HS 600/750/1000 Optical Projector OPERATORS MANUAL Copyright © 2009 Starrett Precision Optical Ltd
HS 600/750/1000 OPERATORS MANUAL
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 Roxburghshire TD8 6LR Scotland Telephone:
+44 (0) 1835 863501
Fax:
+44 (0) 1835 866300
E-mail:
aftersales@starrett-precision.co.uk
Web:
www.starrett-precision.co.uk
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Contents
Page
Safety
4
1 Introduction
4
2 Unpacking
4
3 Installation
5
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
Selecting Location Power Supply Moving the Projector into Position Fitting Canopy Removing Transit Strap and Screw Fitting the DRO Mains Connection Fitting Lenses Commissioning Checks
5 5 5 6 6 6 7 7 7
4
Description of Equipment
8
5 Operation
10
5.1 Controls 5.2 Taking Measurements 5.3 Using the Digital Protractor
10 12 12
6
12
Maintenance
6.1 Access to Components 6.2 Cleaning Lenses 6.3 Cleaning the Mirror 6.4 Removing and Cleaning the Screen 6.5 Changing the Projection Lens 6.6 Renewing the Profile Illumination Lamp 6.7 Renewing the Surface Illumination Lamp 6.8 Lubrication 6.9 Latch Block Adjustment 6.10 Calibration
12 13 13 13 13 13 14 14 14 14
7 Specification
15
8
Spare Parts
16
8.1 8.2 8.3
How to Order Spares Mechanical Parts Electrical Parts
16 16 17
9
Wiring Diagram
18
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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 The Starrett HS 600/750/1000 profile projectors are both free standing models, with a horizontal lens axis, and mirror optical system giving an erect projected image on the screen. The heavy duty work stage and knee are mounted on preIoaded anti-friction bearings. The knee is raised and lowered by means of a ball screw driven via a variable speed D.C. motor. The direction and velocity of both the table and the knee are controlled via a 4 way directional and proportional electronic joystick. This manual applies to the Starrett HS 600/750/1000 Optical Projector which is 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. 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. Digital protractor. Operating instructions for the digital protractor are given in this manual.
2 Unpacking The projector is normally supplied in a wood packing case. For local deliveries the projector is polythene wrapped. For deliveries overseas the projectors are vacuum packed in an aluminium foil moisture barrier material into which an appropriate quantity of silica gel is added. On unpacking, first remove the wooden top and sides of the packing case, leaving the projector standing on the base of the case. (A battery operated drill and screwdriver bit is recommended for removing screws). Release the 4 angle brackets securing the projector to the packing case base and remove the aluminium foil wrapping. Please ensure all loose items of equipment are identified, and fully unpacked before packing material is discarded. Referring to the packing list, identify the following items before discarding the packing material: Optical Projector The projector is supported on a wooden base. Canopy and Curtains QC DRO and Manual Mounting Bracket and Screws For fitting DRO. Edge Detector The edge detector will be fitted over the projector screen. All Lenses Packed separately 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.
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3 Installation 3.1
Selecting Location
The projector is designed to work within a normal workshop environment but it is important to site the unit as far as possible from sources of grinding grit, oil mist and vibrations. Consideration should also be given to siting the projector with the screen facing away from direct sunlight. This will minimise the use of curtains, however the curtains may have to be drawn, when using lenses of high magnification or with surface projection of difficult components. The projector should be placed when in its operating position, on a level firm floor, supported on its three non adjustable feet (one at the front, two at the rear). The two stabilising screws on the underside of the base near the centre of the projector, should be screwed down to make contact with the floor (only light pressure is required). Precise levelling of the projector is not necessary.
3.2 Power Supply A mains supply of the correct voltage is required.
WARNING: Check the mains voltage setting before connecting the mains supply (see 3.7 - Mains Connection below). At the right hand side of the projector is the electrical input junction box and fuse holder, housing a 10 amp fuse. Mains input must be connected through this box. The mains input voltage for which the projector is set, will be as indicated on the instruction plate next to the junction box. In the event that this does not correspond with the mains input voltage, adjustment is possible via the tappings on the primary side of the transformer which is reached via the lower access door on the left handside of the projector body on HS750 and a rear panel on HS600, (Please refer to wiring diagram).
