LDS

Laser Diffraction Sensor

User's manual.
Version : 14.3.0
© 2019 CERSA-MCI

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13480 Cabries. FRANCE
tel: +33 (0)4 42 02 60 44
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web: http://www.cersa-mci.com
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 2 Part I: Introduction

Part I: Introduction
The LDS (Laser Diffraction Sensor) is specially built for dimensional measurements in wire
industry. It measures the diameter with high accuracy on 1 or 2 axes (depending on the version).
Its measurement principle is based on laser diffraction. This method is position and vibration
independent.
With 2 axes, it gives well enough, an indicator of roundness in line process.
The WSR (Wire Sample Rotation) and Foot Pedal accessories are reliable tools used in
laboratory to certify and qualify the production. It integrates in one single instrument the diameter,
the ovality measurement as well as event management and recording.

The LDS instrument uses the latest technology to give the maximum performance.

Main Advantages
Accurate diameter measurement.
Full ovality measurement with WSR accessory.
Vibration measurement independent.
Real time tolerances checking.
Cable position measurement.
Spool length and speed computing.
Compact and hardened industrial instrument.
Local display of measures and parameters.

CERSA-MCI develops and produces also complementary high performance measurement

instruments for wire, cable, tube industry and optical fiber production.

LDS user's manual Version : 14.3.0

 Part II: Specifications 3

Part II: Specifications

1 General specifications
DIAMETER MEASUREMENT
Model : LDS0200 LDS0650 LDS0800 LDS2000

Range : 5-200 µm 15-650 µm 18-800 µm 50-2000 µm

Repeatability +/- 0.03 % of the diam eter
Minimum repeatability: 0.01 µm 0.03 µm 0.04 µm 0.1 µm
Uncertainty: Depends on standard w ire uncertainty +/- 0.1µm
Remarks: All specification include slow ambient temperature fluctuation w ithin 10-
40 °C.
Includes w ire moves w ithin the measurement area
Number of axis : 1 or 2 (both versions are available)
Internal measurement frequency : 400 Hz (no averaging required)
Vertical measurement area : +/- 1.5 m m
Horizontal measurement area : unlim ited
Vertical w ire tilt tolerance: +/- 1.0 °

ANALOG OUTPUT
Quantity : 1 (for diameter control)
Type Voltage Current
Range : ±4V 0-20mA or 4-20mA
Updating frequency 400Hz
Voltage (Av) or current (Aa) option must be specified at order.

DIGITAL OUTPUTS (Open collectors)

For alarms, tolerances...(user configurable)
Quantity : 2 (or 1 if length reset input is used)
(I) option must be specified at order

DIGITAL INPUTS
For WSR, Foot pedal, length counting and length reset.
Quantity : 2
(I) option must be specified at order

DISPLAY AND KEYBOARD

Display 7 segments 4 digit LED display.
Keyboard 3 boutons keyboard for tolerance configuration and length - speed display.
(D) and (K) option must be specified.

RS232 COMMUNICATION
Used to connect the instrument to CIM softw are
Baudrate : user configurable (38400 to 115200)
Maximum cable length : 35 meters (certified only w ith cables supplied by CERSA)

ENVIRONMENTAL CONDITIONS:
Ambient w orking temperature : 10 - 40 °c
Maximal w orking internal temperature : 55 °c
Storage temperature : 0 - 60 °c

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 4 Part II: Specifications

2 Mechanical design
LDS-1 (one axis version):

Weight: 0.9 kg

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 Part II: Specifications 5

LDS-2 (two axes version):

Weight: 2.2 kg

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 6 Part III: CIM software

Part III: CIM software

C.I.M. software (CERSA Instruments Manager) is a PC environment to manage all CERSA-MCI
instruments. It provides a complete set of comprehensive tools to improve and master the
production process as well as all features to certify the whole production specifications.
Refer to CIM manual for further details.

1 Production environment
Main features in production :
Monitoring the process in real time.
Data logging and export (database).
Product definition and configuration.
Production reports.
Instruments configuration and maintenance.

2 Laboratory environment
Main features in laboratory :
Wire/cable sample dimension analysis.
Statistical analysis and reports.
Sample classification with customizable fields
User login management.
Data logging into database.
Instruments configuration and maintenance.

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 Part III: CIM software 7

Wire sample acquisition

WSR FP
Wire sample Foot pedal
rotation

Chart view

Statistics

Sample 1 Sample 2

Data logging and

samples classification

Group A Group B

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 8 Part IV: Measures and principle

Part IV: Measures and principle

1 Generalities
1.1 Available measures
Here below is the list of measures transferred from the instrument to CIM.

Measure unit Description access

level
Diameter [µm] Value of the outer diameter. user
Diameter [µm] Diameter peak to peak value. Gives the stability of the supervisor
PP diameter.
Speed [m/min.] Value of the production speed. user
mmin
Speed ms [m/s] Value of the production speed. user
Temp. [°C] Value of internal temperature of the instrument. Should supervisor
not exceed 55°.

