Renishaw TSA Operating instructions

Repair Manual for OEMs
H-2000-5090-01-A
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INITIAL PART/MODEL
TSA
Motorised Tool Setting Arm
Renishawplc
T
[phone]
New Mills, Wotton-under-Edge, F+44 (0) 1453 524201
Gloucestershire GL12 8JR E[email protected]
United Kingdom www.renishaw.com

© 2002 Renishaw. 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-2000-5090-01-A
Issued: 05 2002
i

Changes to specification
Renishaw plc may modify or change its products or specifications without notice and
without obligation.
Warranty
This document defines the procedure for fault finding and repairing TSA returned to
the OEM after expiry of the warranty.
This document is to be used in conjunction with Renishaw parts supplied in the
Repair Kit(A-2116-0131).
Renishaw plc cannot take responsibility for any Renishaw product repaired by the
OEM.
The OEM may only repair Renishaw product if its warranty has expired.
Equipment requiring attention under warranty must be returned to your supplier. No
claims will be considered where Renishaw equipment has been misused, or
unauthorised persons have attempted repairs or adjustments.
PRECAUTIONS
Safety
Remove power before performing any maintenance operations.
Only competent persons observing relevant safety precautions may carry out repairs.
Anti static handling
The electronic circuit board assemblies within the TSA and those supplied in the
Repair Kit are sensitive to static discharge.
Anti static precautions must be observed during handling or installation of the
electronic circuit board assemblies. Failure to do so could result in permanent
damage to the electronics.
Product integrity
The torque wrench settings defined in this manual ensure the integrity of sealing
elements and fixings within the TSA.
Failure to use these settings when repairing TSA could result in coolant ingress or
poor repeatability.
ii

CONTENTS.
1.0 Initial inspection and test ......Page 1
2.0 Fault diagnosis .......Page 3
3.0 Disassembly / reassembly ......Page 5
3.1 Hub cover plate and gasket. ....Page 5
3.2 Vanes and Soft Limits PCB ....Page 6
3.3 Hub assembly and Hard Limits PCB ...Page 8
3.4 Base cover plate, gasket and Control PCB ..Page 9
4.0 Setting Up . ......Page 12
4.1 Control PCB wiring ......Page 12
4.2 Active stop opto switch vane ....Page 13
4.3 Stow position /Active opto switch vane. ...Page 15
5.0 Troubleshooting .......Page 16
5.1 Collisions .......Page 16
5.2 Diagnostic LEDs ......Page 16
5.3 Trouble shooting charts .....Page 17
5.4 Testing .......Page 19
iii

1.0 INITIAL INSPECTION AND FUNCTIONAL TEST.
Visual Inspection
Look for signs of damage by customer.
Look for signs of coolant ingress/damage.
Guidelines on Damage by Customer
Damage can be assessed by checking the arm tube for any distortion or creasing.
Check for any distortion in alignment of the probe module to the probe holder.
Inspect the hub and base castings for evidence of a machine crash i.e. chipped paint
or dents. Inspect the Damage Limitation Device (fitted between the arm and hub) for
cracks/distortion at the thin webs around the mounting holes.
Leaks
Leaks can only be positively identified upon removal of the cover plates as per
section 3. Leakage can manifest itself as any of a variety of failure modes.
Ingress will be identified by the presence of an oily film over internal components or
visible pools of coolant. If a leak has been over a long period of time, there will be
green deposits around the area of ingress.
Cable
Inspect cable for any sign of damage to the insulation, look for signs of crushing or
chafing along length of cable.
Functional Test
Attach complete TSA assembly to a rigid mounting and connect wiring in accordance
with the TSA Installation & User’s Guide (H-2000-5088-05) section 5.
Make use of the Diagnostic LEDs as detailed in section 5 and the TSA Installation &
User’s Guide section 11.
If the TSA hub is not already up in the ‘Stow’ position, drive it up to the ‘Stow’
position. If the hub fails to move consult section 2 (d) of Fault Diagnosis.
When up in the ‘Stow’ position, ensure: -‘Stow’ status LED is ON
‘Active’ status LED is OFF
If the LEDs do not show the correct status, consult section 2 (b) of Fault Diagnosis.
Drive the hub down to ‘Active’. See that the hub has a soft start and rotates smoothly
down into the ‘Active’ position.
1

