P5

OPERATOR GUIDE
In-process Application

15/05/02 P5_OperatorGuide.doc
 CE
This product complies with EMC requirements as defined by 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 from a high or medium
voltage transformer.

SAFETY WARNINGS
ƒ Follow the grinder manufacturer’s safety procedures.
ƒ Follow all safety procedures at the gauge system location.
ƒ There are NO Customer serviceable parts inside the P5. Always call technical service

MANUFACTURER: MARPOSS S.p.A.

ADDRESS: Via Saliceto 13, Bentivoglio (BO) Italia
http://www.marposs.com

SYSTEM SOFTWARE: from V3.1 to V3.5

HARDWARE MODEL: _________________

APPLICATION SOFTWARE: _________________

MANUAL CODE NO.: D293xxxxUC

DATE OF ISSUE: May 10, 2002
EDITION: -------------------
ISSUED BY: MARPOSS S.p.A., Via Saliceto 13, Bentivoglio (BO) Italy

Data reported in this book are to be referred to standard system software releases indicated in this page.
In case of application with different software release the relevant manual can be requested to the
nearest Marposs Distributor Office making reference to software code “CMxxxxxxxx” printed on the label
in the electrinic gauge back.

MARPOSS S.p.A. mai change the features and data reported in this booklet in any moment and without
notice, in order to inprove the product.
The descriptions reported in this book do not authorize any tampering by non-authorized personnel.
The warranty on the equipment will decay if such tampering is found.

Print performed from: www.marposs.com

© Copyright 2002
 TABLE OF CONTENTS

1. INTRODUCTION ................................................................................................................1
1.1. Operator Guide .............................................................................................................1
1.2. Conventions..................................................................................................................1
1.2.1. Interface between gauge and user ................................................................................... 1
1.2.2. Operator Guide ................................................................................................................. 1
2. HOW THE GAUGE IS ORGANIZED..................................................................................3
2.1. Operating modes ..........................................................................................................3
2.2. Software structure.........................................................................................................3
2.3. Folders..........................................................................................................................5
2.4. Sub-folders ...................................................................................................................6
2.5. Pages ...........................................................................................................................6
2.6. Menu maps...................................................................................................................7
3. USE ....................................................................................................................................9
3.1. Front panel ...................................................................................................................9
3.1.1. Keys................................................................................................................................ 10
3.1.2. Keypad............................................................................................................................ 11
3.1.3. Combination of keys........................................................................................................ 11
3.1.4. F keys ............................................................................................................................. 12
3.1.5. Defining the HOT keys .................................................................................................... 13
3.1.6. Deleting The HOT keys ................................................................................................... 13
3.2. Getting around the Program .......................................................................................14
3.2.1. Cursor controls................................................................................................................ 14
3.2.2. Hot keys.......................................................................................................................... 15
3.2.3. Defining the HOME key................................................................................................... 15
3.2.4. If you get lost................................................................................................................... 15
3.3. Panel test / View the software version ........................................................................16
4. MAKING CHANGES ........................................................................................................17
4.1. Selecting predefined values........................................................................................17
4.2. Changing Numerical Values .......................................................................................17
4.3. Undoing Changes .......................................................................................................18
5. PART TYPES AND CYCLES...........................................................................................19
5.1. Selecting Part Types and Cycles ................................................................................19
6. GAUGE SYSTEM TROUBLESHOOTING .......................................................................21
6.1. Zero Troubleshooting..................................................................................................21
6.1.1. Cannot Mechanically Zero............................................................................................... 21
6.1.2. Cannot Electrically Zero .................................................................................................. 21
6.1.3. Cannot make Zero Adjustments ...................................................................................... 21
6.1.4. Zeroing page is blank...................................................................................................... 22
6.2. Part Types and Cycles................................................................................................23

