Renishaw TONiC DOP User manual

RSLM high accuracy linear encoder
Installation guide
M-9653-9278-01-D
TONiC™DOP (dual output) encoder system

Renishaw plc declares that 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 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 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 2002/95/EC (RoHS)
Patents
Features of Renishaw’s encoder systems and similar products are the subjects of the following
patents and patent applications:
JP 3,202,316 US 5,241,173 EP 0514081 EP 0543513 US 5302820
US 5,861,953 EP 0748436 US 6,481,115 B1 IL 138995 US 6,775,008 B2
EP 1173731 IL146001 GB 2397040 CN 1293983C US 7,367,128
JP2005533247 CN 100543424 US 7659992 US 7624513
C
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.
Further information
Further information relating to the encoder range can be found in the 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.

Storage and handling
+70 °C
-20 °C
N-heptane
CH3(CH2)5CH3
Propan-2-ol
CH3CHOHCH3
Readhead
Acetone
CH3COCH3
Methylated
Spirits
Chlorinated
Solvents
Readhead
Interface
Readhead
+70 °C
0 °C
Humidity
Rated up to +40 °C,
<95% relative humidity
(non-condensing)
Storage Operating

6.3
1.5
>R20 Dynamic bend radius
>R10 Static bend radius
Ø 4.25 ±0.25
35
23
11.5
6
min
2 off mounting holes
M2.5 through, counterbored
Ø3 x 2.3 deep both sides
Set-up LED
CAL/AGC LED
A
0.6
(Pitch tol. ±1.0°)
//
29
22
Detail A
Scale reading surface
Readhead to
scale clearance Rideheight
2.1 ±0.15
Scale
thickness
1.5 ±0.1
Adhesive
thickness
0.2
Alternative
mounting
face
2 off mounting holes
M2.5 through, counterbored
Ø3 x 2.75 deep from
alternative mounting face
Reference mark selector
sensor position
P and Q limit switch
sensor position
P limit magnet
(A-9653-0138)
Recommended
mounting faces
(Roll tol. ±0.5°)
0.08
//
13.5
4.15
4.25
10
13.8*
±0.15
0.25
(Yaw tol. ±0.4°)
//
31
16
15
10
7.8 7.8
Optical centreline
(incremental and reference mark)
18
15.1
14.7
Reference mark selector
(A-9653-0143)
(Only required for
T1010 readheads)
3.7
Q limit magnet
(A-9653-0139)
3
3
Forward direction of
readhead relative to scale
readhead installation drawing (RELM/RSLM scale shown. For other scales, see relevant system installation guide)
Dimensions and tolerances in mm
*Dimensions from substrate surface

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.
Plug the readhead cable into the DOP interface under the cover plate and reassemble interface.
Connect to receiving electronics and power-up.
Ensure 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 travel as indicated by the
readhead and interface set-up LEDs (readhead - green; 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.
If a reference mark is not being used, the calibration routine should now be exited
by pressing the CAL button.
If a reference mark is being used move the readhead back and forth over the
selected reference mark until the CAL LED stops ashing and remains ‘off’.
The system is now calibrated and ready for use.
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.
DOP interface installation drawing
Dimensions and tolerances in mm
48
32
9
12.4
Cable exit
Access hatch for readhead
cable connection
Calibration button
Readhead
cable
PORT NOT CONNECTED
Set-up LED
15
53
Ø3.5 Clearance holes for M3 cap screws and star washers or alternative
Mounting for 35 mm
DIN rail (EN5022)
21
36
3
7
14.2
37.3
85
93.5
21
4-40 UNC hex
standoff 2 positions
Output
26 way hi-density
D-type plug
33.3
2.8 (0.11 inch)
External earthing tag
8.7
10
59.3

