HD400 & HB400 Optical Projector OPERATORS MANUAL
HD400 Optical Projector
HB400 Optical Projector
Copyright Starrett Precision Optical Ltd
Copyright This manual is the copyright of Starrett Precision Optical Ltd and is protected by national and international copyright law.
Starrett Precision Optical Ltd A Division of the L.S. Starrett Company
Oxnam Road Jedburgh TD8 6LR
Telephone: Fax: e-mail: website:
+44 (0) 1835 866317 +44 (0) 1835 866300 sposupport@starrett.co.uk http://www.starrett-precision.co.uk
HD400 and HB400 Operators Manual
Contents Page Safety .................................................................................................................... 1 1
Introduction .......................................................................................................... 1
2
Unpacking ............................................................................................................ 2
3
Installation ............................................................................................................ 3
3.1 3.2 3.3 3.4 3.5 3.6 3.7
Selecting Location ............................................................................................................................... 3 Power Supply ....................................................................................................................................... 3 Moving the Projector into Position ........................................................................................................ 3 Removing Transit Strap and Screw...................................................................................................... 4 Fitting the DRO .................................................................................................................................... 4 Mains Connection ................................................................................................................................ 5 Commissioning Checks ....................................................................................................................... 6
4
Description of Equipment ................................................................................... 7
5
Operation .............................................................................................................. 9
5.1 5.2 5.3
Controls ................................................................................................................................................ 9 Taking Measurements ........................................................................................................................ 11 Using the Digital Protractor ................................................................................................................ 12
6
Maintenance ...................................................................................................... 13
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8
Access to Components ...................................................................................................................... 13 Cleaning Lenses ................................................................................................................................ 14 Cleaning the Mirror ............................................................................................................................. 14 Cleaning the Screen........................................................................................................................... 14 Changing the Projection Lens ............................................................................................................ 15 Lubrication ......................................................................................................................................... 15 Latch Block Adjustment ..................................................................................................................... 15 Calibration .......................................................................................................................................... 16
7
Specification ...................................................................................................... 17
8
Spare Parts ......................................................................................................... 19
8.1 8.2 8.3
How to Order Spares ......................................................................................................................... 19 Mechanical Parts ............................................................................................................................... 19 Electrical Parts .................................................................................................................................. 20
9
Wiring Diagram .................................................................................................. 21 APPENDICES
A
Motorised Workstage Drive ............................................................................... 22
B
CNC Option (412 Amplifier Layout) .................................................................. 27
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HD400 and HB400 Operators Manual
1
Safety Mains Voltage Mains voltage is present inside the screen housing and a 110V supply inside the profile lamp cover. Access must be restricted to authorised and qualified personnel. Switch off and disconnect the mains supply before gaining access to the internal equipment. Before switching on the projector for the first time, check the mains voltage setting as detailed in Section 3 - Installation.
Certification This equipment complies with the Directives and Regulations specified in the EC Declaration of Conformity for Machinery.
1
Introduction This manual applies to the Starrett HD400 (dual lens) and HB400 (single lens) Optical Projectors which are supplied with the following equipment: QC DRO (Quadra Chek Digital Readout). This manual deals with installation of the DRO. For operating the DRO, refer to the QC manual supplied. Digital protractor. Operating instructions for the digital protractor are given in this manual. Edge detector (optional). For use with the DRO; this manual deals with installation of a projector fitted with an edge detector. For operating the edge detector, refer to the QC manual supplied. Motorised workstage drive (optional). Motorised workstage controlled by joystick and pushbutton with 2-axis drive card. Operation and maintenance details for this option are given in Appendix A of this manual. CNC interface (optional). Provision for connecting the projector to a PC for control of workstage movement by CNC software. For further details, refer to the QC manual supplied. Iris Diaphragm (optional). Fitted to the projection lenses. Light Shields (optional). Fitted above the projection lens.
