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MINISCAI..E INSTALLATION 1 _

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I. INTRODUCTIOl'J
Apparently most installers only read the installation instructions when they run into trouble.
For this reason the most important points _.. the ones most likely to result in damage -­
have been put in section H. READ THIS BEFORE STARTING.
Installers are strongly advised to read section II before attempting to install miniscales.

C,'-\UTION
It is important to properly install the miniscales, as
described in this manual. Failure to do so may result in
severe miniscale damage.
WARRANTY DOES NOT COVER FAULTY INSTALLATIONI

If the system was mounted by the supplier before being shipped and it does not work upon arrival:
1. Check for any damage which may have occurred during shipment.
2. Contact the freight company as soon as possible to report any potential damage.

Miniscale Components
1. Spar.
2. Encoder Box which travels along the spar.
3. Cable for power to miniscale and output from miniscale.
4. Connector to digital readout.
5. Alignment bracket.
6. Endcap.
7. Endcap which ca.'} be used in place of alignment bracket after installation, if desired.

cp ~
--@~o[]/
----~-_._-

=-~~------\~ =======0
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Figure 1" Miniscale Components
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II. READ THIS BEF()RE STARTIN(;
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r~ Miniscales contain precision electronic and glass components. po nol drop, bend or hammer on the
miniscales.
o Before beginning installation, verify that your miniscales have the correct travel.
The overall miniscale length is not the travel. The travel is specified by the part number.
Example: An XT350-12 miniscale has a 12 inch travel. Overall length is 16 inches (12 + 4).
D Do not loosen or remove the alignment bracket until installation is complete. The alignment bracket
is designed to simplify installation. For installation, position the table to its maximum travel in one
direction. See Figure 6 for example. If a special application requires removing the alignment bracket
to slide the encoder box over, call the factory for an optional encoder box slide bracket.
o The miniscale may be mounted to a machined surface providing the surface is parallel to the table
movement.
o Do not mount the spar directly to an uneven surface. Use a backplate if the surface is not an
accurately machined surface. See Figure 7 for example.
D The machine must have mechanical stops that prevent overtravel. Mount stops if necessary. Do not
remove stops after miniscale is installed. If table travel is greater than the specified miniscale travel,
contact your dealer to obtain the correct travd length miniscale.
o Do not offset the miniscale (extra travel on one end, insufficient travel on the other end). This is
prevented by:
1. Having the correct travel miniscale, ~
2. Moving the table all the way to its mechanical stop before the miniscale is installed, A1\1D
3. By not removing the alignment bracket until installation is complete.
D Do not drill holes at an angle. Do not improperly space holes. These errors may cause bowing or
sagging of the miniscale. See Figure 2.
..-----------'-'----------_._---
CAUTION
......

Mounting holes are normally transfer punched t:o locate

the proper hole location. Since these holes are hand
drilled, it is advisable to beqln by drilling a smaller guide
hole to prevent the larger drill bit from "walking".

-~-~~~~G- j~l-
,-----------------'
-----------<"j
Figure 2. Improper Drilling
o Use a micrometer or dial indicator to indicate the front and the top of the spar surface. The spar
must be parallel to the table travel to within 0.005 inch, in both planes, over the entire travel of the
miniscale.

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o Adjust encoder box set screws before
tightening the mounting screws. The
encoder box must be centered relative
to the spar. See Figure 3. The alignment
bracket ensures that the encoder box is
properly positioned. Keep the alignment
bracket secured until installation is
complete.

C
Figure 3. Encoder Box Mounting .-vvv.IVWV~~~

o Do not cock the encoder box. Parallelism must be maintained. See Figure 4.
----- ----------

Figure 4. Cocked Encoder Box

U After installation, verify that it is not possible to overtravel the miniscale. The maximum left travel is
the same with or without the alignment bracket. See Figure 5.

