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User guide
F-9950-0400-01 B
XR20-W rotary axis calibrator
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Legal information
Disclaimer
Renishaw has made considerable efforts to ensure the content of this document
is correct at the date of publication but makes no warranties or representations
regarding the content. Renishaw excludes liability, howsoever arising, for any
inaccuracies in this document.
Trade marks
RENISHAW and the probe symbol used in the RENISHAW logo are registered
trade marks of Renishaw plc in the United Kingdom and other countries.
apply innovation and names and designations of other Renishaw products
and technologies are trade marks of Renishaw plc or its subsidiaries.
All other brand names and product names used in this document are trade
names, trade marks, or registered trade marks of their respective owners.
Copyright
© 2018 Renishaw plc. All rights reserved.
This document may not be copied or reproduced in whole or in part, or transferred
to any other media or language, by any means without the written prior
permission of Renishaw plc.
The publication of material within this document does not imply freedom from the
patent rights of Renishaw plc.
Warranty
Equipment requiring attention under warranty must be returned to your equipment
supplier.
Unless otherwise specifically agreed in writing between you and Renishaw, if you
purchased the equipment from a Renishaw company, the warranty provisions
contained in Renishaw’s CONDITIONS OF SALE apply. You should consult these
conditions in order to find out the details of your warranty but, in summary, the
main exclusions from the warranty are if the equipment has been:
• neglected, mishandled or inappropriately used; or
• modified or altered in any way except with the prior written agreement of
Renishaw.
If you purchased the equipment from any other supplier, you should contact them
to find out what repairs are covered by their warranty.
XR20-W rotary axis calibrator
Renishaw part no: F-9950-0400-01
Issued: 07.2018
Renishaw reserves the right to make changes to this document and to the product
described herein without obligation to notify any person of such changes.
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WEEE
The use of this symbol on Renishaw products and/or accompanying
documentation indicates that the product should not be mixed with
general household waste upon disposal. It is the responsibility of
the end user to dispose of this product at a designated collection
point for waste electrical and electronic equipment (WEEE) to
enable reuse or recycling.
Correct disposal of this product will help to save valuable
resources and prevent potential negative effects on the
environment. For more information, please contact your local
waste disposal service or Renishaw distributor.
“La operación de este equipo está sujeta a las siguientes dos condiciones:
(1) es posible que este equipo o dispositivo no cause interferencia perjudicial y
(2) este equipo o dispositivo debe aceptar cualquier interferencia, incluyendo la
que pueda causar su operación no deseada.”
XR20-W rotary axis calibrator
Legal information
International regulations and conformance
EC compliance
Renishaw plc declares that the XR20-W system complies with the applicable
directives, standard and regulations. A copy of the full EC Declaration of
Conformity is available upon request.
In compliance with BS EN 61010-1:2001 the product is safe to use in the following
environmental conditions:
• Indoor use only
• Altitude up to 2000 m
• Maximum relative humidity (non-condensing) of 80% for
temperatures up to 31 °C decreasing linearly to
50% relative humidity at 40 °C
• Pollution Degree 2
Complies with
IDA Standards
DA104642
Radio communications
Class 2 Bluetooth® device
Output power: 0 dBm maximum
Frequency band: 2.402 - 2.480 GHz
Communication distance: 10 m typical operation
For details of national radio approvals for this device, see the Compliance
with radio device regulations document on the Calibration product quality and
conformance web pages.
Further radio approval country specific statements can be found below:
Singapore
Reg. No. N2095-11
Mexico
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低功率電波輻性電機管理辦法
第十二條經型式認證合格之低功率射頻電機，非經許可，公司、商號或使用者均不
得擅自變更頻率、加大功率或變更原設計之特性及功能。
第十四條低功率射頻電機之使用不得影響飛航安全及干擾合法通信；經發現有干擾
現象時，應立即停用，並改善至無干擾時方得繼續使用。前項合法通信，指依電信
規定作業之無線電信。低功率射頻電機須忍受合法通信或工業、科學及醫療用電波
輻射性電機設備之干擾
Este equipamento opera em caráter secundário, isto é, não tem direito a proteção
contra interferência prejudicial, mesmo de estações do mesmo tipo, e não pode
causar interferência a sistemas operando em caráter primário.
XR20-W rotary axis calibrator
RoHS compliance
Packaging
components
Material ISO 11469 Recycling
guidance
Internal box Cardboard Not applicable Recyclable
Outer box Cardboard Not applicable Recyclable
Insert Cardboard Not applicable Recyclable
Bag Low density polyethylene LDPE Recyclable
Taiwan
Brazil
Frequency bandwidth (MHz) 2400 to 2483 MHz
Modulation GFSK
Output power (W) 0.0676 W
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USA and Canadian regulations
FCC
Information to the user (47CFR:2001 part 15. 19)
This device complies with Part 15 of the FCC rules. Operation is subject to the
following conditions:
1. This device may not cause harmful interference.
2. This device must accept any interference received, including interference that
may cause undesired operation.
Information to the user (47CFR:2001 part 15.21)
The user is cautioned that any changes or modifications, not expressly approved
by Renishaw plc or authorised representitive, could void the user’s authority to
operate the equipment.
Canada - Industry Canada (IC)
This device complies with RSS 210 of Industry Canada. Operation is subject to
the following two conditions: (1) this device may not cause interference, and (2)
this device must accept any interference, including interference that may cause
undesired operation of this device.
L’utilisation de ce dispositif est autorisée seulement aux conditions suivantes :
(1) il ne doit pas produire d’interference et (2) l’utilisateur du dispositif doit étre
prêt à accepter toute interference radioélectrique reçu, même si celle-ci est
susceptible de compromettre le fonctionnement du dispositif.
