Mahr Federal Maxum III User manual

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Table of Contents
1.0 Precautions and General 4.0 Operation
Information 4.1 Standard Mode
2.0 Product Features 4.1.1 Initial Setup-
2.1 Max
µ mIII Features Standard/TSP Mode
2.2 Controls – Standard 4.1.2 Setting Tolerance
Mode Limits
2.3 Controls – Enhanced 4.1.3 Reapportioning
Mode Measuring Range
3.0 Setup 4.2 Enhanced Mode
3.1 Changing inch/metric 4.2.1 Enhanced/
Units Actual Mode
3.2 Changing Measuring 4.2.2 Enhanced
Direction Dynamic Measuring
3.3 Changing Digital Range Mode
3.4 Changing Digital 5.0 Maintenance
Resolution 5.1 Changing the Battery
3.5 Selecting Analog 5.2 Checking Accuracy
Scale/Overlay 5.3 Spindle Maintenance
3.6 Selecting Data 5.4 Calibration
Output Format 6.0 Parts & Service
6.1 Replacement Parts
6.2 Accessories
7.0 Specifications

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Table of Contents-continued
8.0 Output Information 8.3 ASCII Output
8.1 Standard Max
µ m8.4 Mating Connectors
Output 9.0 Quick Setup Flowchart
8.2 Digimatic Output

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These instructions apply to the Max
µ mIII
Indicators and Indicating units:
1.0 PRECAUTIONS AND
GENERAL INFORMATION
All Max µ
µµ
µ m

III Models: Your new
Max
µ mIII Digital Electronic Indicator will
provide both Standard and Enhanced
measurements. When placed in the
Enhanced Mode, the Max
µ mIII provides
the capability of measuring relative
maximum, minimum and T.I.R. values
Max
µ mIII units come with battery
installed and operate in the traditional
Standard Max
µ mMode. When not in use
the Indicator or Indicating unit is left in its
“Sleep” mode which conserves battery
power. (Ref. Section 2.1)
The unit also includes removable overlays
for duplication of the previous Max
µ mand
Max
µ mPlus model design where needed.
Max
µ mIII units are ruggedly built to
withstand hard use, and their gasketed
case, crystal and stem assemblies resist
encroachment by most fluids. However,
Max
µ mIII Indicators, Indicating Units and
Digital Transducers should never be
immersed. Regularly inspect all seals and
spindle boots to guard against fluid
penetration.
Digital Output Models:
To prevent contaminants from entering the
6 or 10-pin digital output connectors, the
dust cap should always be firmly in place
whenever an output cable is not connected.
Digital Transducers:
Any Max
µ mIII Indicating Unit can be used
with any Max
µ mIII Digital Transducer.
Make sure the transducer connector is
properly aligned with the indicator connector
before connecting them. Max
µ mIII
Indicating Units may not be used with
Max
µ mand Max µ mPlus style remote

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transducers. Max
µ mIII Digital
Transducers must be used with an adaptor
cable to connect to Max
µ mand Max µ m
Plus Indicating Units.
(See Section 7.0 for adaptor cable part
numbers.) To disconnect the Digital
Transducer, pull the connector straight out;
do not twist or unscrew the connector. Also,
do not severely bend, twist or strain the
transducer cable.
2.0 PRODUCT FEATURES
2.1 Max
µ
µµ
µ m

III Features
Switchable Inch / Metric Units
Allows the indicator to display in “in” units or
“mm” units. Selectable in the Setup Mode.
Tolerance Limits
Allows the selection of left and right
tolerance limits within the analog scale
displayed.
Range Signal
There are two conditions that occur when
the readings are over-range. The Off-Scale
condition occurs when the fan display
exceeds the analog scale and is indicated
by a flashing segment at the most left or
right segment location. The Over-Range
condition occurs whenever the digital
reading is exceeded and is indicated by a
blank display that shows both the polarity
sign and the in/mm units icon. Unit is still
active and not to be confused with the
Sleep Mode condition.

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Selectable Digital Resolution
There are two selections for digital
resolution with each Digital Range
selection. See below;
Digital Range Available Resolutions
±0.100inch / ±1.99mm 0.0005” or 0.0001” / 0.005mm or 0.001mm
±0.040inch / ±1.0mm 0.0005” or 0.0001” / 0.005mm or 0.001mm
±0.0199inch / ±0.199mm 0.00005” or 0.00002” / 0.001mm or 0.0005mm
Selectable Digital Range
The “Short Range” Max
µ mIII unit is
capable of selecting two digital ranges. The
“Short Range” model can select between
±0.040 and ±0.199in (±1.00 and ±0.199mm)
ranges. The “Long Range” model has one
range of ±0.100in (±1.99mm) only.
Selectable Analog Magnification
Each Max
µ mIII unit is capable of
selecting between two minimum analog
graduation values. An inch/metric overlay
can be used for traditional analog display
preference. The “Long Range” model can
select between 0.001 and 0.0005in (0.01
and 0.005mm) resolutions. The “Short
Range” model can select between 0.001
and 0.0005in (0.01 and 0.005mm)
resolutions for the ±0.040in/±1.0mm range
and between 0.0005 and 0.0001in (0.005
and 0.001mm) resolutions for the
±0.0199in/±0.199mm range
Sleep Mode
The Max
µ mIII unit is designed with an
auto power down feature to conserve
battery life. If it senses approximately 10
minutes of inactivity (i.e. no spindle
movement, no buttons pushed, no digimatic
data output request), the unit will go into a
“Sleep” state. Display shows only a “+” or “-“