System connection
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 connector to allow for easy feed-through
during installation.
Connecting the readhead
uRemove the cover plate as shown
(2 x M2.5 hex head screws).
uTaking care not to touch the pins, plug the
connector into the socket in the interface,
ensuring correct orientation as shown.
u 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.
Disconnecting the readhead
uRemove the cover plate on the interface
(2 x M2.5 hex head screws).
uGently lever the connector PCB (on the end of the cable)
out of the socket.
uPlace the connector in an anti-static bag.
u Ret the cover plate.
Cover plate
Ya w
0° ±0.4°
Pitch
0° ±1.0°
Roll
0° ±0.5°
Rideheight
2.1 ±0.15 mm
Green spacer
Green Orange Red
Readhead set-up LED status
Readhead mounting and alignment
Mounting brackets
The bracket must have a at mounting surface and should 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.
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 readhead spacer
with the aperture under the optical centre of the readhead to allow normal LED
function during set-up procedure. Adjust the readhead to maximise the signal
strength and achieve a green set-up LED on the readhead (70 to 135% signal).
Aim for a blue LED on the interface.
NOTE: The readhead should be installed and set-up with the AGC switched off.
RELM/RSLM scale shown.
For other scales, see relevant system installation guide.
Blue Green Orange Red
Interface SIG and OPT LED status

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 non-volatile memory.
Before system calibration, install the readhead to maximise
the signal strength throughout the axis travel.
NOTE: CAL routine maximum speed <100 mm/s
Step 1 – Incremental signal calibration
uEnsure Automatic Gain Control is switched off
(CAL LED on readhead is not illuminated)
before beginning calibration.
uPress and release the CAL button on the
end of the interface as shown.
u The CAL LED will now periodically single-ash
to indicate that it is in incremental signal
calibration routine.
u Move the axis at slow speed, ensuring you do not
pass the reference mark. The CAL LED will
double-ash periodically, indicating the incremental
signal is now calibrated and the new settings are
stored in the readhead memory.
uThe system is now ready for reference mark phasing.
NOTE: For systems without a reference mark, go to ‘Calibration routine - manual exit’
Step 2 – Reference mark phasing
u Move the axis until the reference mark passes the readhead optical centre in any direction,
the CAL LED will continue to double ash periodically.
u Move the readhead back over the selected reference mark; the CAL LED will stop ashing and
remain off. The reference mark is now phased.
u The system automatically exits the CAL routine and is ready for operation.
Calibration routine - manual exit
u To exit the calibration routine at any time press and release the CAL button.
u
The CAL LED will stop ashing and remain off.
u If step 1 is complete (CAL LED is periodically double-ashing) the incremental signal CAL settings
will be stored.
u
Reference mark phasing settings will not be stored for CAL manual exit.
u
If the calibration routine has not been completed, restore factory defaults and then repeat the full
calibration.
Restoring factory defaults
When re-installing the system, or in the case of incomplete calibration, the factory defaults
should be restored.
To restore factory defaults;
uSwitch system off.
uPress 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.
uRelease CAL button.
u Check the ‘Readhead mounting/installation’ and re-calibrate the system.
NOTE: System must be re-calibrated after restoring factory defaults.
NOTE: The LED on the interface will flash blank when the reference mark is detected
(<100 mm/s only). It indicates the presence of a reference mark not the phasing status.
Switching Automatic Gain Control on or off
AGC can be switched on or off via the DOP interface CAL push button switch.
uPress 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.
Txxxx Readhead LED diagnostics
Normal set-up: signal level 70% to 135%
Acceptable set-up; signal level 50% to 70%
Poor set-up; signal may be too low for reliable operation; signal level <50%
Normal phasing
Acceptable phasing
Poor phasing; recalibrate
Automatic Gain Control – On
Automatic Gain Control – Off
Calibrating incremental signals
Calibrating reference mark
Restoring factory defaults
Status
Set-up
CAL
LED Indication
Incremental
Reference mark
Operating
Calibration
Reset
Green
Orange
Red
Green (ash)*
Orange (ash)
Red (ash)
On
Off
Single ashing
Double ashing
Flashing at
power-up (<2s)
DOP interface set-up LED diagnostics
Normal setup; signal level 110% to 135%
Optimum setup; signal level 90% top 110%
Normal set-up: signal level 70% to 90%
Acceptable set-up; signal level 50% to 70%
Poor set-up; signal may be too low for reliable operation;
signal level <50%
Over signal; system in error
Over speed; system in error
Poor set-up; signal level <20%; system in error
Reference mark detected (speed <100mm/s only)
Status
Signal Alarm output*
Indication
Incremental
Reference mark
Purple
Blue
Green
Orange
Red
Purple / blank - ashing
Blue / blank - ashing
Red / blank - ashing
Blank ash
No
No
No
No
No
Ye s
Ye s
Ye s
No
*-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 DOP Data Sheet (L-9517-9411) for details of interface conguration.
-Momentary status only, while fault condition remains.
-Alarm may result in axis position error, re-datum to continue.
*Flash will effectively be invisible when incremental signal level is >70% when passing reference mark.
CAL button
Set-up LED
{

