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Operator's Manual

FPIUniversal Tool Milling and Boring Machine

E611 - 7.81 Edition

Active digital position readout unit, cont'd

Moving past reference Points

The reference points are located near the zero position of

the coarse scale in all three axes.

- Operate M t.t (unless LED is already illuminated).

- Operate @ t.y' LEDs (6) and (9) will light up; actual'

value readout blocked.

- Operate @t.t and the two feed buttons on operator

control panel if reference marks are to be approched at

feed rate.

- Move machine axes (slides) beyond reference marks

consecutively by operating feed control lever and rapid

traverse button: actual-value readouts will start counting

from reference mark; LEDs (9) will be extinguished.

Setting the reference Points(only in 'manual'mode)

After aligning the machine with the workpiece datum, set

actual-value counters to a reference value, usually zero lref'erence point = zero point of actual-value readout).

Align in spindle longitudinal direction, for example with a

bore or workpiece edge, by moving end face of tool intocontact with workPiece.

- Align with reference point (in at least one axis)'

- Operate one of the reference point keys (8).

- Operate El t.t (to zero setpoint readout), key refer-

ence value into setpoint readout (5) on keyboard (l) and

use [l key to determine sign.

- Operate transfer key (2) of axis just aligned: keyed-in

value will appear in actual-value readout. Reference

point in this axis is now stored.

- Repeat this procedure in the other axes.

lf several reference points have been set, the actual-value

readout will show the distance from each reference point

upon operating the associated reference point key.

Example

The 4 reference points definable can be stored as shown below

for machining a workpiece.

Fig2

Use reference point @ for workpiece edges in X and Y

axes.

Reference point @l may be assigned to the lst bore in a

row of bores positioned in chain dimensions.

Reference points @ and @ may be assigned to the central

bores of boring patterns.

Refinding reference points

Switch on unit and move past reference marks as described

above.

o-d#

E 9O2 (12.81)

'rctive digital position readout unit, c-ont'd

Positioning

First set at least one reference point with or without refer'

ence mark evaluation. The position readout will count fromthe momentary reference Point.

ln'manual'mode SlUse handwheel or pow.er feed to move machine slide(s).

Feed motions

- Operate 'Feed'keY @.

- Operate both feed buttons on operator panel and rapid

traverse but in addition, if required.

Automatic positioning

,odes:'absolute dimensions';'incremental (chain) dimensions'.

Absolute d imensions: all dimensions, including setpoints,

refer to the reference point in the axis concerned.

lncremental (chain) dimensions: each dimension refers tothe last previous actual position. Setpoint values will be

keyed in as chain dimensions, but actual-value readouts

show absolute dimensions.

Starting situation: 'manual' mode, necessary reference

points already set.

Preparing the positioning operation

- lf 'REF' lamp (6) is still illuminated, operate 'REF' key

to extinguish LED.

- Operate mode key E otE.

- Set feed rate o,n operator control panel and operate feed

buttons.

rosltlOnlng

- Operate CE key (1)

{not required if previous preset value has already been

transfered to an actual-value counter).

- Key in setpoint value on keyboard (1 ) in either absolute

or chain dimensions. depending on mode selected.

- Operate transfer key X, Y or Z (21 .

- Engage feed control lever in accordance with external

axis and direction indicator (Fig 3): axis will start mov-

ing and stop in setpoint position.

- Disengage feed control lever (move lever to middle posi-

tion).

Any positioning operation can be interrupted by means of

El n.t (131. To resume the positioning operation, again

operate transfer key in the axis concerned.

To change the direction of a motion, disengage feed controlt.ver, key in new position and then operate transfer key in

,e axis concerned.

E 9O2a ( 12.81)

lmportantlf a 'chain dimension' positioning operation is interrupted

by means of 'stop' button (13), the actual position at thatpoint will be the reference point for the next positioning

operation in chain dimension.

Fig 1

g, 4,.6 6 re* not on FP1 Fis 3

The external axis and direction indicator (Fig 3) is con-

nected in parallel with the digital readout unit. lt shows

the operator the direction of feed selected and thus indi-cates which feed control lever has to be moved in what

direction.

lmportantAlways move all feed control levers to zero position before

any change in mode or operating any of the transfer keys

X,Y,Z.

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Active digital position readout unit, cont'd

Tool radius compensation

The active digital readout unit permits tool radius compen'

sations with the aid of keys (10). This requires the input

of the cufter diameter.

Proceed in the following order:

- Use keyboard ( l) to key cutter diameter into setpoint

readout (5).

