ZS Instruments DR300UN User manual

Digital Readout Manual
ABS
TL01 F0.0ipm
8.8.8.8.8.8.8.8.0.0.0.0.0
8.8.8.8.8.8.8.8.0.0.0.0.0
8.8.8.8.8.8.8.8.0.0.0.0.0
Revision 1.6 ©ZS Systems LLC All Rights Reserved

2
DR300-UN
Table of Contents
Introduction
Product Overview .............................................................................................................................................................................3
Installation
Mounting ............................................................................................................................................................................................4
Grounding ..........................................................................................................................................................................................6
Cables ...................................................................................................................................................................................................6
Standard Functions
Units ......................................................................................................................................................................................................7
Absolute and Incremental Modes ..............................................................................................................................................7
Sub-datumMode ..............................................................................................................................................................................9
Feed-rate ..........................................................................................................................................................................................11
Sleep Mode .......................................................................................................................................................................................11
Zero Reference Restore ................................................................................................................................................................12
Calculator .........................................................................................................................................................................................13
Mill Functions
Centerline .........................................................................................................................................................................................14
Incline ................................................................................................................................................................................................14
Smooth Radius ...............................................................................................................................................................................17
Bolt Circle .........................................................................................................................................................................................19
Bolt Array ...........................................................................................................................................................................................21
ToolCompensation ........................................................................................................................................................................23
Lathe Functions
Axis Summing .................................................................................................................................................................................25
Radius/Diameter mode ................................................................................................................................................................25
Axis Vectoring .................................................................................................................................................................................26
TaperMeasurement .......................................................................................................................................................................26
ToolCompensation ........................................................................................................................................................................27
Settings
Machine Type ..................................................................................................................................................................................28
EncoderSettings .............................................................................................................................................................................28
Display Settings ..............................................................................................................................................................................30
System Info ......................................................................................................................................................................................30
Factory Default ...............................................................................................................................................................................30
Specications
Electrical ...........................................................................................................................................................................................31
Physical .............................................................................................................................................................................................31
Environment ...................................................................................................................................................................................31
Disposal .............................................................................................................................................................................................31
Input and Resolution ...................................................................................................................................................................31
Troubleshooting
CommonProblems.........................................................................................................................................................................32
Warranty
Limited Warranty and Disclaimer .............................................................................................................................................33

3
Introduction
Thank you for purchasing ZS Instruments DR300UN DRO. Your new digital readout is capable of many advanced features
that make machining operations fast and easy. This guide will cover the installation and setup of the unit, as well as how to
use all of the included features. Please read through this manual in its entirety before beginning installation or using the
unit to avoid damage to the DRO, encoders, or your machine. Save this manual for future reference.
Product Overview
Power Switch
Mounting Arm
Encoder Ports
Main Power
Information Screen
Power Button
Numeral
Keypad
(Numpad)
Fuse
Compartment
Grounding Port
ABS
TL01 F0.0ipm
8.8.8.8.8.8.8.8.2.2.6.2.5.0
8.8.8.8.8.8.8.8.1.2.8.7.5
8.8.8.8.8.8.8.8.5.7.5.0.0
Serial Number Plate
Axis Readout

4
DR300-UN
Installation
Mounting
The DRO has dierent types of arms for mounting to a mill or a lathe. Check that you have the correct type of arm for your
machine before attempting to install the DRO.
Mill Mounting
Step 1:Determine the ideal mounting location for your particular machine. Using the mounting base as a guide, center
punch, drill, and tap two holes for the 1/4-20 or M6 screws. Attach the arm assembly to the machine as shown. Use the
four set screws to level the mounting arm.
Step 2:Attach the DRO to the end of the mounting arm using the included hardware.
Due to the large number of machines and mounting congurations that are supported by the unit, hardware for
securing the mounting arm to the machine is not included. Use two 1/4-20 or M6 screws of an appropriate length
for your particular mounting arrangement.
Make sure that the DRO and cabling will clear all parts of the machine and
will be shielded from coolant nozzles, ying chips, or other hazards.
Be sure that the mounting arm is securely tightened or damage to
the DRO may occur.
Be sure that the DRO is in the correct orientation