1.2 Events
It is a particular phenomenon that is detected by the instrument. Events are detected in real time,
dated (3ms accuracy) and located (product length). Each event is also characterized by its
extremum value.

Here below is an example of high speed diameter fluctuation which exceeds the tolerances.

Here below is the list of events transferred from the instrument to CIM:
Event unit Description access
level
Diameter [µm] Diameter event is generated in case of out of tolerances. user
Status General status of the instrument. user

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 Part IV: Measures and principle 9

1.3 Real time scopes

Because the measurement frequency of the instrument is very high, it is impossible to transfer all
measures in real time to the computer through RS232.
The instrument stores the main measures continuously in internal buffers of 500 points each .
This function is called Real Time Scope.

Those buffers can be watched through CIM. Only few buffers per seconds can be watched,
because of communication constraints.

The sampling period of each buffer can be modified, depending on the time scale you want to
analyse.

Those tools are very useful for process analysis to qualify the stability, the regulation performance,
and display some particular effects. The F.F.T. processing shows specific oscillations. We
recommend strongly to the process engineer to use those tools for understanding and
improvement of the manufacturing process.

2 Diameter
2.1 Optical principle and structure
Diameter measure is based on Diffraction principle.

2.2 Diffraction scope

This scope shows 1 signal:
CCD diffraction axis 1: Light energy vs pixel. It shows the signal acquired by the CCD.

This scope is used for maintenance purpose to check the signal quality.

Results displayed in the scope:

Diameter: the diameter measure corresponding to the displayed signal.
Status: the alarm code corresponding to the displayed signal.
Amplitude: the fringes amplitude. The value of this parameter allows you to evaluate the good
behavior of the measurement.

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 10 Part IV: Measures and principle

2.3 Real time diameter scope

This scope shows 1 signal:
Real time diameter diffraction: Diameter vs time. It displays real time diameter fluctuations.

This scope is interesting for process study and analysis. It can show high speed phenomenon,
such as diameter oscillations.

The following parameter can be adjusted:

Sampling period [ms]: Represents the duration between 2 storages inside the buffer. It is
used to adapt the time scale. Minimum value: 2.5ms.

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 Part V: Connexions and Interfaces 11

Part V: Connexions and Interfaces

1 Rear panel

OK = Smooth blink NOT USED

ALARM = Fast blink

SUB-D 9
CONNECTOR

DIGITAL I/O NOT USED

CONNECTOR

2 SUB-D 9 connector
This connector integrates:
power supply
serial link (RS232)
Pulse input for length counting

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DB9 Pins nb. IN/OUT Signal

1 IN Pulse input for length counting
6 Negative supply
2 do NOT connect
7 IN Positive supply
3 RS232 gnd
8 OUT RS232 TX
4 IN RS232 RX
9 Do NOT connect
5 Do NOT connect

2.1 External power supply and cable

The power supply inputs are floating.
Max input voltage: 36V
Min input voltage: 18V
Reverse voltage protected
Supply current: 0.55A @ 24V

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 Part V: Connexions and Interfaces 13

The instrument comes with its CERSA MCI’s power supply and cable. This power supply provides
+24V volts rectified and filtered DC voltage with a power of 15W isolated from ground.

A short-circuit protection is included.

Input voltage : from 100V to 240V AC, 50 to 60 Hz.

2.2 Serial link

Communication cable should be shielded.

Communication settings:
baudrate: 115200 bauds (configurable through CIM software)
data bits: 8
parity: even
stop bit: 1

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 14 Part V: Connexions and Interfaces

2.3 Length counting use

Opto-isolated input referenced to the negative supply (reverse voltage tolerant)
Minimum voltage to ensure a high level input : 7,2V
Maximum voltage to ensure a low level input : 2V
sunk current : 4,8mA @ 7,2V. Input impedance : 1200 ohms
If you connect the length counting signal and the reset signal, the instrument will compute the
speed and length with the same reference as your production system. It allows the instrument to
locate accurately all events in the spool. It can help you to determine the portion of product to
reject.

The length counting interface has to be configured under CIM software (Parameters manager /
Digital interface) with the following parameters:

Pulses number: The number of pulses for 1 meter length.

Slip factor: in case of the real speed and the measured speed are not perfectly correlated, you
can adjust this factor. This multiplication factor is applied to the measured speed. Default value:
1.0

3 6 pins digital I/O connector

IN/OUT connector is a circular HIROSE HR10 series 6 pins.

2 floating Inputs / outputs. The direction of each I/O (input OR output) is individually configurable
through the CIM sofware.
The instrument comes with a 5m cable, with compatible connector.

