Instruction Manual SPK-DFGS-031

December 2001
Revision 3

CHATILLON® DFGS Series

ACCUFORCE® AF3 Series

Digital Force Gauges with

Integral Loadcell

Operating Instructions

CHATILLON® DFGS Series ACCUFORCE® AF3 Series

Digital Force Gauge Digital Force Gauge

-1-
 TABLE OF CONTENTS
Page
INSTRUMENT PRECAUTIONS .............................................................................................. 5

1.0 INTRODUCTION AND PRODUCT OVERVIEW ......................................................... 6

1.1 PRODUCT FEATURES .................................................................................................. 6

1.2 ELECTRICAL SAFETY ................................................................................................... 6
1.3 RECHARGING BATTERIES ........................................................................................... 6

1.4 PHYSICAL DIMENSIONS ................................................................................................ 7

1.5 REVERSIBLE HOUSING ................................................................................................. 8
1.6 ABOUT THE DISPLAY ..................................................................................................... 8

1.7 ABOUT THE KEYPAD ..................................................................................................... 9

1.8 CONNECTION TO EXTERNAL DEVICES ................................................................... 10
1.9 CONTACT CLOSURE APPLICATION ........................................................................... 11

1.10 INTERFACE CABLES ..................................................................................................... 11

1.11 SETTING UP FOR SAFE USE ...................................................................................... 12

2.0 FRONT PANEL OPERATION ....................................................................................... 13

2.1 NORMAL MODE .............................................................................................................. 13
2.1.1 Powering Gauge ............................................................................................... 13

2.1.2 Selecting Units of Measure .............................................................................. 13

2.1.3 Selecting Type of Measurement - Capturing Peaks ..................................... 14
2.1.4 Zeroing ............................................................................................................... 15

2.1.5 Setting Limits ..................................................................................................... 16

2.1.5.1 Setting HIGH Limit ............................................................................................. 16
2.1.5.2 Setting LOW Limit ............................................................................................. 17

2.1.6 Activating Limits ................................................................................................ 17

2.1.7 Advanced Options ............................................................................................ 18
2.1.7.1 Activating Audible Alarms ................................................................................ 18

2.1.7.2 Activating Machine Control .............................................................................. 19

2.1.7.3 Activating Auto Shutoff ...................................................................................... 19

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 TABLE OF CONTENTS
Page
2.2 CONFIGURATION MODE ............................................................................................... 20
2.2.1 Configuring Output Ports- Analog Output ........................................................ 21

2.2.2 Configuring Output Ports- Digital Outputs ........................................................ 21

2.2.2.1 Enabling the Mitutoyo Output ................................................................... 22
2.2.2.2 Enabling the RS-232 Port- Numerical Data Only .................................. 23

2.2.2.3 Enabling the RS-232 Port- Full Data ....................................................... 24

2.2.2.4 Modifying Communication Parameters .................................................. 25
2.3 DATA COLLECT MODE .................................................................................................. 26

2.3.1 About Data Collect ............................................................................................ 26

3.0 CALIBRATING THE DFIS/AF2 GAUGE .................................................................... 28

3.1 CALIBRATION PROCEDURE ........................................................................................ 28

4.0 APPLICATION SOFTWARE INTERFACE ................................................................. 30

4.1 NEXYGEN GAUGE Application Software ...................................................................... 30

5.0 TROUBLESHOOTING .................................................................................................... 31

6.0 TECHNICAL REFERENCE AND SPECIFICATIONS ............................................... 32

7.0 MODEL NUMBERS ........................................................................................................ 33

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 TABLES
Page
1.4 Test Stand Adapter Kits .................................................................................................... 7
1.8 I/O Connector Pinout ........................................................................................................ 9

1.10 Interface Cables ................................................................................................................ 10

2.3 Data Collect and ASCII Commands ............................................................................... 26

ILLUSTRATIONS
1.4 Physical Dimensions ....................................................................................................... 7
1.5 Reversible Housing ......................................................................................................... 8
1.6 Display Layout ................................................................................................................. 9

1.7 Keypad Layout ................................................................................................................. 9

1.8 Serial Communication Connection and Pinout Diagram ............................................... 10
1.9 Contact Closure Pinout .................................................................................................... 10

2.2 Configuration Setup Hierarchy ........................................................................................ 19

2.3 Data Collect and ASCII Command Relationship Model ................................................ 25
4.0 NEXYGEN GAUGE Operating Display .......................................................................... 29

PRODUCT WARRANTY
This instrument is warranted against defects in workmanship, material and design for one (1) year from the
date of delivery to the extent that AMETEK will, at its sole option, repair or replace the instrument or any part
thereof which is defective provided, however, that the warranty shall not apply to instruments subjected to
tampering or abuse, or exposed to highly corrosive conditions.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES WHETHER EXPRESS OR IMPLIED AND
AMETEK HEREBY DISCLAIMS ALL OTHER WARRANTIES, INCLUDING, WITHOUT LIMITATION, ANY
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY. AMETEK SHALL
NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT
LIMITED TO, ANY ANTICIPATED OR LOST PROFITS.

This warranty is voidable if the purchaser fails to follow any and all instructions, warnings or cautions in the
instrument’s operation manual.

If a manufacturing defect is found, AMETEK will replace or repair the instrument or replace any defective part
thereof without charge; however, AMETEK’s obligation hereunder does not include the cost of transportation
which must be borne by the customer. AMETEK assumes no responsibility for damage in transit, and any
claims for such damage should be presented to the carrier by the purchaser.

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 PRECAUTIONS

• Read the instruction manual completely before attempting to use the DFGS or ACCUFORCE
3 (AF3) Series. By following the instructions contained in this manual, the optimum accuracy and
performance can be attained.

