Renishaw OTS 1/2 AA Installation guide

Installation guide

H-5401-8505-01-A

OTS - optical tool setter

© 2007 Renishaw plc. All rights reserved.

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.

Contents

Renishaw part no: H-5401-8505-01-A

Issued: 05.2007

Contents

Section 1 Before you get started

Provides information on patents, trademarks, declarations of conformity, warranty and safety .

Section 2 OTS basics

An overview of the OTS

Section 3 System installation

Explanation of how to install the batteries within the probe module, how to mount the OTS on a the machine. Information is also provided on how to site each of Renishaw's receiver units within the machine to obtain the optimum optical performance.

Section 4 Trigger Logic™

The 'Trigger Logic™' method developed by Renishaw, allows

probe settings to be configured using a sequence of stylus deflections.

Section 5 Service and maintenance

Keeping your OTS in good working order .

Section 6 Troubleshooting

Find the solution.

Section 7 Parts list

Find the part you require from our comprehensive list of spare parts and accessories.

OTS installation guide

Contents

(continued)

Section 8

Section 9

Probe settings record table

K now your probe settings at a glance.

Definition of probing terms

Know what is meant by the terms commonly associated with probing .

Before you get started

Contents

(continued)

Before you get started

Contents

Before you get started ....................................................................1.2

Disclaimer ..........................................................................................1.2

Trademarks ........................................................................................1.2

Warranty ............................................................................................1.2

Changes to equipment ......................................................................1.2

CNC machines ..................................................................................1.2

Care of the probe ...............................................................................1.2

Patents ..............................................................................................1.2

EC declaration of conformity..........................................................1.3

FCC declaration (USA) ....................................................................1.3

Safety ................................................................................................1.4

1.1

OTS installation guide

1.2

Before you get started

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

RENISHAW® and the probe emblem used in the RENISHAW logo are registered trademarks of Renishaw plc in the UK and other countries.

apply innovation and Trigger Logic are trademarks of Renishaw plc.

All other brand names and product names used in this document are trade names, service marks, trademarks, or registered trademarks of their respective owners.

Warranty

Equipment requiring attention under warranty must be returned to your equipment supplier.

No claims will be considered where Renishaw equipment has been misused, or where repairs or adjustments have been attempted by unauthorised persons.

Changes to equipment

Renishaw reserves the right to change equipment specifications without notice.

CNC machines

CNC machine tools must always be operated by fully trained personnel in accordance with the manufacturer's instructions.

Care of the probe

Keep system components clean and treat the probe as a precision tool.

Patents

Features of the OTS probe, and other similar

Renishaw probes, are subject of one or more of the following patents and/or patent applications:

EP 0337669

EP 0695926

EP 0974208

EP 1130557

EP 1373995

EP 1397637

EP 1425550

EP 1503524 B

EP 1701234

EP 1734426

JP 2,994,401

JP 2004-522,961

JP 2004-530,234

JP 2005-502,035

US 5,150,529

US 5,669,151

US 6,472,981 B2

US 6,839,563 B1

US 6,869,026 B2

US 6,941,671 B2

US 7145468 B2

C

EC DECLARATION OF CONFORMITY

Renishaw plc declare that the product: -

Name Description

OTS Optical tool setter has been manufactured in conformity with the following standard: -

BS EN 61326:1998/

A1:1998/A2:2001

Electrical equipment for measurement, control and laboratory use -

EMC requirements.

Immunity to annex A - industrial locations.

Emissions to class A

(non-domestic) limits.

and that it complies with the requirements of directives

(as amended): -

89/336/EEC Electromagnetic compatibility

(EMC)

The above information is summarised from the full

EC Declaration of Conformity. A copy is available from

Renishaw on request.

FCC DECLARATION (USA)

FCC Section 15.19

This device complies with Part 15 of the FCC rules.

Operation is subject to the following two conditions:

1. This device may not cause harmful interference.

2. This device may accept any interference received, including interference that may cause undesired operation.

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.

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.

Warning labels to be placed on equipment and for information to be supplied to the user.

1.3

1.4

OTS installation guide

Safety

Information for the user

Handle and dispose of batteries in accordance with the manufacturer's recommendations.