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 Part V: Connexions and Interfaces 15

Corresponding
Pin color on CERSA Description
Number cable
1 White Analog output tension or current (if Av or Aa options specified).
Or
Protected 24V coming from input power supply.
2 Brown Analog return (floating) (if Av or Aa options specified).
Or
Return from input power supply
3 Green digital I/O 1 +
4 Yellow digital I/O 1 -
5 Grey digital I/O 2 +
6 Pink digital I/O 2 -

3.1 Digital Input/Output

Outputs:
Bidirectional floating static relay : 48V / 1A
The logical state when the output is activated is configurable through the CIM software (Output
active high or output active low)
Output active high means that the internal static relay is open when the output is active.
Output active low means that the internal static relay is closed when the output is active.
The signal to be associated with the output pins is configurable through the CIM software

Input states:
Unidirectional opto-isolated input (reverse voltage protected).
Minimum input voltage (IO+ to IO-) to ensure an active input : 5,6V
Maximum input voltage (IO+ to IO-) to ensure an inactive input : 3V
Sunk current : 2mA @ 5,6V, input impedance 2,2k_ohm

IO in OUTPUT configuration :

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IO in INPUT configuration :

Remark:
Lamp, Load and Relay are shown as user application examples.

Settings:
Hold Time Event IO (ms): The time in milliseconds during which the output is maintained
activated even if the configured event has disappeared. Can be useful for "slow" PLC, to be sure
that the output activation will be taken into account properly.

Signal : Events that can be attached to an IO are the following ones :

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 Part V: Connexions and Interfaces 17

Output signals Description when activated

No signal No signal is attached to the output ; the output is maintained inactive
Position Out The object is out of the measurement area
High Diameter The object diameter is over the high tolerance of Diameter measure
Low Diameter The object diameter is lower than the low tolerance of Diameter
measure
Lump & Neck A lump or a neck has been detected accordingly to the parameters
Wrong Position The object position is not correct
Lump A lump has been detected accordingly to the parameters (necks have
no effect)
Neck A neck has been detected accordingly to the parameters (lumps have
no effect)
High - low diameter An out of tolerance on the diameter measure has been detected, either
high or low.
Global Alarm An error has been detected and the instrument is not available for
measurements. That means that an error code is displayed on the local
display.
L&N Length Not used in this instrument
Diameter osc. A diameter oscillation has been detected by FFT analysis accordingly
to the parameters
Warning High Diam The object diameter is over the warning high threshold
Warning Low Diam The object diameter is lower than the warning low threshold
War+Out low Diam The object diameter is lower than the warning low threshold or lower
than the low tolerance.
War+Out high Diam The object diameter is over the warning high threshold or over the high
tolerance.
War High+Low Diam The object diameter is either over the warning high threshold or lower
the warning low threshold
War+Out Diam An out of tolerance, either high or low, or a warning threshold, high or
low, has been detected.
Combinatory_1 Global Alarm or L&N Length
Combinatory_2 Global Alarm or Lump or High Diameter

Input signals Description when activated

No signal No signal is attached to the input ; the input has no effect
Spool Reset Reset the spool time and spool length computed by the instrument and
displayed under CIM to localise the events.

3.1.1 Digital Input/Output parameters

Here below is the list of parameters transferred from the instrument to CIM.

Measure unit Description access

level
Hold time [ms] Represents the minimum time that a digital output is supervisor
event IO activated if the correspondig event is detected.
IO 1 Electrical configuration in input/output 1. supervisor
configuration
IO 1 signal Signal configured for input/output 1. supervisor
IO 2 Electrical configuration in input/output 2. supervisor
configuration
IO 2 signal Signal configured for input/output 2. supervisor
Test digital Test of toggling digital outputs. supervisor

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 18 Part V: Connexions and Interfaces

output
Trigger mode Instrument trigger mode. For example: wire sample supervisor
rotation, foot pedal.
Wait time test [ms] Represents the waiting time that exist if the test is supervisor
output activated.

4 Analog Output
Floating analog output.
Depending on the option chosen at the order, the output signal will be defined as a current loop or
as a voltage.
The associated measurement to this output is the diameter.

Specifications for current loop option :

Current range: 0-20mA or 4-20mA (CIM software configurable)

Resolution: 10uA
Accuracy: +/-100uA
Max voltage: 15V @ 20mA, overvoltage protection @ 48V
Min voltage: 3V

The current is sunk by the instrument. An external biasing is needed (the instrument interface
is passive).
2 solutions can be used :

Specifications for voltage output :

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 Part V: Connexions and Interfaces 19

Voltage range: +/-4V

Output impedance: 100 to 200 ohm
Max output current: 10mA
Resolution: 2mV
Accuracy: ±50mV

Remarks:
Output scales are adjustable with the following parameters under CIM software (Parameters
manager /Analog interface):

Zero point: When the measured value reaches the zero point value, the corresponding analogical
output is set to 0V. The unit of the zero point is the same as the corresponding measure.
Scale: Is the number of volts per measure unit. For example for diameter in millimeters 2 [V/mm]:
if the measure varies of 1mm the value of analog output varies of 2 Volt.
Regulation: If this option is activated, then the zero point value is automatically forced to the
nominal tolerance value of the corresponding measure. Otherwise the zero point can have any
value.
Average time: Is the average time used to compute the analog output signal.