IMPORTANT NOTE: The DFGS and ACCUFORCE 3 (AF3) gauges are identical in function-
ality. The procedures, specifications and operations in this manual apply to both products
unless noted.

• Turn off the DFGS/AF3 Series before connecting or disconnecting any cables to the instrument.

• Do not overload the DFGS/AF3 Series! The instrument can handle an overload of up to 150% of
the rated full scale. The display will read “- - - -” when the gauge exceeds approximately 120% of full
scale. When the force applied is removed and “- - - -” is no longer displayed, the gauge may not read
above 121% of full scale in the Tension Peak or Compression Peak modes. Therefore, you must
contact your local distributor to ensure the load cell was not damaged, unless you are 100% sure the
force applied did not exceed 150% of full scale.

• The DFGS/AF3 Series is designed for axial loading only! Applying load on an angle or eccentric
loading may cause an erroneous reading.

• Do not use tools to attach the shaft adapter and accessories to the gauge. Use “finger-tight”
torque only to prevent damage to the load cell.

IMPORTANT NOTE: Before using your new DFGS/AF3 Series, fully charge the recharge-
able Nicad battery by plugging the supplied battery charger into the battery charger jack at
the top of the gauge and the proper AC outlet. Use only the battery charger supplied with the
gauge. Using other chargers can overcharge and damage the battery.

-5-
1.0 INTRODUCTION AND PRODUCT OVERVIEW
The DFGS/AF3 Series family of digital force gauges manufactured by AMETEK Test and Calibration
Instruments Division. They have been designed to provide accurate compression and tension force
measurements via an internal load cell. These instruments have been precisely crafted to provide years of
reliable service. Each gauge comes equipped with a rechargeable battery pack, AC battery charger,
Accessory Attachments, and a handy Carrying Case.

1.1 PRODUCT FEATURES

The key features of the DFGS/AF3 Series are:

• Load capacity up to 100 lbs (50 kg, 500 N)

• Internal sampling rate of 5000 Hz
• Displays Tension (T) or Compression (C)
• Configurable Setpoints (2) with Audible Alarm
• Simple keypad operation
• Automatic power shutoff
• Mounting arrangements for attaching to Manual and Motorized Test Stands
• Readings can be scaled using several engineering units: LB, KG, N, G, OZ
• Field calibration
• Analog and Digital outputs through common connector
• Can be controlled remotely via RS-232 port

1.2 ELECTRICAL SAFETY

These instruments have been assessed against the essentail health and safety requirements of the Low
Voltage and the EMC Directives listed below. Based on conformity with the listed directives, the DFGS and
AF3 are compliant with the following:

Directive Test Standard

EMC Directive (89/336/EEC) EN 50081-1 EMC Generic Emissions Standard
EN 50082-1 EMC Generic Immunity Standard

Low Voltage Directive (73/23/EEC) EN 61010-1 Safety Requirement for Electrical Equip

1.3 RECHARGING BATTERIES

A rechargeable NiCad battery powers the DFGS/AF3Series. Since NiCad batteries continue to discharge
when not in use, it may be necessary to recharge the unit before use. When the battery power begins to lose
its charge, the Battery Indicator will appear on the display . To recharge the battery, plug the battery charger
included with the gauge into the correct voltage source and insert the charger jack into the receptacle on the
end of the gauge . Charge the battery for 10-12 hours to yield approximately 8-10 hours of continuous
operation. The gauge can be operated continuously with the charger connected.

_ WARNING -
Before using the gauge, please fully charge the Nicad battery. Use only the battery charger supplied with
the gauge. Using other chargers can overcharge and damage the battery.

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1.4 PHYSICAL DIMENSIONS

Test Stand Adapter

Type Part No. Description

LTS - Mounts directly to LTS mechanical test stand

LTC - Mounts directly to LTC mechanical test stand
HTC HTCK-2 Adapts to HTC mechanical test stand
MT SPK-MT-DFGS Adapts to MT mechanical test stand
TT NC002582 Adapts to TT pneumatic tester
LTCM-6 SPK-FM200-019 Adaps to LTCM-6 series motorized stand
TCM201 SPK-FM200-019 Adapts to TCM201 series motorized stand
LFPLUS SPK/LFM/0005 Adapts to LFPLUS series digital stand
TCD200 SPK-FM200-019 Adapts to TCD200 series digital stand

Table 1.4 Test Stand Adapter Kits

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1.5 REVERSIBLE HOUSING
The DFGS/AF3 Series is shipped shaft-down for stand-mounted applications, and the display on the front of
the gauge is configured accordingly. For performing operations in which the gauge will be hand-held, it may
be desirable to rotate the front of the casing so that the display and logo will be shown right side up. To do
so, remove the two screws from the back of the casing, carefully rotate the front of the casing 180 degrees
being careful not to pull, pinch, or twist the wires inside, and then reinstall the screws.
NOTE: When removing the screws to the back casing for any reason, please take the proper ESD (Electro
Static Discharge) precautions. Touching the circuit board without taking the proper ESD precautions may
cause damage to the circuit board.

1.6 ABOUT THE DISPLAY

The display is an LCD seven segment display that is easily read even at a distance. The display illustrates
different symbols such as: battery symbol (BATT) indicating the battery is running low; a “C” for compres-
sion or a “T” for tension. The peak operational modes are also displayed (T PEAK, C PEAK). The right
portion of the display indicates the force measurement units (LB, KG, N, G, OZ). The display updates 4 times
per second.

T C PEAK BATT
Tension Compression Combined with Indicates low
“T” or “C” to battery condition
indicate peak
SET SET T C PEAK BATT
Limits
LB LB, KG, N, G, OZ

1.0.0.0.0 KG
N
Force measurement
indicator

-WARNING -
Force reading accuracy may be affected by a low battery condition. BEFORE using the force gauge for
the first time, fully charge the rechargeable NiCd battery. Plug the charger into the gauge’s charge jack
and into an AC outlet.

