Renishaw TONiC FS T301 Series, TONiC RELM20, TONiC RSLM20, TONiC FS T3 Series, TONiC FS T303 Series Functional Safety Manual

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Page 1

Installation guide

M-6688-9046-02-B

TONiC™ FS T301x RSLM20 / RELM20 high accuracy linear encoder system Functional Safety installation guide and safety manual

Page 2

Contents

Product compliance 1

Denitions 2

Information for use 2

Functional Safety data declaration 2

Safety function 3

Certication 4

Storage and handling 5

TONiC FS T301x readhead installation drawing 6

Measuring lengths 7

Scale installation drawing 8

Readheadmountingandalignment 14

System calibration 15

Diagnostic LEDs 16

Output signals 17

Speed 18

Electrical connections 19

Outputspecications 20

Generalspecications 21

RSLM20scaletechnicalspecications 22

RELM20scaletechnicalspecications 22

Scale installation 9

Reference mark selector and limit magnet installation 10

TONiC FS quick-start guide 11

Cable connection 12

System connection – Ti interface 12

System connection – DOP interface 13

TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Reference mark 22

Limit switches 22

TONiC Ti interface drawing 23

TONiC DOP interface drawing 23

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Product compliance

This document is an installation guide and safety manual, which details the actions required for the safe

integration of the TONiC FS (Functional Safety) encoder system, as designated by the T3 prex in the part

number, into a functionally safe system; this will be referred to as TONiC FS system in the below document.

SIL2

FUNCTIONAL

SAFETY

PLd

The TONiC FS system as dened below is suitable for use in a Category 3 performance leveld(PLd) application in compliance with ISO 13849 and in a safety integrity level 2 (SIL2) application in compliance with IEC61508 and IEC61800-5-2 when installed and operated in accordance with the instructions dened.

Failure to follow the correct use instructions or heed the limitations may result in SIL2 and/or PLd

notbeingachievedandwillinvalidatetheFunctionalSafetycertication.

A copy of the TONiC FS certicate is available from our website at www.renishaw.com/productcompliance

Renishaw plc declares that TONiC FS system complies with the applicable standards and regulations.

A copy of the EU declaration of conformity is available from our website at

www.renishaw.com/productcompliance.

For further details of FS compliance see ‘Certication’ on page 4.

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 modications 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 their 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.

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

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

REACH regulation

Information required by Article 33(1) of Regulation (EC) No. 1907/2006 (‘REACH’) relating to products containing substances of very high concern (SVHCs) is available at www.renishaw.com/REACH

Further information

Further information relating to the TONiC FS encoder range can be found at

www.renishaw.com/fsencoders 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.

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.

1TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 4

Denitions

Functional Safety data declaration

WARNING A hazard with a medium risk of injury if not avoided

ESD handling

Mechanical safe position

Evaluation unit

System manufacturer

System installer

Information for use

The ESD Susceptibility Symbol consists of a triangle, a reaching hand, and a slash through the reaching hand. The triangle means ‘Caution’ and the slash through the reaching hand means ‘Don’t touch’.

The maximum distance the scale might move from its installed position, for example if the xings work loose.

External item of equipment in which the output signal of the encoder is evaluated,

e.g. machine controller or safety relay.

Personnel with responsibility for selecting the encoder and verifying its capability is

appropriate for the safety related application.

Personnel with responsibility for tting the encoder in the specic application.

WARNING Not to be used in environments where there is an explosive atmosphere WARNING Not to be used by medical devices

The TONiC FS system is designed to be used as part of a safety-related control system as specied by the system manufacturer. It is the responsibility of the system manufacturer to set the evaluation unit to implement the appropriate

actions when the TONiC FS system reports an error. The decision to use this system for the intended purpose is the

responsibility of the system manufacturer. The TONiC FS system is certied to the SIL and PL levels as shown in the ‘Functional Safety data declaration’, however the system manufacturer must conduct their own assessment of the full

system to determine its safety capability.

Correct use includes:

X Operating the TONiC FS system within the limits dened in this document. X Installing the system as described in this document. X Maintaining the system as described in this document.

System components:

The TONiC FS system comprises the following parts:

X TONiC FS readhead. X TONiC Ti0000A00A or DOP interface. X RSLM and RELM linear scale – adhesive mount only.

NOTES:

X Clip mounting RELM/RSLM linear scale is not approved for use with the TONiC FS encoder system.

X Only the analogue sine and cosine outputs are functionally safe.

If the original termination supplied with the TONiC FS system is altered or an extension cable used, then it is the responsibility of the system manufacturer to make sure the system is compliant with IEC 61800-5-2 Annex E

–Electromagneticimmunityrequirementforsafetyrelatedsystems.

