Technical Services Installation Instructions
CONTURA G2
Measuring Center
1. Selection of Installation Site and
Installation Conditions
When selecting the installation site, please make sure that the following conditions either already exist or can be implemented there.
The system comprises the following components:
1. Coordinate measuring machine
2. Controller
3. Control console
4. Data station (peripherals)
Ambient Conditions for Operational Readiness
Permissible ambient temperature: +17°C to +35°C
Permissible air humidity:
40% - 60% without condensation
Sound level at installation site: <90dB
Max. altitude above sea level: for 100 - 125 V 3000 m for 220 - 240 V 2000 m
1.1
Required Room Height
This dimension equals the sum of the height of the coordinate measuring machine and a minimum overhead clearance of 200 mm.
Example
:
Contura G2
Height of CMM
Minimum installation clearance
Required minimum room height above floor or foundation
2800 mm
200 mm
3000 mm
Temperature Conditions for Operation of CMM:
The measuring uncertainty specified for your CMM can be guaranteed if:
1. you use a measurement correction program and enter the workpiece and CMM temperatures as well as the temperature expansion coefficients of the workpiece material.
2. the following temperature conditions are observed:
CMM Type
CONTURA G2
CONTURA G2 HTG
(optional)
Temp.
Range
(ºC)
18 - 22
18 - 26
Temperature Gradient
per hour
(ºK/h)
1.0
per day
(ºK/d)
1.5
per m
(ºK/m)
1.0
1.0
1.5
1.0
Please make sure that sufficient lighting is available.
The use of sources of heat near the CMM must be avoided wherever possible.
1.2
Required Floor Surface
A cutout layout plan is included in this brochure to give you a quick overview of the required floor surface. When preparing the space assignment plan, make sure that your CMM is well accessible from all sides.
Please select the installation site so that there is a distance of at least 800 mm between the CMM and the wall.
1.5
General Protective Measures
The CMM must be protected against dirt and foreign particles (e.g. casting sand, metal filings and bore chips, oil, coolants, lubricants and soot). Deposits of materials such as casting sand and swarf may lead to increased expenses for cleaning and maintenance.
1.3
Transport Lanes
Please check the ground-floor and upper-storey floor loading capacity of all transport lanes leading to the installation site. The doorways must be at least 5 cm wider and higher than the largest packaged unit, including the transport vehicle. The dimensions and weights of the transport units are specified in this brochure.
1.4
Ambient Conditions
Bridge-type coordinate measuring machines are hightech products. Their specified quality is attainable only if you ensure that the following conditions are met.
1.6
Vibrations at the Installation Site
The following diagram(s) show(s) the permissible floor vibrations.
Vibrations are often caused by heavy processing machinery, transport vehicles (cranes or stackers) and stamping or forging machines located in adjacent rooms.
A measurement is required to determine the actual magnitude of local floor vibrations. You can order such a vibration analysis from Carl Zeiss Oberkochen. Please call or e-mail your contact person for more details.
In any case, the results must be made available to CZO for evaluation.
Permissible Storage Temperature Range
5°C to 40°C
Pay special attention to the storage temperature during winter. Avoid storing at temperatures below 5°C.
1.7
Floor Load
When calculating or planning any floor reinforcement
(foundation etc.) which may be required, it is advisable to
Installation Instructions
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3
consult a statics engineer who is familiar with your local floor conditions. To determine the floor load exerted by the CMM, see the pertaining information in this brochure.
Acceleration [mm/ss]
1000
100
10
1
0,1
0 10 20
Permissible foundation acceleration for
Contura G2 w. trigger probe and standard damping
Acceleration values above the curve require an additional foundation
30
X axis horizontal
Y axis horizontal
Z axis vertical
40 50
Frequency [Hz]
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4
Installation Instructions
10
1
0,1
0
Acceleration [mm/ss]
1000
100
10 20
Permissible foundation acceleration for
Contura G2 measuring with standard damping
Acceleration values above the curve require an additional foundation
30
X-axis horizontal
Y-axis horizontal
Z-axis vertical
40 50
Frequency [Hz]
Installation Instructions
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5
2. Preparation for installation/Required connections/Transport/
Storage
The following preparations must be made prior to the installation date:
2.1
Preparing the Floor Surface
The floor surface must be clean and the unevenness of the bearing surfaces must not exceed max. 25 mm.