- Operate t.v E (10) : the control will calculate the cut-

ter radius. This will then appear in setpoint readout (5)

and will be stored automatically.

- Key in setpoint on keYboard (l).

- Operate either E key {10) to add cutter radius or p( I 0) to subtract cutter radius from setpoint value (5).

- When operating tool compensation keys twice, the full

diameter will be either added or subtracted, for example

for machining the opposite wall of a pocket.

- Transfer to actual-value counters and automatic position'

ing as described above.

Fault diagnosis

ln the event of faults or defects, the active digital readout

unit will automatically give diagnosis readouts.

- Measuring system defective:

associated actual-value counter will start flashing. To

cancel diagnosis readout, switch off power supply,

remedy fault and restart the unit-

- Defect in electronics:

LEDs above reference point keys will light up.

To cancel diagnosis readout, switch off power supply.

lf fault diagnosis reappears after switching off and on

again, return digital readout unit for repair (state LEDs

lighting up).

- Positioning error:if feed control lever is moved in wrong direction for a

selected positioning operation. the feed motion will be

switched off after 200 pm. Actual-readout (7) will show

'u'symbols.

To cancel diagnosis readout, operate E4 t.v, then rnove

feed control lever in correct direction.

CautionNever remove or insert plugs while unit is energized.

Additional setup and maintenanpe instructions, as well as

examples of operating the unit, will be found in the oper'

ator's manual supplied with the digital position readout

unit.

Printed in the Fedaral Republic of Germany

1211 Fig 1

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E 9o2a ( 1 2.81 )

\ctive digital position readout unit

Electronic linear measuring and positioning system for

automatic slide motions to preselected positions in absolute

and incremental (chain) dimensions.

Def inition of 4 reference points; storage of tool compensa-

tions; meiric inch conversion.

Technical data

Numberof digits ........7Resolution (selectable) . . 0.01/0.005 mm

swirchableto... 0.0005/0.0002inch

,denti{ication of controls

1 lnput k

E,oval ues

Decimal point key

Sign input key(plus sign will not appear in readout)

Cancelling key for setpoint values orerror indications

eyboard

E Numerical keys for preset or setpoint

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Fig 1

Switching on

Switch on machine (main disconnect switch) and digital

readout unit (switch on rear side of housing).

At f irst all LEDs and readouts will light up (lamp test).

Setpoint readout: 88888888

Actual-value readout + 18888888

After approx 1.5 sec the actual-value readouts (counters)

will show the position values assigned to the reference

marks by def ining the reference point [] before the unit

was switched off.

(All scales are provided with a reference mark in addition

to the scale divisions.l

- The readouts will count in the measuring system (mm or

inch) last used. lf required, operate 'inch' key (1 1 )-

- Check resolution (smallest increment shown) in active-

value readouts (71. operatinS key (12) if required.

Move past reference marks if reference points are to be set

reproducibly or previously set reference points are to be

reproduced after switching the readout unit off and later

on again (for details see below).

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2 Command keYs

tr tr tr Transfer keys with LEDs (4) 'Positioninsin progress'

3 Mode-of-operation keys

m Manual positioning mode

r'.' Automatic positioning modeE=J 'Absolute dimensions'

trl Automatic positioning mode

' I ncremental (chain) dimensions'

@} Feed activationKey to activate feed buttons onoperator control panel in 'manual'mode.

4 LEDs 'Positioning in progress'

5 Setpoint readout (preset)

6 Reference point key

7 Actual value readouts for X, Y, Z

8 Reference point selection keys

9 Reference point LEDs lor X, Y , Z

10 Tool compensation keys

1 1 Metric/inch conversion key

l2 Resolution selector key 0.01/0.005 mm or0.0005"/0.0002"

- Stop key for interruption of positioning operation.

E 902 (12.81)

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I 3 Mode-ofoperation switch

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Ea E Numerical keysforpresetorsetpointvalues

Active digital position readout unit

Electronic linear measuring system with positioning and

'Memof ix' unit for automatic slide motions to preselected

positions by absolute and incremental measuring methods'

Tectrnical data

Numberof digits ...""' 7

Snrallestdigital increment (resolution) .' - . . . O'O05mm

Positioning accurdcY t 0.005 mm

Operatingvoltage(selectable) .... 115V|22OV

ldentif ication of controls

1 lnput keyboard

Sign input key(plus sign will not appear in readout)

Decimal point key(appearing automatically after 4th digit)

2 Command keYs

Transfer keys for X, Y , Z axes(used for transferring preset values fromreaout 5 to axis readouts 7; associated LED

illuminated)

Cancelling key for preset or setpoint values

Axis LEDs for X, Y, Z (showing axis activated)

Referecne mark LEDs for X. Y, Z axes

Operation

The digital readout unit is energized together with thennchine by means of the main disconnect switch on thecontrol cabinet. The unit is ready for operation when axisreadout 7 lights up.