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 20 Part V: Connexions and Interfaces

4.1 Analog Output parameters

Here below is the list of parameters transferred from the instrument to CIM.

Measure unit Description access

level
BNC 1 avg. [ms] Average time used to compute the analog signal in supervisor
time output 1.
BNC 1 Electrical configuration in output 1. supervisor
configuration
BNC 1 Measure type in output 1. supervisor
measure
BNC 1 pos. out [V or In case of position out, the voltage value to apply on BNC supervisor
val. A] 1.
BNC 1 Force zero point value to nominal tolerance value in supervisor
regulation output 1.
BNC 1 scale Number of volts per measure unit in output 1. supervisor
BNC 1 zero Measure value corresponding to 0 volts in output 1. supervisor
point
Force value [V or Value to force analog outputs test. supervisor
mA]
Test DAC List of analog outputs tests. supervisor

5 LCD display and keyboard

At start-up, after the led display self test, the led panel displays the serial number of the
instrument.

Then, the led panel displays the measured diameter in µm.

The green "RUN" led is blinking, indicating that the instrument is measuring properly.

In case of an instrument's error, the led panel will alternately display the last measured diameter
and the error code "EXXX", with XXX the corresponding error code. The red "ALARM" led will then
be lighted.

The keyboard can be used to modify some instrument's parameters as described hereafter :

Action Led panel Display Explanation

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 Part V: Connexions and Interfaces 21

Enter the settings menu

Nominal Diameter in micrometers

150.0 Use keys to modify the value

H
1 second

High Diameter tolerance in micrometers

10.0 Use keys to modify the value

L
1 second

Low Diameter tolerance in micrometers

10.0 Use keys to modify the value

Prog Exit the settings menu. All the parameters are

written into the EEPROM’s instrument

Notes:

The keyboard can be inhibited through the CIM software. In that case, the settings menu is then
no more available through the keyboard.

The led display can be inhibited through the CIM software. In that case, only the error codes are
displayed in case of errors. The measured diameter won't be displayed.

To change the values of tolerances with bigger increment keep hold buttons.

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 22 Part VI: Instrument settings

Part VI: Instrument settings

A full set of parameters can be adjusted using CIM software.

Remark:
All parameters are stored and saved in an embedded EEPROM.

1 Tolerances
The instrument monitors in real time if the measures are in or out of the product tolerances.
In case of out of tolerance, the instrument will act as follow:
Digital output state will change. Refer to the Digital I/O chapter.
Data are transferred to CIM which will show events with full details about dating, positioning and
extremum values.

Here below is the logic used for tolerance control:

Measure > Nominal tolerance + Warning high tolerance EVENT WARNING HIGH (Not yet
available)
Measure < Nominal tolerance - Warning low tolerance EVENT WARNING LOW (Not yet
available)
Measure > Nominal tolerance + Out high tolerance EVENT OUT HIGH
Measure < Nominal tolerance - Out low tolerance EVENT OUT LOW

Here below is the full list of tolerances parameters that can be adjusted with CIM software
(Parameters manager /Tolerances):
Parameter unit Description access level

Avg. time diameter [ms] Time during which the diameter will be averaged to supervisor
compute out of tolerances. (enter zero to disable)
Hold time event [ms] Represents the minimum time that diameter event is supervisor
diameter activated if detected.
Nominal diameter [µm] Nominal diameter value. user
Out high diameter [µm] Maximum diameter tolerance. (enter zero to disable) user
Out low diameter [µm] Minimum diameter tolerance. (enter zero to disable) user
Out high temperature [°C] Maximum internal temperature of instrument. supervisor

2 Measure parameters
Here below is the full list of measures parameters that can be adjusted with CIM
software(Parameters manager /Measures):

Parameter unit Description access

level
Avg. time display [ms] Averaging time of the diameter measure shown on the supervisor
diam. local display and transferred to CIM.
DiamPP cmpt. [s] Time interval for diameter peak to peak analysis. supervisor
time
Exposure time Ratio between the default exposure time (factory supervisor
ratio configuration) and effective exposure time.
Pos. out tempo [s] If the object to measure leaves the measurement area supervisor

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 Part VI: Instrument settings 23

during this time, it is considered as position out. All

measures are forced to init value.