Use only the recommended batteries. Do not allow the battery terminals to contact other metallic objects.

Information for the machine supplier/ installer

It is the machine supplier's responsibility to ensure that the user is made aware of any hazards involved in operation, including those mentioned in Renishaw product literature, and to ensure that adequate guards and safety interlocks are provided.

Under certain circumstances, the probe signal may falsely indicate a probe seated condition.

Do not rely on probe signals to halt the movement of the machine.

Information for the equipment installer

All Renishaw equipment is designed to comply with the relevant EEC and FCC regulatory requirements. It is the responsibility of the equipment installer to ensure that the following guidelines are adhered to, in order for the product to function in accordance with the these regulations:

• any interface MUST be installed in a position away from any potential sources of electrical noise, i.e. power transformers, servo drives etc;

•

•

•

• all 0V / ground connections should be connected to the machine 'star point'

(the 'star point' is a single point return for all equipment ground and screen cables). This is very important and failure to adhere to this can cause a potential difference between grounds; all screens must be connected as outlined in the user’s instructions; cables must not be routed alongside high current sources, i.e. motor power supply cables etc, or be near high speed data lines; cable lengths should always be kept to a minimum.

!

CAUTION: The OTS has a glass window.

Handle with care if broken to avoid injury.

OTS basics

OTS basics

Contents

Introduction ................................................................... 2.2

Trigger Logic TM ................................................................ 2.2

Probe settings ............................................................... 2.2

Switch-on method ........................................................... 2.2

Optical start configuration ............................................... 2.2

Probe switch off method ................................................. 2.3

Enhanced trigger filter .................................................... 2.2

Optical power .................................................................. 2.3

Operation ....................................................................... 2.4

Probe specification ...................................................... 2.5

Batteries ........................................................................ 2.6

2.1

OTS installation guide

2.2

Introduction

The OTS is a tool setter with optical transmission suitable for use on small to large machining centres. It is designed to resist optical interference, false triggering and shock.

The OTS operates using ‘Modulated’ mode, and must be used with a modulated receiver.

All OTS settings are configured using the

‘Trigger Logic TM ’ technique. This enables the user to review and subsequently change probe settings by deflecting the stylus whilst observing the LED display.

Configurable settings are:

• Start configuration

• Enhanced trigger filter setting

• Optical power

The tool is driven in the machine Z axis for tool length measurements and broken tool detection.

Rotating tools are set in the machine’s X and Y axes for tool radius offsets.

Screw adjusters allow the stylus to be aligned with the machine’s axes.

Trigger Logic™

The user can configure probe settings quickly and easily by deflecting the stylus in a sequence until the correct colour configuration is observed on the LED display, this programmable method is known as Trigger

Logic™.

Probe settings

Switch on method

The OTS will be switched on in less than

0.5 seconds by an optical signal.

After being switched on, the OTS must be on for

1 second minimum before being switched off.

Optical start configuration

The user can configure the OTS to either

Probe 1 or Probe 2 identification (see Changing the probe settings 4.3).

The OTS is factory set to Probe 2 so that it can be used in a system with modulated spindle probes.

Typically the OTS is used in Probe 2.

A twin tool setter application would require that one of the OTS probes is reconfigured to Probe 1.

Switch off method

A timer automatically switches the probe off

90 minutes after the last trigger if not turned off by an M code.

Enhanced trigger filter

Probes subjected to high levels of vibration or shock loads may trigger without having been contacted. The enhanced trigger filter improves the probe’s resistance to these effects.

When the filter is enabled, a constant nominal

7 ms delay is introduced to the probe output.

It may be necessary to reduce the approach speed to allow for the increased stylus overtravel during the extended time delay.

Probe settings

continued

Optical power

Where the separation between the OTS and the receiver is small, the low optical power may be used.

In this setting the optical transmission operating range will be reduced by approximately 30%. Battery life will also be increased.

Factory set to standard optical power.

The OTS can be in one of three modes:

Stand-by mode

The OTS is waiting for a switch on signal.

Operating mode

The OTS is ready for use.

Configuration mode

The Trigger Logic TM configuration method allows current probe settings to be reconfigured.