Productidentication TONiC FS (Functional Safety)

IEC61508safetydata

TONiC

readhead

Safety integrity level 2

Random hardware failures (per hour)

PFD

avg

1.77 × 10

8.41 ×10

7.57 × 10

8.41 × 10

Not available as this system does not support low

PFH (per hour) 8.41 × 10

Architectural constraints

Type B

HFT 0

−7

−8

−9

SFF 96%

Hardware safety integrity compliance

Systematic safety integrity compliance

Systematic capability SC 2

Demand mode Continuous

TONiC

readhead and

Ti interface

1.77 × 10

1.38 × 10

1.25 × 10

1.38 × 10

demand mode

1.38 × 10

Route 1H

Route 1S

ISO13849safetydata

TONiC

readhead

MTTF

(years) 1300 800 300

Diagnostic coverage Medium (90%)

Category 3

Performance level d

Lifetime/replacement limits 20

TONiC

readhead and

Ti interface

−7

−8

TONiC

readhead and

DOP interface

1.77 × 10

3.49 × 10

3.14 × 10

3.49 × 10

−7

−8

TONiC

readhead and

DOP interface

2TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 5

Safety function

The TONiC FS system provides 1 Vpp (nominal) sine and cosine outputs, where the sine and cosine outputs are 90° phase shifted, in order for the evaluation unit to perform incremental counting and

therebyconrmmachinepositioniswithinsafelimits.

The following restrictions apply to this claim:

X The system installer must perform a veried commissioning test during installation.

X The system repairer must perform a veried commissioning test following replacement of a system part.

X When installed correctly, the TONiC FS system shall have mechanical safe position not exceeding 1 mm.

NOTE: Thermal expansion effects of the scale and readhead mounting tolerances are excluded from the

mechanical safe position.

X The TONiC FS system includes no self-diagnostic function.

NOTE: Faults are detected only by the evaluation unit monitoring. When errors are detected it is the responsibility of the system manufacturer to place the system into a safe state.

Fault exclusions

The following will invalidate the Functional Safety certication of the TONiC FS system (see page 4):

X Faults caused by cutting and reconnecting the readhead cable or extending the readhead cable.

X Incorrect installation of the readhead.

X Incorrect installation of the scale.

X Dismantling of the TONiC readhead or the Ti or DOP interfaces.

X Operating the system outside of the limits specied within this installation guide.

Failure modes

Failure modes are detected by evaluation unit monitoring. See ‘Functional Safety data declaration’ on page 2

for a summary of the FMEDA.

NOTE: For the purposes of the FMEDA calculation, the following conditions have been assumed:

Method: SN29500 Environment: Ground mobile Temperature: 85°C

Installation

For the safety function to be valid the instructions detailed in this installation guide must be followed.

Commissioning test

The following check must be performed when commissioning the TONiC FS system and after any repair of the system.

NOTE: Repair is by replacement of system parts only.

Axis movement check Move the axis over its full travel to verify the following:

X Position output is correct within a tolerance of ±10%.

X Direction of movement is correct.

X The signal amplitude for both sine and cosine signals falls within the limits

dened in ‘Evaluation unit monitoring’.

Evaluation unit monitoring

To achieve full system integrity the evaluation unit must continuously monitor the analogue outputs and,

in the case of fault detection, place the system into a safe state within the process safety time.

Signal amplitude check Nominal signal amplitude value is 1V, indicating full signal strength where

√ (sine2 + cosine2) = 1V. A fault condition must be asserted if the analogue output is ≤0.7 V and ≥1.35 V.

Sine/cosine cross check

Following error check Following error is dened as the difference between the expected position

NOTES:

X The evaluation unit must achieve medium diagnostic coverage (≥90%) according to ISO13849.

X Improper setting of the switching thresholds and hysteresis in signal evaluation can result in incorrect

determination of direction, position or speed.

X A persistent fault condition may indicate a hardware failure of the TONiC FS system or an

installation problem.

Sine and cosine signals must be evaluated separately and the results

compared. A fault condition must be asserted if the phase shift is incorrect with reference to the safe position limit for the system, see ‘Output specications’ on

page 20.

and position feedback. A fault condition must be asserted if the following error

exceeds the safe position limit for the system.

Maintenance

The maintenance check intervals will be dened by the system manufacturer according to their risk assessment. There are no user serviceable parts within the readhead and interface.

The following maintenance actions are advised:

X Check the readhead to bracket screws are correctly tightened.

X Check for worn or damaged cable connecting the readhead to the interface.

X Check that the scale has not been damaged or contaminated. If required, clean the system using

approved solvents (see ‘Storage and handling’ on page 5).

NOTE: Do not attempt to move the linear scale as this will damage the adhesive bond.

Repair

The replacement parts must have the same part number as the original parts. The new system must be installed and commissioned in accordance with the ‘Commissioning test’. In the event of failure the affected parts should be returned to Renishaw for further analysis. Using damaged parts invalidates the Functional Safety certication.

Proof testing

It is the responsibility of the system manufacturer to dene any proof testing of the system. Due to the diagnostic coverage (DC) and safe failure fraction (SFF) required to achieve SIL2, the encoder can only

support continuous demand use.

3TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 6

Certication

EU declaration of conformity

TONiC FS encoder system

FunctionalSafetyCerticateNo.FSC001

SIL2

FUNCTIONAL

SAFETY

PLd

Under the terms of CSA SIRA Functional Safety Certicate SIRA CASS00023/01, for the management and self-certication of functional safety activities up to SIL3/PLd:

Renishaw plc declares that the products listed by this installation guide meet the requirements of:

BS EN IEC 61508-1:2010, BS EN IEC 61508-2:2010 and BS EN IEC 61508-3:2010

BS EN 61800-5-2:2017 (IEC 61800-5-2:2016)

BS EN ISO 13849-1:2015 and BS EN ISO 13849-2:2012

when used as an element/subsystem in safety related systems performing safety functions requiring up to

and including:

SIL2 with HFT = 0 (1oo1)

Category 3, PLd.

