Renishaw H-1000-5071-09-A Installation guide

Installation guide
H-1000-5029-05-B
PI 200 interface for the TP200 system
© 2002 - 2007 Renishaw plc. All rights reserved.
Renishaw® is a registered trademark of Renishaw plc.
This document may not be copied or reproduced in whole or in part, or
transferred to any other media or language, by any means, without the
prior written permission of Renishaw.
The publication of material within this document does not imply
freedom from the patent rights of Renishaw plc.
Disclaimer
Considerable effort has been made to ensure that the contents of
this document are free from inaccuracies and omissions. However,
Renishaw makes no warranties with respect to the contents of this
document and specifically disclaims any implied warranties. Renishaw
reserves the right to make changes to this document and to the
product described herein without obligation to notify any person of
such changes.
Trademarks
All brand names and product names used in this document are trade
names, service marks, trademarks, or registered trademarks of their
respective owners.
Renishaw part no: H-1000-5029-05-B
Issued: 10 2007
PI 200
interface for TP200 probe system
installation guide
FCC
Information to user (FCC section 15.105)
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to Part 15 of the FCC rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference, in which case
you will be required to correct the interference at your own expense.
Information to user (FCC section 15.21)
The user is cautioned that any changes or modifications not expressly approved by
Renishaw plc or authorised representative could void the user’s authority to operate the
equipment.
Special accessories (FCC section 15.27)
The user is also cautioned that any peripheral device installed with this equipment
such as a computer, must be connected with a high-quality shielded cable to insure
compliance with FCC limits.
TÜV
This equipment has been independently certified by TÜV Product Services in
accordance with OSHA (US) and SCC (Canada) requirements to the standards
UL61010-1 Second Edition and CAN/CSA-C22-2 No. 61010-1 Second Edition.
Care of equipment
Care of equipment
Your Renishaw probe and accessories are precision instruments. Please use and
maintain the products in accordance with these instructions. Retain the transit box for
storing the components when not in use.
!
CAUTION: The TP200 probe contains sensitive strain sensors. Permanent
damage may be caused if the probe is dropped or subjected to severe shock
as may be caused by misuse.
Changes to Renishaw products
Renishaw plc reserves the right to improve, change or modify its hardware or software
without incurring any obligations to make changes to Renishaw equipment previously
sold.
Warranty
Renishaw plc warrants its equipment provided that it is installed exactly as defined in
associated Renishaw documentation.
Consent must be obtained from Renishaw if non-Renishaw equipment (e.g. interfaces
and/or cabling) is used or substituted. Failure to comply with this will invalidate the
Renishaw warranty.
Claims under warranty must be made from authorised services centres only, which may
be advised by the supplier or distributor.
Patents
Aspects of the TP200 system and aspects of similar systems are the subjects of the
following patents and patent applications:
EP 0243766
EP 0388993
EP 242747 B
EP 279828 B
EP 0470234
EP 0521703
EP 548328 B
EP 566719 B
EP 0501710
EP 0641427
EP 0392660
EP 0740768
JP 2,545,082
JP 2,539,824
JP 2,647,881
JP 3,004,050
JP 3,346,593
JP 3,294,269
JP 3,279,317
JP 2,510,804
JP 3,634,363
JP 3,018,015
JP 3,546,057
US 4813151
US 4817362
US 4916339
US 5,228,352
US 5,327,657
US 5,404,649
US 5,339,535
US 5,323,540
US 5,505,005
US 5,671,542
US 4769919
US 5,088,337
US 5,755,038
US 5,918,378
US 6012230
WO 97/35164
Safety
Safety
If this product is not used in its intended manner, any protection provided may be
impaired.
There are no user serviceable parts inside this equipment.
The PI 200 interface unit must be connected to a supply incorporating a protective
earth conductor via a three-core mains cable (line cord).
Electrical ratings
Supply voltage range
Power frequency range
100 - 240 V ac + 10%, -15%
47 Hz - 63 Hz
Power consumption
10 W
SSR contact ratings
±50 V pk.
±40 mA pk.
Operating conditions
The PI 200 interface unit is specified to operate under the following conditions as
defined in BS EN 61010-1:2001.
Protection provided by
enclosure
Altitude
Operating temperature
Storage temperature
Relative humidity
Transient overvoltage
Pollution degree
IP30
Maximum 2000 m
0 °C to +50 °C
-10 °C to +70 °C
Maximum 80% RH up to +31 °C, decreasing
linearly to a maximum 50% at +40 °C.
Installation category II
2
The PI 200 is isolated from AC power by disconnection of the IEC mains connector on
the rear panel. If any additional means of isolation is required, it must be specified and
fitted by the machine manufacturer or the installer of the product. The isolator must
be sited within easy reach of the CMM operator and comply with IEC61010 and any
applicable national wiring regulations for the country of installation.
