Functional Safety Installation guide and Safety manual Siemens DRIVE-CLiQ encoder system

Transcription

1 L D accuracy linear encoder RSLM high RESOLUTE Functional Safety Installation guide and Safety manual Siemens DRIVE-CLiQ encoder system

2 Contents Product compliance 1 Symbol definitions 2 Functional Safety data declaration 2 Safety function 3 Certification 4 Storage and handling 5 RESOLUTE installation drawing 6 RESOLUTE side cable outlet installation drawing 7 Installation specifications - RESA 8 Installation specifications - REXA 9 RESA Installation drawing ( A section) 10 Installation 11 Installation drawing ( B section) 13 Interference fit method 14 REXA Installation drawing 15 Installation 16 Siemens DRIVE-CLiQ dual head installation 18 Rotary readhead mounting and installation 18 Linear side exit RESOLUTE installation drawing 20 Adhesive mounting installation drawing 21 Adhesive mounting installation 22 RESOLUTE readhead installation drawing 23 RTLA-S installation drawing 24 Scale application 25 End covers 25 Datum clamp 25 Readhead mounting and installation 26 Linear scale technical specifications 27 System configuration 28 Electrical connections 28 RESOLUTE Functional Safety Siemens DRIVE-CLiQ Serial Comms 29 Siemens DRIVE-CLiQ FS interface drawings 30 Maintenance 31 Repair 31 Proof testing 31 Linear RESOLUTE installation drawing 19

3 Product compliance This document is an Installation guide and Safety manual, which details the actions required for the safe integration of the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system, as designated by the SA for rotary or SL for linear prefix in the part number, into a functionally safe system, this system will be referred to as RESOLUTE Functional Safety in the below document. The RESOLUTE Functional Safety system as defined below is suitable for use in a Category 3 Performance Level d (PLd) application in compliance with ISO13849:2015 and in an SIL2 application in compliance with IEC 61508:2010 when installed and operated in accordance with the instructions defined. Failure to follow the correct use instructions and heed the limitations may result in SIL2 and / or PLd not being achieved and will invalidate the Functional Safety certification. C Renishaw plc declares that RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system 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 modifications not expressly approved by Renishaw plc or authorised representative could void the user s authority to operate the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. NOTE: This unit was tested with shielded cables on the peripheral devices. Shielded cables must be used with the unit to ensure compliance. Further information Further information relating to the RESOLUTE encoder range can be found in the RESOLUTE Data sheets. These can be downloaded from our website and are 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. The packaging of our products contains the following materials and can be recycled. Packaging Component Outer box Inserts Bags Cardboard Polypropylene Low Density Polyethylene Foam Cardboard Material High Density Polyethylene Bag Metallised Polyethylene Not applicable PP LDPE Not applicable HDPE PE ISO Recycling Guidance Recyclable Recyclable Recyclable Recyclable Recyclable Recyclable RoHS compliance Compliant with EC directive 2011/65/EU (RoHS) Patents Features of Renishaw s encoder systems and similar products are the subjects of the following patents and patent applications: CN EP GB IL JP KR CN CN EP GB JP KR US CN EP JP KR US CN60551 EP JP US CN93983 EP US US US 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. 1