CAUTION
Overtraveling the encoder box will result in severe
damage. The miniscale does not have "stops" in it. The
u alignment bracket cannot be used as a mechanical stop.

r ~~- Maximum travel, left side Maximum travel, riight side ----l
I
I
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Figure 5. Maximum Miniscale Travel

U Do not leave miniscale cables hanging loose. They may be caught and pulled out. Dress and secure
with tie-wraps and cable anchors.

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Ill. GENERAL
The following sections describe installation procedures for Bridgeport/Lagun type kneemills. The same
guidelines are applicable for lathes (where miniscales are used), grinders, EDMs, comparators, etc.

Hardware
For systems that include hardware kits, the part number is located on the hardware kit box and on the
corresponding hardware drawing. Verify that you have the correct hardware kit and drawing for your
application.
Machines vary from type to type. Also, machine manufactures may change specifications without notice.
For these reasons, installation hardware may require some modification. Due to the dynamic nature of the
machine tool industry, hardware kits and drawings are subject to change without notice.
Other machine types may require special hardware fabrication; however, actual miniscale installation
follows the same guidelines. The installer must maintain the specified spar alignment tolerances to achieve
optimal performance and accuracy. Custom installations may be completed by the end user without
assistance; however, factory assistance is available if necessary.
Standard machine shop practices should be used always; for example, safety, set up, cleaning of fluids,
swarf, etc.
Mounting Area
The miniscale may be mounted directly to a flat, accurately machined surface such as the back of the table
on a mill, providing the surface is parallel to the table travel. If the surface is not flat, such as the Yaxis
mounting surface on a mill (the knee) or the bed of a lathe, then the use of a backplate (included with
most mill hardware kits for Y axis travel) is required. Also, the use of shim stock between the miniscale
and the table surface can correct minor deviations. Adjustment must also be made for any obstructions
such as oil lines, power feeds, etc.

Cabie Routing
The miniscale may be mounted with the cable exiting in either direction. Mounting considerations and
miniscale cable routing must be taken into account by the installer to determine which orientation is best.

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IV. MILL - X AXIS l\1[INISCALE ][NSTALLATION
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Figure 6. X Axis Miniscale

1. It is recommended that the miniscale be mounted on the back of the table with the encoder box
mounted to the saddle. A miniscale guard (supplied with mill hardware kits) is then mounted over
the miniscale for extra protection.
2. Move the table fully to one end of its travel and lock it in that position. See Figure 6. Determine
whether the miniscale will be mounted with the cable exiting to the left or to the right. Position the
miniscale assembly against the back of the table so that the bottom longitudinal edge of the miniscale
is flush with the lower edge of the table. Position the miniscale so that it does not cover any drain
holes which are located at the ends of some tables. Route cabling so that the miniscale guard will not
snag it.
3. Transfer punch the two mounting holes (located on each end of the miniscale) to the table. Refer to
Section II for drilling precautions. Drill/tap for 1/4-20 x 3/4 low head socket cap bolts and mount the
miniscale.
HELPFUL HINTS
The miniscate can be easily positioned by resting it on two
mag-bases placed under the table.
Holes can be more accurately positioned as follows:
II

..
..
Transfer punch, then drill/tap the first hole.
Mount. the miniscale with one bolt so that it will pivot.
Level the miniscale then transfer punch and drill/tap
+
drill is centered
the second hole.
Using a pencil to draw crosshairs at the punch mark
makes it easier to see if the drill is centered.
1­
drill has walked