Contents
Contents
1 Introduction.................................................................................................................7
2 Product description.....................................................................................................9
2.1
System overview.............................................................................................9
2.2
Probe status signal (SYNC).............................................................................9
2.3
Trigger confirmation signal (HALT)................................................................10
2.4
SYNC and HALT debounce...........................................................................12
2.5
Probe damped signal (PDAMP)....................................................................13
2.6
Stylus mass and ambient temperature compensation...................................14
2.7
RESET button................................................................................................14
2.8
Front panel indicators....................................................................................15
2.9
Audible indicator............................................................................................16
2.10 Rear panel switches and connectors.............................................................16
2.11 Configuration switches..................................................................................17
2.12 Probe polarity switch.....................................................................................21
3 Connector pin-outs...................................................................................................22
3.1
PICS input connector.....................................................................................22
3.2
PICS output connector..................................................................................23
3.3
Solid state relay (SSR) output connector......................................................24
3.4
Stylus change rack (SCR) output connector.................................................25
3.5
Remote reset.................................................................................................25
4 PI 200 dimensions and cable data............................................................................26
5 Part number summary..............................................................................................27
5.1
Replacements................................................................................................28
5.2
Accessories...................................................................................................28
6 Installation procedure...............................................................................................29
6.1
Rack mounting...............................................................................................29
6.2
Mounting with older style Renishaw control units..........................................30
6.3
System interconnection.................................................................................31
6.4
Using TP200 with the ACR1 autochange system..........................................36
6.5
SCR200 stylus change rack..........................................................................37
6.6
Interconnection cables...................................................................................38
6.7
Upgrading older probe systems to TP200 (retrofitment)................................39
Contents
7 PICS terminations.....................................................................................................40
8 Summary of changes from earlier versions..............................................................41
9 Maintenance.............................................................................................................42
9.1
PI 200............................................................................................................42
9.2
TP200 probe and stylus module....................................................................42
9.3
SCR200 rack.................................................................................................42
10 Fault finding..............................................................................................................43
Introduction
1
Introduction
The TP200 probe system comprises the TP200 probe sensor and stylus module, the
PI 200 interface and the optional SCR200 stylus change rack.
The TP200 is a 13.5 mm diameter touch-trigger probe with the facility to quickly change
stylus configurations without the need for requalification. This is achieved by carrying
the stylus on a detachable module that is located on the probe sensor body by a
highly repeatable kinematic coupling and held in place by magnetic force. After initial
qualification of the stylus tip, the module may be removed and replaced as required
without additional requalification by simply recalling the initial qualification data.
The probe sensor uses electronic strain sensing techniques that provide better form
measuring accuracy and operating life than can be achieved with kinematic switching
probes.
The SCR200 stylus change rack provides storage for pre-qualified stylus assemblies
and facilitates automatic stylus changing under measurement programme control.
The dedicated PI 200 interface supplies power and controls the operation of the TP200
probe and SCR200 rack. Communication with other Renishaw equipment and the CMM
controller is via the PICS (product interconnection system) ports.
The TP200 system components (probe sensor, stylus module, PI 200 interface and
SCR200 stylus change rack), illustrated in figure 1, are described in the TP200 probe
system user’s guide (Renishaw part number H-1000-5014).
A version number label (e.g. V9) on the PI 200 rear panel indicates the modification
level of the unit. A summary of the changes made at each level is included later in this
document.
Introduction
SCR200 stylus
change rack
TP200 probe
sensor
TP200 stylus
module
Kinematic
coupling
PI 200 interface
Stylus
Figure 1 - TP200 precision touch-trigger probe system
Product description
2
Product description
2.1 System overview
A small deflection of the stylus tip produces a force which is applied via the stylus
module and kinematic coupling to the strain sensing structure housed in the probe
body. Electronic processing, based on a customised mixed signal integrated circuit
and hybrid microcircuit construction contained within the probe, converts the sensor
responses to a current proportional to strain. The probe output requires only two wires
for transmission to the PI 200 interface, enabling the TP200 to use the existing M8
mounting connector system fitted to a wide range of probe heads and extension bars.
In the PI 200 interface, the probe current is compared with pre-set reference levels
to determine the status of the probe, which may be armed (seated) or triggered. The
probe status (SYNC) and the trigger confirmation (HALT) signals are asserted when the
appropriate conditions are met.
At power-up, or when a probe is first connected, the PI 200 recognises whether
the probe is a kinematic switching probe (TP20/TP6/TP2 type) or a TP200, and
automatically selects the appropriate operating mode.
When using the SCR200 change rack to perform automatic stylus changing, the PI 200
inhibits probe triggers and resets the TP200 probe sensor to account for the loading
effects of the new stylus assembly on the strain sensors. Collision damage is prevented
by an overtravel mechanism and a limit switch in the base of the SCR200. A small
displacement will cause the PI 200 to assert the SYNC, HALT and STOP signals to
stop CMM motion.
2.2 Probe status signal (SYNC)
SYNC is the real time PICS trigger signal used to trigger recording of the machine scale
coordinates when taking a gauge point. SYNC may also initiate the process of stopping
and reversing CMM motion (sometimes called ‘back-off’) to the pre-hit point.
When the stylus contacts the workpiece, a change of strain occurs in the sensing
structure, causing the probe current to increase. SYNC is asserted when the probe
current exceeds the trigger reference level. When the stylus backs off from the
workpiece, the probe current will fall below the trigger reference level and SYNC will be
cleared to the armed state.
10
Product description
The timing relationships for an idealised probe signal are indicated in figure 2.
A solid state relay (SSR) output is provided which mimics the PICS-SYNC output for
connection to older CMM controllers that require voltage-free contacts to simulate the
trigger signal of a kinematic switching probe.
2.3 Trigger confirmation signal (HALT)
To allow the CMM controller to distinguish between a valid trigger and a spurious trigger
caused by vibration or shock, a trigger confirmation signal (HALT) is provided on the
PICS port. HALT will be asserted if the probe current remains greater than trigger level
2 for a pre-set delay time, determined by the settings of configuration switches 11
and 12. The timing relationships for an idealised TP200 probe signal are indicated in
figure 2.
Should the probe current fail to reach the trigger level or drop below the reseat level
before the delay time has expired, as might be the case for a vibration-induced signal,
HALT will not be asserted. The CMM controller may then assume the trigger was
spurious and reject the coordinate data.
