P1 ELECTRONIC AMPLIFIER FOR

IN-PROCESS APPLICATIONS

Instruction Manual
Manual code No. D2950000UC
 12

2 P1D2950000UC
Figure 1. P1 electronic unit

Front panel
1. Readout meter with automatic scale change
2. Led for millesimal scale
3. Led for centesimal scale
4. Mechanical adjustment of meter
5. Function selector
6. Cycle leds
7. Led indicating end of delay
8. Adjustment pushbuttons

P1 3
 12

CE
This product is in conformity with the EMC requirements as for the directives
89/336/CEE dated 03.05.1989
92/31/CEE dated 28.04.1992
93/68/CEE dated 22.07.1993
This product is intended to operate in industrial locations; it is not intended for connections
to a public mains network but is intended to be connected to a power network supplied from
a high or medium voltage transformer.

Manufacturer: Marposs S.p.A.

Address: Via Saliceto 13, Bentivoglio (BO) Italy
http//www.marposs.com

Manual code no: D2950000UC

Issue: June 1999
Edition: 01 / January 2000
Dept.: UTD CSM

MARPOSS S.p.A. does not take on the obligation of notifying possible further changes to the
product.
The descriptions reported in this book do not authorize any tampering by non-authorized
personnel.
The warranty on the equipments will decay if such tampering is found.

© Copyright Marposs S.p.A.2000

4 P1D2950000UC
Preface
The content of this manual concerns all the configurations of P1, therefore only the
sections relevant to the specific application must be consulted.
The configuration of your P1 electronic amplifier is determined based both on code
no. (reported on the plate found on the rear panel) and on coding plan.

Coding plan of P1

Code no.: 8 8 3 H 0 M R F S P
Description Code
“H” Hardware composition
- without casing 0
- with casing 1
“M” measurement type
- measurement with 1 transducer (+ sign) 0
- measurement with 1 transducer (– sign) 1
- measurement with 2 transducers (+T1, +T2) 2
- measurement with 2 transducers (-T1, -T2) 3
- measurement with 2 transducers (+T1, -T2) 4
- measurement with 2 transducers (-T1, +T2) 5
“R” 0
“F” adjustment range of zero-setting potentiometer
- +/- 500 micron (+/- .020”)
- +/- 100 micron (+/- .004”) 1
2
“S” types of meter scale
- scale in metric, white 0
- scale in metric, yellow 1
- scale in metric/inches, white 2
- scale in metric/inches, yellow 3
- scale in inches, white 4
“P” 0

P1 5
 12

Table of contents
1. Specifications and general warnings.............................................................. 8
1.1 Premise....................................................................................................... 8
1.2 Final test and warranty................................................................................ 8
1.3 General safety specifications ...................................................................... 8
2. Installation of electronic unit ........................................................................... 9
2.1 Fastening the electronic unit ....................................................................... 9
2.1.1 Fastening the tilting stand ................................................................... 9
2.1.2 Wall-mounting ................................................................................... 10
2.1.3 Fastening with support bracket ......................................................... 11
2.2 Connections of electronic unit ................................................................... 12
2.2.1 General connections (rear view) ....................................................... 12
2.2.2 Connection to supply voltage ............................................................ 13
2.2.3 Connection to ground........................................................................ 13
2.2.4 Connection to machine logic unit (Inputs/Outputs)............................ 14
3. Installation of measuring head and accessories ......................................... 16
3.1 Definition of mechanical parts ................................................................... 16
3.2 Connections .............................................................................................. 16
3.2.1 Measuring head ................................................................................ 16
3.2.2 Carriage ............................................................................................ 16
3.3 Positioning of measuring head in machine................................................ 17
3.3.1 Vertical adjustment............................................................................ 17
3.3.2 Horizontal adjustment ....................................................................... 17
4. Use of electronic unit ..................................................................................... 18
4.1 Front panel................................................................................................ 18
4.2 Setting the controls trigger point ( , , )........................................ 19
4.3 Setting the delay time (τ)........................................................................... 20
4.4 Setting the zero correction value (Adj) ...................................................... 20
5. Zero-setting ..................................................................................................... 21
5.1 Zero-setting procedure.............................................................................. 21
5.2 Preparation for zero-setting....................................................................... 21
5.3 Mechanical zero-setting of measuring head.............................................. 21
5.3.1 Zero-setting with screw-guides or pawls ........................................... 22
5.3.2 Rapid zero-setting with locking lever................................................. 23
6. Diagnostics at switching on........................................................................... 24

