Sensata Technologies NMS 800 Series Digital Readout System User Manual

: June 1, 2024
: Sensata Technologies

Table of Contents

NMS 800 Series Digital Readout System
Specifications
Electrical
Physical
Environment
Accreditation
Disposal
Input and Resolution
- Product Usage Instructions
Mounting Options
- Standalone Mount Options
- Panel Mount Option
Connection Details
- Frequently Asked Questions (FAQ)
Q: What encoders are compatible with the NMS800 DRO?
Q: How should I dispose of the NMS800 DRO at the end of its

NMS 800 Series Digital Readout System

Specifications

Electrical

EU Directive 73/23/EEC (Low Voltage Directive)
BS EN 55022:1998 Class B
BS EN 55024:1998

Physical

Height: 188mm (7.4 inches)
Width: 306mm (12.072 inches)
Depth: 48mm (1.89 inches)
Weight: 0.5kg (1.1lb)

Environment

Climatic Range:
- Storage Temperature
- Working Temperature
- Working Humidity
IP-Ingress Protection: IP40 Stand Alone, IP54 Panel Mount

Accreditation

CE
UKCA

Disposal

At the end of its life, please dispose of the NMS800 Digital in
a safe manner applicable to electrical goods. Do not burn. The
casework is suitable for recycling. Please consult local
regulations on disposal of electrical equipment.

Input and Resolution

Either the Newall ‘serial’ or ‘digital’ encoders support a TTL
output can be used with the NMS800 DRO depending on which model.
Resolutions are dependent on the encoder type.

Product Usage Instructions

Mounting Options

Standalone Mount Options

– To mount the NMS800 as a standalone unit, follow the provided
instructions for secure installation.

Panel Mount Option

– When choosing the panel mount option, ensure that the minimum
cut-out size for the connection is 122.00mm x 84.00mm.

Connection Details

Important Details:

Secure all cables to prevent connectors from dropping into
hazardous positions when unplugged.
Route all cables to prevent them from being caught on moving
parts.
Ground the NMS800 to the machine using the provided braided
grounding lead before turning on the machine supply.
Disconnect power before connecting encoders. Do not connect
directly to the mains supply.

Frequently Asked Questions (FAQ)

Q: What encoders are compatible with the NMS800 DRO?

A: The serial NMS800 is compatible with Newall Spherosyn Serial
and Microsyn Serial encoders, along with other encoders. The
digital version will work with any TTL encoders.

Q: How should I dispose of the NMS800 DRO at the end of its

life?

A: Please dispose of the NMS800 Digital in a safe manner
applicable to electrical goods. Do not burn the device. The
casework is suitable for recycling; consult local regulations on
disposal of electrical equipment.

| NMS 800 Series
Digital Readout

USER MANUAL

sensata.com/newall

Contents

Specification Electrical Physical Environment Accreditation Disposal Input and Resolution
Mounting Options Stand Alone Panel Mount
Connection Details Important Information Connections
Display and Keypad Understanding the Display Understanding the Keypad
Setting up the Unit (Linear) Navigation Setup DRO Setup Encoder Setup Reset Settings Language Setup Brightness Setup Sleep Timer Setup Axis Legend Setup DRO Type Setup Scale Factor Setup Beep Enable setup Feed Rate Setup Function Setup Digital Type Setup Rotary Mode Setup Digital Res Setup Digital Res Setup teach Signal Check Setup Quad Index Setup Display Resolution Setup Gear Ratio Zero Approach Setup Plane Setup Zero Threshold Summing Setup Encoder Direction Setup Measurement Mode Setup Error Compensation Type of Machine Error Linear Error Compensation Segmented Error Compensation Notes
Standard Functions Absolute / Incremental Zero and Pre Set an Axis Inch/ mm Modes Setting Function Keys Quick Setting Function Keys Using Function Keys DigiFind/ Reference Function Sub Datums / Memory
2

Page 3 Page 3 Page 3 Page 3 Page 3 Page 3 Page 3
Page 4 Page 4 Page 4

Feed Rate Functions Tool Offsets Logging Function Logging Connection Using the Logging Function
Mill Function Arc Contouring Pocket /Island Milling PCD / Bolt Hole Circle Grid

Page 5 Page 5 Page 5

Lathe Function Vector Taper Turning

Page 6 Page 6 Page 6

Trouble Shooting

Page 7
Page 7
Page 8/9 Page 10/11 Page 11 Page 12 Page 12 Page 13 Page 13 Page 14 Page 14 Page 15 Page 15 Page 15 Page 16 Page 16 Page 16 Page 17 Page 17 Page 18 Page 18 Page 18 Page 19 Page 20 Page 20 Page 20 Page 21 Page 21 Page 21/22 Page 22 Page 23 Page 23/24/25/26 Page 27

Page 28 Page 29 Page 30 Page 30 Page 31 Page 31 Page 31 Page 32 Page 33/34

Page 34 Page 34/35/36 Page 37 Page 37 Page 37
Page 38 Page 38 Page 39 Page 40 Page 41
Page 41 Page 42 Page 42
Page 43

Specification

Electrical
EU Directive 73/23/EEC (Low Voltage Directive) BS EN 55022:1998 Class B BS EN 55024:1998

Input to Power Supply Unit (Supplied) 100-240V (47-63Hz) External switch-mode – Output voltage 15VDC Input Voltage to NMS800 12-27VDC ±10% Conforms to Low Voltage Directive

Physical
Height 188mm (7.4″) Width 306mm (12.072″)

Depth 48mm (1.89″) Weight 0.5kg (1.1lb)

Environment Climatic Range

Storage Temperature Working Temperature Working Humidity

-20°C to 60°C 0°C to 55°C 80% R.H. at 30°C

IP-Ingress Protection

IP40 Stand Alone, IP54 Panel Mount

Accreditation CE UKCA

Disposal
At the end of its life, please dispose of the NMS800 Digital in a safe manner applicable to electrical goods

Do not burn

The casework is suitable for recycling. Please consult local regulations on disposal of electrical equipment

Input and Resolution
Either the Newall serial’ ordigital’ encoders support a TTL output can be used with the NMS800 DRO depending on which model.