When a kinematic switching probe (TP20, TP6, TP1, TP2) is connected, the HALT delay
time is fixed at 5 milliseconds as indicated in figure 3.
11
Product description
V
Probe signal
Trigger level 2
and HALT
Trigger level 1
t
SYNC
Debounce times set by
switch 6 and switch 7
HALT
Delay time set by
switch 11 and switch 12
Figure 2 - SYNC and HALT signal timing for a TP200 gauge point
V
Probe signal
Trigger level
t
SYNC
HALT
Debounce fixed
20 ms
Delay time fixed 5 ms
Figure 3 - SYNC and HALT signal timing for a gauge point when
a kinematic probe is connected
12
Product description
2.4 SYNC and HALT debounce
The SYNC and HALT signals are debounced to prevent spurious triggers occurring
as a result of CMM or stylus vibration when the stylus makes contact with or leaves
the surface of the workpiece. A range of switch selectable timing options is provided
to suit the requirements of different types of CMM. Alternatively, the debounce may
be switched off to allow greater flexibility for the CMM’s controller to manage the
PICS signals. Refer to the section ‘configuration switches’ for more information on the
debounce options.
The ‘adaptive’ settings ensure that combinations of CMM vibration and large stylus
assemblies do not cause a false indication of probe status during the back-off move.
Referring to figure 4, it may be seen that the debounce time increases in increments
of either 20 milliseconds or 100 milliseconds until the probe signal remains below the
trigger level for one complete timing period.
When a kinematic switching probe (TP20, TP6, TP1, TP2) is connected, the debounce
times are fixed as indicated in figure 3.
V
Trigger level
t
Debounce timer
Debounce times set by switch 6
SYNC
Figure 4 - Adaptive debounce
Product description
13
2.5 Probe damped signal (PDAMP)
During high-speed position moves (fast traverse), it is necessary to reduce probe
sensitivity to prevent vibration causing unwanted triggers. The CMM controller must
assert the PDAMP signal on the PICS port, to switch the PI 200 into the low sensitivity
mode known as ‘probe damped’. In this mode, deflection of the stylus will generate
SYNC and HALT simultaneously, but only if the probe signal remains above the
damped trigger level for longer than the time delay selected by switches 11 and 12 as
indicated in figure 5.
NOTE: The probe cannot take accurate points when damped mode is active, and the
CMM controller must clear the PDAMP signal to return the probe to normal sensitivity
before taking a gauge point. It is important that PDAMP is only cleared when vibrations
of the CMM and probe stylus have reduced to a sufficiently low level to avoid spurious
re-triggering at the end of the position move.
Probe damped mode is indicated by an LED on the PI 200 front panel.
V
Probe signal
Probe damped
level
Trigger level 2
Trigger level 1
t
SYNC
HALT
Delay time set by
switch 11 and switch 12
Figure 5 - SYNC and HALT signal timing for a trigger in damped mode
14
Product description
2.6 Stylus mass and ambient temperature
compensation
In the TP200, probe a reference strain sensor, outside the strain path, adjusts the
current in the active strain sensors to provide compensation for slow, uniform, changes
of ambient temperature.
Fine compensation for thermal drift is provided by a system known as ‘autozero’ that
nulls the sensor amplifiers at a slow rate when the probe is armed. Under the control
of the PI 200 interface, the autozero automatically switches to a fast rate to reset
the probe sensors during a stylus change with the SCR200 change rack or during
reorientation of a motorised probe head.
When the probe is in the triggered state, the compensation is switched off. If the stylus
remains deflected for longer than 10 seconds, drift of the zero reference may occur.
The audible warning will sound after this period to indicate that the probe must be reset
manually.
2.7 RESET button
!
CAUTION: Probe triggers are inhibited when the RESET button is pressed.
Before pressing the button, the CMM must be stationary in manual mode with
the probe stylus clear of the workpiece.
The RESET button on the front panel selects fast autozero to rapidly null the sensor
amplifiers.
This may be necessary when:
1.
The probe does not arm after manually changing the stylus.
2.
The audible alarm is sounding a continuous tone to warn that the stylus has been
deflected for longer than 10 seconds.
NOTE: Alternatively, the probe may be reset by the action of unlocking and locking the
PH10T or PH10M motorised head. Refer also to the ‘remote reset’ section.
Product description
2.8 Front panel indicators
Figure 6 - PI 200 interface front panel
Table 1 - Front panel indicators
Indicator
POWER ON
TYPE
Colour
Function
Green
Mains power on
STD
Green
Kinematic probe selected
TP200
Green
TP200 probe selected
ON - probe armed (seated)
PROBE
STOP
SEATED
Green
OFF - probe triggered or no probe
connected
DAMPED
Yellow
PICS - PDAMP asserted
Red
PICS - STOP asserted
15
16
Product description
2.9 Audible indicator
The audible indicator has two functions:
1.
To provide a brief indication that a probe trigger has occurred. This function may
be disabled by configuration switch 5.
2.
To warn, by a continuous tone, that the stylus has remained deflected for longer
than 10 seconds. The alarm can be cleared by operation of the RESET button
on the front panel. Refer to the section ‘Reset button’ for more information on
resetting the probe.
2.10 Rear panel switches and connectors
Figure 7 - PI 200 interface back panel
Product description
17
2.11 Configuration switches
CAUTION: Check the PI 200 version number on the rear panel. The switch
information in table 2 refers to PI 200 versions V9 or later. Refer to the
‘Summary of changes from earlier versions’ section in this handbook for details
of previous revisions.
!
All switches are hardware controlled and a change to any switch setting is effective
immediately.
