OPERATING PROCEDURE

For

DIGITAL ROCKWELL HARDNESS

TESTER

Ver. DR 8.4
Ver. DRS 8.4
 INDEX

1 Power ON

2 Indentation Cycle
• PRELOAD
• LOAD
• UNLOAD
• RESULT

3 Display and Keypad

3.1 Key Details
• 0 to 9
• Reset
• Print
• Menu
• Ent
• CS
• 0 to 9

4 Menu
• SETTINGS
• SCALE
• HIGH LIMIT
• LOW LIMIT
• DWELL PRELOAD
• DWELL LOAD
• DWELL RECOVERY
• PRINT (Y/N)
• CYCLE
• RS232 FOR
• BAUD RATE
• Parity
• Correction
• Dia
• BATCH
• NEW
• OPEN
• EXPORT
• DELETE
• RESULT
• VIEW
• DELETE
5 CONTROL CIRCUIT DIAGRAM

6 PRINTED CIRCUIT BOARD (PCB)

7 COMPONENT PLACEMENT DIAGRAM

1. Power ON

As we power ‘ON’ the instrument, Company Name, software model

and version no is displayed. Saved parameters are loaded from
memory.

Then system checks for digital dial. If dial is not connected system
will not proceed to next operation.

Then system checks for load/unload position with help of HOME

limit switch. If it is not pressed, motor is operated and stops at
HOME limit switch. This is to ensure unload position before start.

Initialization of machine is complete.

User can save maximum 350 results and 16 batches with different
parameters therein. All results are auto saved in a selected batch.

2. Indentation Cycle

This include preload, load, unload and result,

• PRELOAD
Preload is initial load applied manually by rotating screw. As we
move screw up the position bar is advanced to SET POINT. At set
point stop. Preload is complete. System checks for HOME limit
switch pressed, if not pressed SET POINT ERROR message is
displayed.
When HOME limit switch is pressed system continues to preload
delay. After set delay is over either auto cycle is started or waits for
CS key press to start cycle.

• LOAD
Loading is done by starting motor and LOADING is displayed. As full
load applied TIMER limit switch is pressed and stops motor for
DWELL timings. Dwell time is load time of machine. After this time
motor starts to unload.

• UNLOAD
The motor is started and UNLOADING is displayed. Unload is
complete at HOME limit switch. Motor stops, RECOVERY DWELL are
started.

• RESULT
After completion of RECOVERY dwell time, RESULT of hardness is
displayed. HI/GO/LOW LED indication is given to indicate status
w.r.t limits entered. HI – high to higher limit, LOW- lower to low
limit and GO- between high and low limit. Scale is also displayed.
Automatic data export on RS232 is done for result.

3. Display and Keypad

LED
Indicator
LCD
Display

16 keys
Keypad

On 2 line x 16 characters LCD, upper line normally displays ‘Bar graph”. Bar graph
helps for initial lifting up to set point.
2nd line displays current selected scale and digital dial reading as shown below.

Bar graph ■ SET

Dial Reading
SCALE HRC 1/1 2
Current Batch no Last result no
3.1 Key details:

• 0 to 9
These are for numeric data entry in menu parameters. Applicable in
menu - High limit, low limit, dwell preload, dwell load, dwell
recovery.

• Reset
This is to reset dial to zero. This is useful at preload to set initial
dial position.

• Print
This key is operational only if Print(Y/N) is N. And applicable after
result is displayed. When pressed transmit result data on RS232
port. The external RS232 printer can be attached or data can be
captured with Hyper Terminal on PC.

• Menu
This is to view and modify settings of machine parameters i.e.
scale, high / low limit etc. This is applicable in preload at initial
position of display and disabled in machine cycle. Press menu no of
times to scroll up to desired menu.

• Ent
This is to accept the edited parameter and saved to memory.

• CS
This is to select alternate options for selected menu parameter.

