Renishaw UCC1 User manual

Installation guide
H-1000-5056-09-B
UCC1 universal CMM controller

© 2000 - 2006 Renishaw plc. All rights reserved.
Renishaw® is a registered trademark of Renishaw plc.
This document may not be copied or reproduced in whole or in
part, or transferred to any other media or language, by any means,
without the prior written permission of Renishaw.
The publication of material within this document does not imply
freedom from the patent rights of Renishaw plc.
Disclaimer
Considerable effort has been made to ensure that the contents of
this document are free from inaccuracies and omissions. However,
Renishaw makes no warranties with respect to the contents of
this document and specifically disclaims any implied warranties.
Renishaw reserves the right to make changes to this document
and to the product described herein without obligation to notify any
person of such changes.
Trademarks
All brand names and product names used in this document are
trade names, service marks, trademarks, or registered trademarks
of their respective owners.
Renishaw part no: H-1000-5056-09-B
Issued: 12 2006

1
UCC1
Universal CMM controller
Installation guide

2
FCC
Information to user (FCC section 15.105)
This equipment has been tested and found to comply with the limits for a class A digital device, pursuant
to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in accordance with the
installation manual, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference, in which case you will be required to correct
the interference at your expense.
Information to user (FCC section 15.21)
The user is cautioned that any changes or modifications not expressly approved by Renishaw plc or
authorised representative could void the user’s authority to operate the equipment.
FCC

3
EC declaration of conformity
The UCC1 has been manufactured in conformity with the following standards:
BS EN 61326:1998 Electrical equipment for measurement, control and laboratory use –
EMC requirements.
Immunity to Annex A - industrial locations.
Emissions to class A (non-domestic) limits.
BS EN 60204-1:1998 Safety of machinery – Electrical equipment of machines
Part 1: General requirements.
and that it complies with the requirements of the following EC Directives (as amended):
89/336/EEC – Electromagnetic compatibility (EMC)
73/23/EEC – Low voltage
EC declaration of conformity

4
Care of equipment
Renishaw probes and associated systems are precision tools used for obtaining precise measurements
and must therefore be treated with care.
Changes to Renishaw products
Renishaw reserves the right to improve, change or modify its hardware or software without incurring any
obligations to make changes to Renishaw equipment previously sold.
Warranty
Renishaw plc warrants its equipment for a limited period (as set out in our Standard Terms and Conditions
of Sale) provided that it is installed exactly as defined in associated Renishaw documentation.
Prior consent must be obtained from Renishaw if non-Renishaw equipment (e.g. interfaces and/or cabling)
is to be used or substituted. Failure to comply with this will invalidate the Renishaw warranty.
Claims under warranty must be made from authorised service centres only, which may be advised by the
supplier or distributor.
Trade marks
Windows 98, Windows XP, Windows 2000 and Windows NT are registered tradenames of the Microsoft
Corporation.
IBM is the tradename of the International Business Machines Inc
All trademarks and tradenames are acknowledged.
Care of equipment

5
References and associated documents
It is recommended that the following documentation is referenced to when installing the UCC1.
Renishaw documents
Documentation supplied on Renishaw UCC software CD.
Document number Title
H-1000-5057 UCC controller programmer’s guide
H-1000-5058 RENICIS user’s guide
H-1000-5220 UCC daughter card installation guide
H-1000-5222 UCC command set
H-1000-5227 UCC servo tuning user’s guide
External documents
National and international standards including the following may be applicable to the finished machine or
installation: -
EN 292-2:1991 Safety of machinery - Basic concepts, general principles for design - Part 2:
Technical principles and specifications.
EN (IEC) 60204-1:1997 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
References and associated documents