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sign depending on measuring direction
selected in setup. Unit is inactive.
(Option) The sleep mode may be disabled
as a factory option when requested at time
of order. However, when using battery
power the life of the battery will be reduced.
This option is typically used with the
Remote External Power option, which
bypasses battery operation.
Transducer Range
Max
µ mIII Remote Indicating Units auto-
sense the type of Digital Transducer
plugged into it. There are two types of
Digital Transducers that are auto-sensed;
“Short Range” versions, which have a
±0.040in/±1.0mm measuring range and
“Long Range” versions, which have a
±0.100in/±1.99mm measuring range.
Digital Output
Each Max
µ mIII unit is capable of
selecting between three choices of data
output format; the Standard Max
µ moutput
format, the Max
µ mSerial output format,
and a digimatic output format.
Digital Calibration
The Max
µ mIII indicator can be calibrated
via pushbutton sequencing for accurate
performance.
Low Battery Signal
The text “Bat” is displayed on the digital
display signifying that a battery change is
necessary which helps avoid collection of
bad data. It initially flashes as a warning
then under continuous use eventually
remains on so that no readings will be
displayed.
Calibration Lockout (Option)
Allows the entry into the calibration mode
via an access key (Order No. 2240545 – 6
pin, Order No. 2240547 –10 pin) when
plugged into the data output port.
Calibration is inaccessible without this
Access Key. Specific models only.

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Setup Lockout (Option)
Allows the entry into the setup mode via an
access key (Order No. 2240545 – 6 pin,
Order No. 2240547 –10 pin) when plugged
into the data output port. Setup mode is
inaccessible without this Access Key.
Specific models only.
Remote External Power (Option)
Allows use of remote power from an
external regulated power supply or data
collector via the data output port. When
remotely powered, battery is bypassed and
it is not used unless remote source is
inactive. Available on models that have a
data output port only. Never use an external
power supply on models that do not have
this special option feature.
Ratio Model (Option)
There are two ratios available for the
Max
µ mIII indicator. All standard models
come with a 1:1 ratio meaning 0.010inch
movement of the spindle results in
0.010inch reading on the indicators digital
display. Some applications require a 4:5
ratio. Max
µ mIII models ordered with this
4:5 ratio will read 0.008inch on the
indicators digital display when the spindle is
moved 0.010inch in linear travel. There are
no other ratios available on this indicator.
This is a factory set option.
CAUTION
Do NOT continuously toggle external
power source on and off as this can
cause damage to the digital indicator
and the remote power source.
Do NOT remove or install the external
power source cable while the
external source in on.

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2.2 Controls – Standard Mode
Makes use of 6 push buttons (mode, left
limit, left display index, right display index,
right limit, autozero) for selections in two
Operating Modes (Standard and Enhanced)
and separately for entering the Setup Mode
and Calibration Mode. Buttons are only
active when a reading is on the display.
(Max µ
µµ
µ m

III indicator shown in TSP mode)
True Spindle Position (1)
Enters unit into its TSP mode to show the
actual position of the spindle in the
Indicator’s measuring range.
Left Tolerance Limit (2)
To set the left arrow at desired limit.
Display Switches (3)
To index the digital readout and analog
display clockwise (right-handed switch) or
counterclockwise (left-hand switch). The
display switches will function only when the
Indicator or Indicating Unit is in the “Auto-
Zero” (Gaging) mode.
Right Tolerance Limit (4)
To set the right arrow at desired limit.
1
2
5
4
3

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Auto Zero (5)
To electronically set both the analog display
and digital readout to zero.
2.3 Controls – Enhanced Mode
Mode (1)
To show the real time static measurement
of the spindle in the indicator’s measuring
range while in Enhanced Mode. (Sec. 4.2)
When the mode button is used to activate
the enhanced function the indicator’s analog
display changes to the alternate mode, i.e.
a normal “Fan” display changes to a “Single
Element” display, and dynamic button
functions become active.
(Max µ
µµ
µ m