P5 – Operator Guide I
II P5 – Operator Guide
1. INTRODUCTION
Gauge computer used to control the grinding cycle. It can be customized to a variety
of applications and measuring heads. The gauge can control and integrate touch
probes and ultrasonic microphones in order to monitor air gap and crash protection.
The gauge processes the signals coming from the measuring head/s and/or the
various sensors and supplies information on the measurement to the machine’s logic
system. There are up to 7 outputs (controls) for changing feed rates and when the
zero size of the workpiece is reached to retract the grinding wheel.
Optional features include TIR, Ovality, Remspeed and Stock Removal.
1.1. Operator Guide
This guide is customized to the grinding machine on which the gauge is installed and
describes its specific measurement application.
This guide was written for the machine operator. It will also be useful for plant
personnel who must perform maintenance and assistance technicians.
This guide describes the following gauge operator functions:
ƒ Selecting part types and cycles.
ƒ Viewing the measurement screens.
ƒ Zeroing the gauge system.
ƒ Correcting the measuring cycle zero.
ƒ Viewing and modifying the grinding cycle controls.
1.2. Conventions
Conventions are standard methods of representing components or functions.
1.2.1. Interface between gauge and user
The gauge software uses graphics and/or icons to show the various functions and
make comprehension and use easy and intuitive.
Other conventions used in this program are:
ƒ Numbers or text inside a dotted line can be changed.
ƒ Icons or text that appear as a phantom image (or grayed out) cannot be selected
on that page or are not available for the application and its options.
1.2.2. Operator Guide
In order to make this guide easy to use, several typographical conventions were
chosen:
ƒ Folders, sub-folders and page names are in Italics.
ƒ Numbers or choices that can be changed are within quotes; i.e. “100 µm".
ƒ Front panel keys or software buttons are shown using the actual icon.
ƒ Section title references within the text are in bold.
ƒ Names of operator functions are followed by their icon.

P5 – Operator Guide 1. Introduction 1

2 1. Introduction P5 – Operator Guide
2. HOW THE GAUGE IS ORGANIZED
2.1. Operating modes
The gauge has two modes of operation – automatic and manual.

MODE ICON FUNCTIONS

Automatic Used during the grinding cycle for:
Monitoring workpiece size.
Viewing the zero values summary.
Viewing the measurement application.
Viewing or changing the control points.
Making zero (size) adjustment.
Manual Used for:
Monitoring workpiece size.
Viewing the zero values summary.
Viewing the measurement application.
Changing the control points.
Making zero (size) adjustment.
Zeroing the gauge system.
Changing damping values for interrupted surfaces.
2.2. Software structure
The gauge Software is divided into folders. Similar functions are grouped into sub-
folders. Related sub-folders are contained in folders. Each matter takes one or more
pages of a sub-folder.
Each page, sub-folder and folder is assigned an icon.
Folders

Sub-folders

Each folder has three sections:

ƒ Icons across the top indicate the folder.
ƒ Sub-folders contained in the folder.
ƒ Messages and information along the bottom.

P5 – Operator Guide 2. How the gauge is organized 3

 Pages

Function
information

Each page has three sections:

ƒ Icons across the top indicate the page.
ƒ Function information in the middle including software buttons.
ƒ Messages and information along the bottom

Message and Information section

1 2 3 4 5 6 7

NAME ICON FUNCTION

Message Either the name of the highlighted icon or button or

1
instructions on which button to press.

Part number Currently selected workpiece number. The

2
software can handle up to 16 different workpieces.

Cycle Currently selected cycle number. The can handle

3
number up to 16 different cycles.

Measurement A graphical representation of the programmed

4 application application. In this case “Single diameter
measurement for external”.

Data display The operator is viewing data

5
Data entry The operator is changing data.

In-process The amplifier is configured for In-process

6
measuring cycles.

Manual
7 Mode
Automatic

4 2. How the gauge is organized P5 – Operator Guide

2.3. Folders
Seven main folders contain all the functions of the gauge.

FOLDER NAME ICON FUNCTION MODE

Viewing Viewing of measurements, zeroing

conditions and application program-
ming.

General Gives access to the pages for zero

Adjustments adjustments and modification of control
points value.

Utilities Gives access to the following

environments:
- measuring head setup (mechanical
zeroing),
- electrical zeroing,
- zero adjustment,
- viewing the controls points,,
- viewing measurement damping for
interrupted surfaces,
- viewing the measurement,
- zeroing summary,
- viewing the programmed data.
Programming Gives access to the environment where
the specific measuring cycle is
parametrized.