Resolutions

Dependant on Encoder (Linear)

Dependant on Encoder (Rotary)

0.1µm (0.00001″)

Program PPR, 0 – 90,000,000

0.5µm (0.00002″)

1µm (0.00005″)

2µm (0.0001″)

5m (0.0002″)

10m (0.0005″)

Newall Measurement Systems Limited reserves the right to make changes to this specification without notice

3

Mounting options
Standalone Mount Options
Panel Mount Option PLEASE NOTE: The Minimum Cut-out Size for the connection is 122.00mm x 84.00mm
4

Connection details
Important Details The serial NMS800 is compatible with Newall Spherosyn Serial and Microsyn Serial encoders, along with other encoders. Digital version will work with any TTL encoders It is important to ensure that:
Secure all the cables to prevent the connectors from dropping into hazardous positions (for example the floor or coolant tray) when they are unplugged.
Route all cables to prevent them from being caught on moving parts.
The NMS800 is grounded to the machine, using the braided grounding lead provided, before the machine supply is turned on.
The power has been disconnected, before the encoder(s) are connected. Do not connect this unit directly to the mains supply.
Connections

Encoder Input Encoder Input Encoder Input Encoder Input Auxillary RS232 Output

External PSU input

Cabinet Equipotential terminal for Grounding to
Machine

5

Display and keypad

Understanding The Display

x Axis 1 y Axis 2 z Axis 3 w Axis 4

Message display

Newall mm

Understanding The Keypad

mm/inch Short cut

Axis selection key

Calculator Mode

inc

set

ABS/INC Zero/Set Short cut Short cut

Switches between zero and axis pre-set modes
Switches between absolute and incremental modes

Switches between inch and mm display

Numeric + Calculator Keys

Back / undo key

Menu key

Enter key

Centre find Tool Offset key

Navigation keys 6

Function key

Setting up the unit

Navigating Setup How to enter setup setup menu

code

PLEASE NOTE: To apply any changes, you must exit back through to the menu. Display Setup
setup menu

display setup

setup- Language

EnG Gb

Eng USa cesky dansk
nederlan francais

deutsh italiano
polski portugue
espanol

setup- brightness setup- sleep timer

mid

high

low

0 (Use numeric keypad, and press)

setup- axis legend

Editing (Use numeric keypad to change axis name)

to exit setup and return to menu, or

to exit setup and return to measurement display

7

Setting up the unit

DRO Setup setup menu

dro setup

setup – dro type

lathe mill
generic

setup – plane 3/4 AXIS ONLY
setup – select z axis 3/4 AXIS ONLY
setup – axis summing 3/4 AXIS ONLY
setup – scale factor

e——3 e——3
e——3

off

on

1.000 (Use numeric keypad, and press)

setup – beep enable setup – feed rate

on minutes

off seconds

setup – function

func- arc

on

MILL ONLY

func- digifind

on

8

off off

Setting up the unit

DRO Setup

func- feed
func- grid MILL ONLY
func- summing
func- logging
func- pcd MILL ONLY
func- pocket MILL ONLY
func- sub datum
func- taper
func-tool offset
func – Vector

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

on

off

to exit setup and return to main menu, or

to exit setup and return to measurement display

9

Setting up the unit

Encoder Setup setup menu

encoder setup

setup – digital type DIGITAL ONLY
setup – rotary mode DIGITAL ONLY

rot dec (Rotary decimal) rot dms (Rotary degrees, minutes and seconds) rot rpm (Rotary revolutions per minute) linear (Linear) contin (Continuous) rollover (Roll Over)

setup – digital res DIGITAL ONLY
setup – GEAR RATIO DIGITAL ONLY

360000 enter value

program teach

setup – quad index DIGITAL ONLY

on

off

setup – signal check DIGITAL ONLY

setup – display res

0.0001

0.005

0.0005

0.01

0.001

0.02

0.002

0.05

PLEASE NOTE: 0.005, 0.01, 0.02, 0.05 are for digital only

10

Setting up the unit

Encoder setup (Continued) setup – zero threshold

enter value

setup – enc direction setup – measure mode
setup – error comp

—-3 e—-
dia rad
none Comp linear
comp segment

teach program

to exit setup and return to menu, or Reset settings
setup menu

to exit setup and return to measurement display

reset settings

no

yes

to exit setup and return to menu, or

to exit setup and return to measurement display

REMINDER: To apply any changes, you must exit back through the menu.

11

Setting up the unit

Language Setup

This setting enables the user to choose the language that is required to be displayed in the NMS 800 display.

There are 13 language settings:

EnG Gb English UK (Default)

EnG us English US cesky Czech dansk Danish
Nerderlan Dutch

Francais French deutsh German
italiano Italian polshi Polish

portugue Portuguese espanol Spanish

Press the axis select key

next to the axis to cycle through the options

Brightness Setup This setting allows the user to alter the brightness of the display, this can be useful in varying ambient light conditions.
Settings available for brightness:

mid The default brightness is medium

Press the axis select key

next to the axis to cycle through the options

high Setting to high brightness increases the display brightness to its maximum

low Setting to low brightness decreases the display brightness to its minimum

12

Setting up the unit

Sleep Timer Setup This setting enables the user to define an automatic sleep mode after a period of time. The user either leaves the default setting at `0′ which deactivates the sleep mode, or selects a numeric value when the sleep mode is initiated after no operation of the NMS 800 To exit sleep mode, simply move an axis or press any key.
0 The default setting is set to 0 minutes
To set the time, simply insert the number of minutes (using the numerical keypad) into the DRO and press

5 Sleep function active after 5 minutes `

Once input, simple press the undo key,

which will take you out of this menu.

Axis Legend setup
The axis legend setting allows you redefine all the axes on the DRO, using the which axis you would like to redefine.

key to select

The numeric keypad then allows you to add which letter you would like to label the axis with.

x Once you’ve selected the axis, your screen will change to show editing. Simply insert the letter you would like to be shown on this axis.