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4. Indicate the spar surface (top) using a depth micrometer, dial indicator or calipers. Adjust the two
miniscale ends so that the spar surface is parallel to the table travel within 0.005 inch over its entire
travel
5. Compensate for any bowing or sagging of the miniscale that may have been caused by inaccurate
drilling.
DO NOT PROCEED BEFORE MAKllI,JG ANY NECESSARY CORRECTIONS.
6. Encoder Box Mounting
a. Verify that the gap between the encoder box and the hardware mounting surface is less than
0.125 inch. See Figure 3. Ifit is not, a block must be fabricated to mount the encoder box.
b. Transfer punch the two encoder box mounting holes to the saddle surface. Move the table so
that holes can be drilled. Drill/tap for 8-32 x 3/4 socket cap screws.
c. Return the table to its end of travel position. Insert and adjust the 4 encoder box set screws
(5-40) until they just touch the mounting surface. Improper adjustment can force the encoder
box out of its calibrated position and may cause erratic miniscale performance and damage.
d. Mount the encoder box with the two 8-32 x 3/4 socket cap screws. Do not overtighten the
encoder box mounting screws.
e. Release the encoder box from the shipping bracket by removing the 10-32 x 3/8 pan head
screw. The alignment bracket may be left on the miniscale or replaced with the end cap provided
in the hardware kit.
NOTE
Save the alignment bracket for future use (Machine
cleaning, service, etc.).
f. Release the table lock and move the X axis table to its two extreme positions while monitoring
the encoder box travel.
VERIFY THAT THE MINISCALE CANNOT BE OVERTRAVELED. See Figure 5.
7. Position the miniscale guard over the spar. Drill/tap for 8-32 x 3/8 pan head screws.
8. Install a cable clamp on the table where the cable just exits under the miniscale guard. See Figure 6.
After installing the miniscale guard, it may be necessary to bend it out to provide additional clearance
for the cable. It is not advisable to exit the cable out the end of the guard since during travel it may
catch and pull the cable from the encoder box.
9. Install the "0" ring in the groove of the guard and mount the miniscale guard using the 8-32 x 3/8
pan head screws.
10. Route and secure the cables to the display. Ensure that the cables are not hanging loose to be caught
on any part of the machine during operation.
NOTE
Do not run miniscale cables parallel with power wires.
Induced noise may cause the display to miscount. Maintain
a minimum of 6 inches between cables and cross at right
angles.

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 v. MILL - Y AXIS MINISCALE INSTALLATI()N

..~.

Figure 7. Y Axis Miniscale

1. It is recommended that the miniscale be mounted on the right side of the mill knee as viewed from
the front. See Figure 7. Due to mill variations and specific applications it may be necessary to mount
the miniscale on the left side. In most cases, the miniscale is best mounted with the encoder box (as it
is locked to the alignment bracket) closest to the front of the mill.
2. Bridgeport mills have holes pre-drilled for backplate mounting. The Bridgeport hardware kit
(515-M-BP) comes with a backplate that mounts directly to these mills. Other mills may also have
these pre-drilled holes. Most imported Bridgeport style mills do not have these holes and they will
have to be drilled into the mill for mounting. Hardware kits for these Bridgeport copy mills have a
backplate with set leveling screws (515-M-BPC). Bridgeport backplates use shim washers between
the backplate and the mill for leveling if necessary.
3. Lagun and some imported mills require a slotted "D" bracket for encoder box mounting to the saddle
instead of the Bridgeport style hardware. This hardware (515-M-LILC) may be mounted oru either
I he rear or the front of the saddle depending on which is best for a particular application. The
hardware drawing for these mills shows the slotted "D" bracket mounted to the rear of the saddle.
Backplates in these hardware kits come with set leveling screws.

