Renishaw TRS2 User manual

#renishaw
TRS2 non-contact broken tool detection
system
www.renishaw.com/trs2
Installation guide

Compliance information for this product is available by scanning the QR code or visiting
www.renishaw.com/mtpdoc

i
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Contents
Before you begin ...................................................................1-1
Warranty ...........................................................................1-1
CNC machines ......................................................................1-1
Care of the system ...................................................................1-1
Patents ............................................................................1-1
Software notices .....................................................................1-2
US government notice ...........................................................1-2
Renishaw software EULA.........................................................1-2
Intended use........................................................................1-2
Safety .............................................................................1-3
Information to the user ...........................................................1-3
Information to the machine supplier/installer ..........................................1-3
Information to the equipment installer ...............................................1-3
Equipment operation ............................................................1-3
Warnings ..........................................................................1-4
TRS2 basics .......................................................................2-1
Introduction.........................................................................2-1
Software routines ....................................................................2-1
Status indicator......................................................................2-1
Signal strength indication ..............................................................2-2
TRS2 typical performance .............................................................2-2
Dimensions of hard-wired TRS2 units and laser warning labels ................................2-3
Dimensions of TRS2 units with connector .................................................2-4
TRS2 specication ...................................................................2-5
System installation..................................................................3-1
Mounting the TRS2...................................................................3-1
Introduction....................................................................3-1
Mounting location guidelines ......................................................3-1
Mounting congurations ..........................................................3-2
Air supply ..........................................................................3-3
Air pressure ........................................................................3-3
Connecting and purging the air supply....................................................3-4
Air blast pack .......................................................................3-6
Electrical connections.................................................................3-7
Power supply ..................................................................3-7
Setting up the TRS2 system............................................................3-8

ii TRS2 non-contact broken tool detection system
Preparation....................................................................3-8
Range setting .................................................................3-8
Spindle speed selection .........................................................3-10
Determining the checking position .................................................3-10
Using the signal monitor function ..................................................3-12
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 preparation pack ......................................................4-5
Removing and retting lter elements ...............................................4-5
Fault-nding .......................................................................5-1
Parts list ..........................................................................6-1

1-1
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Before you begin
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 ofce.
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 dened 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.
CNC machines
CNC machine tools must always be operated by fully-trained personnel in accordance with the
manufacturer’s instructions.
Care of the system
Keep system components clean and treat the unit 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

1-2 TRS2 non-contact broken tool detection system: Before you begin
Software notices
This product includes embedded software (rmware) 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.

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Safety
Information to the user
In all applications involving the use of machine tools, 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.
If the TRS2 unit fails, the output signal may falsely indicate beam not blocked. Do not rely on signals from
the TRS2 unit 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 unit MUST be installed in a position away from any potential sources of electrical noise
(for example, power transformers, servo drives).
• 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 (for example, motor power supply cables),
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 specied by the manufacturer, the protection provided by the
equipment may be impaired.

1-4 TRS2 non-contact broken tool detection system: Before you begin
Warnings
Use of controls or adjustments or performance of procedures other than those specied within this
publication may result in hazardous radiation exposure.
Switch off electrical power to the TRS2 before carrying out maintenance.
When using the TRS2 system, basic safety precautions must always be followed to reduce the risk of re,
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 TRS2 access panel.
• Prevent direct exposure of the eyes to the laser beam.
• Ensure that the beam is not reected into the eyes via any reective surface.
• Prevent the laser beam from straying outside of the immediate work area. A laser warning sign/beam
terminator is supplied with the TRS2, which may be xed 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 classied as a Class 2 product as dened 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 page 2-3, “TRS2 dimensions and laser warning labels”. An adhesive warning label is
also provided. Renishaw advise attaching this label to the outside of the machine tool, in a visible location.

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TRS2 basics
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 specically for solid
centred tools; such as 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 TRS2 output changes when a useable tool is detected by the
receiver. If a tool is broken, the output will not change and the system will not trigger.
Two types of TRS2 are available; hard-wired and connectorised. The connectorised version has a 90°
socket tted to the underside and electrical connections to the machine controller are made via a cable
connector assembly. This method allows quick and easy removal of the TRS2 from its mounting location
and replacement with a similar unit.
The hard-wired version does not have a connector socket; electrical connections to the machine controller
are hard-wired directly to the TRS2.
Both versions of the TRS2 can be adjusted to detect a broken tool over the range of 300 mm (11.81 in) to
2 m (78.74 in).
For reliable detection of a tool with through-tool coolant, the ow of coolant must be stopped before
checking the tool. For all tools, the ow of coolant off the surface of the tool must be stopped before
reliable detection can be carried out.
NOTE: Removing the TRS2 side panel or tampering with the side panel retaining screw will 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
Status indicator
The status LED on the front of the TRS2 indicates the status of the unit to the user.
NOTE: 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.
LED colour Status
Not lit Power off
Red Broken tool or no tool
Green Good tool detected