4 Symbol Definitions: WARNING A hazard with a medium risk of injury if not avoided CAUTION A hazard with a low risk of minor or moderate injury if not avoided NOTICE Notice signs address practices not related to personal injury ESD handling Intended Use: The RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system is intended to be used as part of a safety-related product control system as specified by the machine manufacturer. It is the responsibility of the machine manufacturer to set the machine controller to implement the appropriate actions when the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system reports an error.the decision to use this system for the intended purpose is the responsibility of the machine manufacturer. Correct use includes: u Observing all instructions in this installation guide. u Operating the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system within the limits defined in this document. u Correct mounting of the system as described in this document. u Correct maintenance of the system as described in this document. Limitations of Use: 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 The RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system comprises the following parts: u RESOLUTE Functional Safety readhead. u RESOLUTE Functional Safety Drive CLiQ interface. u Taper mounted A section rings, interference mounted A section/ B section rings, REXA rings. u RESA, RELA and RTLA adhesive mounted linear scale. The following parts are not approved for use with the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system, any customer wishing to use these components in a functional safe environment must first consult with Renishaw to ascertain whether a functionally safe configuration can be achieved. u FASTRACK linear scale mounting system. u Clip mounting for RELA/RSLA linear scale. u A section rings retained by interference fit only (unbolted). The ESD Protective Symbol consists of the reaching hand in the triangle. An arc around the triangle replaces the slash. This umbrella means protection. The symbol indicates ESD protective material. RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system is supplied with an M termination plug. If this termination is altered by the user or an extension cable used, then it will be the responsibility of the user to make sure the system is compliant with IEC : EMC immunity requirements for safety related systems. WARNING Not to be used in environments where there is an explosive atmosphere WARNING Not to be used by medical devices WARNING Not to be used outside of the limits defined by this Installation guide Functional Safety data declaration Product identification: Lifetime/replacement limits: Diagnostic coverage (DC) IEC safety data Safety Integrity Level Random hardware failures (per hour) PFDAVG PFH Architectural constraints Hardware safety integrity compliance Systematic safety integrity compliance Systematic Capability Demand mode Proof test interval ISO safety data MTTFd Diagnostic Coverage Category Performance Level RESOLUTE Siemens DRIVE-CLiQ encoder system 20 years 90% 2 ldd = 1.18E-06 ldu = 1.33E-07 ld = 1.31E-06 ls = 1.93E-06 Not applicable due to continuous demand mode 1.33E-07 Type B HFT = 0 SFF = 96% Route 1H Route 1S SC 2 Continuous Not required for continuous demand mode 87 years Medium 3 d 2

5 Safety function The RESOLUTE FS Siemens DRIVE-CLiQ encoder system shall provide a safe position when requested by the controller. The following restrictions apply to this claim: u The maximum request rate supported is 16 khz. u The RESOLUTE FS Siemens DRIVE CLiQ encoder system can support: Resolution Maximum scale length (L) with 34 bit position word Maximum scale length (L) with 28 bit position word u The RESOLUTE FS Siemens DRIVE CLiQ encoder system shall allow electrical errors to be detected by the controller at least for: Linear systems: electrical error exceeding 600 µm Rotary systems electrical error exceeding 1.5 u Provided it is installed correctly, the RESOLUTE FS Siemens DRIVE-CLiQ Encoder System shall have: Linear systems: mechanical error not exceeding 1 mm Rotary systems: mechanical error not exceeding 2.5, refer to page 8 u Any thermal expansion effects of the scale are excluded from the accuracy of the safe position. u The controller checks whether the obtained position data lie in the position window expected by the controller. Unexpected position data include position jumps and incorrect direction of travel. u When errors are detected by the controller it is the responsibility of the system manufacturer to introduce appropriate safety measures e.g. safe stop etc. u The machine controller that interfaces to the RESOLUTE FS encoder must have its Functional Safety functions enabled (as often it is a configuration parameter to turn on Functional Safety functionality), as this is necessary for the RESOLUTE Functional Safety to be valid. u The system manufacturer must ensure that scale or read head are mounted securely and cannot become detached from their mounting points e.g. a bracket fails. u It is the responsibility of the machine builder to validate the safety functions of the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system in the specific application. u The system manufacturer must perform a verified commissioning test during installation. u The system repairer must perform a verified commissioning test following repair/replacement. Fault Exclusions: Faults caused by the following actions will invalidate the Functional Safety certification of the RESOLUTE FS system: u Cutting and reconnecting the readhead cable or extending the readhead cable. u Incorrect installation of the readhead. u Incorrect installation of the rotary and linear scale. u Failure to follow the instructions contained within this Installation Manual. u Faults caused by the dismantling of the RESOLUTE readhead or the Siemens DRIVE-CLiQ interface. u Faults caused by the operating system outside of the limits specified within this Installation manual. 1 nm m N/A 50 nm N/A m Failure modes: All diagnosed failure modes are detected immediately except for a position discrepancy between the two measurement methods which is detected within 375 µs. Table showing a summary of the FMEDA System element Readhead Interface Totals Safe failure rate l S (1/hours) 8.33E E E-06 Dangerous failure rate l D (1/hours) 8.62E E E-06 NOTE: the following conditions have been assumed: Method: Environment: SN29500 Temperature: 85 C Ground mobile Commissioning test Diagnosed dangerous failure rate l DD (1/hours) 7.75E E E-06 Undiagnosed dangerous failure rate l DU (1/hours) 8.75E E E-07 The following checks MUST be performed following installation and commissioning of the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system for the first time and also following repair of the system (replacement systems parts): Error bit check Scale code check Position count direction Resolution check Power the RESOLUTE Functional Safety Siemens DRIVE-CLiQ encoder system and confirm that the error bit as received by the Siemens controller is clear. Place business card or similar between the readhead and the scale to block the light path. Confirm that the error bit as received by the Siemens controller is active and stays active once the card is removed. Clear the error bit (by cycling power to the system). Move axis over its full travel and check that no errors are latched with the Siemens controller. This check needs to be performed at a traverse speed (circumferential speed for rotary) of <2 m/s to ensure that the readhead checks every code written on the scale. Clear the error bit and check that the position count direction is as expected. Move the axis by a known distance and confirm that the position count changes as expected to a tolerance determined by the manufacturer s risk assessment. 3

