Renishaw TRS2 User manual

TRS2 non-contact broken tool detection
system
Installation guide
H-5450-8400-04-B

Renishaw part no: H-5450-8400-04-B
First issued: 08.2007
Revised 08.2017
12.2022
© 2007–2022 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 plc.
Renishaw plc. Registered in England and Wales. Company no: 1106260. Registered office: New Mills,
Wotton-under-Edge, Gloucestershire, GL12 8JR, UK.
Compliance information for this product is available by scanning the QR code or visiting
www.renishaw.com/mtpdoc

i
Contents
Before you begin .............................................................1.1
Disclaimer .................................................................1.1
Trade marks................................................................1.1
Warranty ..................................................................1.1
CNC machines .............................................................1.1
Care of the probe ...........................................................1.2
Patents ...................................................................1.2
Software notices ............................................................1.2
Intended use ...............................................................1.2
Safety ....................................................................1.3
TRS2 basics..................................................................2.1
Introduction ................................................................2.1
Software routines .........................................................2.1
Probe status LED .........................................................2.1
Bar graph display .........................................................2.2
TRS2 dimensions and laser warning labels: TRS2 and TRS2-S........................2.3
TRS2 dimensions with cable connector ..........................................2.4
TRS2 specification ..........................................................2.5
System installation ...........................................................3.1
Mounting the TRS2 ..........................................................3.1
Introduction ................................................................3.1
Guidelines ..............................................................3.1
Mounting the TRS2 unit ....................................................3.2
Air supply..................................................................3.3
Air pressure................................................................3.3
Connecting and purging the air supply ...........................................3.4
Air blast kit ..............................................................3.5
Electrical connections ........................................................3.6
Power supply ............................................................3.6

TRS2 installation guide
ii
Contents
Setting up the TRS2 system ...................................................3.7
Preparation..............................................................3.7
Range setting ............................................................3.7
Spindle speed selection ....................................................3.9
Determining the checking position ............................................3.9
Using the signal monitor function ............................................3.10
Cleanliness.............................................................3.10
Maintenance .................................................................4.1
Introduction ................................................................4.1
Guidelines ..............................................................4.1
About cleaning ...........................................................4.1
Equipment required .......................................................4.1
Cleaning the system.......................................................4.2
Replacing the receiver lens .................................................4.3
Fitting a sapphire glass window ..............................................4.4
Maintenance – air regulator unit ................................................4.4
Checking the liquid level....................................................4.4
Draining the liquid ........................................................4.5
Removing and refitting filter elements .........................................4.5
Replacing other service kit components .......................................4.6
Fault-finding .................................................................5.1
Parts list .....................................................................6.1

1.1
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.
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.
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 office.
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 defined in associated Renishaw
documentation. You should consult these Standard Terms and Conditions to find 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.
CNC machines
CNC machine tools must always be operated by fully trained personnel in accordance with the
manufacturer’s instructions.
Before you begin

TRS2 installation guide
1.2
Before you begin
Care of the probe
Keep system components clean and treat the probe as a precision tool.
Patents
Features of TRS2 non-contact broken tool detection system, and other similar Renishaw products, are
the subject of one or more of the following patents and/or patent applications:
CN 100569442
EP 1799398
JP 4764427
SG 130252
TW 1415708
US 7732797
US 8537359
Software notices
This product includes embedded software (firmware) to which the following notices apply:
US government notice
NOTICE TO UNITED STATES GOVERNMENT CONTRACT AND PRIME CONTRACT CUSTOMERS
This software is commercial computer software that has been developed by Renishaw exclusively
at private expense. Notwithstanding any other lease or licence agreement that may pertain to, or
accompany the delivery of, this computer software, the rights of the United States Government and/or
its prime contractors regarding its use, reproduction and disclosure are as set forth in the terms of the
contract or subcontract between Renishaw and the United States Government, civilian federal agency
or prime contractor respectively. Please consult the applicable contract or subcontract and the software
licence incorporated therein, if applicable, to determine your exact rights regarding use, reproduction
and/or disclosure.
Renishaw software EULA
Renishaw software is licensed in accordance with the Renishaw licence at:
www.renishaw.com/legal/softwareterms
Intended use
TRS2 is a laser-based non-contact tool recognition system that provides high-speed tool breakage
detection of solid cutting tools on a machining centre under normal operating conditions.

1.3
Before you begin
Safety
In all applications involving the use of machine tools or CMMs, eye protection is recommended.
Information to the machine supplier/ installer
It is the machine supplier’s responsibility to ensure that the user is made aware of any hazards
involved in operation, including those mentioned in Renishaw product literature, and to ensure that
adequate guards and safety interlocks are provided.
Under certain circumstances, the probe signal may falsely indicate a probe seated condition. Do not
rely on probe signals to halt the movement of the machine.
Information to the equipment installer
All Renishaw equipment is designed to comply with the relevant UK, EU and FCC regulatory
requirements. It is the responsibility of the equipment installer to ensure that the following guidelines
are adhered to, in order for the product to function in accordance with these regulations:
• any interface MUST be installed in a position away from any potential sources of electrical noise,
i.e. power transformers, servo drives etc.;
• all 0V/ground connections should be connected to the machine “star point” (the “star point” is a
single point return for all equipment ground and screen cables). This is very important and failure to
adhere to this can cause a potential difference between grounds;
• all screens must be connected as outlined in the user instructions;
• cables must not be routed alongside high current sources, i.e. motor power supply cables etc., or
be near high-speed data lines;
• cable lengths should always be kept to a minimum.
Equipment operation
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired.

