Optimum DPA 22 User manual

GB
OPTIMUM
MASCHINEN - GERMANY
Operating manual
Version 1.0
Digital position display
DPA 22

OPTIMUM
MASCHINEN - GERMANY
Table of contents
Version 1.0 dated 2015-03-31Page 2 Original operating instructions
DPA22GB
Table of contents
1 Safety
1.1 Safety instructions ....................................................................................................................................4
1.1.1 Safety and warranty informations .............................................................................................................4
1.2 Intended use.............................................................................................................................................4
1.3 Identification of danger and notes.............................................................................................................4
1.3.1 Danger classes.........................................................................................................................................4
1.4 Target group.............................................................................................................................................5
1.5 Basic safety information............................................................................................................................5
2 Installation
2.1 Scope of delivery......................................................................................................................................6
2.2 Mechanical installation..............................................................................................................................6
2.3 Electrical installation.................................................................................................................................7
2.4 Power supply speed sensor......................................................................................................................8
2.5 Signal selection for input signal................................................................................................................8
2.5.1 Reader signal plug pinout.........................................................................................................................9
2.6 Installation of magnetic sensor and magnetic strip.................................................................................10
2.6.1 Installation steps.....................................................................................................................................10
2.6.2 Installation examples..............................................................................................................................11
2.6.3 Mounting the magnetic sensor................................................................................................................11
2.6.4 Necessary measures:.............................................................................................................................12
2.6.5 Maintenance...........................................................................................................................................12
2.6.6 Trouble shooting.....................................................................................................................................13
2.7 Installation of ML measuring gibs...........................................................................................................13
2.7.1 Assembly of the measurement gib housing............................................................................................14
2.7.2 Assembly of the reading head ................................................................................................................14
2.7.3 Trouble shooting.....................................................................................................................................15
3Operation
3.1 Parameter settings..................................................................................................................................16
3.1.1 Parameter meanings ..............................................................................................................................17
3.2 Description of the keys ...........................................................................................................................19
3.3 Reference marker function .....................................................................................................................21
3.4 Machine zero point function....................................................................................................................21
3.5 Calculator function..................................................................................................................................22
3.6 Coordinate points along a diagonal line..................................................................................................23
3.6.1 Parameter meanings ..............................................................................................................................23
3.7 Coordinate points on a circle or arc........................................................................................................25
3.7.1 Parameter meanings ..............................................................................................................................25
3.8 Inclined plane..........................................................................................................................................28
3.8.1 Parameter meanings ..............................................................................................................................28
3.9 Arc ..........................................................................................................................................................30
3.9.1 Parameter meanings ..............................................................................................................................30
3.10 Tool data function...................................................................................................................................33
3.10.1 Recall of tool data...................................................................................................................................33
4 Appendix
4.1 Copyright ................................................................................................................................................34
4.2 Liability Claims for Defects / Warranty....................................................................................................34
4.3 Note regarding disposal / options to reuse:............................................................................................35
4.3.1 Decommissioning ...................................................................................................................................35
4.3.2 Disposal of new device packaging..........................................................................................................35
4.3.3 Disposing of the old device.....................................................................................................................35
4.3.4 Disposal of electrical and electronic components...................................................................................35