6 Certification Siemens DRIVE-CLiQ Certificates: C00041 (Rotary) C00042 (Linear) Machine Directive Certificate: SIRA 16MC9355X Functional Safety Certificate: FSP 16008/00 EC Declaration of conformity Renishaw plc declares under its sole responsibility that the equipment identified below is in conformity with all relevant Union legislation. Equipment Name: Description: Part no. The equipment complies with EU directives: /35/EU 2014/30/EU 2006/42/EC RESOLUTE TM Functional Safety Siemens DRIVE-CLiQ encoder system Revision of RESOLUTE, to comply with the requirements of Functional Safety. Readheads: SL34DB* SL28DB* SA26DB* SA29DB* DCi interfaces: A A Low voltage Electromagnetic compatibility (EMC) Machinery and complies with the following technical standards: - BS EN :2010 Safety requirements for electrical equipment for measurement, control and laboratory use. Part 1: General requirements. BS EN :2013 BS EN 62471:2008 BS EN ISO 100:2010 Electrical equipment for measurement, control and laboratory use - EMC requirements - Part 1: General requirements Immunity to Table 2 - Industrial electromagnetic environment. Emissions to Class A - Industrial electromagnetic environment. Photobiological safety of lamps and lamp systems Safety of machinery - General principles for design - Risk assessment and risk reduction The person authorised to compile the technical file and issue the declaration of conformity is: Martin Curtis Regulatory Compliance Manager (EPD) Renishaw plc, New Mills, Wotton-under-Edge, Gloucestershire, GL 8JR, United Kingdom. X 18/10/2016 Signed by: Martin Curtis Place: Wotton-under-Edge Reference no. EU

7 Storage and handling RESOLUTE RESA and REXA are non-contact optical encoders that provide good immunity against contaminants such as dust, fingerprints and light oils. However, in harsh environments such as machine tool applications, protection should be provided to prevent ingress of coolant or oil. Ring Readhead Readhead and DRIVE-CLiQ interface System N-heptane Ring/scale only Acetone Readhead and DRIVE-CLiQ interface only Acetone CH 3 (CH 2 ) 5 CH 3 CH 3 COCH 3 Chlorinated Solvents CH 3 COCH 3 Chlorinated Solvents Propan-2-ol CH 3 CHOHCH 3 Methylated Spirits Methylated Spirits Scale Storage Operating Humidity System Standard +80 C -20 C Readhead Standard +80 C 0 C Minimum bend radius RSLA mm, RTLA-S 150 mm RELA - DO NOT BEND NOTE: Ensure self-adhesive tape is on outside of bend DRIVE-CLiQ interface +55 C 0 C 95% relative humidity (non-condensing) to EN

8 RESOLUTE installation drawing (RESA shown) Dimensions and tolerances in mm (Yaw tol. ±0.5 ) 0.31 Set-up LED 10 > 6.5 min R>20 Dynamic bend radius R>10 Static bend radius Ø 4.7 ± typ* 2 mounting holes M3 through, counterbored each side, 3 deep 18 (Roll tol. ±0.5 ) typ* Rideheight 0.8 ±0.15 = 8.6 (Pitch tol. ±0.5 ) ±1 Scale and optical centreline Optical centreline Forward direction of ring (increasing count) irrespective of readhead orientation * Extent of mounting faces = 0.1 mm on 52 mm rings > 10 ±0.1 for REXA Recommended thread engagement 6 min (9 including counterbore). Recommended tightening torque 0.9 to 1.1 Nm 6