XR20-W rotary axis calibrator
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Contents
Safety information ...............................................7
Safety warnings ................................................7
Battery safety .................................................. 8
Mechanical safety ............................................... 8
Laser optical safety .............................................. 8
Transportation .................................................. 9
EU REACH SVHC communication .................................. 9
System overview ...............................................10
System components ............................................ 11
Calibration software kit ..........................................12
Setting up a test ................................................ 14
Setting up the hardware ......................................... 14
Setup XM system .............................................. 16
Setup XL system............................................... 18
Bluetooth® setup ...............................................21
Feedrate .....................................................22
Different mounting configurations .................................. 23
Setup errors .................................................. 28
Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
XR20-W fault finding ............................................ 32
Status LEDs .................................................. 33
Care and handling .............................................. 34
Recalibration .................................................. 34
Calibration certificate ........................................... 35
Care and maintenance .......................................... 35
Storage and environmental specification ............................35
Cleanliness of optics ............................................ 36
System specification ............................................ 37
USB power supply .............................................39
Power supply: rechargeable battery ................................ 40
Weights and dimensions......................................... 42
XR20-W rotary axis calibrator
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XR20-W rotary axis calibrator
Safety information
Use of controls or adjustments or performance of
procedures other than those specified herein may result
in hazardous radiation exposure.
Ensure that you read and understand the XR20-W user
guide before using any XR20-W system.
The XR20-W rotary axis calibrator can be used in a variety of environments and
applications. To ensure the safety of the user and other personnel in the vicinity
it is therefore paramount that a comprehensive risk assessment is carried out for
the machine under test before using the XR20-W rotary axis calibrator.
This should be carried out by qualified users (requiring machine competency,
applicable technical knowledge and a trained risk assessor) with consideration for
the safety of all personnel. The risks identified must be mitigated prior to using the
product. The risk assessment should pay particular attention to machine, manual
handling, mechanical, laser, electrical, power and fibre optic safety.
Based on current research, the wireless devices used in this product would not
seem to pose a significant health problem for the vast majority of pacemaker
wearers. However, people with pacemakers may want to ensure a minimum
distance of 3 cm between the product and pacemaker.
Safety warnings
The XR20-W rotary axis calibrator system is designed to be used to test machine
tools. As such, the user will need to prepare and run a part program which moves
the machine as required. Do not spin the optics. It is assumed therefore that the
user is thoroughly familiar with the operation of the machine tool and its controller
and knows the location of all emergency stop switches. Also, if it is necessary to
operate the machine with the guards or any safety feature removed or disabled, it
is the responsibility of the operator to ensure that alternative safety measures are
taken in line with the machine manufacturer’s operating instructions or relevant
codes of practice. Safety procedures should be in accordance with the user’s risk
assessment.
The XR20-W device works in conjunction with a Renishaw laser system. Before
using the laser system, please read the safety section of the relevant Laser user
guide.
The XR20-W can reflect the laser beam from the laser around the room as it
rotates. Consideration should be given to other users working in the area.
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.
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XR20-W rotary axis calibrator
Battery safety
The XR20-W rotary axis calibrator is supplied with rechargeable batteries.
• Once depleted, recharge the battery in the charger provided: do not attempt
to charge the battery by other means.
• For specific battery operating, safety and disposal guidelines, please refer to
the battery manufacturers’ literature.
• Replace the batteries only with the specified type.
• Ensure that all batteries are inserted with the correct polarity.
• Do not store batteries in direct sunlight.
• Do not heat or dispose of batteries in a fire.
• Do not short-circuit or force discharge the batteries.
• Do not disassemble, pierce, deform or apply excessive pressure to the
batteries.
• Do not swallow the batteries.
• Keep the batteries out of the reach of children.
• Do not get batteries wet.
• If a battery is damaged, exercise caution when handling it.
Mechanical safety
• When setting up and mounting Renishaw laser calibration equipment,
beware of pinch and/or crush hazards that may be created e.g. due to
magnetic mounting bases.
• Beware of trip hazards that may be created when using Renishaw
equipment, e.g. due to trailing cables.
• Exercise caution if components are to be mounted to moving or rotating
machinery. Beware of cables becoming entangled.
• Exercise extreme caution if Renishaw equipment is to be mounted to
machinery that may accelerate rapidly or move at high speed, which could
lead to items colliding or being ejected.
• If it is necessary to operate the machine with the guards or any safety
feature removed or disabled, it is the responsibility of the operator to
ensure that alternative safety measures are taken in line with the machine
manufacturer’s operating instructions or relevant codes of practice.
• If you are using a part program or error correction parameters generated by
Renishaw software, it is the responsibility of the user to validate these at low
feedrate and be prepared to operate the emergency stop button if necessary.
Laser optical safety
• In accordance with (IEC) EN60825-1, Renishaw XL-80 and XM systems
used to provide a laser source for XR20-W are class 2M lasers and safety
goggles are not required (under normal circumstances the eye will blink and
look away before damage can occur).
• Do not stare directly into the laser beams or view them with optical
equipment such as telescopes, convergent mirrors or binoculars as
permanent retinal damage could occur.
• Do not direct the beam at other people or into areas where people
unconnected with the laser might be present. It is safe to view a diffusereflected beam during system alignment.
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XR20-W rotary axis calibrator
Transportation
Please ensure that you comply with international and national battery transport
regulations when transporting batteries or XM system kits.
The XR20-W uses a lithium ion battery. Lithium batteries are classified as
dangerous goods and strict controls apply on their shipment by air. To reduce the
risk of shipment delays, should you need to return your XR20-W to Renishaw for
any reason, do not return any batteries.