Renishaw plc declares under its sole responsibility that the products identied below are in conformity with all relevant Union legislation.

Name Description

Product Name: TONiC FS encoder system

Description: TONiC optical encoder system, that is FS certied

Part no.: T3xxx (Linear); T4xxx (Rotary)

Valid from: Serial number 2AHF37

Serial number 2AHF79

The products comply with EU directives:

2014/30/EU Electromagnetic compatibility (EMC)

2011/65/EU On the restriction of the use of certain hazardous substances

inelectrical and electronic equipment (recast)

and comply with the following technical standards:

BS EN 12100:2010 Safety of machinery. General principles for design.

Risk assessment and risk reduction

BS EN 61010-1:2010 Safety requirements for electrical equipment for measurement,

control, and laboratory use

Part 1: General requirements

BS EN 61326-1:2013 Electrical equipment for measurement, control and laboratory use.

EMC requirements. General requirements

Immunity to Table 2 - Industrial electromagnetic environment Emissions to Class A - Industrial electromagnetic environment

BS EN 62471:2008 Photobiological safety of lamps and lamp systems

BS EN IEC 63000:2018 Technical documentation for the assessment of electrical and

electronic products with respect to the restriction of hazardous substances

The persons authorised to compile the technical le and issue the declaration of conformity are:

Steve Oakes, Director & General Manager, Encoder Products Division

Martin Curtis, Regulatory Compliance Manager, Encoder Products Division

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

Signed: M. Curtis

Dated: 30/09/2019

Place: Wotton-under-Edge

Reference no. EUD 2019-003

4TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 7

Storage and handling

Scale and readhead

N-heptane

Scale only

Acetone

Readhead only

Acetone

CH3(CH2)5CH

Propan-2-ol

CH3CHOHCH

CH3COCH

Methylated

Spirits

Chlorinated

Solvents

CH3COCH

Methylated

Spirits

Chlorinated

Solvents

Minimum bend radius

RSLM20 – 250 mm RELM20 – DO NOT BEND

NOTE: Ensure self-adhesive tape

is on outside of bend.

Storage

+70°C

−20°C

Operating

+70°C 0°C

Humidity

95% relative humidity

(non-condensing)

to IEC60068-2-78

5TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 8

TONiC FS T301x readhead installation drawing

Dimensions and tolerances in mm

Reference mark selector magnet †

(A-9653-0143)

(Dimensions as P limit)

3.7

14.9 ±0.2

P limit magnet (A-9653-0138)

Nominal P limit trigger point

Selected IN‑TRAC

Reference mark selector

R>20 Dynamic bend radius R>10 Static bend radius

reference mark

sensor position

0.25

Ø4.

Forward direction of

15 ±1

7.8

(Yaw tol. ±0.4°)

0.25

Offset

0.7±0.5

2 mounting holes M2.5 through,

™

counterbored Ø3 × 2.75 deep from alternative mounting face

P and Q limit switch sensor position

readhead relative to scale

Q limit magnet (A-9653-0139) (Dimensions as P limit)

Nominal Q limit trigger point

Recommended mounting faces

(Roll tol. ±0.5°)

0.08

13.5

Alternative

mounting

face

4.25

4.15

8.75

Optical centreline (incremental and reference mark)

6 min

Set-up LED

CAL/AGC LED

2 mounting holes M2.5 through, counterbored Ø3 × 2.3 deep both sides

‡

11.5

(Pitch tol. ±1°)

0.6

4.61.5

Optical centreline marker

Extent of mounting faces. † Reference mark selector magnet is only required with RSLC20 scale and T3010 readheads. ‡ Minimum thread engagement 5mm (7.5 including counterbore). Tightening torque 0.25 to 0.4 Nm.

NOTES: The reference mark selector and limit actuator locations are correct for the readhead orientation shown.

External magnetic elds greater than 6 mT, in the vicinity of the readhead, may cause false activation of the limit and reference sensors.

Rideheight 2.1 ±0.15

1.7 ±0.1 RSLM20

1.8 ±0.1 RELM20

6TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 9

Measuring lengths

Dimensions and tolerances in mm

2.1 ±0.15

Measuring length, ML = (L − 25) with dual 10 mm limits

ML = (L − 10) without limits

7.8

(incremental and reference mark)

Optical centreline

Limit sensor position

0.05

F = axis of motion

Ra 3.2

7TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 10

Scale installation drawing

RSLM20 Use with T3011 readhead

(Centre reference mark)

Alignment dowels, maximum spacing 350

0.5

‡

0.05/50

Datum edge

F = axis of motion

Dimensions and tolerances in mm

14.9 ±0.2

RSLE20 Use with T3011 readhead

(End reference mark)

RSLC20 Use with T3010 readhead

(Customer selected reference mark)

RELM20 Use with T3011 readhead

(Centre reference mark)

20 ±0.25

20≤ × <120 *

L<4 m: L/2 ±0.5 L≥4 m: L/2 ±2

Option A Reference mark position (for 10 mm limits)

Alignment dowels, maximum spacing 350

L/2 ±0.25

Reference mark position

Option B Reference mark position

(for 20 mm and 50 mm limits)

70 ±0.25

Select one or more reference marks using reference mark

selector magnet (A-9653-0143)

200

0.5

‡

0.05/50

F = axis of motion

Datum edge

14.9 ±0.2

Reference mark position

RELE20 Use with T3011 readhead

(End reference mark)

20 ±0.25

NOTES:

Adhesive mounted scale must not be reused after installation.