Inputs & Outputs Allows to select the I/O’s involved in the

test bit function and gives access to
arm ratio and retraction value
autoacquisition functions (if available).

External Info Allows viewing the current configuration

for the specific application.

Note: The Viewing, General Adjustments and Utilities folders are described in
this Operator Guide. The other folders are described in the “Programming
Manual”.

P5 – Operator Guide 2. How the gauge is organized 5

 The highlighted icon shows the current folder. The message in the lower left
corresponds to the selected icon, in this case, the Utilities folder.
Other folders
Current folder

Name of the
highlighted folder

2.4. Sub-folders
The sub-folders are the second level of the gauge software structure, and contain
pages with similar functions.
Enter
Use or to highlight the sub-folder icon and press to access. The
message in the lower left is the name of the highlighted sub-folder.

Folder icon

Sub-folder

Sub-folder
name

2.5. Pages
The pages are the third levels of the gauge software structure. Each contains a
separate function with information and software buttons to perform that task.
Page icon
Zeroing button
Measuring head
programmed
Digital value of
Retraction measurement
status
Measurement
value on bargraph

In the example above, the page for viewing the measurement is shown. The
measurement is shown as a digital value and on a bargraph. Electrical zeroing can be
done from this page (zeroing button). The measuring head used has retraction, so the
status of that function is also shown.

6 2. How the gauge is organized P5 – Operator Guide

2.6. Menu maps
The arrangement of pages, sub-folders and folders is shown by a menu map. Each
different measurement application and operating mode has its own menu map.
Only the menu map folders with operator functions (Viewing, General Adjustments
and Utilities) are shown in this guide. The specific menu maps are in the section
describing each measuring cycle type.

P5 – Operator Guide 2. How the gauge is organized 7

8 2. How the gauge is organized P5 – Operator Guide
3. USE
3.1. Front panel
The gauge front panel allows the operator to view information about the grinding
cycle. The keypad is used to access the various program pages, to zero the gauge
system, to modify control points of the grinding cycle and adjust damping values for
interrupted surfaces.

Two types of front panel are available:

ƒ standard panel (in local or remote version)
ƒ dedicated panel (in remote version only)
The function of the two panels is similar, they differ just in the keys arrangement.

Standard front panel

F keys Display Manual/Automatic

key

Keypad

Hot key Shift key F keys

menu

P5 – Operator Guide 3. Use 9

 Dedicated front panel
Manual/Automatic Shift key
key Hot key Menu
Keypad

F keys Display F keys

3.1.1. Keys
ICON NAME FUNCTION
The F1 to F6 keys can be used in two ways: as Hot keys
or as Function keys. Hot keys are shortcuts for moving
F keys through the various pages and can be assigned by the
operator using the keypad, see section 3.1.5. Function
keys are predefined to do a one task on a page.
Hot key Displays the Hot keys on the screen and removes them.
menu
Automatic Switches the gauge system between Automatic and
Manual Manual modes.
Key used with other keys (see section 3.1.3 “Combination
Shift Shift
of keys” on page 11 ).

10 3. Use P5 – Operator Guide

3.1.2. Keypad
ICON NAME FUNCTION
Returns the program to the Home page. The Home page
Home can be defined using the keypad, see section 3.2.3
View the software version number at power up and test
? ? the panel (see section 3.3 on page 16).
Move the cursor around the screen.
Arrows

Moves the cursor through data groups on a page. Used

TAB with the Shift key to choose the Part/Cycle, see section
5.1 on page 19.
Moves up one level of the program. During a
Esc programming session cancels all changes made.

Enter
Enters data. Moves down one level of the program.
Enter

Used to decrease data values one digit at a time (with

autorepeat function).
Minus
In case of predefined data, allows scrolling parameters or
icons to view the desired one.
Used to increase data values one digit at a time (with
autorepeat function).
Plus
In case of predefined data, allows scrolling parameters or
icons to view the desired one.

3.1.3. Combination of keys

COMBINATION OF KEYS FUNCTION
In Manual mode enable the Part/Cycle selection.
Shift
+
Upon programming they cancel all the changes made
Shift
+ before confirming.

Shift Enter
Upon programming these key disable/restore (with the
+ last programmed value) the selected data, for the data
allowing for it.

