Optimum DPA 2000 User manual

OPTIMUM
MASCHINEN - GERMANY
15.6.11 Page 1Digital position display DPA 2000/ DPA 2000S ; Version 2.1.2
© 2011
GB
Version 2.1.2
Digital position display
DPA 2000/ DPA 2000S
Operating manual
Keep for future reference!

Table of contents
OPTIMUM
MASCHINEN - GERMANY
15.6.11Page 2 Table of contents Digital position display DPA 2000/ DPA 2000S ; Version 2.1.2
© 2011 GB
Table of contents
1 Safety
1.1 Target group ........................................................................................................... 3
1.2 Proper use .............................................................................................................. 3
1.3 Invalid modification of the device ............................................................................ 4
1.4 Possible dangers caused by machine tools ........................................................... 4
1.5 Possible dangers caused by the device ................................................................. 4
1.6 Authorized personnel ............................................................................................. 4
1.7 Additional qualification requirements ...................................................................... 5
1.8 Obligations of the operator ..................................................................................... 5
1.9 Obligations of the user ........................................................................................... 5
1.10 Safety during operation .......................................................................................... 5
1.11 Safety during maintenance ..................................................................................... 5
1.11.1 Disconnecting and making it safe ................................................. 5
1.12 Accident report ....................................................................................................... 5
1.13 General instruction ................................................................................................. 6
1.13.1 Technical data .............................................................................. 6
1.13.2 Working conditions ....................................................................... 6
1.13.3 Precautions ................................................................................... 6
1.13.4 Regular maintenance ................................................................... 6
2 The front panel and rear panel
2.1 The front panel and a description of the keys ......................................................... 7
2.2 The rear panel ........................................................................................................ 8
2.3 Description of the keys ........................................................................................... 9
2.4 Measuring device - Pin Assignment at DPA 2000 ................................................ 12
2.5 Measuring device - Pin Assignment at DPA 2000S ............................................. 12
2.6 Input/output connection ........................................................................................ 13
2.7 Available accessories (only for DPA 2000S) ........................................................ 14
3 Assembly and commissioning
3.1 Delivery volume .................................................................................................... 15
3.2 Storage ................................................................................................................. 15
3.3 Adding the device ................................................................................................. 15
3.3.1 Requirements for the installation site ......................................... 15
3.3.2 Installing the device .................................................................... 15
3.3.3 Assembling the measuring gauges ............................................ 15
3.3.4 Assembly of the reading head .................................................... 16
3.4 Linking the position display to a frequency converter ........................................... 16
3.4.1 System requirements: ................................................................. 16
3.4.2 Electrical connection: .................................................................. 17
3.4.3 Programming the DPA 2000S .................................................... 19
3.5 First commissioning .............................................................................................. 20
3.5.1 Connecting the measuring gauges ............................................. 20
3.5.2 Connecting the power supply ..................................................... 20
3.5.3 Switching on the device .............................................................. 20
4 Description of the basic operation
4.1 Initiation ................................................................................................................ 21
4.2 Deleting ................................................................................................................ 21
4.3 Preset current coordinate value of the axis .......................................................... 22
4.4 Radius/Diameter conversion of the X-axis ........................................................... 23
4.5 Switching the functions turning/milling .................................................................. 23
4.6 Setting machine datum of operation ..................................................................... 23
4.7 Tool data function ................................................................................................. 24
4.8 Display Z+Z0 value (3-axes) ................................................................................ 24
4.9 Metric/inch conversion .......................................................................................... 25
4.10 Function of the reference mark (zero position) of the reading device .................. 25
4.11 Calculator function ................................................................................................ 26

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4.12 Dividing hole along an oblique line function ......................................................... 26
4.13 Dividing hole on the circle function ....................................................................... 28
4.14 Machining along the oblique line function ............................................................ 30
4.15 Arc machining function ......................................................................................... 31
5 Internal parameter setting
5.1 Programming function .......................................................................................... 35
5.2 Setting the cutting linear speed and the workpiece diameter ............................... 37
6 Dimensions and mounting
7 Troubleshooting
8 Appendix
8.1 Copyright .............................................................................................................. 43
8.2 Warranty ............................................................................................................... 43
8.3 Disposal ............................................................................................................... 44
8.4 Product follow-up ................................................................................................. 44
8.5 EC Declaration of Conformity ............................................................................... 45