TRS2 installation guide
1.4
Before you begin
WARNINGS
Use of controls or adjustments or performance of procedures other than those specified within this
publication may result in hazardous radiation exposure.
Switch off electrical power to the TRS2 before carrying out maintenance.
When using the TRS2, basic safety precautions must always be followed to reduce the risk of fire,
electric shock and personal injury, including the following:
• Read all instructions before operating this product.
• The device must only be installed and used by competent, trained personnel.
• Use eye protection to protect against mechanical hazards, coolant and swarf.
• Avoid inhalation of coolant vapour from the machine tool.
• Do not block the air exiting from the laser aperture.
• Prevent direct exposure of the eyes to the laser beam.
• Ensure that the beam is not reflected into the eyes via any reflective surface.
• Prevent the laser beam from straying outside of the immediate work area. A beam terminator is
supplied with the TRS2, which may be fixed to the outside of the machine window for this purpose.
CAUTION – LASER SAFETY
The laser used in the Renishaw TRS2 non-contact broken tool detection system emits visible red
light at a wavelength of 670 nm and has a power output of less than 1 mW. The laser is driven by a
continuous pulse train running at a frequency of 125 kHz. The pulse duration is 2 µs and each pulse
has a maximum energy of 7.2 × 10-9 J.
The laser used is classified as a Class 2 product as defined by BS EN 60825-1:2014.
Complies with 21 CFR 1040.10 and 1040.11 except for conformance with IEC 60825-1 Ed.3., as
described in Laser Notice No.56, dated May 8, 2019.
The standard BS EN 60825-1:2014 directs to attach a laser warning label and explanatory label.
A warning label and explanatory label are permanently xed to one side of the housing, for more
information, see TRS2 dimensions and laser warning labels on page 2.1, “TRS2 basics”. An
adhesive warning label is also provided. Renishaw advise attaching this label to the outside of the
machine tool, in a visible location.
CAUTION: This equipment is rated to IK06 as dened by BS EN 62262:2002.

2.1
Introduction
This guide describes how to install and maintain the Renishaw TRS2 non-contact broken tool detection
system.
The TRS2 is a laser-based non-contact broken tool detection system that is designed specifically for
solid centred tools; for example, drills and taps. A tool that is rotating at a speed of 5000 r/min, 1000
r/min or 200 r/min is moved into the laser beam. The output of the TRS2 is activated and the output
changes when the tool is detected by the receiver.
Three versions of the TRS2 are available. Two are referred to as TRS2 units and one as a TRS2-S unit.
One TRS2 version is fitted with an electrical connector on the underside. Electrical connections to and
from the machine’s controller are made via this connector. This facilitates the quick and easy removal
of the TRS2 from its mounting location and its replacement with a similar TRS2 unit. The other TRS2
version and the TRS2-S unit are not fitted with an electrical connector. Electrical connections to and
from the machine’s controller are wired directly to the TRS2 or TRS2-S.
Both versions of the TRS2 can be adjusted to detect a broken tool over the range 300.0 mm (11.81in) to
2.0 m (78.74 in). The TRS2-S unit has its range preset to 350.0 mm (13.78 in). This cannot be adjusted.
For reliable detection of a tool with through-tool coolant, it should be noted that the flow of coolant
must be stopped before checking the tool. For all tools, the flow of coolant off the surface of the tool
must be stopped before reliable detection can be carried out.
NOTE: That removing the TRS2 side panel or tampering with the side panel retaining screw may
invalidate the warranty.
Software routines
Examples of programs for high-speed broken tool detection of solid tools are available for a wide range of
machine controller types. A TRS2 software package is available for download from www.renishaw.com/trs2
Probe status LED
The status LED on the front of the TRS2 unit indicates the status of the probe to the user.
LED colour Status
Not lit Power off
Red Broken tool or no tool
Green Good tool detected
CAUTION: The tool must be rotating at a speed of 5000 r/min, 1000 r/min or 200 r/min, at the checking
point in the laser beam, for it to be detected.
TRS2 basics

TRS2 installation guide
2.2
TRS2 basics
Bar graph display
The bar graph display on the front of the TRS2 unit indicates the level of light falling on the receiver.
The minimum requirement for effective tool detection is that the amber LED and at least one green
LED must be illuminated.
Align the TRS2 to
illuminate the highest
number.
Green
Green
Green
Green
Amber
TRS2 typical performance
Typically, the TRS2 can detect a solid centred tool that has a diameter of 0.2 mm (0.008 in) or greater
at a range of 300.0 mm (11.81 in). The level of the signal reflected from a tool that is received by the
TRS2 is dependent on the colour, geometry and surface finish of the tool, the machine environment,
and the installation.
NOTE: For a tool to be detected, sufcient light must be reected back to the TRS2 system. Before
running the broken tool cycle, ensure that every tool to be used can be detected by the TRS2 system
as this varies with range, colour and surface nish of the tool, and installation and set-up.
The TRS2 can detect a tool at a distance of between 300.0 mm (11.81 in) and 2.0 m (78.74in),
although it is optimised for use at 1.0 m (39.30 in) and less. Typically, it can detect a tool of Ø2.0mm
(0.08 in) or larger at a range of up to 1.0 m (39.30 in). If the range is greater than 1.0m (39.30 in) or
if the tool is smaller than Ø2.0 mm (0.08 in), there are restrictions on tool detection dependent on the
following points:
• Colour of the tool.
• Geometry and surface finish of the tool.
• Range.
• Machine environment.
• Installation.
IMPORTANT: Remember that excess coolant must always be cleared from the tool before detection is
carried out.