Always charge the battery whenever the BAT indicator is highlited. A minimum charge of 8 hours is
recommended.
-8-
1.7 ABOUT THE KEYPAD
The keypad consists of nine membrane keys. The keys are described below.

ON key is used to power the gauge.

PROG key allows you specify configurable func- ON PROG OFF

tions including an audible buzzer that sounds when
a limit is reached; communication with a test stand
to stop the stand’s crosshead travel when a
setpoint or limit is reached; activate/deactivate the UNIT PEAK
SET
automatic power shutoff feature. t

t
OFF key is used to turn power off to the gauge. An
automatic power shutoff feature may be used that ENTER
ZERO
turns power off to the gauge when the gauge has
been inactive for 10 minutes.
XMIT *
UNIT/__ key is a dual function key. The key is Figure 1.2
used to select the desired force measurement units Keypad Layout
(oz, lb, g, kg, N). The key is also used to navigate
across a displayed value. The
* key is used in conjunction with other key
combinations.
During setup the user can navigate from the left-
most displayed value (Least Significant Count) to ZERO is used to erase all values stored and
the right-most displayed value (Most Significant *
zero the display.
Count) and to the “T” for tension and “C” for com-
pression.
* PROG is used after setpoint setup to activate
the audible alarm.
PEAK/L key is a dual function key. The key is
used to activate/deactivate the Peak Hold feature ZERO key is used to zero the values being dis-
which freezes the display at the peak value that played. Use the ZERO key in combination with the
ocurred during a test. The display will indicate “T * key to erase all values stored in the gauge memory
PEAK” for peak tension or “C PEAK” for peak com- and to zero the display.
pression.

During setup, the key is used to change setpoint

values. Depressing the L key will increase the
currently displayed value by one value.

SET key is used to set the HIGH limit, LOW limit

and to activate/deactivate the setpoint function.

ENTER XMIT is a dual function key. It is used to

accept values configured into the gauge firmware
(ENTER) and also used to initiate data transmis-
sion to an external device, e.g. personal computer
(XMIT).

-9-
1.8 CONNECTION TO EXTERNAL DEVICES
The DFGS/AF3 Series can be configured to accept input from an external source, and/or to send output to
an external data-recording device, such as a strip chart recorder, an RS-232 or MITUTOYO printer, or a
personal computer. It can be used in combination with CHATILLON Test Stands and application software
such as NEXYGEN to meet a wide variety of application requirements. To connect the gauge to a device,
attach the appropriate interface cable to the port located at the top of the gauge, and the other end to the
external device.

9 1
8 2
10
7 12 11 3

6 4
5

I/O Connector
(View from Solder End)

The DFGS/AF3 Series is supplied with a 12-pin female connector to provide both digital and analog outputs.
AMETEK offers a variety of cables to handle most applications (Refer to Section 1.10). Select the cable type
required to connect the gauge to the peripheral device using the mating connector. The pinout of the
connector is shown above. Pin assignments are defined in the table below.

PIN Symbol I/O Purpose Description

1 TXD O RS-232 Transmitted Data

2 RXD I RS-232 Received Data
3 GND - Ground Digital Ground
4 - Clock Mitutoyo Clock
5 I Ready Mitutoyo Ready
6 I Request Mitutoyo Request
7 O Data Mitutoyo Data
8 I Detect Sense Contact Closure
9 O Setpoint Setpoint Output Signal
10 - Ground Digital Ground
11 - Analog GND Analog Ground
12 O Analog SIG Analog Output

Table 4.3 I/O Connector Pinout

- 10 -
1.9 CONTACT CLOSURE APPLICATION
The DFGS/AF3 Series can be configured to capture force and peak readings based on a contact closure.
When Pin 8 and Pin 10 on the output connector are shorted together, the gauge will stop reading data from
the loadcell. The gauge will freeze both the displayed value and the peak value in memory at the moment
the contact closure ocurred. All remaining gauge functions remain operational. The peak value may be
recalled from memory, the units changed, the data transmitted, etc. When the short across Pin * and Pin 10
is reopened, the gauge will return to normal operation.

8
10

Contact Closure Application

(Short Between Pin 8 and Pin 10)

1.10 INTERFACE CABLES

Cable Description
NC000850-1 9 ft (2.7m), Connects to personal computer with 9-pin RS232 connection
NC000850-2 20 ft (6.1m), Connects to personal computer with 9-pin RS232 connection
NC000652 6 ft (1.8m), Connects to a personal computer with a 25-pin RS-232
connection.
NC000652-1 10 ft (3m), Connects gauge to a personal computer with a 25-pin
RS-232 connection.
NC000652-2 15 ft (4.6m), Connectsto a personal computer with a 25-pin RS-232
connection.
NC000652-3 20 ft (6.1m), Connects to a personal computer with a 25-pin RS-232
connection.
NC000653 6 ft (1.8m) Connects gauge to X-Y recorder (double banana)
NC000654 5 ft (1.5m) Connects gauge to a Mitutoyo device, 10-pin
NC000697 10 ft (3m) Connects gauge to a Mitutoyo device,RS232
NC000698 10 ft (3m) Connects gauge to a Datamyte
NC000647 6 ft (1.8m) Connects to CHATILLON Model TCD
ENC0125 8 ft (2.4m) Connects to CHATILLON Model TCM

- 11 -
1.11 SETTING UP FOR SAFE USE
The DFGS/AF3 Series should be properly setup before accurate and most of all, safe measurements can
be made.
Only when you have verified that you will be conducting a safe test, proceed as follows:

1. Determine what and how it will be tested and verify that the DFGS/AF3 Series can handle the test.

2. If desired, mount the gauge in the test fixture.

3. If you will be powering the instrument from the AC line, plug the charger into its jack on the instrument.
Plug the charger into the correct AC voltage outlet (the required AC voltage and frequency are listed on
the charger).