Mains Supply Colour: Black:
Live
Blue:
Neutral
Green/Yellow: Earth
3.3 Moving the Projector into Position (Figure 1) Lifting The projector should be lifted using slings around the four lifting bosses on the base of the projector, any other method may cause damage to the projector.
Fig 1
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Fitting the canopy
The canopy is supported on two tubular arms which are fixed to the projector body by split clamps. The height of the arms can be adjusted as shown in figure 2 to level the canopy. The curtains may now be fitted on the rail provided, the hooks should face the inside of the canopy pelmet so that they are not visible from inside the projector canopy area.
3.5 Removing Transit Strap and Screw (Figure 3-5) The transit straps and transit screw are painted red.
CAUTION: The transit strap and screw must be removed before any attempt is made to move the workstage or to use the projector. 1. Remove the screw A from the transit strap and allow the strap to hang from screw B. 2.
Remove the transit screw C. Remove plate and replace screws.
3.
Remove the transit screw D and completely remove the block.
Fig 2
Keep the screws etc. in a safe place; they must be refitted if the projector is moved at a later date.
Fig 3
Fig 4
Fig 5
3.6 Fitting the DRO (Figure 6-8) 1.
Fit the bracket to the projector, securing it with the four screws fig 6.
2.
Fit the DRO to the bracket, securing it with the two screws B. Using a 3/16” Allen key fig 7.
3.
Fit the two labelled 15-way ‘D’ Type also the 9 way ‘D’ type connectors and the mains connector into the corresponding sockets at the back of the DRO fig 8.
Projectors fitted with edge detector: 4. Fit the reference cable and screen cable connectors to the corresponding sockets at the back of the DRO.
Fig 6
Fig 7
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Fig 8
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3.7 Mains Connection
WARNING: A secure earth connection must be provided. The cable colour code is as follows: Black 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 and remove the Bottom access panel from the main body. 2.
Identify the transformer, and check that the correct mains tapping is set.
3.
Refit the access panel.
Connect the mains cable to the switch fuse box at the side of the projector, this can be hard wired via conduit or a mains cable and plug.
3.8
Fitting Lenses
In order to locate a lens assembly in the rotary turret place the lens assembly in the turret with the large diameter facing outwards. Lock in position using the two flanged clamping bushes and screws. Ensure that the flange shoulder on the lens assembly is fully home and flat against the turret face. When a full compliment of lenses is not available any unused apertures in the turret should be fitted with a cover plate. Note: On the HS600 model when using 10x and 20x lens assemblies in a four lens turret these lenses must be placed diametrically opposite each other in the turret to avoid interference of the lens turret.
3.9 Commissioning Checks
Fig 9
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 the floor. 2.
Fit a workpiece securely to the workstage.
3.
Switch on the power supply.
4.
A digital protractor is displayed on the DRO screen.
5.
Check that the DRO screen shows a numeric display and the display should count up and down when checking 9.
6.
Switch on the profile illumination, and turn the focus handwheel to bring the workpiece into focus. Check that the screen image is satisfactory.
7.
Switch on the surface illumination, and check that the two fibre optic light guides are illuminated if fitted.
8.
Release the latch block on the X-axis slide, check that the slide moves freely, and apply the latch.(Not on CNC models)
9.
Move the joystick controller and check that the workstage moves freely side to side and up and down.
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8
Description of Equipment
The Starrett HS 600/750/1000 Digital Optical Projector is designed for 2-dimensional optical measurement of part profiles and surface features.
The projector comprises the following main items: 1 Main Body Housing The housing contains the projection lens (7), mirror, surface illumination lamp, surface illumination light guides (8), and the mains transformer. 2
Digital Protractor Provides digital indication of angular measurements. Displayed through the QC DRO unit (Q AXIS)
3
QC DRO The QC DRO enables measurement values to be viewed and recorded and part programs created for measuring a number or similar parts. For further details, refer to the QC DRO Operators Manual.