5
Step 2:Attach the mounting arm to the base using the hex screw as shown.
Lathe Mounting
Step 1:Determine the ideal mounting location for your particular machine. Using the mounting
base as a guide, center punch, drill, and tap two holes of the same size and thread type as the screws
you will be using. Attach the arm assembly to the machine as shown. Use the four set screws to level
the mounting arm. Remove the hex screw from the top of the mounting arm base.
Make sure that the DRO and cabling will clear all parts of the machine and
will be shielded from coolant nozzles, ying chips, or other hazards.
Be sure that the mounting arm is securely tightened or damage to
the DRO may occur.
Step 3:Attach the DRO to the end of the mounting arm using the included hardware.
Be sure that the DRO is in the correct orientation
Be sure that the swivel faces upward

6
DR300-UN
Grounding
Once the DRO is mounted to the machine, it must be grounded. Using a 3 prong grounded outlet is sucient; however
we also recommend connecting a ground terminal on the back of the DRO unit to the machine ground with AWG 12
wire. It is important to ensure that the machine itself is properly grounded. Note, these are just general guidelines, always
follow national and local electric codes! Failure to ground the unit may cause equipment damage and/or electric
shock!
Cables
Before attempting to connect the encoders to the DRO, ensure that they are properly installed on the machine. Check the
encoder manual for the installation procedures. Encoder alignment can drastically aect the accuracy of the DRO system,
and severely misaligned encoders will result in premature wear and/or permanent damage.
Once the linear encoders are properly installed, plug the encoder cables into their respective axis inputs on the back of
the unit. Switch the DRO power o before connecting the encoders. Move each axis along its full range of motion to en-
sure that cables are not caught on any parts of the machine and do not rub against sharp edges that may cause damage
to the cables. Secure the cables such that they can not fall into the lubricant tray when disconnected from the DRO.
Power Cable
X-Axis Encoder
Grounding Terminal
Plug the cables into the following locations:
Y-Axis Encoder
Z-Axis Encoder
(if equipped)
Installation

7
Y
X
1.0
1.8
0.5
0.8 A B
C
Y
X
1.0
0.5
0.3
0.8
A B
C
Units
Your Digital Readout can be set to display position in either imperial or metric units of measure. Imperial units are displayed
in inches while metric units are in millimeters. Note that changing units will not aect current position and you may switch
the active units at any time.
The current units are indicated on the information screen. The feed-rate will be displayed in inches per minute (ipm) for
imperial units and in millimeters per second (mm/s) for metric units.
Standard Functions
Absolute and Incremental Modes
The use of absolute and incremental modes allows for dierent methods of referencing measurements. Proper use of these
modes allows the machinist to perform operations without the need for manual calculations. The currently active mode is
displayed on the information screen (“ABS” for absolute and “INC” for incremental).
When the DRO is in absolute mode, the coordinate display is always showing the position from the origin. In the example
part below, we set this origin point on the top surface at the front left corner of the part. If we were to move to drill feature
“A”, the DRO would display X=1.000”and Y=0.500”. To drill feature“B”, move the X axis until DRO displays X=1.800” .
In incremental mode, the coordinate display will show the position relative to the last feature. This can be helpful when
the working dimensions reference two features from each other. In the example part below, we would zero X and Y after
feature “A” is complete, and then move until DRO displays X=0.800”and Y= 0.300” to machine feature “C”.
ABS
TL01 F0.0ipm
ABS
TL01 F0.0mm/s
ABS
TL01 F0.0ipm
INC
TL01 F0.0ipm
In Absolute Mode: In Incremental Mode:
Press the abs/inc button to toggle between absolute and incremental modes.
ABS
TL01 F0.0ipm
INC
TL01 F0.0ipm
Absolute dimensioning Incremental dimensioning

