RENISAW T101XR Tonic Incremental Encoder Installation Guide

RENISAW T101XR Tonic Incremental Encoder

Product Information

Specifications:

• Product Name: TONiC RSLM/RELM Linear Encoder System
• Model: M-9653-9225-05-D
• High-accuracy linear encoder system

Product Usage Instructions

Storage and Handling:
Ensure proper storage and handling of the scale and redhead components. Use N-heptane, Propan-2-ol, Acetone, Chlorinated Solvents, or Methylated Spirits as appropriate for cleaning.

Installation:

• Adhesive Mounting Installation:
  Refer to the adhesive mounting installation drawing for guidance. Ensure proper alignment and secure mounting using adhesive material.

• Clip/Clamp Mounting Installation:
  Refer to the clip/clamp mounting installation drawing for guidance. Securely attach the readhead using clip or clamp mechanisms.

System Connection:
Refer to the TONiC interface drawing for connecting the system components properly. Follow the TONiC quick-start guide for initial setup.

Readhead Mounting and Alignment:
Properly mount and align the readhead as per the provided instructions to ensure accurate measurements.

System Calibration:
Calibrate the system following the specified calibration procedures to ensure accurate readings and performance.

Output Signals and Electrical Connections:
Understand the output signals and make appropriate electrical connections as per the system requirements to enable proper functionality.

Frequently Asked Questions (FAQ):

• Q: Is the TONiC system compliant with regulations?
  A: Yes, Renishaw plc declares compliance with applicable standards and regulations. Copies of declarations are available upon request.

• Q: What cleaning agents are recommended for storage and handling?
  A: N-heptane, Propan-2-ol, Acetone, Chlorinated Solvents, or Methylated Spirits can be used for cleaning specific components. Refer to the storage and handling section for details.

• Q: How should I mount the redhead?
  A: Follow the provided installation drawings for adhesive mounting or clip/clamp mounting methods to securely attach thereadhead.

Product compliance

Renishaw plc declares that TONiC complies with the applicable standards and regulations.
A copy of the EC Declaration of Conformity is available on request.

FCC compliance
This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
The user is cautioned that any changes or modifications not expressly approved by Renishaw plc or authorised representative could void the user’s authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit to ensure compliance.

RoHS compliance
Compliant with EC directive 2011/65/EU (RoHS)

Patents
Features of Renishaw’s encoder systems and similar products are the subjects of the following patents and patent applications:

• EP1173731
• US6775008B2
• JP4750998
• CNCN100543424C
• US7659992
• EP1766334
• JP4932706
• CNCN100507454C
• US7550710 JP5386081
• EP1766335
• CNCN101300463B
• EP1946048
• US7624513B2
• JP5017275
• CNCN101310165B
• US7839296
• EP1957943
• CN1314511
• EP1469969
• JP5002559
• US8987633
• US8466943

Further information
Further information relating to the TONiC encoder range can be found in the TONiC system Data sheet (L-9517-9337). This can be downloaded from our website www.renishaw.com/encoder and is also available from your local representative. 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. The publication of material within this document does not imply freedom from the patent rights of Renishaw plc.

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.
The packaging of our products contains the following materials and can be recycled.

Packaging Component| Material| ISO 11469| Recycling Guidance
---|---|---|---
Outer box| Cardboard| Not applicable| Recyclable
Polypropylene| PP| Recyclable
Inserts| Low-Density Polyethylene Foam| LDPE| Recyclable
Cardboard| Not applicable| Recyclable
Bags| High-Density Polyethylene Bag| HDPE| Recyclable
Metalised Polyethylene| PE| Recyclable

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.

Storage and handling

TONiC T101X readhead installation drawing

Measuring lengths

Adhesive mounting installation drawing

NOTES: Adhesive mounted scale should not be re-used after installation. For readhead dimensions see ‘Readhead installation drawing’. When installing in a groove allow a tolerance for scale width. See ‘Measuring length’ for information on using limits.

Adhesive mounting installation

Clip/clamp mounting installation drawing

NOTES: Datum clamp usually coincident with selected IN-TRAC reference mark. However the position is user selectable depending upon application. For lengths 80≤ L ≤190 ensure scale is clamped or clipped in the middle as well as at both ends.  *Clips omitted for clarity. Reference marks positioned equi- distant from scale ends. For optimum performance the readhead should be installed close to nominal geometry. Care should be taken to ensure sufficient clearance between the readhead/mounting bracket and clips/datum clamp. Only special low-profile screws should be used. Screws are provided with all clips/datum clamps and spares can be supplied if required.

Clip/clamp mounting installation

TONiC interface drawing

CAL button operation

• Push and release (<3 seconds) – Calibration (CAL) routine enable/disable.
• Push and release (>3 seconds) – Automatic Gain Control (AGC) enable/disable.
• Push and hold during power ‘Off/On’ cycle – Restore factory defaults.
• Refer to readhead LED functionality chart for CAL LED indications.