Axis legend

To apply, press the

key.

Editing

13

Setting up the unit

DRO Type setup
This setting enables the user to choose the machine type that the NMS800 operates with. This is important as the machine type defines the default functions for the function keys and function menu.

There are two different settings for this DRO:

Lathe

millv

generic

= Feed Function

= PCD Function

= Summing Function

= Sub-Datum Function

= Blank Function

Note: The function key can be manually set to any function desired, see the function keys

Scale Factor setup
The Scale factor setting on the NMS 800 allows you to scale the DRO to the travel on your lathe or milling machine. This can be set by entering you preferred scale using the numeric keypad.

When on the setting simply insert the scale factor required and hit the

key.

1.000 This shows that the scale factor is set to 1:1 and will show the exact unit.

2.000 This shows that the scale factor is set to 2:1 and will show double what the travel is.

5.000 This shows that the scale factor is set to 5:1 and will show 5 times the travel.

Once input, simple press the undo key,

which will take you out of this menu.

14

Setting up the unit

Beep Enable setup
This DRO setting allows you to enable and disable any noise from the DRO. This function can be enabled or disabled through the DRO setup menu.

On This shows that the DRO will make a sound when keys are pressed.

Off This shows that the DRO will not make a sound when keys are pressed.

To cycle through these options, press the

key next to the `x’ axis and then

to exit.

Feed rate setup
The feed rate setting can be changed between minutes and seconds. These can be in both mm’ andinch’, these give the options of:

In/minutes, in/seconds, mm/minutes and mm/seconds. To set this press the

key.

Minutes This shows that the DRO is set to minutes.

Seconds This shows that the DRO is set to seconds.

To cycle through these options, press the

key next to the `x’ axis and then

to exit.

Function setup

The function setup allows you to scroll through all the different function on the NMS 800 and activate them within the DRO.

To scroll through the different setting press the

key.

on This shows that the function is on.

off This shows that the function is off.

To cycle through these options, press the

key next to the `x’ axis and then

to exit.

15

Setting up the unit (Digital)

Digital type setup
The digital type setting is a very important setting to tell the NMS 800 which type of encoder your using with your machinery.

There are 4 options to use with the NMS 800: (These apply if more than one axes are digital)

Rot Dec This shows that the DRO is for: Rotary decimal.

Rot dms This shows that the DRO is for: Rotary degrees, minutes and seconds.

Rot rpm This shows that the DRO is for: Rotary revolutions per minute.

Linear This shows that the DRO is for: Linear encoders.

To cycle through these options, press the

key next to the `w’ axis and then

to exit.

Rotary Mode setup The Rotary mode setup allows you to change the NMS 800 between two settings. These are for when a rotary encoder is being used with this DRO.
The two settings are: (These apply if more then one axes are digital)
contin Continuous: This feature does not stop at 360° and will carry on past.

rollover Roll over: This feature will stop at 360° and start back at 0°.

To cycle through these options, press the

key next to the `w’ axis and then

to exit.

Digital Res setup
The digital resolution feature is used for rotary encoders, this can be set to the resolution of the rotary encoder. Rotary encoder resolution is usually expressed as PULSE PER TURN (PPT), this is the number of pulses output per revolution

There is two ways to set this resolution, using

key to access these. The two are:

Program Program allows you to input your resolution using the keypad. Teach Teach, using a a reference mark on the encoder, will set the resolution on the NMS800.
16

Setting up the unit (Digital)

Digital Res setup teach

360000 Press the

key next to the “W” axis

digital res

360000 Press the

key

teach

0 Rotate you rotary encoder untill you here two audible tones. this should have then set your DRO to the resolution of your encoder.
rotate axis

Signal Check setup
The signal check feature allow you to enable or disable the comparison of the encoder signal to the table shown below. If this setting is enabled, and the signal does not match the table below, it will return with a SIG-FAIL message. (If 1 or more axes are digital)

To cycle between these press the

key along the `w’ axis.

on This shows the signal check is enabled and will show an error. off This shows the signal check is disabled and will accept any signal.

Once set, press the

key to return.

When this setting is enabled, the NMS 800 will check for the different signals required. If the signal retrieved is an illegal signal, the DRO will return with SIG FAIL as shown in the table below. If a signal comes back and is correct, the DRO will continue as normal.

A

B

RM

STATUS

L

H

SIG FAIL

L

H

X

OK

H

L

X

OK

X

L

OK

X=Don’t care state, L= Low state and H= High state. 17

Setting up the unit

Quad Index setup (Digital)
The quad index setting on he NMS800 activates the reference mark (Z). When this setting is off the DRO will only check for the A and B quadratures signals, but when this setting is activated, the DRO will check for A and B along with the Z quadrature signals.

The Two settings are: on This will be checking for A, B and Z
off This will only check for A and B

Press the axis select key

next to the axis to cycle through the options

Display Resolution setup
The display resolution settings available for each axis can not be finer than the encoder resolution. The inch/ mm setting will also define the resolution that is actually displayed as per the below table:

Display

µm

mm

in

0.1

0.0001

0.000004

0.5

0.0005

0.00002

1

0.001

0.00005

2

0.002

0.0001

5

0.005

0.0002

10

0.01

0.0005

NOTE – Resolution achievable is dependent on the encoder used.

Press the axis select key

next to the axis to cycle through the options

Gear Ratio
The Gear ratio setup allows you to scale your rotary encoder to any equipment in-between your encoder and your end product. The NMS 800 is set to a 1:1 ratio at factor settings.

You can change this ratio setting by pressing the pad.

key, and entering a value using the numeric key-

NOTE – THIS FEATURE IS ONLY AVAILABLE WHEN A ROTARY ENCODER IS CONNECTED

Once set, press the

key to return.