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HD400 and HB400 Operators Manual
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Unpacking Open the packing case and remove loose items and packing material. Referring to the packing list, identify the following items before discarding the packing material: Optical Projector. The projector is supported on a wooden base. QC DRO and Manual Mounting Bracket and Screws (for fitting DRO). Mains Supply Cable Edge Detector and Diopter (if ordered. The edge detector will be fitted over the projector screen; the associated diopter (lens) is for fitting to the condenser lens assembly as detailed in Section 3 - Installation). Additional Lenses (if ordered). Accessories (if ordered, for example workholding equipment, and projector stand).
WARNING: Before attempting to move the projector, refer to Section 3 Installation - 3.3 Moving the Projector into Position.
HD400 and HB400 Operators Manual
3 3.1
3
Installation Selecting Location The projector is designed for use in a normal workshop environment, but should be sited as far away as possible from sources of grinding grit, oil mist and vibration. Choose a convenient location with a firm, level floor, where the screen will not be subject to glare from sunlight or artificial lighting. Make sure that a suitable mains supply is available, (see 3.2 Power Supply below). The projector should be mounted on a bench, or on the optional stand supplied, so that the controls will be easily accessible. Note: The bench must be firm, flat and level. 53.2
Power Supply
A mains supply of the correct voltage is required. WARNING: Check the mains voltage setting before connecting the mains supply (see 3.6 - Mains Connection).
3.3
Moving the Projector into Position (Figure 1) Insert support bars though the holes in the frame and lift the projector using suitable equipment. The weight of the unit is approximately 180kg, (397lb). CAUTION: Do not attempt to lift the unit by the projection lamp cover or screen housing.
Figure 1 Lifting the Projector
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HD400 and HB400 Operators Manual
3.4
Removing Transit Straps (Figure 2) The transit straps are painted red. CAUTION: The transit straps must be removed before any attempt is made to move the workstage or to use the projector.
1.
Remove the screw A from each transit strap.
2.
Slacken screw B, position the strap as shown, and secure it with screw C.
3.
Refit and tighten screws A.
Figure 2
3.5
Transit Straps
Fitting the DRO (Figure 3)
1.
Fit the bracket to the projector, securing it with the four screws A.
2.
Fit the DRO to the bracket, securing it with the two screws B.
3.
Fit the two labelled 15-way and one 9-way connector and the mains connector into the corresponding sockets at the back of the DRO.
Projectors fitted with edge detector:
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4.
Fit the reference cable and screen cable connectors to the corresponding sockets at the back of the DRO.
5.
If an optional x50 or x100 projection lens is to be used, screw the diopter supplied on to the condenser lens assembly (on the face of the projection lamp cover nearest the screen, see Section 6 - Maintenance, Figure 7, item 9).
Figure 3
3.6
Fitting the DRO
Mains Connection WARNING: A secure earth connection must be provided. The cable colour code is as follows: Brown/Red
: Live
Blue
: Neutral
Green/Yellow
: Earth
The mains voltage is factory set to the correct value for the local supply; however it is recommended that the setting is checked before power is applied, as follows: 1.
Refer to Section 6 - Maintenance, Figure 7 and remove the access panel from the screen housing.
2.
Identify the transformer, and check that the correct mains tapping is set.
3.
Refit the access panel. Connect the mains cable to the socket at the rear of the projector, and to a mains outlet socket.
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HD400 and HB400 Operators Manual
3.7
Commissioning Checks Make the following checks before putting the projector into service, referring to Section 5 - Operation as necessary:
1.
Make sure that the projector is secure and level on its bench or stand.
2.
Fit a workpiece securely to the workstage.
3.
Switch on the power supply.
4.
If a digital protractor is fitted, check that the displays and indicators light up for approximately one second.
5.
Check that the DRO screen shows a display.
6.
Switch on the profile illumination, and turn the focus (Z-axis) handwheel to bring the workpiece into focus. Check that the screen image is satisfactory.
7.