When down in the ‘Active’ position, ensure: - ‘Stow’ status LED is OFF
‘Active’ status LED is ON
If the LEDs do not show the correct status, consult section 2 (a) of Fault Diagnosis.
Attempt to rotate the hub by applying slight hand pressure to the arm in the ‘Stow’
and ‘Active’ directions. Ensure there is no rotational movement of the hub with
respect to the base in either direction. If the hub can be moved freely consult section
2 (e) of Fault Diagnosis.
Drive the hub to a position halfway between ‘Stow’ and ‘Active’ and switch off the
power to the TSA.
Holding the hub casting firmly by hand, rotate it in both directions using moderate
force. The maximum permissible rotation is 2°. If the hub can be moved further than
this consult section 2 (e) of Fault Diagnosis.
Switch on the power to the TSA and allow the hub to continue to its ‘Stow’ position.
Disconnect the power to the TSA before removing it.
2

2.0 FAULT DIAGNOSIS.
Possible Faults, Causes and Solutions
Problem: -
(a) Arm moves into ‘Active’ position, but ‘Active’ confirm LED is not lit.
Possible Causes Rectification
a) Opto switch vanes incorrectly set
or damaged Consult section 4.2
b) Soft limits PCB defective Consult section 3.2
c) Hard limits PCB defective Consult section 3.3
d) Operating voltage <21.6 v (min) Measure voltage with suitable meter
and correct supply if possible
e) Motor performance deterioration Return TSA to Renishaw if
renewal/replacement is required
f) Control PCB fault Replace PCB, section 3.4
g) Wiring fault Check all wiring as per TSA
Installation & User’s Guide (H-2000-
5088-05) section 5.
(b) Arm moves into ‘Stow’ position, but ‘Stow’ confirm LED is not lit.
Possible Causes Rectification
a) Opto switch vanes incorrectly set
or broken Consult section 4.3
b) Hard limits PCB defective Consult section 3.3
c) Control PCB fault Replace PCB, section 3.4
d) Loose mechanics Check all recommended torque values
(c) Arm moves too slow or with excessive judder
Possible Causes Rectification
a) Main bearing seizing up Return TSA to Renishaw if
renewal/replacement is required
b) Motor defective Return TSA to Renishaw if
renewal/replacement is required
c) Control PCB fault Replace PCB section 3.4
d) Loose mechanics Check all recommended torque values
3

(d) Arm does not move in either direction.
Possible Causes Rectification
a) Control PCB failure Replace PCB section 3.4
b) Motor failure Return TSA to Renishaw if
renewal/replacement is required
c) Total main bearing seizure Return TSA to Renishaw if
renewal/replacement is required
d) Wiring fault Check all wiring as per TSA
Installation & User’s Guide (H-2000-
5088-05) section 5.
(e) Excessive hub end float and rotation
Possible Causes Rectification
a) Loose main bearing Return TSA to Renishaw if
renewal/replacement is required
b) Anchor plate screws loose Re-tighten screws, section 3.3
c) Loose kinematic structure Return TSA to Renishaw if
renewal/replacement is required
d) Excessive wear in motor assembly Return TSA to Renishaw if
renewal/replacement is required
For additional fault diagnosis, consult section 5.0 - Trouble Shooting
4

Hub Cover Gasket
(M-2116-0085)
Serial Number
Hub Cover Plate
Cable exit hole
M3 Screw
(P-SC17-0308)
8 off
0.7 Nm
3.0 DISASSEMBLY/REASSEMBLY.
Disconnect power before commencing work. Observe anti-static
handling precautions.
A proprietary thread locking compound must be applied to screws
where stated, to prevent loosening during operation of the TSA.
Molybdenum disulphide grease must be applied, where stated, to
maintain smooth running of sealing surfaces.
A spare O-ring (P-RS01-0041) is supplied in the Repair Kit for re-assembly of the
Arm to the Hub. Heatshrink (P-CA57-0032) is also supplied to provide additional
strain relief for the Arm/Probe Cable if required.
3.1 HUB COVER PLATE AND GASKET.
Strip
Remove cover plate and gasket.
Inspect gasket for any damage, and any evidence of coolant ingress.
Ensure both opto switch vanes are securely in place, and screws are
tight.
Rebuild
Renew gasket (M-2116-0085).
Replace cover plate with serial number nearest to arm attachment face.
Tighten all 8 M3 screws (P-SC17-0308) to 0.7 Nm following the
sequence shown in figure 3.1.
Figure 3.1
Opto switch vanes
5
!

