Micrometer AYE 4026


User's Manual

1. Mains connection
2. Set-up of inductive tracers
2.1 Connection of inductive tracers
2.2 Measuring range selection switch
2.3 Positioning of measuring tracers
2.4 Adjustment of classification limits
2.5 Adjustment of amplification
3. Set-up of strain gauge sensors
4. Allocation of the connection plugs
4.1 Analogue output
4.2 Tolerance output
4.3 Tracer plugs
4.4 Strain gauge plug
Note security directions acc. to VDE 0411

The micrometer AYE 4026 is a complete measuring unit with tolerance analysis in 5 classes.
It is possible to connect either strain gauges or inductive tracers as measuring sensors. The measuring value is continuously displayed on an analogue measuring instrument with zero centre position. The measurement range may be changed (measurement ranges: 10; 30; 100; 300 oder 1000m).
The adjustment of the 4 classification limits is done by adjustors.
When adjusting the limits, they are displayed on the measuring instrument.
The green lamp indicates a well-manufactured part.
The white lamps serve as indicators for the warning limits in a 5-class analysis.
The red lamp indicates an oversize part and the yellow one an undersize part, which need to be sorted out.
A 3-class analysis is possible as well. For this purpose, the classification limits 1 2 and 3 4 are put on top of each other, whereby only the red, green and yellow signal lamp are lit.

AYE 4026 contains an analogue measuring value output (5mV/m), which may be connected to a measuring value storage device (e.g. AYE 4348 or Procon A&V 8817).

1. Mains connection
Connect the micrometer via the power lead (Euro-Norm) with 230V, 50Hz and switch on the mains switch.
The unit should be switched on at least 10 minutes before the first measurement and the calibration in order to rule out any temperature influence.

2. Set-up of inductive tracers
2.1 Connection of inductive tracers
The inductive tracers are connected to the plugs -A, A, -B, B according to the measurement task and the switch tracer/strain gauge is set to tracer. The tracers at the plugs A and B work in positive direction. This means that the measuring value becomes more positive when pressing the tracer. The tracers connected to the plugs A and B work in negative direction.

2.2 Measuring range selection switch
With the measuring range selection switch it is possible to choose the relevant measuring range for the measurement task. On the respective scale, the measuring value may be read. For the measuring ranges +/-10/100/1000 m, the measuring value is to be read from the upper scale. For the measuring ranges +/-30/300 m, the value is to be read from the lower scale.

2.3 Positioning of measuring tracers
If no measuring tracers are connected, the display is set approximately to zero with the zero point adjustor so that it is in centre position. Connect the measuring tracer and insert the nominal master value into the measuring device. Position the measuring tracer in a way that a value close to the nominal master value is displayed. For the fine-tuning, the exact master value is set on the display at the front with the zero point adjustor. If two measuring tracers are used, the first tracer must be positioned at a value approximately half of the master value. After connection of the second tracer, this is positioned in a way that the display shows approximately the master value. The exact master value is then positioned with the zero point adjustor.

2.4 Adjustment of classification limits
The classification limits are adjusted with the tolerance adjustors 1 to 4 at the front. For this purpose, the respective tolerance adjustor is selected through the tolerance selection switch (the red luminous diode above the tolerance selection switch is lit). Afterwards, the displayed classification limit is adjusted at the display instrument. The classification limits have to be positioned increasingly from 1 to 4. After having done the adjustment of the classification limits, it is necessary to switch the tolerance selection switch to zero, in order to set the micrometer back to measurement (the red luminous diode is not lit).

2.5 Adjustment of amplification
The amplification was already adjusted in the factory and only needs to be checked or re-adjusted in rare cases (e.g. when using a special tracer or a strain gauge). A regular control of the adjustment is not necessary. For the adjustment of the amplification, a second master is needed. After the measuring tracers have been positioned, the second master is set in the measuring device and the difference of the two nominal master values is set at the back. Once the adjustment of the amplification was carried out, the positioning of the measuring tracers needs to be done again.

