00S READOUTS FOR MILLING APPLICATIONS REFERENCE MANUAL
TABLE OF CONTENTS General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warranty Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Installing the Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS Incremental Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Example: Incremental Dimensions . . . . . . . . . . . . . . . . . . . . . . 17 Using Incremental Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Example: Incremental & Absolute Position Presets . . . . . . . . . 19 Centerline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Setting Datum on a Centerline. . . . . . . . . . . . . . . .
GENERAL Overview This manual will guide you through the installation, setup, and operation of the 100S system. Use it to get your system up and running “out of the box” and as a quick reference guide for your day-to-day operations.
GENERAL Preparation Packing List Verify that you have received all of the components for your system: • • • • Readout & installation instructions Mounting arm ENC 125 scale(s) - Cable mounting hardware - Scale mounting hardware Warranty card If a component is missing, contact your 100S distributor immediately for replacement. Warranty Records Complete the warranty card included with your 100S system.
GENERAL Installing the Scales Please see the manual included with the scale for installation instructions. Installing the Readout Follow the readout installation instructions that are included with your mounting arm bracket kit. The electrical specifications for the readout are listed on pg. 33. After the installation is complete, proceed to “Power Up.
GENERAL Power Up Press the switch on the back of the readout to power up the system. A series of tests will check that the display, keypad, and memory are all working properly. If a problem is detected, an error code will appear on the screen. (Error messages and solutions are listed on pgs. 31 - 32.) It is important to note that the E1 message will appear every time you power up your system and does not indicate a problem. It merely indicates that the system had lost power.
SETUP Parameter Setup There are five parameters that you can define on your system: • • • • • Display resolution (diS) Linear error compensation (LEC) Scale resolutions (rES) Scale count directions (Ct dir) Position Recall (recall) Establish each setting the first time you power up the system. You can change the parameters later by returning to Setup and then using the ENTER key to scroll to the appropriate category.
SETUP Display Resolution The display resolution determines how detailed each scale’s position will be displayed on the readout. Use the setting that best suits each job. To change the display resolution: • Press the SETUP key. (“diS” will show on the display.) • Press the X, Y, or Z key for the display you want to change. For 10µm scales, the display resolution will toggle between 0.01 mm (0.0005”) and 0.02 mm (0.001”). For 5µm scales, it will toggle between 0.005 mm (0.0002”) and 0.01 mm (0.0005”).
SETUP Linear Error Compensation With 100S, you can compensate for machine tool wear. If you know the linear error compensation (LEC) value in parts per million (PPM), you can enter it directly. If you don’t know the LEC, use the formula on the next page to determine the value for each axis. To change the linear error compensation: • Move to the “Linear Error Compensation” display in the Setup mode. (Press SETUP and then the ENTER key until the display appears).
SETUP How to Determine the Linear Error Compensation Follow this procedure for each axis: • In the DRO mode. • Place a standard of known length on the table. Make sure it’s parallel with the table’s travel. • Put the readout in the absolute display mode (ABS/INCR key). • Using an edge finder or dial indicator, locate one end of the standard. • Press the ZERO key twice for the axis you are measuring. “0” should appear on the display.
SETUP Scale Resolution To ensure accurate readings, the scale resolution shown for each axis must correspond with the resolution of the scales on your machine. To change the scale resolution: • If necessary, choose “Scale Resolution” from the Setup menu. (Press SETUP and then the ENTER key until the screen appears). • Press the appropriate axis key until the appropriate resolution appears. Choose 0.01 mm for 10µm (0.0005”) scales, 0.005 mm for 5µm (0.0002”) and 0.001 mm for 1µm (0.00005”)scales.
SETUP Count Direction Use the count direction setting to define the positive counting direction for each scale. The direction will be displayed as a “1” or a “2” (the numbers are not assigned to a particular direction). You only need to change the count direction if the scale is counting in the negative direction during a positive table move, or vice versa. Refer to Conventions on pg. 37 for more guidelines. To change the count direction: • Move to the “Count Direction” display in the Setup mode.
SETUP Testing the Scales Follow these steps to confirm that the scale has been installed properly. The Counting Test will confirm the scale’s electrical operation, and the Repeatability Test will check the installation integrity. Counting Test • Move the table along each axis, one at a time. Check that the readout correctly displays the table’s movement. If it doesn’t, then the scale resolution you selected may not be accurate. Refer to Scale Resolution, pg. 9.
OPERATION Power On Position Recovery With the 100S there are two means of position recovery, Position Recall and Reference Mark Evaluation. Position Recall When this feature is active (see setup parameters) the last displayed position is stored in memory when power is lost or turned off. When power is restored, the stored position is recalled and displayed. Note: Any movement that occurs while power is off will be lost.
OPERATION Setting the Datum (Absolute Zero) 100S allows you to measure both absolute and incremental dimensions. A dimension measured from the point you define as the datum is an absolute dimension. A dimension measured from any other point on your print is an incremental dimension. Datum, also known as absolute zero or workpiece zero, is the reference point from which 100S will base all of your part’s coordinates.
