Renishaw TONiC diagnostic kit User manual

User guide
M-9589-9081-02-A
TONiC™diagnostic kit

TONiC diagnostic kit
User guide
TONiC diagnostic kit
User guide
Contents
1. General information 1
1.1. Minimum system requirements 1
1.2. General specications 1
1.3. Legal notices 1
1.4. Dongle kit contents 3
1.5. Dongle dimensions 4
1.6. Dongle interface dimensions 4
1.7. Signals 4
2. Software installation 5
3. Using Renishaw’s TONiC diagnostic kit 5
3.1. Connecting the system 6
3.1.1. TONiC with a digital Ti interface (Ti0004 - Ti4000) 6
3.1.2. TONiC with digital Ti interface (Ti10KD or Ti20KD) or analogue Ti interface (Ti0000) 6
3.2. Starting the software 7
3.3. Using the software 8
3.3.1. Signal size 8
3.3.2. Reference mark phasing 9
3.3.3. Pitch indicator 9
3.3.4. Limits 9
3.3.5. CAL button 10
3.3.6. AGC button 10
4. Faultnding 11
4.1. Driver installation failure 11
4.2. Communication error 11
4.3. Calibration failure 12
4.4. Pitch indicator failure 12
5. Hardware driver installation 13
5.1. Automatic driver installation 13
5.2. Manual hardware driver installation 13
6. Repairing/uninstalling the software 13

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TONiC
User guide
1. General information
1.1. Minimum system requirements
Microsoft Windows 8, Windows 7 or Windows XP
Microsoft .NET Framework 4.0 Full
USB port
Internet connection for software download
1.2. General specications
Power supply 5 V ±10% The dongle can be powered from the USB port or an external
5 V dc supply with the requirements for SELV or standard IEC
60950-1
Dongle current consumption <50 mA
Dongle interface current consumption <100 mA
Ripple <200mVpp maximum at frequency up to 500 KHz
Temperature Storage -20 °C to +70 °C
Operating 0°C to +70 °C
Humidity 95% relative humidity (non-condensing) to IEC 60068-2-78
Sealing IP20
1.3. Legal notices
Copyright
© 2015-2021 Renishaw plc. All rights reserved.
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 prior written permission of Renishaw.
Trade marks
RENISHAW® and the probe symbol are registered trade marks of Renishaw plc. Renishaw product names, designations and the
mark ‘apply innovation’ are trade marks of Renishaw plc or its subsidiaries.
Other brand, product or company names are trade marks of their respective owners.
Disclaimer
WHILE CONSIDERABLE EFFORT WAS MADE TO VERIFY THE ACCURACY OF THIS DOCUMENT AT PUBLICATION, ALL
WARRANTIES, CONDITIONS, REPRESENTATIONS AND LIABILITY, HOWSOEVER ARISING, ARE EXCLUDED TO THE
EXTENT PERMITTED BY LAW.
RENISHAW RESERVES THE RIGHT TO MAKE CHANGES TO THIS DOCUMENT AND TO THE EQUIPMENT, AND / OR SOFTWARE
AND THE SPECIFICATION DESCRIBED HEREIN WITHOUT OBLIGATION TO PROVIDE NOTICE OF SUCH CHANGES.
Terms and conditions and warranty
Unless you and Renishaw have agreed and signed a separate written agreement, the equipment and/or software are sold
subject to the Renishaw Standard Terms and Conditions supplied with such equipment and/or software, or available on request
from your local Renishaw ofce.
Renishaw warrants its equipment and software for a limited period (as set out in the Standard Terms and Conditions), provided
that they are installed and used exactly as dened in associated Renishaw documentation. You should consult these Standard
Terms and Conditions to nd out the full details of your warranty.
Equipment and/or software purchased by you from a third-party supplier is subject to separate terms and conditions supplied
with such equipment and/or software. You should contact your third-party supplier for details.
Product compliance
Renishaw plc declares that TONiC diagnostic kit 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.