8
DR300-UN
Zeroing or Presetting Axis Position
In either absolute or incremental mode, the current position can be zeroed (setting the origin to the current position) or
preset to any number (osetting the origin from the current position by the specied distance). The value for each axis is
set independently.
In addition, incremental mode supports the All Axis Zero and Recall Last Value functions.
Abs Set
X: 0 in 8.8.8.8.8.8.8.8.0.0.0.0.0.
All Axis Zero
In the incremental mode, to zero all axes at once, press the Ax0 button.
.8.8.8.8.8.8.8.
.8.8.8.8.8.8.8.
0.0.0.0.0
.8.8.8.8.8.8.8.
0.0.0.0.0
0.0.0.0.0
Abs Set
X: 2.5 in 8.8.8.8.8.8.8.8.2.5.0.0.0.
Standard Functions
To zero an axis, press the axis button and then, with the axis reading 0.0000, press the OK button.
To oset zero from the current position in an axis, press the axis button and then type in the desired oset
and press the OK button.

9
Recall Last Value
In incremental mode the digital readout can recall the last preset value entered for each axis. This function is useful when
the same move must be repeated several times.
Example: a part requires a series of holes to be drilled at 2.25 inch intervals along the X axis. The recall function can be used
to quickly get the same oset each time
Standard Functions
Step Buttons Information Screen
1 Move to the position of the rst hole and drill to the desired depth
2 Press X, enter 2.25 on the numpad, and press OK
3 Move the X axis until the X display reads zero and drill the second
hole
4 Press Recall, then press X
5 Move the X axis until the X display reads zero and drill the third
hole
6 Repeat steps 4 and 5 until all of the holes are drilled
Inc Set:
X: 2.25 in
Inc Recall
Press X Y Z Cncl
Sub-datum Mode
Up to 200 sub datum points can be added to dene the position of features relative to the absolute origin zero point. When
a sub-datum is selected the DRO will display the distance to the sub-datum position such that when you are at the correct
position the DRO axis displays will read zero. Because all sub-datum features are relative to the absolute mode origin point,
when the origin is moved, as in re-zeroing on a new part, all the sub-datum points will move with it.
To enter into the sub-datum mode recall an existing datum using the REC button. To create a new datum use the SET
button.
When in sub-datum mode, the current sub-datum is shown on the information screen: “DT001” means Datum 001
DT001
TL01 F0.0ipm

10
DR300-UN
Set Sub-datum
Setting a sub-datum point assigns an oset to that datum from the absolute zero. Sub-datum points can be set either by
sensing the current tool position in relation to the absolute origin or by explicitly entering an oset from the Abs zero.
Values for each axis are set independently, so it is possible to choose dierent methods for dierent axis. Sub-datums are
stored in non-volatile memory, so datum points will not be lost during a loss of power.
Standard Functions
Step Buttons Information Screen
1 Press the Set button
2 Use the up and down arrows to select the datum you would like to
edit
3 Press OK to conrm
4 Press 1 to sense the current position
OR
Press 2 and enter an oset value using the numpad
5 Repeat step 4 for the remaining axis
6 Press 1 if you would like to store this datum
OR
Press 2 if you would like to discard these settings and select
another datum to edit
OR
OR
X Abs Datum 001
1-Store 2-Discard
X Abs Datum 001
1-Sense 2-Enter
Datum to Edit:
001
To Recall a Previously set Sub-datum:
Step Buttons Information Screen
1 Press the Rec button
2 Use the up and down arrows to select the datum you would like
to recall
3 Press OK to conrm
4 The tool position is now displayed in relation to the selected
datum and the information screen shows the selected datum
DT001
TL01 F0.0ipm
Recall Datum
001

11
Exit Sub-datum Mode
If you wish to exit the sub-datum mode and return to absolute mode, press the Ax0 button while in sub-datum mode
Toggle Between Incremental and Sub-datum Mode
Once a datum has been set and recalled, you can toggle between sub-datum and incremental modes just like between
absolute and incremental.
Press the abs/inc button to toggle between sub-datum and incremental modes.
Standard Functions
Feed-rate Display
The feed rate is automatically displayed on the information screen either in inches per minute (ipm) or millimeters per
second (mm/s) based on the active units.
OR
Sleep Mode
Sleep mode can be toggled by pressing the power button on the front panel of the DRO. Sleep mode saves power by
turning o axis displays and the LCD back-light but continues to track tool position. It is safe to move machine axis while
the DRO is in sleep mode, and position loss will not occur.
Sleep mode...
PWR to WakeUP
DT001
TL01 F0.0ipm
INC
TL01 F0.0ipm
DT001
TL01 F0.0ipm
ABS
TL01 F0.0ipm
ABS
TL01 F0.0ipm
ABS
TL01 F0.0mm/s