4. Otherwise, if you will be powering the instrument from batteries, fully charge the batteries before using.

IMPORTANT NOTE: Before using your new DFGS/AF3 Series, fully charge the recharge-
able Nicad battery by plugging the supplied battery charger into the battery charger jack at
the top of the gauge and the proper AC outlet. Use only the battery charger supplied with the
gauge. Using other chargers can overcharge and damage the battery.

5. Attach all necessary attachments and plug in the cables. Route the cables so they do not interfere with
the test.

6. Zero the gauge by depressing the ZERO key.

7. Attach the specimen and begin to take measurements.

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2.0 FRONT PANEL OPERATION
The DFGS/AF3 Series can operate in one of the three modes: Normal, Data Collect and Configuration.

2.1 NORMAL MODE

The principal function of the Normal mode is to provide indications of load applied to the load cell.
Instantaneous force, peak-tension and peak-compression readings can be displayed and scaled in a
variety of units of measure.
2.1.1 Powering Gauge
There are dedicated function keys to power the DFGS/AF3 Series. To apply power to the gauge, depress
the ON key. To remove power to the gauge, depress the OFF key.

ON OFF

SET T C PEAK BATT

LB

1.0.0.0.0 KG
N

2.1.2 Selecting Units of Measure

Force indications can be displayed in LB, KG, and N or G, OZ and N. The gauge displays the active units
of measure on the LCD display. Pressing the UNIT key will cycle between the three available measuring
units.

LB
KG
UNIT N
t

OZ
G
N

With gauge power ON, depress the UNIT key to cycle through available force measurement units (LB, KG,
N, G, OZ). Release the key when the desired unit is displayed.

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2.1.3 Selecting Type of Measurement – Capturing Peaks
The gauge continuously measures instantaneous tension or compression forces (normal readings). It also
captures peak-tension and peak-compression forces. The gauge displays which measurement is being
indicated. Pressing the PEAK key will cycle between the available force measurement modes.

-WARNING -
Normal mode readings are an average of 600 instantaneous readings taken over a 120mS period. It is
the force displayed whenever the peak mode is not configured (T PEAK or C PEAK). This digital filtering
is used to eliminate the effects from noise or vibration that may cause false readings.

No digital filtering is used when the peak mode is configured. A noise elimination algorithm is employed
however.

The peak reading is the maximum value of the individual instantaneous reading which the gauge
captures.

C
LB

PEAK
T PEAK
LB

C PEAK
LB

With gauge power ON, depress the PEAK key to cycle through available force modes (C, T, T PEAK, C
PEAK). Release the key when the desired unit is displayed. The display will indicate C until tension is
applied to the loadcell. This will cause the display to indicate tension (T).

- 14 -
2.1.4 Tare, Zero and Clear Memory
Zeroing allows you to exclude the weight of accessories and attachments from the indicated force readings.
It also clears captured peak tension and compression readings. To zero the gauge, momentarily press the
ZERO key. Only the current measurement type (i.e., NORM, T-PK, C-PK) will be zeroed. To zero and clear
all measurement types press and hold the PEAK key and then press the ZERO key. Zeroing the gauge
takes approximately 0.5 seconds.

C PEAK
LB

0 0.0 0
ZERO

To TARE, affix the required adapter or fixture to the gauge. Orient the gauge so that it is positioned as it
will be during testing. Depress the ZERO key to tare the gauge.

To ZERO, after a test, depress the ZERO key to zero the force readings. Removing power to the gauge
will also zero the force readings.

To CLEAR all stored force readings in the gauge memory, simulataneously depress and ZERO.
*

- 15 -
2.1.5 Setting Limits
Limits are set by depressing the SET key. It is very important when setting limits to clearing understand the
relationship between limits and whether the gauge is in tension or compression mode.

-WARNING -
Tension (T) is considered as negative compression. Therefore, the more negative of the two limits for
the gauge must be stored as the LOW LIMIT.

For tension testing, where the two limits are 5 lbs and 20 lbs, the 20 lb limit is more negative and must
be entered as the LOW LIMIT. The HIGH LIMIT would be set at 5 lbs.

For compression testing, where the two limits are 5 lbs and 20 lbs, the 5 lb limit is more negative and
must be entered as the LOW LIMIT. The HIGH LIMIT would be set at 20 lbs.

The audible alarm will “buzz” if the limits are set incorrectly.

2.1.5.1 Setting High Limit

SET C
LB

85.0 0
UNIT PEAK
SET
t
t

To set the HIGH LIMIT (C), depress SET. The high limit will be displayed. The SET icon will also be
displayed along with the “C” indicating that you are in the setup mode for HIGH LIMIT.

The least significant count (right-most number) will flash repeatedly. A flashing number may be changed
using the t key. To change the number, depress the t
key to the required number. When the
gauge displays the required number, move to the next number by depressing the key. The number
t

will flash indicating that it can be changed. Use the t key to change the number. Continue moving
through the display until you have specified the desired HIGH LIMIT.

Depress the ENTER key to accept the displayed HIGH LIMIT value. You may depress the ENTER key
at any time to accept the displayed value.

-WARNING -
The least significant count is only displayed as a half count (5 or 1) on gauges with the following
capacities: 10 and 100.

- 16 -
2.1.5.2 Setting Low Limit

SET T
PEAK LB

15.0 0
UNIT
SET
t
t

To set the LOW LIMIT (T), depress SET. The low limit will be displayed. The SET icon will be displayed along
with the “T” indicating that you are in the setup mode for LOW LIMIT.