Preset {5}

lnput keyboard 1 serves to set any desired value on preset

readout 5. Use @ key for zeroing preset readout 5. Topreset - 234.565 proceed in the following order:

+2+3-4-.*5+6-+5-->-.Tfre fl key will alternatively make the preset value posi-

tive and negative (plus sign will not be shown).Operate one of the lransfer buttons 2 (X, Y or Zl to trans-fer the preset value to the respecitve axis readout 7: the as-

sociated LED 8 will light up.

FP3LV FP3

Using the 'Memofix'feature {6)

The measuring system will operate in the incremental mode:

any workpiece datum point within the entire working range

of the machine can be selected as a zero point.

However, in the event of a power failure or when the main

disconnect switch is switched off , the actualvalues indicated

in the counters as well as the datum point will be lost.

The scales of the measuring system are provided with ref-

erence marks. ln coniunction with the 'Memof ix'featurethese reference marks will permit rapid ref inding of a

selected datum point.

Positions of reference points (R)

Readout unit

FE2

Position 'A'of system reference point 'R'as measured

from zero point'0'of machine axes (approx mm) :

A FPI F?2 FP3 FP3L FP3LV

X Longitudonal 35pas 1 5/365 151465 52 42

Tranwerse 35/1 35- 12 12 12 12

z Vertical 3s/335 37 37 37 37

' Manual positioning only ( | I

The starting point '0' will always be on the side of the coarse

scale zero point.

(t/ 'Manual' (position readout

mode)

g' Automatic Positioning in+- 'absolute dimensions'

F Automatic Positioning in+-' incrementa I d imensions'

LED'positioning operation initiated'Preset or setpoint value readout'Memofix'switchActual value readout for X, Y, Z axes

(not forY axison FPl)

45

67

8

9

III

E 678a (s.80)

Fis 1

Workpiece

FP3 FP3LV

Active digital position readout unit' cont'd

Using the'Memofix' feature

Determining the datum point and measuring its distance

from the system reference Point

- Set mode-of-operation switch 3 to'Manual"

- Move to (or determine) workpiece datum point B (edge'

scribed line or bore). Repeat this procedure for other

machine axes if required.

- Set preset readout 5 to zero and transfer zero to axis

readout 7.

- Set 'Memof ix' switch 6 to 'red''Move machine slide in this axis to system reference

point: when reference mark 'R' is passed, LED 9 will

light up and counter will stop.

Note down the value indicated (distance R/B) with

sign.

Set'Memofix' switch 6 to 'green"

Move past reference mark R again towards workpiece

datum point: LED 9 will go out, counter 7 will start

counting as from R (with the value at which counter

previously stopped) and will thus show the absolute

dimension.

Refinding a workpiece datum point B

(if lost by switching off machine or by power failure)

Set mode-of-operation switch 3 to 'Manual"

Set 'Memof ix' switch 6 to 'red'.

Move past system reference point in the axis con'

cerned: LED 9 will light uP.

Set previously noted-down value with sign on preset

counter 5 and transfer to axis counter 7'

Set'Memof ix' switch to 'green''

- Move past system reference point again (see above)'

Counter 7 will start at R from the preset value and thus

indicate the absolute dimension'

The machine will now be ready for manual positioning'

lf automatic positioning is to be used, f irst proceed as

follows:

- move machine axis to workpiece datum point (axis

readout 7 = Ol;

- set preset readout 5 to zero.

Fig 1

As an alternative to the above procedure. the machine slide

can also be moved to the datum point by partially automat-ic operation:

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Set mode-of-operation switch 3 to 'Manual'.

Set'Memof ix' switch to 'red'.Move past system reference Point.Set previously noted-down value with sign on

axis counter 7 via preset.

Set 'Memof ix' switch to 'green'.

same as

above

Set preset counter 5 to zero. set 'minus'sign (only ifreference point position is at beginning of axis).Move a few mm beyond reference point by hand.

Set mode-of-operation switch 3 to 'Absolute dimension'.