The operation of wireless appliances on aircraft is forbidden by many airlines
to prevent interference with communication systems. Remove the battery from
the receiver unit when boarding an aircraft to ensure it cannot be switched on
inadvertently.
EU REACH SVHC communication
Please see the relevant battery manufacturers’ website for further
information:
Varta:
https://www.varta-storage.com/wp-content/uploads/2017/08/
VARTA_Design_Library_56456_701_099.zip
The use of this symbol on the batteries, packaging or accompanying documents
indicates that used batteries should not be mixed with general household waste.
Please dispose of the used batteries at a designated collection point. This will
prevent potential negative effects on the environment and human health which
could otherwise arise from inappropriate waste handling. Please contact your
local authority or waste disposal service concerning the separate collection
and disposal of batteries. All lithium and rechargeable batteries must be fully
discharged or protected from short circuiting prior to disposal.
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XR20-W rotary axis calibrator
System overview
XR20-W is a rotary axis calibrator designed for measuring rotary axes, key
features include:
• Compatible with Renishaw’s XL-80 or XM systems
• Compact and lightweight
• Quick and simple mounting system
• Easy alignment with built-in alignment aid
• Wireless operation by utilising Bluetooth communication
• Battery powered (can be powered by external USB if required)
• Typical system configurations are shown in figure 1 and 2 for use with XL-80
and XM-60.
Figure 1 - typical set-up for calibrating a rotary axis using XL-80 as the laser
reference.
Figure 2 - typical set-up for calibrating a rotary axis using XM as the laser
reference.
The CARTO data capture software uses both the measured angle and the
position from the XR20-W’s internal encoder scale to very accurately measure
the positioning performance of the table under test. The rotation of an axis is
calibrated by rotating it sequentially through a number of angular targets, pausing
at each defined target to capture a reading. As the axis rotates, the software
counter-rotates the XR20-W to ensure that the laser beam is returned back to the
laser, maintaining signal strength.
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XR20-W rotary axis calibrator
System components
1
XR20-W
2
Centration aid
3
Mounting ring
4
Mounting ring adaptor
5
Battery Li-Polymer
6
Calibration software kit
7
Battery charger & cables
8
XR20-W case
9
Chuck adaptor
6
8
7
5
2
9
3
4
1
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XR20-W rotary axis calibrator
Calibration software kit
The XR20-W rotary axis calibrator is supplied with the “Calibration software kit”
which comprises:
• CARTO suite
• User guides and documentation for XM, XL-80 and XC-80.
The CARTO suite features two applications:
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XR20-W rotary axis calibrator
Mounting ring
The mounting ring bolts or clamps directly to the surface of machine and locks the
XR20-W in position.
Mounting ring adaptor
The mounting ring adaptor plate enables the XR20-W to be fitted to rotary tables
with unsuitable centre recesses. It can also be used to secure the XR20-W rotary
axis calibrator to the chuck adaptor and custom mounts.
Chuck adaptor
The chuck (lathe) adaptor has a 40 mm diameter to fit most popular chuck sizes. It
can also be used to secure the XR20-W to custom mounts.
Centration aid
The centration aid allows the mounting ring to be easily centred to the axis of
rotation of the machine under test before the XR20-W rotary axis calibrator is
mounted to the machine.
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XR20-W rotary axis calibrator
Setting up a test
Setting up the hardware
Before proceeding please read the safety section.
1. Prepare the machine for calibration. Remove all tools from the spindle of the
machine and retract them into the tool holder. Ensure surfaces are clean and
free of swarf, debris and burrs. Ensure that the laser beam can reach the rotary
table without obstruction.
2. The XR20-W will require a defined test method to be entered into the machine
tool control via a part program. The test method and part program can be
generated from the CARTO software. For further information, see the CARTO
Capture manual.
3. Ensure that your PC is Bluetooth enabled and that the CARTO software is
installed. See the Bluetooth setup section for more information.
4a. For XL-80 use mount the laser head on the stage and tripod. Turn on the laser
and it will begin stabilisation. For safety, the shutter of the laser should initially
be rotated to its closed position.
4b. For XM system use, suspend the XM launch unit within the machine
environment, switch on the laser unit to begin stabilisation. For safety, the
shutter of the XM launch unit should be in the closed position.
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XR20-W rotary axis calibrator
Both XL-80 and XM laser systems are classified as Class 2 and
safety goggles are not required (under normal circumstances
the eye will blink and look away before damage can occur).
Please refer to the relevant laser system manual.
5.
Connect the laser to the PC. If you want to monitor the environment during
calibration, then plug the environmental compensator to the PC. Place the
temperature sensors in suitable positions on or around the machine and connect
them to the environmental compensator. For more information on setting up the
laser and environmental compensator, refer to the relevant laser user guide.
6. Before mounting the XR20-W to the rotary axis ensure the mounting ring and
XR20-W facing ring are clean and free of swarf, debris and burrs. See the Care
and handling section for more information.
7. Alignment of the rotary table can be carried out visually with the centration aid
from the XR20-W kit or by using a dial test indicator (DTI). The centration of the
mounting ring should be aligned to the following specification:
XL-80 use <± 1 mm:
XM-60 use <± 0.25 mm:
8. Once aligned, the mounting ring should be fixed to the axis using bolts
mounted through the mounting holes into the machine’s T-Slots. When the
T-Slots do not pass under the mounting holes then toe clamps may need to be
used. Remove the centration aid.
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XR20-W rotary axis calibrator
9. Switch on the XR20-W briefly to check the battery power by confirming that
the LED goes green, then switch off again to conserve battery power. If the
LED is amber then change the battery. See the power supply: rechargeable
battery section for more details and the Diagnostics and trouble shooting
section for a full list of LED states.