18

Setting up the unit

Zero Threshold setup
Zero threshold is a visual indicator that helps the operator identify when approaching zero on the display. The zero threshold the maximum setting defines the band of where the visual indication begins. For example if the setting was 5mm, the visual indication will begin when moving negative from 5mm or moving positive from -5mm.
Settings available for zero approach max are:

mm setting (Metric) 1 +/- 1mm 2 =/- 2mm 3 +/- 3mm 5 +/- 5mm
10 +/- 10mm

Inch setting (Imperial) 0.04 +/- 0.04″ 0.08 +/- 0.08″ 0.1 +/- 0.1″ 0.2 +/- 0.2″ 0.4 +/- 0.4″

Press the axis select key

next to the axis to cycle through the options

When activating the Zero Threshold feature on the NMS800, you will be asked to input a value on the desired axis.

x 1.00y 60.00z 0.00w

Enter the value you would like, and hit the
Example – If you set the zero thresh to 0.00. Along the “Y” Axis shows when you are closer to your threshold.
The “Z” Axis shows when you are a good amount of distance out. The direction of the arrows show which way you need to move to get to your point.
The “W” Axis shows what your display will look like when you hit the threshold point.

Newall mm

inc

set

NOTE – THIS FUNCTION IS ONLY AVAILABLE WITH 3/4 AXIS UNITS. 19

Setting up the unit

Plane Setup
The plane setting shows you currently which axes, or planes, are currently being summed together. You can change this so which ever axes that are required to being pairs.

To change the axes which will be summed, press the

key.

e——3x This screen currently shows that the X’ andY’ axes are pairs together for summing.

e——3y

z Pressing the

key next to the `X’ axis on the

DRO will cycle the `Y’ axis down through the remaining
w axes.

Which ever the axis is highlighted when coming out of this
menu will be pairs together and show the combined total of both encoders.

Newall mm

inc

set

NOTE – THIS FUNCTION IS ONLY AVAILABLE WITH 3/4 AXIS UNITS.

Summing Setup

The summing setting on the NMS 800 allows your to activate whether the two axes, or planes, that you have selected with the Plane setting show as one unit on the DRO screen.

Press the axis select key

next to the axis to cycle through the options

on This shows the summing feature is activated and will show the total of the axes.

off This shows the summing feature is disabled and will show each axes as is.

NOTE – THIS FUNCTION IS ONLY AVAILABLE WITH 3/4 AXIS UNITS. 20

Setting up the unit

Encoder Direction setup

This setting allows the user to match the NMS800 to the actual direction of travel of the axes fitted to the machine.

The two settings available for each axis are

—-3 and E—-

Press the axis select key Example: If the current setting is setting to E—-

next to the axis to cycle through the options
—-3 and the travel is positive from right to left, changing the will reverse the direction to measure positive from left to right

Measurement Mode setup
The radius /diameter function allows the user to display actual (radius) or twice-actual (diameter) measurements for each axis.

This function is generally used in turning applications, such as the cross travel on a lathe where the diameter reading is displayed rather than the radius.

There are two setting for each axis:

Radius

rad

Diameter

dia

Press the axis select key

next to the X’,Y’ or `Z’ axis to cycle through the options

Error Compensation
The digital readout (DRO) system helps to improve productivity. It decreases the number of scrapped parts, as there is no concern about making mistakes related to counting the revolutions on the dials. The DRO system also helps to eliminate some errors related to ball-screw backlash.
The DRO system will operate to its published accuracy, provided all components are in working order and properly installed. Field calibration is not necessary.
Accuracy problems with machined parts may be caused by machine error, DRO system error, or a combination of both. The first step in determining the source of error is to check the DRO system. To do this compare the movement of the Newall reader head to the position reading shown on the display. A high accuracy standard, such as a laser interferometer is required. A dial indicator can be used to check short distances, but a laser provides the best results. If a dial indicator must be used, be sure it is the highest available accuracy.

21

Setting up the unit

Error Compensation Continued
To check the accuracy of the DRO system:
1. Place the target of the laser or the needle of the dial indicator directly on the Newall reader head. It is absolutely critical that the readings are taken directly from the Newall reader head. If a dial indicator must be used, be sure that the needle of the indicator is perpendicular to the reader head and not angled. If readings are taken anywhere else on the machine, machine errors may distort the results.
2. When the reader head moves, the movement registers on the laser / indicator and DRO display.
3. Set the laser / dial indicator and DRO position displays to 0.
4. Make a series of movements and compare the position readings between the laser / dial indicator and the DRO display. If the readings match within the accuracy specified, it proves that the DRO system is operating properly. If this is the case, proceed to the next step: evaluating the machine errors. If the readings do not match, the DRO system must be repaired before proceeding with error compensation.
To evaluate machine errors:
1. Put the laser target / dial indicator on the part of the machine where the machining is done.
N 2. Make a series of movements and compare the position readings between the laser / dial indicator and
the DRO display. The difference between the laser / dial indicator reading and the reading on the DRO display is the machine error.
3. Plot the machine error along the entire axis of travel to determine the nature of the error. If it is a linear error, use linear error compensation. If the error is not linear, use segmented error compensation.
Types of Machine Error There are many types of machine error, including pitch, roll, yaw, flatness, straightness, and
N Abbé error. The diagrams below demonstrate these errors.

Way errors

Pitch Axis

Typical Pitch Deviation

Yaw Axis

Typical Yaw Deviation

Straightness

Roll Axis

Flatness

Travel

Abbé error

C2
B
greater than
A
End Effector

C1
B1
Encoder
A1
Linear encoder

C2
B2
less than encoder A2

End Effector

C1
B1
Encoder
A1
Linear encoder

Shown with encoder on concave side Shown with encoder on convex side of

of bearing path

bearing path

C2

B
22

C1

C2

B1

B2

A1

A2

A1

Setting up the unit
Linear Error Compensation In this mode, a single constant correction factor is applied for each axis for all displayed measurements. Calculate the correction factor, and specify it in parts per million (ppm).
When following the procedure ensure that a stepped standard is used, and approach each edge from the same direction; or if each edge must be approached from opposite directions, then subtract the width of the tool or measuring probe from the value displayed on the NMS300.
Segmented Error Compensation The scale travel is broken down into as many as 200 user-defined segments, each with their own correction factor, measured against a high-accuracy standard. The following parameters need to be identified:
Each Correction Point is measured with respect to the Starting Point – zero – which is usually set close to one end of the scale. The Reference Point can be set anywhere along the scale, and does not need to coincide with either the absolute datum or any of the correction points. However, it may be convenient to make the absolute datum and the reference point the same. Always approach the Starting Point, Correction Points and Reference Point from the same direction. If not, then the size of the tool or probe will render the measurement inaccurate.
23

Setting up the unit

Teach Mode

Teach mode is an easier way of calculating linear errors by using the NMS800 to automatically calculate the error. This is achieved by comparing the actual measurement and the physical movement. The procedure to do this is shown below.
Navigate to the Error compensation selection screen setup- err comp

The default value for each of the axis is

nonE

Navigate to the Error compensation selection screen setup- err comp

The default value for each of the axis is

nonE

When wanting to change each axes, press the

key to take you to the options.