2.3

OTS installation guide

2.4

Operation

Z X/Y

Y

X

Stylus

Rotate tool in reverse direction for diameter setting

Software routines

Software routines for tool setting are available from Renishaw for various machine controllers and are described in data sheet

H-2000-2289, In addition data sheet

H-2000-2298 lists available Renishaw software programs. Both data sheets can be downloaded from www.renishaw.com/mtp

Achievable set-up tolerances

The tolerances to which tools can be set depend upon the flatness and parallelism of the stylus tip setting. A value of 5 µm (0.0002 in) front to back and side to side is easily achievable over the flat portion of the stylus tip, and 5 µm (0.0002 in) parallelism is easily achievable with the axes of a square tip stylus. This setting accuracy is sufficient for the majority of tool setting applications.

Recommended rotating tool feed rates

Cutters should be rotated in reverse to the cutting direction. Renishaw tool setting software calculates speeds and feeds automatically using the following information.

First touch – machine spindle rev/min

Rev/min for the first move against the probe stylus:

Diameters below 24 mm, 800 rev/min is used.

Diameters from 24 mm to 127 mm, rev/min is calculated using a surface speed of 60 m/min

(197 ft/min).

Diameters above 127 mm, 150 rev/min is used.

First touch – machine feed rate

The feedrate (f) is calculated as follows: f = 0.16 × rev/min f units mm/min (diameter set) f = 0.12 × rev/min f units mm/min (length set)

Second touch – machine feed rate

800 rev/min, 4 mm/min (0.16 in/min) feedrate.

Probe specification

dimensions mm (in)

67.8 (2.67) 44.7 (1.76)

X/Y

3.5

(0.14)

X/Y

3.5

(0.14)

Z

6

(0.24)

Ø51 (2.01)

Base

Cap head bolt and T nut

ØM12 (0.50) MAX supplied by user

Disc

Ø12.7

(Ø0.5)

Machine table

Ø62.5 (2.46)

Ø54 (2.125)

Two holes for dowel pins

Ø

6.13 (0.24)

5.95 (0.23) x 13 (0.51) deep MIN equi-spaced on Ø54 (2.125) PCD at 45° to OTS axis

8 (0.31)

Square

19.05 (0.75)

8 (0.31)

Disc stylus

Ø12.7 mm × 8 mm (Ø0.5 in × 0.31 in)

Tungsten carbide 75 Rockwell C

Square stylus

19.05 mm x 19.05 mm (0.75 in x 0.75 in)

Ceramic 75 Rockwell C

Principal application:

Dimensions:

Weight:

Machining centres

Length with square stylus

Width:

Height with disc stylus without batteries

831 g (29.31 oz)

122 mm (4.08 in)

60 mm (2.36 in)

103.25 mm (4.06 in) batteries

17 g (0.60 oz)

2.5

2.6

OTS installation guide

Probe specification

continued

Transmission type:

Turn on control:

Turn off control:

Transmission operating range: infra-red optical transmission

Machine M code

Machine M code

Up to 5 m (16.4 ft)

Receiver/interface:

Sense directions:

OMI-2T, OMI-2H or OMI-2

Omni-directional ± X, ± Y, + Z

Repeatability: 1.00 µm (0.00004 in)

Maximum mean 2s value. Valid as tested with a

35 mm (1.4 in) straight stylus and a velocity of

480 mm/min at the centre of the stylus tip

Stylus trigger force:

(factory set using 50 mm (1.97 in) stylus) 1.3 N to 2,4 N / 130 gf to 240 gf (4.5 ozf to 8.5 ozf) depending on sense direction

Stylus overtravel:

Battery type:

Battery reserve life:

Low battery indication:

Dead battery indication:

XY ± 3.5 mm (0.14 in)

Z 6 mm (0.23 in)

1/2 AA size Lithium Thionyl Chloride (3.6 V) x 2

Approximately 1 week after a low battery warning is first given

Blue flashing LED in conjunction with normal green probe status LED

Constant or flashing red

Lithium thionyl chloride (LTC) battery life

Stand-by life

(days - typical)

Standard power mode

Low power mode

180 180

5% usage = 72 minutes/day

(days - typical )

Standard power mode

Low power mode

100 120

Continuous use

(hours - typical)