When installing in a groove allow a tolerance for scale width.

See ‘Measuring lengths’ on page 7 for information on using limits.

Adhesive datum clamp

Clamping in this way ensures scale positional stability relative to substrate.

12 10

Double-sided

adhesive tape †

Reference marks positioned equidistant from scale ends.

†

Double-sided adhesive tape is included with all scale lengths.

‡

When scale is to be mounted horizontally on a vertical surface, position the dowels so that the datum edge is supported.

RGG-2, 2-part epoxy (A-9531-0342), usually positioned

coincident with user selected scale datum

8TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 11

Scale installation

NOTE: Ensure the guidance in ‘Storage and handling’ on page 5 is followed.

Thoroughly clean and degrease the substrate with a lint-free cloth.

Clean underside of scale using approved solvents

(see ‘Storage and handling’ on page 5).

Thoroughly mix and apply epoxy then remove

remaining backing liner.

Mark area for epoxy on adhesive tape.

Support dowels

Remove backing liner from one side

and stick to underside of scale.

Locate scale against dowels or ledge and rotate down onto substrate.

Press down with rm nger

pressure.

Remove excess

epoxy

Area for RGG-2 epoxy (A-9531-0342)

Mounting ledge

Allow 24 hours for epoxy to cure fully, then

clean scale using Renishaw scale wipes

(A-9523-4040) or a clean, dry, lint-free cloth.

9TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 12

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-dened location along the scale, but the reference mark selector magnet (T3010 readhead only) should be positioned adjacent to the selected 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 sufciently 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.

Applicator tool

(A-9653-0201)

P limit magnet

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 ‘TONiC

FS T301x readhead installation drawing’ on page 6).

NOTES:

X Reference mark selector magnet is only required for

RSLC20 scale and T3010 readheads.

X Reference and limit magnets may creep when

inuenced by magnetic materials in close proximity.

In such cases, they should be held in place using an

additional llet of epoxy glue or similar at each end of

the magnet assembly.

X The reference mark selector and limit actuator

locations are correct for the readhead installation shown.

X External magnetic elds greater than 6mT, in the

vicinity of the readhead, may cause false activation of

the limit and reference sensors.

Remove

self-adhesive

backing paper

Reference mark selector magnet

Selected IN‑TRAC

reference mark

Q limit magnet

10TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 13

TONiC FS quick-start guide

This section is a quick-start guide to installing a TONiC FS 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.

If required, ensure reference mark selector magnet is correctly positioned (see ‘TONiC FS T301x readhead installation drawing’ on page 6).

Plug the readhead cable into the Ti/DOP interface under the cover plate and reassemble interface. Connect to receiving electronics and power up.

Ensure Automatic Gain Control (AGC) is switched off – the CAL LED on the readhead should be off (if not, press and hold the CAL button on the interface until the CAL LED on the readhead switches off).

Install and align the readhead to maximise signal strength over the full axis of travel as indicated by the readhead and interface set-up LEDs (readhead – Green; DOP interface – ideally Blue/Purple).

CALIBRATION

Press and release the CAL button on the interface. The CAL LED on the readhead will be single-ashing.

Move the readhead along the scale at slow speed (<100 mm/s), without passing a reference mark, until the CAL LED starts double-ashing.

No reference mark

If a reference mark is not being used, the calibration routine should now be

exited by pressing and releasing the CAL button.

The system is now calibrated and ready for use.

For the safety function to be valid, customer commissioning tests must be performed: see ‘Commissioning test’ on page 3.

AGC can now be switched on if required by pressing and holding the CAL button until the CAL LED on the readhead switches on.

CAL values and AGC status are stored in readhead non-volatile memory at power down.

NOTE: If calibration fails, restore factory defaults by pressing and holding the CAL button whilst switching on. Then repeat the installation and calibration routine.

Move the readhead back and forth over the selected reference mark until the

CAL LED stops ashing and remains ‘off’.

Reference mark

11TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 14

Cable connection

X The cable must be secured to a part that does not move relative to the readhead using a suitable clip

within 50mm of exiting the readhead with a minimum bend radius >10mm.

X Cable rolling radius must be >25mm when the cable is routed through moving trunking / a cable chain.

X The cable must be routed to avoid all moving parts of the machinery and the readhead itself.

X Route the cable away from operating environments that will exceed the EMC limits dened in

IEC61800-5-2 Annex E.

X Use only Renishaw approved cables between the readhead and the interface.

X The customer is responsible for verifying the product function where the readhead to interface cable has

been re-terminated, including the installation of extension cables. This includes EMC performance of the installed system dened by IEC61800-5-2 Annex E.