The three options are:

none No error compensation is in use
Comp linear Point to point error compensation
comp segment Multiple point error compensation Once you have selected the option you will get the option of teach or program. Use the lect the teach option.

key to se-

lin1-

0 last compensation value calculated / used

teach

to choose teach rather than program

tch1-

0.000 encoder position (start point) start

1000.000 encoder position (end point)

tch1-

END

24

Setting up the unit

Teach Mode Continued tch1- movement enter the actual measurement using the numeric keypad
1000.500 value entered in previous step tch1- movement

tch1-

-500 Linear compensation value (ppm) accept

lin1-

-500 teach

To exit setup and return to menu, or

to exit setup and return to measurement display

Program Mode Program mode allows the linear compensation to be calculated manually and then entered as a PPM value into the NMS800 display. The procedure to do this is shown below:
To illustrate the calculation an example is being used where the standard distance is 500.000mm and the measured distance is 500.200mm.
Correction factor = error / actual x 1,000,000 Correction factor = (500.000 – 500.200) / 500.000 x 1,000,000 Correction factor = -400 PPM
To enter this value into the display:

Navigate to the Error compensation selection screen setup- err comp

The default value for each of the axis is

nonE

Navigate to the Error compensation selection screen setup- err comp

The default value for each of the axis is

nonE

25

Setting up the unit

Program Mode Continued When wanting to change each axes, press the

key to take you to the options.

When selected choose whether you need teach or program, select program.

seg1- program

to choose program rather than teach

2.000 Correction point position 0.150 Correction value (compensation)

prg 1- seg 001

Note: Pressing

will delete both correction point position and correction value (Set to 0)

to move to segment 2 and the repeat the process above

to exit setup and return to menu, or

to exit setup and return to measurement display

When segmented compensation is enabled it is necessary to move to a start / reference point when the unit has had its power cycled. The below message will be shown on the NMS300 display when this is required.
reset
reset- segments Reset Setup
This setting enables the NMS800 to be reset to its default parameters. WARNING:: Enabling this setting will erase any data that was previously stored in the functions and settings of the readout.

setup-

reset Navigate to this message display in settings

reset-

no sure

Confirm that a reset is required by pressing the axis key

to exit setup and return to menu, or yes

to exit setup and return to measurement display

reset-

sure

26

Setting up the unit
Notes
27

Standard functions
Function Menu func- arc Arc contouring function – Generic & Mill
func- digifind Digifind reference function – Generic, Mill and Lathe func- feed Feed rate function – Generic, Mill and Lathe func- grid Grid Hole Function – Generic & Mill
func- summing Summing function – Generic, Mill & Lathe func- logging Logging function – Generic, Mill & Lathe (ONLY SELECT MODELS) func- tool comp Tool Compensation function – Generic, Mill & lathe
func- pcd Pitch Circle Diameter / bolt-hole function – Generic & Mill func- pocket Pocket or island milling – Generic & Mill func- sub datum Sub datum memory Function – Generic, Mill & Lathe func- tapper Tapper turning – Generic & Lathe func-tool offset Tool offsets – Generic, Mill & Lathe func- vector Vector Function – Generic, Mill (ONLY 3/4 AXIS)
28

Standard functions

Absolute / Incremental

Press the

key to toggle between absolute and incremental

Abs

modes.

The NMS800 has a dedicated key to switch the positional displays

between absolute (abs) and incremental (inc) measurements. The

current display mode is indicated at the bottom of the screen as

Inc

shown on the right.

Using incremental mode

In Incremental mode the DRO displays the position relative to
the last position. This is also known as point-to-point use. In this mode set the value for each axis, or zero it to create an Incremental datum. This does not effect the machine’s Absolute datum that is configured in Absolute mode.

Using absolute mode

30

70

In Absolute mode the DRO displays the positions of all the axes with respect to a fixed datum. The datum is set by entering an axis position when in Absolute mode.

Absolute (abs) mode has been selected
Incremental (inc) mode has been selected

40

50

Example of absolute and incremental use

Set absolute zero at lower left corner of the part 0.000
0.000
Move to second position in ABS (hole B) 150.000
100.000
Make an incremental move to hole C
0.000
50.000

Move to first position in ABS (hole A) 30.000 30.000
Switch to incremental mode and zero the display
0.000 0.000
Switch to absolute mode
150.000 150.000

200 30

30 100

140 190

Y
A (0,0) 30

300 C
B
150

50

100

29

Standard functions

Zero and Pre-set an Axis

Press

to toggle between set and zero modes.

Set

The NMS800 has a dedicated key to switch the operation of the axis

selection key between zero and set modes. The currently selected mode

is indicated at the bottom right of the screen as shown.

