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Description of changes


Minor changes to expert system; results from return stroke added to calculation of drift to improve accuracy in some cases; code changes to the loading of static measurements to help with loading of moved files.


Corrected display faults when using Windows 7 and text is selected to appear larger than 100%. In particular the fault made the “Adjustments” page unreadable and unusable.


Upgrade to stop bottom of display being hidden from view with some operating systems and screens.


Minor graphics bug fixes.


Bug fixed that was causing errors with application window size.


The window size now scales to suit the display size. Can be used with screen resolutions from 800x600 upwards. Some rewording for improved clarity also.


Minor bug fix. When dome alignment was GOOD, adjustments were sometimes calculated from 1st iron measurement instead of 3rd iron, which is generally the more accurate.


Improved layout of the ‘Adjustments’ page


Required re-alignment adjustments can now also be viewed in horizontal and vertical directions.


Warnings added if gauge has not been Zero Calibrated recently and if the “doming override” function (which forces the Doming part of the measurement to be captured) is activated .


‘Default Punch’ and ‘Default Ram’ gain calibration files are automatically regenerated if they have been deleted.


Expert System updated and reworded, particulary with regard to ram droop issues. Dome misalignment scaling factor in Set-up reworded for better clarity, and automatically disabled if bodymaker type is not Ragsdale.


Gauge orientation during Zero Calibration explained more clearly.


Improvements to Expert System: Advice about toolpack re-alignment has been changed to guard against aligning it to the punch sleeve position when ram alignment is bad or the ram is bent, which can cause wall thickness range to increase. Also, suggested adjustments are now shown graphically.


Fixes to a couple of minor bugs, plus some re-wording for better clarity.


Setup option added to force measurement of dome station misalignment to be made in AUTO mode (resolves problem where this is sometimes omitted when the gauge is in the 3rd die posn.)

Calibration procedure changed for gauge orientations where sensor 2 or 4 is at the top, so that cable does not have to go underneath the calibration cradle.


Automatic detection of faulty sensors added. Sensor voltage readings displayed on Static Measurement page as well as Calibration page. Font size enlarged where possible.


Target/alarm level for tool-pack alignment on return stroke can be set to a different value than for the forward stroke. If set to the clearance between 3rd die and punch, measurements outside of the target will indicate damaging contact.

Vertical Bodymaker added as option for bodymaker type.

The need to input actual and nominal gauge ring diameter when setting up a new gauge ring has been removed.


Improvement to Expert System to give the required adjustments to toolpack alignment that will give the best compromise between what is required at 1st and 3rd die positions, even if these are quite different.


Corrected bug in Expert System that prevented the required adjustments to toolpack alignment from being given for CMB/Standun bodymakers with toolpack angled at 30°.


Corrected bug that caused units to be set incorrectly when loading static measurement files by opening them directly from the data files folder.


Corrected bug in version 2.03 that was causing some USB interface boards to not be recognised.


Added an option to select the Board number for the USB interface. Minor changes to the expert system.

Reworded final part of Zero Calibration procedure for clarity.


Changed “Start of Run” and “End of Run” to “First 5 strokes” and “Last 5 strokes” respectively to avoid confusion with Forward and Return strokes.


Added “Stripper” as one of the static measurement positions. Stripper alignment can be measured with the gauge at the 3rd die end of the tool-pack and the punch sleeve in the stripper (provided stripper is stiff enough to move the ram).

Individual static measurements can now be deleted.

Fixed software bug affecting dynamic measurement made using new USB interface box. The measurement of an occasional stroke was incorrectly processed giving apparent rogue readings.


User’s Manual was revised with simpler procedure for re-aligning the Calibration Fixture (Calibration Cradle)


Added capability of connecting gauge to computer via a USB port in addition to the PCMCIA option.

Added option in the setup file to enable dynamic measurement to work if the sensors go out of range between start of punch sleeve and ram.

Fixed bug that was causing the calibration to be wrongly set if the gauge orientation during measurements was set differently to when the Zero Calibration was done.


Rewording of “Special Zero Calibration” procedure to clarify when calibrating to a specific punch sleeve.

Now able to open saved static measurements by double clicking the file from Windows My Computer.

Fixed bug that caused program to close when default setup file was loaded.

Fixed bug that caused program to get stuck in a loop if gain was incorrectly set to zero.


Enabled software to be installed on a shared drive.

Expert system updated to include “ram alignment” as a possible cause of punch sleeve alignment movement as it passes through the gauge ring on the forward stroke.