9 RESOLUTE side cable outlet installation drawing (REXA shown) Dimensions and tolerances in mm 10 ±0.1 > (Yaw tol. ±0.5 ) 0.31 Set-up LED 6.5 min R>20 Dynamic bend radius R>10 Static bend radius Ø 4.7 ± mounting holes M3 x 9 deep counterbored 3 deep typ* typ* 18 (Roll tol. ±0.5 ) Rideheight 0.8 ±0.15 = 3.8 = (Pitch tol. ±0.5 ) ± 1 Scale and optical centreline Optical centreline * Extent of mounting faces = 0.1 mm on 52 mm rings > 10 for RESA Recommended thread engagement 6 min (9 including counterbore). Recommended tightening torque 0.9 to 1.1 Nm Forward direction of ring (increasing count) irrespective of readhead orientation 7

10 Installation specifications - RESA Installation temperature 20 ±5 C Operating temperature range 0-80 C Mounting hub CTE µm/m/ C The RESA ring scale must be installed and operated with the following specifications. The Mechanical Safe Position is the maximum distance the scale might move from its installed position and will be undetected by the readhead. RESA taper mount Safety factor 2 Safe position ±0.2 mm RESA A section interference fit Safety factor 2 Safe position ±1 mm RESA B section Safety factor 2 Safe position ±1 mm Ring diameter (mm) Max permissible speed (rpm) Mechanical safe position ( ) Ring diameter (mm) Max permissible speed (rpm) Mechanical safe position ( ) Ring diameter (mm) Max permissible speed (rpm) Mechanical safe position ( )

11 Installation specifications - REXA Installation temperature 20 ±5 C Operating temperature range 0-80 C Mounting hub CTE µm/m/ C Safety factor 2 Safe position ±1 mm The REXA ring scale must be installed and operated with the following specifications. The Mechanical Safe Position is the maximum distance the scale might move from its installed position and will be undetected by the readhead. Ring diameter (mm) Max permissible speed (rpm) Mechanical safe position ( )

12 RESA installation drawing ( A section) Dimensions and tolerances in mm Nominal external diameter (mm) DO (mm) DI (mm) Mounting holes DH (mm) N θ N holes equally spaced on PCD ØDH Ø3.5 through c/bore Ø6 x 3 deep N holes equally spaced on PCD ØDH M3 x 0.5 through c/bore Ø3.5 x 4 deep NOTE: The scale zero position is radially aligned with the centre of the mounting hole to the left of the Renishaw logo A A Ring rotation to give increasing count NOTE: θ is the angle between one tapped hole and the adjacent clearance hole. The angle between two clearance holes is 2θ θ x 45 6 Scale ± ØDI ØDH 3 1 x ØDO Section A-A * 9 *NOTE: There are no tapped holes on the 489 mm ring IMPORTANT: RESOLUTE Functional Safety readheads must be used with the correct size RESA ring. Ensure matching part numbers when ordering. 10