OPTIMUM
MASCHINEN - GERMANY
Preface
Version 1.0 dated 2015-03-31 Page 3Original operating instructions
DPA22 GB
4.4 Disposal via municipal collection............................................................................................................36
4.5 RoHS, 2002/95/EC.................................................................................................................................36
4.6 Product follow-up....................................................................................................................................36
4.7 EC Declaration of Conformity.................................................................................................................37
Preface
Dear customer,
Thank you very much for purchasing a product made by OPTIMUM.
OPTIMUM metal working machines offer a maximum of quality, technically optimum solutions and convince
by an outstanding price performance ratio. Continuous enhancements and product innovations guarantee
state-of-the-art products and safety at any time.
Before commissioning the device please thoroughly read these operating instructions and get familiar with
the device. Please also make sure that all persons operating the device have read and understood the oper-
ating instructions beforehand.
Keep these operating instructions in a safe place nearby the machine.
Information
The operating instructions include indications for safety-relevant and proper installation, operation and main-
tenance of the device. The continuous observance of all notes included in this manual guarantee the safety
of persons and of the device.
The manual determines the intended use of the device and includes all necessary information for its eco-
nomic operation as well as its long service life.
In the paragraph "Maintenance" all maintenance works and functional tests are described which the operator
must perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the current state of
construction of your device. Being the manufacturer we are continuously seeking for improvements and
renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the
device may be different from the illustrations in these instructions with regard to a few details. However, this
does not have any influence on the operability of the device.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors are reserved!
Your suggestion with regard to these operating instructions are an important contribution to optimising our
work which we offer to our customers. For any questions or suggestions for improvement, please do not hesi-
tate to contact our service department.
If you have any further questions after reading these operating instructions and you are not able to
solve your problem with a help of these operating instructions, please contact your specialised
dealer or directly the company OPTIMUM.
Optimum Maschinen Germany GmbH
Dr.- Robert - Pfleger - Str. 26
D-96103 Hallstadt
Mail: [e-mail]
Internet: www.optimum-maschinen.com

OPTIMUM
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Safety
Version 1.0 dated 2015-03-31Page 4 Original operating instructions
DPA22GB
1 Safety
1.1 Safety instructions
1.1.1 Safety and warranty informations
In order to carry out installation correctly, we strongly recommend this document is read
very carefully. This will ensure your own safety and the operating reliability of the device.
Your device has been quality controlled, tested and is ready for use. Please respect all
warnings and information which are marked either directly on the device or in this docu-
ment.
Warranty can only be claimed for components supplied by Optimum Maschinen Germany
GmbH. If display is used together with other products, the warranty for the complete sys-
tem is invalid.
Repairs should be carried out only at our works. If any information is missing or unclear,
please contact Optimum Maschinen Germany GmbH .
1.2 Intended use
Combined with external sensors, the digital position display represents a high-precision meas-
uring system. The electronic display serves exclusively for processing and indicating position
and rotational speed values.
Observe all safety instructions contained herein.
Arbitrary modifications and changes to this electronic display are forbidden.
Observe the prescribed operating and installation conditions.
Operate the electronic display exclusively within the technical data and the specified limits.
1.3 Identification of danger and notes
Safety notes consist of a signal sign and a signal word.
1.3.1 Danger classes
Symbol Warning alert Definition / consequence
DANGER! Immediate danger that may cause irreversible bodily harm resulting in
death, property damage or unplanned device reactions if you disregard
the instructions given.
WARNING! Danger that may cause irreversible bodily harm, property damage or
unplanned device reactions if you disregard the instructions given.
CAUTION! Danger that may cause minor injury, property damage or unplanned
device reactions if you disregard the instructions given.
ATTENTION! Important operating information that may facilitate operation or cause
unplanned device reactions if disregarded including possible property
damage.
INFORMATION Application tips and other important/helpful or useful information and
notes.
No dangerous or harmful consequences for persons or objects.

OPTIMUM
MASCHINEN - GERMANY
Safety
Version 1.0 dated 2015-03-31 Page 5Original operating instructions
DPA22 GB
1.4 Target group
Installation instructions and user manual are intended for the engineering, commissioning and
installation personnel of plant or machine manufacturers. This group needs profound knowl-
edge of an position indicator's necessary connections of a electronic display and its integration
into a complete machinery.
WARNING!
Insufficiently qualified personnel
Insufficiently qualified personnel cause personal injury, serious damage to machine or actuator.
Configuration, commissioning, mounting and maintenance by trained expert personnel only.
This personnel must be able to recognize danger that might arise from mechanical, electri-
cal or electronicequipment.
Qualified personnel
are persons who
are familiar with the safety guidelines of the electrical and automation technologies when
performing configuration tasks;
are authorized to commission, earth and label circuits and devices/systems in accordance
with thesafety standards.
1.5 Basic safety information
DANGER OF EXPLOSION!
Do not use the electronic display in explosive zones.
Identification
The type label shows the model name with model number and serial number.