4
Workstage Movable in the X and Y axes for measurement, and in the Z axis? for focus. Two dovetail slots for fitting workholders with angular clamping screws. The dimensions are as follows (in mm):
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Projection Lamp Cover Houses the projection lamp, condenser lens, (see Section 5 - Operation - Controls).
6
Projection Lens Projects the image on to the screen via the mirror in the screen housing (1). available; for details see Section 7 - Specification.
A range of lenses are
For changing lenses see Section 6 - Maintenance. 7
Surface Illumination Light Guides Optical fibre guides which conduct the light from the lamp for surface illumination of parts. (See Section 5 - Operation - Controls).
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Operation
5.1 Controls (Figure 11) 1
Screen Glass screen, with overlay clips.
2
Angular Adjustment Handwheel For rotating the screen, for angular measurement. There is a clamp knob for locking screen rotation.
3
QC DRO Display X,Y & Q axis position. For operating details, see the QC DRO Operators Manual.
4
Manual Horizontal Table Movement 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, pressing the handle down re-engages the drive. Fine adjustment is then possible using the small hand wheel on the right end of the traverse rod. (the roller nut is locked permanently on CNC models)
5
Helix Control In order to project helical components such as worms, threads etc. it is necessary to swivel the workstage table to bring the profile of the component to be projected square to the lens axis. This is achieved by first releasing the two table swivel clamps, beneath the table (figure 12) one on each side of the knee. The angle can be set to position using the vernier scale (fig 13). Fig 12
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The angular vernier scale is provided (figure 13) to facilitate accurate setting of the swivel table. Where the helix angle is not known the image should be set to give an even band of shadow around the thread to be projected and then a slight adjustment of focus control will give a clearly focused image. NOTE: It is only possible to focus one thread profile at a time. Projection of very steep helix angles with deep profiles may cause problems with interference, causing a loss of image clarity on root and tip. This problem is common to all type of projector but most threads, worms and other helical components should give a satisfactory image. Standard thread overlay profiles, for a wide range of threads are available from Starrett Precision Optical. 7
Vertical and Horizontal Workstage Movement A variable speed D.C. motor controlled by an electronic joystick, elevates or lowers the workstage and moves the workstage left and right. The further the distance the joystick is moved away from the centre, the faster the workstage travels. Depressing the centre push button on top of the handle gives instant fast traverse, irrespective of the position of the stick or the direction selected.
8
Focus Handwheel Focus is achieved by turning the small handwheel on the left hand side of the knee.
9
Surface Illumination Two types of surface illuminator are available as follows:
9a.
Fibre optic illuminator (standard fitting) This system consists of a pair of large diameter fibre optic bundles terminating in ‘flex and stay’ tube guides. These guides are fully adjustable and can be extended by pulling them out of the projector body, finally securing each tube through the clamp screws on the side of each of the support guides.(see figure 14) For the brightest reflected image, place the light guides as close as possible to the face of the component to be inspected. Where components have directional surface finish e.g. ground faces, the surface texture should be placed at right angles to the table long axis, this will give the brightest reflected image on the screen. As the fibre optic cable is a ‘cold light’ source, no heat is radiated on to the component under test.
Fig 14
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HS 600/750/1000 OPERATORS MANUAL 9b
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Twin Lamp Focusing Surface Illumination (optional extra) This form of surface illumination is used where a larger area is to be illuminated than is possible with the standard fibre optic unit. Release the clamp on top of each of the lamps and swivel each lamp to give the best possible area of illumination on the component to be projected. Final adjustment is made by sliding the condenser mounting in or out by releasing the lock knob until the required area of illumination is achieved then tighten the lock knob. NOTE Both these types of surface illuminators work best on comparatively rough surfaces i.e. machined parts and in some cases it may be an advantage to rotate the workpiece about the lens axis so that the surface texture is at the best angle to the lamps. This technique can often give a dramatic increase in image brightness.
10
Switch Panel Rocker switches for POWER on/off and the PROFILE illumination lamp the SURFACE illumination lamps.