6
Safety
Electrical requirements
The UCC1 is powered from the a.c. mains supply via an IEC 320 connector. The operating voltages of the
unit are as follows:
90 - 132 V ac and 180 - 264 V ac 47 - 63 Hz 80 W maximum
This equipment must be connected to a protective earth conductor via a three core mains (line) cable.
The mains plug shall be inserted only into a socket outlet provided with a protective earth contact.
The protective earth contact shall not be negated by the use of an extension cable without protective
conductor.
An earth stud is provided to allow bonding of the CMM’s metal parts to the protective earth.
CAUTION: Any interruption of the protective conductor may make the equipment
dangerous. Make sure that the grounding requirements are strictly observed.
Environmental requirements
The following environmental conditions comply with (or exceed) BS EN 61010-1:1993
Safety
!
Indoor use
Altitude
Operating temperature
Storage temperature
Relative humidity
Transient overvoltages
Pollution degree
IP30 (no protection against water)*
up to 2000 m
0 °C to +50 °C
-10 °C to +70 °C
80% maximum (non-condensing) for temperatures up to +31 °C.
Linear decrease to 50% at +40 °C
Installation category II
2
NOTE: If a higher IP rating is required following a risk assessment by the installer of the equipment
an additional external enclosure will be required to house the UCC1. It is also the responsibility of the
installer to ensure that, if the equipment is used in a dusty environment, that filtering is supplied in the
enclosure to prevent excessive dust ingress.
NOTE: UCC1 main unit weight = 6 kg

7
Contents
Contents
1 Safety considerations .......................................................................................................................11
1.1 Installation..............................................................................................................................11
1.2 Incoming supply .....................................................................................................................11
1.3 Protection against electric shock............................................................................................12
1.4 Control functions ....................................................................................................................12
1.5 General use............................................................................................................................12
2 Scope and items supplied ................................................................................................................13
2.1 Scope.....................................................................................................................................13
2.2 CMM host computer...............................................................................................................13
2.3 Installation software (RENICIS) .............................................................................................14
2.4 Version ...................................................................................................................................14
2.5 Items supplied........................................................................................................................15
3 Description of the UCC1...................................................................................................................16
3.1 UCC1 controller, general........................................................................................................17
3.2 Motherboard...........................................................................................................................18
3.3 TP200 interface......................................................................................................................19
3.3.1 Differences between the PI 200 and the UCC1 interface .......................................19
3.3.2 Connectors .............................................................................................................19
3.4 Daughtercards........................................................................................................................19
3.5 Power supply unit...................................................................................................................20
3.5.1 Input........................................................................................................................20
3.5.2 Output .....................................................................................................................20
3.6 Fuses .....................................................................................................................................20
4 Optical interface board and cable.....................................................................................................21
4.1 Optical interface board ...........................................................................................................21
4.2 Fibre optic cable link ..............................................................................................................21
5 Connecting the UCC1 to a CMM......................................................................................................23
5.1 The controller’s 24 V supply ...................................................................................................25
5.2 Motor engagement.................................................................................................................25

8Contents
5.3 Amplifier enabling...................................................................................................................26
5.4 Contactor energisation...........................................................................................................26
5.5 Motor command signals.........................................................................................................27
5.6 Motor command polarity.........................................................................................................27
5.7 Controller switch outputs to the CMM ....................................................................................27
5.8 Controller switch inputs from the CMM ..................................................................................28
6 Connectors and signals....................................................................................................................29
6.1 Rear panel connectors...........................................................................................................29
6.2 CMM reading head input connections....................................................................................29
6.2.1 CMM’s reading head interface circuit......................................................................31
6.3 COMMS Ch1 connector.........................................................................................................31
6.4 Machine’s I/O connector.........................................................................................................32
6.4.1 Details of the machine’s I/O signals........................................................................36
6.5 The SCR 200 connector.........................................................................................................37
6.6 Servo power ampilfier connector............................................................................................38
6.7 Trigger probe connector .........................................................................................................41
6.8 Analogue probe connector.....................................................................................................42
7 Installation of the UCC1 components...............................................................................................43
7.1 General wiring standards .......................................................................................................43
7.1.1 Preparations...........................................................................................................................44
7.2 Installing the optical interface board.......................................................................................44
7.2.1 Optical interface board preparation PCI version .....................................................44
7.2.2 Optical interface board preparation ISA version .....................................................44
7.3 Optical interface board installation .........................................................................................45
7.4 Connecting UCC1 cables to and from CMM ..........................................................................46
7.5 Connecting the UCC1 mains supply ......................................................................................46
7.6 Installation of daughtercards..................................................................................................47
7.7 Probe head LED switch setting ..............................................................................................47
8 Renishaw license key manager system ...........................................................................................48
8.1 Using the Renishaw license key manager .............................................................................48
8.2 Ordering extra functionality / upgrading .................................................................................49
8.3 Obtaining the key ...................................................................................................................49
8.4 Applying the key.....................................................................................................................49

