HE400 Optical Profile Projector Manual

HE400 Digital Optical Projector OPERATORS MANUAL

Copyright © 2003 Starrett Precision Optical Ltd. Revised September 2015

HE400. 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. Oxnam Road Jedburgh Scotland TD8 6LR Telephone: +44 (0) 1835 863501 Fax: +44 (0) 1835 866300 E-mail: sales@starrett-precision.co.uk web site www.starrett-precision.co.uk

HE400. Operators Manual

Contents Page

Safety............................................................................................................ 1

1 Introduction.................................................................................................. 1 2 Unpacking.................................................................................................... 1 3 Installation.................................................................................................... 2 3.1 3.2 3.3 3.4 3.5 3.6 3.7

Selecting Location .................................................................................................................2 Power Supply.........................................................................................................................2 Moving the Projector into Position..........................................................................................2 Removing Transit Strap and Screw........................................................................................3 Fitting Handle to Y-axis Handwheel........................................................................................3 Fitting the DRO.......................................................................................................................3 Mains Connection...................................................................................................................4

3.8

Commissioning Checks..........................................................................................................5

4

Description of Equipment........................................................................... 5

5 Operation...................................................................................................... 7 5.1 Controls..................................................................................................................................7 5.2 Taking Measurements............................................................................................................8 5.3 Using the Digital Protractor.....................................................................................................9

6 Maintenance .............................................................................................. 10 6.1 Access to Components.........................................................................................................10 6.2 Cleaning Lenses................................................................................................................... 11 6.3 Cleaning the Mirror............................................................................................................... 11 6.4 Removing and Cleaning the Screen..................................................................................... 11 6.5 Changing the Projection Lens..............................................................................................12 6.6 Renewing the Profile Illumination Lamp...............................................................................12 6.7 Renewing the Surface Illumination Lamp.............................................................................13 6.8 Lubrication............................................................................................................................13 6.9 Latch Block Adjustment........................................................................................................13 6.10 Calibration............................................................................................................................13

7

Specification.............................................................................................. 14

8

Spare Parts................................................................................................. 15

8.1 8.2 8.3

How to Order Spares............................................................................................................15 Mechanical Parts .................................................................................................................15 Electrical Parts .....................................................................................................................16

9

Wiring Diagram.......................................................................................... 17

1

HE400. Operators Manual

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 HE400 Digital Optical Projector.

The HE400 is supplied with the following equipment:

HE400 : 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

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 usually supported on a wooden base.

QC DRO and Manual

Mounting Bracket and Screws (for fitting DRO).

Handle for Y-Axis Handwheel, Fixing Screw, Washer and M3 Allen key

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).

All Lenses are 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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2

3 Installation 3.1

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.

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).

3.3

Moving the Projector into Position (Figure 1) Lift the projector using suitable equipment, applying support to the frame outside the mounting feet as indicated by the labels. There are holes in the base to slide bars through, and also 4 plastic bungs to blank the holes off after positioning The weight of the unit is approximately 94kg.

CAUTION:

Do not attempt to lift the unit by the projection lamp cover or screen housing.

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HE400. Operators Manual

3.4

Removing Transit Strap and Screw (Figure 2) The transit strap 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.

Keep the screws in a safe place; they must be refitted if the projector is moved at a later date.

Figure 2

3.5

Transit Strap and Screw

Fitting Handle to Y-Axis Handwheel (Figure 3)

1.

Turn the Y-axis handwheel so that the screw hole is opposite the hole in the projector frame.

2.

Fit the handle and washer, inserting the fixing screw through the hole in the frame and tightening it with the M3 Allen key provided.

Figure 3

3.6

Fitting Handle to Y-Axis Handwheel

Fitting the DRO (Figure 4)

1.

Fit the bracket to the projector, securing it with the four screws A. Using a 5mm Allen key

2.

Fit the DRO to the bracket, securing it with the two screws B. Using a 3/16� Allen key

HE400. Operators Manual

3.

4

Fit the two labelled 15-way ‘D’ connectors, 9-way D connector and the mains connector into the corresponding sockets at the back of the DRO.

Figure 4

Fitting the DRO

Projectors fitted with edge detector:

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 (the condenser is on the lamphouse cover nearest the screen, see Figure 5, item 5).

3.7

Mains Connection

WARNING:

A secure earth connection must be provided. The external 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 8 and remove the top 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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HE400. Operators Manual

3.8

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.