Safety
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© 2011 GB
1 Safety
Glossary of symbols
This part of the operating manual
explains how to use the device properly,
points out dangers which might come into existence when disregarding this operating
manual,
informs you about how you can avoid dangers.
In addition to this operating manual please observe
the applicable laws and regulations,
the legal regulations for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the device.
Dring installation, operation, maintenance and repair of the device the applicable standards and
country-specific regulations of each country need to be observed.
ALWAYS KEEP THIS OPERATING MANUAL CLOSE TO THE DEVICE.
INFORMATION
If you are not able to solve a problem by using this manual, please contact us under:
Optimum Maschinen Germany GmbH
Dr. Robert-Pfleger-Str. 26
D- 96103 Hallstadt
E-Mail: [e-mail]
Technical Hotline: 09 00 - 19 68 220 (0.49 €/min if you call from the German fixed network,
this information is dated at the time of printing)
1.1 Target group
This operating manual is addressed to operation organizations, the operators and the main-
tenance staff.
1.2 Proper use
WARNING!
In the event of improper use, the digital position display
• will endanger personnel,
• will endanger the device and other material property of the operator,
• may affect proper operation of the device.
The device provided for the position display of traveling tools respectively tool slides on lathes,
milling machines, etc. The device is designed and manufactured to be used universally in
environments where there is no potential danger of explosion. For the operation, additionally
absolute or incremental measuring systems for the position acquisition are required.
gives additional indications
calls on you to act
enumerations

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If the device is used in any way other than described above or modified without the authorisation
of Optimum Maschinen Germany GmbH, then it is being used improperly.
We cannot be held liable for any damage caused by improper use.
It is also part of proper use that the operating manual and inspection and maintenance instruc-
tions are observed.
1.3 Invalid modification of the device
WARNING!
Very serious injury.
It is forbidden to make any modifications or alterations to the operating values of the
device! They could endanger personnel working on the device and cause damage to the
device.
We would like to emphasize that any modifications to the construction, or technical or technolo-
gical modifications that have not been authorized by Optimum Maschinen Germany GmbH will
also render the guarantee null and void.
1.4 Possible dangers caused by machine tools
The device is operated in immediate proximity of machine tools.
Always switch off the device and pull the mains plug when performing cleaning or main-
tenance work on the device or on the machine tool.
WARNING!
Machine tools must only be used with activated safety devices. Disconnect the lathe
whenever you detect a failure in the safety devices or when they are not fitted!
1.5 Possible dangers caused by the device
The operating safety of digital position display has been tested. It has been designed and built
using the latest technological advances.
Nonetheless, there remains a residual risk, since the device operates with electrical voltages
and currents.
We have used construction resources and safety techniques to minimize the health risk to per-
sonnel resulting from this hazard.
Nonetheless, if the device is operated or maintained by personnel who are not duly qualified,
there may be a risk resulting from incorrect operation or improper maintenance.
1.6 Authorized personnel
The only personnel authorized to operate and maintain this machine are trained and instructed
technical staff working for the operator and manufacturer.
All personnel involved in assembly, commissioning, operation and maintenance need to be duly
qualified and follow this operating manual.