Table 2 - Configuration switch functions
Switch
number
Function
Switch
position
Description
1
HALT polarity
UP
DOWN
HALT active HIGH
HALT active LOW
2
Head LED control
UP
DOWN
External control via PICS
LED mimics SYNC
3
STOP disabled
UP
DOWN
PI 200 ignores PICS - STOP
STOP asserts HALT/SYNC
4
SYNC polarity
UP
DOWN
SYNC HIGH and SSR closes on trigger
SYNC LOW and SSR opens on trigger
5
Audible indicator
UP
DOWN
No beep on trigger
Indicator beeps on trigger
6
Debounce time
Selects SYNC debounce time
Refer to figure 8
7
Debounce mode
Selects SYNC debounce mode
Refer to figure 8
8
Zero debounce
UP
DOWN
Sets debounce time <2 ms
Debounce set by switches 6 and 7
9
Probe signal filter
UP
DOWN
Filter active
Filter off
10
Trigger level
UP
DOWN
Trigger level 2 selected
Trigger level 1 selected
11
PDAMP/HALT
filter delay
12
Coded to select delay time
Refer to table 3
18
Product description
Switch 1:
Inverts the polarity of the HALT output.
Switch 2:
Selects control of the LEDOFF output to either internal PI 200 control according to the
status of SYNC, or sets the output to high impedance for control of the head LED by
external switching.
Switch 3:
Sets the PI 200’s response to STOP when asserted from an external source. When
enabled, the PI 200 will assert SYNC, HALT and open the SSR relay.
Switch 4:
Inverts the polarity of the SYNC and SSR relay outputs.
Switch 5:
When enabled, a tone will sound for approximately 160 milliseconds when the probe
triggers and SYNC is asserted. When disabled, the tone will activate only when the
stylus has remained deflected for 10 seconds.
Switches 6 and 7:
These switches select the debounce time and mode of operation as indicated in
figure 8.
Switch 8:
Overrides the settings of switches 6 and 7, reducing the trigger and reseat debounce
times to less than 2 milliseconds.
Switch 9:
The probe signal filter has a 300 µs time constant to reduce the effects of stylus
vibration when the stylus makes contact with the workpiece. Renishaw recommends
that this switch is set to the UP position for normal use.
19
Product description
V
Probe signal
Trigger level
t
SYNC
Switch 6 - Down
Switch 7 - Down
20 ms
SYNC
20 ms
adaptive
Switch 6 - Up
Switch 7 - Down
100 ms
SYNC
Switch 6 - Down
Switch 7 - Up
20 ms
SYNC
100 ms
adaptive
20 ms
Switch 6 - Up
Switch 7 - Up
100 ms
80 ms
Figure 8 - SYNC debounce options
20
Product description
Switch 10:
In operating situations where there is an unusually high level of background vibration,
it may be necessary to reduce the sensitivity of the TP200 to avoid false ‘air’ triggers.
These may occur on some types of CMM when large steel stylus arrangements are
used or where the CMM is inadequately isolated from the floor transmission of vibration
from nearby machinery or vehicle traffic.
Trigger level 1 is the highest sensitivity mode and provides the best measuring
performance.
Trigger level 2 reduces the vibration sensitivity from level 1 for a small loss of
measuring accuracy.
!
CAUTION: All stylus tips must be requalified if the trigger level
is changed.
Switches 11 and 12:
To prevent a HALT signal (or HALT and SYNC if probe damped mode is set) from being
falsely asserted when the probe is subjected to vibration, a time delay filter is applied.
Refer to the description in ‘trigger confirmation signal (HALT)’ section.
If a collision occurs at fast traverse speed (i.e. a position move), the filter delay time
will incur additional CMM overtravel before motion stops. It is important that the CMM
motion can stop within the available overtravel, particularly if collisions can occur
directly along the main axis of the probe in the +Z direction. To minimise the overtravel
in a collision situation, the filter delay time must be set to the shortest possible time that
will prevent ‘air’ triggers from occurring during fast traverse moves when probe damped
mode is asserted.
Switches 11 and 12 are used to select the nominal filter times indicated in table 3.
Table 3 - Function of switches 11 and 12
Time delay
Switch 11
Switch 12
2.0 ms
DOWN
DOWN
7.5 ms
DOWN
UP
15.0 ms
UP
DOWN
50.0 ms
UP
UP
Product description
21
2.12 Probe polarity switch
The TP200 probe is polarity sensitive and must be connected to the PI 200 such
that the centre contact of the M8 connector is positive and the thread is ground (0
V). A reversed polarity connection will cause the POWER and STOP indicators to
be illuminated on the front panel. Sliding the switch to the REV position should allow
normal operation. Incorrect setting of the polarity switch should not damage the probe.
22
3
Connector pin-outs
Connector pin-outs
3.1 PICS input connector
The PICS input connector is a 9 pin ‘D’ type socket. The pin numbers are illustrated in
figure 9 and their functions are shown in table 4.
5
3
4
9
8
2
7
1
6
Figure 9 - PICS input connector pin numbers
Table 4 - PICS input connector
Pin number
Description
1
STOP
2
PPOFF
3
Ground (0 V)
4
Reserved
5
Probe signal input
6
STOP +5 V pull-up
7
PDAMP
8
LEDOFF
9
Probe signal ground
Shell
Screen
Connector pin-outs
3.2 PICS output connector
The PICS output connector is a 9 pin ‘D’ type plug. The pin numbers are illustrated in
Figure 10 and their functions are shown in table 5.