10. Attach the XR20-W to the mounting ring. Ensure the clamp levers are
released (in the up position). Align the red spot on the facing ring with the
red spot on the mounting ring so that the slots in the facing ring are aligned
with the clamps. Lower the facing ring on to the table surface, then rotate the
XR20-W clockwise until the clamps are aligned above the clamping surfaces.
11. Lock the clamp levers down to secure the XR20-W.
For XL-80, proceed to page 18.
Setup XM system
1. Attach the beam blocker to the front of the XM launch unit.
1
Beam blocker
1
2. Translate the laser launch horizontally and vertically so that the laser beam hits
the target on the alignment aid as shown:
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XR20-W rotary axis calibrator
3. Observe the reflected beam on the launch beam blocker. Adjust the pitch of the
launch so that the reflected beam is on the centreline.
1
Beam aperture
2
Reflected beam
2
1
4. Translate vertically to align the beam again as per image in step 2.
5. Turn the XR20-W optics back around so that the retroreflectors are pointing
back towards the laser within ±2°.
Note: if it is difficult to access the optics, use the 180° rotation feature in
the software. Refer to the jog function section in CARTO software for more
details.
Now XM system setup is complete, go to page 22.
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XR20-W rotary axis calibrator
Setup XL system
1. For XL-80 use, assemble the magnetic base, optics mounting kit and the
angular interferometer optic and attach to the machine spindle as shown. In this
example the input aperture of the angular interferometer is on the right hand
side. See Optical setup section for alternative mounting schemes. Refer to the
XL laser system user guide for more information on the optics mounting kit and
angular interferometer.
1
Mounting pillar
2
Magnetic mount
3
Clamp block
4
Angular interferometer
1
3
2
4
2. Move the machine using the hand wheel in X, Y and Z to provisionally position
the angular interferometer between the laser and the XR20-W. The angular
interferometer should be relatively close to the XR20-W angular reflector to
optimise measurement performance but ensure that it cannot collide during the
test. Ensure that the angular interferometers input aperture is aligned with the
right hand retro reflector in the angular reflector.
3. Using the machine’s handwheel raise the interferometer, attached to the
spindle, out of the way in Z only. Do not move X or Y so that the alignment
between the XR20-W and the angular interferometer is maintained.
4. Rotate the alignment aid on the back of the angular reflector so that it faces the
laser.
Note: if it is difficult to access the angular reflector, it can be moved using
the jog functions in CARTO Capture.
5. Position the laser and tripod in front of the machine. To simplify setup, use
a level on the top of the laser to ensure that the laser is level and hence
nominally perpendicular to the machine’s axis of rotation.
6. Rotate the laser shutter to the 6 mm beam alignment position.
1
Beam aperture
2
Target
1
2
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XR20-W rotary axis calibrator
7. Adjust the laser so that the beam hits the alignment aid. For more information
on laser alignment controls, refer to the relevant laser user guide.
8. Transate the XL-80 horizontally and vertically so that the laser beam hits the
target on the alignment aid as shown:
9. To minimise measurement errors the laser beam should be aligned
perpendicular to the machine’s axis of rotation. Refer to the setup errors
section for more information. Adjust the pitch of the laser so that the beam
reflects onto an imaginary horizontal line which passes through the centre of
the shutter’s output aperture as shown.
1
Beam aperture
2
Reflected beam
1
2
Note: do not be concerned if the laser is destabilised.
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XR20-W rotary axis calibrator
10. Turn the laser shutter so that the 3 mm aperture is set. Check that the beam
returning from the retroreflectors is concentric inside the white target. Make
translation adjustments to the laser and tripod, if required.
1
Reduced beam aperture
2
Target
2
1
11. Fix a target into the input aperture of the angular interferometer and lower the
interferometer back into position by using the Z control on the handwheel. The
beam from the laser should now be concentric with the white target.
1
Angular interferometer
2
Reduced laser beam
3
Target
3
1
2
12. Remove the target from the angular interferometer. The beams should now
pass through the angular interferometer and both beams returned from the
XR20-W’s angular reflector should now overlap on the middle of the laser
shutter’s target.
1
Reduced beam aperture
2
Target
2
1
13. Turn the shutter to 6 mm aperture and check that good signal strength is
obtained.
1
Beam aperture
2
Detector aperture
1
2
14. Switch on the XR20-W and check the status LEDs go green.
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XR20-W rotary axis calibrator
Bluetooth® setup
The XR20-W rotary axis calibrator communicates with the PC using Bluetooth
wireless technology.
Before you can connect the XR20-W you must provide Bluetooth capability on
your PC. This can be done either by enabling the PC’s internal Bluetooth device
(if available) or by using a proprietary USB Bluetooth dongle recommended by
Renishaw.
The CARTO software will only work with Bluetooth devices which use the
Microsoft stack (a stack is software which enables communication between a PC
and a Bluetooth device).
Setup for a PC with a built in Bluetooth device
Windows 10:
1. Right click on the start menu
2. Select the “device manager” button
Proceed to point 5
Windows 7:
1. Click on the start menu
2. Right click on Computer
3. Manage
4. Select the “device manager” button
5. If the device list shows “Generic Bluetooth Radio” and “Microsoft Bluetooth
Enumerator”, then your PC is both Bluetooth capable and has the Microsoft
stack installed
6. Ensure that Bluetooth functionality is switched on (see PC user instructions)
7. Run the CARTO software and connect the XR20-W to establish communication
If your PC does not have the Microsoft stack installed, please refer to the
Calibration service, support and training web pages for further instructions.
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XR20-W rotary axis calibrator
Setup for a PC without a built in Bluetooth device
If you do not have on-board Bluetooth capacity on your PC then you will need to
obtain a USB Bluetooth dongle.
