Gapman Gen3

User Manual
Capacitec, Inc.

Capacitec, Inc.
87 Fitchburg Rd.
PO Box 819
Ayer, MA 01432
Copyright 2010 by Capacitec, Inc.

Manual Revision 1.0

Gapman Gen3 User Manual

Gapman Gen3 User Manual
CHAPTER 1 Introduction 5
New features 6
Contents of the package 8
Main unit and wand 9
Quick Check Block 9
Banana ground plug 10
Batteries 11
Universal AC to USB adapter 12
Operating considerations 13
Password protection 13
Conventions 14
System requirements 14
Parts List 14

CHAPTER 2 Testing with the Gapman as a

Standalone Unit 17
Reading the Gapman Gen3 display and using the
function buttons 17
Acquiring new readings 20
Taking an effective reading 21
Installing the USB driver for Windows 26

CHAPTER 3 Reading and Uploading

Measurements with the Software
Utility 29
Setting up the hardware 29
For non-contact wands 29
For contact sabers 31
Setting up the software application interface 32
Uploading measurements from the Gapman
Gen3 35
Taking measurements using the Reader software 38
Installing the Gapman Utility reader software 38
Acquiring new readings 41
Uploading measurements from the Gapman Gen3 44

Gapman Gen3 User Manual

 Exporting readings to a file 45
Saving setting parameters to a configuration file 46
Uploading measurements using other software 47

CHAPTER 4 Testing with the Gapman using the

Calibration Software Utility 49
Accessing advanced functions 49
Setting up supervisor functions 52
Send and Save 53
Shortcut Buttons 54
Measurement Method 54
Sound 54
Configuration Tracking 55
Unit of Measure 55
Calibrating the Gapman Gen3 56
Calibrating the non-contact wand 57
Calibrating the contact saber 65

CHAPTER 5 Troubleshooting 81
Hardware problems 81
Problem 81
Possible Solutions 82
Problem 82
Possible Solutions 82
Software problems 83
Problem 83
Possible Solutions 83
Problem 83
Possible Solutions 83

Gapman Gen3 User Manual

CHAPTER 1 Introduction

The Gapman Gen3 is a hand-held electronic gap measuring tool that is portable,
easy to use, and highly accurate. The unit uses two types of a precision feeler
gauges: non-contact; which looks for a grounded return plate, and contact, which
measures the top and bottom of an air gap. It can measure gaps between contact,
which can measure non-conductive material such as fiber composites. Typical
applications include aerospace components, coatings, plastic extrusions, structural
assemblies, photocopiers, and packaging materials.

The Gapman Gen 3 is programmed and configured at the factory so that it is ready
to use out-of-the-box. Typically, you will measure and record gaps using the
internal reader software and the simple function buttons on the unit, and then
download the measurement data for review using a robust and simple Windows-
based utility. For supervisors with an engineering password, the Gapman Gen3 can
also be used to perform advanced functions, including calibration and setup.

This user manual introduces the features of the Gapman Gen3 and details how to
use the unit and its accompanying Microsoft Windows application software for gap
measurements and analyses.

Gapman Gen3 User Manual 5

 Introduction

New features
Capacitec redesigned the Gapman Gen3 primarily based on feedback from its
customers. Toward that goal, Capacitec has enhanced the unit to include the
following characteristics:
• Ease of use. Five shortcut function buttons have been added onto the Gapman
Gen3, including a push power button. See Figure 1.1. For more information
about the function buttons, see “Reading the Gapman Gen3 display and using
the function buttons” on page 17.

Figure 1.1 Function buttons

• Dynamic display. Gapman Gen3 adopts a matrix Organic Light Emitting Diode
(OLED) in place of the previous version’s 7-segment LED. With the new LED,
you now can view Site and Location, a unique setup name, and the unit of
measure during Measure mode. See Figure 1.2.

Figure 1.2 OLED display

For more information about the OLED display, see “Reading the Gapman Gen3
display and using the function buttons” on page 17.

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New features

• A more rugged enclosure. The enclosure is smaller and easier to hold. It is also
more effectively sealed so that no metal bits can get inside. Figure 1.4 on page 8
illustrates the case open with the unit and components housed inside.
• No pre-amp oscillation when measuring smaller gaps. By eliminating the
requirement for pre-amp oscillation, the Gapman Gen3 can use a thinner wand
and more easily measure smaller gaps.
• Improved temperature stability. The Gapman Gen3 does not require warm-up
time; thereby preserving battery life and saving you testing time.
• More reliable and easier service. The Gapman Gen3 has been designed with a
simplified firmware and Windows-based application software. As a result the
hardware is more stable, and the software is more user-friendly. See Figure 1.3.

Figure 1.3 Windows utility

• Improved ground connection. The snap connection used in the previous

version of Gapman has been replaced with a full-size, 90-degree banana plug
for ground connection using non-contact wands, enabling more flexibility and
ease of use. See Figure 1.6 on page 10 for an illustration of the plug.

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 Introduction

• Reduced power consumption. Gapman Gen3 reduces the power consumption

by about 2.5 times. This results in an increase of battery life by about 50% using
fewer batteries (3 AA-type instead of 4 from the previous version).
• Improved battery compartment. In addition to using a smaller compartment
that requires one fewer batteries (3-AA, illustrated as packaged in Figure 1.7),
the Gapman Gen3 also uses a retaining screw in the compartment to prevent the
battery from falling out of the unit.
• Higher accuracy and resolution. Higher poly terms and a new calibration
method have been added to improve the accuracy and simplicity of calibration.
12-bit ADC has been replaced with 14-bit ADC, resulting in better resolution.