• Blank key
Additional feature is assigned to blank key to display major and
minor load, indenter used. Press blank key at the start of preload
and view these parameters related to scale selected.
At the hardness result display press this to indicate Depth of
indentation, scale conversion to HV, HB and Tensile stress(TS) in
MPa.
Press this multiple times to advance to next parameter and
return to original screen of loading / Hardness result.
4. Menu
• SETTINGS - To alter batch parameter settings in selected
batch.
• BATCH – To create, select, delete, export a batch.
• RESULT – To view, Delete results in selected batch
Press menu to scroll between above 3 menu.
Press Enter to open submenu.

SETTINGS Submenu
• SCALE
The Digital Rockwell hardness tester includes HRA, HRB, HRC, HRD,
HRE, HRF, HRG HRH, HRK, HRL, HRM, HRP, HRR, HRS, HRV scales.
The superficial Hardness tester includes 15N, 30N, 45N, 15T, 30T,
45T, 15W, 30W, 45W, 15X, 30X, 45X, 15Y, 30Y, 45Y scales in
addition.
To alter scale press ‘Ent’ then ‘CS’ no of times till desired scale is
displayed. Press ‘Ent’ to select scale and return to Menu settings.
Press ‘Reset’ to return to preload screen

• HIGH LIMIT
This input is higher permissible limit of hardness.
To alter limit press ‘Ent’ then numeric keys to input data. Press ‘Ent’ to
save and return to Menu settings.
Press ‘Reset’ to return to preload screen

• LOW LIMIT
This input is lower permissible limit of hardness.
To alter limit press ‘Ent’ then numeric keys to input data. Press ‘Ent’ to
save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• DWELL PRELOAD (DWELL PREL)

This is to input dwell after preload. Permitted limit is 0.1 to 4.0
seconds.
To alter limit press ‘Ent’ then numeric keys to input data. Press ‘Ent’ to
save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• DWELL LOAD
This is to input dwell after load. Permitted limit is 2.0 to 6.0 seconds.
To alter limit press ‘Ent’ then numeric keys to input data. Press ‘Ent’ to
save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• DWELL RECOVERY (DWELL RECO)

This is to input dwell after unload. Permitted limit is 0.2 to 5.0
seconds.
To alter limit press ‘Ent’ then numeric keys to input data. Press ‘Ent’ to
save and return to Menu settings.
Press ‘Reset’ to return to preload screen.
• PRINT (Y/N)
This is to enable(Y) or disable (N) output result to RS232. This output
can be connected to serial printer or PC. Readings are put on RS232
port after result is displayed.
When selected ‘Y’ and ‘RS232 FOR’ option is ‘PR’ then output format is
for printer.
When selected ‘N’ and ‘RS232 FOR’ option is ‘PR’ then no output.
This selection is irrelevant when ‘RS232 FOR’ option is ‘PC’.
To alter press ‘Ent’ then ‘CS’ key to change Y to N or N to Y. Press ‘Ent’
to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• CYCLE (AUTO/SEMI/MAN)
This is for automatic/semiautomatic/manual cycle start after set point
in preload.
To alter press ‘Ent’ then ‘CS’ key to change Y to N or N to Y. Press ‘Ent’
to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.
Select AUTO to start cycle after preload delay completion. Select SEMI
to start cycle by pressing CS button after preload delay. Select MAN to
switch off motor and do manual cycle provided this is supported.

• RS232 FOR
This is to select option of PC(PC) or printer (PR) format for RS232 data
output. When selected for PC results can be output to PC and can be
acquired by windows Software. Select baudrate 19.2, parity NONE
for PC software. When selected PR gives data output for printer. The
data includes serial no, scale, Hardness value and status(HI/GO/LO).
User can use any printer with RS232 data input. The settings for
RS232 parameters i.e. baud rate, parity are to be changed as per
printer settings.
To alter press ‘Ent’ then ‘CS’ key to change PC to PR or PR to PC. Press
‘Ent’ to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• BAUD RATE
The RS232 data includes settings for baud rate. The options are 9.6K,
19.2K, 38.4K and 57.6K. The other options are data bits 8; stop bits 1
and Flow control NONE. Parity as per selection.
To alter press ‘Ent’ then ‘CS’ key to change baud rate to alternate
selections. Press ‘Ent’ to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• Parity
The parity is to be selected out of NONE, ODD and EVEN.
To alter press ‘Ent’ then ‘CS’ key to change parity to alternate
selections. Press ‘Ent’ to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.
• CORRECTION
The convex/concave correction is to be selected out of NONE, convex(
CNX) and concave(CNV).
To alter press ‘Ent’ then ‘CS’ key to change to alternate selections.
Press ‘Ent’ to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

• DIA
This is to input job diameter in mm and enabled after correction is
selected. Permitted limit is 5 to 40 mm.
To alter diameter press ‘Ent’ then numeric keys to input data. Press
‘Ent’ to save and return to Menu settings.
Press ‘Reset’ to return to preload screen.