When you first use the USB Bluetooth dongle, DO NOT INSTALL the software
provided with the device, simply plug the dongle into a spare USB port and then
run CARTO and connect the XR20-W to establish communication.
Note: Some USB Bluetooth dongle software provide Bluetooth stacks
(other than the Microsoft version) which are not compatible with CARTO
software.
Feedrate
If the target interval is greater than 10 degrees then the XR20-W rotary axis
calibrator will automatically track the movement of the machine under test so that
the XR20-W’s angular reflector continues to face the laser as the machine moves
so the laser’s beam does not break.
The feedrate of the test can be determined automatically or entered into the
software manually via the test menu.
The XR20-W system can determine the velocity of the machine under test
automatically, during the machine overrun move, at the beginning of the test. To
allow the feedrate to be automatically determined, an overrun move of 5° should
be programmed. If during this move the software can not determine the velocity of
the machine, it will display a warning message. If a warning message is displayed,
try the following:
• Decrease the programmed machine feedrate by modifying the part program.
Refer to the part program section for more details.
• Increase the angle of the overrun move to allow it to get up to its
programmed feedrate.
• Manually enter the feedrate into the software.
Enter the feedrate set in the machines part program. Alternatively, for optimum
performance, enter the reported feedrate displayed by the machine controller
during a move.
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XR20-W rotary axis calibrator
Different mounting configurations
The XR20-W rotary axis calibrator can be mounted to many different types of
rotary axis. Setup 1-3 show typical setups using the fittings supplied with the
standard XR20-W kit. Always ensure the mounting surface of the table under test
and the XR20-W facing ring are clean and free of swarf, debris and burrs.
Mounting setup 1 (default configuration)
In most applications the facing ring of the XR20-W can be mounted directly to the
surface of the axis under test (as shown) using the mounting ring.
1
1
2
1
Mounting bolt
2
Mounting ring
The mounting ring should be fixed to the table using bolts secured through the
mounting holes into the machines T-slots.
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XR20-W rotary axis calibrator
Mounting setup 2 (machine with large centre bore)
The adaptor plate should be used if the axis under test has a centre bore or
recess that prevents the XR20-W mounting ring being mounted securely and
parallel to the rotary axis. Mount the XR20-W to the axis under test as shown.
Ensure the correct screws are used to mount the adaptor plate to the mounting
ring.
The mounting screws required are as follows:
• The screws to fix the adapter plate to the mounting ring are 3 off M5 x 12
long countersunk screws.
1
1
1
Mounting bolt
2
Mounting ring
3
Adaptor plate
4
Countersunk
screws M5 x 12
2
4
3
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XR20-W rotary axis calibrator
Mounting setup 3 (lathes)
When calibrating lathes, the chuck adaptor should be used.
The mounting screws required are as follows:
• The screws to fix the chuck adapter to the adapter plate are 4 off M4 x 12
long cap head screws.
Note: when mounted to the chuck adaptor, each of the components must
be screwed in the locations indicated in the image using the correct
screws. Refer to the specification section for more information. To ensure
optimum measurement performance, it is recommended that the TIR of the
top surface of the adaptor plate is checked using a digital gauge. Refer to
the setup errors section for more information.
Machine setup 4
A variation of the chuck adaptor can be used for mounting to small or partially
concealed axes (e.g. behind access corners). This uses a through bolthole to
secure to the test axis. Note, however, that the orthogonality of the adaptor to the
test axis is crucial to capturing ‘clean’ data.
1
Mounting ring
2
Adaptor plate
3
Chuck adaptor
4
Cap head screws
M4 x 12
1
2
3
4
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XR20-W rotary axis calibrator
Optical setups using XL-80
Optical setup 1
This optical setup is used when the axis under test has a vertical axis of rotation.
An example of how to set this up is described in the getting started section; see
setting up the hardware section for more details.
1
Laser
2
Angular interferometer
4
XR20-W
5
Mounting ring
5
4
3
2
1
3
Angular retroreflector
Optical setup 2
This scheme may be required if it is not possible to mount the laser directly in front
of the XR20-W rotary axis calibrator due to machining guarding. In this example
the beam enters the angular interferometer through the side aperture rather than
the front aperture
1
Angular interferometer
1
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XR20-W rotary axis calibrator
Optical setup 3
If the beam emerging from the laser is parallel to the machine axis of rotation then
an additional turning mirror will be needed. The turning mirror turns the beam
through 90° into the angular interferometers input aperture as shown. Refer to the
XL Laser system user guide for more information about the turning mirror.
1
Angular interferometer
2
Turning mirror
2
1
Optical setup using XM-60
If using XM system laser source, use custom fixturing to suspend launch unit from
spindle.
Note: To avoid measurement error, the XM launch unit should not be
mounted to a tripod.
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XR20-W rotary axis calibrator
Setup errors
When mounting the XR20-W rotary axis calibrator and setting up the optics, it
is important to get them aligned as accurately as possible. Small misalignments
are expected to exist so this section indicates how tolerant the software is at
minimising or eliminating them, or the effect they have on captured data.
Axes of rotation parallel but not coincident
E
• Optics translate during rotation
• To avoid signal strength loss, ensure:
• For XL-80, E = <± 1 mm
• For XM system, E = <± 0.25 mm
Axes of rotation coincident but not parallel
Induced error
E
Sinusoidal component measurement error induced into the captured data over
360° rotation. Size of error dependent on E and shows one cycle in 360°.*
• For induced error to be less than ±1 arcsecond, ensure E<0.025° or the TIR
is <0.04 mm at a radius of 50 mm from the centre of rotation of the machine
under test.*
• For induced error to be less than ±10 arcseconds, ensure E<0.23°, or the
TIR is <0.4 mm at a radius of 50 mm from the centre of rotation of the
machine under test.*
*Note: it is relatively easy to achieve the alignment tolerances quoted
when calibrating a rotary table where there is a mounting surface which is
perpendicular to the axis of rotation. Care should be taken to ensure the
rotary tables and XR20-W mounting surface are clean and free from
debris, swarf and burrs.