Contents of the package

Each Gapman Gen3 is shipped in a kit and includes all of the components required
to function in most gap measurement applications. The unit and accessories are
shipped in a watertight, shock-resistant case. The enclosure is packaged completely
sealed so that no metal bits can get inside the box and degrade the contents.
Figure 1.4 illustrates the packaging.

Figure 1.4 Gapman Gen2 enclosure, shown open with complete contents

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Contents of the package

An air-purge valve under the handle makes the unit airtight. If you have difficulty
opening the case, make sure this valve is open.

NOTE: The easiest way to open the case is one latch at a time, with one hand
pressing down on the case, and the other releasing the latch.

Main unit and wand

The Gapman Gen3 circuitry cannot function without a gap sensor. This sensor, also
called a wand or probe, is connected to the Gapman Gen3 using a patented coaxial
pressure connector. The two sensing elements, along with their respective shields,
travel the length of the wand, from the sensing region to the pressure connectors.

Quick Check Block

The Quick Check Block (illustrated in Figure 1.5) included with the kit includes
three fixed gaps. The standard gaps are, nominally, 0.020", 0.050", and 0.100"
(these gaps are not certified).

Figure 1.5 Gapman Gen2 calibration block

Capacitec uses these fixed gaps to periodically test the operation of the unit. The
exact value of the gaps in the calibration block are programmed into the Gapman
electronics and provided on a label on the block itself. Using the exact figure for
recalibration will result in a more accurate calibration.

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 Introduction

For more information about calibration, see “Calibrating the Gapman Gen3” on
page 56.

Banana ground plug

A full-size, 90-degree banana plug is used for ground connection, enabling more
flexibility and ease of use. Figure 1.6 illustrates the plug.

Figure 1.6 Banana plug

For information about using the banana plug to ground the unit and the testing
source, see “For non-contact wands” on page 29.

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Contents of the package

Batteries

Two sets of three AA-type lithium batteries are supplied with each Gapman Gen3.

Figure 1.7 Batteries as packaged with unit

Gapman Gen3 reduces the power consumption by about 2.5 times. This results in
an increase of battery life by about 50% using fewer batteries (3 AA-type instead of
4 from the previous version). Each battery has a nominal output of 1.5V each, but
the level drops as the battery is used. Capacitec recommends that you use the
supplied or your own lithium batteries; however, the Gapman Gen3 can also run on
alkaline 1.5V AA-type batteries, resulting in about two times shorter life.

In addition to using a smaller compartment that requires one fewer battery, the
Gapman Gen3 also uses a retaining screw in the compartment to prevent the battery
from falling out of the unit. See Figure 1.8 on page 12.

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 Introduction

Figure 1.8 Battery compartment

Universal AC to USB adapter

The Gapman Gen3 does not require warm-up time; thereby preserving battery life.
However, it is recommended that the unit be turned off when not in use. You can
also save battery life by using the supplied universal AC to USB adapter, shown in
Figure 1.9, to power the Gapman Gen3 and bypassing the batteries.

Figure 1.9 AC Adapter

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Operating considerations

Operating considerations
The following list includes important information you should consider before
operating the Gapman Gen3.
• The Gapman Gen3 runs on 3, AA-type lithium batteries. Although you can also
use alkaline batteries, Capacitec recommends that you use the supplied or your
own lithium-type batteries for longest operating times.
• The Gapman Gen3 does not require warm-up time; thereby preserving battery
life. However, it is recommended that the unit be turned off when not in use.
• The USB cable is designed with a latch-and-lock design; be sure to press the
latch while firmly inserting the cable into the USB port on the unit and releasing
to lock. Do not force the cable into or out of the unit as you may break the
locking mechanism.
• You can power the Gapman Gen3 using the supplied universal AC to USB
adapter, thereby bypassing the batteries and preserving their life.
• You must use the banana ground cable for non-contact wands and connect it to
the target being measured. The Gapman Gen3 will not make accurate
measurements without a proper ground.

Password protection
To maintain the integrity of the testing and the sensitivity of the results, advanced,
engineering functions are password-protected for technical personnel. Engineering-
enabled functions include calibration, and Set to Standard, and supervisor setup, all
which require a unique password. Engineers can also configure the system
operation, shortcut buttons, the configuration name, the unit of measure, and the
measurement method. The Connection and Reading tabs on the user interface do
not require a password.

During configuration, you can apply the level of access as necessary to meet your
needs. For more information on how to set the password for specific access, see
“Installing the Gapman Utility reader software” on page 38.

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 Introduction

Conventions
This manual uses the following conventions for describing the Gapman Gen3.

Table 1.1 Terms used in this manual

Term Meaning
Refers to the Gapman Utility screen that displays when the software is
Dialog box
started
Refers to the sections or screens within the dialog box that each
Tab
display a page with functions specific to the corresponding tab name
Refers to the Gapman and Edit menus on the dialog box that drop
Menu
down to enable you to choose an item
Button Refers to the function buttons on the Gapman Gen3 unit
Refers to areas on the dialog box where you type a value, or where a
Field
non-editable value is displayed, corresponding to the field name
Refers to the Organic Light Emitting Diode screen on the top of the
OLED Screen Gapman Gen3 unit that displays the Site, Location, unit of measure,
configuration, and live gap value

System requirements
The Gapman Gen3 is easy to use with minimal hardware and software requirements
to use the unit effectively. The Windows application runs on Microsoft Windows
XP, Vista, and 7 with minimal hardware.