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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 modications 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.
Further information
Further information relating to the TONiC encoder range can be found in the TONiC system Data sheet and Installation guides.
These can be downloaded from our website www.renishaw.com/tonicdownloads and are also available from your local
Renishaw representative.
Packaging
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.
WEEE recycling guidelines
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.

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1.4. Dongle kit contents
A-9411-0011:
1
2
3
4
5
6
7
The dongle interface/Ti interface connector is not designed for multiple insertions and removals. The sacricial interconnect
PCB’s should be used and replaced when worn or damaged.
Packs of 10 replacement PCB’s are available to order:
Item 6: A-9411-0016
Item 7: A-9411-0017
Item Description Quantity
1Dongle 1
2Dongle interface 1
3USB cable 1
4Interface cable for ATOM™ 15-way D-type readheads 1
5Interface cable for TONiC and ATOM readheads 1
6Sacricial interconnect PCB for TONiC and ATOM cabled readheads 10
7Sacricial interconnect PCB for ATOM FPC readheads 10

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15
1
8
9
TONiC
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Dimensions and tolerances in mm
16
4-40 UNC x 2
8
40
6 min
62
67
CAL/AGC push switch
access hole Ø2.4
R>20 Dynamic bend radius
R>10 Static bend radius
Cover plate
Requires 2 mm
hex key
Diagnostic LED
33.3
1.6. Dongle interface dimensions
1.5. Dongle dimensions Dimensions and tolerances in mm
62
33.3
12.5
33.3 39
Communication LED
USB port
1.7. Signals
Dongle interface Dongle
Function Signal Output pin
(male 15-way D-type)
Input pin
(female 15-way D-type)
Ouput pin
(male 15-way D-type)
Power 5 V 7, 8 7, 8 7, 8
0 V 2, 9 2, 9 2, 9
Incremental A+14 14 14
−6 6 6
B+13 13 13
−5 5 5
Reference mark Z+12 12 12
−4 4 4
Limits P 11 11 11
Q 10 10 10
Alarm E+11 11 11
−3 3 3
External set-up X1 1 -
Shield Inner screen 15 15 15

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TONiC
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2. Software installation
Full administration rights are necessary to install and uninstall the TONiC hardware drivers and software.
Before installing a new version of the TONiC software ensure that any previous versions have been uninstalled
(‘6. Repairing/uninstalling the software’, page 13).
Download the TONiC diagnostic software installation le from the TONiC downloads page on www.renishaw.com/
tonicdownloads
It will ask ‘Do you want to run or save TONiC installer.exe from renishaw.com?’.
Cick Run.
The InstallShield Wizard will start automatically.
Follow the instructions on the screen and the installation program will automatically run through the installation process.
NOTE: On Windows 8 it will ask :
‘Do you want to allow the following program from an unknown publisher to make changes to this computer ?’
Click Yes to continue the installation.
Once the software installation has completed click Finish to close the window.
The software will have installed an icon on the desktop.
3. Using Renishaw’s TONiC diagnostic kit
The TONiC diagnostic kit can be used to connect the TONiC system, via a USB link, to a PC to assist with the set-up.
The software displays:
Signal size
Reference mark phasing
Limits
Readhead pitch
It also allows system calibration to be initiated and Automatic Gain Control (AGC) to be toggled. The dongle can be powered via
the USB connection or in-line with the customers’ electronics.