Standard power mode

Low power mode

300 350

System installation

System installation

Contents

Preparing the OTS for use .............................................................. 3.2

Fitting the stylus and captive link ....................................................... 3.2

Installing the batteries ....................................................................... 3.3

Mounting the probe on the machine table ......................................... 3.4

Positioning the optical module ........................................................... 3.5

Stylus level setting ............................................................................. 3.6

Square stylus setting ......................................................................... 3.8

Typical probe system with OMI-2T/OMI-2H ................................. 3.11

Performance envelope when using the OTS with an OMI-2T/OMI-2H/OMI-2 (Modulated transmission) .............. 3.12

3.1

OTS installation guide

3.2

Preparing the OTS for use

Fitting the stylus, break stem and captive link

2.6 Nm

(1.92 lb.ft)

Stylus break stem

1.1 Nm

(0.81 lb.ft)

NOTE: Always hold the support bar in position to counteract twisting forces and avoid over-stressing the stylus break stem Support bar

1.1 Nm

(0.81 lb.ft)

2.6 Nm

(1.92 lb.ft)

Installing the batteries

Installing the batteries

V Take care not to short the battery contacts as this may be a fire hazard.

Ensure the contact strips are located securely.

When installing batteries, do not allow coolant or debris to enter the battery compartment.

Check that the polarity is correct.

NOTE: If dead batteries are inadvertently inserted into the probe then the LEDs will remain constant red

Review current probe settings in accordance with 'Section 4

- Trigger Logic™

3.3

OTS installation guide

Mounting the probe on the machine table

3.4

1

2.5 mm A/F

0.8 Nm (0.6 lbf.ft)

1

2

2.5 mm A/F

0.8 Nm (0.6 lbf.ft)

Mounting the probe on the machine table

1. Select a position for the tool setter on the machine table. Position to minimise the possibility of collision and ensure the optical window faces towards the receiver.

2. Separate the base from the body by slackening four screws 1 and two screws 2 using a 2.5 mm AF hexagon key.

3. Fit the cap head bolt and T nut (not supplied by Renishaw) and tighten to secure the base to the machine table.

NOTE: A smaller washer may be fitted for a smaller bolt by disassembling the base.

Body

1

2

1

M12 bolt and T nut

(supplied by user)

Locating pin

Base

4. Refit the body onto the base and tighten screws 1 and 2 . (If a square stylus is fitted and fine rotational adjustment is required,

(see page 3.8 - Stylus rotational setting), before tightening screws 2 ).

5. Fit the stylus (see page 3.2 - Fitting the stylus, break stem and captive link).

Dowel pins (shown on page 2.5)

Two dowel pins (supplied in the tool kit) may be fitted on installations where there is a requirement to remove and remount the tool setter.

To fit the dowel pins, drill two holes in the machine table to correspond with the two probe base holes. Place the dowel pins in the holes and refit the probe base.

Positioning the optical module

The optical module can be set in one of seven positions at 15° increments, to allow the optical window to point towards the receiver.

1. To align the optical module, slacken and pull back the clamp screw.

2. Rotate the optical module to line up a reference mark on the optical housing with the reference feature on top of the body.

3. Re-locate the clamp screw and tighten.

Body

Reference feature

45°

30°

15°

0°

15°

30°

45°

3.5

Optical module

Clamp screw

4mm A/F

5 Nm (3.7 lbf.ft)

OTS installation guide

3.6

Stylus level setting

The top surface of the stylus must be set level, front to back and side to side.

Front to back level adjustment

1

Height adjusting screw

4 mm AF

2

Locking screw

4 mm AF

5 Nm (3.69 lbf.ft)

To raise front

Slacken locking screw 2 and adjust height adjusting screw 1 until the stylus is level.

Then tighten fully locking screw 2 .

To lower front

Slacken height adjusting screw 1 and adjust locking screw 2 until the stylus is level.

Then fully tighten locking screw 2 .

Side to side level adjustment

3

2 mm AF

1.1 Nm

(0.81 lbf.ft)

Side to side level adjustment is obtained by alternately adjusting grubscrews 3 , which causes the probe module to rotate and change the stylus level setting.

When a level stylus surface is obtained, tighten screws 3 .