Parts List
A complete parts list of the Gapman Gen3 system is shown in Table 1.2 on page 15.

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System requirements

Table 1.2 Parts list for the Gapman Gen3

Qty Description
Computer, Microsoft Windows XP, Vista, or 7 operating system with DVD
1
drive (user-supplied)
1 Installation DVD or USB flash drive
1 Keyboard with pointing device
1 USB cable
1 Banana ground cable
1 Universal AC to USB adapter
1 Contact saber or non-contact wand
3 AA batteries (two packs)
1 Quick Check Calibration Block
1 Multi-purpose enclosure
1 User Manual

Gapman Gen3 User Manual 15

 Introduction

16 Gapman Gen3 User Manual

CHAPTER 2 Testing with the Gapman
as a Standalone Unit

This chapter details how to set up and operate the Gapman Gen3 as a standalone
unit. This is typically the way you will use the Gapman Gen3 to quickly perform
gap measurement tests for most applications.

The first section helps you gain familiarity with the display and function buttons so
that you can quickly start taking measurements, while subsequent sections detail
how to acquire and take effective readings with the unit that can be later uploaded
to a PC through a USB interface (this is detailed in the next chapter, “Reading and
Uploading Measurements with the Software Utility” on page 29.

Reading the Gapman Gen3 display and using the

function buttons
When the Gapman Gen3 is first turned on, the OLED screen illuminates, as
illustrated in Figure 2.1 on page 18.

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 Testing with the Gapman as a Standalone Unit

Figure 2.1 OLED display

The Gapman Gen3 uses a matrix OLED in place of the previous version’s 7-
segment LED. With the new OLED, you can view the following functions on the
screen:
• Site-Location, located at the upper-left of the screen, are reading groupings or
indexes. These incremental indexes help you keep track of where the readings
are taken.
• The unit of measure, located in the upper-right of the screen, displays either
inches (in), mils (mil), millimeters (mm), or um.
• The live gap value, located in the main part of the screen, is the current
measured gap value in the selected unit of measure.
• Demo2, displayed in the bottom-middle of the screen, is the unique number for
each setup and calibration. The configuration designation must be no longer
than 8 characters. This identification is especially helpful in situations where
multiple wands or multiple calibrations are used on a single Gapman Gen3.

To make the Gapman Gen3 operate, use the five function buttons on the top of the
unit or below the OLED screen. See Figure 2.2 and Figure 2.3 on page 19.

Figure 2.2 Function buttons at top of OLED screen

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Reading the Gapman Gen3 display and using the function buttons

Figure 2.3 Function buttons below OLED screen

These buttons have the following functions:

• The Power button turns the unit on and off. Push and hold the button down for 3
seconds.
• The UNIT button changes the unit of measure from inch, mils, mm, um if
enabled.
• The SET button enables you to make an offset adjustment based on a Master or
Standard gap. This can be useful for changing from metal to composite target
material.
• The DATA button enables you to upload readings from the Gapman Gen3 to the
data collector through the USB port.

NOTE: A future version will enable you to upload data through a wireless
interface.
• The DEL button deletes the readings on the Gapman Gen3. After deleting
reading, the Site and Location resets to 1-1.
• The DOWN button decreases the Location in increments of 1.
• The READ button takes one reading. The Location automatically increments by
1 when you press this button.
• The UP button increases the Site in increments of 1.

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 Testing with the Gapman as a Standalone Unit

Acquiring new readings

To acquire a reading:

1. Install the three 1.5V lithium batteries in the battery compartment of the
Gapman Gen3. See Figure 2.4.

Figure 2.4 Battery compartment

2. Press the Power button for three seconds to turn on the Gapman
Gen3.

The Organic Light Emitting Diode (OLED) display lights, indicating that the
Gapman Gen3 is ready to take readings.

3. Insert the sensor into the gap to be measured.

4. Click the READ button on the Gapman Gen3.

The Site-Location and corresponding gap for that Site and Location displays on
the OLED screen.

5. To increase the Site in increments of one, click the UP button.

6. To decrease the Location in increments of one, click the DOWN button.

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Taking an effective reading

For more information on additional functions you can perform with the unit, see
“Reading the Gapman Gen3 display and using the function buttons”, on page 17.

Taking an effective reading

The measurements taken from the Gapman Gen3 are noninvasive and unaffected by
alloy variations; therefore, they are not subject to the dramatic rises in error rates
that alloy variations can create when other measurement processes are used. Still,
as with any gap measurement device, it is crucial that you use the device properly to
take maintain accurate measurements critical to the success of your application.

When taking readings with the Gapman Gen3, the most accurate readings are with
the wand parallel to the target. For example, Figure 2.5, Figure 2.6, and Figure 2.7
illustrate three correct alignments that will take accurate readings. In each case, the
wand is parallel to the target.

Figure 2.5 Example 1: Correct wand-to-target alignment

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 Testing with the Gapman as a Standalone Unit

Figure 2.6 Example 2: Correct wand-to-target alignment

Figure 2.7 Example 3: Correct wand-to-target alignment

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Taking an effective reading

If the wand is tilted, the apparent gap will be slightly smaller than the actual gap (as
much as 3% F.S., typically). Therefore, in order to make an accurate measurement
of the gap, the best practice is to flex (or rotate) the wand slowly during the reading.
The Maximum is the most accurate.

Figure 2.8, Figure 2.9, and Figure 2.10 illustrate alignments that will cause
readings to be more inaccurate or unreliable. In each case, the wand is tilted at an
angle to the target.