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XR20-W rotary axis calibrator
However, special care must be taken when calibrating rotating axes without such
mounting surfaces. In this case it is recommended that the TIR (Total Indication
Run out) of the surface the XR20-W is to be mounted to is checked (whilst rotating
the axis under test) using a dial gauge. This allows alignment to be verified before
the test starts.
Laser beam not perpendicular to reflector, axes of rotation coincident
• Use the XR20-W alignment aid to align the laser beam to be perpendicular to
the shutter. Refer to the getting started section for more information.
• E is the angle between the normal of the XR20-W alignment aid and the
beam from the XL-80/XM system.
• For XM system/XL-80 E < 2 mrad
E
E
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XR20-W rotary axis calibrator
The angle of E can be calculated within the setup by measuring the vertical
position of beam 2 relative to 1 and then using the comparison table below.
1
Beam aperture
2
Reflected beam
2
1
1
2
Distance between XL80/
XM and the XR20-W (m)
Maximum vertical offset
(mm)
0.1 0.4
0.2 0.8
0.5 2
1 4
2 8
3 12
4 16
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XR20-W rotary axis calibrator
Reflector not perpendicular to laser beam when laser is datumed at start of
optical set up calibration cycle
E
• Limited danger of beam obstruct (only if E > 10°). To avoid signal strength
loss, ensure E<2°.
• Use alignment aid to align optics perpendicular to laser beam
• Error eliminated by optical set up calibration cycle
Reflector separation not exactly 30 mm
30 mm
E
• Caused by thermal expansion and manufacturing tolerances
• Error eliminated by optical set up calibration cycle
• No danger of beam obstruct
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XR20-W rotary axis calibrator
Diagnostics and troubleshooting
XR20-W fault finding
The following table should be used for fault finding. If you experience further difficulties, please see the Calibration service, support and training web pages, or contact
your local Renishaw office.
Problem Possible cause Action
Bluetooth communication cannot be established
(XR20-W status stays green)
PC Bluetooth is not activated or PC is out of range
• Check Bluetooth is enabled on PC (or presence of
USB Bluetooth dongle)
• Ensure the Bluetooth is setup correctly on PC
• Move PC closer to XR20-W
Intermittent Bluetooth communication Machine enclosure preventing communication
• Attach Bluetooth dongle to USB extension lead and
position inside of machine enclosure
XR20-W status LED off
• XR20-W switched off
• No battery fitted
• Battery flat
• Battery fault
• Environment is outside XR20-W operational
temperature range
• Ensure XR20-W is switched on
• Switch the XR20-W off and then on
• Replace the battery
• Ensure the USB cable is disconnected and reinsert
battery
• Connect USB power supply
Red XR20-W status LED XR20-W fault
• Switch the XR20-W off then on
• Replace the battery
• If problems persist, contact your local Renishaw
office
XR20-W status LED is slow flashing blue and
CARTO software DRO (Digital Read Out) is dim
XR20-W and software in power saving mode • Click on DRO to resume live reading
Software has not installed in the required language
of operation
The PC’s regional settings are not set to the users
preference
• Change the ‘regional settings’ in the PC’s control
panel to the required language
Battery life is too short
Dirt/contamination on battery contact in the battery
cap
• Clean the battery contact
• The inside of the cap should be cleaned with a soft
cloth and appropriate solvent, e.g. IPA.
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XR20-W rotary axis calibrator
Status LEDs
LED status Description
OFF Off, no power or power down mode
Solid green On, communication has not been established
Solid blue Communication established and drive disabled
Flashing blue Communication established and drive enabled
Slow flashing blue Power saving, see below
Solid amber Battery low and drive disabled. Charge battery
Flashing amber Battery low and drive enabled. Change battery
Red Fault, see fault finding section
Power saving
If the system is idle for 2 minutes, then the DRO in the CARTO software will go
dim and the XR20-W status LEDs will slowly flash blue as the system goes into
power saving mode. To exit power saving mode, click on the DRO. The XR20-W
will need to be re-referenced before testing can continue.
If the XR20-W is idle for 5 minutes it will switch itself off and the status LED will go
off. The unit will need to be switched off, then on again, and re-referenced before
testing can continue.
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XR20-W rotary axis calibrator
Care and handling
Recalibration
Why recalibrate?
As with any recalibration equipment, it is recommended that the Renishaw
XR20-W rotary axis calibrator is periodically recalibrated to give confidence that
the system:
• is currently still within original specified (or required) performance
• is likely to remain within its specified (or required) performance until its next
recalibration
This is the reason that recalibration of calibration test equipment is a mandatory
requirement of most quality management/assurance systems.
An added benefit of periodic calibration is that the inspection Renishaw carries
out when recalibrating your XR20-W can also show up accidental damage that
you might have not been aware of. Renishaw’s recalibration procedure includes
general cleaning.
Compared to your investment in the measurement system, staff and procedures,
periodic recalibration is a modest additional cost and could prevent far more
expensive and bigger problems arising later.
Recalibration periods
The Renishaw recommended recalibration period for an XR20-W is 3 years.
Note: This is 3 years from sale by Renishaw rather than from factory
calibration date as stated on the calibration certificates supplied with the
new equipment, since the units are stored under controlled conditions by
Renishaw prior to sale.