The least significant count (right-most number) will flash repeatedly. A flashing number may be changed
using the t key. To change the number, depress the t key to the required number. When the

t
gauge displays the required number, move to the next number by depressing the key. The number
will flash indicating that it can be changed. Use the t key to change the number. Continue moving
through the display until you have specified the desired LOW LIMIT.

Depress the ENTER key to accept the displayed HIGH LIMIT value. You may depress the ENTER key
at any time to accept the displayed value.

2.1.6 Activating Limits

Once the Limits setup is complete and the ENTER key is depressed, the display will indicate “LLO”. If the
“LLO” is flashing, the specified limits are ACTIVE. If the “LLO” is displayed in a steady state (Not flashing),
the limits are not active.

PEAK

L L0
UNIT
SET
t
t

The gauge will display a flashing LLO when the LIMITS are ACTIVE. To change to an inactive state,
depress the key.

If the display indicates a steady LLO, the LIMITS are NOT ACTIVE. To change to an active state, depress
the key.

- 17 -
2.1.7 Audible Alarm, Auto Shutoff, Machine Control
-WARNING -
The Audible Alarm (buzzer), Auto Shutoff and Machine Control features cannot be independently
configured. All three features must be configured each time a change is made to any of the three
features.

2.1.7.1 Activating Audible Alarm- Buzzer

The DFGS/AF3 Series features an audible alarm that is associated with the setup of limits. When limits are
setup for the gauge, the gauge can be configured to “buzz” whenever the HIGH or LOW limit is reached. The
audible alarm cannot be configured until the limits have been configured. The user can also elect not to use
the audible alarm and deactivate the alarm feature.

PROG
C
LB

B E.E P
ENTER
XMIT
*
-WARNING -
To activate the audible alarm, you must first configure the High and Low LIMITS. The alarm will not
“buzz” unless the limits are first selected. You may NOT configure the alarm before the limits are set.

To activate the ALARM “buzzer”, depress and HOLD the key and simultaneously depress the PROG
key. The display will indicate a flashing “BE.EP”. *
To enable the audible ALARM, depress the ENTER key. The display will indicate a flashing “S .SP” showing
that the “buzzer” will sound whenever a limit has been reached and that the gauge is ready for machine
control setup.

To disable the audible ALARM, depress the PROG key. The display will indicate a steady “S .SP” showing
that the “buzzer” is not active. The “buzzer” will NOT sound whenever a limit is reached.

- 18 -
2.1.7.2 Activating Machine Control
Whenever the DFGS/AF3 Series is used with a TCD Series test stand, the gauge must be setup for machine
control. This function permits the gauge to send the appropriate signal to the test stand to STOP the
crosshead whenever the configured HIGH or LOW LIMIT is reached.

PROG
C
LB

S .S P
ENTER
XMIT
*
-WARNING -
To activate Machine Control, you must first configure the High and Low LIMITS. Next you must configure
the audible alarm. You may NOT configure the gauge for Machine Control until the Limits are setup and
the audible alarm has been configured to be active or inactive.

To activate MACHINE CONTROL, depress the ENTER key. The display will indicate a flashing “L .H”.
This indicates that the gauge is configured for machine control. Whenever a limit is reached, the gauge
will send a signal to the test stand that will stop the crosshead.

To deactivate MACHINE CONTROL, depress the PROG key. The display will indicate a steady “L .H”
showing that the gauge is not setup with machine control.

2.1.7.3 Activating Auto Shutoff

The automatic shutoff feature is intended for battery operations and is designed to help preserve battery life.
If the DFGS/AF3 Series is inactive (no changes in load, no key actions, no communications) for a 10 minute
period, the gauge will automatically power down and shutoff.

PROG
C
LB

L. H
ENTER
XMIT
*
-WARNING -
The Auto Shutoff feature removes power to the gauge. Whenever power is removed from the gauge, the
gauge ERASES all stored peak data from memory. This information is NOT recoverable. Exercise care
when activating this feature.

To activate AUTO SHUTOFF, depress the ENTER key. The gauge will display the specified operating
mode.

To deactivate AUTO SHUTOFF, depress the PROG key. The gauge will display the specified operating
mode.
- 19 -
2.2 CONFIGURATION MODE
The Configuration Mode facilitates the communications setup for the gauge.

Communication
MODE

000H - MITUTOYO Option

19.20 - 19,200 Baud
9600 - 9600 Baud (Factory Setting)
4800 - 4800 Baud
2400 - 2400 Baud
1200 - 1200 Baud
600 - 600 Baud
300 - 300 Baud

UNITS

0 1 - Transmit with Units (Factory Setting)

0 2 - Transmit without Units

WORD LENGTH
STOP BITS

7 - 2 - 7 bit Word/2 stop bits (Factory Setting)

8 - 1 - 8 bit Word/1 stop bit

PARITY

E P - Even Parity
- P - No Parity (Factory Setting)

Figure 2.2 Communication Setup Hierarchy

- 20 -
2.2.1 Configuring Output Port- Analog Output
The analog output is always available at the output port without configuration. The analog output is
0 to -2.0Vdc (+0.018Vdc) in tension mode and 0 to 2.0Vdc (+0.018Vdc) in compression mode.

2.2.2 Configuring Output Port- Digital Output

The DFGS/AF3 gauge supports three types of digital output: Modified BCD (Mitutoyo), RS232 Numerical
Data Only and RS232 Full Data.