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4. Attach the miniscale to the backplate. Do not tighten as adjustment will be needed when indicating.
Be sure that the miniscale's alignment bracket will clear the backplate mounting holes. If it does not,
remove the miniscale, and flip the backplate over and remount the miniscale. Mounting holes are
offset to allow room for the alignment bracket.
5. With the hardware bracketry pre-assembled, hold it up to the mi1Jl to determine the mounting
locations. Bridgeport backplates may be mounted to the pre-drilled holes. After locating the
mounting area, mark both ends using the ways as a reference with a precision instrument, such as
calipers. Drill/tap for 5/16-18 x 1-7/8 socket cap bolts. Mount the backplate (with the miniscale
attached) to the mill. Verify that the encoder box bracket and the rest of the bracketry will mount to
the encoder box. Adjust the backplate for parallelism using the leveling screws (or washer/shim for
Bridgeport hardware) as necessary.
SETSCREWS MUST BE PROPERLY ADJUSTED. IMPROPER ADJUSTMENT MAY CAUSE
WARPING OR TWISTING OF THE BACKPLATE.
6. Indicate the spar surface (top) with respect to the ways using a depth micrometer, dial indicator or
calipers. Adjust the two miniscale ends so that the spar surface is paraillel to the table travel within
0.005 inch over its entire travel. Use the ways as a reference. Indicate the miniscale face housing
surface from end to end to within 0.005 inch over its entire travel. Adjust the backplate and/or
miniscale using the leveling screws (or washer/shim for Bridgeport hardware) as necessary.
7. Move the table fully to its end of travel closest to the operator (standing in front of the machine) and
lock it into position. Align the pre-assembled encoder box bracket to the miniscale's encoder box and
to the area on the saddle where the bracke:t is to be mounted. Mark the saddle location and drill/tap
for 1/4-20 x 3/4 socket cap bolts. Mount the bracket assembly
8. Encoder Box Mounting
a. Verify that the gap between the encoder box and the mounting bracket is less than 0.125 inch.
See Figure 2. If it is not, adjust the backplate or modify the hardware as necessary.
b. Transfer punch the two encoder box mounting holes to the bracket. Drill/tap for 8-32 x 3/4
socket cap screws.
c. Insert and adjust the 4 encoder box set screws (5-40) until they just touch the mounting surface
Improper adjustment can force the encoder box out of its calibrated position and cause erratic
miniscale performance and damage. .
d. Mount the encoder box with the two 8-32 x 3/4 socket cap screws. Do not overtighten the
encoder box mounting screws.
e. Release the encoder box from the alignment bracket by removing the 10-32 x 3/8 pan head
screw. The alignment bracket may be left on the miniscale or replaced with the end cap provided
in the hardware kit.
NOTE
Save the alignment bracket for future use (Machine
cleaning, service, etc.).
f Release the table lock and move the Y axis table to its two extreme positions while monitoring
the encoder box travel.
VERIFY THAT THE MINISCALE CANNOT BE OVERTRAVELED. See Figure 5.

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 9. No miniscale guard is provided for the mill Y axis since the miniscale is mounted underneath the
saddle. However, an optional miniscale guard! may be obtained by contacting your dealer or the
factory.
10. Route and secure the cables to the display. Ensure that the cables are not hanging loose to be caught
on any part of the machine during operation.
NOTE
Do not run miniscale cables parallel with power wires.
Induced noise may cause the display to miscount. Maintain
a minimum of 6 inches between cables and cross at right
angles.

VI. MILL - QUILL MINISCALE INST ALLA TION

The hardware provided in the quill kit is designed to be used with Bridgeport style mills. A ball and
cylinder gadget is used to mount the encoder box as shown in the hardware drawing. This may not work
for all mills since quill feeds vary. Modification and/or fabrication of hardware may be necessary.

VII. MILL - KNEE MINISCALJ[ ll'rST ALLA TION

Where rniniscales are used, the guidelines for installiation are the same as for the Y axis. H is suggested
that the miniscale be mounted with the encoder box facing to the back of the mill. A miniscale guard
should also be placed over the unit after installation is completed. The knee hardware kit is designed to
universally fit most mills. Some modification and/or fabrication of hardware will be required by the
installer.

VIII. LA THE MINISCALE INSTAL]~ATION

.
Installation guidelines are the same for lathe miniscales. Follow the lathe hardware drawing for
installation of the lathe miniscales and encoder box guards. Custom backplate fabrication may be required
for some lathes. Lathe miniscales are mounted on the side of the carriage farthest from the chuck. Use X
axis instruction guidelines for miniscales mounted directly to the table. Use Y axis instruction guidelines
where miniscales are mounted on a backplate and attached to the bed travel. Miniscales mounted on the
compound (Z axis) follow normal miniscale installation procedures.

IX. DISPLAY INSTAl,LA TIOl'r

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I. With the miniscales installed and the cables routed, the display is now ready to be installed. Refer to
the applicable display manual for display installation
2. Connect the miniscale's connectors to the display and screw them in place. Verify that the miniscale
is connected to the correct axis on the digital readout.