13 RESA installation ( A section shaft preparation) A section Mounting shaft specifications 1* 7 min Taper mount 15 ±0.2 DT *Allow 2 mm for 417 mm, 489 mm and 550 mm rings only. 5 mm Max. Recommended for all installations; Enables simplest adjustment. Offers highest accuracy. Enables eccentricity to be compensated. Offers excellent mechanical stability against thermal cycling, shock and vibration. Minimises cost of substrate preparation. Taper mount method Step 1 u Clean shaft taper and internal taper of RESA as recommended in the storage and handling section. u Insert the first screws: For RESA rings with 6, 9 or 18 mounting holes, use 3 equally spaced M3 screws. For RESA rings with, 16 or 20 mounting holes, use 4 equally spaced M3 screws. NOTE: Do not lubricate the screws Do not use a locking compound u The recommended screw type is M3 x 0.5 and must comply with: ISO 4762/DIN 9 grade 10.9 minimum/ ANSI B18.3.1M with a CTE of µm/m/ 20 C. u The recommended thread engagement is 6 mm. u Insert the screws so that the RESA is loosely connected to the shaft, then roughly align the ring by eye and touch. u Lightly tighten the screws. Use a Dial Test Indicator (DTI) to check the radial displacement at the screw locations. NOTE: Disregard the radial displacement between the screw locations. DTI Recommended taper roundness Recommended taper diameter (DT) Diameter (mm) Roundness value (mm TIR) DO (mm) DT (mm) DO (mm) DT (mm) Use a non-contact or low force <0.04N DTI with ruby ball to ensure scale surface is not marked to Recommended surface finish Ra 1.2 NOTE: It is recommended that the mounting surface is a turned, rather than ground finish u Adjust the screws to reduce the range of radial displacement. When adjusting, identify the screw location with the lowest radial displacement and tighten that screw, aiming for the average of the highest and lowest indicator readings. u Repeat this process until the DTI readings are within ±5 µm at the screw locations. NOTE: It may be necessary to loosen screws whilst tightening other screws. NOTE: At this stage, the screws should only be lightly tightened (less than 0.5 Nm) to allow further final adjustment. DO = Nominal external diameter 11

14 Taper mount method (continued) Step 2 Step 4 u Insert the next screws: For RESA rings with 6, 9 or mounting holes, insert all the remaining M3 screws. For RESA rings with 16 mounting holes, insert 3 equally spaced M3 screws. For RESA rings with 18 mounting holes, insert 6 equally spaced M3 screws. For RESA rings with 20 mounting holes, insert 8 equally spaced M3 screws (in four groups of two) between existing screws. u As described in Step 1, adjust all the screws inserted thus far, so that the radial displacement at each screw location is within ±5 µm. u Again, at this stage, the screws should only be lightly tightened (less than 0.5 Nm). Diameter (mm) to to Recommended torque range (Nm) u Rotate the RESA ring, measuring the radial displacement at all of the screw locations. u Tighten the screw with the lowest radial displacement so that it matches the average radial displacement, whilst ensuring the maximum torque specified in the table is not exceeded. u Again, rotate the RESA ring and re-check the radial displacement at all of the screw locations, tightening the screw with the lowest radial displacement so that it matches the average. u Repeat this process until the radial displacement at all of the screw locations is within ±3 µm and that all screw torques are within the specified range. u Excessive tightening of screws can have a small effect on accuracy. Please contact your local representative for more details. NOTE: You may notice that the torque required to achieve the radial displacement tolerance will be slightly higher during step 2 than during step 1. This is normal. Step 3 u Insert screws into the remaining mounting holes.

15 RESA installation drawing ( B section) Dimensions and tolerances in mm N holes equally spaced on PCD ØDH Ø3.5 through Nominal external diameter (mm) DO (mm) DI (mm) Mounting holes DH (mm) N θ N holes equally spaced on PCD ØDH M3 x 0.5 through A A θ NOTE: The scale zero position is radially aligned with the centre of the mounting hole to the left of the Renishaw logo. NOTE: θ is the angle between one tapped hole and the adjacent clearance hole. The angle between two clearance holes is 2θ x 45 6 Scale 0.5 Ring rotation to give increasing count 6.5 R0.5 ØDI ØDH ØDO 3 Section A-A 13

16 Interference fit method ( A and B section) Mounting shaft specifications Interference fit DO (mm) DS (mm) A section B section NOTE: Alternative installation will not correct eccentricity of the supporting shaft. DO NOTE: Do not lubricate the screws DS Do not use a locking compound Ensure that all screws are tightened to 1.6 Nm The recommended screw type is M3 x 0.5 and must comply with: ISO 4762/DIN 9 grade 10.9 minimum/ansi B18.3.1M with a CTE of µm/m/ 20 C. The recommended thread engagement is 6 mm NOTE: 417, 489 and 550 mm rings should be taper mounted only. DO = Nominal external diameter DS = Recommended shaft diameter to enable interference fit 14