1
3
2
6
7
5
4
8
9
Figure 10 - PICS output connector pin numbers
Table 5 - PICS output connector
Pin number
Description
1
STOP
2
PPOFF
3
Ground (0 V)
4
Reserved
5
SYNC
6
HALT
7
PDAMP
8
LEDOFF
9
Not used
Shell
Screen
23
24
Connector pin-outs
3.3 Solid state relay (SSR) output connector
The solid state relay output connector is a 7 pin DIN socket. The pin numbers are
illustrated in figure 11 and their functions are shown in table 6.
3
7
5
6
2
1
4
Figure 11 - SSR output connector (view on rear panel)
Table 6 - SSR output connector
Pin number
Description
1
Not used
2
Screen
3
Not used
4
SSR 1
5
SSR 2
6
Not used
7
Not used
Shell
Screen
Connector pin-outs
25
3.4 Stylus change rack (SCR) output connector
The SCR200 stylus change rack is connected to the PI 200 via a 6 pin miniature DIN
socket. The pin numbers are illustrated in figure 12 and their functions are shown in
table 7.
Figure 12 - SCR200 output connector (view on rear panel)
Table 7 - SCR output connector
Pin number
Description
1
Reset
2
Fault
3
Inhibit
4
+5 V
5
Ground (0 V)
6
Not used
3.5 Remote reset
There are two methods of connection to a remote push button that will achieve the
same effect as the RESET button on the front panel of the PI 200 interface. Such a
facility may be useful if manual stylus changing is to be frequently used, or if the PI 200
is difficult for the operator to access.
A momentary action push button or switch may be connected to pins 1 and 5 on the
SCR200 miniature DIN connector on the rear panel. If the connector is already in use
for connection of a SCR200 stylus change rack, a dual rack cable type PL97 (refer to
table 8, cable no. 11) may be used to provide an additional connector.
Alternatively, the button may be directly wired to the PPOFF and ground (0 V) pins (pins
2 and 3) on either of the PICS connectors on the rear panel of the PI 200.
26
4
PICS dimensions and cable data
PI 200 dimensions and cable data
Dimensions 1/3 rack wide x 2U high
140 mm x 88 mm x 183 mm deep
Weight 1.25 kg
Mounting method 19 in rack or freestanding
Mounting screws M5 x 8 mm maximum penetration
Probe voltage (open circuit) 12.4 V
Probe cable resistance Max. 5 W/conductor
Probe cable length Max. 50 m
Wire gauge 0.22 mm2
Part number summary
5
Part number summary
PI 200 interface
Contents:
A-1207-0050
PI 200 interface unit
Installation guide
Rubber feet (self-adhesive)
Rack mounting hardware:
1/3 x 2U blanking panel
Rack mounting bracket
Link bracket
A-1018-0123
A-1018-0124
A-1018-0126
TP200 probe kit - standard force
A-1207-0001
TP200 probe kit - low force
A-1207-0002
Contents:
TP200 probe sensor
Stylus module (standard or low force)
Tools/cleaning kit
Test certificate
User’s guide
Stylus module - standard force
A-1207-0010
Stylus module - low force
A-1207-0011
Stylus change rack kit - standard force
A 1207-0030
Stylus change rack kit - low force
A-1207-0070
Contents:
1 x SCR200 rack
3 x stylus modules (standard or low force)
Mounting kit
Datuming stylus (PS2R)
SCR200 cable - 5 m long (PL63)
A-1016-7630
SCR200 cable - 10 m long (PL64)
A-1016-7631
SCR200 cable - 20 m long (PL65)
A-1016-7632
Dual SCR200 cable adaptor (PL97)
A-1016-7660
M12 location piece (for SCR200)
M-1371-0298
27
28
Part number summary
5.1 Replacements
TP200 probe system user’s guide
(English + multilingual CD)
H-1000-5014
PI 200 interface for TP200 probe system installation guide (English)
H-1000-5029
Cleaning material
A-1085-0016
S1 ‘C’ spanner
A-1042-1486
S9 double-ended ‘C’ spanner
A-1047-3932
S7 M2 stylus pin spanner
M-5000-3540
Hexagon key 1.5 mm AF
P-TL03-0150
Datuming stylus (PS2R)
A-5000-3603
Rubber feet (for PI 200)
P-FE01-0003
5.2 Accessories
Refer to ‘Probing systems for coordinate measuring machines’ (Renishaw part number
H-1000-5050) for details of the available range of probe heads, extension bars and
other accessories.
High performance GF stylus kit
A-5003-2310
Autojoint to M8 adaptor: PAA1
A-1051-0417
Rotary adjustment module: M8 - M8
A-1047-7022
Rotary adjustment module: autojoint to M8
A-1051-0679
Module storage rack for manually operated stylus changing applications:
MSR1 (wall mounted)
A-1371-0330
MSR1 (CMM table mounted)
A-1371-0347
Installation procedure
6
29
Installation procedure
!
WARNING: Ensure the PI 200 is disconnected from the mains supply during
installation.
!
WARNING: Take care not to exceed the operation ambient of 50 °C around
the unit. Do not install near sources of heat. Forced cooling may be required
in final installation.
6.1 Rack mounting
The PI 200 may be mounted in a standard 19 in equipment rack either alone or
alongside a Renishaw controller as indicated in figures 13 and 14.
R
PROBE INTERFACE
POWER
ON
TYPE
STD
PROBE
RESET
TP200 SEATED DAMPED STOP
A-1018-0123
Figure 13 - Mounting the PI 200
To mount the PI 200 as indicated in figure 13 requires 2 x 1/3 blanking panel kits (part
number A-1018-0123). Remove the blanking plugs from both sides of the PI 200 and fit
the panels using the M5 x 6 mm long screws provided.