X The sine and cosine signals must be connected as described in ‘Electrical connections’ on page 19.

System connection – Ti interface

Approved ESD precautions must be followed at all times during readhead and interface electrical

connections.

The readhead is connected to the Ti interface via a small, rugged PCB connector to allow for easy

feed-through during installation.

Connecting the readhead

Remove the cover plate as shown (2 × M2.5 hex head screws).

Ret the cover plate ensuring the cable ferrule is located in the recess on the inside and no wires

are trapped under the cover plate.

To ensure good electrical connection of the shield the tightening torque for cover screws is between

0.25Nm and 0.4Nm.

Taking care not to touch the pins, plug the connector into the socket in the interface, ensuring correct

orientation as shown. Press-t the PCB connector to ensure a good connection.

Mounting the interface to the receiving electronics is via 2 × 4-40 UNC screws. The tightening

torque is between 0.25Nm and 0.4Nm, or as required specic to the application and orientation

of mounting.

12TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 15

Disconnecting the readhead

Remove the cover plate on the interface

(2 × M2.5 hex head screws).

Gently lever the connector PCB (on the

end of the cable) out of the socket.

Do not pull the cable to remove the

connector.

System connection – DOP interface

Approved ESD precautions must be followed at all times during readhead and interface electrical

connections.

The readhead is connected to the DOP interface via a small, rugged PCB connector to allow for easy

feed-through during installation.

Connecting the readhead

Remove the cover plate on the

interface (2 × M2.5 hex head screws).

Taking care not to touch the pins,

plug the connector into the socket in the interface, ensuring correct orientation as shown.

Ret the cover plate ensuring the

cable ferrule is located in the recess on the inside and no wires are

trapped under the cover plate.

Cover plate

Place the connector in an anti-static bag.

Ret the cover plate.

DOP mounting

The DOP interface readhead is mounted to a suitable surface using customer-supplied screws appropriate

to the application details.

NOTES:

X Recommended screw type M3 × 0.5 and must comply with:

ISO4762/DIN 912 grade 8.8 minimum/ANSI B18.3.1M.

X No washer is required under the screw head.

X Minimum thread engagement 6 mm.

X Tightening torque 0.9 Nm to 1.1 Nm.

X The DIN rail mounting where used must comply with EN50022.

Disconnecting the readhead

Remove the cover plate on the interface (2 × M2.5 hex head screws).

Gently lever the connector PCB (on the end of the cable) out of the socket.

Place the connector in an anti-static bag.

Ret the cover plate.

13TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 16

Readhead mounting and alignment

Mounting brackets

The bracket must have a at mounting surface and should provide adjustment to enable conformance to the installation tolerances, allow adjustment to the rideheight of the readhead, and be sufciently stiff to prevent deection or vibration of the readhead during operation. It must not be allowed to work itself loose due to vibration.

NOTES:

X Recommended screw type M2.5 × 0.45 and must comply with:

ISO4762/DIN 912 grade8.8 minimum/ANSIB18.3.1M.

X The use of a thread locking compound is recommended.

X No washer is required under the screw head.

X Minimum thread engagement 5mm (7.5mm including counterbore).

X Tightening torque 0.25Nm to 0.4Nm.

X Mounting hole clearance will contribute to mechanical safe position.

Readhead set-up LED status

Green Orange Red

Pitch 0±1°

Readhead set-up

Ensure that the scale, readhead optical window and mounting face are clean and free from obstructions.

NOTE: When cleaning the readhead and scale apply cleaning uid sparingly, do not soak.

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 DOP interface

is used, aim for a Blue LED on the interface.

NOTE: The readhead should be installed and set up with the Automatic Gain Control (AGC) switched off (CAL LED off). When re-installing the readhead, factory defaults should be restored (see page 15).

Ya w

0°±0.4°

DOP interface set-up LED status

Blue Green Orange Red

Purple

Roll

0°±0.5°

* For further information on LED status see page 16.

Green spacer

Rideheight

2.1±0.15 mm

14TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 17

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

X Clean the scale and readhead optical window (contamination around the reference mark may result in

reference mark dephasing).

X If re-installing the readhead, restore factory defaults.

X Maximise the signal strength along full axis of travel.

NOTE: Calibration (CAL) routine should be carried out at slow speed (<100 mm/s or less than the

readhead maximum speed, whichever is slowest).

Step 1 – Incremental signal calibration

X Ensure Automatic Gain Control (AGC) is switched off – Calibration (CAL) LED on readhead is not

illuminated – before beginning calibration.

X Press and release the CAL button on the end of the interface using a 2mm Allen key or similar tool as

shown.

NOTE: Activating the CAL switch only requires 2.5 Nforce. Applying excess force may permanently

damage the switch.

Set-up LED

CAL button

{

Step 2 – Reference mark phasing

X Move the readhead back and forth over the selected reference mark until the CAL LED stops ashing

and remains off. The reference mark is now phased.

X The system automatically exits the CAL routine and is ready for operation.

X For the safety function to be valid, customer commissioning tests must be performed:

see ‘Commissioning test’ on page 3.