9
Contents
8.5 Demonstration mode..............................................................................................................49
8.6 Repairing upgraded systems .................................................................................................50
8.7 Error reporting........................................................................................................................50
8.8 Available functionality.............................................................................................................50
8.8.1 Triggering ................................................................................................................50
8.8.2 Digitising functions..................................................................................................50
8.8.3 Scanning functions .................................................................................................50
9 UCC1 troubleshooting ......................................................................................................................51
9.1 Front panel LED displays .......................................................................................................51
9.1.1 UCC1 power not switched ON ................................................................................51
9.1.2 UCC1 power switched ON ......................................................................................51
9.1.3 Initialisation/Test .....................................................................................................51
9.1.4 System file downloading .........................................................................................51
9.1.5 Servo active LED ....................................................................................................52
9.1.6 Probe seated LED ..................................................................................................52
9.1.7 System ready and probe seated LED’s flashing .....................................................52
9.2 Probe head LED configuration...............................................................................................52
9.3 Fault finding............................................................................................................................53
9.3.1 Fatal faults...............................................................................................................53
9.3.2 Motors will not engage / re-engage ........................................................................53
9.3.3 Poor positioning accuracy.......................................................................................55
9.3.4 Controller will not respond to host PC ....................................................................56
9.3.5 Motor stalling ..........................................................................................................57
9.3.6 Machine overspeed report ......................................................................................57
9.3.7 Scale reading (‘grating’) failures .............................................................................58
9.3.8 Timing out during moves or scans ..........................................................................58
9.3.9 Cannot start a move ...............................................................................................59
9.3.10 Cannot start a scan.................................................................................................60
10 Specifications ...................................................................................................................................61
10.1 Physical specification .............................................................................................................61
10.2 Cable lengths .........................................................................................................................61
10.2.1 UCC1 to CMM measuring scale reading head .......................................................61
10.2.2 UCC1 to CMM servo power amplifier input.............................................................61
10.2.3 Fibre optic cable link ...............................................................................................61
10.3 Scale readhead signal speed.................................................................................................62
10.4 Electrical power requirements................................................................................................62
10.4.1 Controller output supplies .......................................................................................62

10
10.4.2 Optical interface board............................................................................................62
11 System interconnections ..................................................................................................................63
11.1 Fixed probe of manual probe head system............................................................................63
11.2 PH10 probe head and 2 wire touch trigger probe system......................................................64
11.3 PH10 probe head and ‘multiwire’ probe system .....................................................................65
11.4 PH10 probe head, ‘multiwire’ probe system and ACR1..........................................................66
11.5 PH10 probe head and ‘multiwire’ probe system using external PHC10-2..............................67
12 Maintenance.....................................................................................................................................68
13 Testing and verification.....................................................................................................................69
14 Index.................................................................................................................................................70
15 Revision history................................................................................................................................71
What’s new in release 02-B ...................................................................................................71
What’s new in release 03 .......................................................................................................71
What’s new in release 04 .......................................................................................................71
What’s new in release 05 .......................................................................................................72
What’s new in release 06 .......................................................................................................72
What’s new in release 07 .......................................................................................................72
What’s new in release 08 .......................................................................................................72
What’s new in release 09 .......................................................................................................72
Contents

11
1 Safety considerations
When installing a CMM there are many safety factors that have to be taken in to consideration. The
following section outlines these considerations:
1.1 Installation
The machine manufacturer or the installer of this equipment is responsible for ensuring that the finished
machine complies with the necessary safety regulations and standards including those referenced in this
handbook.
Before switching on the installer must perform comprehensive wiring checks. Certain types of fault could
cause incorrect motion and the installer is cautioned to not enter the danger zone until all checks have
been successfully completed.
It is the responsibility of the machine manufacturer or installer to ensure that position sensors or limit
switches are supplied and fitted to the appropriate standards.
The machine manufacturer or the installer must ensure that all wiring external to UCC1 meets the
requirements of the UCC1 installation instructions and the appropriate technical standards including
EN60204-1.
Following replacement, modification, update of software or other changes to the UCC2, the test and
verification procedures specified in the technical documentation must be performed.
1.2 Incoming supply
The UCC2 is isolated by disconnection of the IEC mains connector on the rear panel. If an additional
means of isolation is required for the complete machine, it must be specified and fitted by the machine
manufacturer or the installer of the product. Where such devices for disconnecting and switching off are
fitted, the installer must decide whether any additional protection is required to prevent unauthorised,
inadvertent or mistaken connection.
Switching off or isolating the UCC1 does not guarantee freedom from unexpected machine movement.
Isolate the machine from the electricity supply, compressed air or other energy sources in accordance
with the machine manufacturer’s instructions before entering the danger zone or performing any
maintenance operations.
Safety considerations