Figure 2.8 Example 1: Incorrect wand-to-target alignment

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 Testing with the Gapman as a Standalone Unit

Figure 2.9 Example 2: Incorrect wand-to-target alignment

Figure 2.10 Example 3: Incorrect wand-to-target alignment

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Taking an effective reading

For roller gaps, try to insert the wand perpendicular to the rollers. At the end of the
reading, the Gapman Gen3 should be set to report the highest reading as the true
gap. In typical measurement situations, this will reduce the error to less than 0.5%
throughout the full range of the wand, and less than 2% up to the extended range (a
little less than twice the full range). It is important to not manually adjust or wiggle
the sensor too quickly as this might result in erroneous readings.

When measuring a tight gap, it is once again important that you position the wand's
sensor parallel to the target surface. It might be necessary to gently straighten the
wand by running your fingers up its length. This will take any curl out of the wand.
If you are using a non-contact wand, the target gap must be grounded to the
Gapman Gen3 using the banana ground cable, illustrated in Figure 2.11.

Figure 2.11 Banana plug

The gap measurement technique uses the capacitive principle of measurement

physics as applied to determining the distance between two capacitor plates. Each
of the wand's two sensors and their corresponding targets form a capacitor. The
grounding of the target completes the circuit. If the target is not grounded, the
readings tend to be higher and unstable, resulting in an inaccurate measurement.

For instructions on connecting the banana cable to ground, see “For non-contact
wands” on page 29.

Each of the two sensors on the wand is interfaced to a built-in amplifier. When the
detected capacitance is input to the amplifier, the output can be linearly ratiod to
digital units and then to engineering metric or English units as related to the gap

Gapman Gen3 User Manual 25

 Testing with the Gapman as a Standalone Unit

between each sensor and its target. The dual sensors’ guard rings are driven to
alleviate degrading fringing effects that would reduce the sensor’s measurement
range. The air gaps of the two sensors are added to the overall sensor thickness to
arrive at the true gap.

Installing the USB driver for Windows

In order for Windows to recognize the Gapman Gen3, you must first install the
USB driver.

1. In Windows Explorer, navigate to the folders on the supplied DVD or flash

drive.

2. Double-click CDM20802_Setup.exe to begin installation.

3. Connect the Gapman Gen3 to the PC with the USB cable and power the unit on.

4. Open the Windows Device Manager and locate the USB serial port COM1, as
illustrated in Figure 2.12 on page 27.

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Taking an effective reading

Figure 2.12 USB Serial Port number designation on Device Manager

For more information on driver installation, please refer to the FTDI Driver
Installation Guide (FTDI_Drivers_Installation_Guide.pdf).

Gapman Gen3 User Manual 27

 Testing with the Gapman as a Standalone Unit

28 Gapman Gen3 User Manual

CHAPTER 3 Reading and Uploading
Measurements with the
Software Utility

The Gapman Gen3 enables you to perform high-precision, non-contact gap

measurements using a portable digital device. This chapter details how to set up the
hardware, connect to the software interface, and run the software utility to take and
upload measurements using the Reading software utility.

Setting up the hardware

After you have ensured that you have all the included parts, connect the main unit
and cables as detailed in the following sections.

For non-contact wands

If you are using a non-contact wand, make sure to use banana ground cable. The
ground cable consists of a flexible, coiled, single conductor cable, with connectors
at both ends. One connector snaps onto the side of the Gapman Gen3 enclosure.
The other end of the ground cable has a dual connector that has a "banana" plug
with a removable alligator clip.

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 Reading and Uploading Measurements with the Software Utility

To connect the banana ground cable:

1. Plug one end of the banana ground cable into the bottom of the Gapman Gen3
unit, as illustrated in Figure 3.1.

Figure 3.1 Banana plug coming from unit

2. Plug the other, banana-shaped end to the target object that you are measuring.

3. Secure the banana end of the cable with the removable alligator clip. This end
of the ground cable should be attached to the target that is being gauged, as
close as possible to the actual measurement area.

NOTE: At the selected location, the ground cable must maintain a conductive path
between the Gapman Gen3 and the target surfaces. The Gapman Gen3 will not
make accurate measurements without a proper ground.

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Setting up the hardware

4. Plug the USB cable from the input connector on the bottom of the Gapman
Gen3 to the USB port on your PC. Be sure to grasp and fully press the latch on
the USB connector while inserting the connector into the unit, and then release
to lock it in place. Figure 3.2.

Figure 3.2 USB latch-and-lock connector

For contact sabers

1. Plug the USB cable from the input connector on the bottom of the Gapman
Gen3 to the USB port on your PC. Be sure to grasp and fully press the latch on
the USB connector while inserting the connector into the unit, and then release
to lock it in place. See Figure 3.2.

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 Reading and Uploading Measurements with the Software Utility

Setting up the software application interface

To set up the software, you must first install the USB driver so that, when you
connect the USB cable from the Gapman Gen3 to the PC, the PC can recognize the
Gapman Gen3. You must then select your comm Port number on the data collector
to configure the device in Windows and set up the software utility. The default Baud
rate is 9600.

To set up the software interface:

1. In Windows Explorer, navigate to the folders on the supplied DVD or flash

drive.

2. Double-click CDM20802_Setup.exe to begin installation.

3. Connect the Gapman Gen3 to the PC with the USB cable and power the unit on.

4. Open the Windows Device Manager.

5. Expand the Ports section and locate the USB serial port COM1, as illustrated in
Figure 3.3 on page 33.

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Setting up the software application interface

Figure 3.3 USB Serial Port number designation on Device Manager

For more information on driver installation, please refer to the FTDI Driver
Installation Guide (FTDI_Drivers_Installation_Guide.pdf).