6 P1D2950000UC
List of illustrations
Figure 1. P1 electronic unit........................................................................................ 3
Figure 2. Overall dimensions with casing and tilting stand.......................................... 9
Figure 3. Drilling for wall-mounting............................................................................ 10
Figure 4. Overall dimensions of the wall-mounted version........................................ 10
Figure 5. Fastening with support bracket 1502010400 ............................................. 11
Figure 6. Connections of the electronic unit (rear view) ............................................ 12
Figure 7. I/O connection diagram (optoinsulated inputs and outputs) ....................... 14
Figure 8. Vertical adjustment of measuring head...................................................... 17
Figure 9. Horizontal adjustment of measuring head.................................................. 17
Figure 10 . Zero-setting with screw-guides or pawls ................................................. 22
Figure 11 . Rapid zero-setting with locking lever ...................................................... 23

P1 7
 12

1. Specifications and general warnings

1.1 Premise
This instruction manual supplies all the specific information necessary to know and
correctly use your Marposs equipment.
The descriptions reported in this manual are aimed to the following personnel:
- MARPOSS personnel or Customer's personnel who has to install the equipment.
- Customer's technicians who directly operate the MARPOSS equipment.
- Customer's technicians who are responsible of the maintenance of the production
line where the MARPOSS equipment is installed.

Beware
The technical service or extraordinary maintenance interventions
must be performed by authorized personnel only.

ALL RIGHTS ARE RESERVED. THIS MANUAL IS INTENDED FOR CUSTOMER'S INTERNAL USE
ONLY. ANY OTHER USE IS FORBIDDEN.

1.2 Final test and warranty

The defects of the materials are covered by the warranty with the following limitations:
- DURATION OF THE WARRANTY: the warranty covers all repairs made within the
agreed terms.
- OBJECT OF THE WARRANTY: the warranty is applied to the product and to its
parts marked with serial number or other identification number used by
MARPOSS.
The above mentioned warranty has to be considered valid, unless of different
agreements between MARPOSS and the Customer.
1.3 General safety specifications
The equipment has been manufactured in conformity with CEI EN60950
specifications.

8 P1D2950000UC
 2. Installation of electronic unit

2. Installation of electronic unit

BEWARE
When installing the electronic unit, it is necessary to respect some
basic safety rules:
• The parts of the gauging system (electronic unit, measuring head, connection
cables) must be accessible and positioned so as not to hinder the correct
operation of the machine tool and the movements of the operator.
• The connection of the earth wire of the gauging system and that of the machine
tool must be made at the same point.
• The operations relevant to the electric connections of the electronic unit must be
carried out supplying the correct voltages, as indicated in this book.
2.1 Fastening the electronic unit
2.1.1 Fastening the tilting stand

2 bores for fastening

screws M5, center
distance 248 mm.

The maximum rear dimensions, due to the measuring head connector, depend on the type of
measuring head used.

Figure 2. Overall dimensions with casing and tilting stand

P1 9
 12

2.1.2 Wall-mounting
The unit is fastened to wall through four pins M3x12 with 120x120 mm center
distance.

Figure 3. Drilling for wall-mounting

The maximum rear dimensions, due to the measuring head connector, depend on the type of
measuring head used.

Figure 4. Overall dimensions of the wall-mounted version

10 P1D2950000UC
 2. Installation of electronic unit

2.1.3 Fastening with support bracket

Fasten the bracket with four screws M6.
Remove the two screws A (M5x10) and fasten the P1 to the support bracket.

4 bores ø 6.5

Figure 5. Fastening with support bracket 1502010400

P1 11
 12

2.2 Connections of electronic unit

2.2.1 General connections (rear view)

A
B

D
E

I/O W1

Figure 6. Connections of the electronic unit (rear view)

A Identification plate (code and serial number) of the electronic amplifier

B Plate with supply data (values of supply voltage and fuse)
C Power-on switch
D Fuse on supply voltage.
E Connector for connection to supply voltage.
I/O Cannon I/O 25-pole male connector. Connection to machine logic unit
(Inputs/Outputs). See paragraph 2.2.4 on page 14.
W1 10-pole male connector. Connection of measuring head. If the measuring
head has two transducers and two connectors, the special Y-shaped
connection cable is used.

Terminal (type M4) for grounding connection.