X If the CAL LED continues double-ashing after passing the chosen reference mark many times, it is not

detecting the reference mark.

- Ensure that the correct readhead conguration is being used. Readheads can either output all

reference marks or only output a reference mark where a reference selector magnet is tted.

- Check that the reference selector magnet is tted in the correct location relative to readhead orientation (see ‘TONiC FS T301x readhead installation drawing’ on page 6).

NOTE: The LED on the interface will ash blank when the reference mark is detected (>100mm/s only). It indicates the presence of a reference mark, not the phasing status.

Calibration routine – manual exit

X To exit the calibration routine at any stage press the CAL button. The CAL LED on the readhead will then

stop ashing.

X For the safety function to be valid, customer commissioning tests must be performed:

see ‘Commissioning test’ on page 3.

CAL LED Settings stored

Single-ashing None, restore factory defaults and re-calibrate

Double-ashing Incremental only

Off (auto-complete) Incremental and reference mark

Ti interface DOP interface

X The CAL LED will now periodically single-ash to indicate that it is in incremental signal calibration

mode.

X Move the readhead along the axis, ensuring you do not pass the selected reference mark, until the CAL

LED starts double-ashing, indicating the incremental signal is now calibrated and the new settings are

stored in the readhead memory.

X The system is now ready for reference mark phasing.

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

X If the system does not automatically enter the reference mark phasing stage (no double-ashing

of the CAL LED) the calibration of the incremental signals has failed. After ensuring failure is not due

to overspeed (>100 mm/s or exceeding the readhead maximum speed), exit the calibration routine,

restore factory defaults and check the readhead installation and system cleanliness before repeating the calibration routine.

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

X Switch system off.

X Press and hold the CAL button whilst switching the system on. The CAL LED on the readhead will ash

several times, indicating that the factory defaults have been restored.

X Release CAL button.

X Check ‘Readhead mounting and alignment’ on page 14 and re-calibrate the system.

NOTE: System must be re-calibrated after restoring factory defaults.

Switching AGC on or off

AGC can be switched on or off via the interface.

X 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.

15TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 18

Diagnostic LEDs

T301x readhead LED

LED Indication Status

Set-up

Incremental

Reference mark

CAL

Operating

Calibration

Reset

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

†

For Functional Safe applications the set-up LED must be Green. See ‘Evaluation unit monitoring’ on page 3.

Green Normal set-up; signal level >70%

Orange

Red

Green (ash) *

Acceptable set-up; signal level 50% to 70%

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

Normal phasing

†

Orange (ash) Acceptable phasing

Red (ash) Poor phasing; clean scale and recalibrate if required

On AGC – On

Off AGC – Off

Single-ashing Calibrating incremental signals

Double-ashing Calibrating reference mark

Flashing at power-up (<2s)

Restore factory defaults

DOP interface set-up LED

Signal Indication Status

Incremental

Purple Normal set-up; signal level 110% to 135% No

Blue Optimum set-up; signal level 90% top 110% No

Green Normal set-up: signal level 70% to 90% No

Orange

Red

Acceptable set-up; signal level 50% to 70%

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

†

Purple / blank – ashing Over signal; system in error Ye s

Blue / blank – ashing Over speed; system in error Ye s

Red / blank – ashing Poor set-up; signal level <20%; system in error Ye s

Reference mark

†

For Functional Safe applications the LED must be Purple, Blue or Green. See ‘Evaluation unit monitoring’ on page 3.

NOTES:

X Alarm output will take the form of 3-state or line driven E signal depending on interface conguration. Also, some

congurations do not output overspeed alarm. See TONiC FS Data Sheet (L-9517-9878) for details of interface conguration.

X Momentary Alarm output status only, while fault condition remains.

X Alarm may result in axis position error, re-datum to continue.

Blank ash

Reference mark detected (speed <100mm/s only)

Alarm

output

16TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 19

Output signals

NOTE: Only analogue sine and cosine outputs are functionally safe.

Ti0000 interface output

DOP interface output

Function Output type Signal Pin

Power

5 V Power 4

5 V Sense 5

0 V Power 12

0 V Sense 13

Incremental signals

Cosine V

Analogue

Reference mark

Limits

Sine V

Analogue V

Open collector

Set-up – V

+ 9

− 1

+ 10

− 2

+ 3

− 11

Calibrate – CAL 14

Shield – Inner shield Not connected

– Outer shield Case

Readhead output

Function Output type Signal Colour

Power

Incremental signals

Cosine V

Analogue

Sine V

Reference mark

Analogue V

Limits

Open collector

Set-up – V

Calibrate – CAL Orange

Shield – Inner shield Green/Yellow

– Outer shield Outer screen

5 V Brown

0 V White

+ Red

− Blue

+ Yellow

− Green

+ Violet

− Grey

Pink

Black

Clear

Output connector for

Ti interfaces;

15-way D-type plug

Function Output type Signal Pin

Power 5 V Power 26

5 V Sense 18

0 V Power 9

0 V Sense 8

Incremental signals

Reference mark

Alarm

Limits

Readhead set-up

Shield

RS422A digital

Cosine V

Analogue

Sine V

RS422A digital Z

Analogue V

RS422A digital E

Open collector

– X 10

– Inner shield

+ 24

− 6

+ 7

− 16

+ 1

− 19

+ 2

− 11

+ 15

− 23

+ 12

− 20

+ 25

− 17

P 4

Q 13

Not

connected

– Outer shield Case

Output connector for

DOP interfaces;