Switch on the surface illumination, and check that the fibre optic light guides are lit; (HD400: three guides, HB400: two guides).
8.
Release the latch block on the X-axis slide, check that the slide moves freely, and apply the latch.
9.
Operate the X and Y axis controls and check that the workstage moves freely: (projectors with manual workstage controls: X and Y axis handwheels, projectors with motorised workstage drive: joystick).
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7
Description of Equipment (Figure 4) The Starrett HD400 and HB400 Optical Projectors are designed for 2dimensional optical measurement of profiles and surface features of parts.
Figure 4
HD400 Optical Projector
The projector comprises the following main items: 1
Screen Housing The housing contains the projection lenses (7), mirrors, surface illumination light guides (8), and the mains transformer.
2
Digital Protractor Provides digital indication of angular measurements.
3
QC DRO The QC DRO enables measurements to be viewed and recorded, and programs to be created for measuring a number or similar parts. For further details, refer to the QC DRO Operators Manual.
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HD400 and HB400 Operators Manual 4
Projection Lamp Cover Houses the projection lamp, condenser lens, and surface illumination lamp. On a projector fitted with an edge detector, the diopter lens supplied is attached to the condenser lens if an optional x50 or x100 projection lens is in use. The diopter intensifies the light beam to provide a good light-to-dark reference for the edge detector.
5
Workholding Equipment Workholding accessories are available, including centres and vees, a rotary vice, and a vertical glass plate workholder for small flat components.
6
Workstage Movable in the X and Y axes for measurement, and in the Z axis for focus, with two dovetail slots for fitting workholders with angular clamping screws. The dimensions are as follows (in mm):
7
Surface Illumination Light Guides Optical fibre guides which conduct the light from the surface illumination lamp for surface illumination of parts. (See Section 5 - Operation Controls). The HD400 has three guides; the HB400 has two.
8
Projection Lenses The lens projects the image on to the screen via the two mirrors in the screen housing (1). The HD400 has two lenses mounted on a slide; the HB400 has a single lens. A range of lenses is available; for details see Section 7 Specification. For changing lenses see Section 6 - Maintenance.
HD400 and HB400 Operators Manual
5 5.1
9
Operation Controls (Figure 5)
Figure 5 1
Controls
Screen Bevelled glass screen, with overlay clips.
2
Angular Adjustment Handwheel For rotating the screen and angular measurements.
3
QC DRO For details, see the QC DRO Operators Manual.
4
Switch Panel Rocker switches for POWER on/off, the SURFACE illumination lamp with integral dimmer potentiometer and the PROFILE illumination lamp with HIGH/LOW settings.
5
Helix Control Skew the beam from the projection lamp for viewing the true profile of helical features such as screw threads.
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HD400 and HB400 Operators Manual 6
Latch Block Quick-release control for moving the workstage along the X-axis. Lift the lever to release the latch, move the workstage to the required position, and lower the lever. (Use the X-axis handwheel 7 for fine adjustment).
7
Y-Axis Handwheel Raises and lowers the workstage.
8
Focus Handwheel Moves the workstage along the Z-axis for focusing.
9
X-Axis Handwheel For fine adjustment of the workstage along the X-axis.
10
Surface Illumination Light Guides Provide surface illumination for measuring surface features of flat components. For the optimum illumination, pull out the guides and position them as close to the component as possible. The guides provide a 'cold light' source; minimal heat is radiated to the component. For components with a directional surface finish (such as ground faces), the surface texture should be vertical to give the brightest image on the screen. HB400: Slacken the clamp screws, and retighten them after positioning the guides:
HD 400: Select the required projection lens by moving the slide before positioning the guides:
11
Projection Lens Slide (HD400)
HD400 and HB400 Operators Manual
11
Enables the required lens to be selected by moving the slide. 12
Digital Protractor Provides digital indication of angular measurements.
5.2
Taking Measurements
1.
Secure the component to the workstage with a suitable workholder.
2.
Turn on the POWER switch.
3.