When the digital output is configured for RS232 Numerical Data Only, the format of the data being transmitted
to the external device is:

- XXXXX^^^<CR><LF>
<LF> = Line Feed

<CR> = Carriage Return

^^^ = 3 spaces (Note: ^^^ are NOT shown)

X X X X X = 5-character Force Value with decimal point

SPACE = Compression Reading (C)

- = Tension Reading (T)

When the digital output is configured for RS232 Full Data, the format of the data being transmitted to the
external device is:

- XXXXX^YY <CR><LF>
<LF> = Line Feed

<CR> = Carriage Return

YY = Units of Measure (2 characters)

^ = 1 space (Note: ^ is NOT shown)

X X X X X = 5-character Force Value with decimal point

SPACE = Compression Reading (C)

- = Tension Reading (T)

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2.2.2.1 Enabling MITUTOYO Digital Output
To enable the MITUTOYO digital output, turn the gauge power OFF.

ON PROG

000H
ENTER
XMIT

- NOTICE -
You must power down the gauge to configure the digital output and
communication specifications for the gauge.

To enable the MITUTOYO output, with gauge power OFF, DEPRESS and HOLD the XMIT key while
simultaneously depressing the gauge power ON key. Release the XMIT key after approximately 2
seconds.

The gauge will display a flashing 000H which denotes the MITUTOYO option. To enable the MITUTOYO
output, press the ENTER key. The gauge will activate the MITUTOYO option. The 000H display will stop
flashing and the gauge will return to the standard operating mode ready for a test.

To change the MITUTOYO output to an RS232 option,you must turn the power OFF to the gauge. With the
power OFF, depress and HOLD the XMIT key while simultaneously depressing the gauge power ON key.
The gauge will display a flashing 000H (denotes Mitutoyo output option). Depress the PROG key and the
gauge will display 19.20 representing a 19.2 baud rate. Continue to depress the PROG key until the
desired baud rate is displayed. Press ENTER to enable the desired baud rate.

Once you have selected the baud rate, the gauge will sequence you through the remaining communication
setup parameters, e.g UNITS, WORD LENGTH/STOP BITS and PARITY. Press PROG key to select
different parameters and Press the ENTER key to enable the desired setup for each parameter.

- NOTICE -
Your gauge is shipped with the following factory settings:
Baud Rate = 9600
Units = 0 1 (Transmit with Units)
Word Length/Stop Bits = 7 - 2 (7 bit word/2 stop bits)
Parity = -P (No Parity)

- 22 -
2.2.2.2 Modifying Communication Parameters
You may change the communication parameters for the force gauge by sequencing through the communi-
cation setup display.

ON PROG

9600
ENTER
XMIT

- NOTICE -
You must power down the gauge to configure the digital output and
communication specifications for the gauge.

To modify any communication parameter, with gauge power OFF, DEPRESS and HOLD the XMIT key
while simultaneously turning the gauge power switch to the ON position. Release the XMIT key after
approximately 2 seconds.

The gauge will display the first available option designated as 000H for Mitutoyo output. To change to a
BAUD RATE, depress the PROG key until the desired baud rate appears. Select XMIT to enable the
desired baud rate.

- NOTICE -
Your gauge is shipped with the following factory settings:
Baud Rate = 9600
Units = 0 1 (Transmit with Units)
Word Length/Stop Bits = 7 - 2 (7 bit word/2 stop bits
Parity = -P (No Parity)

- 23 -
2.2.2.3 Enabling RS232 Digital Output- Numerical Data Only (NO UNITS)
To enable the RS232 digital output with numerical data only (configure the gauge to transmit without units),
turn the gauge power OFF.

ON PROG

0 2
ENTER
XMIT

- NOTICE -
You must power down the gauge to configure the digital output and
communication specifications for the gauge.

To enable the RS232 NUMERICAL DATA ONLY (transmit without units) output, with gauge power OFF,
DEPRESS and HOLD the XMIT key while simultaneously depressing the gauge power ON key. Release
the XMIT key after approximately 2 seconds.

The gauge will display the current communication parameters for the gauge beginning with the Mode (See
Figure 2.2). The parameters will be displayed in the following order: Baud Rate, Units, Word Length/Stop
Bits and Parity.

- NOTICE -
Your gauge is shipped with the following factory settings:
Baud Rate = 9600
Units = 0 1 (Transmit with Units)
Word Length/Stop Bits = 7 - 2 (7 bit word/2 stop bits
Parity = -P (No Parity)

To select the RS232 NUMERICAL DATA ONLY output, change the UNITS to 0 2 by depressing the PROG
key until 0 2 is displayed. Once 0 2 is displayed (0 2 will flash), depress the XMIT key to accept and
proceed to the next communication parameter.

- 24 -
2.2.2.4 Enabling RS232 Digital Output- Full Data (Default) (UNITS)
To enable the RS232 digital output with full data (transmit output with units), turn the gauge power OFF. Full
data means that UNITS will be included with your force value during transmission to an external device.

ON PROG

0 1
ENTER
XMIT

- NOTICE -
You must power down the gauge to configure the digital output and
communication specifications for the gauge.

To enable the RS232 FULL DATA output, with gauge power OFF, DEPRESS and HOLD the XMIT key while
simultaneously depressing the gauge power ON key. Release the XMIT key after approximately 2
seconds.

The gauge will display the current communication parameters for the gauge. The parameters will be
displayed in the following order: Baud Rate, Units, Word Length/Stop Bits and Parity.

- NOTICE -
Your gauge is shipped with the following factory settings:
Baud Rate = 9600
Units = 0 1 (Transmit with Units)
Word Length/Stop Bits = 7 - 2 (7 bit word/2 stop bits
Parity = -P (No Parity)

To select the RS232 FULL DATA output, change the UNITS to 0 1 by depressing the PROG key until 0 1
is displayed. Once 0 1 is displayed (0 1 will flash), depress the XMIT key to accept and proceed to the
next communication parameter.