Figure 14 - PI 200 with PHC10-2
To mount the PI 200 adjacent to a Renishaw controller, as indicated in figures 14 and
15, the following parts are required:
• Rack mounting bracket - part number A-1018-0124
• Enclosure link bracket - part number A-1018-0126
30
Installation procedure
Figure 15 - Mounting the PI 200 adjacent to the Renishaw PHC10-2
Remove the blanking plugs from the sides of each unit. Separate the halves of the link
bracket and screw them to the interface/controller units, using the M5 x 6 mm long
screws provided. Bring the units together and screw the brackets together. Screw the
rack mounting brackets to the free ends of each unit and assemble into the equipment
rack.
6.2 Mounting with older style Renishaw control units
To fit the PI 200 into an existing installation adjacent to an older style PHC10 or ACC2
(with extruded aluminium side panels), a link bracket (part no. M‑1018-0097) and 2 ×
M5 × 6 mm long screws (part no. P-SC29-0506) are required.
Remove the blanking plugs from the sides of the PI 200 and screw the bracket in place.
On the older style enclosure, prise out the rubber cover from the corner moulding
and loosen the two screws at the top and bottom of the moulding. Locate the bracket
between the corner moulding and the unit’s front panel, tighten the screws and replace
the rubber cover. Fit the rack mounting bracket to the other end of the PI 200 and
assemble into the equipment rack.
Installation procedure
6.3 System interconnection
Interconnection diagrams for the most common product combinations are given in
figures 16 - 21. The standard interconnection cables are listed in table 8. Contact
Renishaw for other cable lengths, cable specification or special configurations.
Consult the appropriate product installation guide for information about setting the
configuration switches of the PHC10-2 or ACC2-2 system controllers:
• PH10 series installation guide - part number H-1000-5071
• Autochange system installation guide - part number H-1000-6010
Cable 2
PI 200
Cable 1
MH8
TP200
PICS output
CMM controller
Figure 16 - System interconnection - MH8 head
31
32
Installation procedure
Cable 2
PI 200
Cable 1
0
MIH
PAA1 adaptor
PICS output
CMM controller
TP200
Figure 17 - System interconnection - MIH head
Cable 4
PHC10-2
Cable 3
PH10T
TP200
Cable 5
Communications to
CMM controller
PICS output
CMM controller
PI 200
SCR200
Cable 6
Figure 18 - System interconnection - PH10T head
Installation procedure
Cable 4
PHC10-2
Cable 3
V.
1
PH10M
PAA1 adaptor
10
RS 232
HCU
Serial
MADE IN
UK
OUTPUT
PICS OUT
11
Cable 5
14
HEAD
15
18
Communications to
CMM controller
TP200
PICS output
CMM controller
PI 200
SCR200
Cable 6
Figure 19 - System interconnection - PH10M head
33
34
Installation procedure
Cable 4
PHC10-2
Cable 3
PH10M
Cable 7
PAA1
adaptor
Cable 8
SP600M
TP200
Communications to
CMM controller
SP600M
PI 200
AC2
Cable 9
Cable 10
Communications to
CMM controller
ACC2-2
To ACR1 rack
PICS output CMM controller
Figure 20 - System interconnection - SP600M scanning probe and autochange
Installation procedure
Cable 4
PHC10-2
Cable 3
PH10M
Cable 7
PAA1
adaptor
Cable 8
TP7M
Communications to
CMM controller
TP200
PI 200
Cable 5
PI 7-2
Communications to
CMM controller
ACC2-2
To ACR1 rack
PICS output CMM controller
Figure 21 - System interconnection - TP7M touch-trigger probe and autochange
35
36
Installation procedure
6.4 Using TP200 with the ACR1 autochange system
105
A
0
Figure 22 - Shock absorbing pad fitted to PH10M
The CMM controller must assert the probe damping signal (PDAMP) on the PICS port
when the probe is approaching the rack, to prevent a false trigger being generated
when the probe contacts the docking port lid.
If this is not possible, a shock absorbing pad (part number A-1085-0294 supplied
with ACR1) must be fitted to the autojoint connector on the probe head at the point of
contact with the port lid. Refer to figure 22.
37
Installation procedure
6.5 SCR200 stylus change rack
The miniature DIN connector on the base of the SCR200 rack is connected to the
‘SCR200’ connector on the PI 200 rear panel using cable PL63/PL64/PL65 according to
the length required. Refer to table 8, cable number 12.
For applications requiring two racks, a dual rack splitter cable is needed. Refer to table
8, cable number 11 and figure 23.
The dual SCR200 adaptor cable must be fitted at the PI 200 end.
PI 200
SCR200
Cable 12
Cable 12
SCR200
Figure 23 - Connection of dual SCR200 stylus change racks
Refer to the ‘TP200 and SCR200 user’s guide’ (Renishaw part number H‑1000-5014)
for information on setting up and operating the SCR200 rack.
38
Installation procedure
6.6 Interconnection cables
Table 8 - Interconnection cables
Cable
number
1
2
3
4
5
6
7
Cable
ident.