Turn on the PROFILE lamp switch, and turn the focus control to produce a sharp image on the screen.
4.
Refer to the QC manual for setting up the DRO (and edge detector if fitted) and taking measurements. Refer to 5.3 - Using the Digital Protractor for using the protractor. Use the manual controls as required: Linear measurements
: X and Y axis handwheels
Angular measurement
: Angular adjustment control and digital protractor
Helical features
: Helix control
Surface features
: Surface illumination and light guides.
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HD400 and HB400 Operators Manual
5.3
Using the Digital Protractor. The QC DRO unit displays the angular position of the screen, this can be shown in degrees decimal, or degrees, minutes & seconds DMS. And is easily accessed through the menu on the QC DRO unit. The axis is zeroed by the zero key at the side of the digital display corresponding to the rotary axis. Incremental and absolute readings can be measured again easy access is given through the facia button assigned incremental/ absolute. See section 7.11 DRO instruction manual for calibration and set-up on angular display and measurement.
.
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6
Maintenance
6.1
Access to Components (Figure 7) WARNING Mains voltage is present inside the screen housing and a 110V supply inside the profile lamp cover. Access must be restricted to authorised and qualified personnel. Switch off and disconnect the mains supply before gaining access to the internal equipment. The access panel gives access to the mirrors (2) and transformer (3), The profile lamp cover (6) can be removed after taking out the securing screw (7) for access to the profile illumination LED’s, surface illumination LED’, and condenser lens (9).
1 2 3
Access panel securing screws Mirrors Transformer
Figure 7
4 5 6 7
Profile lamp cover Profile lamp cover securing screw Condenser lens Heat shield
Access to Components
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HD400 and HB400 Operators Manual
6.2
Cleaning Lenses CAUTION Do not use polishes, or window cleaning aerosols and liquids for cleaning lenses. Do not touch the inner surfaces, (those facing away from the workpiece), of the projection or condenser lens. The projection lens is the most critical; a finger mark on the inner surface will degrade the quality of the projected image. Remove any accumulated dust with a photographic lens brush. Remove any grease or finger marks with a new photographic cleaning tissue, which may be moistened with methanol if necessary.
6.3
Cleaning the Mirrors CAUTION The mirrors should be cleaned as infrequently as possible. It is recommended that cleaning is performed by service engineers. Do not finger the surface of the mirrors. If necessary, remove loose dust with a photographic lens brush. If necessary, remove grease and finger marks with surgical quality cotton wool moistened with methanol. Apply the cotton wool lightly, then gently polish the surface with clean dry surgical quality cotton wool. CAUTION Do not use force.
6.4
Cleaning the Screen CAUTION To avoid damaging the screen markings, do not use excessive pressure when cleaning the screen. Clean the screen with anti static, alcohol based glass cleaner, (e.g. as used for VDU screens, notebooks, photocopier glass, etc.), using a clean, soft cloth. The screen should dry free from smears.
HD400 and HB400 Operators Manual
6.5
15
Changing the Projection Lenses (Figure 7) CAUTION Do not touch the surfaces of the lens.
1.
Each lens is secured by a bayonet fitting. Rotate the lens anti-clockwise and withdraw it.
2.
Fit the replacement lens, rotate it clockwise until it is secure, and check that the two red spots are aligned.
6.6
Lubrication Periodically lubricate the slides with light oil.
6.7
Latch Block Adjustment (Figure 8) The tension of the latch block on the X-axis slide latch may require adjustment after a period of use. If necessary, re-set the tension as follows:
1.
Withdraw the end cap (the cap is a push fit).
2.
Unscrew and remove the engagement handle.
3.
Insert an Allen key into the socket lock screw, slacken the screw, and hold the internal nut in position with the key.
4.
Rotate the bearing mount/collet to give the required tension.
5.
Tighten the socket lock screw.
6.
Refit the engagement handle and end cap.