12
DR300-UN
Zero Reference Restore
To allow the user to recover the position of the tool after a power loss, this digital readout is equipped with a zero reference
restore function. To enable this feature, a reference zero must be set prior to loss of power. Each axis must be set and
recalled independently.
To Set Reference Zero:
Step Buttons Information Screen
1 Press F to navigate to the reference function
2 Press 1 to set a reference
3 Press the axis button for the axis you would like to set
4 Move the axis slowly until the information screen shows a brief
“found” message and the unit returns to normal operation
Reference (Abs)
1-Set 2-Restore
Found X=1.6012
Saving...
Standard Functions
To Restore Reference Zero:
Step Buttons Information Screen
1 Press F to navigate to the reference function
2 Press 2 to restore a reference
3 Press the axis button for the axis you would like to restore
4 Move the axis slowly until the information screen shows a brief
“found” message and the unit returns to normal operation
Reference (Abs)
1-Set 2-Restore
Found X=1.6012
Loading...
Note: If scales with single/periodic reference marks are used, it is important to always to start from the end of travel and
to move the axis in the same direction during both setting and restoring reference
If scales with smart (distance coded) reference marks installed, it will only take about 1”of movement anywhere in either
direction along the axis to set or recover the absolute position.

13
Calculator
The digital readout comes with a built-in calculator, which can be used to perform simple mathematical and trigonometric
functions. Type on the numpad to enter the desired numbers and the various operator buttons (+, –, *, ÷) followed by
equals (=) to solve. To use a trigonometric function, rst enter the input value, then press the desired function button. The
result of the operation will be displayed with one to ve places after the decimal (see settings section to choose desired
rounding precision).
Press the Cal button to toggle between calculator and normal operation mode.
ABS
TL01 F0.0ipm
***Calculator***
0
Standard Functions

14
DR300-UN
Mill Functions
Centerline
To set the midpoint between zero and the current position as the new zero for the selected axis, use the Centerline function.
This function can be used in absolute or incremental mode and is axis-specic, meaning that you must select an axis on
which to perform the function. If you would like the midpoint for more than one axis, the function can be performed on
each axis individually.
Step Buttons Information Screen
1 Press the centerline button
2 Press the axis on which you would like to nd the midpoint
3The axis display will now show the distance to the midpoint. Move
the axis until the display reads zero to put the tool on the centerline
Centerline
Press X Y Z Cncl
Incline
To machine a surface on a plane that is not parallel to two of the axes of machine travel, use the Incline feature. When
machining an incline feature the digital readout will sequentially display the coordinates of the two axes where the tool
needs to be positioned to create the incline surface. This program requires the following inputs:
• The cut plane of the incline (XY, YZ, or XZ)
• Whether tool compensation will be applied to the right or left (only for XY cut plane)
• The position of the starting and ending points of the incline
• The maximum cut size (smaller number produces smoother result but requires more machining steps).
The Incline feature can be saved to one of 99 slots or it can be run immediately without saving
Note: A ball end mill MUST be used when milling inclines on the XZ or YZ planes.
X Start Point
Y Start Point
X End Point
Y End Point
Right Compensation
Left Compensation
Y Axis
X Axis
Datum

15
To Create a New Incline Feature:
Mill Functions
Step Buttons Information Screen
1 Press the incline button to access the incline feature
2 Press 1 to setup a new incline program
3 Select a cut plane using the up and down arrows, then
press OK to conrm
4 If you chose the XY plane:
Use the up and down arrows to select whether tool
compensation will be applied to the right or left, then
press OK to conrm
5 Enter the starting point of the incline for each axis:
Press 1 to sense the current position
OR
Press 2 to enter the position using the numpad
Press OK to conrm
6 Enter the ending point of the incline for each axis:
Press 1 to sense the current position
OR
Press 2 to enter the position using the numpad
Press OK to conrm
7 Enter the maximum cut using the numpad, then press
OK to conrm
8 Press 1 to save the program
Choose one of the 99 program slots to save it in using
the up and down arrows
OR
Press 2 to run the program without saving
***INCLINE***
1-New 2-Load
Cut Plane
1 XY
Tool Compensation
1 Right
OR
X Start Point
1-Sense 2-Enter
OR
Maximum Cut:
0 in
OR
X End Point
1-Sense 2-Enter
***INCLINE***
1-Save 2-Run
***INCLINE***
Save As: 01