2-2 TRS2 non-contact broken tool detection system: TRS2 basics
Signal strength indication
Multiple LED’s on the front of the TRS2 unit provide an indication of the signal strength. The minimum
requirement for effective tool detection is that the amber LED and at least one green LED are illuminated.
TRS2 typical performance
The TRS2 is designed to function over a 300 mm (11.81 in) to 2 m (78.74 in) range, although it is
optimised for use at 1 m (39.37 in) or less. At the minimum distance of 300 mm (11.81 in), the TRS2 can
detect a solid centred tool that has a diameter of 0.2 mm (0.008 in) or greater. At 1 m (39.37 in) distance, a
2 mm (0.08 in) diameter or larger tool can be detected.
For a tool to be detected, sufcient light must be reected back to the TRS2. Before running the broken
tool cycle, ensure that each tool can be detected by the TRS2 system. The following factors affect the tool
detection capabilities (particularly if the range is greater than 1 m (39.37 in) or the tool diameter is less
than 2 mm (0.08 in)):
• Colour of the tool.
• Geometry and surface nish of the tool.
• Range.
• Machine environment.
• Installation.
IMPORTANT: Remember that excess coolant must always be cleared from the tool before detection is
carried out.
Signal strength indicators
(align the TRS2 to
illuminate the highest
number).

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Dimensions of hard-wired TRS2 units and laser warning
labels
73 (2.87)
4.5 (0.18)
Warning label Explanatory label
68 (2.68)
83 (3.27)
78 (3.07)
Labels
16 (0.63)
4.5 (0.18)
Ø4.7 (0.19)
38 (1.50)
Receiver lens
Signal
strength
indication
Laser aperture
32 (1.26)
Status LED
14.5 (0.57)
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.
670nm670nm
6.5 (0.26)6.5 (0.26)
31 (1.22)
4 holes
M6 x 8 mm deep
19 (0.75)
7 (0.28)
Ø6.5 (0.26)
18.5
(0.73)
19 (0.75)
3.5 (0.14)
2 identical slots
for M6 screws
36.5 (1.44)
28.75 (1.13)
25 (0.98)
5 (0.20)
Receiver
focus
screw
Laser
aperture
Laser focus
screw 2 (0.08)
23.5 (0.93)
6.5
(0.26)
Laser focus screw Receiver focus screw TRS2 access panel/
laser aperture
Dimensions given in mm (in)
TRS2 access
panel

2-4 TRS2 non-contact broken tool detection system: TRS2 basics
Dimensions of TRS2 units with connector
83 (3.27)25.4 (1.00)
73 (2.87)
51 (2.01)
39.4 (1.55)
38 (1.50)
28
(1.10) 107 (4.21)
66 (2.60)
Cable with
connector
assembly
tted
TRS2 without mounting bracket
41 (1.61)
18 (0.71)
153°
14 (0.55)
122°
TRS2 with mounting bracket
Dimensions given in mm (in)

2-5
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TRS2 specication
Principal
application
High-speed non-contact tool breakage detection of solid tools on all sizes of
vertical and horizontal machining centres, all gantry machining centres and
multi-tasking machines.
Dimensions Height
Width
Depth
83 mm (3.27 in)
38 mm (1.50 in)
73 mm (2.87 in)
Weight 750 g (1.65 lb), including 10 m (32.80 ft) of cable
Transmission type Hard-wired transmission
Tool breakage
detection
Ø0.2 mm (0.008 in) 1 2
Detection range TRS2 adjustable between 300 mm (11.81 in) and 2 m (78.74 in).
Factory set to 350 mm (13.78 in).
Supply voltage 11 Vdc to 30 Vdc
Supply current 65 mA @ 12 Vdc, 42 mA @ 24 Vdc
Output signal Status output.
Voltage-free solid-state relay (SSR) output, congurable normally open or normally
closed.
Input/output
protection
Supply/output protected by resettable fuses
Electrical
connection
arrangement
Hard-wired systems: cable on the underside of the unit.
Systems with connector: connector socket on the underside of the unit.
Cable
(to machine
controller)
Specication Hard-wired systems: Ø4.85 mm (0.19 in), 5-core screened
cable, each core 18 × 0.1 mm insulated.
Systems with connector: 12.5 m (41.01 ft) length, cable/
connector assembly with threaded plug. Ø6.5 mm (0.26 in),
7-core screened cable, each core 19 × 0.1 mm insulated.
Length Hard-wired systems: 5 m (16.40 ft),10 m (32.80 ft).
Systems with connector: 12.5 m (41.01 ft).
Pneumatic supply Ø4 mm (0.16 in) air pipe (for more information, see page 3-3, “Air supply”).
The air supply to the TRS2 must conform to BS ISO 8573-1: Class 1.7.2.
Laser type Class 2 laser product:
1 mW maximum output emitted wavelength 670 nm.
WARNING: Laser radiation. Do not stare into the beam.
Mounting Mounting bracket provided, with M6 (2 off) clearance slots.
Alternative xing arrangements are available.