BATCH Submenu
• NEW
This is to create a new batch.
Press ‘Ent’ to select submenu and new batch no is displayed, if
available. Press “Ent” to create and return to submenu.
Press ‘Menu’ to go to submenu.
Press ‘Reset’ to return to preload screen.

• OPEN
This is to select a batch as current batch.
Press ‘Ent’ to select submenu and put batch no in 2 digits. Press “Ent”
to Open and return to submenu.
Press ‘Menu’ to go to submenu.
Press ‘Reset’ to return to preload screen.

• EXPORT
This is to send readings in a batch to RS232 port for PC software.
RS232 settings baud rate, parity are as per settings in batch required.
Press ‘Ent’ to select submenu and put batch no in 2 digits. Press “Ent”
to export data and return to submenu.
Press ‘Menu’ to go to submenu.
Press ‘Reset’ to return to preload screen.

• DELETE
This is to delete a batch and all readings in batch.
Press ‘Ent’ to select submenu and put batch no in 2 digits. Press “Ent”
to Delete and return to submenu. System selects available batch or
default batch 1 as current batch. User can select another batch from
‘Open’ submenu.
Press ‘Menu’ to go to submenu.
Press ‘Reset’ to return to preload screen.
RESULT Submenu
• VIEW
This is to view a result from current batch.
Press ‘Ent’ to select submenu and last result no is displayed. To alter
put result no(001 to last result no) in 3 digits. Press “Ent” to View
result. Press blank key to view conversion to HV, HB, TS. Press key
multiple times to advance to next parameter and return to
screen of Hardness result.
Press ‘Ent’ to view result.
Press ‘Reset’ to return to preload screen.

• DELETE
This is to delete a result from current batch.
Press ‘Ent’ to select submenu and last result no is displayed. To alter
put result no(001 to last result no) in 3 digits. Press “Ent” to delete
result.
Press ‘Ent’ to delete result.
Press ‘Reset’ to return to preload screen.
 CONTROL CIRCUIT DIAGRAM

P1 - RFI/EMI Filter with fuse & switch – EP3823M WITH 2A FUSE

T1 – TRANSFORMER 230VAC/7.5VAC, 1A
M – SINGLE PHASE AC MOTOR
P,N,E – 3 PIN SOCKET FOR 1 PH 230VAC INPUT
 6. PRINTED CIRCUIT BOARD (PCB)

J5

J4

J3

J8 J7
PCB with Connector Placement

Connection Details are as under

1/J3 – NC
2/J3 – 7/ D type connector C1- RTS
3/J3 – 3/ D type connector C1- RX
4/J3 – 2/ D type connector C1- TX
5/J3 – 5/ D type connector C1- GND

(J4 is put reverse)

1/J4 – VDC 1.8V to Dial
2/J4 – Dial Data1
3/J4 – Dial Data2
4/J4 – GND

1/J5 – GND /SHIELD - COMMON

2/J5 – TIMER limit switch – LS2 NO
3/J5 – HOME limit switch – LS1 NO

1/J7 – 7.5VAC
2/J7 – 7.5VAC

1/J8 – P1
2/J8 – NC
3/J8 – M
7. COMPONENT PLACEMENT DIAGRAM

PCB
T1

LS1
M
LS2

C1
P1

P1 - RFI/EMI Filter with fuse & switch – EP3823M

T1 – TRANSFORMER 230VAC/7.5VAC, 1A
M – SINGLE PHASE AC MOTOR
LS1 – LIMIT SWITCH FOR HOME POSITION
LS2 – LIMIT SWITCH FOR TIMER DWELL
C1 – RS232 interface 9 pin D type Female connector