12 P1D2950000UC
 2. Installation of electronic unit

2.2.2 Connection to supply voltage

P1 is provided with automatic change of voltage that allows a connection to supply
voltage according to the following specifications:

Supply voltage 100V -10% – 240V +5%

Max. input current 0.2 A
Frequency 50 – 60 Hz
Fuse 1A 250V 5x20 Slow-blow

a) Power-on switch (C) in position “O”.

b) Connect the free end of the power-supply cable (supplied with the unit) to
network.
c) Plug the power-supply connector into socket (E).
d) Switch the equipment on by setting the switch (C) to position ”I”.

2.2.3 Connection to ground

Connect terminal (type M4) to the machine ground center terminal.

Nut M4

Cable terminal

Yellow/green cable
Terminal Section 2.5 mm²

P1 13
 12

2.2.4 Connection to machine logic unit (Inputs/Outputs)

The interface with the machine logic unit can indifferently be of the Source type
(source at output - sink at input) or Sink type (sink at output - source at input).

Machine side

Input common
-Vee(Source);+Vcc(Sink)
Start Cycle

Output Common

Delay End
Automatic

OUTPUTS
rd
3 Control
nd
2 Control
st
1 Control
th
0 Control

25-pin wander connector code 6134286100

Figure 7. I/O connection diagram (optoinsulated inputs and outputs)

External supply of machine I/O circuits

(+24Vext – Gnd24) : 24Vdc (-15/+20)%

14 P1D2950000UC
 2. Installation of electronic unit

Technical data of output circuits:

• Operating voltage: 24Vdc (-15/+20)%
• Current for each output: 10 mA
• Max. short-circuit duration: 0.5 sec.

OPTOINSULATED INPUTS
The input circuits must be controlled by supplying the voltage necessary between pin
13 (input common) and every single pin used, through a microswitch or other
equivalent systems.
Pin 13 Input common: -Vee (Source); +Vcc (Sink)
Pin 12 Connection terminal relevant to the Start Cycle signal. When voltage is cut
out, the gauging system is enabled for the machining cycle.

OPTOINSULATED OUTPUTS
The output signals are taken by connecting the external loads (relays or other
compatible inputs) between a phase of the supply voltage and every single pin used.
The other phase must be connected to pin 9 (output common).
Pin 9 Output common: -Vee (Sink); +Vcc (Source)
Pin 7 Connection terminal relevant to the signal of “delay time (τ)” end. This signal
can be used to enable the solenoid valve, if any, used for pneumatic
retraction of the measuring head.
Pin 6 Connection terminal relevant the Automatic signal
Pin 4 Connection terminal relevant to the third control
Pin 3 Connection terminal relevant to the second control.
Pin 2 Connection terminal relevant to the first control.
Pin 1 Connection terminal relevant to zero control (final dimension).

P1 15
 12

3. Installation of measuring head and accessories

3.1 Definition of mechanical parts
A. Measuring head
It detects the actual dimensions of the workpiece and converts them into electric
signals which are sent to the electronic unit through a connection cable.
B. Support
It is used to fasten the measuring head on the machine tool or on a carriage. It
can be equipped with horizontal and/or vertical adjustment for a correct
positioning of the measuring head.
C. Carriage
It is used to bring the measuring head to measuring position.

3.2 Connections
3.2.1 Measuring head
A. Connection cables
Connect the cable of the measuring head to the electronic unit as indicated in
paragraph 2.2.1 “General connections (rear view)” on page 12.

BEWARE
While installing the measuring head connection cable, which is usually
subject to systematic movements, make sure that the minimum bending
radius of the cable is not lower than the following: minimum bending
radius = cable diameter x 15

B. Pneumatic retraction
Some types of measuring head can be provided with pneumatic retraction which
is controlled through the air supply plant of the machine tool.

3.2.2 Carriage
The carriage must be suitably controlled by the hydraulic or pneumatic system of the
machine tool. The function of the two fittings (forward or backward shift) is determined
by experience.

16 P1D2950000UC
 3. Installation of measuring head and accessories

3.3 Positioning of measuring head in machine

3.3.1 Vertical adjustment
Position the measuring head in order to allow the execution of mechanical zero-
setting on the contacts.
So in some cases a support with vertical adjustment of position is indispensable. Act
as follows:
a) loosen screws 1 and 2
b) act on screw 3 to bring the
measuring head to a position
that allows to carry out the
zero-setting
c) tighten screws 1 and 2.