2-6 TRS2 non-contact broken tool detection system: TRS2 basics
Environment IP rating IPX8 BS EN 60529:1992+A2:2013 ³ [electronics and internal
components]
IK rating IK06 BS EN 62262:2002 [for glass window]
Storage
temperature
–25 °C to +70 °C (–13 °F to +158 °F)
Operating
temperature
+5 °C to +55 °C (+41 °F to +131 °F)
1Each TRS2 unit is tested with a Ø0.5 mm (0.02 in), blue nish, HSS jobber drill at a range of 350 mm (13.78 in).
Test conditions: dry tool, spinning at 5000 r/min, which must be detected by the TRS2 within 1 second.
2Depending on range, tool geometry, surface nish and colour, machine environment and installation.
3 If the air supply is cut during operation, the transmitter lens outer surface may become contaminated (for more information,
see page 4-2, “Cleaning the system”).

3-1
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System installation
Mounting the TRS2
Introduction
This section provides guidance on mounting the TRS2 inside a machine. This is a critical part of the
installation process, as the mounting location and method can impact the product performance.
CAUTION: Do not expose the TRS2 to cutting uid or coolant that is corrosive to aluminium.
Mounting location guidelines
• The TRS2 must be installed on a sufciently rigid mounting surface, so that the laser beam cannot
move due to vibration or exing of the surface. If the laser beam moves, tools may not be detected.
• Ensure the receiver focus screw and laser focus screw can be accessed at the chosen mounting
location (for more information see page 3-9, “Adjusting the receiver focus screw” and “Adjusting the
laser focus screw”).
• The TRS2 can be mounted on its side, upright or upside down. Ensure that the mounting orientation
and location does not subject the unit to direct bombardment of swarf or coolant, and that coolant
pooling does not occur on the product.
• The tool must be able to move in the Z axis relative to the TRS2 unit, so that tools of different lengths
can be checked.
• Install the TRS2 perpendicular to the tool axis. Performance is affected if perpendicularity is not
achieved, and this effect increases with separation.
• The closer the TRS2 is to the tool, the greater the reected light level. Small diameter tools or those
with a dark nish are more easily detected when the tool checking position is closer to the TRS2 unit.
• Ensure the laser beam cannot strike a reective surface inside the machine which will reect the
beam into the receiver lens. If any of the signal strength indicators are lit when no tool is in the beam,
this highlights a potential problem. To prevent this, either move the TRS2 so this does not happen or
place a non-reective object, such as black non-reective tape, in the beam path.
• At speeds of 200 r/min or 1000 r/min, the use of an air blast is recommended to clear coolant from the
tool. Ensure the selected location is suitable for the mounting of an air blast (for more information see
page 3-6, “Air blast pack”).
NOTE: The TRS2 unit must be mounted so that the laser beam does not shine out of the machine. A laser
warning sign/beam terminator, which is supplied with the TRS2, may be xed to the outside of the machine
window.

3-2 TRS2 non-contact broken tool detection system: System installation
Mounting congurations
1. Mount the TRS2 unit on a rigid part of the machine (see the gure below for possible mounting
congurations).
2. Tighten the mounting screws as follows:
For M6 mounting screws, tighten to 14 Nm (10.30 lbf.ft) using a 10 mm A/F spanner and a 5mmA/F
hex driver.
For M4 mounting screws, tighten to 4 Nm (2.90 lbf.ft) using a 3 mm A/F hex driver.
3. When the TRS2 unit is rear mounted, t the M6 locking screw and washer (see the gure on
page3-2) and tighten to 14 Nm (10.30 lbf.ft) using a 5 mm A/F hex driver.
4. Fit the cable conduit and air pipe spring cover to the unit (for instructions describing how to t the
cable conduit and air pipe spring cover to the unit, see page 3-4, “Connecting and purging the air
supply”).
5. Connect the cable to the machine controller (for instructions on connecting cables, see page 3-7,
“Electrical connections”).
M6 mounting screw
(supplied)
Rear mounting
Mounting bracket
M6 screws
(not supplied)
M6 locking screw
and washer
(supplied)
M6 nut (supplied) Part of machine
structure
M6 locking screw
and washer
(supplied)
M6 nut (supplied)
Side mounting Bottom mounting
M4 mounting
screws
(not supplied) M6 mounting
screws
(not supplied)
Bracket
(not supplied)