26 pin high density D type plug
Connections
DOP output
RS422A digital
Cosine
Analogue
Sine
RS422A digital
Analogue
RS422A digital
Open collector
–
–
–
5 V Power
5 V Sense
0 V Power
0 V Sense
A+
A-
B+
B-
V1+
V1-
V2+
V2-
Z+
Z-
V0+
V0-
E+
E-
P
Q
X
Inner shield
Outer shield
Signal
Output type
26
18
9
8
24
6
7
16
1
19
2
11
15
23
12
20
25
17
4
13
10
Not connected
Case
Pin
Power
Incremental signals
Reference mark
Alarm
Limits
Readhead set-up
Shield
Function
V0V1V2-
V0V1V2+
120R
Standard RS422A line receiver circuitry
Interface
120R
A B Z E-
Customer
electronics
Cable Z0= 120R
A B Z E+
Recommended signal termination
Digital outputs Analogue outputs
P Q
R*
5 to 24 V
*Select R so max. current does not
exceed 20 mA
Limit outputs
Alternatively, use a suitable relay
or opto-isolator
Electrical connections
DOP system grounding and shielding
Interface
Customer
electronics
Inner shield
Outer shield
Output
signals
0 V
5 V
Readhead
Extension cable
max. 50m dependent
on output frequency
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: The external earthing tag on the interface should be used when mounting the interface on a DIN rail.
NOTE: Maximum cable length between readhead and interface is 10 m.

Output specications
Digital output signals
Form - Square wave differential line driver to EIA RS422A (except limits P and Q)
Analogue output signals
NOTE: Analogue signals are also available direct from all TONiC readheads
20 µm
Incremental 2 channels V1and V2differential sinusoids in quadrature
(90° phase shifted)
0.7 to 1.35 Vpp with green
LED indication (readhead)
and 120R termination.
Centred on 2.5 V
(V1 +)-(V1 -)
(V2 +)-(V2 -)
45° Bi-directionally repeatable
Differential pulse V0
centred on 45°
(V0 +)-(V0-)
0.8 to 1.2 Vpp
360° (nom)
0°
Reference
Limits Open collector output, asynchronous pulse
Repeatability
<0.1 mm
~Length of limit actuator
P Q
P Q
Repeatability
<0.1 mm
~Length of limit actuator
Active high or Active low
Set-up*
Voltage
at X
1
100%
0
0
Signal level
Inverse signals not shown for clarity
*
Set-up signal as shown is not present during calibration routine
Setup signal voltage proportional to incremental signal amplitude
AlarmAsynchronous pulse
or 3-state alarm (option)
Differentially transmitted signals forced open circuit for >15 ms when alarm conditions valid.
>15 ms
E
Incremental2 channels A and B in quadrature
(90° phase shifted)
Signal period P
Resolution S
A
B
Z
Z
Reference
Wide reference
NOTE: Select ‘standard’ or ‘wide’ reference at time of ordering, to match the requirements of the controller being used.
Synchronised pulse Z, duration as resolution
Synchronised pulse Z,duration as signal period
S (µm)
5
1
0.5
0.2
0.1
0.05
0.02
0.01
0.005
0.002
0.001
Model
DOP0004
DOP0020
DOP0040
DOP0100
DOP0200
DOP0400
DOP1000
DOP2000
DOP4000
DOP10KD
DOP20KD
P(µm)
20
4
2
0.8
0.4
0.2
0.08
0.04
0.02
0.008
0.004
Alarm asserted when signal level is less than 20% or greater than 135%.
Alarm is also asserted if readhead speed is too high for reliable operation.