OPTIMUM
MASCHINEN - GERMANY
Installation
Version 1.0 dated 2015-03-31Page 6 Original operating instructions
DPA22GB
2 Installation
2.1 Scope of delivery
Digital position display
Fixture
External power supply
Speed sensor, without commercial permanent magnets as a signal transducer
2.2 Mechanical installation
CAUTION!
Failure of electronic display
When mounting pay attention to the IP type of protection.
Avoid impact on the device.
Do not modify the device in any way.
Assembly
Screw the device in place on the fixture using the threaded holes (spacing 60 x 25mm - 4x M4,
7 deep) on the back.
Device dimension: height 260mm, width 230mm, depth 80mm

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MASCHINEN - GERMANY
Installation
Version 1.0 dated 2015-03-31 Page 7Original operating instructions
DPA22 GB
2.3 Electrical installation
WARNING!
Destruction of parts of equipment and loss of regulation control
Check all line connections and plug connections before switching on supply voltage.
ATTENTION!
Basically, all connections are protected against external interference. Choose a place of opera-
tion that excludes inductive or capacitive interference influences on the electronic display or its
connecting lines. When mounting the system keep a maximum possible distance from lines
loaded with interference. If necessary, provide additional installations including screening
shields or metallized housings. Contactor coils must be wired with spark suppression.
Working temperature 0 °C ... +40 °C
Storage temperature -30 °C ... +70 °C
Humidity 90 % bei 20°C + - 5°C maximum
Protection type IP51
Weight 2.5 kgs
Electrical data
Power supply
Power supply 12 V to 30 V DC 230V
Current consumption ~ 20W
Power supply connection

OPTIMUM
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Installation
Version 1.0 dated 2015-03-31Page 8 Original operating instructions
DPA22GB
2.4 Power supply speed sensor
Power is supplied via the rear jack plug . Connect the sensor for speed measurement from the
scope of delivery with the electronic display.
2.5 Signal selection for input signal
Up: Sine 11uApp
Down TTL differential signal
Speed sensor connection
Jumper for reader signal selection

OPTIMUM
MASCHINEN - GERMANY
Installation
Version 1.0 dated 2015-03-31 Page 9Original operating instructions
DPA22 GB
2.5.1 Reader signal plug pinout
INFORMATION
The digital position display is designated for the operation with measuring devices which pro-
vide a 11uApp sine output signal (sine 1Vpp signal = voltage between the upper and lower
peak of the wave is 1 Volt) or a TTL differential (TTL square wave) signal. We recommend the
application of original measuring gibs and magnetic measuring systems from OPTIMUM.
If the digital display is to be operated with measuring devices from other manufacturers, pay
attention that this measuring gib provides an output signal of one of the two signal types and
the pin assignment is consistent with the following table.
PIN No. 1 2 3 4 5 6 7 8 9
sine 1Vpp signal
for OPTIMUM
measuring gauge ML 0° 180° +5V 0V 90° 270° Z Blank Shielding
TTL differential signal
for OPTIMUM magnetic
measuring system A+ A- +5V 0V B+ B- Z+ Z- Shielding