16
DR300-UN
To Recall a Saved Incline Feature:
Step Buttons Information Screen
1 Press the incline button to access the incline feature
2 Press 2 to load an existing incline program
Select the program you would like to load using the up
and down arrows, then press OK to conrm
3 The DRO will cycle through all of the setup parameters
Press OK for each if the information is correct
OR
Change the desired values using the numpad or the up
and down arrows
4 When the information screen reads INCLINE, the rst
point is displayed. Move the tool until the axis displays
read zero
5 If the cut plane is the XY plane, plunge to the desired
depth and leave the tool at that depth for the duration
of the program
If the cut plane is the XZ or YZ plane, make a pass of the
desired length along the remaining axis
6 Press the up arrow to advance to the next point and
move the tool until the axis displays read zero
If the cut plane is the XZ or YZ plane, make a pass of the
desired length
7 Repeat step 6 until all points are completed
When the program nishes, press cancel to exit the
program and 1 to conrm
***INCLINE***
1-New 2-Load
Cut Plane
1 XY
Terminate ?
1-Yes 2-No
*** INCLINE ***
Pt. 001 of 025
Load
Incline 01

17
Smooth Radius
To machine a radius or rounded feature in any plane, use the Smooth Radius feature. When machining a Smooth Radius
feature the digital readout will sequentially display the coordinates of the two axes where the tool needs to be positioned
to create the curved surface. This program requires the following inputs:
• The cut plane of the radius (XY, YZ, or XZ)
• Whether the cut will be external or internal
• The position of the center point of the radius
• The starting and ending angles (counterclockwise from the three o’ clock position)
• The radius of the feature
• The maximum cut size (smaller number produces smoother result but requires more machining steps)
The Smooth Radius feature can be saved to one of 99 slots or it can be run immediately without saving
Note: A ball end mill MUST be used when milling radii on the XZ or YZ planes.
To Create a New Smooth Radius Feature:
Step Buttons Information Screen
1 Press the radius button to access the smooth radius
feature
2 Press 1 to setup a new smooth radius program
3 Select a cut plane using the up and down arrows, then
press OK to conrm
4 Use the up and down arrows to select whether the cut
will be internal or external
Press OK to conrm
5 Enter the center point of the radius for each axis:
Press 1 to sense the current position
OR
Press 2 to enter the position using the numpad
Press OK to conrm
*SMOOTH RADIUS*
1-New 2-Load
Cut Plane
1 XY
Cut direction
1 External
Mill Functions
X Center
Y Center
Start Angle
End Angle
Radius
External
Cut
Internal
Cut
Edge of Cut
Y Axis
X Axis
Datum
OR X Center
1-Sense 2-Enter