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3.1. Connecting the system
Choose the appropriate interconnect cabling for your system from the options below and connect the TONiC readhead to the dongle.
3.1.1. TONiC with a digital Ti interface (Ti0004 - Ti4000)
Items required for connection:
• Item 1, dongle
• Item 3, USB cable
Connect the TONiC readhead to the Ti interface. See the relevant TONiC installation guide for details of connecting the
readhead to the Ti interface (System connection).
Connect the output of the Ti interface to the input of the dongle
If using the diagnostic dongle ‘in-line’ connect the output of the dongle to the customers’ controller
Proceed to section 3.2. (‘3.2. Starting the software’, page 7)
TONiC
User guide
Item 1
3.1.2. TONiC with digital Ti interface (Ti10KD or Ti20KD) or analogue Ti interface (Ti0000)
NOTE: Ti0000, Ti10KD and Ti20KD are not compatible with the diagnostic dongle so the system should be connected using the
dongle interface
Items required for connection:
• Item 6, sacricial interconnect PCB for TONiC or ATOM cabled readheads.
• Item 5, Interface cable for TONiC or ATOM readheads.
• Item 2, dongle interface.
• Item 1, dongle.
• Item 3, USB cable.
Do not connect the readhead to the interface.
Connect the sacricial interconnect PCB to the JST connector on the interface cable (Item 5).
Connect the mini PCB on the cabled TONiC readhead to the sacricial interconnect PCB for cabled readheads (Item 6).
Ensure correct orientation of the connector, both cables will come out of the same side of the pcb.
Open the cover plate on the dongle interface (Item 2) and connect the mini PCB into the interface.
See the relevant TONiC installation guide for details of connecting the readhead to the dongle interface (System connection).
Connect the output of the dongle interface to the input of the dongle (Item 1).
Proceed to section 3.2 (‘3.2. Starting the software’, page 7)
NOTE: The dongle interface/Ti interface connector is not designed for multiple insertions and removals.
The sacricial interconnect PCB’s should be used and replaced when worn or damaged.
Item 6 Item 5 Item 2 Item 1
Readhead Interface Section
TONiC Ti0004 - Ti4000 3.1.1.
TONiC
Ti0000
Ti10KD
Ti20KD
3.1.2.

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3.2. Starting the software
ON FIRST USE DO NOT CONNECT THE SYSTEM TO THE
USB PORT BEFORE STARTING THE SOFTWARE.
On rst use the software will automatically install the hardware
drivers (‘5. Hardware driver installation’, page 13).
Double click on the ‘TONiC diagnostic’ icon on the desktop.
The software will open a ‘greyed out’ window displaying the
‘Start page’ with an orange circle saying ‘Please connect to
device’ indicating that it is waiting for the TONiC system to
be connected.
Using the USB cable (item 3) connect the dongle via the
USB port to the PC.
See ‘3.1. Connecting the system’, page 6 for details on
connecting the TONiC readhead to the dongle.
The ‘Start page’ will then become active.
• The PSU voltage will display USB showing it is powered via
the USB port or the supply voltage if used ‘in-line’.
• The diagnostic LED on the dongle interface or Ti interface
will now double ash orange and the communication LED
on the dongle will be green. The CAL LED on the readhead
will double ash orange.
Click on the green arrow to enter the software.
• The ‘Signal’ screen will now be displayed
(‘3.3. Using the software’, page 8).
• The diagnostic LED on the dongle interface or Ti interface
will continue double ashing orange and the communication
LED on the dongle will be green.
The CAL LED on the readhead will stop ashing.

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3.3. Using the software
This section explains the functions of software. It should be used in conjunction with the relevant TONiC installation
guide for details on how to install and set the system up. Only one copy of the software should be opened at a time
with only a single TONiC system connected to it.
3.3.1. Signal size
The signal size is displayed as a percentage and as a colour bar, the bar changes colour dependant on the signal size.
Signal size is also available as an audible indication.
Ensure the volume on the PC is switched on.
Click on the sliding switch in the top right hand corner to toggle the audible indication, the switch will be
orange when the audible signal is activated. The tone gets higher as the signal level increases.
NOTE:
When the TONiC dongle is connected the diagnostic LED on the dongle interface or Ti interface
will ash orange, it will not display the signal size. The set-up LED on the readhead will function as
normal. See the relevant TONiC installation guide for more information on the readhead LED function.
Signal size
Reference mark phasing
CAL button
Clickable link to
Renishaw website Resize screen
AGC button
Audible signal strength
indicator switch
Flashing signal size bar indicates system is in error.
Readhead pitch indicator
P and Q limits
Signal size Colour Indicates
>110% Purple Good set-up, no further adjustment required
90% to 110% Blue Optimum set-up
70% to 90% Green Good set-up, no further adjustment required
50% to 70% Orange Acceptable set-up but below the recommended level
<50% Red Poor set-up, signal may be too low for reliable operation; adjust set-up