Safety
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1.7 Additional qualification requirements
Work on electric components or equipment must only be carried out by qualified electricians.
1.8 Obligations of the operator
The operator must instruct the staff on all safety standards that apply to the device and to the
operation.
1.9 Obligations of the user
The user has to
read and understood the operating manual,
be familiar with all safety devices and regulations,
be capable of operating the device.
1.10 Safety during operation
Check the digital position display at least once per shift. Inform the person responsible immedia-
tely of any damage, defect or change in operating function.
WARNING!
Before activating the device, double-check that this will, even in combination with the
machine tool, not
• lead to any danger with respect to people,
• cause any damage to equipment.
Avoid any unsafe working practices:
Do not work on the device or the machine if your concentration is reduced, for example,
because you are taking medication.
Observe the rules for preventing accidents issued by your association for the prevention of
occupational accidents and safety at the workplace or other inspection authorities.
1.11 Safety during maintenance
Inform operators timely on maintenance and repair work.
Report all safety-relevant changes or performance details of the device. Document all changes,
have the operating manual changed accordingly and train the machine operators.
1.11.1 Disconnecting and making it safe
Switch off the device before starting any maintenance or repair work.
Pull the mains plug.
Place a warning sign on the machine tool.
1.12 Accident report
Inform your superiors and Optimum Maschinen Germany GmbH immediately in the event of
accidents, possible sources of danger and any actions which almost led to an accident (near
misses) that are connected with the digital position display and the machine tool.

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1.13 General instruction
This manual explains the installation, the operation and the maintenance of the position display
DPA 2000S in detail, which is widely used as add-on to axis-driven machine tools.
1.13.1 Technical data
Mains voltage: AC 230V + - 10 %, 50 - 60Hz
Power consumption: about 5W, fuse 2A
Weight: about 2.5kg
Display: X, Y/Z0, Z-axis with 8-digit LED display each, at which the first figure stands for the
sign.
1.13.2 Working conditions
Avoid exposing the device direct solar radiation or high temperatures, and it should be used
in temperatures ranging from 0°C to 40°C;
Environment temperature for storage must be ranging from -30°C to 70°C;
Environmental relative humidity: <90% (at 20°C± 5°C);
Keep away from high voltage, strong electric current and strong magnetic field;
Signal cable of the grating should be far away from the power cable;
Avoid working in environments with scrap iron, oil, water, dust and strong vibration;
Do not expose the position display to corrosively acting chemicals and highly corrosive acids
or bases.
1.13.3 Precautions
When unpacking, perform a visual check if the position display is in good order. If anything is
out of order, please immediately contact our company or the distributor . Do not dismantle
the device by yourself in order to repair it;
Please do not connect the position display to any readers of other trademarks, otherwise it
may cause display errors or damages on the position display;
Please do not open the cover of the position display, do not remove the reader before having
disconnected the whole measuring system;
Make sure that the position display is well grounded.
1.13.4 Regular maintenance
Switch off the power before cleaning the position display;
Polish the cover with soft and dry cloth;
Do not clean the cover using abrasive cleaning agents or agents which would change the
surface of plastic materials;
Clean the display window at the front side of the position display using an neutral and anti-
statically acting cleaning agent.

The front panel and rear panel
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2 The front panel and rear panel
2.1 The front panel and a description of the keys
Abb.2-1: DPA 2000S front side

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2.2 The rear panel
Abb.2-2: DPA 2000 rear side
Abb.2-3: DPA 2000S rear side
Power switch
Fuse
Power socket
Grounding screw
Interface for data transfer
Signal selection for grating input
Up: Sine 1Vpp signal
Down: TTL square wave signal
The setting is depending on the
type of the used measuring system.
Power switch
Fuse
Power socket
Grounding screw
Photo-elektrical input for schwitch
Transducer for signal input
Interface for data transfer

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2.3 Description of the keys
No. Sign on the key Name of the key Function description
1the X-axis key To select the X coordinate axis
(the indicator light is located on its left)
2the Y-axis key To select the Y coordinate axis
(the indicator light is located on its left)
3the Z0/Y-axis key
(3 axes) To select the Z0/Y-coordinate axis
(the indicator light is located on its left)
4the Z axis key
(3 axes) To select the Z coordinate axis
(the indicator light is located on its left)
5Numeric keys For numeric entry
6The decimal point/linear cut-
ting speed setting key For decimal point input or linear cutting speed setting
7The plus and minus signs /
initial (max.) work piece
diameter setting
For input of plus and minus numbers or set-
ting of initial (max.) work piece diameter
8Delete key To clear displayed value of a specific axis or
give up the current operation
9Enter key To confirm the data input
10 Radius/diameter conversion
key Radius/Diameter conversion
(the indicator light is located above it)
11 The metric/inch conversion
key Metric/Inch conversion
(the indicator light is located above it)