6. If you are using data collector software not provided by Capacitec, configure
the Comm port using free PuTTY software as illustrated in Figure 3.4 on
page 34.

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 Reading and Uploading Measurements with the Software Utility

Figure 3.4 Com port configuration for non-Capacitec data collector

34 Gapman Gen3 User Manual

Uploading measurements from the Gapman Gen3

Uploading measurements from the Gapman Gen3

You can upload any existing parameters stored on the Gapman Gen3 to the Gapman
to review at any time.

To upload data from the Gapman Gen3:

1. Ensure that the Gapman Gen3 is connected to the PC with the USB port.

2. Click the DATA button on the Gapman Gen3.

A data upload message appears on the screen, as illustrated in Figure 3.5.

Figure 3.5 Data upload message

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 Reading and Uploading Measurements with the Software Utility

3. Click the UP arrow to proceed with the upload.

Figure 3.6 illustrates the measurements format with a checksum.

Figure 3.6 Measurements format with checksum

4. To delete data stored in memory, click the DEL button on the Gapman
Gen3.

A delete measurements message appears on the screen, as illustrated in

Figure 3.7 on page 37.

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Uploading measurements from the Gapman Gen3

Figure 3.7 Delete measurements message

5. Click the UP arrow to proceed with the deletion.

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 Reading and Uploading Measurements with the Software Utility

Taking measurements using the Reader software

Capacitec provides a software utility that enables you to configure and read
measurements from the Gapman Gen3. This software enables you to download the
saved measurements on the Gapman Gen3 to the software and to save
measurements to text file in .dat and .csv formats.

The software also provides the measurement acquisition in two different methods
(single or continuous readings).

Installing the Gapman Utility reader software

The following procedure details how to install the Gapman Gen3.

1. Insert the provided installation DVD or flash drive into your computer.

2. In Windows Explorer, navigate to the DVD or drive and click the folder at the
top of the directory to view its contents. A sample directory is illustrated in
Figure 3.8.

Figure 3.8 Software directory

3. Double-click GapmanUtility.exe to open the utility.

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Taking measurements using the Reader software

4. Click the Gapman menu to open the menu options. See Figure 3.9.

Figure 3.9 Gapman menu

5. Choose Gapman => Configuration.

The Configuration Password dialog box displays. See Figure 3.10 on page 40.

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 Reading and Uploading Measurements with the Software Utility

Figure 3.10 Configuration Password dialog box

6. Leave the Password field blank and click OK. If one of the following
passwords, depending on the level of access you want for the utility.

NOTE: To use just the Connection and Reading tabs displayed by default when you
run the utility, you do not need to enter a password. To perform advanced functions
on the Set to Standard and Calibration tabs, contact Capacitec to acquire a special
password. An additional tab, Capacitec Setting ONLY, can only be enabled by
Capacitec personnel for specific settings set at the lab before shipment.

7. Click Connection to display the Connection tab.

8. Choose the USB Serial Port number from the Connection menu and click
Connect.

9. If you previously connected to a port and subsequently changed the port

designation, click Refresh Ports to clear the configuration.

When connected, all the parameters currently stored in memory on the Gapman
Gen3 are automatically populated to the Connection and Reading tabs when you
connect the unit. This feature is helpful for conducting a review of tests by
enabling to reload data into the software application. Status: Connected displays
at the bottom of the Connection area. See Figure 3.11 on page 41.

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Taking measurements using the Reader software

Figure 3.11 Connecting to the USB Serial Port

Acquiring new readings

When you press the DATA button to download measurements from the Gapman
Gen3 memory, the measurements populate the Reading tab.

To take a new reading:

1. Click Clear List at the bottom of the Readings from Gapman2 window to clear
the table. See Figure 3.12 on page 42.

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 Reading and Uploading Measurements with the Software Utility

Figure 3.12 Reading tab

2. Click Read in the Manual area of the Reading tab of the Gapman Utility.

Readings from either method display on the Reading tab. You can acquire gap
readings in one of two modes: manual (a single reading at a time); or continuous
(consecutive readings at a specified refresh rate).

To take a manual reading:

1. Insert the sensor into the gap to be measured.

2. Click Read from the Manual area of the Reading tab. The Site-Location and
corresponding gap for that Site and Location will display one after the other for
each click in the Readings from Gapman2 window. See Figure 3.13 on page 43.

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Taking measurements using the Reader software

Figure 3.13 Site-Location readings on Reading tab

3. You can increase the site in increments of one by clicking the Up arrow and you
can decrease the location in increments of one by clicking the Down arrow in
the Acquire Readings area (see Figure 3.14).

Figure 3.14 Acquire Readings area on Reading tab

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 Reading and Uploading Measurements with the Software Utility

To acquire continuous readings:

1. Insert the sensor into the gap to be measured.

2. Click the Reading tab on the Gapman Utility user interface.

3. Choose a refresh rate for the continuous readings from the Hz menu in the
Continuous area of the Reading page. See Figure 3.14 on page 43.

4. Click Start in the Continuous area of the Reading page. The Site-Location and
corresponding gap for that Site and Location will display one after the other in
the Readings from Gapman2 window and continue indefinitely until you click
Stop.

Uploading measurements from the Gapman Gen3

You can upload measurements stored on the Gapman Gen3 to the Gapman to
review at any time.