OPERATION Datum To set the datum at the tool’s current position: • Position the workpiece on the table. Move the table until the tool is centered on the edge of the workpiece at the location where you would like to establish the datum. • Using the ABS/INCR key, select the absolute (ABS) mode. • Press the X-axis ZERO key twice to establish the current X-axis position as the datum. Repeat for the Y- and Z-axes.
OPERATION Example: Absolute Dimensions Let’s say that your print looks like this: Datum Here’s how you would drill the holes using absolute dimensions. Notice that all of the dimensions are measured from the point that was established as datum (0, 0, 0). • Check that ABS is selected on the DRO display (press the ABS/INCR key, if necessary). By selecting ABS, you’re telling 100S to measure the machine’s movement on the X-, Y-, and Z-axes from your datum (0, 0, 0).
OPERATION Incremental Dimensions As described earlier, incremental dimensions are measured from the current tool position to the next. If the tool is currently at 2” and you want to move an additional 3.125”, you would select the incremental mode, zero out the axis, and move the table until the display reads 3.125. An example of how to measure using incremental dimensions is shown on the next page.
OPERATION Example: Incremental Dimensions Let’s say that your print looks like this: Hole 1 is an absolute dimension (measured from the datum), while Holes 2 and 3 are measured incrementally. By putting 100S in the incremental mode for the last two holes, you can measure their distances just as the print specifies, without any calculations. 1. Press the ABS/INCR key until ABS is selected on the DRO display. Press the MM key until “Inches” is selected (the MM display is not lit up). 2.
OPERATION 6. Now repeat the process for the third hole. Press the ZERO key for the X-axis to measure from your tool’s current position. 7. Move the table until X = 2.00” and Y = 0.000”. Drill Hole 3. Using Incremental Presets In the standard incremental mode, you would reset the display at “0” and move the table until the scale counts up to the point you want to reach.
OPERATION 4. Repeat the step above for another axis or press ENTER to return to the DRO display. To reach the preset position, move the table until the display for each preset axis reads “0.” Example: Incremental & Absolute Position Presets Datum Hole 1 is an absolute dimension because it’s measured from datum. Hole 2 is an incremental dimension (measured from one hole to the next). Hole 3 is an absolute dimension from datum. 1. Press the ABS/INCR key until ABS is selected on the DRO display.
OPERATION Centerline With 100S, you can find the centerline (midpoint) between any two positions on your part. You can establish centerline as your datum by using absolute dimensions or you can create a centerline using incremental measurements without affecting your current datum. Refer to “Setting the Datum (Absolute Zero)” on pg. 13. Setting the Datum on a Centerline 1. Press the ABS/INCR key until ABS is selected. 2. Move the table to the first location. 3.
OPERATION Example: Setting the Datum on a Centerline Here’s how you would establish the datum on the centerline of the part shown: 1. Using the ABS/INCR key, select the absolute (ABS) mode. Check that the proper measurement (inch or mm) is selected. 2. Rest the indicator against any point on the left or right side of the circle. (In graphic 1 above, we started on the left side.) Press the ZERO key for the X-axis twice. 3. Move the table until the indicator rests against the other side of the circle.
OPERATION Locating Centerline Using Incremental Dimensions 1. Press the ABS/INCR key to select the incremental display mode. 2. Move the table to the first location. 3. Press the ZERO key for the appropriate axis. Doing so will zero the current position. 4. Move the table to the second location along the same axis. 5. Press the C/L (centerline) key. Dashes will flash on the screen. 6. Press the appropriate key (X, Y, or Z) for the axis you’re measuring. 7.
OPERATION Bolthole Patterns Creating a Bolthole Pattern Hole 1 A bolthole pattern is defined by its number of holes (up to 99), center point, radius, and start angle. 100S will automatically position “Hole 1” at the start angle and space the holes equally throughout the pattern. To create a bolthole pattern: 1. Press the BOLT DEF key. "HOLES" will appear on the X-axis display. 2. Enter the number of holes (1-99) in the pattern. Press the ENTER key. 3. Press the ENTER key again.
OPERATION 6. Press the Y key. Enter the bolthole pattern’s center point on the Y-axis. Use a decimal point and minus (-) sign if necessary. 7. Press the ENTER key. 8. Press the ENTER key again. “Radius” will appear. 9. Enter the radius of the circle pattern. Press ENTER. 10. Press ENTER again. "START" will appear on the X-axis display. 11. Enter the start angle of the first hole in the bolthole pattern. (0 degrees is at the 3 o’clock position.) Use a decimal point and minus (-) sign if necessary. 12.