Zero

Set mode has been selected
Zero mode has been selected

Using set mode With the set mode selected, the select axis key prompts a numeric entry into the desired axis. Once the correct value has been selected, it can be set into the axis by pressing the enter key. This can be seen in the example on the right.
Zeroing an axis in set mode With set mode selected, it is possible to zero an axis conveniently by holding down the axis select key for at least 3 seconds. This allows the user to zero an axis but stay in the pre-set mode. Use of this feature can be seen in the example on the right.
Using zero mode With zero mode selected, this enables the select axis keys to zero each axis independently. This can be seen in the example on the right.
Inch and mm Modes

0.000 0
-145.230 -145.230
0.000 -145.230
0.000

Press

to toggle between Inch and mm measurement modes.

mm

The NMS800 has a dedicated key to switch the positional displays between imperial (inch) and metric (mm) measurements. The current display mode is indicated at the bottom left of the screen as shown right. In

30

Metric (mm) mode has been selected X
Imperial (In) mode has been selected

Standard functions

Setting Function keys define fn bins

Func –

PCD

to select different

func 1

function

to select different function key

Func –

Line func 2

to save and return to menu, or

to save and return to measurement display

Quick Setting Function Keys
It is possible to set the function keys without having to go though the menu structure, this enables the function keys to be defined quicker if they need to be changed more often.

Long

or

Func –

PCD

to select different

func 1

function

Or

or

to save and return to measurement display

Using Function Keys

Before being able to use a function key it must be assigned to a function as per the above instructions, this may have been completed by setting the unit to a machine type in the setup.

or

Set the parameters and/or use the function selected

31

Standard functions

Digifind / reference function
NOTE: THIS FUNCTION WILL ONLY FUNCTION WHEN YOUR NMS800 IS IN ABSOLUTE MODE
The NMS800 comes equipped with Digifind, a feature unique to Newall digital readout products. Digifind eliminates the risk of losing position and datum Set-Up. With Digifind, precise Set-Up of a work-piece is carried out only one time. When the NMS800 is powered on, it displays the position at power off, compensated for any movement of a Spherosyn encoder up to 0.2500″ (6mm) and a Microsyn encoder up to 0.1000″ (2.5mm) in either direction since the unit was last used. If the machine has moved beyond 0.2500″ (6mm) – Spherosyn [0.1000″ (2.5mm) – Microsyn], Digifind allows a quick means to find the datum if lost. A mark must be made on both a stationary part and moving part of the machine. The marks must be aligned and will serve as the machine “home” position. The mark must be indelible, and it must allow the operator to move the machine to within a 0.2500″ (6 mm) – Spherosyn [0.1000″ (2.5mm) – Microsyn ] band around the mark at any time. Alternatively, use a convenient reference point on the work-piece.
To use digifind one of the function keys must be assigned to the digifind function – see the section function keys
Setting the reference
Press the function key that has been assigned to digifind, (in this example the digifind has been assigned to the F3 key).

digi- set ref

ST rf- sel axis

Press the axis select key

next to the X’,Y’ or `Z’ axis that requires the reference setting.

Finding the reference “
If the reference is lost at anytime it is possible to `find’ the reference again. Position the machine to within 6mm (0.2500″) band for Spherosyn and 2.5mm (0.1000″) band for Microsyn. Press the function key that has been assigned to digifind, (in this example the digifind has been assigned to the F3 key).

digi- find ref

fd rf- sel axis

Press the axis select key

next to the X’,Y’ or `Z’ axis that requires the reference to be found.

Finding zero
If the datum is lost at anytime it is possible to `find’ the datum again. Position the machine to within 6mm (0.2500″) band for Spherosyn and 2.5mm (0.1000″) band for Microsyn. Press the function key that has been assigned to digifind, (in this example the digifind has been assigned to the F3 key).

digi-

find 0

fd 0- sel axis

Press the axis select key

next to the X’,Y’ or `Z’ axis that requires the reference setting.

NOTE – WHEN USING THE REFERENCE, THE VALUE YOU HAVE INPUT WILL BE YOUR RETURN DATUM. – WHEN USING FINDING ZERO. ZERO WILL BE YOUR RETURN DATUM

32

Standard functions

Sub datums / memory
The NMS800 can store up to 200 SDM (Sub-Datum) positions, or machining steps into the memory. Using SDM allows the operator to work to zero by calling up stored dimensions, instead of “working up” to drawing dimensions. This eliminates the need to constantly refer to the drawing, and reduces the possibility of scrapping parts due to misread dimensions. It also speeds up positioning because the operator works to zero. The SDMs are stored as co- ordinates relative to the current absolute / incremental datum position. If the absolute / incremental datum position changes, the SDMs will “shift” to the new datum. Once a repetitive sequence of co-ordinates is entered into SDM, the co-ordinates can be recalled at any time. The positions remain in memory until altered by the operator. Simply assign any SDM number 1 – 200 to each machining step. When machining, call up each step (SDM) number and work to zero. There are two ways to store Sub datums, Teach mode and program mode. See example on the next page:
To use sub datums one of the function keys must be assigned to the sub datum (SDM) function – see the section function keys
Teach Mode
To use sub datums one of the function keys must be assigned to the sub datum (SDM) function – see the section function keys
Press the function key that has been assigned to sub datums, (in this example the sub datum has been assigned to the F2 key).

Sdm-

teach

Sdm-

tch 001

Move the axis X’,Y’ and/or `Z’ to the 1st location

Sdm- captured

Sdm-

tch 002 Repeat the above process for additional SDM locations

to return to the main SDM menu
Program Mode Press the function key that has been assigned to sub datums, (in this example the sub datum has been assigned to the F2 key).

Sdm-

program

Sdm-

prg 001

Press the axis select key

next to the X’,Y’ or `Z’ axis that requires the position setting, enter the

dimension using the numeric keypad.

Note: Pressing

will delete all offset values displayed (Set to 0)

Sdm-

prg 002 Repeat the above process for additional SDM locations

To return to the main SDM menu

33

Standard functions

Delete Mode

Press the function key that has been assigned to sub datums, (in this example the sub datum has been assigned to the F2 key).

Sdm-

delete

no

yes

Sdm-

sure

Sdm-

sure

Important note: this will delete all the current data in all SDM’s

Use Mode

Press the function key that has been assigned to sub datums, (in this example the sub datum has been assigned to the F2 key).