Fig 15
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. If a digital protractor is fitted, refer to 5.3 - Using the Digital Protractor on page 12. Use the manual controls as required:
Linear measurements Angular measurement Helical features Surface features
: X- and Y-axis handwheels. : Angular adjustment control and digital protractor Q axis : Helix control : Surface illumination light guides or Hot lamps
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. See DRO instruction manual for further information on angular measurement.
6 Maintenance 6.1 Access to Components 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 Side access panel gives access to the mirror, and transformer. The profile lamp cover can be removed for access to the profile illumination lamp and Yellow green filter.
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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 fingermarks with a new photographic cleaning tissue, which may be moistened with methanol if necessary.
6.3 Cleaning the Mirror CAUTION The mirror should be cleaned as infrequently as possible. It is recommended that cleaning is performed by an authorised service engineer. Do not finger the surface of the mirror. 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, and then 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. lean 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.
6.5 Changing the Projection Lens CAUTION Do not touch the surfaces of the lens. 1. Slacken the two screws securing the clamps (2), Remove screws and clamps this allows the lens to be removed, and withdraw the lens. 2.
Fit the replacement lens, also the clamps to secure, and tighten the securing screws.
6.6 Renewing the Profile Illumination Lamp (Figure 16) CAUTION Do not finger the surface of the new lamp; handle it in its protective wrapping as detailed below. Any fingermarks will be fired into the surface of the quartz envelope, reducing the output and life of the lamp. If the envelope is accidentally finger marked, remove the marks immediately with a cotton wool swab moistened with methanol. 1. Remove the 3 securing screws from the profile lamp cover and lift the cover clear. 2.
Remove the used lamp by holding it carefully between finger Fig 16 and thumb and pulling it gently upwards until the terminal pins are clear of the connectors (4).
3.
Remove the new replacement lamp from its box and with a sharp knife cut approximately 6 mm (1/4 in) from the bottom of the protective wrapping, allowing the terminal pins to protrude.
4.
Holding the lamp by its protective wrapping, insert the terminal pins into the connectors (4).
5.
Check that the lamp is vertical and securely located, and dispose of the protective wrapping.
6.
Refit the lamp cover and secure it with the 3 screws.
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6.7 Renewing the Surface Illumination Lamp (Figure 17) 1.
Remove the two screws securing the cover.
2.
Remove the surface illumination lamp cover.
3.
Raise the wire handle of the lamp ejection clip on the housing to lift the lamp pins out of their connectors, and remove the used lamp.
4.
Insert the new lamp into the housing.
5.
Refit the lamp cover and secure it with the two screws.
6.8 Lubrication Jack gear boxes and other wearing mechanical parts are lubricated for life on assembly and no routine lubrication of the equipment will be necessary in normal usage.
Fig 17
6.9 Latch Block Adjustment 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, release the screw, and hold the internal nut in position with the key.
4.
Rotate the bearing mount/collet to give the required tension.
No.
Description
5.
Tighten the socket lock screw.
1
Slide Bar
6.
Refit the engagement handle and end cap.