3.7

OTS installation guide

3.8

Square stylus setting

Rotational adjustment allows the stylus to be aligned with the machine axes

1 Coarse rotational adjustment

Slacken grubscrew 1 and rotate the stylus by hand to obtain alignment, then fully tighten the grubscrew

Support bar

Stylus break stem

1

2 mm AF

1.1 Nm (0.81 lbf.ft)

NOTE: Always hold the support bar in position to counteract twisting forces and avoid overstressing the stylus break stem

2 Fine rotational adjustment

2

2

2

2

Slacken the four body locking screws 2.

3

Opposing grubscrews 3 are tightened against a locating pin fixed to the base.

By alternatively slackening and re-tightening these grubscrews, fine rotational adjustment of the stylus is achieved.

Then tighten lightly.

Continued on next page

Locating pin

3

2.5 mm AF

0.8 Nm (0.6 lbf.ft)

3.9

3.10

OTS installation guide

2

2

2

2.5 mm AF

0.8 Nm (0.6 lbf.ft)

Fully tighten body locking screws 2 .

2

Typical probe system with OMI-2T/OMI-2H

Spindle probe for inspection

Spindle probes must use modulated transmission

Stylus

Workpiece

CNC machining centre spindle

Typical inspection probe

OMI-2T/OMI-2H

Mounting bracket

CNC machine control

Cable

Power supply unit

(optional)

OTS tool setter

Alternative orientations

3.11

OTS installation guide

OTS performance envelope with an OMI-2T/OMI-2H/OMI-2 (modulated transmission)

The OTS probe and receiver diodes must be in the other’s’ field of view and within the performance envelope shown. The OTS performance envelope is based on the receiver being at 0° and vice-versa.

3.12

NOTE: A single OTS (configured to probe 1) can be used with an OMI-2

(configured to use level input).

45°

60°

75°

5 (16.4)

4 (13.1)

3 (9.8)

2 (6.5)

1 (3.3)

30° 15°

OTS

Operating envelope

Reflective surfaces within the machine may increase the signal transmission range.

Coolant and swarf residue accumulating on the optical window will have a detrimental effect on transmission performance. Wipe clean as often as is necessary to maintain unrestricted transmission.

Some reduction in range may result when operating in temperatures of 0° C to 5° C

(32° F to 41° F) and 50° C to 60° C (122° F to 140 °F).

OMI-2T/OMI-2H/OMI-2

75°

60°

45°

30°

0°

15°

0° 15°

30°

1 (3.3)

2 (6.5)

3 (9.8)

4 (13.1)

5 (16.4)

75°

60°

45°

15°

30°

45°

60°

75°

Typical plot at 20° C (68° F)

Transmission around probe axis in metres (feet)

Switch on/off

Operating - standard power mode

Operating - low power mode

Probe standard power or low power setting

If two machines are operating in close proximity to each other, take care to ensure that signals transmitted from a probe on one machine are not received by the receiver on the other machine, and vice versa.

When this is the case, it is recommended that the low optical power setting on probes is used, and that the low range setting is used on the receiver.

Please refer to the receiver User’s Guide.

Receiver position

To assist finding the optimum position for the installation, signal condition is displayed on the

OMI-2T/OMI-2H/OMI-2 receiver.

Trigger Logic TM

Trigger Logic TM

Contents

Reviewing the probe settings ......................................................... 4.2

Placing the probe in configuration mode ...................................... 4.3

Changing the probe settings .......................................................... 4.3

Operating mode ............................................................................... 4.4

4.1

4.2

OTS installation guide

Reviewing the probe settings

Key to the symbols

LED short flash.

LED long flash.

1

2 wait more than

5 seconds

3

LED check

Enhanced trigger filter setting

Off On or

Probe identification

Probe 1 Probe 2 or

Low

Optical power

Standard or

Battery status (probe seated)

Battery good Battery low or

Probe in standby

7

Placing the probe in configuration mode

Key to the symbols

LED short flash.

LED long flash.

Deflect the stylus. Wait less than 4 seconds before moving to next menu option.

Deflect the stylus. Wait more than 4 seconds before moving to next menu.

To exit, leave the stylus untouched for more than 20 seconds.