2.2
Electric Power Supply
We recommend connecting the system to a power source which does not supply electricity to peak-load or high-consumption equipment (elevators, air conditioning systems). Due to the possibility of negative influences, avoid installing the CMM near
– High-consumption equipment
(e.g. welding machines)
– High-interference (EMI) equipment
(e.g. electron discharge machines).
The use of mobile telephones or walkie talkies within a radius of 3m surrounding the CMM is also prohibited.
This precaution is necessary to prevent malfunctions,
especially in connection with data processing systems.
A permanent connection (max. 16A) must be provided for the system. Alternatively, a 3-wire CEE-form plug connection is also acceptable. A 5-plug multiplex outlet must be provided by you (the customer) for the data station.
We recommend the on-site installation of a surge arrester, e.g. Phoenix Flashtrab FLT 25-400, as basic protection against surge voltage.
We recommend making the connection as shown in the following drawing,
taking into account that all pertaining national regulations also must be observed.
2.3
Electric Power Supply Parameters
To ensure trouble-free data transmission between the
Connection diagram
Proposed permanent connection (customer installation (national voltage))
CMM and the data station, the line power supply must comply with the following specifications.
Line power supply:
– Line voltage:
1/N/PE 100/110/115/120/125/230/240 VAC
– Max. voltage fluctuations:
±10 %
– Frequency:
50 or 60 Hz
– Max. frequency fluctuations:
±3.5%
– Max. power sag:
10 ms
(Max. one half-wave may be missing at 50 Hz)
– Interference peaks
Max. rise time at 5 ns: ± 500 V
Max. rise time at 50 µs: ± 1000 V
Max. amount of heat generated:
3600 kJ/h
Max. total power requirement:
CMM: max. 1000 VA
Peripheral workstation: max. 1000 VA
2.4
EMC
EN 61326-1 Appendix A, Class A
Warning !
This is a class A device, and may therefore cause radio interference in the surrounding area. In such cases, the operator may be required to take appropriate action and bear any costs thus incurred.
2.5
Stabilizing the line voltage
If out-of-tolerance r.m.s. fluctuations of the nominal voltage briefly occur, a line analysis must be performed.
Please contact us if you have such a requirement. We will be glad to advise you and suggest suitable measures. In most cases, it is sufficient to install a separate stub cable from the main distributor to the CMM.
3x 2.5 mm
2
cable included in scope of supply
L
N
PE
C16 A
Fault current breaker
(if required)
Terminal box
CMM
Multiplex outlet with
5x 3-wire sockets
Multiplex
3-wire outlet
Peripherals: max. 1000 VA
Connecting cable, min. 5 m
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6
Installation Instructions
2.6
Machine parameters
– Overvoltage category:
ΙΙΙ
– Pollution degree:
2
– Protection class:
1
2.7
Teleservice
You will require an Internet connection for Teleservice.
For more details, please refer to the
"Teleservice"
brochure.
2.8
Compressed Air Supply
Please make sure that the air pressure required to operate your CMM is available as described below:
● Minimum pressure 6 bar, max. pressure 10 bar.
●
Prefiltered air; completely free of contaminating particles, oil vapors and water residues.
● Air quality in compliance with ISO 8573 Part 1 Classification 4, which includes:
Par. 6.1: Max. particle size 15 µm, max. dirt particle concentration 8 mg/m
3
Par. 6.2: Max. compressed air dew point +3 °C
Par. 6.3: Max. oil concentration of 5 mg/m
3
If the above air quality is not attained, it may be necessary to add an additional downstream air filtration unit and, in some cases, a membrane dryer to the compressed air line of the CMM. These units can be ordered from CZ. Please ask your contact person for more information.
Note!
Failure to comply with the above air quality specifications could result in damage not covered by your warranty.
Air consumption of CMM:
Max. 30 l/min at 5 bar (150 normal liters/min at 1 bar)
Connecting point for compressed air
A connection with a compressed air coupling for a ¼“
NPT plug-in fitting is required to connect the machine to the compressed air supply. This connection must be provided by you as illustrated in the section entitled
"CMM installation dimensions and arrangement of the steel plates"
. A compressed air hose with a ¼“ NPT plug-in fitting (included in the scope of supply) must be laid and connected during installation.
When laying the connection up to the CMM, make sure that the connecting parts are readily accessible and are not obstructed by the base of the CMM.