- 25 -
2.3 DATA COLLECT MODE
The DFGS/AF3Series can accept and execute commands through the RS-232 serial port. The command
set is tailored to make it easy to configure and operate the instrument under computer control.

2.3.1 About Data Collect Mode

Data transmitted by the gauge in Data Collect mode is a filtered average of 45 instantaneous force readings.
Digital filtering is employed to eliminate false readings resulting from noise and vibration.

The external device, which the gauge is communicating to, e.g. personal computer, must be configured to
transmit an ASCII character “F” to the gauge. This signals the gauge to go into, or out of DATA COLLECT
mode.

When the external device sends an ASCII character “?” or “X” to the gauge, the gauge will always respond
even if the instantaneous reading is a zero value. This permits real time data collection to begin at a force
reading or zero value. The ASCII character “?” or “X” is a request to the gauge to transmit data.

The gauge will return to Normal mode when it receives and ASCII character “F”. The table on the next page
shows the available ASCII characters and their functions.

The diagram below will illustrate how the gauge operates based on these ASCII characters.

- NOTICE -
Each ASCII character transmission will advances the gauge one step, similar to a keypad entry.

Data Collect Mode

PC D
ASCII
ASCII
“?” or “X”
“F”

ASCII ASCII
“P” N “P”
ASCII ASCII
“P” Normal “P”
Mode

ASCII
C ASCII T ASCII
“F” “P” “F”
Compression Tension
Peak Mode Peak Mode
D D
ASCII
Data Collect Mode “P” Data Collect Mode

Figure 2.3
Data Collect Mode and ASCII Command
Relationship

- 26 -
The DFGS/AF3Series can accept and execute commands through the RS-232 serial port. The command
set is tailored to make it easy to configure and operate the instrument under computer control. The string
commands are sent as ASCII characters. The following string commands are recognized:

Command Response Description

Legend:
^ is space (20 hex);
9 is a number 0 through 9;
± is a space or a minus;
<CR> is Carriage Return (0D hex);
<LF> is Line Feed (0A hex).

^^^^^^^^^^<CR><LF> On power-up, this line is sent.

A Unit^=^lb^<CR><LF> Sends currently selected units to external

Unit^=^kg^<CR><LF> device.
Unit^=^N^^<CR><LF>

F Toggles between Data Collect and the

Normal and PeakModes

P Steps through Normal and Peak Modes:

Normal, Tension Peak, Compression Peak

R Resets the gauge: zeroes all modes.

S Sends currently selectedmode: Normal,

^N-MODE^^^<CR><LF>
Tension Peak, or Data Collect
TP-MODE^^^<CR><LF>
CP-MODE^^^<CR><LF>
DC-MODE^^^<CR><LF>

U Steps through Units in the following order:

lb, kg, N

X or ? ±99.99^lb<CR><LF> Sends data on display with the position of

±99.99^kg<CR><LF> the decimal place the same as on display.
If in Data Collect Mode, sends the Data
±999.9^N^<CR><LF>
Collect filter instead. If “Transmit Units” is
set to transmit without units, lb, kg, and N
are replacedby ^^.

ERROR^^^^^<CR><LF> Response during force overload.

Z Zeroes the currently selected

mode: Normal, Tension Peak
or Compression Peak.

- 27 -
3.0 CALIBRATING THE DFGS/AF3 SERIES
The DFGS/AF3 Series may be field calibrated, however, for optimum performance, it is recommended that
your gauge be factory calibrated at least every other year or more frequently depending on your frequency
of use. Field calibration is recommended every 6 to 12 months. A 2-point calibration (0% and 100%) is all
that is required to properly calibrate the force gauge. It is not necessary to perform a multi-point calibration.

- WARNING -
The DFGS/AF3 Series should always be calibrated to full capacity. A 100 lbf capacity gauge should be
calibrated at a full scale reading of 100 lbs. If you have a 100 lbf capacity gauge, yet you use the
gauge between 0 and 50 lbf, YOU CANNOT calibrate the gauge as thought the full load is 50 lbf.

! You must have a way to mount the load cell vertically oriented before applying tension and compres-
sion force.

! The DFGS/AF3 Series should be calibrated using deadweights representing 100% of the rated full
scale.

! You must have a safe method of axially applying the deadweights to the load cell in compression
direction.

- WARNING -
You must depress ZERO at the completion of the calibration procedure to record the calibration data
into the instrument’s electronics. Data is NOT SAVED until the ZERO key is depressed.

If, at any time during the calibration procedure that incorrect data is being displayed, simultaneously
depress PEAK and ZERO keys to restart the calibration procedure.

3.1 CALIBRATION STEPS

This section leads you step-by-step through the calibration process for a DFGS/AF3Series:

! STEP 1 Gauge Pre-Set

With gauge power OFF, PRESS and HOLD the UNITS and PROG
key. Depress the power ON key.
0000 LB

Note: The gauge must be laying flat in a horizontal position with no

load applied.

Note: Let the gauge warm-up a minimum of 5 minutes prior to the

calibration procedure.

- 28 -
! STEP 2 Mount gauge securely to a weight stand in the compression position.
Attach a platen or hanger to loadcell shaft.

! STEP 3 Calibrate Zero (0% load)

C Exercise the loadcell three (3) times by applying and then removing a
LB
full load weight. With the platen or hanger attached and no weight
1.1 1 1 added, depress the ZERO key. The display should read 1111. You
should proceed to calibrate the gauge span.

! STEP 4 Calibrate Span (100% load)

C After you have successfully calibrated 0% load, apply full load to the
LB
gauge in the compression direction.
0.000
Note: If you are using a 100 lbf capacity gauge and operating normally
at 50 lbf, you must calibrate the gauge at full load, e.g 100 lbf. You
cannot calibrate the gauge span using any other weight other than the
gauge full load.