OPTIMUM
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Installation
Version 1.0 dated 2015-03-31Page 10 Original operating instructions
DPA22GB
2.6 Installation of magnetic sensor and magnetic strip
INFORMATION
An active reading head is necessary in order to use magnetic strips with the DPA22.
Item no. 338 3934
TTL differential signal pinout
Installation may only be carried out in accordance with the specified IP protection. If necessary
the system must be protected against environmental influences, such as Sprayed water, sol-
vent, dust, shocks, vibrations, temperature fluctuations.
The mounting surface / measuring track must be flat. Buckles or bumps will lead to measuring
inaccuracies.
For technical reasons the strip should be approx. 30mm longer than the actual measuring dis-
tance.
ATTENTION!
For an optimum of adhesion, all anti-adhesive substances (such as oil, grease, dust etc.)
must be removed by using residue-free (=evaporating) cleaners. Suitable cleansing
agents are e.g. ketones (acetone) or alcohols; Messrs.octite and 3M can both supply
such cleansing liquid. Make sure that the surface to be glued is dry and apply the stop
with maximum pressure. Glueing should preferably be undertaken at temperatures
between 20° to 30° Celsius and in dry atmosphere.
INFORMATION
When applying long pieces of magnetic strip do not immediately remove the complete protec-
tive foil, but rather peel back a short part from the end sufficient to fix the strip. Now align the
strip. As the protective strip is then peeled back and out press the tape firmly onto the mount-
ing surface. (a wallpaper roller wheel could be used to assist in applying pressure onto the
magnetic strip when fixing it in position)
2.6.1 Installation steps
Clean mounting surface (1) carefully.
Remove protective foil (2) from the adhesive side of the magnetic strip (3).
Stick down the magnetic strip (4).
Clean surface of magnetic strip carefully.
Remove protective foil (6) from adhesive tape on the cover strip (5).
Fix cover strip (both ends should slightly overlap).
PIN No. 1 2 3 4 5 6 7 8 9
TTL differential signal A+ A- +5V 0V B+ B- Z+ Z- Shielding

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Installation
Version 1.0 dated 2015-03-31 Page 11Original operating instructions
DPA22 GB
Secure the overlapping ends of the cover against detachment .
ATTENTION!
Do not expose the system to magnetic fields. Any direct contact of the magnetic strip
with magnetic fields (e.g. adhesive magnets or other permanent magnets) is to be
avoided. Sensor movements during power loss are not captured by the follower
electronics.
2.6.2 Installation examples
The simpler installation method using beveled protective tape ( Img.2-1:) is only to be rec-
ommended in thoroughly protected surroundings. In less protected mounting places the strip
may peel. In such cases, mounting methods as shown in  Img.2-2: and  Img.2-3: are
more suitable.
Optimal protection can be achieved through mounting in a groove ( Img.2-4:), which should
be deep enough that the magnetic strip can be fully embedded.
2.6.3 Mounting the magnetic sensor
Use two M3 screws to fix the magnetic sensor. We recommend to use washers.
Cable layout should avoid damages due to cable strain or other machine parts. If necessary
use a drag chain or protective hose and provide for strain relief.
Sensor must be aligned correctly with respect to the counting direction. This can be ignored
if counting direction can be changed via the follower electronics.
Maximal travel speed < 5m/s
Img.2-1: Img.2-2:
Img.2-3: Img.2-4:

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Installation
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Img.2-5: Definition of counting direction
Distance measurements between sensor and magnetic tape and angular tolerances, must
be maintained over the entire test section! ( Img.2-6: to  Img.2-8:)
The max. gap without cover strip is 0.2 mm + 0.1 / -0mm. When using cover strip, the gap is
reduced by the thickness of cover strip including its cover strip. The sensor must not touch the
magnetic strip.
Img.2-6: Distance sensor / magnetic strip
Img.2-7: Max. deviation
Img.2-8: Installation of sensor
2.6.4 Necessary measures:
The sensor should be positioned well away from cables with interference; if necessary a
protective screen or metal housing must be provided. The running of wiring parallel to the
mains supply should be avoided.
Contactor coils must be wired with spark suppression.
2.6.5 Maintenance
We recommend cleaning the magnetic strip's surface from time to time with a soft rag. This
avoids dirt(dust, chips, humidity ... ) sticking to the strip.
Cable outlet
Travel direction
Sensor
Counting direc-
tion negative
active side
0,2 +0,1 /- 0mm
< 1°< 3°
< 3°