17 REXA installation drawing Dimensions and tolerances in mm ±0.1* *NOTE: Graduations are centred within this dimension 6 Scale Nominal external diameter (mm) 52 = 57 = D Dimensions D2 D N 4 4 Holes D u Scale centreline A Ring rotation to give increasing count NOTE: The scale zero position is radially aligned with the centre of the mounting hole to the left of the Renishaw logo. u D2 D1 D = 52 mm and 57 mm rings have dimple fiducial features and no slots. Section A-A Fiducial marks, 4 positions, to aid installation A N holes Ø6 through equi-spaced D4 15

18 REXA installation REXA should be flange mounted onto a flat surface, this eliminates all installation errors except eccentricity, which can be compensated using twin readheads. u Although taper mounting is best for thin cross-section rings, it is not suitable for thick cross-section REXA rings. u The REXA ring should be flange mounted onto a flat surface to minimise 2-per-rev distortion. Mounting method Step 1 u Clean the mounting face on the lower side of the REXA. Clean the mating surface on the mounting shaft. u Place the REXA onto the mounting shaft, then insert four off M5 screws with flat washers into the four screw holes by the fiducial marks. DO NOT tighten the screws at this point simply engage the threads ensuring that the heads do not touch the ring. NOTE: Do not lubricate the screws Do not use a locking compound u Some eccentricity of the ring is acceptable because it will be compensated by the use of twin readheads. u To avoid distorting the scale, the REXA should not be interference fitted. Dimple or slot indicates fiducial mark u The recommended screw type is M5 x 0.8 and must comply with: ISO 4762/DIN 9 grade 10.9 minimum/ ANSI B18.3.1M. u The recommended thread engagement is 10 mm. DO NOT INTERFERENCE FIT u Set up a Dial Test Indicator (DTI) to measure the run-out on the REXA ring. Shaft preparation There is a mounting face on the lower side of the REXA ring. A flat surface should be prepared on the mounting shaft to match. The total axial run-out of the mounting surface should be better than 10 µm. D4 u NOTE: Use a DTI with low contact force to avoid scratching the scale surface. A DTI with a ruby ball stylus is recommended as a further precaution against scratches. u Rotate the ring through 360 making a note of the high and low readings. N x M5 x 0.8 x 10 deep (<D1-0.75) 0.01 A u NOTE: At this stage the ring is not firmly fixed, so to avoid causing the ring to shift position, rotate the ring slowly and smoothly. For dimensions D1, D2, D3, D4 and number of holes N, please refer to ring drawing. A D4 D2 Ø 0.2 A D1 D3 u Where the DTI shows the lowest radius reading, gently tap the opposite side of the ring on the edge using a rubber mallet, until the DTI reading is approximately at the mid point of the run-out. u Now find the new lowest radius reading and again tap the opposite side of the ring with a rubber mallet until the DTI reading is at the mid point of the run-out. u Continue this process until the run-out of the ring is approximately 30 µm (0.00 inches). This is the initial adjustment. Now adjust to 10 µm at the fiducial points. 16

19 Step 2 Adjust ring position until the DTI (Dial Test Indicator) reading at these points agrees to 10 µm. Slot fiducial Alternative method -using adjustment screws It is essential that 4 adjustment screws are used, aligned to the 4 fiducial points (indicated by a slot or dimple mark machined into the front face of the ring). IMPORTANT: To achieve the highest accuracy, the ring must not be distorted. When adjusting the ring position using adjustment screws, always work in opposing pairs, loosening one screw before tightening the other. Once the ring has been set to 10 µm in one plane, loosen both those adjustment screws before adjusting the other plane. For ease of adjustment, 4 off M5 screws with washers should be inserted into the ring and tightened finger-tight. These mounting screws should be fitted in the bolt holes aligned to the 4 fiducial marks. Take run-out measurements at the opposing fiducial points and centre the ring in that plane to within 10 µm in the same way. Step 3 Now adjust the ring position until the DTI (Dial Test Indicator) reading at these points agrees to 10 µm. Slot fiducial NOTE: Run-out at the slots does not have to equal the run-out at the dimples. Finally re-check the original plane. NOTE: 52 mm and 57 mm rings have dimple marks only, so select diametrically opposed dimples as adjustment points. Once the ring is set in both planes fit the remaining M5 screws and torque to 7 Nm. Dimple fiducial Dimple fiducial Step 4 u Re-check the run-out at the two slot fiducial points, to ensure the run-out at the two slot points is still better than 10 µm. Adjust if necessary. u Gradually tighten the 4 screws, a quarter-turn at a time, so as to avoid moving the position of the ring. Finally, insert the remaining M5 screws and torque all the screws to 4 Nm. u Re-check the run-out at the two slot fiducial points, then at the two dimple fiducial points. The run-out values at the slot fiducial points do not have to match the run-out values at the dimple fiducial points. If the ring has moved position outside the 10 µm limit, the screws must be loosened and the ring adjusted. 17