26-way high-density

D-type plug

17TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 20

Speed

Clocked output

option

(MHz)

50 10 10 10 6.48 3.24 1.62 0.648 0.324 0.162 0.065 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

8 10 6.48 3.24 1.29 0.648 0.324 0.130 0.065 0.032 0.013 0.0065

6 10 4.50 2.25 0.90 0.450 0.225 0.090 0.045 0.023 0.009 0.0045

4 10 3.37 1.68 0.67 0.338 0.169 0.068 0.034 0.017 0.0068 0.0034

1 4.2 0.84 0.42 0.16 0.084 0.042 0.017 0.008 0.004 0.0017 0.0008

Analogue output

(Ti0000 and DOP)

DOP

0004 5µm

DOP 0020

1µm

DOP

0040

0.5µm

DOP 0100

0.2µm

Maximum speed (m/s)

DOP 0200

0.1µm

DOP

0400

50nm

10 (−3dB)

DOP 1000

20nm

DOP 2000

10nm

DOP

4000

5nm

DOP

10KD

2nm

DOP

20KD

1nm

18TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 21

Electrical connections

TONiC FS system grounding and shielding

Customer

Readhead

IMPORTANT: The outer shield must be connected to the machine earth (Field Ground). The inner shield

must 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.

NOTES:

X Maximum cable length between readhead and interface is 10m.

X Maximum extension cable is dependent on cable type, readhead cable length and clock speed. Contact

your local subsidiary for more information.

X For DOP interfaces the external earthing tag on the interface must be used when mounting the interface

on a DIN rail.

Inner shield

Outer shield

Interface

Extension cable

electronics

5 V

Output signals

0 V

Signal termination

Analogue outputs

V0 V1 V2+

120R

V0 V1 V2−

Limit output

5 to 24 V

Vp Vq P Q

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

Digital outputs

Readhead

ABZ E+

0 V

220 pF

Customer

electronics

Remote CAL operation

CAL

0 V

Ti and DOP 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.

Cable Z 0 = 120R

A B Z E−

Standard RS422A line receiver circuitry. Capacitors recommended for improved noise immunity.

120R

220 pF

0 V

19TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 22

Outputspecications

Analogue output signals

Digital output signals (DOP only)

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

Incremental 2 channels V1 and V2 differential sinusoids in quadrature (90° phase shifted)

20 µm

0.7 to 1.35 Vpp with Green LED

(V1 +) − (V1 −)

0°

(V2 +) − (V2 −)

indication (readhead) and 120R termination.

Centred on 1.65 V.

NOTE: DOP centred on 2.5 V.

Reference

0.8 to 1.2 Vpp

(V0+) − (V0 −)

45°

360° (nominal)

Bi-directionally repeatable. Differential pulse V0 , centred on 45°.

Differential signals V0+ and V0− centred on ~1.65 V

NOTE: DOP centred on 2.5 V.

Limits Open collector output, asynchronous pulse

Ti0000 interface only

Active high

Repeatability <0.1 mm

Vp V

Length of limit actuator

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

T301x readhead only

Active low

Repeatability <0.1 mm

Vp V

Length of limit actuator

Incremental † 2 channels A and B in quadrature (90° phase shifted)

Signal period

Resolution

Reference †

Wide reference

NOTE: Select ‘standard’ or ‘wide’ reference at time of ordering, to match the requirements of the controller being used.

†

Bi-directionally repeatable pulse Z, duration equal to the resolution

Bi-directionally repeatable pulse Z, duration equal to the signal period

Limits Open collector output, asynchronous pulse

Active high or Active low

Repeatability <0.1mm

P Q

Length of limit actuator

Repeatability <0.1 mm

P Q

Length of limit actuator

Ti0000 set-up

3.3 (nom)

Voltage

Between 50% and 70% signal level, VX is a duty cycle. Time spent at 3.3 V increases with incremental signal level. At >70% signal level VX is nominal 3.3 V.

at V

0 50% Signal level 70% 100%

†

Alarm

Line driven (Asynchronous pulse)

>15 ms

Alarm asserted when: – Signal amplitude <20% or >135%.

– Readhead speed too high for reliable operation.

or 3-state alarm

Differentially transmitted signals forced open

circuit for >15 ms when alarm conditions valid.

* Set-up signals as shown are not present during calibration routine. † Inverse signals not shown for clarity.

at X

Signal level

100%

DOP set-up

Voltage

Set-up signal voltage proportional to incremental signal amplitude

20TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 23

Generalspecications

Power supply

Temperature (system)

Sealing (readhead) IP40

(Ti interface) IP20

(DOP interface) IP30

Acceleration (readhead)

Shock (system)

Vibration (system)

Mass

Environmental Compliant with EU Directive 2011/65/EU (RoHS)

Readhead cable Double-shielded, outside diameter 4.25 ±0.25 mm

5 V ±10%

Ripple

Storage

Operating

Non-operating

Operating

Readhead

Ti interface

DOP interface 205 g

Readhead only <100 mA

T301x with Ti0000 <100 mA

T301x with DOP <275 mA

NOTE: Current consumption gures refer to unterminated systems For digital outputs a further 25 mA per channel pair (e.g., A+, A−) will be drawn when terminated with 120R.