To upload measurements from the Gapman Gen3:

1. Ensure that the Gapman Gen3 is connected to the PC and the Gapman Utility is
running.

2. Click the Reading tab.

3. Click Data from the Stored Readings area of the Reading tab to view the
downloaded data on the page. See Figure 3.15.

Figure 3.15 Stored Readings area of Reading tab

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Taking measurements using the Reader software

4. To erase the downloaded measurement data from the Reading tab, click Delete
from the Stored Readings area of the Reading tab, as illustrated in Figure 3.15
on page 44. A confirmation message appears, as illustrated in Figure 3.16.

Figure 3.16 Erase confirmation message

5. Click OK to permanently delete the measurements on the Gapman Gen3.

Exporting readings to a file

You can export readings to a text or .csv file.

1. From the Export Readings area of the Reading tab, choose Format and select
a file format to save to a file anywhere on your PC. See Figure 3.17.

Figure 3.17 Export Readings area on Reading tab

2. Click Save to save the readings to the specified file.

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 Reading and Uploading Measurements with the Software Utility

Saving setting parameters to a configuration file

The configuration file is an .XML file that contains all the parameters on the
window application. You can save the current settings to a file and reopen them
later. This is useful for multiple calibrations on a single Gapman Gen3.

3. From Configuration File area of Configuration tab, click Open. See

Figure 3.18.

Figure 3.18 Configuration File area of Configuration tab

4. From the Browse XML file dialog box, select the file you want and click OK.

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Uploading measurements using other software

Uploading measurements using other software

You can use other data collector software to upload measurements.

To upload measurements from other data collector software:

1. If you have not yet done so, install the USB driver software. See “Setting up the
software application interface” on page 32.

2. Configure the Comm port using free PuTTY software as illustrated in

Figure 3.19.

Figure 3.19 Com port configuration for non-Capacitec data collector

3. After connecting to the Gapman Gen3, press the DATA button on the unit to
upload the measurements to software. Figure 3.20 on page 48 illustrates an
example of the measurements being uploaded to PuTTY.

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 Reading and Uploading Measurements with the Software Utility

Figure 3.20 Measurements uploaded from PuTTY

48 Gapman Gen3 User Manual

CHAPTER 4 Testing with the Gapman
using the Calibration
Software Utility

The Gapman Gen3 enables you to perform high-precision, non-contact gap

measurements using a portable digital device. This chapter details how to use the
unit with the calibration utility to perform advanced functions that set up and
Calibrate the Gapman Gen3. Capacitec recommends that you obtain training from
Capacitec before using these functions.

Accessing advanced functions

Set-up and calibration menus are password protected. Contact Capacitec for a
password to access these menus. After you have received a password from
Capacitec, do the following:

1. Click the Gapman menu to open the menu options. See Figure 4.1 on page 50.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.1 Gapman menu

2. Choose Gapman => Configuration.

The Configuration Password dialog box displays. See Figure 4.2 on page 51.

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Accessing advanced functions

Figure 4.2 Configuration Password dialog box

3. In the Password field, type the password and click OK.

The Gapman Utility software displays with the advanced tabs enabled and
visible. See Figure 4.3 on page 52.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.3 Gapman Utility with advanced tabs enabled

Setting up supervisor functions

The Gapman Gen3 ships pre-set according to the user’s specification. Capacitec
recommends that you do not modify the settings; however, if you do, you must save
the settings to the unit so they do not get lost. To do so, click Save to Gapman on
the Connection tab.

NOTE: Changing and modifying the set-up configuration does not require that you
run a calibration again.

The following sections detail the functional areas, menus, fields, and option buttons
on the Supervisor Setup tab, illustrated in Figure 4.4 on page 53.

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Setting up supervisor functions

Figure 4.4 Supervisor Setting tab

Send and Save

• Send Reading to PC via USBVirtual Comport? Check this box to allow the
single measurement to be sent over the USB port every time you press the
READ button.
• Send Reading to PC via Zigbee wireless? Check this box to allow the single
reading measurement to be sent over a wireless connection every time you press
the READ button.

NOTE: This function is not implemented in this version. Contact Capacitec for
information.

• Save Reading to Gapman Memory? Check this box if want the measurement
to be saved every time you press the READ button.

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Shortcut Buttons

Shortcut buttons refer to the buttons on the Gapman Gen3.

• Unit of Measurement: Check this box to allow the unit of measure to be
change from inch, mils, mm, and um when you press the UNIT button.
• Set to Standard: Check this box to allow the offset adjustment to the
measurement when you press the SET button.

NOTE: This feature is not implemented in this version.

• Erase reading on Gapman: Check this box to enable you to delete the saved
readings or measurements in the Gapman Gen3 memory when you press the
DEL button. Even though there is confirmation after pressing the DEL button,
be careful when using use this button because the readings will be permanently
deleted.
• DATA Upload: Check this box allows the saved readings or measurements on
the Gapman Gen3 to be uploaded to the data collector when you press the
DATA button. USB, wireless or both can be selected.

NOTE: The wireless data upload feature is not implemented in this version.

Measurement Method

NOTE: Only the Manual Mode is implemented in this version.

• Auto Mode: Select this option button to measure the minimum gap of the roller
target gap.
• Manual Mode: Select this option button to measure the flat target gap.

Sound

NOTE: The Sound features are not implemented in this version.

• Buzzer Enable: Check this box to generate the audible buzzing sound when
any of the buttons are pressed.
• Audible Key click Reading: Check this box to generate the audible buzzing
sound when the READ button is pressed.