2 wait more than

5 seconds

1

3

LED check

3

Deflect the stylus and hold deflected until after the battery status has been displayed at the end of the review sequence.

Changing the probe settings

Battery status (probe triggered)

Battery good Battery low or

4.3

To change enhanced trigger filter setting

Off On

Probe 1

Probe identification

Probe 2

Low

To change optical power

Standard

Return to

‘To change enhanced trigger filter setting’

New settings complete

OTS installation guide

4.4

Operating mode

Transmit LEDs x 4

Reference feature

Reference mark

Receive diode

Multi-coloured probe status LED

LED colour

Flashing green

Flashing red

Flashing green and blue

Flashing red and blue

Constant red

Flashing red or flashing red and green or sequence when batteries are inserted

Probe status LEDs

Probe status

Probe seated in operating mode

Probe triggered in operating mode

Probe seated in operating mode

- low battery

Probe triggered in operating mode

- low battery

Battery dead

Unsuitable battery

Graphic hint

NOTE:

Due to the nature of Lithium Thionyl Chloride batteries, if a 'low battery' LED sequence is ignored or overlooked, then it is possible for the following sequence of events to occur:

1. When the probe is active, the batteries discharge until battery power becomes too low for the probe to operate correctly.

2. The probe stops functioning, but then re-activates as the batteries recharge sufficiently to provide the probe with power.

3. The probe begins to run through the LED review sequence (see page 4.2).

4. Again, the batteries discharge and the probe ceases to function.

5. Again, the batteries recharge sufficiently to provide the probe with power and the sequence repeats itself.

Service and maintenance

Service and maintenance

Contents

Cleaning ........................................................................................... 5.2

Service .............................................................................................. 5.2

Maintenance ..................................................................................... 5.2

Eyelid removal/replacement ........................................................... 5.3

Changing the batteries .................................................................... 5.4

5.1

OTS installation guide

5.2

Cleaning

Clean the window to maintain signal range.

!

CAUTION: The OTS has a glass window. Handle with care if broken to avoid injury

Maintenance

The probe is a precision tool and must be handled with care.

Ensure the probe is firmly secured to its mounting.

The probe requires minimal maintenance as it is designed to operate as a permanent fixture on

CNC machining centres, where it is subject to a hot chip and coolant environment.

1. Do not allow excessive waste material to build up around the probe.

2 Coolant residue accumulating on the transmission window will have a detrimental effect on tranmission performance. Wipe clean as often as necessary to maintain unrestricted transmission

3. Keep all electrical connections clean.

Spring

Front cover

Service

You may undertake the maintenance routines described in these instructions.

Further dismantling and repair of Renishaw equipment is a highly specialised operation, which must be carried out at authorised

Renishaw Service Centres.

Equipment requiring repair, overhaul or attention under warranty should be returned to your supplier.

Metal eyelid seal

Inner diaphragm seal

Probe module

O ring

4. The probe mechanism is protected by an outer metal eyelid seal and an inner flexible diaphragm seal.

Approximately once a month, inspect the probe inner diaphragm seal. If it is pierced or damaged please contact Renishaw.

The service interval may be extended or reduced depending on experience (see next page for inspection instructions).

Eyelid removal/replacement

Spanner

5 mm AF

2.6 Nm (1.92 lbf.ft

)

Spanner

24 mm or 15/16 in

3 Nm (1.47 lbf.ft)

Inner diaphragm seal

Metal eyelid seal

Spring

Stylus and break stem assembly

Front cover

1. Remove the stylus/break stem assembly using the 5 mm AF spanner.

2. Use a 24 mm or 15/16 in spanner to remove the probe’s front cover. This will expose the metal eyelid seal, spring and the inner diaphragm seal.

Remove the metal eyelid and spring.

CAUTION – these may fall out.

3. Wash inside the probe, using clean coolant.

(DO NOT use sharp metal objects to clean out debris).

4. Inspect the diaphragm seal for signs of piercing or damage. In the event of damage, return the probe to your supplier for repair, as coolant entering the probe mechanism could cause the probe to fail.

5. Refit the spring and metal eyelid

(the spring’s largest diameter is against the metal eyelid).