Check that the DRO screen shows a display

5.

The digital protractor is displayed on the DRO, turn the screen drive wheel and check the Q axis displayed is working.

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.

8.

Release the latch block on the X-axis slide, check that the slide moves freely, and apply the latch.

9.

Turn the X-axis and Y-axis handwheels and check that the workstage moves freely, and the movement of each axis corresponds to the correct one displayed on the DRO.

4

Description of Equipment

(Figure 5)

The Starrett HE400 Digital Optical Projector is designed for 2-dimensional optical measurement of profiles and surface features of parts.

HE400. Operators Manual

1

2

3

The projector comprises the following main items: Screen Housing The housing contains the projection lens (7), mirror, surface illumination lamp, surface illumination light guides (8), and the mains transformer.

Digital Protractor Provides digital indication of angular measurements. Displayed through the QC DRO unit.

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.

4 Workstage

6

5

Movable in the X and Y axes for measurement, and in the Z axis for focus. Single dovetail slot for fitting workholders with angular clamping screws. The dimensions are as follows (in mm):

Projection Lamp Cover Houses the projection lamp, condenser lens, and helix control (see Section 5 Operation - Controls).

On a projector fitted with an edge detector, the diopter 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.

6

Workholding Equipment

Workholding accessories are available, including centres and vees, a rotary vice, and a vertical glass plate workholder for small flat components.

7

Projection Lens

Projects the image on to the screen via the mirror in the screen housing (1). A range of lenses are available; for details see Section 7 - Specification.

For changing lenses see Section 6 - Maintenance.

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HE400. Operators Manual

8

Surface Illumination Light Guides

Optical fibre guides which conduct the light from the lamp for surface illumination of parts. (See Section 5 - Operation - Controls).

5 Operation 5.1

1

2

3

4

5

6

Controls (Figure 6)

Screen Bevelled glass screen, with overlay clips.

Digital Protractor Provides digital indication of angular measurements.

Angular Adjustment Handwheel For rotating the screen, for angular measurement.

QC DRO For details, see the QC DRO Operators Manual.

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 9 for fine adjustment).

Helix Control Skews the beam from the projection lamp for viewing the true profile of helical features such as screw threads.

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8

7

8

9

10

Y-Axis Handwheel Raises and lowers the workstage.

Focus Handwheel Moves the workstage in and out for focusing.

X-Axis Handwheel For fine adjustment of the workstage along the X-axis.

Surface Illumination Light Guides

Provide surface illumination for measuring surface features of flat components. For the optimum illumination, release the clamp screws and pull out the guides. Position the guides as close to the component as possible to obtain optimum illumination, and tighten the clamp screws.

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.

The guides provide a ‘cold light’ source; minimal heat is radiated to the component.

11

5.2

Switch Panel Rocker switches for POWER on/off, the SURFACE illumination lamp, and the PROFILE illumination lamp with HIGH/LOW settings.

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.

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HE400. Operators Manual

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

: X- and Y-axis handwheels.

Angular measurement

: Angular adjustment control and digital protractor

Helical features

: Helix control

Surface features

: Surface illumination and light guides.

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 Datum facia button assign Datum 1 for Absolute and Datum 2 for incremental.

SEE DRO instruction manual for further information on angular measurement.

HE400. Operators Manual

10

6 Maintenance 6.1

Access to Components (Figure 8)

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 top access panel gives access to the mirror (12), transformer (11), and surface illumination lamp. The profile lamp cover (6) can be removed for access to the profile illumination lamp and condenser lens (3). On later models a side access panel is provided for changing the surface illumination lamp.

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HE400. 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 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

6.4

Do not use force.

Removing & 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.

To remove the screen first use a metric Allen key and turn the top wheel eccentric to give maximum clearance so the screen can be remove see fig photo below.

Then using an Allen key again place in encoder wheel recess and move wheel upwards to give clearance of encoder wheel and screen edge.

The screen can then be removed. To replace the screen perform the procedure in reverse order.

HE400. Operators Manual

6.5

12

Changing the Projection Lens (Figure 8)

CAUTION

Do not touch the surfaces of the lens.

1.

The lenses are a bayonet fixing, rotating the lens to allows the lens to be removed.

2.

To replace a lens, locate the lens into the lens mounting hole and turn until locked in position, in position the red spots on the lens and body should line up.