Length (m)
Part number
Notes
PL1
0.26 - 0.71
A-1016-0004
Coiled
PL2
0.41 - 1.27
A-1016-0006
Coiled
PL3
0.68 - 2.32
A-1016-0012
Coiled
PL4
4.5
A-1016-0001
Plain
PL27
0.225
A-1016-6370
Coiled
PL29
0.74
A-1016-6420
Coiled
PL22
0.4
A-1057-0131
PL5
0.40 - 0.80
A-1016-0131
Coiled
PL6
0.80 - 1.60
A-1016-7673
Coiled
PL12
0.10
A-1016-7674
Plain
PL13
0.10 - 0.20
A-1016-7675
Coiled
PLM6
6
A-1016-7564
Unterminated one end
PLM7
4
A-1016-7563
Unterminated one end
PLM8
6
A-1016-7677
PLM9
4
A-1016-7678
PL25
0.30
A-1016-0124
PL63
5
A-1016-7630
PL64
10
A-1016-7631
PL65
20
A-1016-7632
PL38
25
A-1016-7625
Unterminated one end
PL42
15
A-1016-7624
Unterminated one end
PL56
12
A-1016-7626
Unterminated one end
PL44
8
A-1016-7627
Unterminated one end
PL46
3.7
A-1016-7628
Unterminated one end
Unterminated one end
PL45
1.8
A-1016-7629
8
PL70
2
A-1016-7634
9
PL76
1
A-1016-7643
Installation procedure
39
Table 8 - Interconnection cables continued
Cable
number
Cable
ident.
Length (m)
Part number
10
PL112
1
A-2172-0004
11
PL97
0.25
A-1016-7660
PL63
5
A-1016-7630
PL64
10
A-1016-7631
PL65
20
A-1016-7632
12
Notes
6.7 Upgrading older probe systems to TP200
(retrofitment)
To successfully retrofit a TP200 probe system, the following points will need to be
considered:
• The CMM controller must service the PICS - PDAMP control signal. Upgrade of the
controller may be necessary if this signal is not available.
• The probe signal wires from the M8 connector on the probe head must be routed
directly to the PI 200 interface. If an in-line interface for kinematic switching probes
(TP1/TP2/TP6) is present, it must be removed.
• The signal wire resistance must be less than 5 ohms per conductor.
• Some experimentation with typical stylus arrangements may be necessary to obtain
a satisfactory setting for the PDAMP/HALT filter delay time. The trigger/reseat
debounce time and other configuration options will also need to be set. Refer to the
‘configuration switches’ section for more information.
• If upgrading from TP2, measurement programs may need to be changed to suit the
length of the TP200, which is 5 mm longer than the TP2.
• If upgrading from TP2, star or offset (cranked) stylus arrangements will require a
minimum 5 mm extension piece to be added for use with the TP200.
• If cables other than those supplied by Renishaw are used, equivalent cable
screening and connector bonding must be used to maintain compliance with the
EMC standards.
40
7
PICS terminations
PICS terminations
The Renishaw product interconnection system (PICS) has been developed to
standardise the format for real-time communications between Renishaw products and
the CMM controller. PICS facilitates the integration of multiple probe interfaces and
system controllers without the need for additional hardware or software overheads on
the CMM controller.
Refer to the section ‘connector pin-outs’ for the pin assignments used on the 9 way ‘D’
type PICS connector ports.
Refer to figures 16 - 21 in the section ‘system interconnection’ for examples of the
PICS connections for typical installations. Note that the order in which the system
components are connected is important. In particular, the autochange controller
(ACC2-2) should be the last in the chain before the CMM controller (figures 20 and 21)
to allow it to disable probe damping (PDAMP) during the ACR1 set-up procedure.
Installations incorporating the PI 800-2 probe interface are an exception and the
TP800-2 installation guide (Renishaw part number H-1000-5111) should be consulted
for further information.
For further information, please refer to the PICS installation guide (H‑1000‑5000).
Summary of changes from earlier versions
8
41
Summary of changes from earlier versions
The table below summarises the changes made from version V7 - V11 as indicated by
the label on the rear panel of the PI 200.
NOTE: No changes have been made that affect measuring accuracy.
Table 9 - Summary of changes from earlier versions
Part number
Version
label
Summary of changes
PCB layout and component changes due to component
obsolescence.
A-1207-0050-10
V11
A-1207-0050-09
V10
Layout of rear panel changed and IEC mains connector
now unfiltered. Text appearance changed on front
panel and RESET button now adjacent to STOP LED.
New PLD, mains power supply and 5 V to 15 V dc-dc
converter.
Functionality identical.
A-1207-0050-08
V9
Withdrawn.
Additional PDAMP filter delay time option (2.0 ms and
7.5 ms) added. Switches 11 and 12 coded to offer the
four delay options.
Switch 10 function deleted - now trigger level selector
(was switch 11).
Mounting brackets removed from kit.
PL25 and PL26 cables removed from the top level kit.
A-1207-0050-07
V8
Circuit changes to improve immunity to ESD applied to
the probe stylus when in TP2 mode.
Early reseat, short debounce option (switch 7 UP, switch
6 DOWN) changed from 20/80 ms to 20/20 ms.
A-1207-0050-06
V7
Fault corrected that caused fast autozero to latch on if
PI 200 was powered up with PPOFF asserted and no
TP200 connected.
Change to prevent a false audible alarm after a rapid
series of soft (low signal level) triggers.
42
9
Maintenance
Maintenance
9.1 PI 200
Periodically check the security of mounting screws and electrical connectors.
Periodic electrical safety checks should include inspection of the mains cable for
damage and safe connections. An earth continuity (ground bonding) test may be
applied between the protective earth pin of the mains connector and the metal case at
a test current no greater than 25 A.
Remove dust from the external surfaces with a proprietary cleaning cloth.
9.2 TP200 probe and stylus module
The kinematic coupling mechanism, connecting the probe sensor to the stylus module,
incorporates precision ball/V groove seatings. The coupling mechanism has been
tested in a wide range of environments and is highly tolerant of non-metallic dust, but
regular inspection and cleaning with the material supplied is recommended to ensure
continued high performance.
Instructions for use are included with the cleaning material (Renishaw part number
A‑1085-0016).
The user should determine the frequency of cleaning according to the conditions of use.