3. Adjustment of strain gauges
What goes for the set-up of inductive tracers is basically also true for the set-up of strain gauges. The strain gauges are either connected to plug A or strain gauge and the switch tracer/strain gauge (DMS) is set to strain gauge (DMS).
The zero point adjustment is carried out by providing a known force or a known torque (e.g. with a torque key) at the strain gauge and by positioning this value with the zero point adjustor on the display instrument. In order to adjust the amplification, a second value is provided and the difference is adjusted with the amplification adjustor. The zero point adjustment needs to be done again afterwards.

4. Allocation of connection plugs
4.1 Analogue output
The analogue output is needed for further statistic analysis of measurement cycles. To the analogue output, the measuring value storage device, e.g. AYE 4348, may be connected. In the range of +/- 5V, the analogue output gives an output signal of +/- 5mV/m which is independent of the measuring ranges. When using the analogue output, the tolerance lamps and the display instrument are switched off via this plug by connecting pin 2 to mass.

Allocation of plugs:
PIN 1 - Mass
" 2 - Display switch-off
" 3 -
" 4 -
" 5 - Analogue output
" 6 - Mass

4.2 Tolerance output
The tolerance output gives signals which are dependant on the tolerance classes for further analysis (e.g. for selection of big display lamps).

Allocation of plugs:
PIN 1 - Common base point
" 2 - Oversize
" 3 - Lower warning limit
" 4 - Good
" 5 - Upper warning limit
" 6 - Undersize

4.3 Tracer plugs
Up to four inductive tracers (e.g. the Vo QET4001 or TESA GT 21) may be supplied with the 10 kHz generator signal via the tracer plugs. The signal lies on pin 1 and 5 and has a temperature-stabilised amplitude of 1.5V. The input of the display amplifier lies on pin 3. It is also possible to conntect strain gauges at plug A instead of tracers, via pin 4.

Allocation of plugs:
PIN 1 - Generator signal
" 2 - Mass
" 3 - Tracer input
" 4 - Strain gauge input (only plug A)
" 5 - Generator signal

4.4 Strain gauge plug
To the strain gauge plug, strain gauges may be connected in order to measure e.g. torques or forces.
The strain gauge plug is supplied with the 10 kHz generator signal at pin B and C. Pin D is the strain gauge input.

Allocation of plugs:
A - Tracer input
B - Generator signal
C - "
D - Strain gauge input
E - Mass

Security comments according to VDE 0411

        General technical

Time for warming up   20 min.
Temperature   0...+40°C
Atmospheric humidity   up to 75% rel.
Power supply voltage   230 V +10%, -15%  
Frequency   50/60 Hz
Security   according to VDE 0411, protection class 1
This unit is built and checked under DIN 57411 part 1/VDE 0411 part 1 and left the factory in a safe and perfect condition. To preserve this condition and to guarantee a safe working, the user has to follow the comments and warnings which are given in these instructions.

Before turning on the power, you have to make sure that the voltage of operation and the mains voltage correspond.
The mains plug may only be inserted into a socket with ground contact. The safety effect may not be abolished by an extension lead without ground connection.
The opening of covers or removing of components, except if it is possible to do by hand, might uncover parts or connections under dangerous voltage. Racks may only be used inside a cover.
If an adjustment, a maintenance or a repair at the opened unit under voltage is unavoidable, it may be done only by a qualified employee, who is well acquainted with the dangers involved.

After the end of those works, the unit has to be checked according to VDE 0411, part 1
You have to make sure, that only fuses of the given type and values are taken for replacement. The use of mended fuses or short-circuiting them is inadmissible.
If it is presumed, that a safe work is not possible, you have to take this unit out of work. A safe work may not be possible, if
- there are visible damages at the unit,
- the unit does not work,
- after longer storage under unfavourable circumstances,
- after heavy stress of transport.