18
DR300-UN
To Recall a Saved Radius Feature:
Mill Functions
Step Buttons Information Screen
1 Press the radius button to access the smooth radius
feature
2 Press 2 to load an existing smooth radius program
Select the program you would like to load using the up
and down arrows, then press OK to conrm
3 The DRO will cycle through all of the setup parameters
Press OK for each if the information is correct
OR
Change the desired values using the numpad or the up
and down arrows
4 When the information screen reads SMOOTH RADIUS,
the rst point is displayed. Move the tool until the axis
displays read zero
5 If the cut plane is the XY plane, plunge to the desired
depth and leave the tool at that depth for the duration
of the program
If the cut plane is the XZ or YZ plane, make a pass of the
desired length along the remaining axis
6 Press the up arrow to advance to the next point and
move the tool until the axis displays read zero
If the cut plane is the XZ or YZ plane, make a pass of the
desired length
7 Repeat step 6 until all points are completed
When the program nishes, press cancel to exit the
program and 1 to conrm
*SMOOTH RADIUS*
1-New 2-Load
Terminate ?
1-Yes 2-No
Load
Smooth Rad. 01
Cut Plane
1 XY
*SMOOTH RADIUS*
Pt. 001 of 025
Step Buttons Information Screen
6 Enter the starting angle using the numpad
Press OK to conrm
7 Enter the ending angle using the numpad
Press OK to conrm
8 Enter the radius length using the numpad
Press OK to conrm
9 Enter the maximum cut using the numpad, then press
OK to conrm
10 Press 1 to save the program
Use the up and down arrows to choose a program slot
to save in and press OK
OR
Press 2 to run the program without saving OR
Start Angle:
0 Deg
End Angle:
90 Deg
Radius:
1.5 in
Maximum Cut:
0.125 in
*SMOOTH RADIUS*
1-Save 2-Run
*SMOOTH RADIUS*
Save As: 01

19
Mill Functions
Bolt Circle
To automatically calculate the position of holes in a circular pattern use the Bolt Circle function. It requires the following
inputs:
• The position of the center of the circle
• The number of holes to be drilled (up to 999)
• The starting and ending angles (counterclockwise from the three o’ clock position)
• The radius of the circle.
The Bolt Circle feature can be saved to one of 99 slots or it can be run immediately without saving
To Create a New Bolt Circle Feature:
X Axis
Y Axis
X Center
Y Center
Start Angle
End Angle
Radius
Datum
Step Buttons Information Screen
1 Press the bolt circle button to access the bolt circle
feature
2 Press 1 to setup a new bolt circle program
3 Enter the center point of the circle for each axis:
Press 1 to sense the current position
OR
Press 2 to enter the position using the numpad
Press OK to conrm
4 If your machine is equipped with a Z axis scale, enter the
depth of the holes:
Press 1 to sense the current position
OR
Press 2 to enter the position using the numpad
Press OK to conrm
**BOLT CIRCLE**
1-New 2-Load
OR Z Depth
1-Sense 2-Enter
OR X Center
1-Sense 2-Enter

20
DR300-UN
To Recall a Saved Bolt Circle Feature:
Step Buttons Information Screen
1 Press the bolt circle button to access the bolt circle
feature
2 Press 2 to load an existing bolt circle program
Select the program you would like to load using the up
and down arrows, then press OK to conrm
3 The DRO will cycle through all of the setup parameters
Press OK for each if the information is correct
OR
Change the desired values using the numpad or the up
and down arrows
4 When the information screen reads BOLT CIRCLE, the
rst point is displayed. Move the X and Y axis until the
axis displays read zero
5 If your machine is equipped with a Z axis scale, plunge
the tool until the Z axis display reads zero
If your machine is not equipped with a Z axis scale,
plunge the tool to the desired depth
In either case, retract the tool above the workpiece once
the hole is drilled
6 Press the up arrow to advance to the next point and
move the tool until the X and Y axis displays read zero
Repeat step 5
7 Repeat step 6 until all points are completed
When the program nishes, press cancel to exit the
program and 1 to conrm
**BOLT CIRCLE*
1-New 2-Load
Terminate ?
1-Yes 2-No
Load
Bolt Circle 01
**BOLT CIRCLE**
Pt. 001 of 025
X Center (Abs)
0 in
Mill Functions
**BOLT CIRCLE**
Save As: 01
Step Buttons Information Screen
5 Enter the number of holes using the numpad or the up
and down arrows
Press OK to conrm
6 Enter the starting angle using the numpad
Press OK to conrm
7 Enter the ending angle using the numpad
Press OK to conrm
8 Enter the radius of the circle using the numpad
Press OK to conrm
9 Press 1 to save the program
Use the up and down arrows to choose a program slot
to save in and press OK
OR
Press 2 to run the program without saving
Number of Holes:
004
Start Angle:
0 Deg
Radius:
2 in
**BOLT CIRCLE**
1-Save 2-Run
End Angle:
270 Deg
OR