Operate axis transfer key 2 {readout will remain in

stopped condition).Upon engaging the respective control lever (feed but'ton on control panel depressed), machine slide willautomatically move to B = 0.

lmportantAlways set all feed control levers to neutral before

operating mode-of-operation selector 3 or any oftransfer keys 2 in X, Y, Z axes.

E 678a (5.80)

Active digital position readout unit, cont'd

Positioning in the 3 modes of operation

First determine workpiece datum point with or withoutusing the 'Memof ix'feature.

Positioning by absolute or incremental (chain) dimensions

is possible only if both feed buttons on the control panel

are in depressed condition.

'lVlanual' mode of operation

- Move and position machine slides by manual or power

feed to digital indication {referred to workpiece datumpoint or system reference Point).

Automatic positioning in'Absolute' mode(selected axis will move to keyed'in position value)

- Set modeofoperation switch 3 to 'Absolute dimension'.

- Set desired value (distance between setpoint position

and datum point) with sign on preset counter 5 by means

of input keys.

- Set desired feed rate on operator control panel.

- Engage the required feed control lever in the direction

shown on the external axis and direction indicator (Fig

2) to start the positioning operation: the machine slide

will start moving and stop when the preset setpoint has

been reached.

Automatic positioning in'lncremental' mode(selected axis will move from actual position by the value

keyed-in; new position will be indicated)

- Set mode-of-operation switch 3 to 'lncremental dimen-

sio n'.

- Proceed as under'Absolute dimension': transfer desired

value (= chain dimension) with sign to the respective

@unter 7 by means of input keys via preset.

- Engage the respective feed control lever: the machine

slide in the selected axis will move to the 1st setpointposition.

- Subsequently, either the same or a new chain dimension

ialue (input via preset) can be used to move to the nextsetpoint position by operating the associated transferkei'2.

Axis readout 7 will in all cases show the distance betweenthe aauai position and the workpiece datum point.

FP3LV

5

Axis and direqtion indicator

The external axis and direction indicator (Fig 2) is con-

nected in parallel with the digi-tal readout unit. lt shows theoperator the selected directionof feed and thus indicates whichfeed control lever has to be

moved in what direction.

lf the feed control lever of the activated axis is moved in

the wrong direction or if the wrong control lever is operated,

the feed drive will stop after a very short movement ofmax 0.2 mm. Subsequently, however, the required control

lever can immediately be moved in the c.orrect direction

without any additional correction and without any loss in

accuracy.

Rear side of readout unit (Fig 3)

10 Measuring system inputs for X, Y, Z axes

11 Connector for power supply cable

12 Voltage selector 22V/115V13 Power fuse - 220 V: 0.2 A slow/'l 15 V: 0.4 A slow

14 Control line connector

Fig 3

ln the event of trouble (except for blown fuse) inform

Deckel Technical Service or nearest Deckel agency'

CAUTON Watch for correct pow€r supply voltage. Never connect

or disconnoct cables while system is energized.

FP3

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E 678b {5.80)

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Digital position readout unit with mm/inch converterPhotoelectric linear measuring system for 3 axes withMEMOFIX unit.

Technical dataMeasuring ranges depending on traversing ranges of machine

slides. Model VRZ771 (bidirectional counter)

Number of digits 6 (mm)/7 (inch)

Resolution .:.... .'. 0.01mm/0.0005"Operating voltage, selectable 115 V /22O V ac

ldentification of readouts and controls (Fiq l)1, 2, 3 = counters for X, Y, Z axes

4. 5, 6 = LEDs for reference point indication in X, Y, Z

preset indication (readout of keyed-in values)

preset keyboard (setting of reference values)

lTl Numerical keys for setting the.desired refer-ence value.

Sign key for setting positive or negative refer-ence value.

Cancelling key for preset indication: '0'willappear when this key is depressed (correc-

tion facility).

El Transfer keys for transferring preset value tocounters.Decimal point key.

MEMOFIX switchmm/inch selector (toggle switch)This switch serves to convert the metric meas-

uring signals in such a way that either mm orinch values are indicated. lt should be noted,however, that a metric value already shown can-

not be directly converted by means of control10: upon preselecting mm or inch indicationfirst set the readout to zero and then proceed inthe usual manner.

Er€ctrrcal connection:- e ranning heads are connected to the readout unit by-':eans of plug connectors. Power supply through connectingcable from control cabinet.The measurirg system will be operative upon switching-onthe main disconnect switch of the machine and the powerswitch on the readout unit.I n the event of malfunctions check power fuse and replaceif defective. lf other trouble occurs consult the manufac-turer's operating i nstructions.

ution: watch for correct power supply voltage; nevsr connect ordisconoect cables while rynem is energized.