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Setting up supervisor functions

Configuration Tracking
In the Configuration Name field, type a configuration name that is 8 characters or
less. This name will be displayed on the Gapman Gen3 OLED so that you can
identify the setup and calibration that applies to your unit.

Unit of Measure
• Units: Select the option button corresponding to the unit of measure you want to
apply to the Gapman Gen3 readings (inch, mil, mm, or um).
• Reading Precision: Select Display to choose the Gapman Gen3 display
resolution from this menu. Select Com Port to choose the readings resolution
when you send and upload the readings over a USB or wireless connection.

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 Testing with the Gapman using the Calibration Software Utility

Calibrating the Gapman Gen3

Trained personnel or supervisors can calibrate the Gapman Gen3 using the
Calibration tab, illustrated in Figure 4.5.

Figure 4.5 Calibration tab

All settings on the tab are pre-set at the factory to the unit and wand specification.
You may need to recalibrate the system occasionally, either as part of normal
maintenance or any time you add a new wand. Capacitec recommends recalibration
every six months to compensate for long term electronic changes.

NOTE: Do not modify the amplitude percentage or calibration gaps. If you need to
make changes to these settings, contact Capacitec for assistance.

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Calibrating the Gapman Gen3

Calibrating the non-contact wand

In the example illustrated in Figure 4.6, a calibration is performed with a GPD-5F

with the measurable range of 0.017" to 0.120". The example illustrates the
calibration using certified gage blocks and the triangular bases. However, the
calibration can also be performed using a certified micrometer in place of the gage
blocks.

Figure 4.6 Non-contact wand calibration example

To calibrate the wand:

1. Ground the target gap using the provided ground cable.

2. Position the wand top sensor facing up and as flat to the triangular base as
possible. This is illustrated in Figure 4.7.

Figure 4.7 Non-contact wand positioning with triangular base

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3. Click Start on the Calibration tab. See Figure 4.8.

Figure 4.8 Calibration tab after starting the calibration

4. Put the 0.120" gage block for Gap 1, as indicated in the Gap 1 field. The setup
is illustrated in Figure 4.9 on page 59.

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Figure 4.9 Gage block positioning for Gap 1

5. Click the Read button corresponding to Gap 1 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.10.

Figure 4.10 Live Counts for Gap 1

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 Testing with the Gapman using the Calibration Software Utility

6. Put the 0.080" gage block for Gap 2, as indicated in the Gap 2 field.

7. Click the Read button corresponding to Gap 2 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.11.

Figure 4.11 Live Counts for Gap 2

8. Repeat Steps 6 and 7 for the gaps three through five. Figure 4.12 on page 61
illustrates the live counts displayed on the Calibration tab.

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Figure 4.12 Live Counts for Gap 3, Gap 4, and Gap 5

9. Turn the Gapman Gen3 and wand over so that the bottom sensor is facing up,
and the wand is as flat to the base as possible. See Figure 4.13.

Figure 4.13 Wand and sensor repositioning for target gap

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 Testing with the Gapman using the Calibration Software Utility

10. Put the 0.120" gage block for Gap 6, as indicated in the Gap 6 field. The setup
is illustrated in Figure 4.14.

Figure 4.14 Gage block positioning for Gap 6

11. Click the Read button corresponding to Gap 6 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.15 on
page 63.

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Figure 4.15 Live Counts for Gap 6

12. Repeat Steps 10 and 11 for gaps seven through ten. Figure 4.16 on page 64
illustrates the live counts displayed on the Calibration tab.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.16 Live Counts for Gap 7, Gap 8, Gap 9, and Gap 10

13. Make sure all the counts are below 55000 and above 350.

NOTE: The Predicted Error values should be less than 0.2% of the first Gap value
(0.120"). If the values are higher than that, try re-calibrating the wand.

14. Click Stop.

15. Click Save to Gapman to save the calibration on the unit.

16. If necessary, save the settings including the Setup and Calibration to a
configuration file (*.XML). The configuration file is helpful if you need to re-
load the setup and calibration into the Gapman Gen3. For instructions, see See
“Saving setting parameters to a configuration file” on page 46.

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Calibrating the Gapman Gen3

Calibrating the contact saber

In the example illustrated in Figure 4.17, a calibration is performed with a GPD-

5D-A-500-FX90 with a measurable range of 0.030" to 0.150". The example
illustrates the calibration using a certified micrometer. However, the calibration can
also be performed using certified gage blocks and triangular bases in place of the
micrometer.

Figure 4.17 Contact wand calibration example

To calibrate the wand:

1. Position the wand top sensor facing up and as flat to the side as possible. This is
illustrated in Figure 4.18 on page 66.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.18 Contact saber wand positioning with micrometer

2. Click Start on the Calibration tab.

3. Put the 0.120" gage block for Gap 1, as indicated in the Gap 1 field, illustrated
in Figure 4.19 on page 67.

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Calibrating the Gapman Gen3

Figure 4.19 Calibration started for Gap 1

4. Click the Read button corresponding to Gap 1 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.20 on
page 68.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.20 Live Counts for Gap 1

5. Adjust the micrometer so that the Gap is 0.090" as shown for the Gap 4 value,
as indicated in the Gap 4 field.

6. Click the Read button corresponding to Gap 4 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.21 on
page 69.

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Calibrating the Gapman Gen3

Figure 4.21 Live Counts for Gap 4

7. Adjust the micrometer so that the Gap is 0.060" as shown for the Gap 7 value,
as indicated in the Gap 7 field.

8. Click the Read button corresponding to Gap 7 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.22 on
page 70.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.22 Live Counts for Gap 7

9. Move the micrometer or the contact saber so that the top side of the contact
saber is as flat to the gap as possible. The setup is illustrated in Figure 4.23 on
page 71.