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12 The grating reference mark
key To put the grating to zero position
(the indicator light is located above it)
13 The machining datum mark
setting key For machining datum mark setting
(the indicator light is located above it)
14 The lathe/miller function swit-
ching key For lathe/miller function switching
(the indicator light is located above it)
15 Z+Z0 key (3 axes) For display of the Z+Z0 value
16 Programming key For internal parameter settings
17 The calculator function key Calculator functions
(the indicator light is located above it)
18 The addition / dividing hole
along oblique line key The addition operation of the calculator or dividing hole along oblique line
19 The subtraction / dividing
hole on the circle key The subtraction operation of the calculator or dividing hole on the circle
20 The multiplication /
machining along oblique line
key
The multiplication operation of the calculator
or machining along oblique line
21 The division / arc machining
key The division operation of the calculator or arc machining
22 The square root key The square root operation of the calculator
23 The cutter 1 key To display the datum mark coordinates of
cutter 1 (the indicator light is located above it)
24 The cutter 2 key To display the datum mark coordinates of
cutter 2 (the indicator light is located above it)
25 The cutter 3 key To display the datum mark coordinates of
cutter 3 (the indicator light is located above it)

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26 The cutter 4 key To display the datum mark coordinates of
cutter 4 (the indicator light is located above it)
27 The cutter 5 key To display the datum mark coordinates of
cutter 5 (the indicator light is located above it)
28 The cutter 6 key To display the datum mark coordinates of
cutter 6 (the indicator light is located above it)
29 The cutter 7 key To display the datum mark coordinates of
cutter 7 (the indicator light is located above it)

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2.4 Measuring device - Pin Assignment at DPA 2000
The functional designation of the wires, that each pin at the 9-Pin-SubD-plug is allocated, must
have the same assignment as the connector at the digital display.
The assignment is shown in the following tables.
INFORMATION
The DPA 2000 is designated for the operation with measuring devices, that provides a
Sine 1Vpp output signal (= voltage between the upper and lower peak of the wave is 1 Volt).
NFORMATION
We are recommending the application of original OPTIMUM measuring gibs, because this will
ensure a quick and failure-free operation.
If it is indented to operate the digital display with measuring devices from other manufacturers,
pay attention that this measuring gib is providing an output signal from the type „Sine 1Vpp“ and
the pin assignment is consistent to the following table.
2.5 Measuring device - Pin Assignment at DPA 2000S
INFORMATION
The DPA 2000S is designated for the operation with measuring devices, that provides a
Sine 1Vpp output signal or a TTL square wave output signal.
NFORMATION
We are recommending the application of original measuring gibs and magnetic measuring sys-
tems from OPTIMUM, because this will ensure a quick and failure-free operation.
If it is indented to operate the digital display with measuring devices from other manufacturers,
pay attention that this measuring gib is providing one of the supported output signal types and
the pin assignment is consistent to the following table.
PIN No. 12 3 4 5 67 8 9
sine 1Vpp signal
for OPTIMUM mea-
suring gibs ML 0° 180° +5V 0V 90° 270° Z Blank Shielding

The front panel and rear panel
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2.6 Input/output connection
The meanings of the prong signal of a 15-pin D-type socket are listed in the following table:
PIN No. 12 3 4 5 67 8 9
sine 1Vpp signal
for OPTIMUM mea-
suring gibs ML 0° 180° +5V 0V 90° 270° Z Blank Shielding
TTL square wave
signal, for
OPTIMUMmagnetic
measuring system
A+ A- +5V 0V B+ B- Z+ Z- Shielding
PIN
No. Meaning Destination
1Photoelectricswitch
Plus Tachometer photoelectric switch pulse output
2 +12V Tachometer photoelectric switch power supply Plus
3 Initial signal SIN External switch initial signal
5Speed adjustment
output
ADJ Transducer frequency setting terminal
6Digital grounding DGND Tachometer photoelectric switch power supply Minus
External switch common cable
7Low speed state
LIN External switch low speed signal
9Analog grounding AGND Transducer analog signal common terminal