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Presetting a reference value

Set selector 10 for either mm or inch indication.The preset unit permits the input of predetermined reference

values in mm or inches by means of the preset keys and thetransfer of such values to the counters.Example (mm): desired value - 12.34 (mm)

Operate keys in this order: -+ 1 --> )+ ' -+ J + Q

Example (inch): desired value - 1.2345 (inch)

Operate keys this order: --+ 1 -+''+ 2 + 3 + 4 + 5

The first numeral will appear at the first left-hand digit ofthe preset indication, all other numerals will follow to the

right.

IMPORTANTThe unit permits the input of max 6 digits for mm readings

and 7 digits for inch readings. The decimal point will appear

automatically after the fourth digit (mm) or the third digit(inch). After the decimal point, only 2 numerals can be

keyed-in for mm readings and 4 for inch readings.

Upon pressing the transfer button X, Y or Z, the preset

value will be transferred to the respective counter.

ln the inch position of selector 10, the last digit will onlyshow either '0' or '5'.

lndication when passing zero point:

inch

- 000. 0015

-000. 0010

- 000. 0005000. 0000000. 0005000. 0010000. 0015

9l0

mm

- 0000. 03

- 0000. 02

- 0000. 01

0000. 000000. 01

0000. 020000. 03

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E 366c {5:AO)

I

Reference point and MEMOFIXWhen the counter is switched off, all stored values will be

lost. For this reason, and to permit in-process checks, thegratings are provided with at least one reference mark (fixed

reference point). The MEMOFIX feature permits fast and

very simple measuring of the distance between the referencepoints and workpiece datum point: the reference point is

merely passed over at rapid rate and no tedious searching

is required. lf the rqading of the counter is noted down, the

value can again be keyed into the preset indication after a

power failure and then, at the reference point, be trans'ferred to the counter. Renewed setting of the workpiecedatum point will thus be avoided.

Positions of reference points

0 = axis end point Fig 2

Position A or reference point R as measured from zeropoint 0 of machine axis (in mm) :

MEMOFIX Switch 9 (Fig 3)

The switch has two positions {red and greenl.

Red counter will stop when machine slide moves past

reference mark for the first time and will remain

stopped when slide moves past reference mark

again.

counter will be restarted when slide moves past

reference mark again.

s/

Working with MEMOFIX (Fig 3lDetermining the workpiece datum point B (zero point)

- Move to workpiece datum point (edge or bore). Set

counter to zero (button C and transfer keys! or key-inother desired reference value by means of preset feature.

- Set MEMOFIX suritch to'red'.- Move past reference point R (reference LED will light

up), note down counter readout with sign (= distancebetween R and zero).

- Set MEMOFIX switch to'green'.

- Move past reference point again (reference LED will go

out): counter will now indicate distances from selected

reference point.

Refinding the workpiece datum point

- Set MEMOFIX switch to'red'.- Move beyond reference point (reference LED will light

up)'

- Use preset feature to set previously noted-down value

with sign (distance between R and zero point) in each

axis and transfer to counter(s).

- Set MEMOFIX switch to'green'.

- Again move past reference point (as above) : at the refer-ence point, the counter will start counting with the preset

value and indicate the correct position relative to theworkpiece datum point.

Rear side of readout unit (Fig 4)

13114/15 Measuring system input for XN /Z axes

16 Connector for power supply cable17 Power fuse - 22O Y: O.2 A/115 V: 0.4 A18 Voltage selector 22OV/1'l 5V ac

19 Power switch20 Dimmer switch (bright or dim indication)

Fig 4

ln the event of trouble (except for blown fuse) inform

Technical Service of supplier. lf required, remove readout

unit, pack carefully and return for overhaul.

I Keep ropes clear of readout unit when transporting the

I machine.

Green =

20

19

18

17

16

10

Ref erence point indication 4 (5, 6) (Fig 1 and 3)Lighting-up indicates the stop condition of the counter. TheLED goes out lvhen the counter is restarted by the slide

moving past the reference point in 'green' position; it re-

mains in extinguished condition when the counter is

switched off and then on again (counter start, eg after error).

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A FP1 FP2 FP3 FP3L FP3LV FP4

Lo ng i-t udinal

35285

35385

35485 52 42 35

ffi5Tra ns-verse

35135

12 13 t3 r3 35385

Verti-cal

35335 38 38 34 36 35

435

E 366c (1.8O)