6.6

Renewing the Profile Illumination Lamp (Figure 8)

CAUTION

Do not finger the surface of the new lamp; handle it in its protective wrapping as detailed below. Any finger marks 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 securing screw (7) from the profile lamp cover (6) and lift the cover clear.

2.

Lift off the heat shield (5).

3.

Remove the used lamp by holding it carefully between finger and thumb and pulling it gently upwards until the terminal pins are clear of the connectors (4).

4.

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.

5.

Holding the lamp by its protective wrapping, insert the terminal pins into the connectors (4).

6.

Check that the lamp is vertical and securely located, and dispose the protective wrapping.

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HE400. Operators Manual

7.

Refit the heat shield (5).

8.

Refit the lamp cover (6) and secure it with the screw (7).

6.7

Renewing the Surface Illumination Lamp (Figure 8)

1.

On earlier models, remove the four screws (1) securing the top access panel and take off the panel. On later models, remove the four screws (13) and take off the side access panel.

2.

Remove the surface illumination lamp cover (8).

3.

Raise the wire handle of the lamp ejection clip (10) on the housing (9) 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 (8). Refit the access panel and secure it with the four screws.

6.8 Lubrication

Periodically lubricate the slides with light oil.

6.9

Latch Block Adjustment (Figure 9)

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 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 9 Latch Block Adjustment

6.10 Calibration

Have the machine calibrated yearly for optical size and mechanical deviations.

(Contact Starrett Precision Optical Ltd. or an authorised distributor for details of this service).

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14

Specification

Overall dimensions

Width

Height

886.3mm (35in)

Depth

1167.2mm (46in)

Weight

823.2mm (32.4in) with workstage centralised on X-axis

97kg (213lb)

Workstage

Construction

Top Plate Size

Single dovetail hard anodised aluminium top plate 480 x 120mm (18.9 x 4.7in)

Horizontal Travel

(X-axis ) 254(10in)

Vertical Travel

(Y-axis) 101.6mm (4in)

Focus travel

54mm (2.125in) max.

Capacity Between

Centres

203.5 x 101.6mm (8 x 4in)

Max Load Capacity

25 kg

Projection Lenses

Mount

Single Lens

Standard x10

Optional Lens

x20, x25, x31.25, x50, x100 Working Distance

Maximum Diameter - Full and Half field of view Full Field Diameter

Half Field Diameter

x10

78mm

180mm

210mm

x20

76mm

210mm

210mm

x25

70mm

185mm

210mm

x31.25

55mm

115mm

140mm

x50

50mm

115mm

140mm

x100

41mm

90mm

105mm

Electrical Transformer Input

Tappings

From 110-240V, 50-60 Hz

Standard power socket

12V 100W halogen lamp

Surface illumination

12V 100W halogen lamp

Input

Light Sources Profile illumination

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HE400. Operators Manual

8 8.1

Spare Parts

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 Lamp Holder

LH11

STD

Digital Screen (glass only)

7F08

Digital

Linear Transducer Scale (X-axis) 270mm

VPP270

Digital

Linear Transducer Scale (Y-axis) 120mm

VPP170

Digital

X10 lens Assembly

4E010

Optional

x20 Lens Assembly

4E020

Optional

x25 Lens Assembly

4E025

Optional

x31¼ Lens Assembly

4E031.25

Optional

x50 Lens Assembly

7E050

Optional

x100 Lens Assembly

4E100

Optional

Diopter Assembly (for Edge Detector)

7T01

Optional

Y Axis Handwheel and Knob

4F10

STD

Base Swivel Foot

7A77

STD

Readout Mounting Screws ¼ UNC x ½”

19N02

Digital

Overlay Clips (4)

0DS23

STD

HE400. Operators Manual

8.3

16

Electrical Parts

Refer to Section 9 - Wiring Diagram

Description

Ref

Part No

Type

Profile Illumination Lamp 12V 100W

L1

LH14

STD

Surface Illumination Lamp 12V 100W

L2

F007

STD

Power/Neon Switch

S1

5H05

STD

Profile High/Low Switch

S3

5H07

STD

Surface Illumination Switch

S12

8E02

STD

Cooling Fan 80mm

F1, F2

LH08

STD

Transformer 115/240V

T1

5H10

STD

Power Entry socket

-

9J02

STD

Digital Protractor Display

DRO

-

Digital

RFI Filter

FILTER

QA09

STD

Digital Readout

DRO

-

Digital

Fuse 6.3A

FS4

9J03

STD

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HE400. Operators Manual

9 Wiring Diagram