Receiver clock
frequency (MHz)
40 to 50
<40
analogue
Maximum
cable length (m)
25
50
50
General specications
Power supply 5 V ±10% Readhead only <100 mA
System <275 mA
NOTE: Current consumption gures refer to
unterminated systems.
For digital outputs a further 25 mA per channel pair
(eg A+, A-) will be drawn when terminated with 120 Ω.
For analogue outputs, a further 20 mA in total will be
drawn when terminated with 120 Ω.
Power from a 5 V dc supply complying with the
requirements for SELV of standard EN (IEC) 60950.
Ripple 200 mVpp maximum @ frequency up to 500 kHz
Temperature (system) Storage -20 °C to +70 °C
Operating 0 °C to +70 °C
Sealing (readhead) IP40
(interface) IP30
Acceleration (readhead) Operating 500 m/s2BS EN 60068-2-7:1993
(IEC 68-2-7:1983)
Shock (system) Non-operating 1000 m/s2, 6 ms, ½ sine BS EN 60068-2-27:1993
(IEC 68-2-27:1987)
Vibration (system) Operating 100 m/s2, 55 Hz to 2000 Hz BS EN 60068-2-6:1996
(IEC 68-2-6:1995)
Mass Readhead 10 g
Interface 205 g
Cable 26 g/m
Environmental Compliant with EU Directive 2002/95/EC (RoHS)
Readhead cable Double shielded, outside diameter 4.25 ±0.25 mm.
Flex life >20x106cycles at 20 mm bend radius.
UL recognised component
Maximum cable length
Readhead to interface 10 m
Interface to controller
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.
Speed
Minimum receiver
clock frequency
(MHz)
50
40
25
20
12
10
8
6
4
1
Maximum speed (m/s)
DOP
0004
5 µm
10
10
10
10
10
10
10
10
10
4.2
DOP
0020
1 µm
10
10
10
10
9
8.10
6.48
4.50
3.37
0.84
DOP
0040
0.5 µm
10
10
8.10
6.75
4.50
4.05
3.24
2.25
1.68
0.42
DOP
0100
0.2 µm
6.48
5.40
3.24
2.70
1.80
1.62
1.29
0.90
0.67
0.16
DOP
0200
0.1 µm
3.24
2.70
1.62
1.35
0.900
0.810
0.648
0.450
0.338
0.084
DOP
0400
50 nm
1.62
1.35
0.810
0.675
0.450
0.405
0.324
0.225
0.169
0.042
DOP
1000
20 nm
0.648
0.540
0.324
0.270
0.180
0.162
0.130
0.090
0.068
0.017
DOP
2000
10 nm
0.324
0.270
0.162
0.135
0.090
0.081
0.065
0.045
0.034
0.008
DOP
4000
5 nm
0.162
0.135
0.081
0.068
0.045
0.041
0.032
0.023
0.017
0.004
DOP
10KD
2 nm
0.065
0.054
0.032
0.027
0.018
0.016
0.013
0.009
0.0068
0.0017
Analogue output 10 (-3dB)
DOP
20KD
1 nm
0.032
0.027
0.016
0.013
0.009
0.0081
0.0065
0.0045
0.0034
0.0008
Angular speed depends on ring diameter - use the following equation to convert to rev/min.
Angular speed (rev/min) = V x 1000 x 60
π DWhere V = maximum linear speed (m/s) and D = external diameter of RESM or REXM (mm)

RSLM high accuracy linear encoder
Renishaw plc
New Mills, Wotton-under-Edge,
Gloucestershire GL12 8JR
United Kingdom
T+44 (0)1453 524524
F+44 (0)1453 524901
[e-mail]
www.renishaw.com
For worldwide contact details,
please visit our main website at
www.renishaw.com/contact
RENISHAW®and the probe emblem used in the RENISHAW logo are
registered trademarks of Renishaw plc in the UK and other countries.
apply innovation is a trademark of Renishaw plc.
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