TONiC quick-start guide
This section is a quick-start guide to installing a TONiC system. More detailed information on installing the system is contained in the following sections of the Installation guide.

INSTALLATION

CALIBRATION

System connection

Approved ESD precautions must be followed at all times during readhead and interface electrical connections. The redhead is connected to the Ti/TD interface via a small, rugged connector to allow for easy feed-through during installation.

Connecting the readhead

Disconnecting the readhead

Readhead mounting and alignment

Mounting brackets
The bracket must have a flat mounting surface and should provide adjustment to enable conformance to the installation tolerances, allow adjustment to the rideheight of the readhead, and be sufficiently stiff to prevent deflection or vibration of the readhead during operation.

Readhead set-up
Ensure that the scale, readhead optical window and mounting face are clean and free from obstructions. To set nominal rideheight, place the Green readhead spacer with the aperture under the optical centre of the readhead to allow normal LED function during set-up procedure. Adjust the readhead to maximise the signal strength along the full axis of travel to achieve a Green set-up LED on the readhead (>70% signal). If a digital Ti/TD interface is used, aim for a Blue LED on the interface.
NOTE: The readhead should be installed and set-up with the AGC switched off
(CAL LED off). When re-installing, factory defaults should be restored.

Readhead set-up LED status

Reference mark selector and limit magnet installation
For accuracy and ease of positioning of reference mark selector and limit magnets, the applicator tool (A-9653-0201) should be used. The magnet should be attached to the applicator tool as shown below. Limit magnets can be positioned at any user defined location along the scale, but the reference mark selector magnet (T1010 readhead only) should be positioned adjacent to the chosen IN-TRAC reference mark as shown below. As the TONiC readhead passes the reference mark selector magnet or limit switch magnet, a force of up to 0.2 N is generated between the magnet and the concentrators on the readhead. The design of the bracket should be sufficiently stiff so that it is able to tolerate such force without distorting. Following the clamping instructions on the scale installation will prevent this magnetic force from disturbing the scale.
NOTE: Reference and limit magnets may creep when influenced by magnetic materials in close proximity. In such cases, they should be held in place using an additional fillet of epoxy glue or similar at each end of the magnet assembly.

System calibration

Calibration is an essential operation that completes readhead set-up, with the optimum incremental and reference mark signal settings stored in the readhead’s non-volatile memory.

Before system calibration:

• Clean the scale and readhead optical window (contamination around the reference mark may result in reference mark dephasing).
• If re-installing restore factory defaults.
• Maximise the signal strength along full axis of travel.
  NOTE: CAL routine maximum speed <100 mm/s (all Ti/TD interface models). TD interface can be calibrated in either resolution.

Step 1 – Incremental signal calibration

• Ensure Automatic Gain Control is switched off (CAL LED on readhead is not illuminated) before beginning calibration.

• Press and release the CAL button on the end of the interface using a 2 mm allen key or similar tool.
  WARNING! Activating the CAL switch only requires 2.5 N force. Applying excess force may permanently damage the switch.

• The CAL LED will now periodically single-flash to indicate that it is in incremental signal calibration mode.

• Move the readhead along the axis, ensuring you do not pass the selected reference mark, until the CAL LED starts double-flashing, indicating the incremental signal is now calibrated and the new settings are stored in the readhead memory.

• The system is now ready for reference mark phasing.

• For systems without reference mark, go to ‘Calibration routine – manual exit’

• If the system does not automatically enter the reference mark phasing stage (no double-flashing of the CAL LED) the calibration of the incremental signals has failed. After ensuring failure is not due to overspeed (>100 mm/s), exit the calibration routine, restore factory defaults and check the readhead installation and system cleanliness before repeating the calibration routine.

Step 2 – Reference mark phasing

• Move the readhead back and forth over the selected reference mark until the CAL LED stops flashing and remains off. The reference mark is now phased.
• The system automatically exits the CAL routine and is ready for operation.
• If the CAL LED continues double-flashing after passing the chosen reference mark many times,

it is not detecting the reference mark. Ensure that the correct readhead configuration is being used. Readheads can either output all reference marks or only output a reference mark where a reference selector magnet is fitted.

Calibration routine – manual exit

• To exit the calibration routine at any stage press the CAL button. The CAL button will then stop flashing.
  CAL LED| Settings stored
  ---|---
  Single flashing| None, restore factory defaults and re-calibrate
  Double flashing| Incremental only
  Off (auto-complete)| Incremental and reference mark

Restoring factory defaults
When re-installing the system, or in the case of continued calibration failure, factory defaults should be restored.