Renishaw recommended recalibration periods are only a recommendation and
are based on typical use of the equipment in a typical environment. Under such
conditions your XR20-W system should still be performing within Renishaw’s
specification at the end of this period.
However, there are several factors that may generate the need for more or less
frequent calibrations including:
• Environmental conditions
• Frequency and duration of use
• Harsh treatment of the equipment during storage, transportation or use
• Level of accuracy required by the user
• The requirements of company QA procedures and/or local regulations
Ultimately it is for you to determine the appropriate calibration period after taking
into account your own operational environment and performance requirements.
Recalibration reminders
Because evidence of calibration is important for users and their customers, there
are several reminders built into both the main system hardware and system
software.
Hardware reminder
The XR20-W has the calibration date indicated on a label on the side of the unit.
Software reminders
Further reminders are built into the CARTO software. If an XR20-W is out of
calibration, you will see displayed on the screen the last recalibration date and
recommended date for recalibration.
Recalibration facilities
Recalibration of the XR20-W requires specialist test rigs and software to give
results comparable to the original factory calibration. Renishaw therefore
recommends that items are returned to our specialist facilities via your local
Renishaw office.
Periodic recalibrations and recalibrations following repairs (if required) are carried
out in accordance with the same procedures used for new systems and an
identical format certificate will be issued.
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XR20-W rotary axis calibrator
Calibration certificate
Each Renishaw XR20-W rotary axis calibrator is delivered with a calibration
certificate. This demonstrates that the system has been calibrated at the Renishaw
factory against reference systems with traceability to National Standards. It is
proof of the equipment’s performance as tested before delivery.
The certificate is a valuable document. You should keep it safe as it may be
required to satisfy your own or your customers quality assurance requirements.
Duplicate documents can be supplied but there will be a charge for this service.
Certificate content
Each certificate is unique and is identified by a certificate number. All XR20-W
certificates provide the following key information:
• Serial number of calibrated XR20-W
• Specific test results and graph
• Statement of accuracy
• Traceability data (calibration details, see below)
• Test conditions and methodology
The first page gives graphical representation of test results and specification
limits as well as tabulated details of the specific test results and uncertainty of
measurement. This enables you to see clearly whether or not the unit meets
published specifications and/or your own requirements. To enable “traceability”,
details of the test equipment used are given. The date of testing and the date
of printing the certificate are separately noted and the results are signed by a
Renishaw authorised person.
The second page gives generic details of the test procedure, test environment,
and applicable standards, all in accordance with requirements of ISO 17025.
Care and maintenance
The Renishaw XR20-W rotary axis calibrator system is precision-engineered to
ensure very high levels of measurement accuracy and repeatability. Correctly used
and handled, it will give you excellent service.
• To ensure optimum measurement performance ensure the XR20-W facing
ring, mounting ring and adaptor plate are clean and free from debris, swarf
and burrs before use.
• Place the XR20-W mounting ring and adaptor plate into the case when not in
use.
• Switch off the unit before transporting it.
Care should be taken to avoid extremes of environment (heat, humidity etc.)
and to avoid any sharp blows or violent vibration. Do not attempt to clean using
water or any other fluids. The system should not be exposed to dusty or misty
environments as particles could enter housings and cause damage, preventing
correct operation and affecting accuracy. Renishaw system cases provide secure
storage for the equipment when not in use.
Storage and environmental specification
The equipment should always be inspected before use to check for any signs of
damage on all system components (including optics and tripods) such as cracks,
dents or other evidence of physical damage, loose joints, cracked or pinched
cables etc.
This is important as the equipment may still function but the accuracy of the
reading may have been affected.
If you are in any doubt, contact your local Renishaw office for advice and
guidance. Defective products should be returned to Renishaw for repair.
There are no user-serviceable parts inside the main calibration system equipment.
Never remove housings as doing so may invalidate the warranty and cause
additional damage. If in any doubt, contact your local Renishaw office for advice
and guidance.
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XR20-W rotary axis calibrator
Cleanliness of optics
The optics must be kept as clean as possible. Dirty optical surfaces are likely to
result in a loss of signal strength making calibration more difficult.
Clean the optics only when necessary. The emphasis should be on handling and
storing the optical components so that they don’t become dirty or smeared, rather
than frequent cleaning.
• Do not touch the optical surfaces
• Do not use in contaminated atmospheres
• Store securely when not in use
Cleaning recommendations
• Wipe only with non-abrasive lens tissue or cloth, for example spectacle
cleaning cloths.
• Use cleaning fluid suitable for spectacles or similar (do not use acetone).
• Clean the optics using a gentle wiping action. Never use a scrubbing action.
Failure to follow these recommendations may lead to damage to the coatings
and glass elements of the optics.