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2.7 Available accessories (only for DPA 2000S)
Designation Item No.
Perforated disk for speed sensor,
lathes to including D360 3383926
Perforated disk for speed sensor,
lathes more largely D360 3383927
Magnetic tape MB 100 3383941
Read head activated 3383932

Assembly and commissioning
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3 Assembly and commissioning
The digital position display DPA 2000S is preassembled.
INFORMATION
If you want to use the digital position display you need at least one measuring gauge. Measuring
gauges are not part of the delivery volume of the digital position display.
The position display DPA 2000S offers you the option to connect absolutely measuring as well
as incrementally measuring position sensors.
Only use original OPTIMUM path-measuring systems, since the position display is only adju-
sted to such path-measuring system and this way will guarantee a safe functioning.
3.1 Delivery volume
Upon delivery immediately check if the device had been damaged during transport. Compare
the delivery volume with the data on the delivery note.
3.2 Storage
CAUTION!
In case of improper storage it is possible that important components are being damaged
and destroyed.
Store the packed or already unpacked device only at dry environmental conditions at a
temperature from 0 °C to 40 °C.
If you need to store the device or any accessory parts for more than three months and under
other environmental conditions than those prescribed by this manual, contact the company
Optimum Maschinen Germany GmbH.
3.3 Adding the device
3.3.1 Requirements for the installation site
CAUTION!
When choosing the installation site, please take into account the length of the connection
lines for the measuring gauges.
The installation site needs to be dry and vibration-free and comply with the ergonomic requi-
rements of a working place. Observe the safety instructions for working nearby machine tools.
The working area for the operation, maintenance and repair works must not be hindered by
adding the position display.
3.3.2 Installing the device
The device needs to be positioned freely at an appropriate place or be mounted to a horizontal
subsurface or to a wall using the attached fixing material.
3.3.3 Assembling the measuring gauges
Measuring gauges are linear measuring systems which collect the position of mobile machine
parts via a sensor and forward them coded to the position display.

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CAUTION!
Only use path-measuring systems recommended by OPTIMUM. When assembling the
path-measuring systems imperatively follow the instructions of the manufacturer.
Before mounting it on the machine, check the operability of the measuring gauges. To do so,
use the digital position display DPA 2000S or a similar device.
Install the measuring gauge in a way that it will not be damaged by cutting tools or coolants.
If required, mount a cover.
If possible, mount the enclosed measuring gauges with the sealing lips showing downward.
If possible, place the reading head stationary in order to avoid damages of the connection
lines by its movements.
CAUTION!
The path-measuring system and its add-on pieces can cover important components on the ma-
chine tool (e.g. lubricating nipples).
Before mounting the path-measuring systems, please note such limitations in functions and
make arrangements accordingly.
3.3.4 Assembly of the reading head
Mount a fixture for the reading head.
Fix the reading head to the fixture.
Remove possibly existing assembly aids from the reading head.
Check the orientation of the reading head using a dial gauge
(refer to the tolerances for the assembly given by the manufacturer).
Check if all components are moving freely.
3.4 Linking the position display to a frequency converter
The position display DPA 2000S is equipped with the function „cutting constant“ which allows to
influence the spindle speed of a lathe in a way that the same cutting speed will result at the wor-
king point of the tool independent from the workpiece radius.
To do so, the control of the DPA 2000S will directly influence the frequency converter (FC).
We mainly use frequency converters of the manufacturer LENZE for OPTIMUM lathes.
Therefore, we will explain the linking of the DPA 2000S to this frequecy converter in detail below.
3.4.1 System requirements:
To operate only using the function „cutting constant“ a frequency converter (FC) having an
analog input 0 V - 10 V DC is required.
For an operation using the function „cutting constant“ for remaining options of the manual speed
regulation, a frequency converter with two analog inputs is required:
0 V - 10 V DC for speed control via DPA 2000S (cutting constant control)
0 V - 05 V DC for speed control via the potentiometer
The following items are required in addition:
ON/OFF switch to switch over between the manual speed setting and the cutting constant
control