OPERATION Running a Bolthole Pattern When you run a bolthole pattern, 100S always assumes that you want to start with the first hole. It will display “Hole 1,” and then the distance to the hole from your tool’s current position. Move the table until it reaches 0, 0. After you’ve drilled the hole, press the BOLT USE key again, and “Hole 2” will appear. Move the table to “0,” drill the hole and continue with the rest of the pattern.
TROUBLESHOOTING Troubleshooting Introduction Refer to this troubleshooting guide whenever you have questions or concerns about the operation of the 100S system. This guide is arranged in three columns entitled Symptom, Probable Cause and Recommended Corrective Action. The symptoms are listed in the order of the most common, easiest to check, and least expensive to correct. First locate the symptom that best describes the problem you are trying to solve.
TROUBLESHOOTING Symptom Probable Cause Screen is blank No power to the readout Recommended Corrective Action Check that the power switch on the back of the console is “on.” Check that the readout’s power cord is properly connected to the power supply. Check the fuse. (Located above the power switch). Check that the power source meets the specifications required by your system (pg. 33). LED failure Contact your 100S distributor for repair/ replacement procedures.
TROUBLESHOOTING Recommended Corrective Action Symptom Probable Cause Dashes appear on screen (cont’d) Display overflow Move the table toward the “0” position. As the scale counts down, the display will show the correct position. Error message (E1) appears Power loss occurred This is a normal message at power up. If the message appears at any other time during operation, a problem may have occurred. Refer to pg. 31 for details.
TROUBLESHOOTING Recommended Corrective Action Symptom Probable Cause Scale won’t count Loose cable Check that the scale cable is securely connected to the readout. Wrong input Check that the scale cable is connected to the correct input on the back of the readout. Refer to the readout installation instructions. Scale not installed properly Check the scale and reading head for proper installation (refer to scale installation instructions).
TROUBLESHOOTING Recommended Corrective Action Symptom Probable Cause Setup does not save values Improper procedure Press the ENTER key after each value is entered into a Setup screen. If you press another key instead, the new value will not be saved. Refer to pgs. 5 - 11 for proper procedures. Numbers don’t appear/are faded on the display LED failure Turn the system “off” and then “on” again, using the switch on the back of the readout.
TROUBLESHOOTING Error Messages (General) When 100S is powered up, it will run a series of tests to ensure that the software is working properly. If an error message appears, refer to the charts on this page and the next for a diagnosis and solution. E1 E2 E3 A power loss has occurred. This message will appear every time you power up the system and can be cleared by pressing the CLEAR key.
TROUBLESHOOTING Error Messages (Keypad Test) The messages below indicate that a problem was found during the keypad test at startup. If an error message appears, turn the system off, press the appropriate key to release it back into position, and then restart the system. (Or you can press the CLEAR key to clear the error message.) If the key does not work during normal operation, contact your distributor for repair/replacement procedures.
REFERENCE Electrical Specifications Follow these specifications when installing your 100S system.
REFERENCE Factory Default Settings Display Resolution (0.0005"/0.01 mm for 10µm scale) Linear Error Compensation 0 parts per million Scale Resolution 0.0005”/0.
REFERENCE Keypad Here’s an overview of the 100S keypad. Each key’s function is described below. X, Y, Z Correspond with the scales on the X-, Y-, and Z-axes. Used to specify a change to a particular axis. ZERO These keys reset the incremental or absolute display position at “0” for the corresponding axis. ABS/INCR Used to switch between absolute (ABS) and incremental (INCR) measurements. The active mode will be displayed at the top of the DRO display.
REFERENCE BOLT DEF Used to create a bolthole pattern. BOLT USE Used to run a bolthole pattern. CLEAR Acts as backspace key during numeric entry; otherwise, it clears or cancels the last operation. ENTER Completes numeric operations; selects next parameter in SETUP or BOLT DEF operations. ± 36 Changes the sign of the entered value from positive(+) to negative(-) or vise versa. Numbers are positive unless a (-) appears in front of them. . Decimal point can be used during numeric entry.
REFERENCE Conventions This section identifies the standard conventions that apply to your 100S system. Count Direction 100S uses positive and negative numbers to determine the position of the table and tool on each axis. The graphic below shows a typical setup for the positive and negative count directions for the X-, Y-, and Z-axes on a vertical knee mill. All of the examples in this manual are based upon this setup.
REFERENCE Warranty ACU-RITE Companies, Inc. Products and accessories are warranted against defects in material and workmanship for a period of three (3) years from the date of purchase. ACU-RITE will, at its option and expense, repair or replace any part of the ACU-RITE product that fails to meet this warranty. This warranty covers both materials and factory labor. In addition, authorized ACU-RITE service representatives will provide service labor (field service) for a period of one (1) year at no charge.
ACU-RITE Readout Systems are manufactured in the USA ACU-RITE IS AN ISO 9001 CERTIFIED MANUFACTURER 532821-20 ACU-RITE COMPANIES, INC. ONE PRECISION WAY MASON INDUSTRIAL PARK JAMESTOWN, NY 14701 www.acu-rite.