III indicator shown in Gaging
mode)
MIN (2)
Activates the dynamic minimum value
retention function. Displays the lowest or
most negative measurement seen by the
indicated movement.
1
2
5
4
3

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TIR (3)
Activates the dynamic Total Indicated
Reading value retention function. Displays
the lowest and highest points on the analog
scale (if not exceeded) and the total reading
of max minus min (max – min) on the digital
readout.
HOLD (4)
Activates the “Hold” function, which freezes
the displayed reading at that moment in
time. A second press of the button releases
the frozen reading and “Updates” the
display to the current spindle position. This
function can also be remotely triggered via
the output port on specific models – see
section 8.0 Output Information.
MAX (5)
Activates the dynamic maximum value
retention function. Displays the highest or
most positive measurement seen by the
indicated movement.
RESET (6)
Electronically sets both the analog display
and digital readout to zero when in the
Enhanced Actual or TIR modes.
Electronically sets both the analog and
digital readout to the current spindle
position location in the minimum or
maximum modes. This function can also be
remotely triggered via the output port on
specific models – see section 8.0 Output
Information.

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3.0 SETUP MODE
The Max µ mIII has six operator
changeable features, which are selectable
in the indicators Setup mode. These
features are; changing linear units between
inch and millimeter, changing of measuring
direction polarity, selecting of two digital
ranges (full or reduced – short range
models only), selecting the digital
resolution, how to select the analog scale
magnification including proper overlay
usage, and selecting of data output format
to be used with an external device. The
Max
µ m

III uses the two “mushroom” push
buttons to enter setup mode, make feature
selections, and exit setup mode. A quick
reference sheet of button operation for the
Max
µ m

III setup menu is provided at the
end of the manual –Section 9.0.
ENTERING SETUP MODE
Entering the Setup mode is accomplished
by pressing and holding the ‘HOLD’ button
for three or more seconds until the display
shows “SEt”, indicating Setup mode.* At
the “SEt” screen, press and release the
‘RESET’ button to enter the selection menu
of setup features.
Note: For models with the Setup Mode
Lockout Option this mode is accessible
with the Access Key (Order No.
2240545 –6pin, Order No. 2240547 –
10pin) when plugged into the data
output port. Setup mode is inaccessible
without this Access Key.
!
*NOTE: THE SETUP MODE CAN
ONLY BE ENTERERD WHILE THE
UNIT IS IN BOTH STANDARD
MODE AND THEN TSP (TRUE
SPINDLE POSITION) MODE.
!

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Once in the Setup mode simply press the
corresponding button to toggle through the
features and choices. The ‘RESET’ button
toggles thru the setup menu items and the
‘HOLD’ button toggles thru the indicated
feature selections. The selection displayed
is the one that is saved when exiting the
Setup mode.
(Max µ
µµ
µ m

III indicator shown in Setup mode)
EXITING SETUP MODE:
To exit Setup mode press and hold the
‘RESET’ button a minimum of 3 seconds
then release the button. The setup menu
item should disappear and the unit is back
into its operating TSP mode. If the unit has
not exited from the Setup mode, then repeat
this step again.

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3.1 Changing inch / metric units
a) Enter setup mode
b) Press the ‘RESET’ button until the
letter “u” indicates the Units setup
feature.
c) Press the ‘HOLD’ button to toggle
between inch (“in”) and metric
(“mm”) units. Notice the in/mm icon
will indicate the selected units on
the LCD display.
(shown in millimeter units) (shown in inch units)

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3.2 Changing Measuring Direction
a) Enter setup mode
b) Press the ‘RESET’ button until the
letter “d” shows in the last digital
position of the LCD display. The “d”
indicates the Direction setup
feature.
c) Press the ‘HOLD’ button to toggle
between Normal (“n”) and Reverse
(“r”) direction. Notice the tolerance
arrows will also indicate the
direction change.
(shown in reverse polarity direction) (shown in normal polarity direction)

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3.3 Changing Digital Range
a) Enter setup mode
b) Press the ‘RESET’ button until the
letter “r” shows in the last digital
position of the LCD display. The “r”
indicates the digital Range setup
feature.
c) Press the ‘HOLD’ button to toggle
between standard range and
reduced range selections. Notice on
the LCD display that the digital readout
will change from one measuring range
to another. Only “Short Range” models
have this selection available.
For long range models the choice is fixed at
.100in (1.99mm).
For short range models the choices will be
.040in and .020in – for the .0199” range
(1.00mm and 0.199mm).
(“Short Range” model shown in Standard Range) (“Short Range” model shown in Reduced Range)

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3.4 Changing Digital Resolution
a) Enter setup mode
b) Press the ‘RESET’ button until the
letter “r” shows in the last digital
position of the LCD display. The “r”
indicates the digital Range setup
feature.
c) Press the ‘RESET’ button once to
enter the Digital Resolution setup
feature. Note that there is no half-
digit icon used for this setup
feature.
d) Press the ‘HOLD’ button to toggle
between standard digital resolution
and high digital resolution
selections. Resolution selections
are dependent on indicator model
and digital range selection (See
Table 3.5)
(High digital resolution shown) (Standard digital resolution shown)