3.2 VANES AND SOFT LIMITS PCB.
Strip
Unscrew and carefully remove both opto switch vanes to give complete
access to the Soft Limits PCB. Do not bend the vanes as this could affect
operation.
Remove 2 off Ty-raps, unsolder probe wires from pins and unplug Hard
Limits PCB cable loom from Soft Limits PCB.
Unscrew 3 off M3 screws to remove Soft Limits PCB.
Rebuild
Insert Soft Limits PCB (A-2116-0570) into hub and secure with 3 off M3
screws (P-SC17-0304).
Solder probe wires to pins. Plug Hard Limits PCB cable loom into socket
on Soft Limits PCB as per figure 3.2a.
Fit new Ty-raps (P-CA66-0922) around probe wires and cable loom to
Soft Limits PCB to give strain relief as shown.
Refit opto switch vanes as per figure 3.2.
Note: For set up of opto switch vanes, consult section 4.2 & 4.3 of
Setting Up.
To continue rebuild go to section 3.1
Figure 3.2
6
Stow position
/Active opto
switchvane
M3washer
(P-SC17-0304)
4 off
Active stop opto
switchvane
M3 Screw
(P-SC17-0304)
4 off
Soft Limits PCB
A-2116-0570
Probewires
solder pins
Hard Limits PCB
A-2116-0560

Figure 3.2a
Redwire
Bluewire
Soft Limits PCB
(A-2116-0570)
Ty-rap, 2 off
(P-CA66-0922)
Hard Limits PCB
loom
Apply pressure at
this point only
7

Fit with this face
towards base
casting
M4 Screws
(P-SC01-0412)
4 off
2Nm
Apply grease to
this face after seal
has been placed
Side view of V-seal
3.3 HUB ASSEMBLY AND HARD LIMITS PCB.
Strip Unplug 8-way connector from Hard Limits PCB. Undo 2 off M5 nuts.
Hard Limits PCB is now free to remove.
Undo 4 off M4 screws in centre of hub plate and remove hub.
Rebuild
Apply grease to front kinematic spools and lugs on structure.
Renew face seal (P-RS05-0006) as per figure 3.3a. Ensure the lip stands
up evenly all the way around.
Locate hub assembly onto bearing end face and check for free rotation
of hub in both directions. If this rotation is restricted to less than 90° of
rotation and a repair or replacement is required, then the TSA must be
returned to Renishaw.
To secure hub to bearing as per Figure 3.3, apply thread locking
compound to 4 off M4 screws and torque to 2 Nm.
Place Hard Limits PCB (A-2116-0560) onto locating tubes and secure
with 2 off M5 nuts. Plug in 8-way connector and push excess wire back
down tube. Stretch 1 off O-ring (P-RS01-0093) over hub and locate into
groove instead of the garter spring.
To continue rebuild go to section 3.2
Figure 3.3 Figure 3.3a
Bearing
V-seal
Hard Limits PCB
(A-2116-0560)
8

3.4 COVER PLATE, GASKET AND CONTROL PCB.
Strip
Remove all screws from cover plate.
Inspect gasket for any damage, and any evidence of coolant ingress.
Before removal, ensure the Control PCB is securely fixed and that the
main cable wires are correctly connected as per section 4.1 of
Setting Up. Remove byloosening the single M3 socket screw in the
keyhole slot in the middle of the PCB and withdrawing the PCB from the
connector and over the screw.
Figure 3.4
M3 Screw
(P-SC02-0306)
17 off
Base Cover Plate
Base Cover Gasket
(M-2116-0084)
Cable Gland
(side exit
option only)
Blanking Plug
9

Rebuild
Insert the control PCB (A-2116-0520) into the assembly and push the
board into the connector at the same time as pushing the keyhole slot in
it over the M3 socket screw. Tighten the screw to secure PCB in place
as per figure 3.4a.
Re-connect the main cable wires as per section 4.1 of Setting Up.
Renew cover gasket (M-2116-0084)
Place base cover plate onto casting and secure with 17 off M3 screws
(P-SC02-0308). Torque all screws to 0.7 Nm as per tightening sequence
shown in figure 3.4b.
To continue rebuild go to section 3.1
Figure 3.4a
Motor Connector
M3 Screw
(P-SC17-0306)
Control Board
(A-2116-0520)
10

