RENISHAW T103x Linear Incremental Encoder Installation Guide

RENISHAW T103x Linear Incremental Encoder

Product Information

Specifications

• Product Name: TONiC RTLC-S Encoder System
• Compliance: FCC, RoHS
• Storage and Handling: N-heptane, Propan-2-ol, Acetone, Methylated Spirits
• Humidity: 95% relative humidity (non-condensing) to EN 6008-2-78

Product Usage Instructions

Storage and Handling
Store the scale and readhead in a suitable environment. Handle with care to avoid damage.

Installation
Refer to the TONiC RTLC-S installation guide for detailed installation instructions.

Mounting and Alignment
Ensure proper alignment of the readhead relative to the scale for accurate readings.

Calibration
Calibrate the system according to the provided guidelines to ensure precise output signals.

Electrical Connections
Make secure electrical connections following the electrical connection diagram provided.

FAQ

• Q: What materials are used in the packaging of the product?
  A: The packaging contains cardboard, polypropylene, low-density polyethylene foam, high-density polyethylene bags, and metalized polyethylene.

• Q: What is the humidity range for operating the product?
  A: The product can operate in environments with up to 95% relative humidity (non-condensing) as per EN 6008-2-78 standards.

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:

EP0748436 US5861953 EP1173731 US6775008B2 JP4750998 CNCN100543424C US7659992 JP4932706 CNCN100507454C US7550710 EP1766335 CNCN101300463B EP1946048 US7624513B2 JP5017275 CNCN101310165B US7839296 EP1957943 US8141265 EP2294363 CN102057256 JP5475759 JP5755299 KR20110033204 CN1314511 EP1469969 JP5002559 US8466943 US8987633

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 T103x readhead installation drawing

RTLC-S installation drawing (adhesive datum clamp)

Scale application
There are two versions of applicator for use with RTLC-S scale: side mounted (A-9589-0115) and top mounted (A-9589-0094)

1. Allow scale to acclimatize to installation environment prior to installation.

2. Mark out the ‘START’ and ‘FINISH’ points for the scale on the axis substrate – ensure that there is room for the optional end covers if required (see ‘RTLC-S installation drawing’).

3. Thoroughly clean and degrease the substrate using recommended solvents (see ‘Storage and handling’). Allow substrate to dry before applying scale.

4. Mount the appropriate scale applicator to the readhead mounting bracket using M2.5 screws. Place the shim supplied with the readhead between the applicator and substrate to set the
   nominal height.
   NOTE: Scale applicator can be mounted either way round to enable easiest orientation for scale installation.

5. Move axis to ‘START’ of travel.

6. Begin to remove the backing paper from the scale and insert scale into the applicator up to the ‘START’ point (as shown). Ensure backing tape is routed under the splitter screw.

7. Apply finger pressure to the scale at the ‘START’ point, using a clean lint-free cloth, to ensure scale end adheres well to the substrate.

8. Slowly and smoothly move the applicator through the entire axis of travel, ensuring the backing paper is pulled manually from the scale and does not catch under the applicator.
   Top mount applicator

9. Remove applicator and, if necessary, adhere the remaining scale manually. Apply firm finger pressure via a clean lint-free cloth along the length of the scale after application to ensure complete adhesion.

10. Clean scale using Renishaw scale cleaning wipes (A-9523-4040) or a clean, dry, lint-free cloth.

11. Fit end covers.

12. Allow 24 hours for complete adhesion of scale before fitting reference mark selector magnet, limits and datum clamps.

End covers
The end cover kit (A-9585-0035) is designed to be used with RTLC-S scale.

NOTE: End covers are optional and can be fitted before or after readhead installation.

1. Remove the backing tape from the adhesive tape on the back of the end cover.
2. Align marker on the edges of the end cover with the end of the scale and place end cover over the scale.

NOTE: There will be a gap* between the end of the scale and the adhesive tape on the end cover.

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 RTLC-S installation guide

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

Ensure scale, readhead optical window and mounting faces are clean and free from obstructions.

System connection

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

Connecting the readhead

1. Remove the cover plate as shown (2 x M2.5 hex head screws).
2. Taking care not to touch the pins, plug the connector into the socket in the interface, ensuring correct orientation as shown.
3. Refit the cover plate ensuring the cable ferrule is located in the recess on the inside and no wires are trapped under the cover plate. NOTE: The tightening torque should be between 0.25 Nm and 0.4 Nm.

Disconnecting the readhead

1. Remove the cover plate on the interface (2 x M2.5 hex head screws).
2. 3. Gently lever the connector PCB (on the end of the cable) out of the socket. Do not pull the cable to remove the connector.
3. Place the connector in an anti-static bag.
4. Refit the cover plate.

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 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 reinstalling factory defaults
should be restored.

Readhead set-up LED status

Reference mark selector and limit magnet installation
IMPORTANT: Allow 24 hours after scale application before fitting magnets.
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 should be positioned adjacent to the chosen IN-TRAC reference mark as shown below.

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 along the outer edge of the magnet assembly.
Optional bolted reference and limit magnets are available, refer to ‘RTLC-S installation drawing’ for details.