2.9
Transport Vehicles
Please provide a forklift with sufficient carrying capacity and fork length to unload the packaged units and transport them to the storage or installation site. The loading capacities required of these vehicles are specified on the following pages.
All transport lanes and approaches should be kept open during the entire installation and startup period to help ensure trouble-free installation.
The transport locks and braces on the CMM, pallet (
shipping crate)
and lashing straps must be returned to CZ.
Packing materials such as e.g. foils or styrofoam chips ("popcorn") are recycled by Carl Zeiss and
Note!
should be returned to CZ along with the transport stops and braces if they are clean and no dirt has been mixed in with them.
2.10 Unloading/Storing/Unpacking
With outdoor temperatures below 0°C, CMM assemblies with granite guideways are not enclosed in a protective
PVC bag, but sealed air-tight along with a drying agent in an aluminum-coated foil (insulated packaging).
Unloading and transport must be performed only with transport lugs or pallets.
Be careful not to damage the insulated packaging!
Please remember that your CMM is a valuable, high-precision instrument. For this reason, you should avoid jolting or knocking the crate at all times.
Please leave the crates packed and store them in a sheltered location as close as possible to the installation site.
Adaptation to room temperature:
Store the crates in a room with a minimum ambient temperature of 15° C at least 2 days before our system specialist arrives. The crates may be unpacked and the insulated packaging may be removed only by our system specialist! Please also make sure that a place suitable for depositing the empty containers is provided.
2.11 Moving the CMM to another location
Note!
A system specialist should always be present when moving the CMM to another location as a precaution to ensure that it is not damaged.
Installation Instructions
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7
3. Shipping Crates and Pallets
3.1
Dimensions and Weights
The machine components are delivered on transport pallets with insulated packaging. They are delivered in a shipping crate only for air cargo and overseas shipments.
Note!
H
L
W
.
Crate dimensions in mm (max.)
Max. tare wt. (kg) Max. gross wt. (kg)
Shipping crate for
L W H m
3
Sea/air cargo crate
Truck pallet w. sea/air cargo crate with truck pallet
CONTURA G2
X=700, Y=700, Z=600
X=700, Y=1000, Z=600
X=1000, Y=1200, Z=600
X=1000, Y=1600, Z=600
X=1000, Y=2100, Z=600
CONTURA G2
(opt. granite U-profile)
Upper part, X=1000, Y=1200, Z=600
Upper part, X=1000, Y=1600, Z=600
Upper part, X=1000, Y=2100, Z=600
CONTURA G2
(opt. granite U-profile)
Base, X=1000, Y=1200, Z=600
Base, X=1000, Y=1600, Z=600
Base, X=1000, Y=2100, Z=600
Pal box with accessories
Controller
2820
2820
2870
2870
3280
2870
2845
3330
1805
2210
2515
1755
1755
1755
765
765
740
1475 1070 1095
1100
1960
1960
2265
2265
2265
2265
2110
2110
1100
2515
2515
2515
2515
2515
2515
2515
2515
1100
13.9
13.9
16.4
16.4
18.7
16.4
15.1
17.7
2.5
3.0
3.3
1.8
1.4
696
696
883
883
826
852
958
987
164
171
209
69
90
407
407
545
545
540
555
727
761
60
76
64
1986
2236
3176
4016
5997
3092
3602
6084
284
304
394
206
227
1692
1951
2851
3358
5625
2795
3372
5857
180
209
249
Note:
All values specified above are maximum values. Any values not entered were not available at the time of printing. For
technical reasons
the dimensions of the shipping crates (L, W and H) may deviate from the values specified here
by as much as +50 mm
.
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8
Installation Instructions
4. CMM Installation Dimensions and Arrangement of Steel Plates
4.1
Installation Dimensions for CONTURA G2
(all dimensions in mm, scale 1:30)
Min. overhead clearance: 200 mm
845
850 b
203
283
T-T c a min. 800 f t
Height of secured CMM assembly without pallet and without Z tower
2450
2200
Height of secured
CMM assy incl. pallet
2800
CONTURA G2
X/Y/Z measuring range
700/700/600
700/1000/600
1000/1200/600
1000/1600/600
1000/2100/600
Net weight of CMM
ca. 1280 kg ca. 1550 kg ca. 2310 kg ca. 2810 kg ca. 5171 kg
Max. permissible workpiece weight
560 kg
730 kg
1150 kg
1500 kg
1814 kg
T-T = Distance between table and bottom of probe
VAST
XT probe
RDS probe
716
665
Controller
Length: ca. 756
Width: ca. 575
Height: ca. 700 g
X/Y/Z measuring range
700/700/600
700/1000/600
1000/1200/600
Length
- a -
1430
1430
1743
Length
- b -
1525
1830
2030
Length
- c -
920
Length
- t-
1603
1000/1600/600
1743 2430
1000/2100/600
1743 2945 1756 c
= On-site air supply connection, precleaned compressed air supply with pressure of 6-10 bar.