Figure 8
Latch Block Adjustment
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HD400 and HB400 Operators Manual
6.8
Calibration Have the machine calibrated yearly for optical size and mechanical deviations. (Contact Starrett Precision Optical or an authorised distributor for details of this service).
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17
Specification
Overall dimensions Width
930mm (36.5 in.)
Height
1085mm (42.5 in.)
Depth
1035mm (40.5 in.)
Weight
180kg (397 lb)
Screen Diameter
400mm (16 in), with precision cross-lines and calibration markings
Workstage Construction Top Plate Size
Single dovetail cast iron top plate HD400: 460 x 130mm (18.1 x 5.1 in) HB400: 430 x 130mm (16.9 x 5.1 in)
Horizontal Travel
(X-axis)
HD400: 406mm (16 in) HB400: 305mm (12 in)
Vertical Travel Focus travel Capacity between Centres Load Capacity
(Y-axis) 152mm (6 in) (Z-axis) 53mm (2.1 in.) max. HD400: 335mm (13.2 in) HB400: 305mm (12 in) 10kg (22lb) negligible deflection, 50kg (110lb) max
Illumination Profile Surface
Fan-cooled LED Lighting lamp, switchable high/low intensity with yellow/green filter Fan-cooled LED fibre optic system
Measurement and Display Systems Linear
Heldenhaln scales (0.001mm resolution) Quadra-Chek DRO systems with edge detector option
Angular
Digital protractor (1 minute resolution)
Electrical Transformer Input Tappings Consumption Input
From 110-240V, 50-60 Hz 5A Standard power socket
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HD400 and HB400 Operators Manual
Projection Lenses Mount
HD400: Dual Lens (bayonet fitting) HB400: Single Lens (bayonet fitting)
Options Lens
x10, x20, x25, x31Âź, x50, x100 (x5 to special order) Field of View
Working Distance
Maximum Work Diameter Full Field
Half Field
x5
80mm
135mm
280mm
280mm
x10
40mm
80mm
245mm
180mm
x20
20mm
76mm
245mm
200mm
x25
16mm
62mm
263mm
250mm
x31Âź
12.8mm
56mm
115mm
140mm
x50
8mm
50mm
188mm
125mm
x100
4mm
41mm
106mm
98mm
HD400 and HB400 Operators Manual
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Spare Parts
8.1
How to Order Spares
19
Contact your local dealer, or contact Starrett Precision Optical by telephone, fax or e-mail: Starrett Precision Optical Ltd Oxnam Road Jedburgh TD8 6LR Telephone: +44 (0) 1835 866317 Fax: +44 (0) 1835 866300 e-mail: sposupport@starrett.co.uk Please quote part numbers when ordering spares.
8.2
8.3
Mechanical Parts Description
Part No
Type
Digital Screen (glass only)
7F08
STD
Linear Transducer Scale (X-axis), HB400: 270mm
8P03
STD
Linear Transducer Scale (X-axis), HD400: 320mm
DW02
STD
Linear Transducer Scale (Y-axis) 120mm
6C06
STD
Fibre Optic Clamp Screws, HB400
8S10
STD
X10 Lens Assembly
7E010
Optional
x20 Lens Assembly
7E020
Optional
x25 Lens Assembly
7E025
Optional
x31¼ Lens Assembly
7E031,25
Optional
x50 Lens Assembly
7E050
Optional
x100 Lens Assembly
7E100
Optional
Diopter Assembly
7T01
Optional
Y Axis Handwheel and Knob
4F10
STD
Base Swivel Foot
7A77
STD
Mirrors
2A43, 2A16
STD
Readout Mounting Screws ¼ UNC
19N02
STD
Overlay Clips (4)
0DS11
STD
Electrical Parts Refer to Section 9 - Wiring Diagram
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HD400 and HB400 Operators Manual
Description
Ref
Part No
Type
Power/Neon Switch
S1
5H05
STD
Profile High/Low Switch
S4
5H07
STD
Surface Illumination Switch
S12
7E10
STD
Transformer 115/240V
T1
7E01
STD
9J02
STD
Power Entry socket Digital Protractor Card/Display
ESP
9G06
STD
RFI Filter
FILTER
QA09
STD
Fuse 6.3A
FS4
9J03
STD
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Wiring Diagram HB400-2 WIRING DIAGRAM Ser. No 4030> March 95
*
* See Appendix A - Motorised Workstage Drive, A.4 Motor Drive Wiring Diagram, BLK22 and BLUE18
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HD400 and HB400 Operators Manual
APPENDIX A A.1
Motorised Workstage Drive Description of Equipment On machines with motorised workstage drive, X- and Y-axis handwheels are not fitted. The X- and Y-axis workstage motors are controlled from the joystick console via a 2-axis drive card. The drive card is mounted on the inside of the access panel at the rear of the projector, and is configured to operate a heavy duty motor (the Y-axis motor), and a light duty motor (the X-axis motor).