For analogue outputs, a further 20 mA in total will be drawn when terminated with 120R.

Power from a 5 Vdc supply complying with the requirements for PELV of standard IEC60950.

200 mVpp maximum @ frequency up to 500 kHz

−20 °C to +70 °C

0 °C to +70 °C

500 m/s², 3 axes

500 m/s², 6 ms, ½ sine, 3 axes

100 m/s², 55 Hz to 2000 Hz, 3 axes

10 g

100 g

Cable

26 g/m

Flex life >20 × 106 cycles at 20 mm bend radius

UL recognised component

Maximum cable length

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.

Readhead to interface

Interface to controller Clocked output option

10 m

(MHz)

40to50 25

<40 50

Analogue 50

Maximum cable length

(m)

21TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 24

RSLM20scaletechnicalspecications

Reference mark

Form (H × W) 1.5 mm × 14.9 mm

Pitch 20µm

Accuracy (at 20 °C) ±1.5 µm for lengths up to 1 m

±2.25 µm for lengths from 1 m to 2 m

±3 µm for lengths from 2 m to 3 m

±4 µm for lengths from 3 m to 5 m

(includes slope and linearity)

Calibration traceable to International Standards

Supplied lengths 20 mm to 5 m (available in increments of 10mm)

Material Hardened martensitic stainless steel

Coefcientofthermalexpansion(CTE)

(at 20 °C)

Mounting Epoxy datum point and adhesive tape (nominal thickness

Mass 172 g/m

Storage Lengths over 1.13m are coiled (>600mm diameter)

10.1 ±2 µm/m/°C

0.2mm)

RELM20scaletechnicalspecications

Form (H × W) 1.6 mm × 14.9 mm

Pitch 20µm

Accuracy (at 20 °C)

(includes slope and linearity)

Supplied lengths 20 mm to 1.5 m (available in increments of 10mm)

Material ZeroMet™. High stability, low-expansion nickel-iron alloy

Coefcientofthermalexpansion

(at 20 °C)

Mounting Epoxy datum point and adhesive tape (nominal thickness

Mass 184 g/m

Certied to ±1µm for lengths up to 1m, ±1µm/m for lengths >1m to 1.5m

Calibration traceable to International Standards

0.75 ±0.35 µm/m/°C

0.2mm)

Type IN‑TRAC auto-phase optional reference mark, no physical adjustments required

Position RSLM20 Midpoint of scale length

RSLE20 (Option A) – 20mm from end of scale (for use with 10mm limits)

RSLE20 (Option B) – 70mm from end of scale (for use with 20mm and

50mm limits)

RSLC20 Selectable reference marks every 200mm

RELM20 Midpoint of scale length

RELE20 20mm from end of scale

Phasing Auto-phased by readhead calibration routine

Mounting Self-adhesive backing tape

Repeatability Repeatability to unit of resolution throughout specied temperature range

Limit switches

Type Magnetic actuators; with dimple triggers Q limit, without dimple triggers P limit

(see ‘TONiC FS T301x readhead installation drawing’ on page 6)

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

Mounting Customer placed at desired locations

Self-adhesive backing tape

Repeatablity <0.1mm

22TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 25

TONiC Ti interface drawing

Dimensions and tolerances in mm

TONiC DOP interface drawing

Dimensions and tolerances in mm

4-40 UNC × 2

Cover plate

15 8

Ø3.5 Clearance holes for M3 cap

33.3

screws and star washers or alternative

Calibration button

PORT NOT CONNECTED

Set-up LED

59.3

4-40 UNC hex

stand-off 2 positions

Output

26-way

high-density

D-type plug

8.7

33.3

12.4

Cable exit

Access hatch for readhead

cable connection

Mounting for 35 mm

DIN rail (EN50022)

External earthing tag

14.2

2.8

(0.11inch)

37.3

CAL/AGC push-button switch access hole Ø2.4

CAL/Calibration button operation

Push and release (<3 seconds) – CAL routine enable/disable. Push and release (>3 seconds) – AGC enable/disable. Push and hold during power ‘Off/On’ cycle – Restore factory defaults.

Refer to readhead LED functionality chart for set-up LED indications.

93.5

23TONiC RSLM20/RELM20 Functional Safety installation guide and safety manual Original instructions

Page 26

Renishaw plc

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

United Kingdom

T +44 (0)1453 524524 F +44 (0)1453 524901 E uk@renishaw.com

www.renishaw.com

For worldwide contact details, visit www.renishaw.com/contact

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.

RENISHAW and the probe symbol used in the RENISHAW logo are registered trade marks of Renishaw plc in the United Kingdom and other countries. apply innovation and names and designations of other Renishaw products and technologies are trade marks of Renishaw plc or its subsidiaries.

All other brand names and product names used in this document are trade names, trade marks or registered trade marks of their respective owners.

*M-6688-9046-02*

Part no.: M-6688-9046-02-B

Issued: 11.2019