P5 – Operator Guide 3. Use 11

3.1.4. F keys

The to keys on the front panel can be used either as Function keys or Hot
keys.
Note: Function keys have an F number in the upper left corner of the icon.
Function key Hot key
F number

Function keys
Function keys are only available on a specified page. They are predefined to do a
specific task on that page and cannot be changed by the operator.

Function
keys

Note: Function keys are available only after the page is selected.
Enter
To select the page, press .

Hot keys
These are shortcuts to any page of the program and are defined by the operator via
keypad. This allows customization of the gauge system to specific needs or
preferences. Six Hot keys are available in Automatic mode and another six in Manual
mode. For instructions on how to define these keys, see section 3.1.5 on page 13.
Hot keys are available at the folder, sub-folder or page level as shown below. Press

to view the Hot keys currently defined. These are examples of typical hot keys
definitions.

12 3. Use P5 – Operator Guide

 folder

sub-folder

page

3.1.5. Defining the HOT keys

1. Get to the desired page using the menu maps. Highlight the page icon.
2. Press and hold the desired “F#” key until the icon is no longer highlighted, about
5 seconds.
3. Release “F#”, the Hot Key is now defined.
3.1.6. Deleting The HOT keys
1. With the hot key to be deleted, call out the page currently stored.

2. Press to highlight the page icon.

3. Press and hold the desired “F#” key until the icon is no longer highlighted, about
5 seconds.
4. Release “F#”: the Hot Key is deleted.

P5 – Operator Guide 3. Use 13

3.2. Getting around the Program
There are three ways of moving through the program:
1. Using the cursor controls.
2. Shortcuts via the Hot Keys.
3. Home key to the default screen.

3.2.1. Cursor controls

ƒ The and keys move the cursor at the same level between folders,
sub-folders or pages.

ƒ The keys move the cursor around a page.

- or moves the cursor clockwise.

- or moves the cursor counter clockwise.

Enter
ƒ Pressing the key moves the program down one level.

ƒ Pressing the key moves the program up one level.

Enter
ƒ With a folder icon highlighted, press to move to the sub-folder level.
Enter
ƒ With a sub-folder icon highlighted press to move to the page level.
Referring to the appropriate menu map select the path to the desired page.
Example:
Follow these steps to the page for “Viewing the measurement in manual mode”.

1. At the folder or top level of the program, press to highlight the Utilities
folder icon.
Utilities
folder

Enter
2. Press to go to the sub-folder or second level of the program.

3. Press or to highlight the Measure Setup sub-folder icon.

14 3. Use P5 – Operator Guide

 Measure
Setup
sub-folder

Enter
4. Press to go to the page level of the program. Press to highlight the
Enter
View Measure Bargraph icon, if needed. Press to select the page.
View Measure
Bargraph page

3.2.2. Hot keys

To use the shortcuts method of getting around the program:

1. Turn on Hot key menu by pressing .

2. Press the F1 / F6 hot keys associated with the page icon.
3.2.3. Defining the HOME key
The Home key defines a Home Page or default screen. A Home Page is available in
both Manual and Automatic modes. When power is turned on the Manual Home Page
is shown.
The operator defines the Home key:
1. Go to the desired page, see menu maps. The page icon should be highlighted.

2. Press and hold until the icon is not highlighted, about 5 seconds.

3. Release , the Home Page for the current mode is now defined.
3.2.4. If you get lost

ƒ Press .

ƒ Press as many times as needed to reach the folder level of the program.
Then refer to the menu map for the path to the desired page or use a Hot key
shortcut.

P5 – Operator Guide 3. Use 15

3.3. Panel test / View the software version
?
Hold down the key at the system power-on: the following appears:

SOFTWARE VERSION Software version

Firm:3.1 Data:1.3 Text:1.3 (example)

<F1> For keyboard test

<F2> For display test
<Escape> To continue

<F1> Press to test the keypad (follow the directions appearing on display)

<F2> Press to test the display (follow the directions appearing on display).
A sequence of five pages is displayed (three pages in the basic colors
RGB for color display, a black page and a white page for the b/w display)
to carry out a visual check of the display efficiency.

<Escape> Press to continue.