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3.3.2. Reference mark phasing
This shows the phasing of the reference mark.
The bar in the centre will move and change colour depending upon the phasing of the reference mark. When the reference mark
is correctly phased the bar will ash green as the readhead passes over the chosen reference mark with the start and end of the
bar in the boxes at either end.
Example of a correctly phased reference mark:
Green bar
Start and end point of bar within the boxes
If the bar ashes orange or red as the readhead passes the chosen reference mark the reference mark is not phased. Refer to
the relevant installation manual for details of troubleshooting if the reference mark is not phased.
Examples of poorly phased reference marks:
Red or orange bar
Start or end point of bar not within the boxes
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3.3.3. Pitch indicator
The pitch of the readhead is displayed as a spirit level. To ensure the correct pitch the ‘bubble’ should be positioned between the
two thick black lines. The ‘bubble’ will move briey to either end of the bar as it passes over a reference mark.
NOTE: When setting the pitch of the readhead ensure the readhead is not near a reference mark.
NOTE: If switching power on/off via the USB to restore factory defaults the power must be cycled again (i.e. USB unplugged and
reconnected) for the software to function correctly. If the power is not cycled the pitch indicator will not function. See the relevant
TONiC installation guide for details on restoring factory defaults.
3.3.4. Limits
When the readhead is moved over a limit the corresponding limit will turn green.
NOTE: If using a digital Ti interface (Ti0004 - Ti4000) option E, F, G or H the P limit will turn green when the alarm is initiated as
the P output is used for the alarm (E+) output.

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3.3.5. CAL button
Before system calibration, ensure AGC is switched off and signal is maximised the along the full axis of travel.
Refer to the relevant TONiC installation guide for details of system installation and calibration procedure.
NOTE: Signal strength must be ≥70% before calibration can be initiated. The CAL button will be ‘greyed out’ if
the signal strength is too low for calibration.
Calibration routine:
Click on the CAL button to initiate the calibration procedure.
• The display will be ‘greyed out’ and a box showing a moving
readhead above some scale and an arrow will be displayed for
10 seconds. The CAL LED on the readhead will
periodically single-ash.
NOTE: The signal strength meter and reference mark phasing
indicator will not be active whilst the display is ‘greyed out’.
Move the readhead along the axis, ensuring you do not pass
a reference mark. The CAL LED on the readhead starts
double-ashing.
Move the readhead backwards and forwards across the chosen reference mark.
The CAL button will turn grey and the signal size and reference mark displays will be reactivated indicating the system has
completed its calibration routine and is ready for operation. The CAL LED on the readhead will stop ashing.
NOTE: Clicking on the CAL button initiates the CAL routine and indicates the action required. It does not indicate
that calibration is complete or has been successful. Refer to the relevant TONiC installation guide for details of the
calibration routine.
3.3.6. AGC button
Once the system has been calibrated AGC can be enabled/disabled by clicking on this button.
Click the AGC button.
• The display will be ‘greyed out’ and an orange circle with
‘Toggling AGC status’ will be displayed.
The display will return to normal and the signal strength meter and reference mark display will be reactivated.
The AGC status has been toggled.
NOTE: The software does not display whether AGC is on or off. To see the status of AGC use the CAL LED on the readhead as
detailed in the relevant installation guide.