3 Interface parameters
Here below is the full list of interface parameters that can be adjusted with CIM
software(Parameters manager / Informations / Interface):

Parameter unit Description access

level
Keyboard enabled Enable or disable keyboard. supervisor
Display enabled Enable or disable measurement in LCD interface. Alarms supervisor
are always displayed.
Print label prefix String used for label printing. supervisor
Print label serial Initial value for serial number used for label printing. supervisor
Diameter unit Configures the unit used for LCD displaying. (µm or supervisor
mils).

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 24 Part VII: Installation on the line

Part VII: Installation on the line

1 Mounting
You must have the ability of a manual adjustment for the position of the instrument on the wire
axis.
The wire should pass in the center, perpendicular to the instrument casing.

LDS-1 (one axis version):

A correct adjustment is obtained when the wire is tangent with the "T bars" when they are in the
high position.
When adjusted, the "T bars" must be pushed down to avoid the wire coming into contact with
them while the machine runs.
The wire can vibrate around this central position (+/-2 mm).
Wire axis

High position
mark

Adjustment Running
conditions conditions

T bar

LDS-2 (two axes version):

Two guiding bars help to the mechanical alignment of the instrument on the machine. These 2
guiding bars have 2 positions:
1. Retracted during production.
2. Completely released for position adjustment, a correct adjustment is obtained when the wire
is tangent inside the "V" shape of the guiding bars.

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 Part VII: Installation on the line 25

Guiding bar
Adjustment
conditions

Running Wire axis

conditions

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 26 Part VIII: Laboratory use

Part VIII: Laboratory use

1 Wire laboratory support
This accessory is used to place properly the wire in the optical field in order to make single
measurement.

1.1 Mounting
1. Insert the support containing the horizontal bar inside the hole of second support.
2. Be careful to position the second support by keeping the curved side outwards.
3. Insert the support in the LDS.

Flat side 2 Curve side

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 Part VIII: Laboratory use 27

1.2 Wire handling

Place the wire sample on the support and pull the two ends.
The sample must be straight

2 Wire Sample Rotation (WSR)

For fine die and wire, we propose complementary tool in order to easily fix, tighten and rotate the
wire samples at constant and adjustable tension for accurate diameter and ovality measurement.
The ergonomic design is made to handle easily and quickly.
We propose 2 models of WSR:

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 28 Part VIII: Laboratory use

WSR-F WSR-S

WSR-F WSR-S
Wire sample rotation for Fine wire Wire sample rotation Standard
Diameter range: < 100µm 50 to 450µm

Fixing method double face adhesive tape clamps

2.1 WSR-S. Spring adjustment

The following accessories are delivered together with your WSR-S:

6mm screw 6/7mm hexagonal key

for spring exchange and
length adjustment
7mm screw

Tool for cursor removing

(spring exchange)

spring #3

spring #1

The internal spring can be adjusted in order to respect the following conditions:
the wire must be straight in order to obtain an accurate measurement
a too high strength (traction) can elongate the sample, and then modify its diameter.

Refer to the following table for spring choice (#1, 2 or 3) and length adjustment.

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 Part VIII: Laboratory use 29

The spring #2 is factory mounted.

Annealed Annealed Cold drawn Alloyed Cold drawn

copper stainless copper stainless
steel steel
Elastic resistance(daN/mm²) 7 20 30 50 80

Diameter (µm) Section Max strength (daN or Kg) to avoid wire elongation
(mm²)
20 0.0003 0.002 0.006 0.009 0.016 0.025
40 0.0013 0.009 0.025 0.038 0.063 0.101
60 0.0028 0.020 0.057 0.085 0.141 0.226
80 0.0050 0.035 0.101 0.151 0.251 0.402
100 0.0079 0.055 0.157 0.236 0.393 0.628
120 0.0113 0.079 0.226 0.339 0.565 0.905
140 0.0154 0.108 0.308 0.462 0.770 1.232
160 0.0201 0.141 0.402 0.603 1.005 1.608
180 0.0254 0.178 0.509 0.763 1.272 2.036
200 0.0314 0.220 0.628 0.942 1.571 2.513
220 0.038 0.266 0.760 1.140 1.901 3.041
240 0.045 0.317 0.905 1.357 2.262 3.619
260 0.053 0.372 1.062 1.593 2.655 4.247
280 0.062 0.431 1.232 1.847 3.079 4.926
300 0.071 0.495 1.414 2.121 3.534 5.655
320 0.080 0.563 1.608 2.413 4.021 6.434
340 0.091 0.636 1.816 2.724 4.540 7.263
360 0.102 0.713 2.036 3.054 5.089 8.143
380 0.113 0.794 2.268 3.402 5.671 9.073
400 0.126 0.880 2.513 3.770 6.283 10.053
420 0.139 0.970 2.771 4.156 6.927 11.084
440 0.152 1.064 3.041 4.562 7.603 12.164

Spring # Relax length Initial Minimum Minimum Maximum Strength /

length in strength length strength length
the WSR (daN) (mm) (daN) (daN/mm)
(mm)
1 53 38.6 0.129 12.8 0.360 0.009
2 44.5 38.6 0.136 15.1 0.670 0.023
3 38.6 38.6 0 16.2 1.3 0.058