A.2
Operation (Figure A.1) Joystick Controls the direction and speed of workstage travel. The greater the deflection of the joystick, the higher the speed. JOYSTICK Pushbutton Press the button to signal to the control system that a required action or measurement has been taken. AXIS LOCK Pushbutton Press the button once to lock the axes. The workstage can then only be moved in one axis at a time. Press the button again to cancel the axis lock. SLOW Pushbutton Press the button once to reduce the workstage speed to a fine creep feed, (for example when using lenses of high magnification). Press the button again to restore normal speed. E-STOP Button (optional) Press the button to stop workstage movement. (Press the button again - or press the RESET button to return to normal operation?) RESET Pushbutton Press the button to reset the control system after a system fault such as a drive motor trip. Pressing the button resets the motor regulators without disrupting the QC DRO system.
HD400 and HB400 Operators Manual
Figure A.1
A.3
23
Motorised Workstage Drive Controls
Drive Card Adjustments and Connections WARNING: Any adjustments or other work carried out on the card must be performed by competent, qualified and authorised personnel. Isolate the projector from the mains supply before attempting to gain access to the drive card. Any adjustments made with the power supply connected must be made with due regard for safety. To gain access to the card, remove the screws securing the access panel at the rear of the projector, and carefully lay the panel horizontal, taking care not to put a strain on the connecting cables. Adjustments can be made to modify the performance of the motors and their response to joystick movement as detailed below. Refer also to A.4 Motor Drive Wiring Diagram and A.5 - Drive Card Layout.
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HD400 and HB400 Operators Manual
A.4
WH55 Motor Drive Wiring Diagram
HD400 and HB400 Operators Manual
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HD400 and HB400 Operators Manual
WH55 2 AXIS DRIVE CARD SETTINGS Use RS232 connector to input settings to the card the motor will not drive when the RS232 connector is plugged in so remove from card to Test. CLICK TETRA TERM ICON SPO SHOP PC OR FOR XP HYPERTERMINAL SET TO SERIAL OK SETUP/TERMINAL/SET LOCAL ECHO OK PLUG IN RS232 INTO CARD CHECK OR APPLY SETTINGS EXAMPLE SETTING FORMAT S XD 5 (SPACES BETWEEN IMPORTANT) SET NULL SWITCH ON LEFT BOTTOM (use a pointed tool for this i.e. A pencil) .
HB/HD400
X AXIS
SET TO
DEADBAND
S XD
5
S YD
5
CURRENT
S XC
10
S YC
10
GAIN HIGH SPEED S XGH
60
SYGH
100
GAIN LOW SPEED
S XGL
95
S YGL
60
FEQUENCY
S XF
10
S YF
8
TO VIEW X AXIS SETTINGS TYPE Q X TO VIEW Y AXIS SETTINGS TYPE Q Y TO VIEW SOFTWARE VERSION Q SV
Y AXIS
SET TO
HD400 and HB400 Operators Manual
APPENDIX B
CNC Option
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