Limit trigger point
The limit output is nominally asserted when the readhead limit switch sensor passes the limit magnet leading edge, but can trigger up to 3 mm before that edge.(See ‘RTLC-S installation drawing’)

Datum clamp (A-9585-0028)

The datum clamp fixes the RTLC-S scale rigidly to the substrate at the location chosen. The metrology of the system may be compromised if the datum clamp is not used. The datum clamp does not need to be fitted adjacent to a reference mark.
It can be positioned anywhere along the axis depending upon the customers’ requirements.

1. Place the datum clamp with cut-out against the scale at the chosen location.
2. Place a small amount of adhesive (Loctite® 435™) in the cut-out on the datum clamp, ensuring none of the adhesive wicks onto the scale surface. Dispensing tips P-TL50-0209 are available.

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 reinstalling restore factory defaults.
• Ensure Automatic Gain Control is switched off (CAL LED on readhead is not illuminated)
• 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

• Press the CAL button on the end of the interface for <2 seconds 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 routine.
• Move the readhead along the axis, ensuring you do not pass the selected reference mark until the CAL LED starts double-flashing. This indicates 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. NOTE: Only the chosen reference mark that has been used in the calibration routine is guaranteed to remain 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
The calibration routine can be exited at any stage. To exit the calibration routine press the CAL button. On successful exit the CAL button will stop flashing.

Restoring factory defaults
When realigning the readhead, reinstalling 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 recalibrate the system. NOTE: System must be recalibrated 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.

T103X readhead LED diagnostics

Incremental

| Green| Normal set-up: signal level >70%
Orange| Acceptable set-up; signal level 50% to 70%
Red| Poor set-up; signal may be too low for reliable operation; signal level <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 incremental signal level is >70% when passing reference mark.

Ti0004 to Ti20KD and TD4000 to TD0040 Interface LED diagnostics

Red

| Poor set-up; signal may be too low for reliable operation; signal level <50%| ****

No

Red / blank – flashing| Poor set-up; signal level <20%; system in error| Yes
Blue / blank – flashing| Over speed; system in error| Yes
Purple / blank – flashing| Over signal; system in error| Yes
Reference mark| Blank flash| Reference mark detected (speed <100 mm/s only)| No

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

Analogue

|

Cosine

|

V1

| +| 9
–| 1

Sine

|

V2

| +| 10
–| 2
Reference mark|

Analogue

|

V0

| +| 3
–| 11
Limits|

Open collector

| Vp| 7
Vq| 8
Set-up| –| VX| 6
Calibrate| –| CAL| 14
Shield| –| Inner shield| Not connected
–| Outer shield| Case

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
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 V| –| –| –| 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

Ti0004

5 µm

| Ti0020

1 µm

| Ti0040

0.5 µm

| Ti0100

0.2 µm

| Ti0200

0.1 µm

| Ti0400

50 nm

| Ti1000

20 nm

| Ti2000

10 nm

| Ti4000

5 nm

| Ti10KD

2 nm

| Ti20KD

1 nm

50| 10| 10| 10| 6.48| 3.24| 1.62| 0.648| 0.324| 0.162| 0.0654| 0.032
40| 10| 10| 10| 5.40| 2.70| 1.35| 0.540| 0.270| 0.135| 0.054| 0.027
25| 10| 10| 8.10| 3.24| 1.62| 0.810| 0.324| 0.162| 0.081| 0.032| 0.016
20| 10| 10| 6.75| 2.70| 1.35| 0.675| 0.270| 0.135| 0.068| 0.027| 0.013
12| 10| 9| 4.50| 1.80| 0.900| 0.450| 0.180| 0.090| 0.045| 0.018| 0.009
10| 10| 8.10| 4.05| 1.62| 0.810| 0.405| 0.162| 0.081| 0.041| 0.016| 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

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

Single ended alarm signal termination (Ti options A, B, C, D)

Analogue outputs

Limit output (No limits on TD interfaces)

*Select R so maximum current does not exceed 20 mA. Alternatively use a suitable relay or opto-isolator.

Remote CAL operation (Analogue versions only)

All Ti/TD interfaces include a push button switch to enable CAL/AGC features. However, remote operation of the CAL/AGC is possible via pin 14 of analogue Ti0000 interfaces. For applications where no interface is used, remote operation of CAL/AGC is essential.

TD interface resolution switching

Connect pin 10 to 0 V to switch to lower resolution.

Output specifications

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

NOTE: Select ‘standard’ or ‘wide’ reference at time of ordering, to match the requirements of the controller being used. Wide reference mark not available on Ti0004 interfaces.

Limits Open collector output, asynchronous pulse

Analogue output signals

Limits Open collector output, asynchronous pulse
Ti0000 interface only

NOTE: Ti0000 interface contains a transistor to invert the readhead’s ‘active low’ signal to give an ‘active high’ output.

General specifications

Renishaw encoder systems have been designed to the relevant EMC standards, but must be correctly integrated to achieve EMC compliance. In particular, attention to shielding arrangements is essential.

Scale technical specifications

*For lengths >2 m RTLC with FASTRACK is recommended.

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, please visit our main website at www.renishaw.com/contact

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.
Loctite® is a registered trademark of the Henkel Corporation.
© 2010-2023 Renishaw plc All rights reserved
Issued 0823

References

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

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