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Calibrating the Gapman Gen3

Figure 4.23 Micrometer and contact saber positioning

10. Adjust the micrometer so that the Gap is 0.130" as shown for Gap 2 value.

11. Click the Read button corresponding to Gap 2 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.24 on
page 72.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.24 Live Counts for Gap 2

12. Adjust the micrometer so that the Gap is 0.090" as shown for Gap 5 value.

13. Click the Read button corresponding to Gap 5 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.25 on
page 73.

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Calibrating the Gapman Gen3

Figure 4.25 Live Counts for Gap 5

14. Adjust the micrometer so that the Gap is 0.060" as shown for Gap 8 value.

15. Click the Read button corresponding to Gap 8 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.26 on
page 74.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.26 Live Counts for Gap 8

16. Move the micrometer or the contact saber so that the contact saber is as
paralleled to the target gap as possible. The setup is illustrated in Figure 4.27 on
page 75.

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Calibrating the Gapman Gen3

Figure 4.27 Micrometer and contact saber positioning

17. Adjust the micrometer so that the Gap is 0.130" as shown for Gap 3 value.

18. Click the Read button corresponding to Gap 3 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.28 on
page 76.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.28 Live Counts for Gap 3

19. Adjust the micrometer so that the Gap is 0.090" as shown for Gap 6 value.

20. Click the Read button corresponding to Gap 6 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.29 on
page 77.

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Calibrating the Gapman Gen3

Figure 4.29 Live Counts for Gap 6

21. Adjust the micrometer so that the Gap is 0.060" as shown for Gap 9 value.

22. Click the Read button corresponding to Gap 9 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.30 on
page 78.

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 Testing with the Gapman using the Calibration Software Utility

Figure 4.30 Live Counts for Gap 9

23. Adjust the micrometer so that the Gap is 0.033" as shown for Gap 10 value.

24. Click the Read button corresponding to Gap 10 to record the Live Counts into
the Top Counts and Bottom Counts fields, as illustrated in Figure 4.31 on
page 79.

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Calibrating the Gapman Gen3

Figure 4.31 Live Counts for Gap 10

25. Make sure all the counts are below 55000 and above 350.

NOTE: The Predicted Error values should be very small. If the values are too
high, then try re-calibrating the wand.

26. Click Stop.

27. Click Save to Gapman to save the calibration on the unit.

28. If necessary, User save the settings including the Setup and Calibration to a
configuration file (*.XML). The configuration file is helpful if you need to re-
load the setup and calibration into the Gapman Gen3. For instructions, see See
“Saving setting parameters to a configuration file” on page 46.

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80 Gapman Gen3 User Manual

CHAPTER 5 Troubleshooting

This chapter details what types of hardware and software-related errors you may
encounter when using the Gapman Gen3, how to report them, and how to perform
troubleshooting techniques yourself to recover from them. Where appropriate,
alternate suggestions or workarounds are detailed.
There are no user serviceable parts inside the Gapman Gen3. Only the batteries and
wand should ever be changed in the field. If you find that the operation of the unit is
not proceeding as expected, Capacitec recommends that a supervisor connect it to a
PC and produce all of the reports and examine them.

If you encounter problems that do not contain solutions documented in this chapter,
you can contact Capacitec for assistance.

Hardware problems
The following sections detail hardware problems and their possible solutions.

Problem
My gap measurement readings are not accurate, or are not consistently what is
expected.

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 Troubleshooting

Possible Solutions

1. Make sure the surfaces being measured should be clean and free of debris
moisture and oils (or other materials).

2. If you are using a contact saber, make sure the wand top sensor is facing up and
as flat to the side as possible.

3. If you are using a non-contact wand:

A. Make sure that the target is grounded to the Gapman Gen3 using the
provided banana plug. Make sure your target is connected as directly as
possible to the ground snap on the side of the Gapman Gen3 or your
readings might be inaccurate.

B. Position the wand top sensor facing up and as flat to the triangular base as
possible.

4. If you are conducting flat gap measurements, slowly rotate the wand around
inside the gap. This provides the Gapman Gen3 with a wide range of readings,
allowing it to select the most accurate readings.

Problem

When I turn the unit on, the startup screen does not appear.

Possible Solutions

1. Make sure the batteries are properly installed and do not need to be changed.

2. Make sure the switch is turned towards the battery or external power as
appropriate.

3. If you need to change the batteries, remove the cover with a small, flat
screwdriver. The screw, if not unscrewed all the way, will remain in the cover.
Remove the batteries by gently prying up the positive (+) end (the one that is
not touching the coil spring). After removing the batteries, replace them with
fresh ones. Replace the cover and turn the unit on to continue.

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Software problems

Software problems
The following sections detail software problems and their possible solutions.

Problem

The calibration function is not enabled.

Possible Solutions

Contact Capacitec for a password to enable the tab that contains this functionality.

Problem

Microsoft Windows does not recognize the Gapman Gen3 when you connect the
USB cable from the unit to the PC, the PC.

Possible Solutions

1. Turn on the Gapman Gen3 and the PC.

2. Install the USB driver software.

3. Make sure you select your comm Port number on the data collector to configure
the device in Windows.

4. If you are using data collector software not provided by Capacitec, configure
the Comm port using PuTTY.

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 Troubleshooting

84 Gapman Gen3 User Manual