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3.5 Selecting Analog Fan Scale/ Overlay
3.5.1 Setting-up the Indicator Analog Fan
Scale
a) Enter setup mode
b) Press the ‘RESET’ button until the
letter “F” shows in the last digital
position of the LCD display. The “F”
indicates the analog Fan display
setup feature.
c) Press the ‘HOLD’ button to toggle
thru the analog graduation value
selections.
Notice the fan display toggles between half
full scale (only half the LCD fan segments
are on) and full scale (all the LCD fan
segments are on). This ½ fan scale and full
fan scale help the operator in deciding
which overlay to use. The ½ fan scale
indicates that the 25-0-25 overlay should be
used. The full fan scale indicates that either
the 5-0-5 or 50-0-50 overlay should be
used. See the following section 3.5.2 and
corresponding Table 3.5 for correct
installation and choice when using the
overlay option.
(Standard Full Scale Indication shown) (High half Scale Indication shown)

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3.5.2 Installing and Removing the
Overlay Scale
Once the pushbutton settings have been
set, if desired, install the corresponding
overlay onto the front of the Max
µ mIII per
table 3.5. The following is a recommended
procedure for installing and removing the
overlay from the front of the Max
µ mIII
indicator.
TABLE 3.5 Overlay Selection Table
INCH
Digital
Digital
Analog
Analog
Overlay
Legacy Model
Range
Resolution
Graduation
Scale
Used
LONG RANGE MODEL
New ±0.100in 0.0005 0.0005 25 25-0-25
New ±0.100in 0.0005 0.0010 50 50-0-50
New ±0.100in 0.0001 0.0005 25 25-0-25
DEI-X7XXX ±0.100in 0.0001 0.0010 50 50-0-50
New ±0.040in 0.0005 0.0005 25 25-0-25
New ±0.040in 0.0005 0.0010 50 50-0-50
DEI-X2XXX ±0.040in 0.0001 0.0005 25 25-0-25
DEI-X3XXX ±0.040in 0.0001 0.0010 50 50-0-50
SHORT RANGE MODEL
New ±0.040in 0.0005 0.0005 25 25-0-25
New ±0.040in 0.0005 0.0010 50 50-0-50
DEI-X2XXX ±0.040in 0.0001 0.0005 25 25-0-25
DEI-X3XXX ±0.040in 0.0001 0.0010 50 50-0-50
DEI-X1XXX ±0.0199in 0.00005 0.0001 5 5-0-5
New ±0.0199in 0.00005 0.0005 25 25-0-25
DEI-X0XXX ±0.0199in 0.00002 0.0001 5 5-0-5
New ±0.0199in 0.00002 0.0005 25 25-0-25
METRIC
Digital
Digital
Analog
Analog
Overlay
Legacy Model
Range
Resolution
Graduation
Scale
Used
LONG RANGE MODEL
New ±1.99mm 0.005 0.005 25 25-0-25
New ±1.99mm 0.005 0.01 50 50-0-50
New ±1.99mm 0.001 0.005 25 25-0-25
DEI-X6XXX ±1.99mm 0.001 0.01 50 50-0-50
New ±1.0mm 0.005 0.005 25 25-0-25
New ±1.0mm 0.005 0.01 50 5 or 50
New ±1.0mm 0.001 0.005 25 25-0-25
DEI-X5XXX ±1.0mm 0.001 0.01 50 5 or 50
SHORT RANGE MODEL
New ±1.0mm 0.005 0.005 25 25-0-25
New ±1.0mm 0.005 0.01 50 5 or 50
New ±1.0mm 0.001 0.005 25 25-0-25
DEI-X5XXX ±1.0mm 0.001 0.01 50 5 or 50
DEI-X4XXX ±0.199mm 0.001 0.001 5 5 or 50
New ±0.199mm 0.001 0.005 25 25-0-25
New ±0.199mm 0.0005 0.001 5 5 or 50
New ±0.199mm 0.0005 0.005 25 25-0-25

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INSTALLATION
1) Chose the correct color and overlay
scale from the table above (Table
3.5). Inch readout uses the green
side of the overlay and metric (mm)
uses the yellow side of the overlay.
2) Remove protective sheets from the
overlay. Take the overlay and place
one side of the long edge under the
lip of the housing.
3) Slightly bend the overlay and insert
it under the front housing lip on the
opposite side.
4) Once the overlay is installed over
the crystal operate the indicator to
make sure the readings correlate to
the settings selected in the
indicator.
(unit shown without overlay) (unit shown with yellow metric overlay)