“Gain Calibration” and “Quick Zero” moved off of main calibration page into “Advanced Calibration Functions” to discourage unnecessary or incorrect use. “Quick Zero” renamed as “Special Zero Calibration”.

All options moved onto a single page.

Location of Data Files added to options. This enables data files to be stored at any location, e.g. a shared drive.

“Database Setup” function added in file menu.

Enabled dome station misalignment measurement to be disabled if required. May be needed for use with food can dome stations if the tooling design is such that punch nose does not necessarily centralise in the dome tooling.


Fixed bug where arrows in static alignment display were not filled in.

Fixed bug that resulted in incorrect files being loaded if default gain calibrations were selected.


Fixed bug that was setting gain to zero when a new default ram calibration was created.


Put in warning to retighten punch nose after a zero calibration done in the bodymaker.

Fixed bug where dome station misalignment measurements were incorrectly given in split screen display when “Just Before Domer” position was not measured.

Fixed bug to give correct dome station misalignment measurement when “Just Before Domer” or “In Domer” positions are only  partially visible at the ends of the graphs.


Saving of static alignment measurements changed so that multiple measurements at same gauge position can be saved in same file.


Added extra field in load/save dynamic measurement dialog boxes to differentiate between measurements made whilst making cans or with no cans.


Fixed bug where right side of split screen display displayed the wrong Additional Info.


Added Automated Saving of dynamic measurements, so just bodymaker number has to be selected. Previously required a filename to be typed in. Loading of files also made easier.

Title bar layout changed to give bodymaker, line and plant rather than the filename.


Alarm level for static alignment measurements added.

Default ram and punch sleeve gain calibrations changed to realistic values.

Saving of static measurements allowed.

Option to disable gauge positions in setup file added.


Expert system updated to include heating of ram from oil in bushing as possible cause of alignment drift.


Enlarged static alignment graph and numeric display for ease of use when viewed from a distance.


“Zero Calibrate with recheck of calibrator alignment” function changed to “Zero Calibrate”, and “Zero Calibrate” changed to “Quick Zero Calibrate”


Updated expert system to include flooded tool-pack as possible cause of alignment drift. Also reworded other sections.

Added warning that dome station misalignment measurement may not be accurate if the ram alignment measurement during the “In Domer” part of the stroke is unstable.


Added option for user to set alarm levels.

Relaxed levels for punch sleeve movement or vibration above which it is noted in the Expert System.


Moved Doming part of measurement to the centre of the display and Return Stroke to right side.

Added the welcome screen.


Updated expert system. Removed overly alarmist comment suggesting that hydrostatic bushing misalignment might be possible cause of problems.


Minimum range on graphs increased to 10 thou.

Reworded “Calibration Cradle Alignment Compensation” function to “Zero Calibrate with re-check of calibrator Alignment”.

Reworded “Fully Automatic” and “Semi Automatic” triggering to “Auto” and “Manual” respectively.

Added 2 more gauge orientation options to make a total of 4.


Dynamic measurement stopped by clicking anywhere in window. Option added for bodymakers running less than 160cpm.


Dome station alignment display changed to give actual misalignment. Previously gave position of dome station and position of punch sleeve just before hitting dome station.

Bodymaker type, wearbar position and gauge orientation added to setup file to replace “toolpack orientation”. Also “making cans” option added.


Changed gain calibration procedure to place feeler stock in before first measurement and remove it before second.


Changed gain calibration procedure to place feeler stock between gauge ring and only one cradle arm.


Added Ragsdale letterbox style bodymaker as a setup option.


Added option for Zeroing Method.


Made the trigger level a variable that is set when resetting the measurement zone. Previously it was fixed. Change needed as different gauge rings need different trigger levels.


“Likely causes” in expert system changed to “Possible causes”.

Descriptive levels in expert system changed to Good, Moderate, Severe and Extreme.

Ragsdale bodymaker added as option in setup file.

Added facility to have multiple gauge rings recognised within the software.




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Get the latest version of the software

User’s Manual download

Software updates:

Revised June 2019. (If this link opens an earlier version, you will need to delete your temporary internet files first)

WARNING: The sensors in the FSA gauge rings can come loose and cause a loss of accuracy. To prevent this, the locking set screws should be checked with a 2.5mm allen key every few weeks. Stress relaxation causes them to loosen, especially when new. They should only be nipped up finger tight so as not to damage the sensors. If they do become loose, the sensors cannot move much because of the cable. Accuracy will be restored by simply retightening them. Any small change in position of the sensors will not affect the accuracy, as the Zero Calibration takes account of this.