2
End Cap
3
Bearing
4
Bearing Mount Collet
6.10 Calibration
Fig 18
Have the machine calibrated annually for optical size and 5 mechanical deviations. (Contact Starrett Precision Optical Ltd 6 or an authorised distributor for details of this service). 7
Internal Lock Nut Socket Lock Screw Engagement Handle
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15
Specification
Overall Dimensions Width Height Depth Weight Workstage Construction Top Plate Size Horizontal Travel Vertical Travel Focus travel Max Load Capacity Projection Lenses Mount Lenses
823.2mm (32.4in) with workstage centralised on X-axis 886.3mm (35in) 1167.2mm (46in) HF600: 510kg HF750: 660kg HS600: 1050kg HS750: 1330kg Double dovetail Cast Iron top plate 630 x 230mm (25 x 9in) (X-axis ) 300(12in) (Y-axis) 200mm (8in) (Z-axis) 75mm (3in) max. 150 kg (330lb) Evenly distributed Turret 4 lens HF600, Turret 3 Lens HF750 x10,x20, x25, x50,& x100
HS600 Projector Lens
Working Distance
Maximum Diameter - Full and Half Field of View Full Field Diameter
Half Field Diameter
x10
138mm
280mm
280mm
x20
127mm
280mm
280mm
x25
103mm
280mm
280mm
x50
88mm
270mm
280mm
x100
44mm
98mm
104mm
HS750 Projector Lens
Working Distance
Maximum Diameter - Full and Half Field of View Full Field Diameter
Half Field Diameter
x10
151mm
340mm
400mm
x20
101mm
240mm
340mm
x25
92mm
220mm
280mm
x50
60mm
125mm
145mm
x100
48mm
130mm
160mm
Electrical Transformer Input Tappings From 110-240V, 50-60 Hz Input Switch/fused box Light Sources Profile illumination Surface illumination Fibre optics Hot Lamps Set
24V 150W Halogen lamp 12V 100W Halogen Reflector lamp 24V 150W Halogen lamp
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Spare Parts
8.1 How to Order Spares Contact your local dealer, or contact Starrett Precision Optical by telephone, fax or e-mail: Starrett Precision Optical Ltd Oxnam Road Jedburgh Scotland TD8 6LR Telephone:
+44 (0) 1835 863501
Fax: +44 (0) 1835 866300 E-mail:
sales@starrett-precision.co.uk
Please quote part numbers when ordering spares.
8.2 Mechanical Parts Description
Part No
Type
Surface Illumination Lamp Holder
6G06
STD
Profile Illumination and Hot Lamp Lamp Holder
LH11
STD
Digital Screen HF600(With Clips)
6F004
Digital
Digital Screen HF750 (With Clips)
0DS9
Digital
Linear Transducer Scale (X-axis) 320mm
VPP320
Digital
Linear Transducer Scale (Y-axis) 220mm
VPP220
Digital
Fibre Optic Thumb Screws
FO14
STD
Readout Mounting Screws 1/4” UNC x 1/2”
19N02
Digital
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8.3 Electrical Parts Refer to Section 9 - Wiring Diagram Description
Ref
Part No
Type
Profile Illumination Lamp 24V 150W
L1
LH19
STD
Surface Illumination Lamp 12V 100W
L2
F007
STD
Power Switch
S1
CB15
STD
Profile Switch
S3
SP02
STD
Surface Illumination Switch
S12
SP02
STD
Cooling Fan Profile 120mm
F1
LH26
STD
Cooling Fan Fibre Optic 80mm
F2
LH08
STD
Cooling Fan Hot Lamp Set 80mm
F3
HL101
STD
Transformer 115/240V
T1
WH33
STD
9J02
STD
Power Entry Socket RFI Filter
FILTER
QA09
STD
Fuse 6.3A
FS4
9J03
STD
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9 Wiring Diagram L
S28 BLK2
FS12
N
L/B2 SUPPLY VOLTAGE 110/220 VOLTS 1PH
E
T4
110V
BLK11
22V
11V
BLK22 L7
BLK110
L/B110
BLK110
ESP
L/B110
BLK110
DRO
L/B110
BLK110
F2 L/B110
BLK112
FAN PROFILE BLK21
BLK22
L/B18
PROFILE
BLK110
L3
F1 L/B110
BLK111 FAN
SURFACE BLK13
BLK11 SURFACE
L/B11 L2
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Y X
S14
JOYSTICK
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D2
D1
S42
BLK5
S41
BLUE42
BLUE41
BLUE40
BLUE39
BLUE38
BLUE7
BLK6
BLUE5
BLK4
BLUE18
BLK20
BLUE18
MOTOR DRIVE CIRCUIT
M2
X AXIS
Y AXIS
M1
BLK7
9
8
7
6
5
4
3
2
1
12
11
10
+
LOAD
BLK20
WH55
12 AMP
+
LINE
BLUE18
E STOP
2 AXIS MOTOR DRIVE CARD
FILTER
-
BLK22
TO TRANSFORMER
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