Figure 8. Vertical adjustment of measuring head

3.3.2 Horizontal adjustment

The measuring heads must be positioned so that the contacts (or contact) detect the
diameter (or radius) of the workpiece; for this reason a dovetail-support with
horizontal adjustment is provided.
a) loosen screws 1 and 2
b) act on screw 3 to bring the contacts (or contact) approximately on the diameter
c) tighten screws 1 and 2
d) zero-set the gauging system (see 5.3 “Mechanical zero-setting of measuring
head” on page 21).
e) loosen screws 1 and 2
f) act on screw 3 making the
meter read the maximum
value
g) tighten screws 1 and 2
h) if the measurement
displacement is excessive,
repeat the zero-setting
operations
3 1 2
Figure 9. Horizontal adjustment of measuring head

P1 17
 12

4. Use of electronic unit

4.1 Front panel
References in Figure 1.
1 Readout meter with automatic change of centesimal/millesimal scale: it displays
the difference between the actual measurement and the final value you want to
obtain.
The scale can be in metric, or inches or double (metric/inches):
- scale in metric (centesimal: 500-0-100; millesimal: 50-0-10)
- scale in inches (centesimal: 20-0-4; millesimal: 2-0-0.4)
- scale in metric/inch. (centesimal: 500-0-100/20-0-4; millesimal: 50-0-10/2-0-
0.4)
2 Led on with millesimal scale (the value read is real)
3 Led on with centesimal scale (the value read must be multiplied by 10).
4 Adjustment of readout meter mechanical zero.
If when the equipment is the meter needle is not exactly on zero, act on the
screw under cap “4”. This operation must always be performed with the
equipment switched off.
5 Function selector:
• positions , , : display / setting of zero correction value
• position τ : display / setting of “delay time ”
• positions 1, 2, 1+2 : selection of contacts for zero-setting execution
- position 1: 1-contact measurement or first contact with 2-contact
measurement
- position 2: second contact with 2-contact measurement
- position 1+2: sum of the two contacts (2-contact measurement)
• position Adj : display / setting of zero correction value
• position : electronic amplifier in Automatic; the control signals are
supplied at output. During the normal operation, the selector must be in this
position.
6 Control leds. They light up to indicate that the relevant control has triggered.
rd
- 3 control
nd
- 2 control
st
- 1 control
- zero control (final dimension)
7 “Start Cycle” Led. Lit on when the head is at home position. It lights off to indicate
the starting of time delay with subsequent machining cycle.
8 Pushbuttons with leds for zero adjustment.

18 P1D2950000UC
 4. Use of electronic unit

The adjustment range

+/- 100 µm Æ resolution 0.2 µm (+/- .004” Æ resolution .00001”)
or
+/- 500 µm Æ resolution 1 µm (+/- .020” Æ resolution .00005”)
depends on the configuration of the electronic unit (see “Coding plan of P1 ” on
page 5).
Zero adjustment can be obtained in two ways:
- by steps: when the pushbutton is pressed there is an increase (+) or
decrease (-) of the needle position corresponding to the resolution value
- continuous: by holding the button pressed the needle position is continuously
increased (+) or decreased (-) for a rapid zero adjustment.
The led corresponding to the button just pressed flashes to indicate that the value
is being changed; otherwise if the led lights up steadily it means that the end of
the adjustment range has been reached.
Press the two pushbuttons simultaneously to move to the center of the
adjustment range.

4.2 Setting the controls trigger point ( , , )

References in Figure 1.
a) Set selector 5 to position , , corresponding to the control to be set.

b) By means of pushbuttons bring the needle of the readout meter to the

desired value
The controls that can be set are:
rd
- position : 3 control – range 0 to +500 µm - resolution 2 µm (0 to .020”
resolution .00010”)
nd
- position : 2 control – range 0 to +500 µm - resolution 2 µm (0 to .020”
resolution .00010”)
st
- position 1 control – range 0 to +250 µm - resolution 1 µm (0 to .010”
:
resolution .00005”)
The control relevant to the final dimension (zero control) is pre-set to zero.

Press simultaneously the pushbuttons to reset the value of selected

control.

P1 19
 12

4.3 Setting the delay time (τ)

References in Figure 1.
Setting of delay time between the Start Cycle of machining and the enabling of
gauging system (controls enabling).
The delay time can be set on the readout meter from 0 to 50 seconds (resolution 0.5
seconds).

a) Set selector 5 to position τ.

b) By means of pushbuttons bring the needle of the readout meter to the

desired value.

Press simultaneously the pushbuttons to reset the value of delay time.