16 3. Use P5 – Operator Guide

4. MAKING CHANGES
The operator can make some changes (e.g. modifying control points value).
Any number or text inside a dotted line can be changed.
4.1. Selecting predefined values
The values that can be given to some parameters are selected from a predefined list
(numerical value or icon).

1. Use or to highlight the desired parameter.

2. Press or to scroll through the values or icons available to the desired

one.
Enter
3. Press to confirm.
4.2. Changing Numerical Values
There are two methods to change a numerical value.
Method 1

1. Use or to highlight the number.

2. Press or to increase or decrease the value.

Enter
3. Press , the number has been changed.
Method 2

Enter
1. Use or to highlight the number and press .

2. Press to highlight the digit that needs changing.

3. Press or to increase or decrease the digit.

4. If more than one digit needs changing, press to highlight the next digit,

then press or to increase or decrease the digit.

Enter
5. Press , the number has been changed.

P5 – Operator Guide 4. Making changes 17

4.3. Undoing Changes
Shift
While holding down press to reset the values.

18 4. Making changes P5 – Operator Guide

5. PART TYPES AND CYCLES
The gauge can store the machining data relevant to different part types and grinding
cycles. There are sixteen part types each one with sixteen cycles available for a total
of 256 combinations.
The Part Type and Cycle are defined and programmed through the front panel keys.
Each operation type can be defined with different part types and/or cycle numbers as
long as it matches the machine’s logic programming.
5.1. Selecting Part Types and Cycles
Note: In manual mode, the Part/Cycle must be selected prior to performing any
zeroing procedure or viewing of screens.

Note: Selection of the Part/Cycle in Automatic mode is made by the machine’s

logic.

ƒ Manual mode only

Shift
1. While holding down press to highlight the Part/Cycle selection box on
the lower right side of the screen. The current Part/Cycle are shown.
Part Cycle Single diameter
Measurement application

2. Press or to scroll to the programmed Part/Cycle. The icon changes

to represent the different measurement applications.

Example: Part type 2 and Cycle 1 have been selected.

Enter
3. Press to select the Part/Cycle required. The program automatically exits
the selection box and returns to the page.

P5 – Operator Guide 5. Part types and cycles 19

20 5. Part types and cycles P5 – Operator Guide
6. GAUGE SYSTEM TROUBLESHOOTING
6.1. Zero Troubleshooting
Whenever the gauge system cannot be zeroed, there are several possible causes
and solutions.
6.1.1. Cannot Mechanically Zero
The measuring head finger/contact assembly is retracted.

1. Release finger/contact assembly onto master workpiece using machine controls.

2. Check if machine’s logic is sending the “Retraction” signal.
3. Check if gauge is receiving the “Retraction” signal.
6.1.2. Cannot Electrically Zero
The Zeroing range of the measuring head has been exceeded.

1. Perform Mechanical Zeroing and Electrical Zeroing of the corresponding

measuring head.
6.1.3. Cannot make Zero Adjustments
The accumulated Zero Adjustments have exceeded the zeroing range for the
measuring head.
1. Perform Mechanical Zeroing and Electrical Zeroing of the corresponding
measuring head.

P5 – Operator Guide 6. Gauge System Troubleshooting 21

6.1.4. Zeroing page is blank
The Zeroing pages have the message:

Measuring Head not Enabled

This appears if the “Head Presence Flag” box on the Hardware Module programming
page does not have an X in it.

Head Presence Flag

box does not have an
X in it.

1. Place an “X” in the “Head Presence Flag” box, see Programming Manual.
2. Perform Mechanical Zeroing and Electrical Zeroing of the corresponding
measuring head.
Measuring Head not Programmed
The gauge system has not been programmed into the hardware module.

No measuring head
programmed into
Hardware module.

Call Marposs service, the measuring head must be configured into the hardware
module, followed by programming the measurement.

22 6. Gauge System Troubleshooting P5 – Operator Guide

6.2. Part Types and Cycles
Shift
If holding down and pressing does not access the Part Type and Cycle
Selection box at the bottom of the screen, only ONE Part Type and Cycle has been
defined.

To define additional Part Types and Cycles see the setup section of the Installation
Manual.

*************************** End of Document ***************************

P5 – Operator Guide 6. Gauge System Troubleshooting 23