12
1.3 Protection against electric shock
Automatic disconnection by the use of a residual current device (RCD) is recommended.
It is the responsibility of the machine manufacturer or product installer to ensure that the complete machine
or installation complies with the requirements for equipotential bonding.
1.4 Control functions
The following and similar programming options, which may reduce the protection against accidental
collisions (crashes), should be used with extreme caution. These include:-
• Touch probe override.
• Setting/unsetting of ‘soft’ limits.
Emergency stop and emergency switching off systems for the complete machine, if required according to
the installer’s or user’s risk assessment, must be implemented externally to the UCC1 and routinely tested.
The machine safety system, including emergency stop, limit switches, air pressure switch and touch-trigger
probe, should be checked regularly for correct function.
1.5 General use
Certain hardware failure modes or software corruption could have a detrimental effect on machine motion
and metrology. It is recommended that periodic metrology checks be made using a datum ball, MCG
checking gauge or other suitable artifact.
When using a touch-trigger or analogue contact probe it is essential that a stylus is fitted. Apart from a
stylus changing procedure, the CMM should never be moved when a probe is not fitted with a stylus.
With the use of extension bars it may be possible that the probe can be moved out of the recognised
machine working volume.
The machine operator should keep out of the CMM’s operating area whenever possible. This is
particularly important during the switch on and homing processes, and during an automatic program, when
unexpected movement can occur.
Safety considerations

13
2 Scope and items supplied
The purpose of this chapter is to describe the capabilities of the UCC1 version supplied and the options
which are available.
2.1 Scope
The UCC1 installation manual describes the UCC1 co-ordinate measuring machine (CMM) controller,
and provides a guide for the installation of the UCC1 and optical interface board/fibre-optic cable which
connects the UCC1 to the CMM host computer.
The pin-outs for the connectors on the cables which connect the UCC1 to the CMM are listed so that the
cables can be assembled by the user.
For a description of the operation of a UCC1 system, refer to the UCC programmers guide (Renishaw
part number H-1000-5057).
Scope and items supplied
Figure 1 - UCC1 assembly with the joystick or MCU interface board and optical interface board with
fibre-optic cable
2.2 CMM host computer
For this version of the UCC1 controller, the CMM’s host computer must be an IBM PC compatible with
Windows 98, Windows NT (SP6 or later), Windows 2000 or Windows XP Professional as an operating
system, a floppy disc drive, a CD-ROM drive, and a hard disc drive. The storage requirements of the
UCC1 system are less than 250 Mbytes, however, 550 Mbytes are required for a full software installation.
The PC must have one free PCI slot or ISA slot depending on the optical interface board type specified.
NOTE: A PCI optical board is supplied with every UCC1, ISA cards are available by special order only.

14 Scope and items supplied
2.3 Installation software (RENICIS)
The Renishaw RENICIS program is an optional tool to assist the user to install, commission and maintain
a CMM system based on the UCC1 controller.
It also has features which assist in the development of a software interface between any existing CMM
application program and the UCC1.
Please refer to the RENICIS user’s manual (Renishaw part number H-1000-5058) for more information on
this product.
2.4 Version
The UCC1 CMM controller has the capability of:
• Controlling three axes of a CMM (accepting digital reading head signals and generating three axes
drive motor control signals).
• Generating output control signals for 3 servo amplifiers.
• Accepting input signals from emergency stop, air pressure, crash detector, contactor feedback,
amplifier faults and X, Y and Z inner and outer travel limit switches.
• Generating seven uncommitted general purpose output signals.
• Accepting six uncommitted general purpose input signals (opto-isolated).
• Providing a +24 V supply for use by the CMM switches.
• Directly supporting the TP1, TP2, TP6, TP200 and SP600 probes, other Renishaw probes can be
integrated to the UCC1 system.
• Providing a PICS (product inter-connection system) interface for Renishaw peripherals.