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MASCHINEN - GERMANY
Installation
Version 1.0 dated 2015-03-31 Page 13Original operating instructions
DPA22 GB
2.6.6 Trouble shooting
Below are some typical errors which may occur during installation and operation:
The value shown on the display does not correspond to the actual value because the
parameter setting for the counting resolution is set improperly.
Magnetic strip incorrectly mounted (active surface must be mounted towards the sensor).
To protect the magnetic tape the supplied cover tape was not used. Must always be non-
magnetic.
Sensor incorrectly connected. Check connection
Tolerance for the gap between magnetic sensor and magnetic strip not observed over the
total traveldistance ( Img.2-6:).
Cable squeezed / interrupted / cut by sharp edges.
Sensor's active side not mounted towards the magnetic strip (  Img.2-8: and  Img.2-
8:) .
Sensor has not been aligned according to Img.2-5: and Img.2-7:
The input signal on the Digital Position Indicator is not set to a TTL signal.
2.7 Installation of ML measuring gibs
Plug pinout sine 11uApp
NOTE !
The following statements describe the procedure for attachment of OPTIMUM ML-type absolute
measuring glass scales.
Please follow the installation instructions and requirements accompanying the given component
when installing incrementally measuring magnetic measurement systems from OPTIMUM, or
for measurement systems from third-party manufacturers.
Depending on the attachment possibilities on your machine, mounting and connection to the
machine axes may differ.
The following drawing should aid in selection of the required measuring gib lengths and
description of the mounting situation.
ATTENTION!
Only use path-measuring systems recommended by OPTIMUM. When assembling the
path-measuring systems imperatively follow the instructions of the manufacturer.
NOTE !
The path-measuring system and its add-on pieces can cover important components on the
machine tool (e.g. lubricating nipples).
Before mounting the path-measuring systems, please take note of any such limitations in func-
tions and make arrangements accordingly.
PIN No. 1 2 3 4 5 6 7 8 9
sine 1Vpp signal 0° 180° +5V 0V 90° 270° Z Blank Shielding

OPTIMUM
MASCHINEN - GERMANY
Installation
Version 1.0 dated 2015-03-31Page 14 Original operating instructions
DPA22GB
2.7.1 Assembly of the measurement gib housing
Before mounting it on the machine, check the operability of the measuring gauges. To do
so, use the digital position indicator 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 or drip moulding.
If possible, mount the enclosed measuring gauge 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.
2.7.2 Assembly of the reading head
The measuring jib and sensor head are to be mounted separately on parts of the machine
which are movable in relation to one another. The fixed and movable parts of the machine must
correspond to the requirements and maximum tolerances as given in  Img.2-9:.
Img.2-9:
Check the measuring gib mounting level as shown in  Img.2-9:.
Mount a fixture for the reading head.
Fix the reading head to the fixture.
Measuring length
Mounting length
Total length
a (Measuring jib top surface) b (Measuring jib side surface)

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Installation
Version 1.0 dated 2015-03-31 Page 15Original operating instructions
DPA22 GB
Check the orientation of the reading head using a dial gauge.
The parallel error between the orthogonal side surfaces of the measuring gib and the
machine-tool guide must be less than 0.2mm across the entire range.  Img.2-10:
The maximum gap between the two parallel surfaces of the measuring gib and the sensor
head is 1.2 to 1.5mm.
After installation of the measuring gib, remove the plastic support.
Img.2-10:
2.7.3 Trouble shooting
Below are some typical errors which may occur during installation and operation:
The value shown on the display does not correspond to the actual value because the
parameter setting for the counting resolution is set improperly.  "Factory settings:“ on
page 18
Reading head is incorrectly connected. Check connection
The gap tolerance between measuring head and measuring gib was not maintained across
the entire measurement range  Img.2-10:
Cable squeezed / interrupted / cut by sharp edges.
Moisture has penetrated extension cable plugs.
Travel speed is too high; it should not exceed 0.5 meters per second.
The replacement measuring gib is not from the same manufacturer as the original measur-
ing gib. The actual counting resolution of the measuring gib does not correspond to the set
value.
The input signal on the Digital Position Indicator is not set to 11 uApp.
Plastic support Plastic support
1.2 - 1.5
0.2
0.2

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Operation
Version 1.0 dated 2015-03-31Page 16 Original operating instructions
DPA22GB
3 Operation
The device's display is in the default state when initially turned on.
3.1 Parameter settings
Press button for 3 seconds to access parameter settings.
Press the key again to exit parameter settings.
Press button to cancel an input.
Press button to save an input.