Figure 3.4b
M3 Screw
(P-SC02-0306)
17 off
0.7 Nm
11

4.0 SETTING UP.
4.1 CONTROL PCB WIRING.
Connect main cable to Control PCB as per figure 4.1.
Control board connectors
1
2
3
4
5
6
7
8
9
10
11
Black
Red
Brown
Grey
Orange
Yellow
White
Pink
Blue
Turquoise
Violet
Figure 4.1
12

4.2 ACTIVE STOP OPTO SWITCH VANE.
This set-up requires:
•That the Control PCB (A-2116-0520) is already fitted.
•All connectors are plugged in and wires are connected.
•Power is supplied to the TSA
Adjust the tightness of the 2 off M3 screws (P-SC17-0304) such that the vane can be
rotated by hand under moderate pressure.
Figure 4.2
Activestop
opto switch
vane
M3 screws
(P-SC17-0304)
M3washers
(P-WA01-0030)
13

Figure 4.2a
Slide the vane fully anti-clockwise such that the flap lies midway between the poles of
the opto switch.
Drive the hub from ‘Stow’ to ‘Active’ and watch for movement of the pillar relative to
the Soft Limits PCB. Approximately 1mm movement is required.
A lack of movement means that the kinematics will not be preloaded by the
springs and this will result in poor repeatability.
If there is no movement, slide the vane clockwise slightly then drive the hub from
‘Stow’ to ‘Active’ again. If necessary, repeat, making clockwise/anti-clockwise
adjustments until approximately 1mm of relative movement between the pillar and
PCB is observed.
Tighten both screws to 0.7Nm.
Visually check that the springs in the hub wind up approximately 1 mm.
2 poles of
opto switch
flap
pillar
Soft Limits PCB
14

Stow position/Active
opto switch vane
M3 screws
(P-SC17-0304)
M3washers
(P-WA01-0030)
4.3 STOW POSITION /ACTIVE OPTO SWITCH VANE
Figure 4.3
Move the vane to a central position as shown above. Adjust the tightness of the 2 off
M3 screws (P-SC17-0304) such that the vane can be rotated by hand under
moderate pressure.
1. Shield the exposed hub from any external light source.
2. From the active position drive the hub to the stow position.
3. Aim to have the hub stop such that the arm mounting face is 90°±0.5° from the
base mounting face.
4. Adjust the stow position of the hub by sliding the vane clockwise or anti-clockwise
depending on the required position.
5. Repeat from 1. Until the correct position is achieved.
6. Tighten both screws to 0.7Nm.
Note: After adjusting the vane position always drive the hub from the active position
to recheck new set-up. This is a very sensitive operation and may require several
adjustments before the desired result is observed.
15

5.0 TROUBLE SHOOTING.
If the system exhibits poor repeatability or gives spurious readings, all aspects
of the installation and operation should be investigated (eg operating
method/conditions, software etc).
5.1 COLLISIONS.
In the event of collision, re-calibration of the probe is necessary.
5.2 DIAGNOSTIC LEDS.
Diagnostic LEDs have been incorporated in this product to assist installation and fault
finding. These can be viewed by removing the M20 Viewing Plug located on the side
of the TSA base as per figure 35 on page 61 of the TSA Installation and User’s
Guide. The LEDs are mounted on the PCB and assigned as follows:
LED name Colour Lit when
Move Command Green ‘Move’ command
received
Direction Command Red ‘Move to Active’
command received
Stow Confirm Amber Arm reaches Stow
position
Active Confirm Green Arm reaches Active
position
Probe Status Red Arm in Active and probe
triggered or arm is in
Stow
Inputs Outputs LEDS
Move
L=Move
H=Stop
Direction
L=Active
H=Stow Trigger
Input Active
Confirm Stow Confirm Probe
Out Probe Out
Move
LED on
Green
Direct
LED on
Green
Stow
LED on
Red
Stow
LED on
Amber
Trigger
LED on
Red
Move Stow HL L Hüüü
Move
Active LHü ü ü
Stop Active LHü ü
Note: A resettable fuse is incorporated in the circuit. This will automatically
reset 30 seconds after the power is removed.
16