15
Scope and items supplied
2.5 Items supplied
The part numbers of the UCC1 kits and upgrades are:
Kits
A-1333-0003 UCC1 with JI interface card kit (allowing touch trigger functionality)
or
A-1333-0006 UCC1 with MCU interface card kit (allowing touch trigger functionality)
Upgrades
A-1333-0004 for digitising functionality upgrade
or
A-1333-0005 for known part scanning functionality upgrade (includes A-1333-0004 capability)
Each kit contains the following items:
• UCC1 main unit
• PCI optical interface board
• Joystick or MCU daughter card
• Optical fibre (10 m)
• UCC1 and RENICIS programs and manuals on CD-ROM

16 Description of UCC1
3 Description of the UCC1
The purpose of this chapter is to provide a general description of the construction of the UCC1 controller
and its motherboard, daughterboards and power supply unit.
Plug-in daughterboards
I/O expansion board
Additional axis
Joystick interface, or
MCU interface board
Temperature sensor interface board
PICS/RS232 interface board
PH1050 interface board
Additional CMM I/O
Additional reading heads
User’s joystick unit
Manual control unit
Temperature sensors
PICS/RS232 devices
Probe head To CMM
UCC1 main unit
X, Y, Z scale heads
SP600 probe
Basic PICS
Internal RS232
Motor commands
CMM I/O signals
TP200 probe
Host PC
Optical I/F board
Figure 2 - UCC1 system components, diagrammatic view

17
Description of UCC1
3.1 UCC1 controller, general
The Renishaw UCC1 controller is designed to link a CMM host computer to the hardware of a CMM. The
controller can provide services to the component parts of a CMM system.
The controller unit contains all the logic circuitry and processor software necessary to:
• Respond to commands from the CMM’s host computer to control the CMM and allow measurements
to be made.
• Process the control commands from the CMM’s host computer to drive a CMM around a scanning
sequence on a workpiece.
• Process the measured raw data produced by the CMM’s probe and scales.
• Pass the processed data to the CMM’s host computer.
The controller receives instructions from the CMM host computer and passes information to it. It controls
the motion of the axes of the CMM by supplying start/stop/velocity signals to the CMM’s servo-amplifiers
calculated using positional information from the reading heads installed on the axes of the CMM.
The UCC1 is programmed to provide optimum probing conditions on the CMM by controlling the
acceleration, velocity and deceleration of the CMM’s axes.
The UCC1 consists of a mains-powered controller in a rack-mountable enclosure with a micro-processor
based computer system. It is coupled to the CMM’s host computer by a two-way fibre-optic serial link, and
to the CMM by external cable interface connectors.
The external cable interface input/output connectors are mounted on the rear panel of the controller.
The front panel of the enclosure has LEDs indicating Power On, System Ready, Servo Status, Probe
Status and Error Status.

18 Description of UCC1
3.2 Motherboard
The motherboard consists of:
• Central processor unit (CPU)
• System memory, I/O and interconnection logic
• On-board connectors for optional plug-in daughter-boards
• Rear panel connectors for the external interface cables to and from the CMM
• Rear panel fibre-optic connector for the two-way serial link to the CMM’s host computer
• CMM digital measuring scales reading head circuitry
• Axis servo control circuits
• Status indicating LEDs
• Control electronics for probes and peripheral devices attached to the CMM
It is a multi-layer PCB housing the microprocessor controlled computer system. An internal proprietary
bus interfaces with the plug-in option boards.
A 32-bit RISC microprocessor controls the CMM as required by the CMM’s host computer.
A small program stored on EPROM on the UCC1 motherboard controls the boot-up sequence of the
UCC1. The operating programme has to be downloaded from the CMM’s host computer over the two-way
fibre-optic serial link.
LEDs visible through the front panel of the UCC1 enclosure indicate the operational status of the UCC1.
Sub-circuits on the motherboard control the following interfaces through connectors on the rear panel of
the enclosure:
• X, Y and Z data input from the CMM reading heads
• Optical data link to the CMM
• A Communications port (CH1), reserved for use on a future product
• CMM status switches and transducers
• Supplies and control signals for an SCR200 stylus changer rack
• Signal outputs to the axis drive motors servo amplifiers of the CMM
• Connections to a TP200 probe or a range of touch-trigger probes
• Power to and input signals from a Renishaw SP600 analogue probe
A switch is provided to control the LED on a fixed probe head, see chapter 8.