Sdm-

use

Sdm- 001

Or use the numeric keypad to input sub datum required

Sdm- 002

To exit SDM use and return to SDM menu, or

to exit setup and return to measurement display

The function can also be exited by pressing the function key that has been assigned to sub datums

Feed Rate Function

To use the feed rate function one of the function keys must be assigned to feed – see the section function keys Press the function key that has been assigned to feed, (in this example feed has been assigned to the F2 key).

feed-

0

Important note: the feed rate will be shown for the fastest moving axis

Tool Offsets

To use tool offsets feature, simple hit the

key (short press).

This will then take you to the tool offset function menu which you then press the key next to the “X” axis.

A long press of this key will turn off the tool offset function.

The NMS800 can store up to 50 tool offsets, this large number allows tools to be grouped where more than one set is used. For convenience, it is highly recommended that tools are physically marked with their corresponding tool number. There are multiple ways to set tool offsets, teach mode, program mode and quick edit mode. Note: Once tools are enabled they stay enabled even when other functions are used, until disabled.
34

Standard functions

Teach Mode

TEACH MODE IS ONLY ACTIVE WHEN YOUR DRO IS IN LATHE MODE THE UNIT MUST NOT BE IN “USE TOOL” MODE TO TEACH.

Tool-

teach

Take a skim cut with X and/or a face cut with Z

Tool-

to capture all axes

Tool-

tch 01 to select different tool
captured

Note: to capture a single axis press the axis select key instead of the enter key

Display will now show

0 . 000 0 . 000

Note: at this point the tool can be moved away from the part

Tool-

value

Measure the part with an accurate gauge and enter this value into the relevant axis Repeat the process above for all other tools required

To return to the previous tools menu, or

to exit tools menu and return to measurement display

Program Mode

Note: Pressing

Tool- program
Toolwill delete all offset values displayed (Set to 0)

0 . 000 prg 01

To select different tool

Take a skim cut with X and/or a face cut with Z

Note: at this point the tool can not be moved away from the part
Measure the part with an accurate gauge and enter the difference between the measured diameter and the readout value into the relevant axis (see using set mode page 22)
Repeat the process above for all other tools required

to return to the previous tools menu, or Use Mode

to exit tools menu and return to measurement display

Tool-

use

TL- 01

to select different tool

Note: Different tools can be selected by entering the tool number required using the numeric keypad

35

Standard functions

Quick Edit Mode
While in the using tool offsets mode tools can be edited / created quickly, without having to go back though the tool program or teach modes. The procedure to do this is demonstrated below:

0 . 000
Set
0 . 000
tl – 01

to select different tool

of axis required

Datum recall

tlDTM – RECALL

Enter position value using numeric keypad

Repeat the above process for other axes or tools

Delete mode

This function is designed to delete ALL the tool offsets, if one tool is to be changed quick tool edit should be used.

Tool-

delete

Tool –

No sure

Tool –

Yes sure

36

Standard functions

Logging Function (ONLY SELECT VARIANTS)
The NMS800 readout is capable of offering basic serial communications via a dedicated hardware RS232 compatible port, This is only used for output purposes and is how the logging function operates.

The communication parameters for the NMS800 are: 115200 band, no parity, 1 stop bit, 8 data bit.

Logging Connection (RS232)
On the back of the NMS800 is a 15 way D female connector that is used to allow logging data to be output to another compatible RS232 device. The connections required to make this happen are detailed below:

Pin 5 – RS232 GND

Pin 3 – RS232 TXD

Pin 15

Pin 2 – RS232 RXD Pin 1

A serial cable is available from Newall, please quote part number 307-83210 when contacting your local Newall supplier for more details.
Using the Logging Function
Whilst using the logging function you will have the option between two output types “ENT” and “PERIODIC”

To change between these two output types simply press the

Key.

eNT This output type is “ENT” or enter allowing logging every time the OUTPUT TYPE

key is hit.

periodic This output type is periodic, this allows you to set a logging function every set time. OUTPUT TYPE

10.00 The imputed figure shows how many seconds are in between logging, this is set to 10 seconds period

to exit setup and return to main menu, or

to exit setup and return to measurement display

37

Mill functions

Arc contouring

To use arc contouring one of the function keys must be assigned to the arc contouring function – see the section function keys Press the function key that has been assigned to arc contouring, (in this example arc contouring has been assigned to the F3 key).

The NMS800 calculates positions for a series of equally spaced holes in an arc. The message display prompts the user for

various parameters it needs to do the calculations.

Once the NMS800 completes the calculations, the axis displays show the distance to each hole. The operator works

to zero for each hole location. See example below.

Arc-

Centre

Enter centre co-ordinate

3 . 35000

2 . 36000

Arc-

start

Enter start co-ordinate

2 . 25000 4 . 82600

ArcArc-

end radius

Enter end co-ordinate Enter the radius of the arc

5 . 35000 4 . 17400 2 . 70000

Arc-

Tool dia

Enter the tool diameter being used

0 . 50000

Arc-

max offset

Arc- cut type

Enter the maximum cut required Enter the cut type required

0 . 15000 int

RUN FUNCTION

At any stage the

keys will move back and forth through the above menus to

Make any further adjustments, if the settings are OK then press

-2 . 3520

-4 . 5974

Arc-hole

001

Navigate through the sequence of holes by using

Alternatively use the numeric keypad to select the hole required.

4.826″

Y axis
0.5″ tool diameter

0.15″ max cut

4.174″ 2.36″

2.7″ Radius Arc
centre

Internal cut

The maximum number of holes for this function is 999 To exit line hole use and return to line hole menu, or

Datum

To exit line hole and return to measurement display

2.25″ 3.35″ 5.35″

The function can also be exited by pressing the function key that has been assigned to line hole

38

Mill functions

Pocket / Island Milling

To use pocket milling one of the function keys must be assigned to the pocket milling function – see the section function keys Press the function key that has been assigned to pocket milling, (in this example pocket milling has been assigned to the F1 key).

