 Versitron Operation Manual...