d
= Power supply ( two outlets with max. 16 A) to be installed by the customer.
e
= Telephone connection (ISDN) f
= CMM compressed air supply connection g
= CMM
↔
control connecting cable
t
= Transport height without base
1225 min. 800 c d e
CONTURA G2
X/Y/Z measuring range
700/700/600
700/1000/600
1000/1200/600
1000/1600/600
1000/2100/600
Max. cable leng.
CMM
↔
control
g ca. 3700 mm ca. 3550 mm ca. 6300 mm ca. 6000 mm ca. 5700 mm
Installation Instructions
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9
4.2
Installation Dimensions for CONTURA G2 with opt. U-profile
(all dimensions in mm, scale 1:30)
Min. overhead clearance: 200 mm
1048
850 b
203
T-T c a min. 800 f t
Height of secured CMM assembly without pallet and without Z tower
2653
3003
CONTURA G2 with optional U-profile
X/Y/Z
Measuring range
1000/1200/600
1000/1600/600
1000/2100/600
Net weight of
CMM
ca. 2583 kg ca. 3163 kg ca. 5755 kg
Max. permissible workpiece weight
1150 kg
1500 kg
1814 kg
2403
Height of secured
CMM assy incl. pallet
T-T = distance betw. table and lower edge of probe
VAST
XT probe
RDS probe
919
868
Controller
Length: ca. 756
Width: ca. 575
Height: ca. 700 g c d e
CONTURA G2 with optional U-profile
X/Y/Z
Measuring range
1000/1200/600
1000/1600/600
Length
- a -
1743
1743
Length
- b -
2030
2430
Length
- c -
1200
Length
- t-
1806
1000/2100/600
1743 2945 1959 c
= On-site air supply connection, precleaned compressed air supply with pressure of 6-10 bar.
d
= Power supply (two outlets with max. 16 A) to be installed by the customer.
e
= Telephone connection (ISDN) f
= CMM compressed air supply connection g
= CMM
↔
control connecting cable
t
= Transport height without base
CONTURA G2
X/Y/Z
Measuring range
1000/1200/600
1000/1600/600
1000/2100/600
Max. cable leng.
CMM
↔
control
g ca. 6300 mm ca. 6000 mm ca. 5700 mm min. 800
283
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10
Installation Instructions
4.3
Installation of Floor Stripe or Chain
The dangers posed by the CMM are impossible - or at least difficult - for untrained personnel to recognize. For this reason, a restricted-access zone must be set up around the machine to prevent damage or injury caused by untrained personnel.
The entrance to this area should be be clearly marked by a warning sign reading:
"Admittance only for authorized personnel"
and may be entered only by persons who have received proper training (operators).
min. 200 min. 200
Controller c min. 1000 min. 600
Floor marking or chain
(black-and-yellow) min. 1000 min. 1000 min. 700 d c
The back door of the controller cabinet must be located at least 200mm away from the wall.
Note!
Moreover, the air exchange with the surrounding environment should not be blocked. The control cabinet should be placed so that the rear side of the controller always faces away from the CMM.
min. 100 min. 100 d
CMM table (optional) with computer and printer
Installation Instructions
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11
4.4
Arrangement of the Steel Plates for Contura G2
The relative unevenness of the bearing surfaces must not exceed max. 25mm (1“)..