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XR20-W rotary axis calibrator
System specification
XR20-W system
Recommended recalibration period 3 years or under typical use
Max feed rate 10 rpm
Performance specifications
Rotary (with XL-80)
Accuracy ±1 arcsec (at 20°C)
Resolution 0.1 arcsecs
Range 0° to 360°
Rotary (with XM system)
Accuracy ±1.2 arcsec (at 20°C)
Resolution 0.1 arcsecs
Range 0° to 360°
Operating and storage environment
Operating environment
Pressure 600 mbar - 1150 mbar Normal atmospheric
Humidity 0% to 95% RH Non-condensing
Temperature 0°C to 40°C
Storage environment
Pressure 550 mbar - 1200 mbar Normal atmospheric
Humidity 0% to 95% RH Non-condensing
Temperature -20°C to 60°C
Note: to protect against battery damage the XR20-W rotary axis calibrator
will not power up when operated below 0°C and above 40°C
Radio communication
Class 1 wireless communication device
Output power 0 dBm nominal
Frequency band 2.402 GHz - 2.480 GHz
Communication distance 10 m typical operation
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XR20-W rotary axis calibrator
Battery and charger
Technical data: part # 56446 702 099 (rechargeable Li-Polymer)
Battery type Varta EasyPack XL part # 56446 702 099
(rechargeable Li-Polymer), 3.7 V 2260 mAh 8.4 Wh
Max current 3.7V DC
Battery life 3 hours typical operation (for new batteries)
Technical data: part # 56456 702 099 (rechargeable Li-Polymer)
Battery type Varta EasyPack XL part # 56456 702 099
(rechargeable Li-Polymer), 3.7 V 2400 mAh 8.9 Wh
Max current 3.7V DC
Battery life 3 hours typical operation (for new batteries)
Spec for charger
Technical data
Input voltage 100 V to 240 V
AC, 50 Hz / 60 Hz
Output Voltage 4.2 V nominal
Input current Max. 0.2 A (100 V
AC)
Output current 0 A - 1.0 A
Output power rating Max. 6 W
Safety standard EN(IEC)60950
Power supply
USB power supply
Minimum current 1A
Shielded USB2 Full or high speed
For cable length less than 3 m 28AWG/2C (for signals), +24 AWG/2C
(for power)
For cable length greater than 3 m 28AWG/2C (for signals), +20AWG/2C
(for power)
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XR20-W rotary axis calibrator
USB power supply
The USB power supply can be used to power the XR20-W rotary axis calibrator.
The USB power supply should be used if no charged batteries are available or the
user is performing a long test.
Ensure the plug adaptor that is compatible with your country or region is attached
to the USB power supply. Push the plug adaptor firmly until it is securely held in
place. Connect the USB power supply to the XR20-W USB port via the supplied
USB cable. Finally connect the USB power supply to the electrical outlet.
Do not connect the USB power supply to the XR20-W during a test, or
measurement errors may result.
Note: There is no need to remove the battery when using the USB power
supply.
Important: to ensure correct operation only use the USB power supply supplied
and USB cables with the correct power rating.
Replacement USB power supplies and USB cables and are available from
Renishaw.
The XR20-W should not be connected to a standard PC’s USB port. If connected
the XR20-W will not recognise the PC as a suitable power supply and therefore
will not turn on.
Care must be taken that the USB cable does not snag inside the machine as the
rotary axis rotates. Snagging of the cable may cause damage to the XR20-W.
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XR20-W rotary axis calibrator
Power supply: rechargeable battery
The XR20-W rotary axis calibrator kit contains Li-Polymer Varta Easypack
batteries and associated charger. These batteries are the only type which should
be used with the XR20-W unit.
Before charging or using the battery it is recommended that you read the battery
safety section of this manual.
To remove a battery, turn the battery cover on the bottom of the XR20-W
anticlockwise, and remove to reveal the battery compartment.
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XR20-W rotary axis calibrator
When fitting a battery, ensure the terminals of the battery sit over the terminals
inside the battery compartment.
Battery life
Battery life in use will depend on many variables including age and condition of
battery; initial charge and test cycle and duration. The published specification is for
a new battery and with the XR20-W used in a typical configuration.
For optimum battery performance only fit fully charged batteries.
A battery should be continued to be used until battery low is indicated by the
XR20-W status LEDs. Once battery low is indicated, replace the battery with a fully
charged one as soon as possible.
The battery contact inside the battery cap must be kept clean. Dirt build up on
the contact can cause a high resistance circuit which can give false battery flat
indication. The inside of the cap should be cleaned with a soft cloth and appropriate
solvent, e.g. IPA.
Note: batteries should be removed during transportation.
Battery charger
The XR20-W will indicate that the battery charge is getting low via the status LEDs
on the side of the unit. To recharge the battery, remove it from the unit and place it
into the slot in the battery charger. Ensure that the terminals of the battery line up
with the terminals inside the charger. The colour status for the LED on the charger
are shown below:
LED status Description
Solid green If there is a battery in the charger,
the green LED indicates that is fully
charged and ready to be used. If there
isn’t a battery in the charger, the green
LED indicates the charger is plugged
in and ready to charge a battery.
Solid amber This means that the battery in the
charger is in the process of being
charged.
Flashing amber This indicates that the charger is going
through its pre-charge cycle.
Off The charger is not plugged in.
Red This indicates a fault with the charger.
See the battery charger booklet
provided in the XR20-W kit for more
information.
To maintain optimum battery performance, batteries should be recharged every 6
months irrespective of use.
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XR20-W rotary axis calibrator
Weights and dimensions
Description Weight
XR20-W weight 1.2 kg
XR20-W system weight in case 6.5 kg
XR20-W
83
96
59
130
96
22
Chuck adaptor
Ø 101
Ø 60
Ø 40
4 x 80 PCD, C’BORE
Ø 9.2 x 7 DP &
Ø5.5 THRO’
Ø 28
58
18
4
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XR20-W rotary axis calibrator
Mounting ring
Ø 60
Ø 120 PCD
Ø 128 PCD
4 SLOTS Ø 10.6
Ø 150
Ø 96
60°
60°
11
17
Mounting adaptor
Ø 60
Ø 150
Ø 80 PCD
4 POSN’S M5
THRO’
6
6
Page 44
Renishaw plc
New Mills, Wotton-under-Edge
Gloucestershire, GL12 8JR
United Kingdom
T +44 (0)1453 524524
F +44 (0)1453 524901
E uk@renishaw.com
www.renishaw.com
For worldwide contact details, visit
www.renishaw.com/contact
*F-9950-0400-01*
© 2018 Renishaw plc
Issued: 07. 2018
Part no. F-9950-0400-01-B
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