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Operation
Version 1.0 dated 2015-03-31 Page 17Original operating instructions
DPA22 GB
3.1.1 Parameter meanings
Meanings of parameters and settings.
Accuracy of representations on the display
When a higher representational accuracy value is set on the display than the actual counting
resolution, the representational accuracy value will be shown accordingly.
Counting direction:
The measurement counting direction (positive or negative). 0 for a positive counting direction, 1
for a negative counting direction.
Counting resolution:
Counting resolution of the respective axis The counting resolution set must correspond to the
selected measuring gib or active measuring strip reading device.
5
6
1
2
3
4
1
2
3

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Operation
Version 1.0 dated 2015-03-31Page 18 Original operating instructions
DPA22GB
When a higher representational accuracy value is set on the display than the actual
counting resolution, the representational accuracy value will be shown accordingly.
Correction factor:
Linear error compensation coefficient. The value range for linear error compensation coeffi-
cients extends from -9.999 to 9.999mm, and gives the value to be adjusted per meter.
Number of impulses per revolution
the set value of the number of pulses per revolution of the revolution speed signal The number
of impulses per revolution of the revolution speed signal depends on the number of output
pulses per revolution of the transducer in use (i.e. rotational speed disc). The greater this value
is, the higher will be the resolution of the revolution speed. The range of possible setting values
extends from 1 to 3600.
Measurement time:
the set value of the time for speed measurement
The maximum set value is 10 (i.e. 1 second) and the minimum set value is 1 (i.e. 0.1 second).
The greater this value is, the higher will be the resolution of the revolution speed, and the
slower this value will be refreshed.
The representational accuracy of the rotational speed indicator shown directly on the display =
600 / (number of impulses per revolution x measurement time)
1
4
Factory settings:
Where delivered as a standalone device. In applied delivery state with machine tool.
Please record the values before making any changes.
= 0.005mm =
= 0 =
= 0.005mm =
= 0.000mm =
=
=
1
1
2
2
3
3
4
4
5
6
5
6

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Operation
Version 1.0 dated 2015-03-31 Page 19Original operating instructions
DPA22 GB
3.2 Description of the keys
No. Sign on the key Name of the key Function description
1 X axis key To select the X coordinate axis
2 Y axis key To select the Y coordinate axis
3Z0/Y-axis key
(3 axes) To select the Z0/Y coordinate axis
4Plus and minus signs with numerical keys and decimal
point
For input of negative or positive signs
For numeric entry
For input of decimal places; decimal point
7 Delete key To clear displayed value of a specific axis or
give up the current operation
8 Enter key To confirm the data input
9Radius or
Diameter X-axis display when used on lathes
10 Shift key
Metric / inches
Display of values
• in the metric system
• in the Anglo-American measurement sys-
tem
11 Reference marker function for setting relative coordinates
 "Reference marker function“ on page 21
12 Machine zero point
for setting an
absolute zero-point in the coordinate system
 "Machine zero point function“ on page 21

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13 Z+Z0 key (3 axes) For display of the Z+Z0 value
Z and Z0 are added
14 Programming key For internal parameter settings
 "Parameter settings“ on page 16
15 The calculator function key  "Calculator function“ on page 22
16 Arrow keys For selection of menu parameters and pages
in a menu
17
Key with double allocation
• Coordinate points along
a diagonal line
• Addition
 "Coordinate points along a diagonal line“
on page 23
 "Calculator function“ on page 22
18
Key with double allocation
• Coordinate points on a
circle
• Subtraction
 "Coordinate points on a circle or arc“ on
page 25
 "Calculator function“ on page 22
19 Key with double allocation
• Inclined plane function
• Multiplication
 "Inclined plane“ on page 28
 "Calculator function“ on page 22
20 Key with double allocation
• Arc function
• Division
 "Arc“ on page 30
 "Calculator function“ on page 22
21 Tool data function  "Tool data function“ on page 33
 "Recall of tool data“ on page 33