The deviation tolerance for the center-to-center plate distance is (A) ±10 mm (all dimensions in mm)
CONTURA G2
X=700, Y=700
CONTURA G2
X=1000, Y=1200
822
521
219
244
1032
CONTURA G2
X=700, Y=1000
1234
773
311
299
1192
CONTURA G2
X=1000, Y=2100
1070
674
276
244
1032
CONTURA G2
X=1000, Y=1600
Page
12
1556
973
389
299
1192
Support (A):
Cast iron plate Ø 150
(included in delivery)
Point of support
(tilt protection only)
Installation Instructions
1971
1232
493
297
1186
Floor load on the supports (A)
X=700, Y=700
CONTURA G2
34.8 N/cm
2
X=700, Y=1000
43.1 N/cm
CONTURA G2
2
X=1000, Y=1200
X=1000, Y=1600
65.4 N/cm
2
81.5 N/cm
2
X=1000, Y=2100
132.1 N/cm
2
CONTURA G2 w. granite U-table (option)
X=1000, Y=1200
X=1000, Y=1600
X=1000, Y=2100
70.6 N/cm
2
88.2 N/cm
2
143.1 N/cm
2
5. Dimensions of Granite Table and Fastening Hole Matrix
5.1
Measuring Table for Measuring Range of X=700, Y=700
152
58,4
Bridge running surface
Y grid position
4
744,8
3
2
544,8
344,8
1
Y
144,8
X
100
237
1189
700
M12 (16x)
Meas. range
700
1041
1321
256 456 656 856
1 2 3 4
X grid position
89
127
Bridge drive
Installation Instructions
Page
13
5.2
Measuring Table for Measuring Range of X=700, Y=1000
1189
700
M12 (24x)
Meas. range
152
58,4
Bridge running surface
Y grid position
6 1144,8
5
4
3
2
944,8
744,8
544,8
344,8
1
Y
144,8
100
237
X
1000
1346
1626
256 456 656 856
1 2 3 4
X grid position
89
127
Bridge drive
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14
Installation Instructions
5.3
Measuring Table for Measuring Range of X=1000, Y=1200
1492
1000
M12 (42x)
Meas. range
152
58,4
Bridge running surface
Y grid position
7
1344,8
6
1144,8
5
4
3
2
944,8
744,8
544,8
344,8
1
Y
144,8
100
237
X
1200
1545
1825
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Installation Instructions
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15
5.4
Measuring Table for Measuring Range of X=1000, Y=1600
1492
1000
M12 (54x)
Meas. range
152
58,4
Bridge running surface
5
4
3
2
Y grid position
9
1744,8
8
1544,8
7
6
1344,8
1144,8
944,8
744,8
544,8
344,8
1
Y
144,8
100
237
X
1600
1945
2225
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Page
16
Installation Instructions
5.5
Measuring Table for Measuring Range of X=1000, Y=2100
152
58,4
Bridge running surface
Y grid position
11
2144,8
10
1944,8
9
8
7
6
5
4
3
2
1744,8
1544,8
1344,8
1144,8
944,8
744,8
544,8
344,8
1
Y
144,8
X
100
237
1494
1000
M12 (66x)
Meas. range
2100
2464
2743
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Installation Instructions
Page
17
5.6
Measuring Table with U-Profile for Measuring Range of X=1000, Y=1200
1492
1000
M12 (42x)
Meas. range
152
58,4
Bridge running surface
Y grid position
7 1344,8
6 1144,8
5
4
3
2
944,8
744,8
544,8
344,8
144,8 1
Y
X
237
125
1200
1545
1825
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Page
18
Installation Instructions
5.7
Measuring Table with U-Profile for Measuring Range of X=1000, Y=1600
1492
1000
M12 (54x)
Meas. range
152
58,4
Bridge running surface
5
4
3
2
Y grid position
9
1744,8
8
1544,8
7
6
1344,8
1144,8
944,8
744,8
544,8
344,8
1
Y
144,8
125
237
X
1600
1945
2225
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Installation Instructions
Page
19
5.8
Measuring Table with U-Profile for Measuring Range of X=1000, Y=2100
152
58,4
Bridge running surface
Y grid position
11
2144,8
10
1944,8
9
8
7
6
5
4
3
2
1744,8
1544,8
1344,8
1144,8
944,8
744,8
544,8
344,8
1
Y
144,8
X
237
125
1494
1000
M12 (66x)
Meas. range
2100
2464
2743
256 456 656 856 1056 1256
1 2 3 4 5 6 X grid position
89
127
Bridge drive
Page
20
Installation Instructions
6. Cutout Patterns for Customer Floor Plan
6.1
Cutout Patterns for Contura G2
Scale: 1:30
CONTURA G2
X=700, Y=700
CONTURA G2
X=1000, Y=1200
CONTURA G2
X=1000, Y=1600
CONTURA G2
X=700, Y=1000
Controller
CONTURA G2
X=1000, Y=2100
Installation Instructions
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