4.4 Setting the zero correction value (Adj)

References in Figure 1.
The value of the measurement zero correction can be set on the readout meter within
the range +/-100µm (+/-.004”) or +/-500µm (+/-.020”) based on the configuration of
the electronic unit (see “Coding plan of P1 ” on page 5).
a) Set selector 5 to position Adj.

b) By means of pushbuttons bring the needle of the readout meter to the

desired value.

Press pushbuttons simultaneously to reset the correction.

20 P1D2950000UC
 5. Zero-setting

5. Zero-setting
5.1 Zero-setting procedure
This chapter contains a description of the operations to be performed on the
electronic amplifier and on the measuring head in order to zero-set the gauging
system.
Act with particular care in order to obtain the accuracy and repeatability results
guaranteed by the gauging system.
5.2 Preparation for zero-setting
a) Prepare both the electronic amplifier and the machine tool for zero-setting:

• Simultaneously press pushbuttons for zero adjustment (reference 8

in Figure 1) to move to the central position of the zero adjustment range.
• Place in machine the master gauge used for zero-setting.
b) Zero-set the gauging system by acting on the measuring head and on the
electronic amplifier as indicated in paragraph 5.3 “Mechanical zero-setting of
measuring head” on page 21).

5.3 Mechanical zero-setting of measuring head

The measuring heads is zero-set by means of particular mechanical elements that
will be examined in detail in the next paragraphs. Consider only the description
relevant to the specific application.
- Zero-setting with screw-guides or pawls (chapter 5.3.1 on page 22).
- Rapid zero-setting with locking lever (paragraph 5.3.2 on page 23).

P1 21
 12

5.3.1 Zero-setting with screw-guides or pawls

References in Figure 1 and in Figure 10.
a) Bring the head to measuring position.
b) Set selector 5 (Figure 1) to position “1”.
c) Loosen screw 2.
d) Act on screw 1 until the meter reads zero, tighten screw 2.
e) Set selector 5 (Figure 1) to position “2”.
f) Loosen screw 3.
g) Act on screw 4 until the meter reads zero. Tighten screw 3.
h) Set selector 5 (Figure 1) to position “1+2”.

i) If necessary, act on pushbuttons for zero adjustment making the meter

read zero.
Note
In applications with measuring head provided with one contact only, carry out only
operations a), b), c), d) and i) relevant just to contact T1.

A) With pawls

B) with adjustable screw-guides

Figure 10 . Zero-setting with screw-guides or pawls

22 P1D2950000UC
 5. Zero-setting

5.3.2 Rapid zero-setting with locking lever

References in Figure 1 and in Figure 11.
a) Set selector 5 (Figure 1) to position 1+2.
b) Move the locking lever A to SET UP position so the movement of heads T1 and
T2 will be slightly loose.
c) Open the heads so as they can be inserted on the workpiece in safety conditions.
d) Bring the heads to measuring position.
e) Simultaneously press the two little levers B, found on the armsets, and with a
single movement close the heads bringing the contacts onto the master
workpiece.
f) Hold the little levers B pressed and rotate lever A to RUN until the heads are
locked.

g) Bring the needle of the meter exactly to zero by means of pushbuttons

for zero-adjustment (reference 8 in Figure 1)
h) By means of selector 5 (Figure 1)verify that both contacts are within the range of
the readout meter, otherwise repeat the zero-setting phases.

Figure 11 . Rapid zero-setting with locking lever

P1 23
 12

6. Diagnostics at switching on
During P1 switching on, the following internal checks are performed:
1. Test of checksum of EPROM memory
ƒ In case of error the led of pushbutton flashes and the gauge remains
in this status.
Remedy: switch off and then on again. Should the problem persist, ask for
Marposs technical support.
2. Test of RAM memory
ƒ In case of error the led of pushbutton l flashes and the gauge remains
in this status.
Remedy: switch off and then on again. Should the problem persist, ask for
Marposs technical support.
3. Test of checksum of E2PROM memory
ƒ In case of error the led of controls flash simultaneously and the gauge
remains in this status.
Remedy: move the selector 5 (Figure 1) so to define a pre-set programming
compatible with the position of configuration internal jumpers.
Note: This error will surely occur at the first switching on.
4. Consistency test between programming in E2PROM and position of
configuration internal jumpers.
ƒ in case of error (inconsistency between jumpers and stored parameter-
setting) all the LEDs of controls flash sequentially and the gauge remains in
this status.
Remedy: move the selector 5 (Figure 1) so to define a pre-set programming
compatible with the position of internal jumpers
or
switch the gauge off and restore the jumpers position.

**** End of document ****

24 P1D2950000UC
Note
Note
2

Printed in Italy