6. Refit the remaining components.

5.3

OTS installation guide

5.4

Changing the batteries (

Battery type: 1/2 AA Lithium Thionyl Chloride (3.6 V) x 2)

3

Ecocel:

Saft:

EB 1425, EB1426

LS 14250 C, LS 14250

Sonnenschein: SL-750

Xeno: XL-050F

Dubilier:

Maxell:

SB-AA02

ER3S

Sanyo: CR 14250 SE

Sonnenschein: SL-350, SL-550

Tadiran:

Varta:

TL-4902 TL-5902,

TL-2150, TL-5101

CR 1/2 AA

!

CAUTION

Do not leave exhausted batteries in the probe.

!

CAUTION

Please dispose of exhausted batteries in accordance with local regulations.

Do not dispose of batteries in a fire

After removing old batteries, wait more than

5 seconds before inserting new batteries.

Installing the batteries

V Take care not to short the battery contacts as this may be a fire hazard. Ensure the contact strips are located securely.

When changing batteries, do not allow coolant

or debris to enter the battery compartment.

When changing batteries, check that the

polarity is correct.

Troubleshooting

Troubleshooting

Contents

Fault finding ..................................................................................... 6.2

6.1

6.2

OTS installation guide

Fault finding

- If in doubt, consult your probe supplier.

Symptom

Probe fails to power up

(no LED illuminated, or fails to indicate current probe settings)

Probe fails to switch-on

Probable cause

Dead batteries

Wrong batteries

Batteries inserted incorrectly

Wrong optical start mode selected

Dead batteries

Wrong batteries

Batteries inserted incorrectly

Optical/magnetic interference

Transmission beam obstructed

Probe out of range/not aligned with receiver

No receiver start signal

Remedial action

Change batteries.

Change batteries

Check battery insertion

Reconfigure transmission mode

Change batteries

Change batteries

Check battery insertion.

Check for interfering lights or motors

Consider removing interfering source

Check that probe and receiver windows are clean, and remove any obstruction

Check alignment and if receiver fixing is secure

Refer to relevant user’s guide.

Check connections and fuses

Probe turns on unexpectedly Probe receiving turn-on signal from receiver on adjacent machine

Machine stops unexpectedly during a probing cycle

Optical communication obstructed

Interface/receiver/machine fault

Dead batteries

False probe trigger

Probe unable to find target surface

Adjacent probe

Reduce turn-on range on receiver on adjacent machine

Check interface/receiver and remove obstruction

Refer to interface/receiver/machine

User’s guide

Change batteries

Enable enhanced trigger filter

Check that part is correctly positioned and that stylus has not broken

Reconfigure to low power mode and reduce range of receiver

Symptom

Probe crashes

Probable cause

Tool length offset incorrect

Controller wired to respond to inspection probe instead of tool setter

Remedial action

Review offsets

Review installation wiring

Poor probe repeatability and/ or accuracy

Debris on part or stylus

Loose probe mounting on machine bed or loose stylus

Excessive machine vibration

Probe fails to switch off

Clean tool and stylus

Check and tighten as appropriate

Calibration out of date and/or incorrect offsets

Calibration and probing speeds not the same

Measurement occurs as stylus leaves surface

Measurement occurs within the machine’s acceleration and deceleration zone

Probing speed too high

Enable enhanced trigger filter

Eliminate vibrations

Review probing software

Review probing software

Review probing software

Review probing software and probe filter settings

Perform simple repeatability trials at various speeds

Minimise temperature changes Temperature variation causes machine and workpiece movement

Machine tool faulty

Optical/magnetic interference

Probe out of range

Perform health checks on machine

Check for interfering lights or motors.

Consider removing the interfering source

Check position of receiver

Increase receiver signal start range

Ensure window is clean

Review performance envelopes

6.3

6.4

OTS installation guide

This page left intentionally blank

Parts list

Parts list

Contents

OTS systems parts and accessories ............................................. 7.2

7.1

OTS installation guide

7.2

OTS system parts and accessories

Please quote the part number when ordering equipment.