The NMS800 calculates positions for each corner of pocket / island required. The message display prompts the user for various parameters it needs to complete the calculations. Once the NMS800 completes the calculations, the axis displays show the distance of each corner from the datum. The operator works to zero to complete a circumference cut of the pocket / island. See example below.
350 . 000 Enter centre co-ordinate
400 . 000

Pckt-

centre

200 . 000 Enter Dimension of the pocket / island required

200 . 000

Pckt- dimention

8 . 000 Enter the tool diameter being used

Pckt- tool dia

int Enter the cut type

Pckt- cut type

Run function

Pckt-

go At any stage the

keys will move back and forth through the above menus to

-254 . 000 make any further adjustments, if the settings are OK then press

-304 . 000

pckt-point

1

Navigate through the sequence of corners by using
Alternatively use the numeric keypad to select the corner required. The number of pocket points will always be 4 it is expected the user will reach point 4 and move on to point 1 to complete the pattern
To exit line hole use and return to line hole menu, or
To exit line hole and return to measurement display
The function can also be exited by pressing the function key that has been assigned to line hole

39

Mill functions

PCD / bolt hole circle

To use PCD / bolt hole circle one of the function keys must be assigned to the PCD function – see the section function keys Press the function key that has been assigned to PCD, (in this example the PCD has been assigned to the F2 key).

The NMS800 calculates positions for a series of equally spaced holes around the circumference of a circle. The message display prompts the user for various parameters it needs to do the calculations. Once the NMS800 completes the calculations, the axis displays show the distance to each hole. The operator works to zero for each hole location. See example below.
125. 250 Enter centre co-ordinate
99. 700

PCD-

Centre

PCD-

150. 000 Enter diameter value diameter

PCD-

5 Enter the number of holes holes

18 Enter the start angle

PCD-

angle

Important note: The PCD will be calculated from the 3 O’clock position, anti- clockwise. Enter the angle as a negative value if it is given as clockwise from the 3 O’clock position.

RUN FUNCTION At any stage the

keys will move back and forth through the above menus to

make any further adjustments, if the settings are OK then press

-196. 580

-122. 880

PCD-hole

1

Navigate through the sequence of holes by using

Y axis

(-196.580, -122.880) Starting hole
Circle centre

Alternatively use the numeric keypad to select the hole required. 99.7mm

The maximum number of holes for this function is 999

to exit PCD use and return to PCD menu, or

Datum

to exit PCD and return to measurement display

125.25mm

The function can also be exited by pressing the function key that has been assigned to PCD

150mm diameter

X axis

40

Mill functions

Grid
To use grid, one of the function keys must be assigned to the grid function – see the section function keys Press the function key that has been assigned to line hole, (in this example the line hole has been assigned to the F3 key).
The NMS800 calculates positions for a series of equally spaced holes in a grid. The message display prompts the user for various parameters it needs to do the calculations.
Once the NMS800 completes the calculations, the axis displays show the distance to each hole. The operator works to zero for each hole location. See example below.

0.00 0.00

Enter starting co-ordinate of where you want your grid to start.

Start point

5 Enter the number of holes required for your grid on the “X” and “Y” axis.

5 To change the number press the Number of holes

next to the axis, and use the keypad.

20.000 Enter the dimensions of the outer perimeter of the Grid.

20.000 To change the number press the

next to the axis, and use the keypad.

dimention

45.000 Enter the angle you would like the grid to be at.

To change the number press the

next to the axis, and use the keypad.

angle

run function

Use the

key to scroll through all holes that the NMS800 has worked out for you

For each hole, you will take the readout down to zero and drill your holes.

41

Lathe functions

Vecor
Vectoring combines the movement of the “X” and “Z” axis with the angle of the compound
NOTE: THIS FUNCTION IS ONLY AVAILABLE ON 3 AND 4 AXIS UNITS
If the compound is set at and angle, vector is the function you need. If the compound is aligned with the “X” or “Z” axis, then the summing function should be used.

30.000 Enter the desired vector angle using the keypad angle

Once hitting the

this will take you back to the home page and show the vector is running.

Taper Turning
To use the taper one of the function keys must be assigned to the taper function – see the section function keys Press the function key that has been assigned to taper, (in this example taper has been assigned to the F2 key).
The taper function shows the angular displacement of the displayed (X,Z) position.

touch tool to one end of the taper and zero both axes, then touch the tool on the other end of the taper.
10 . 000 50 . 000 Taper 11 . 30993

10.000 mm

50.000 mm

42

Trouble shooting guide

Symptom

Solution

The display is blank
The display works, but resets from time to time without any keys being pressed.

· The NMS800 maybe in sleep mode. Press any key to exit sleep mode · Check that the power supply is correctly connected to a working mains outlet · Check that the power supply cables are not damaged · Check that the power supply voltage is 15 – 24Vdc ±10%
Either the supply voltage is too low, or the power supply or mains supply has an intermittent fault. · Check that the power supply voltage is 15 – 24Vdc ±10%. · Check that all the connections are secure.

The display works, but gives erratic readings, the last digit jitters or the measurements jump to new figures unexpectedly.

There may be a poor earth (ground) connection. Both the NMS800, and the machine on which it is installed, must have proper earth (ground) connections.
There may be a problem with the encoder.

The unit does not respond to any key presses.

Disconnect the NMS800 from its power supply, wait 15 seconds and then reconnect.

NO Sig’ /SIG FAIL’ or `1.x’ appears in the display.

This indicates that the unit is not receiving a proper signal from the encoder. · Check that the encoder connections are secure. · Check that there is no damage to the connectors or to the encoder. · Switch the NMS800 off and back on again.

Readings are incorrect.

· Check the Encoder Type to ensure it is correct.
· Check the resolution set in NMS800 matches the encoder connected. · Check a scaling factor has not been set in the NMS800. · Check the Error Compensation factors.
· Check that there is no damage to the encoder or its cable. · Check that the encoder is fixed firmly and aligned correctly, as described in the Spherosyn / t Microsyn Installation manual. · Check that there is no binding on the scale. With the scale brackets slightly loosened, you should t be able to slide the scale back and forth with minimal resistance. · If a Spherosyn scale is in use, check that the scale is not bent, by removing it and rolling it t on a flat surface.

If the solutions suggested above do not solve the problem, contact Newall for further instruction

43

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October 25, 2023

CONTACT US
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