• To restore factory defaults;
  • Switch system off.
  • Press and hold the CAL button whilst switching the system on. The CAL LED on the readhead will flash several times, indicating that the factory defaults have been restored.
  • Release CAL button.
  • Check the ‘Readhead mounting/installation’ and re-calibrate the system.
    NOTE: System must be re-calibrated after restoring factory defaults.

Switching Automatic Gain Control (AGC) on or off
AGC can be switched on or off via the interface.

• Press and hold the CAL button on the interface for >3 seconds to switch AGC on or off. The CAL LED on the readhead will be illuminated when AGC is active.
  NOTE: The system must be calibrated before switching AGC on.

T101x readhead LED diagnostics

<50%
Reference mark| Green (flash)*| Normal phasing
Orange (flash)| Acceptable phasing
Red (flash)| Poor phasing; clean scale and recalibrate if required
CAL| Operating| On| Automatic Gain Control – On
Off| Automatic Gain Control – Off
Calibration| Single flashing| Calibrating incremental signals
Double flashing| Calibrating reference mark
Reset| Flashing at power-up (<2s)| Restore factory defaults

*Flash will effectively be invisible when the incremental signal level is >70% when passing the reference mark.

Ti0004 to Ti20KD and TD4000 to TD0040 Interface LED diagnostics

• Alarm output will take the form of 3-state or line-driven E- signal depending on interface configuration.
  Also, some configurations do not output overspeed alarm. See product nomenclature for details.

  • Momentary status only, while fault condition remains.
  • Alarm may result in axis position error, re-datum to continue.

Output signals

Interface output (analogue) Ti0000 only

Readhead output

Analogue

| Cosine| V1| +| Red
–| Blue
Sine| V2| +| Yellow
–| Green
Reference mark| Analogue|

V0

| +| Violet
–| Grey
Limits| Open collector| Vp| Pink
Vq| Black
Set-up| –| VX| Clear
Calibrate| –| CAL| Orange
Shield| –| Inner shield*| Green/Yellow
–| Outer shield| Outer screen

*No inner shield on UHV cables.

Interface output (digital) Ti0004 to Ti20KD and TD4000 to TD0040

Interface output (digital) Ti0004 to Ti20KD and TD4000 to TD0040| Interface
---|---
Ti0004 – Ti20KD| TD4000 – TD0040
Function| Output type| Signal| Pin| Pin
Power|  | 5 V| 7, 8| 7, 8
0 V| 2, 9| 2, 9
Incremental| RS422A digital| A| +| 14| 14
–| 6| 6
B| +| 13| 13
–| 5| 5
Reference mark| RS422A digital|

Z

| +| 12| 12
–| 4| 4
Limits| Open collector| P| 11| –
Q| 10| –
Set-up| RS422A digital| X| 1| 1
Alarm ‡|

–

|

E

| +| –| 11
–| 3| 3
Resolution   switching| –| –| –| 10
Shield| –| Inner shield| –| –
–| Outer shield| Case| Case

• Becomes alarm (E+) for Ti options E, F, G, H
• The alarm signal can be output as a line driver signal or 3-state. Please select the preferred option at time of ordering.
• On TD interfaces pin 10 should be connected to 0 V to switch to lower resolution.

Speed

0.0081
08| 10| 6.48| 3.24| 1.29| 0.648| 0.324| 0.130| 0.065| 0.032| 0.013| 0.0065
06| 10| 4.50| 2.25| 0.90| 0.450| 0.225| 0.090| 0.045| 0.023| 0.009| 0.0045
04| 10| 3.37| 1.68| 0.67| 0.338| 0.169| 0.068| 0.034| 0.017| 0.0068| 0.0034
01| 4.2| 0.84| 0.42| 0.16| 0.084| 0.042| 0.017| 0.008| 0.004| 0.0017| 0.0008
Analogue output| 10 (-3dB)

NOTE: TD maximum speeds are resolution-dependent as defined above.

Electrical connections

TONiC grounding and shielding
IMPORTANT: The outer shield should be connected to the machine earth (Field Ground). The inner shield should be connected to 0 V at receiving electronics only. Care should be taken to ensure that the inner and outer shields are insulated from each other. If the inner and outer shields are connected together, this will cause a short between 0 V and earth, which could cause electrical noise issues.
NOTE: Maximum cable length between readhead and Ti/TD interface is 10 m

Recommended signal termination

Output specifications

Digital output signals
Form – Square wave differential line driver to EIA RS422A (except limits P and Q)

Analogue output signals

General specifications

Scale technical specifications

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Renishaw plc
New Mills, Wotton-under-Edge,
Gloucestershire GL12 8JR

United Kingdom
T +44 (0)1453 524524
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E uk@renishaw.com
www.renishaw.com

References

• Renishaw: enhancing efficiency in manufacturing and healthcare
• Contact us
• Encoders for position and motion control

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