By rotating the 6mm screw, you can adjust the spring length, and then the strength.
The spring length is readable with the cursor

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 30 Part VIII: Laboratory use

6mm screw

cursor moves when rotating the screw

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 Part VIII: Laboratory use 31

2.2 WSR-S. Spring exchange

If you want to exchange the spring, you first have to remove the cursor:

unscrew and remove

the cursor with
special tool

Then you will remove the spring by unscrewing the spring support:

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 32 Part VIII: Laboratory use

7mm screw

Unscrew and remove

the spring support

Finally, you replace you spring, put back the spring support and screw it.
Don't forget to put back the cursor!

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 Part VIII: Laboratory use 33

2.3 WSR mounting and configuration

First, you must remove one optic protection to not block the WSR mounting:
Warning: When removing the optic protection, take care to not hurt the opposite lens!
to remove the protection, you must rotate and pull on at the same time.

Then you put the WSR inside the LDS:

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 34 Part VIII: Laboratory use

Plug I/O connector

Screw on both side to fix WSR

on LDS

Configure the trigger mode to "WSR" in CIM software (Parameters manager -> Digital interface -
> Digital I/O) .

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 Part VIII: Laboratory use 35

2.4 WSR-S, Wire handling

Important: The central part of the wire must not be touched else must be cleaned, otherwise
measurement accuracy will decrease a lot.

3 3

1: Tighten the wire with a suitable distance between your 2 hands to easily operate the clamps
2: Push the right clamp in order to compress the internal spring
3: Open both clamps
4: Put the wire inside and release clamps

Clamp is close Clamp is open

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2.5 WSR-F, Wire handling

Important: The central part of the wire must not be touched else must be cleaned, otherwise
measurement accuracy will decease a lot.

Tighten the wire with a suitable distance between your 2 hands to easily fix the wire.

Adhesive tape wheel for tension adjustment

The wire is fixed with double-face adhesive tape.

You must twist the wire around both side support.

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 Part VIII: Laboratory use 37

wire must pass inside the pulley

Then you must turn the right-side wheel in order to apply a tension on the wire.
The target is to make the wire straight, but you must take care to not pull too much on it to avoid
elongation (diameter reducing)

2.6 Wire sample acquisition (rotation)

Rotate the crank of 360deg. Total rotation time must be around 2-10 seconds.
The system includes an angular encoder.
Only the number of points will change according to the rotation speed.
We recommend a minimum of 100 points to have measurement results independent on the
rotation speed.

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 38 Part VIII: Laboratory use

During the rotation, the instrument displays the angular position from 0 to 180deg

2.7 Results reading

At the end of the rotation, measurement results are displayed on the local display.
By pushing on the red button, you switch between a mnemonic code and the measurement result
in the following way

Display example Explanation

-
Average diameter
40.25

H
Maximum diameter during rotation
40.42

L
40.11 Minimum diameter during rotation

E
0.31 Wire ovality (max - min)

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 Part VIII: Laboratory use 39

240 Number of measurement points during

rotation

We recommend to use CIM Lab software in order to benefit from data logging, and statistics
features.

3 Foot pedal
The foot pedal is used in laboratory conditions in order to send acquisition order to the instrument
by keeping your hands free.
It must be used together with the "Wire laboratory support". See wire laboratory support chapter
for more details.

3.1 Foot pedal connexion and configuration

Plug I/O connector

Plug the Digital IO cable in rear panel of the instrument.

Configure the trigger mode to "FOOTPEDAL" in CIM software (Parameters manager -> Digital
interface -> Digital I/O) .

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3.2 Foot pedal acquisition and results

In order to have representative statistics of your wire sample:
Move and turn the wire during the acquisition.
Acquire a sufficient number of points.

We describe here below the procedure for acquisition:

1. Place the wire sample on the wire laboratory support.

2. By a short press on the pedal, the LDS stores the point, and then the number of stored points
is incremented and displayed.

Display example

1 ... 2 ... 99
You can store a maximum of 99 points.

3. By a long press (3seconds) on the pedal, you close the acquisition.

Display

End
4. The statistics of acquisition are displayed with the following sequence
Display example Explanation

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 Part VIII: Laboratory use 41

476.8 Average diameter

H
476.9 Maximum diameter.

L
476.6 Minimum diameter

If you want to display it again, you just have to make a long press again.

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 42 Part IX: Maintenance, security and troubleshooting

Part IX: Maintenance, security and

troubleshooting
1 Optical system cleaning
The lenses cleaning should be performed regularly depending on the environment.
In most of the cases, a simple dry air blowing action each month into the lenses protection is
sufficient.
Remember that dusts on the lenses degrade the measurement’s accuracy.