20 CAUTION Siemens DRIVE-CLiQ dual head installation Accuracy The dual head interface is designed for use with two RESOLUTE readheads and REXA ring only and compensates for the effect of bearing wander and eliminates all odd error harmonics including eccentricity. However, even error harmonics such as ovality remain. This results in high angular accuracy to ±1arc second, as shown in the below table. REXA diameter 100 mm 75 mm 57 mm Interface output Total installed accuracy (with 2 readheads) ± 1 arc second ± 1.5 arc second ± 2 arc second For readheads (RH1 and RH2) mounted such that the angle between them is θ. Ring rotation to give increasing count Rotary readhead mounting and installation Mounting brackets The bracket must have a flat mounting surface, enable conformance to the installation tolerances, allow adjustment of the rideheight of the readhead, and be sufficiently stiff to prevent deflection of the readhead during operation. It must not be able to work itself loose due to vibrations. For the RESOLUTE Functional Safety readhead mounting: u The recommended screw type is M3 x 0.5 and must comply with: ISO 4762/DIN 9 grade 10.9 minimum/ansi B18.3.1M. u The recommended thread engagement is 6 mm. u Torque to Nm. u The use of a thread locking compound is recommended. u The readhead to interface 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. u Cable rolling radius must be >25 mm when the cable is routed through moving trunking/a cable chain. u Route the cable away from operating environments that will exceed the EMC limits defined EN 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 L shaped aperture under the optical centre of the readhead to allow normal LED function during set-up procedure. Adjust the readhead to maximize the signal strength around the full axis rotation to achieve a Green or Blue LED. RH1 Readhead set-up LED and DRIVE-CLiQ interface STATUS LED status Yaw 0 ±0.5 Blue Green Orange Red θ/2 θ NOTE: Flashing of set-up LED indicates scale reading error. Flashing state is latched. Roll 0 ±0.5 Pitch 0 ±0.5 RH2 Output Rideheight 0.8 ±0.15 mm The dual head DRIVE-CLiQ interface takes simultaneous readings from both readheads and calculates the mean of them. The output is therefore at an angle of θ/2 and is in the position shown when the scale is orientated with increasing count as shown. (REXA shown) NOTE: The scale zero position is radially aligned with the centre of the mounting hole to the left of the Renishaw logo. 18

21 Linear RESOLUTE installation drawing (RSLA and RELA, RELA shown) Dimensions and tolerances in mm 14.9 ±0.2 (Yaw tol. ±0.5 ) 0.31 Set-up LED 6.5 min R>20 Dynamic bend radius R>10 Static bend radius mounting holes M3 through, counterbored each side, 3 deep = (Roll tol. ±0.5 ) 0.05 Ø 4.7 ± typ* 6 typ* Rideheight 0.8 ± ±1 Scale and optical centreline 1.7 (Adhesive mounting) RSLA 1.8 (Adhesive mounting) RELA 3.8 (Pitch tol. ±0.5 ) 0.31 Optical centreline *Extent of mounting faces. = Recommended thread engagement 6 min (9 mm including counterbore). Recommended tightening torque 0.9 to 1.1 Nm. 19

22 Linear side exit RESOLUTE installation drawing (RSLA and RELA, RELA shown) Dimensions and tolerances in mm 14.9 ± ±0.5 (Yaw tol. ±0.5 ) 0.31 Set-up LED 6.5 min R>20 Dynamic bend radius R>10 Static bend radius Ø4.7 ± typ* 2 mounting holes M3 x 8.5 deep (counterbored 3 deep) = typ* (Roll tol. ±0.5 ) (Pitch tol. ±0.5 ) typ 8.25 ±1 1.7 (Adhesive mounting) RSLA 1.8 (Adhesive mounting) RELA Rideheight 0.8 ±0.15 Optical centreline Scale centreline *Extent of mounting faces. = Thread depth from mounting face. Recommended thread engagement 6 mm (9 including counterbore). Recommended tightening torque 0.9 to 1.1 Nm. 20