Assembly and commissioning
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ON/OFF switch to switch over between the working ranges 1 and 2 for cutting constant opera-
tion (refer to commissioning)
Potentiometer for the manual speed setting (e.g. 1kΩfor frequency converters made by the
manufacturer LENZE)
Application module made by LENZE (type E 82 ZAFAC 001)
Perforated disk for the speed recording (with 8 holes for small and 16 holes for large lathe
chuck seats)
Fork light barrier for speed recording
Please refer to the current OPTIMUM main catalog for optional accessories.
3.4.2 Electrical connection:
The connection to the DPA 2000S is performed via the cable included in the delivery volume
using SubD plugs - 15 pins (refer to page 11 paragraph 2.5)
1. Connect the grey cable (1) from the SubD plug to the black cable of the fork light barrier.
2. Connect the brown cable (2) to the brown cable of the fork light barrier.
3. Connect the blue cable (6) to the blue cable of the fork light barrier.
4. Bridge over the green (3) and the blue cable (6).
5. Connect the red cable (5) to the frequency converter at the input for the control voltage
(0 V - 10 V)
6. Connect the yellow cable (7) via the switch (NO switch) to the blue cable (6).
7. Connect the white cable (9) for analog grounding GND to GND at the frequency converter
(for LENZE FU terminal 7).
Wiring diagram to connect the DPA 2000S on the following page
You need to set the maximum admissible speed of the lathe using the FC.
Danger!
Do not exceed the maximum speed of the clamping devices. You can only make sure the
limitation of the maximum speed by using the FC.
Set the frequency converter in a way that the maximum admissible speed of the clamping
device will not be exceeded for both working ranges of the DPA 2000S.
In order to achieve the maximum possible speeds for the „cutting constant control“ which is
resulting of the combination of your lathe with the position display it might be necessary to use
clamping devices of a higher maximum speed.
If it is required to change over to manual speed setting an allpication module with two analog
inputs will be additionally required. For programming data please refer to the attached manual.

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Wiring diagram to connect the DPA 2000S

Assembly and commissioning
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3.4.3 Programming the DPA 2000S
When using the function „cutting constant“ the following settings of the parameters need to be
programmed:
( „Internal parameter setting“ on page 5-36)
P19: Please enter the number of switchings on the fork light barrier per revolution (e.g.
perforated disk with 8 holes = 8 switchings)
P20: Enter the value „1“ (recommended)
NOTE:
The DPA 2000S supports two gear levels. Determine the two gear levels of your lathe in which
you want to use the cutting constant functions. All control values which you have set on the DPA
2000S are this way only referring to this gear level. For another gear level the modified transfor-
mation will lead to deviations between the target value and the actual value, in particular for
spindle speeds.
DANGER!
If the lathe is operated in another gear level, the admissible maximum speed can be
exceeded. This way, the retention force of the clamping devices will be reduced when the
centrifugal force is increasing. In doing so, the workpiece might get loose and fly off the
machine.
For your own safety use the cutting constant function only for the two selected gear
levels for which you have specified and entered the parameters.
To do so, determine the minimum and maximum speed of the selected gear levels.
Example:
Nominal speed of the gear level: 900 1/min
Set frequency range on the FC from 10 Hz to 50 Hz
Minimum speed for 10 Hz 180 1/min
Maximum speed for 50 Hz 900 1/min
P21: Enter the value of the maximum speed for the selected gear level 1.
P22: Enter the value of the minimum speed for the selected gear level 1.
P23: Enter the value of the maximum speed for the selected gear level 2.
P24: Enter the value of the minimum speed for the selected gear level 2.
When you have executed the above steps the commissioning of the DPA 2000S is terminated.
Switch over between the manual speed setting and the cutting constant control using the corres-
ponding ON/OFF switch. The two switch settings need to be marked by the function markings
which are being switched.