OTS

Type

Batteries

Battery cap

Seal

Break stem kit

Stylus holder kit

Disc stylus

Square stylus

Mounting bracket

Part number

A-5401-2001

P-BT03-0007

Descripion

OTS probe with disc stylus, batteries, tool kit and User’s guide

(optical on/optical off, set to: filter off, Probe 2 start standard power)

1/2 AA batteries (pack of two)

A-5401-0301 OTS battery cap assembly.

A-4038-0301

A-5003-5171

A-2008-0389

Battery housing seal.

Stylus protection kit comprising: break stem (x 1), captive link, grubscrew flat ended (x 3), cap head screw (x 2), with tools

(hexagon wrenches, spanner 5 mm AF, and support bar).

Stylus holder kit comprising stylus holder and screws.

A-2008-0382

A-2008-0384

A-2033-0830

A-5439-0049

A-5401-8500

Disc stylus Ø12.7 mm (Ø0.5 in), tungsten carbide, 75 Rockwell C.

Square tip stylus 19.05 mm (0.75 in), ceramic, 75 Rockwell C.

OMI-2T/OMI-2H/OMI-2 mounting bracket with fixing screws, washers and nuts

OMI-2T complete with cable 8 m (26.25 ft) long

Quick start guide for rapid set-up of the OTS probe

OMI-2T

Quick start guide

Publications

Probe software for machine tools

Styli

Software features Data sheet H-2000-2289

Software list Data sheet H-2000-2298

Styli and accessories Catalogue H-1000-3200

Probe settings record

Probe settings record

Contents

Probe settings record table ............................................................ 8.2

8.1

8.2

OTS installation guide

Probe settings record table

Enhanced trigger filter

Probe identification

Optical power setting

OFF

ON

Probe 1

Probe 2

Low power

Standard power

✔ tick

OTS serial no ..............................................

Definition of probing terms

Definition of probing terms

Contents

Definition of terms commonly associated with probing .............. 9.2

9.1

OTS installation guide

9.2

Definition of terms commonly associated with probing

Accuracy

The closeness of agreement between the results of a measurement and the true value of the part being measured.

Repeatability

The variation in measurements obtained when multiple readings are taken with the same instrument and technique on the same part or item. In Renishaw terms, repeatability is the ability of a probe to trigger at the same point each time.

Calibration

The operation that identifies and corrects any deviation from the stated performance targets.

Probe calibration

Where a datum feature, of known size and position, is measured to establish the average pre-travel for the stylus concerned.

Datum

The reference feature from which other co-ordinates are measured.

Hysteresis

A systematic error arising from the difference in direction of a probing move resulting from the preceding reseat.

Kinematic seating

A seating mechanism in which the spatial position of a movable component is constrained in all 6 degrees of potential movement. This is achieved in a Renishaw probe by 6 contact points formed by a system of radial rollers (or ‘V’ grooves) and ball bearings.

Kinematic switching probe

A contact probe in which the kinematic seating forms an electrical circuit that is broken by the action of displacing the stylus, to provide the trigger signal. After displacement, the stylus ball returns to the highly repeatable position defined by the kinematic location points.

Lobing

The variation in trigger point position from a perfect spherical locus, as the direction of probing varies.

Overtravel

The distance travelled by the probe after the trigger point has been reached.

Pre-travel

The displacement from the point where the stylus ball contacts the workpiece, to the point where a probe trigger is asserted.

Pre-travel variation

The deviation of the pre-travel from its average value as it varies with trigger direction. This may be specified for 2D (X-Y) or 3D (X-Y-Z) measurements. Pre-travel itself is not a form of error, since it can easily be compensated for, by probe calibration.

Strain gauge probe

Although a strain gauge probe still uses a kinematic mechanism to retain the stylus, it does not use the resistance through the contact elements as the means to sense a trigger. Instead, a set of strain gauges are positioned on carefully designed webs within the probe structure, beyond the kinematics.

These gauges measure the contact force applied to the stylus and generate a trigger.

This provides a low trigger force, low pre-travel and therefore low pre-travel variation.

Renishaw plc

New Mills, Wotton-under-Edge,

Gloucestershire, GL12 8JR

United Kingdom

T +44 (0)1453 524524

F +44 (0)1453 524901

E [email protected]

www.renishaw.com

For worldwide contact details, please visit our main website at www.renishaw.com/contact

*H-5401-8505-01*