3-3
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Air supply
The TRS2 requires a clean air supply to protect the laser transmitter from the machining environment. It is
recommended that the air supply is switched on at all times to prevent contamination of the TRS2 access
panel. If it is necessary to switch off the air supply, ensure that the coolant supply is switched off rst.
The air supply to the TRS2 system must conform to BS ISO 8573-1: air quality of class 1.7.2 and be
moisture-free. If the air quality cannot be guaranteed, an optional air ltration system is available from
Renishaw (see page 6-1, “Parts list”).
Failure of the air supply may cause the TRS2 system to become contaminated. Contamination is indicated
if the laser spot is dispersed instead of being sharp when shone on to a piece of white paper (refer to the
two images below). If contamination is suspected, carry out the cleaning procedure (for more information,
see page 4-2, “Cleaning the system”).
Air pressure
The graph shown below shows the recommended air pressure against the length of air pipe.
Good spot Dispersed spot
Air pressure
(bar)
Length of air pipe (m)
5
1.5
2
2.5
3
3.5
4
4.5
5
10 15 20 25 30
Recommended air pressure
Minimum air pressure

3-4 TRS2 non-contact broken tool detection system: System installation
Connecting and purging the air supply
CAUTIONS:
Do not connect the TRS2 system to an oiled air supply. Purge all piping prior to connection.
Safety glasses must be worn.
1. Locate a source of clean air that conforms to BS ISO 8573-1: Air quality of class 5.9.4. Connect a
suitable pipe to the air supply.
2. Before connecting the pipe to the inlet of the air preparation pack, briey switch on the air supply to
clear out all debris from the pipe.
3. Connect the free end of the air pipe into the air preparation pack inlet.
4. Take a length of Ø4 mm air pipe that will connect the air preparation pack outlet to the TRS2. Cut to
length as short as possible to minimise the drop in air pressure. Make a note of this pipe length.
5. Plug the measured pipe length into the air preparation pack outlet.
6. Measure and cut the spring cover to length if necessary.
NOTE: The internal diameter of the spring cover increases at the end that will be tted to the TRS2 air
tting. When cutting to length, ensure that the length is measured from this end.
7. Temporarily tape over the free end of the pipe to ensure that no coolant or debris is able to enter it.
8. Push the free end of the air supply pipe through the spring cover.
9. Remove the tape from the end of the air pipe. Before connecting the pipe to the inlet of the TRS2 unit,
briey switch on the air supply to clear out any debris from the pipe.
10. Connect the free end of the pipe to the TRS2 unit.
11. Push the spring cover over the air tting on the TRS2 unit.
12. Switch on the air supply and set the pressure (for instructions describing how to set the correct air
pressure, see page 3-3, “Air pressure”).

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Air preparation pack
CAUTION: If it is necessary to switch off the air supply, ensure that the coolant supply is switched off rst
to prevent contamination of the TRS2 access panel.
Air outlet
TRS2 unit
Spring cover
Cable conduit
Ø4 mm
air pipe

3-6 TRS2 non-contact broken tool detection system: System installation
Air blast pack
The air blast pack is an optional device available from Renishaw (see page 6-1, “Parts list”). It can be
used prior to the broken tool detection cycle to clean coolant and swarf from a tool. When checking a tool
that is rotating at either 200 r/min or 1000 r/min, it is recommended that the air blast is used for optimum
performance.
• Mount the air blast pack on a rigid surface.
• Use an air feed controlled with a solenoid valve and M-code.
• Do not take the air feed controlled from the TRS2 air preparation pack, use a separate supply.
• Set the air pressure to 4 bar.
• Position the tool as shown in the gure below.
• Switch on the air supply for 1 second while the tool is spinning.
55 (2.17)
Ø13 (0.51) though
hole for M12
mounting screw
27.5 (1.08)
15 (1.59)
Non return valve
1/4 in BSP
36 (1.42)
Top view
67.9 (2.67)4.8 (0.19)
89.2 (3.51)
Air
nozzle
73.7 (2.90)
45°
Dimensions given in mm (in) 83 (3.27)
21 (0.83)
2 (0.08)
10 (0.39) 30 (1.18)
1/4 in BSP