Stylus balls, threads and mating faces should be cleaned with proprietary cloths or
solvent.
Stylus modules that are not in use should be stored in spare ports in the SCR200 rack
or in their transport boxes.
9.3 SCR200 rack
Periodic cleaning of the rack ports, lids and outer surfaces using a proprietary cloth is
recommended to prevent contamination of the modules.
Fault finding
10
43
Fault finding
Table 10 - The CMM will not register a probe trigger, but the probe operates
normally when the stylus is deflected by hand.
PI 200 indicators:
‘STOP’ LED is ON.
‘TP200’ LED is ON.
‘SEATED’ LED operates normally.
Checks/remedies
Possible cause
• The CMM controller or a
Renishaw system has activated
the STOP signal.
• The SCR200 overtravel
mechanism is deflected.
• Check the status of the Renishaw
motorised probe head or other systems.
• Check the status of the Renishaw
motorised probe head or other systems.
Table 11 - The probe fails to trigger and the probe LEDs glow only dimly when
the stylus touches the workpiece, but the probe operates normally when the
stylus is deflected by hand.
PI 200 indicators:
‘SEATED’ LED is ON.
Checks/remedies
Possible cause
• The trigger speed is too slow.
• Probe normally to the workpiece surface.
• The stylus is too heavy.
• Increase the gauging speed.
Table 12 - The probe will not arm or the probe does not stay armed when the
RESET button is released. The probe LEDs are always OFF.
PI 200 indicators:
‘STD’ LED is ON.
‘SEATED’ LED is OFF.
Possible cause
• The probe sensor is faulty.
• The probe wiring is open circuit.
Checks/remedies
• Remove the probe and test by
substitution.
• Check the wiring from the probe to the
PI 200 interface.
44
Fault finding
Table 13 - The probe will not arm or the probe does not stay armed when the
RESET button is released. The probe LEDs are always ON.
PI 200 indicators:
‘TP200’ LED is ON.
‘SEATED’ LED is OFF.
Possible cause
• The probe sensor is faulty or has
been damaged by a collision.
Checks/remedies
• Remove the probe and test by
substitution.
Table 14 - False (‘air’) triggers occur while the CMM is stationary and the probe
LEDs flicker.
PI 200 indicators:
‘TP200’ LED is ON.
‘SEATED’ LED operates normally.
Possible cause
• The probe sensor is faulty.
• The probe is loose in the probe
head.
• There is excessive vibration from
an external source.
• There is excessive vibration from
the CMM.
Checks/remedies
• Remove the probe and test by
substitution.
• Correctly tighten the probe.
• Remove the cause or isolate the CMM.
• Check the CMM’s air supply.
• Maintain the CMM’s air bearing system.
Table 15 - False (‘air’) triggers occur at gauging speed and the probe LEDs
flicker.
PI 200 indicators:
‘DAMPED’ LED is OFF.
‘SEATED’ LED operates normally.
Possible cause
Checks/remedies
• The stylus is too large or too
heavy.
• Use stylus arrangements within
recommendations.
• There is excessive vibration from
the CMM.
• Check the CMM’s air supply.
• Maintain the CMM’s air bearing system.
Fault finding
Table 16 - False (‘air’) triggers occur at traverse speed and the probe LEDs
flicker.
PI 200 indicators:
‘DAMPED’ LED is ON.
‘SEATED’ LED operates normally.
Possible cause
Checks/remedies
• The stylus is too large or too
heavy.
• Use stylus arrangements within
recommendations.
• There is excessive vibration from
the CMM.
• Check the CMM’s air supply.
• The traverse speed is too high.
• Maintain the CMM’s air bearing system.
• Reduce the traverse speed.
Table 17 - The probe triggers during an SCR200 stylus change.
PI 200 indicators:
‘SEATED’ LED operates normally.
Possible cause
• The SCR200 is not connected to
the PI 200.
• Incorrect SCR200 operating
mode.
Checks/remedies
• Check the SCR200 indicator lamps.
• Reconnect the cable.
45
46
Fault finding
Table 18 - There is an unexpected loss of accuracy.
PI 200 indicators:
‘TP200’ LED is ON.
‘SEATED’ LED operates normally.
Checks/remedies
Possible cause
• The stylus ball is damaged or dirty. • Clean the stylus ball, or replace and
requalify the stylus.
• The stylus is too large or too
heavy.
• Use stylus arrangements within
recommendations.
• The probe is loose or not correctly
assembled.
• Check the stylus joints.
• The kinematic coupling is
damaged or dirty.
• Ensure the module is correctly seated
and the probe is tight in the probe head.
• The gauging speed has been
changed.
• Inspect and clean the kinematic coupling.
• Requalify the stylus tips.
• The trigger threshold has been
changed.
Table 19 - The deflection alarm is active.
PI 200 indicators:
Audible indicator is ON.
Possible cause
• The stylus is or was deflected for
longer than 10 seconds.
Checks/remedies
• Move the stylus clear of any obstruction
and press the RESET button.
• The stylus module was changed
manually.
Table 20 - TP200 fails to work.
PI 200 indicators:
‘STOP’ LED ON.
‘POWER’ LED ON.
Possible cause
• The M8 bush polarity is incorrect.
Checks/remedies
• Change the PI 200 probe polarity switch
to the opposite state.
Renishaw plc
New Mills, Wotton-under-Edge,
Gloucestershire, GL12 8JR
United Kingdom
T +44 (0)1453 524524
F +44 (0)1453 524901
E uk@renishaw.com
www.renishaw.com
For worldwide contact details,
please visit our main website at
www.renishaw.com/contact
*H-1000-5029-05-B*