Renishaw TONiC FS T3 Series Instruction Manual

Installation guide
M-6688-9044-02-B
TONiC™FS T303x RTLC20-S linear encoder system
Functional Safety installation guide and safety manual

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 T303x readhead installation drawing 6
RTLC20-S scale installation drawing 7
Scale application 8
End covers 8
Reference mark selector and limit magnet installation 9
Datum clamp 9
TONiC FS quick-start guide 10
Cable connection 11
System connection – Ti interface 11
System connection – DOP interface 12
Readhead mounting and alignment 13
Systemcalibration 14
Diagnostic LEDs 15
Output signals 16
Speed 17
Electrical connections 18
Outputspecications 19
Generalspecications 20
RTLC20-Sscaletechnicalspecications 21
Reference mark 21
Limit switches 21
TONiC Ti interface drawing 22
TONiC DOP interface drawing 22
TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Contents

1TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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.
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.
C
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.
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.
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
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.
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.
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.
EP0748436 US5861953 EP1173731 US6775008B2 JP4750998
CNCN100543424C US7659992 JP4932706 CNCN100507454C US7550710
EP1766335 CNCN101300463B EP1946048 US7624513B2 JP5017275
CNCN101310165B US7839296 EP1957943 US8141265 EP2294363
CN102057256 JP5475759 JP5755299 KR20110033204 CN1314511
EP1469969 JP5002559 US8466943 US8987633
SIL2
FUNCTIONAL
SAFETY
PLd
Patents
Features of Renishaw’s encoder systems and similar products are the subjects of the following
patents and patent applications:

2TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Denitions Functional Safety data declaration
WARNING A hazard with a medium risk of injury if not avoided
ESD handling 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’.
Mechanical safe position The maximum distance the scale might move from its installed position, for example if
the xings work loose.
Evaluation unit External item of equipment in which the output signal of the encoder is evaluated,
e.g. machine controller or safety relay.
System manufacturer Personnel with responsibility for selecting the encoder and verifying its capability is
appropriate for the safety related application.
System installer 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:
XOperating the TONiC FS system within the limits dened in this document.
XInstalling the system as described in this document.
XMaintaining the system as described in this document.
System components:
The TONiC FS system comprises the following parts:
XTONiC FS readhead.
XTONiC Ti0000A00A or DOP interface.
XRTLC20-S tape scale with end covers.
NOTES:
XOnly RTLC20-S scale using end covers is functionally safe.
XOnly 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.
Information for use
Productidentication TONiC FS (Functional Safety)
TONiC
readhead
TONiC
readhead and
Ti interface
TONiC
readhead and
DOP interface
MTTFD (years) 1300 800 300
Diagnostic coverage Medium (90%)
Category 3
Performance level d
Lifetime/replacement limits 20
TONiC
readhead
TONiC
readhead and
Ti interface
TONiC
readhead and
DOP interface
Safety integrity level 2
Random hardware
failures (per hour)
lS1.77 × 10−7 1.77 × 10−7 1.77 × 10−7
lD8.41 ×10−8 1.38 × 10−7 3.49 × 10−7
lDD 7.57 × 10−8 1.25 × 10−7 3.14 × 10−7
lDU 8.41 × 10−9 1.38 × 10−8 3.49 × 10−8
PFDavg
Not available as this system does not support low
demand mode
PFH (per hour) 8.41 × 10−9 1.38 × 10−8 3.49 × 10−8
Architectural
constraints
Type B
HFT 0
SFF 96%
Hardware safety integrity
compliance Route 1H
Systematic safety integrity
compliance Route 1S
Systematic capability SC 2
Demand mode Continuous
IEC61508safetydata
ISO13849safetydata

3TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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:
XThe system installer must perform a veried commissioning test during installation.
XThe system repairer must perform a veried commissioning test following replacement of a system part.
XWhen 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.
XThe 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):
XFaults caused by cutting and reconnecting the readhead cable or extending the readhead cable.
XIncorrect installation of the readhead.
XIncorrect installation of the scale.
XDismantling of the TONiC readhead or the Ti or DOP interfaces.
XOperating 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:
XPosition output is correct within a tolerance of ±10%.
XDirection of movement is correct.
XThe 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
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 19.
Following error check Following error is dened as the difference between the expected position
and position feedback. A fault condition must be asserted if the following error
exceeds the safe position limit for the system.
NOTES:
XThe evaluation unit must achieve medium diagnostic coverage (≥90%) according to ISO13849.
XImproper setting of the switching thresholds and hysteresis in signal evaluation can result in incorrect
determination of direction, position or speed.
XA persistent fault condition may indicate a hardware failure of the TONiC FS system or an
installation problem.
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:
XCheck the readhead to bracket screws are correctly tightened.
XCheck for worn or damaged cable connecting the readhead to the interface.
XCheck 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.

4TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Certication
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.
TONiC FS encoder system
FunctionalSafetyCerticateNo.FSC001
SIL2
FUNCTIONAL
SAFETY
PLd
EU declaration of conformity
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:
and comply with the following technical standards:
2014/30/EU Electromagnetic compatibility (EMC)
2011/65/EU On the restriction of the use of certain hazardous substances
inelectrical and electronic equipment (recast)
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

5TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
+70°C
−20°C
Minimum bend radius
RTLC20-S – 150 mm
NOTE: Ensure self-adhesive tape
is on the outside of bend.
95% relative humidity
(non-condensing) to
IEC60068-2-78
Humidity
Storage
+70°C
0°C
Operating
Storage and handling
N-heptane
CH3(CH2)5CH3
Propan-2-ol
CH3CHOHCH3
Scale and readhead Readhead only
Acetone
CH3COCH3
Methylated
Spirits
Chlorinated
Solvents

6TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
TONiC FS T303x readhead installation drawing
Dimensions and tolerances in mm
Forward direction of readhead
relative to scale
R>20 Dynamic bend radius
R>10 Static bend radius
Ø4.25 ±0.25
Set-up LED
CAL/AGC LED
Optical centreline marker
A
0.6
(Pitch tol. ±1°)
35
23
11.5
6 min
18
16
7.8 7.8
2 off holes M2.5 through,
counterbored Ø3 × 2.75 deep
from alternative mounting face
Reference mark selector
sensor position
P and Q limit switch
sensor position
Selected IN‑TRAC
™
reference mark
0.08
(Roll tol. ±0.5°)
11
†
13.5
4.25
4.15
10
8.75
†
Offset 2.75 ±0.5
3
0.25
(Yaw tol. ±0.4°)
29
22
Detail A
Scale reading surface
5 *
Rideheight 2.1 ±0.15
Optical centreline
(incremental and reference mark)
Recommended
mounting faces
Scale thickness 0.4
(including adhesive)
3
P limit magnet
Reference mark
selector magnet
Q limit magnet
*Dimensions from substrate surface. † Extent of mounting faces. ‡ Minimum thread engagement 5mm (7.5 including counterbore). Tightening torque 0.25 to 0.4 Nm.
31
8
Alternative
mounting
face
2 off mounting holes 2.5 through, counterbored
Ø3 × 2.3 deep both sides
‡

7TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
RTLC20-S scale installation drawing Dimensions and tolerances in mm
Scale length (L)
Overall length ( L + 37 )
Measuring length ML = ( L − 17) (ML = (L − 32) with dual limits)
Readhead optical detector position at extent of travel
P limit magnet
(A-9653-0138)
P and Q limit switch
sensor position
TONiC readhead
Nominal P limit
trigger point
Q limit magnet
(A-9653-0139)
(Dimensions as P limit)
Reference mark selector magnet
(A-9653-0143)
(Dimensions as P limit)
8
B
Optical centreline (incremental and reference mark)
5
10
9.2
15 RTLC20-S scale
Datum clamp
(A-9585-0028)
End cover
(Pair A-9585-0035)
5
START (see page 8) FINISH (see page 8)
A
C
Detail B
End cover
alignment
indicator
Detail C
0.5 F
0.2/100
0.05 F
F = axis of motion
F = axis of motion
Nominal Q limit
trigger point
Ra 3.2
Detail A Optional bolted reference mark selector and limit magnets
22
18
10
3.7
Ø2.2
†
*Dimension from substrate surface. †Supplied with 2 × M2 × 4 screws.
1.85
3.7
1.5 *
4.5 12
15 ±1
18.5 ±1
0.8
3.5
(adhesive datum clamp)
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.
Bolted magnet type Part number
P limit A-9653-0292
Q limit A-9653-0291
Reference mark selector A-9653-0290

8TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
1 Allow scale to acclimatize to installation environment prior to installation.
2 Mark out the ‘START’ and ‘FINISH’ points for the scale on the axis
substrate – ensure that there is room for the end covers (see ‘RTLC20-S
scale installation drawing’ on page 7).
3Thoroughly clean and degrease the substrate using recommended
solvents (see ‘Storage and handling’ on page 5). Allow substrate to
dry before applying scale.
4Mount the appropriate scale applicator to the readhead mounting
bracket using M2.5 screws. Place the shim supplied with the readhead
between the applicator and substrate to set the nominal height.
NOTE: Scale applicator can be mounted either way round to enable
easiest orientation for scale installation.
5Move axis to ‘START’ of travel, leaving enough room for the scale to be
inserted through the applicator, as shown below.
6Begin to remove the backing paper from the scale and insert scale into
the applicator up to the ‘START’ point (as shown). Ensure backing tape
is routed under the splitter screw.
7 Apply nger pressure to the scale at the ‘START’ point, using a clean
lint-free cloth, to ensure scale end adheres well to the substrate.
Scale application
There are two versions of applicator for use with RTLC20-S scale: side mounted (A-9589-0115) and top mounted (A-9589-0094).
NOTE: Ensure the guidance in ‘Storage and handling’ on page 5 is followed.
9 Remove applicator and, if necessary, adhere the
remaining scale manually. Apply rm nger pressure
via a clean lint-free cloth along the length of the scale
after application to ensure complete adhesion.
8 Slowly and smoothly move the applicator through the
entire axis of travel, ensuring the backing paper is
pulled manually from the scale and does not catch
under the applicator.
START
>8.5 mm
Limit of travel
Direction of scale
application
RTLC20-S
Splitter screw
Backing tape
Top mount applicator
End covers
The end cover kit (A-9585-0035) is designed to be used with RTLC20-S scale.
NOTE: End covers can be tted before or after readhead installation.
1 Remove the backing tape from the adhesive tape
on the back of the end cover.
2 Align marker on the edges of the end cover
with the end of the scale and place end cover
over the scale.
NOTE: There will be a gap *between the
end of the scale and the adhesive tape
on the end cover.
*gap
10 Clean scale using Renishaw scale cleaning wipes
(A-9523-4040) or a clean, dry, lint-free cloth.
Side mount applicator
START
>8.5 mm
Limit of travel
RTLC20-S
Backing tape
Splitter screw
Direction of
scale application
START point
M2.5 mounting holes
Side mount applicator
Top mount applicator
M2.5 mounting holes
START point

9TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Reference mark selector and limit magnet installation
IMPORTANT:Allow24hoursafterscaleapplicationbeforettingmagnets.
For accuracy and ease of positioning of reference mark selector and limit magnets, the
applicator tool (A-9653-0201) should be used. The magnet should be attached to the
applicator tool as shown.
Limit magnets can be positioned at any user-dened location along the scale, but
the reference mark selector magnet should be positioned adjacent to the selected
IN‑TRAC reference mark as shown.
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 scale installation instructions will
prevent this magnetic force from disturbing the scale.
Datum clamp
IMPORTANT:Allow24hoursafterscaleapplicationbefore
ttingdatumclamp.
The datum clamp (A-9585-0028) xes the RTLC20-S scale
rigidly to the substrate at the location chosen.
The metrology of the system may be compromised if the
datumclampisnotused.
The datum clamp does not need to be tted adjacent to a
reference mark. It can be positioned anywhere along the axis
depending upon the customer’s requirements.
1 Remove the backing paper from
the datum clamp. Place the datum
clamp with cut-out against the scale
at the chosen location.
2 Place a small amount of adhesive
(Loctite® 435™) in the cut-out on
the datum clamp, ensuring none
of the adhesive wicks onto the
scale surface.Dispensing tips
P-TL50-0209 are available.
P limit magnet Remove
self-adhesive
backing paper
Reference
mark selector
magnet
Selected IN‑TRAC
reference mark
Q 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 ‘RTLC20-S scale installation drawing’ on page 7).
Applicator tool
(A-9653-0201)
NOTES:
XReference 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 along the outer edge of the magnet
assembly. Optional bolted reference and limit magnets are available: for details
see ‘RTLC20-S scale installation drawing’ on page 7.
XThe reference mark selector and limit actuator locations are correct for the
readhead installation shown.
XExternal magnetic elds greater than 6mT, in the vicinity of the readhead, may
cause false activation of the limit and reference sensors.
Ensure the adhesive wicks along
the entire length of cut-out.

10TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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 ‘RTLC20-S scale installation drawing’ on page 7).
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.
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.
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 CAL LED will stop ashing.
Reference mark
Move the readhead back and forth over the selected reference mark until the
CAL LED stops ashing and remains ‘off’.

11TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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.
Cable connection
XThe 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.
XCable rolling radius must be >25mm when the cable is routed through moving trunking / a cable chain.
XThe cable must be routed to avoid all moving parts of the machinery and the readhead itself.
XRoute the cable away from operating environments that will exceed the EMC limits dened in
IEC61800-5-2 Annex E.
XUse only Renishaw approved cables between the readhead and the interface.
XThe 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 in IEC61800-5-2AnnexE.
XThe sine and cosine signals must be connected as described in ‘Electrical connections’ on page 18.
Connecting the readhead
1 Remove the cover plate as shown (2 × M2.5 hex head screws).
2Taking 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.
3 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.
4 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 RTLC20-S Functional Safety installation guide and safety manual Original instructions
3 Place the connector in an anti-static bag.
4 Ret the cover plate.
Disconnecting the readhead
1 Remove the cover plate on the interface
(2 × M2.5 hex head screws).
2 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
1 Remove the cover plate on the
interface (2 × M2.5 hex head screws).
2Taking care not to touch the pins,
plug the connector into the socket
in the interface, ensuring correct
orientation as shown.
3 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.
DOP mounting
The DOP interface readhead is mounted to a suitable surface using customer-supplied screws appropriate
to the application details.
NOTES:
XRecommended screw type M3 × 0.5 and must comply with:
ISO4762/DIN 912 grade 8.8 minimum/ANSI B18.3.1M.
XNo washer is required under the screw head.
XMinimum thread engagement 6 mm.
XTightening torque 0.9 Nm to 1.1 Nm.
XThe DIN rail mounting where used must comply with EN50022.
Disconnecting the readhead
1 Remove the cover plate on the interface (2 × M2.5 hex head screws).
2 Gently lever the connector PCB (on the end of the cable) out of the socket.
3 Place the connector in an anti-static bag.
4 Ret the cover plate.
Cover plate

13TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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.
XThe use of a thread locking compound is recommended.
XNo washer is required under the screw head.
X Minimum thread engagement 5mm (7.5mm including counterbore).
XTightening torque 0.25Nm to 0.4Nm.
XMounting hole clearance will contribute to mechanical safe position.
Green Orange Red
Readhead set-up LED status
*Ya w
0°±0.4°
Pitch
0±1°
Roll
0°±0.5°
Rideheight
2.1±0.15 mm
Green spacer
DOP interface set-up LED status
*
Blue Green Orange Red
Purple
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 14).
*For further information on LED status (see page 15).

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14TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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
XClean the scale and readhead optical window (contamination around the reference mark may result in
reference mark dephasing).
XIf re-installing the readhead, restore factory defaults.
XMaximise the signal strength along full axis of travel.
NOTES: 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
XEnsure Automatic Gain Control (AGC) is switched off – Calibration (CAL) LED on readhead is not
illuminated) – before beginning calibration.
XPress 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
XThe CAL LED will now periodically single-ash to indicate that it is in incremental signal calibration
mode.
XMove 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.
XThe system is now ready for reference mark phasing.
XFor systems without reference mark, go to ‘Calibration routine – manual exit’.
XIf 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.
Step 2 – Reference mark phasing
XMove 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.
NOTE: Only the chosen reference mark that has been used in the calibration routine is guaranteed to
remain phased.
XThe system automatically exits the CAL routine and is ready for operation.
XFor the safety function to be valid, customer commissioning tests must be performed:
see ‘Commissioning test’ on page 3.
XIf 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 ‘RTLC20-S scale installation drawing’ on page 7), and re-calibrate the system.
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
XTo exit the calibration routine at any stage press the CAL button. The CAL LED on the readhead will then
stop ashing.
XFor the safety function to be valid, customer commissioning tests must be performed:
see ‘Commissioning test’ on page 3.
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
XSwitch system off.
XPress 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.
XRelease CAL button.
XCheck ‘Readhead mounting and alignment’ on page 13, 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.
XPress 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.
Ti interface DOP interface
CAL LED Settings stored
Single-ashing None, restore factory defaults and re-calibrate
Double-ashing Incremental only
Off (auto-complete) Incremental and reference mark

15TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
T303xreadhead LED
LED Indication Status
Set-up
Incremental
Green Normal set-up; signal level >70%
Orange Acceptable set-up; signal level 50% to 70%
†
Red Poor set-up; signal may be too low for reliable operation;
signal level <50%
Reference
mark
Green (ash) *Normal phasing
Orange (ash) Acceptable phasing
Red (ash) Poor phasing; clean scale and recalibrate if required
CAL
Operating On AGC – On
Off AGC – Off
Calibration Single-ashing Calibrating incremental signals
Double-ashing Calibrating reference mark
Reset Flashing at
power-up (<2s) Restore factory defaults
Signal Indication Status Alarm
output
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 Acceptable set-up; signal level 50% to 70%
†No
Red Poor set-up; signal may be too low for reliable
operation; signal level <50% No
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 Blank ash Reference mark detected (speed <100mm/s only) No
DOP interface set-up LED
† For Functional Safe applications the LED must be Purple, Blue or Green. See ‘Evaluation unit monitoring’ on page 3.
NOTES:
XAlarm 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.
XMomentary Alarm output status only, while fault condition remains.
XAlarm may result in axis position error, re-datum to continue.
Diagnostic LEDs
*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.

16TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Output signals
NOTE: Only analogue sine and cosine outputs are functionally safe.
Ti0000 interface output
Output connector for
Ti interfaces;
15-way D-type plug Output connector for
DOP interfaces;
26-way high-density
D-type plug
Function Output type Signal Pin
Power 5 V Power 4
5 V Sense 5
0 V Power 12
0 V Sense 13
Incremental
signals
Analogue
Cosine V1
+ 9
−1
Sine V2
+ 10
−2
Reference
mark Analogue V0
+ 3
−11
Limits
Open collector Vp7
Vq8
Set-up – Vx6
Calibrate – CAL 14
Shield –Inner shield Not connected
–Outer shield Case
Function Output type Signal Colour
Power 5 V Brown
0 V White
Incremental
signals
Analogue
Cosine V1
+ Red
−Blue
Sine V2
+ Yellow
−Green
Reference
mark Analogue V0
+ Violet
−Grey
Limits
Open collector
VpPink
VqBlack
Set-up – VxClear
Calibrate – CAL Orange
Shield –Inner shield Green/Yellow
–Outer shield Outer screen
Readhead output
DOP interface output
Function Output type Signal Pin
Power 5 V Power 26
5 V Sense 18
0 V Power 9
0 V Sense 8
Incremental
signals
RS422A digital
A+ 24
−6
B+ 7
−16
Analogue
Cosine V1
+ 1
−19
Sine V2
+ 2
−11
Reference
mark RS422A digital Z+15
−23
Analogue V0
+ 12
−20
Alarm RS422A digital E+25
−17
Limits Open collector P4
Q13
Readhead
set-up – X 10
Shield – Inner shield Not
connected
– Outer shield Case

17TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
Speed
Clocked output
option
(MHz)
Maximum speed (m/s)
DOP
0004
5µm
DOP
0020
1µm
DOP
0040
0.5µm
DOP
0100
0.2µm
DOP
0200
0.1µm
DOP
0400
50nm
DOP
1000
20nm
DOP
2000
10nm
DOP
4000
5nm
DOP
10KD
2nm
DOP
20KD
1nm
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
810 6.48 3.24 1.29 0.648 0.324 0.130 0.065 0.032 0.013 0.0065
610 4.50 2.25 0.90 0.450 0.225 0.090 0.045 0.023 0.009 0.0045
410 3.37 1.68 0.67 0.338 0.169 0.068 0.034 0.017 0.0068 0.0034
14.2 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) 10 (−3dB)

18TONiC RTLC20-S Functional Safety installation guide and safety manual Original instructions
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.
Analogue outputs
V0V1V2−
V0V1V2+
120R
VpVq P Q
R*
5 to 24 V
* Select R so maximum current does not exceed 20mA.
Alternatively use a suitable relay or opto-isolator.
Limit output
Signal termination
Electrical connections
TONiC FS system grounding and shielding
Interface
Customer
electronics
Inner shield Extension cable
Outer shield
Output signals
0 V
5 V
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:
XMaximum cable length between readhead and interface is 10m.
XMaximum extension cable is dependent on cable type, readhead cable length and clock speed. Contact
your local subsidiary for more information.
XFor DOP interfaces the external earthing tag on the interface must be used when mounting the interface
on a DIN rail.
Standard RS422A line receiver circuitry.
Capacitors recommended for improved noise immunity.
Customer
electronics
120R
A B Z E−
Cable Z
0= 120R
Readhead
ABZ E+
0 V
0 V
220 pF
220 pF
Digital outputs