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4. Faultnding
4.1. Driver installation failure
If, during installation, the software does not nd the hardware drivers, ’Device driver software was not successfully installed’,
the drivers should be manually installed (‘5.2. Manual hardware driver installation’, page 13).
4.2. Communication error
If communication is lost with the dongle or attached interface
‘Comm Error’ warning will ash 10 times.
The display will be ‘greyed out’ and display an orange
circle with ‘Please connect to device’ until communication
is re-established.
Communication error means that the software cannot talk to the TONiC dongle.
Complete the following checks and take remedial actions as required:
Check the correct interconnect cabling has been used between the readhead and the dongle interface (‘3.1. Connecting the
system’, page 6). The dongle must be used with the dongle interface unless using a Ti0004 - Ti4000.
Check connections between the dongle and the dongle interface and dongle interface and readhead.
Close software application, unplug USB cable from the dongle, restart the software and reconnect the USB cable. The signal
level LED on the dongle interface/Ti interface should start ashing orange and there should be a green LED on the dongle
next to the USB connection.
If the software still does not recognise the TONiC system it may be because the hardware drivers have not been correctly
installed. See ‘5.2. Manual hardware driver installation’, page 13 for details on how to manually install the drivers.
NOTE: Hardware drivers need to be installed for each USB port.
If the software becomes corrupt see ‘6. Repairing/uninstalling the software’, page 13 for details on repairing and
uninstalling the software

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4.3. Calibration failure
The software does not display if the calibration routine has failed. To check calibration status use the CAL LED on the TONiC
readhead. If calibration fails restore factory defaults by pressing and holding the CAL button on the dongle interface whilst
cycling the power. See the relevant TONiC installation guide for details of the calibration routine and restoring factory defaults.
4.4. Pitch indicator failure
Ensure the readhead is not over a reference mark when checking the readhead pitch. If the pitch indicator ‘bubble’ does not
move on pitching the head or remains to one side of the centre unplug and reconnect the USB to cycle the power.

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5. Hardware driver installation
5.1. Automatic driver installation
The hardware drivers will automatically be installed when the software is started for the rst time.
DO NOT CONNECT THE SYSTEM TO THE USB PORT BEFORE STARTING THE SOFTWARE FOR THE FIRST TIME
AS THE DRIVERS MAY NOT INSTALL CORRECTLY.
NOTE: Hardware drivers need to be installed for each USB port being used for connection to the software.
Click on the ‘TONiC diagnostic’ icon on the desktop.
The Device Driver Installation Wizard will start automatically.
Follow the instructions on the screen and the drivers will automatically be installed for that USB port.
NOTE: On Windows 8 it will ask:
‘Do you want to allow the following program from an unknown publisher to make changes to this computer ?’.
Click Yes to continue the driver installation.
Click Finish and the software is ready to use.
5.2. Manual hardware driver installation
If the drivers have not automatically installed they can be manually installed.
Browse C: Program les (x86)/Renishaw/TONiC diagnostic.
Depending upon if it is a 32 bit or 64 bit PC select Drivers (x32) or Drivers (x64).
Click on DPInst and the Device Driver Installation Wizard will open.
Follow the instructions on the screen and the drivers will automatically be installed for that USB port.
NOTE: On Windows 8 it will ask:
‘Do you want to allow the following program from an unknown publisher to make changes to this computer ?’.
Click Yes to continue the driver installation.
Click Finish and the software is ready to use.
6. Repairing/uninstalling the software
Ensure there are no copies of Renishaw’s TONiC software running before attempting to uninstall.
Go to Control panel >>Programs and Features.
Select TONiC diagnostic.
Select uninstall, change or repair as required.
The InstallShield Wizard software will start automatically.
Follow the instructions on the screen to remove or repair the software as required.
TONiC
User guide

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
Part no.: M-9589-9081-02-A
Issued: 02.2021
*M-9589-9081-02*
Renishaw plc. Registered in England and Wales. Company no: 1106260.
Registered ofce: New Mills, Wotton-under-Edge, Gloucestershire, GL12 8JR, UK.
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