Once full load has been applied to the gauge, depress the ZERO key.
The gauge will display 0000.
C Loadcell Error
- - - - LB If your gauge displays - - - - during any point in the calibration process,
. you must repeat Step 1. This indicates that either the gauge has lost
communications with the loadcell or that the loadcell is damaged or
that it has been overloaded.

! STEP 5 Normal Operation

Once you have successfully calibrated to full load and the display
reads 0000, you may now remove the full load. The display should
read the full capacity of the force gauge being calibrated.

Your force gauge is now ready for use.

- 29 -
4.0 APPLICATION SOFTWARE
The DFGS/AF3 Series gauge may be used with the NEXYGEN GAUGE Series application software (p/n
40/0739) to provide you with an easy-to-use, economical data acquisition system.

The optionally available NEXYGEN GAUGE software package allows you to connect your force gauge
to your personal computer and perform the following advanced functions:

• Graphically present force vs. time results for each of your tests
• Record and stored tabular test results including peak values, load at break, pass/fail results

4.1 NEXYGEN GAUGE SETUP REQUIREMENTS

If using the optional NEXYGEN GAUGE application software, please refer to the product’s operating
manual (p/n 01/ for software application and operational instructions.

NEXYGEN GAUGE applications require a personal computer with the following minimum specifications:

Pentium® II 400 MHz Processor

128MB RAM
16550 UART
250MB Free Disk Space
VGA Windows Display Driver
1024 x 768 or Higher Monitor

- 30 -
5.0 TROUBLESHOOTING
The DFGS/AF3 Series digital force gauge has been designed to be very easy to use. Intunitive
displays, intelligent prompts and function keys have been provided to support all levels of users.

The following table is provided to aide in basic troubleshooting for your DFGS/AF3 Series force gauge.
For detailed troubleshooting assistance, please contact your local Sales Representative or your nearest
AMETEK Sales Office.

No display after pressing ON key Make sure that the battery is fully charged.

If using with AC power adapter, make sure that

the source power is on and that the gauge is
properly connected.

The display indicates “- - - -”. The loadcell may be have been over-ranged, or
the gauge may be in need of calibration.

Perform the calibration procedure in Section X.0.

If after calibration, the gauge continues to display

“- - - -”, the loadcell is likely damaged from being
over-ranged. Return for repair.

Gauge does not communicate to my TCD test Check to ensure that the proper cable is being
stand. used to communicate to the test stand.

Make sure the gauge is setup for machine control.

You must setup the gauge HIGH and LOW limits.

Gauge does not communicate to my personal Check to ensure that the proper cable is being used
computer. to communicate to the personal computer.

Make sure the gauge communication output param-

eters are configured properly.

The external device, which the gauge is communi-

cating to, e.g. personal computer, must be config-
ured to transmit an ASCII character “F” to the gauge.
This signals the gauge to go into, or out of DATA
COLLECT mode.

- 31 -
6.0 TECHNICAL REFERENCE
Accuracy Digital Output
DFGS Series +0.15% of Full Scale +1 LSC RS-232 and MITUTOYO
AF3 Series: +0.2% of Full Scale +1 LSC
Display Update
Tare Capacity 8 updates per second in Normal or Peak Mode
10% in order to utilize Full Scale (in lb Mode); can
tare more than 10%, however user may not have Sampling Rate
use of gauge’s Full Scale capacity during testing 5,000 samples per second

Deflection (Inches) Battery Life

0.007 +0.003 for loadcell 8-10 hours of continuous operation between
charges
Safe Overload
Gauge will display “- - - -” when the force applied Temperature Range
exceeds approximately 120% of the gauge’s ca- 40 to 110oF (5 to 45oC)
pacity
Temperature Stability
Overload 0.06% per oF
Maximum overload is 150%. Load Cell deform-
ation may occur when overload exceeds 150%. Warranty
Contact your local AMETEK Representative if you 1 year
experienced an overload beyond 150%.

Analog Output
-2.00 to +2.00 +0.018Vdc

- 32 -
7.0 MODEL NUMBERS

CHATILLON® Brand AMETEK® Brand

Model Capacity Model Capacity

DGGS 8 oz x 0.005 oz AF3-250G 8 oz x 0.005 oz

250 g x 0.1 g 250 g x 0.1 g
2.5 N x 0.001 N 2.5 N x 0.001 N

DFGS2 2 lb x 0.001 lb AF3-002 2 lb x 0.001 lb

1 kg x 0.001 kg 1 kg x 0.001 kg
10 N x 0.01 N 10 N x 0.01 N

DFIS10 10 lb x 0.005 lb AF3-010 10 lb x 0.005 lb

5 kg x 0.005 kg 5 kg x 0.005 kg
50 N x 0.05 N 50 N x 0.05 N

DFIS50 50 lb x 0.02 lb AF3-050 50 lb x 0.02 lb

25 kg x 0.02 kg 25 kg x 0.02 kg
250 N x 0.2 N 250 N x 0.2 N

DFIS100 100 lb x 0.05 lb AF3-100 100 lb x 0.05 lb

50 kg x 0.05 kg 50 kg x 0.05 kg
500 N x 0.5 N 500 N x 0.5 N

- 33 -
- 34 -
- 35 -
 Internet Addresses:
www.ametek.com
www.chatillon.com
TEST AND CALIBRATION INSTRUMENTS www.lloyd-instruments.co.uk

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AMETEK Test and Calibration AMETEK Lloyd Instruments AMETEK Lloyd Instruments
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AMETEK and CHATILLON are registered AMETEK Precision

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Pub No. NC001563

Issued 12/01 Copyright 2001, by AMETEK, Inc. Printed in U.S.A.
- 36 -