Clean from the

Clean with cotton center to the edge
and alcohol

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 Part IX: Maintenance, security and troubleshooting 43

To clean the lenses, please follow this procedure:

1. Unplug the power supply.
2. Remove the optic protection.
3. Use dry air to eliminate the biggest particles.
4. Use cotton or dry tissue with IPA (IsoPropylic Alcohol) and clean carefully each lens.
5. Check visually the surface of the lenses.
6. Replace the mechanical protection.

Warning: When removing the optic protection, take care to not hurt the opposite lens!
to remove the protection, you must rotate and pull on at the same time.

2 Calibration and accuracy

2.1 Overview
We describe here the way CERSA-MCI proceeds to calibrate and linearize LDS instruments in
order to benefit the maximum of their performance. It indicates also how we can certify the
maximum uncertainty of the instruments.

In cooperation with fine wire specialized foreign national laboratories and university, CERSA-MCI
has developed a complete process for ultra fine wire calibration and the linearization of its LDS
instruments. We also have developed a complete test and validation procedure to certify the
performance of each instrument. That opens the way to very demanding applications like gold
wires.

2.2 Partner reference laboratories

National laboratories:

METAS, Switzerland, Lindenweg 50, CH3003 BERN-WABERN

NIST, USA, 100 Bureau Drive, Stop 8211, GAITHERSBURG MD 20899-8211

Private laboratory:

CARY (TESA Division), Switzerland, Rue de France 55, CH2400 LE LOCLE

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2.3 Metrological certificates

The following certificates (available on demand) certify our “original reference wires”:

April 04th 2005: CARY certificate # 33001.05201, 33002.05201, 33003.05201, 33004.05201,

33005.05201

January 19th 2006: CARY certificate # 33301.06119, 33302.06119, 33303.06119, 33304.06119,

33305.06119, 33306.06119, 33307.06119, 33308.06119

February 20th 2006: CARY certificate # 33003.06151

May 11th 2007: NIST certificate # 821/274945-07

July 07th 2007: NIST certificate # 821/275229-07

October 10th 2010: METAS certificate # 111-05211

May 14th 2013: METAS certificate # 111-08151

2.4 CERSA reference LDS instruments

The diffraction instruments are not absolute (reference) measurement instruments. At the
opposite, the CERSA-MCI instruments benefit of an exceptional repeatability and long term
stability. Then, the key point is to give them measurement references at the level of their
performance. To do that we use reference wires measured by international laboratories,
compared with theoretical analysis. We proceed as follows:

1. From different high quality stainless steel wires with a very good surface quality and limited
ovality we produce wires on supports from 30µm to 2mm.

2. 20 wires have been sent to the specialized reference laboratories for calibration to become our
“original reference wires”. An official document keep in CERSA-MCI certifies the calibration
of these wires. The full uncertainty is given within ±0.15µm. They are kept in CERSA under
safety conditions.

3. We keep permanently swithced ON one LDS of each range (0200, 0800, 2000) named
“reference instrument”. Those instrument are calibrated and linearized with the certified
“original reference wires”.

4. From the “original reference wires”, we generate a regression curve, which represents the
shape of the diffraction deviation, in order to minimize the uncertainties of each individual wire
This is the finest way to reference the instruments at its level of performance.

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 Part IX: Maintenance, security and troubleshooting 45

The deviation of all wires from the regression curve is within ±0.1µm and mainly ±0.05µm.
The regression curve accuracy is better than the “reference wires”.

2.5 CERSA standard wires. SWB

From the same source of wires, we generate pieces of wires on supports which are calibrated from
the reference instruments. These wires are delivered to our customers by sets 4 wires in a box to
check at the measurement stability of each instrument.
We recommend you to purchase a set of standard wires together with your LDS for periodical
checking.

Here below are the available diameters:

Reference Wire 1 Wire 2 Wire 3 Wire 4
SWB0200 30 90 140 190
SWB0800 30 190 400 800

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SWB2000 90 400 1000 2000

values in µm

2.6 Customer linearization

The feedback shows that measure is stable year after year. There is no deviation over the time.
Nevertheless, if you really need to adapt your measure to your references (kind of material: gold,
copper, tungsten, etc...) please proceed to the following points:

1. Wait for the temperature stabilization for at least 1 hour.

2. Be sure of the cleanness of the optical system.
3. Check the diameter calibration with your reference wires (SWB). If deviation appears you need
to be sure that this deviation comes from the instrument and not from reference wires.
4. Install TLBXlindiametre_lds software in your computer.
5. Restart CIM software and go to Toolbox
6. Launch CIM software and add your device to the connections list. Launch TLBXlindiametre
application. (Please refer to CIM manual for more details).
7. Select the instrument if you have more than one device connected to CIM.

The linearization graph display the standard diameter versus the diffraction diameter in blue color.
In order to underscore the non linearity of the curve the software display the difference between the
standard value and the diffraction value with red dots.
In these conditions (Regression deactivated) the instrument will use linear approximation between
points of this table.

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 Part IX: Maintenance, security and troubleshooting 47

Another solution consists in using an order 3 regression curve (A0 + A1 * Diameter + A2 *

Diameter ^2 + A3 * Diameter ^3).
You need more than 3 points to use this approach. Select "Regression" parameter, the computed
coefficients and the curve are displayed as follow:

You can delete points from the linearization table with Delete button. When you add à point a
window appears to enter the standard value.
When you finish the acquisition click on "Transfer to instrument" in order to load parameters in the
instrument.
You can save and load different calibration according to your references, materials, etc...

The maximum number of references to enter in linearization table is 20.

2.7 Standard wire coming from weight

measurement
In case of you want to make the linearization with your own wires, in order to take in account the
ovality and to not be sensitive to the wire orientation, you can use WSR accessory.
In this case follow this procedure:

1. initialize the table (erase all points and transfer to instrument).

2. Using WSR and CIM Lab software, measure all your standard wires.
3. In TLBXlindiametre_lds, edit both columns : Diffraction diameter (average result from CIM Lab)

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 48 Part IX: Maintenance, security and troubleshooting

and Standard diameter (your own reference diameter from weight measurement)
4. Transfer to instrument.

3 Error codes
In case of measurement problem or error, the instrument will show on the local display an error
code "EXXX" only for the negative values of the event code following table.
This code is also transferred to CIM which will display a short text. For further details about these
codes, please refer to the following table:

Event Text displayed in Description

code CIM
value
5 OUT HIGH Tolerance current state out high
2 OUT LOW Tolerance current state out low
0 OK Tolerance current state ok
-1 COMM_ERROR Prioritary CIM information. Instrument deconnexion.
Comm error.
-2 CHANGE SPOOL Indicates a spool change. Time length reset.
-3 EVENT OVF Internal event used for events management
-4 EVENT MAX Internal event used for events management
-16 RS232 ERR. Internal event used for comm management
-200 HIGH TEMP Temperature is too high
-202 UNST TEMP Temperature is not stable
-204 EEPROM Internal storage error
-209 HW VER. INC. Internal communication error
-211 CAPT_T Internal temperature sensor failure.
-212 WATCHDOG Internal software failure.
-300 POSITION OUT Wire position is not correct
-301 WRONG POSITION Wire position is not correct
-402 SIGNAL DIRTY Signal is not correct for analyze. Refer to Diffraction scope.
-498 SIGNAL Signal is not correct for analyze. Refer to Diffraction scope.

Positive event code value are not displayed on the local display
"OK" event code is not displayed on the local display, and is replaced by the green led "RUN"
blinking.
Error codes "RESET SPOOL" and "EVENT MAX" are displayed only under CIM software.

4 Safety rules
Laser source information:
Class 1M laser device according to the classifications given by the "American National Standards
Institute", document ANSI Z136.1-2007, page 1.

The system is considered incapable of producing hazardous light exposure conditions during
normal operation unless the beam is viewed with an optical instrument.

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Part X: Embedded software versions

The following history table highlights the technical changes made to the instrument embedded
software.

Embedded Date Evolution CIM

version compatibilit
y
2013/07/01 2013/07/01 LS ONE version Not
compatible
V1 2014/11/30 LDS iw now compatible with CIM software CIM 6.0
V4 2015/07/10 Diameter linearization with 20 points. CIM 6.4
Diameter peak to peak computed separately by axis.
New keyboard configuration.
Fix some minor bugs with CIM interface.
Add exposure time ratio parameter.
V5 2019/04/16 Fix diameter peak to peak computing issues. CIM 7.4
Fix out of tolerance if position out.
Fix diffraction rate error for 2 axis configuration.
Fix bug in measurement when save default parameters.
Fix LCD displaying issues.
Fix bug in scope results refresh.
Fix overflow events for diameter.
Imperial display available for LCD interface.
Blocking code available for specific error.
New embedded software for CPLD component (V6).
Add diameter streaming mode.
Change progress displaying in WSR mode.

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Part XI: User's manual versions

The following history table highlights the technical changes made to the instrument user's manual.

User's manual Date Evolution Embedded

version software
4.9 2013/07/01 Old LS ONE version 2013/07/01
13.0 2014/11/30 LDS iw now compatible with CIM software V1
14.0 2015/07/10 Update specifications for LDS. V4
Update Toolbox linearization graphs and
number of points.
Add list of parameters for analog and digital
outputs.
14.1 2016/06/02 Fix error in description of laser class. Safety V4
rules topic.
14.2 2018/05/02 Add Interface parameters topic in instrument V5
settings.
Add LDS0650 range in specifications.
14.3 2018/07/24 Add vertical wire tilt tolerance. V5
Add maximum fluctuation in optical field.
(Confidential)

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