23 Adhesive mounting installation drawing* (RSLA and RELA, RELA shown) Dimensions and tolerances in mm L Alignment dowels, maximum spacing 350 = 0.5 F 0.05/50 F = axis of motion Datum edge Increasing count direction NOTE: Head can be mounted in either orientation. Encoder count direction is dependent only on scale orientation. Measuring length, ML = (L-10) 5 5 Optical centreline Adhesive datum clamp 10 RGG-2, 2-part epoxy, usually positioned coincident with user selected scale datum Double-sided adhesive tape NOTE: Adhesive mounted scale should not be reused after installation. *RELA shown. RSLA installation is the same but the scale has no chamfers. = When scale is to be mounted vertically, position the dowels so that the datum edge is supported. Double-sided adhesive tape is included with all scale lengths. 21

24 Adhesive mounting installation 1 Thoroughly clean and degrease the substrate 2 Mark area for epoxy on adhesive tape 3 Remove backing liner from one side and stick to underside of scale Clean underside of scale using approved solvents (see Storage and handling ) 4 Apply epoxy then remove remaining backing liner 6 Support dowels 7 Area for RGG-2 epoxy (A ) Remove excess epoxy or 8 5 Locate scale against dowels or ledge and rotate down onto substrate Mounting ledge After 24 hours when adhesive is cured, clean scale using Renishaw scale wipes (A ) or a clean, dry, lint-free cloth. 22

25 RESOLUTE readhead installation drawing (RTLA-S shown) Dimensions and tolerances in mm (Yaw tol. ±0.5 ) 0.31 Set-up LED min R>20 Dynamic bend radius > R>10 Static bend radius Ø 4.7 ±0.2 > typ* 2 mounting holes M3 through, counterbored each side, 3 deep 18 = (Roll tol. ±0.5 ) 0.05 A 6 typ* * Extent of mounting faces = Dimensions from scale surface Recommended thread engagement 6 min (9 mm including counterbore) 8.6 = 3.8 = (Pitch tol. ±0.5 ) 0.31 Recommended tightening torque 0.9 to 1.1_ Nm 4.25 ±1 Scale and optical centreline Optical centreline Detail A Orientation of scale determines count direction Scale reading surface Scale thickness 0.2 Adhesive thickness 0.2 Increasing count direction Increasing count direction NOTE: Reversing head orientation has no effect on count direction Readhead to scale clearance Rideheight 0.8 ±

26 RTLA-S installation drawing (adhesive datum clamp) Dimensions and tolerances in mm START Overall length (L + 37) Scale length (L) FINISH Measuring length ML = (L-17) F 0.2/100 F = axis of motion A 5 B Datum clamp (A ) Optional end cover (Pair A ) Readhead optical detector position at extent of travel Ra F F = axis of motion C Optical centreline Detail A Detail B Detail C.5 End cover alignment indicator

27 Scale application The scale applicator A is designed specifically for use with RESOLUTE readheads and RTLA-S scale. 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 optional end covers if required (see RTLA-S installation drawing ). 3 Thoroughly clean and degrease the substrate using recommended solvents see 'Storage and handling'). Allow substrate to dry before applying scale. 4 Mount 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. 5 Move axis to START of travel. 6 Begin 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. START point End covers The end cover kit A is designed to be used with RTLA-S scale to provide protection for exposed scale ends. NOTE: End covers are optional and can be fitted before or after readhead installation. 1 Remove the backing tape from the adhesive tape on the back of the end cover. 2 Align markers 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 7 Apply finger pressure to the scale at the START point, using a clean lint-free cloth, to ensure scale end adheres well to the substrate. 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. Direction of scale application RTLA-S Limit of travel Datum clamp (A ) The datum clamp fixes the RTLA-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. It can be positioned anywhere along the axis depending upon the customers requirements. 1 Place the datum clamp with cut-out against the scale at the chosen location. Splitter screw Backing tape >8.5 mm 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-TL are available. 9 Remove applicator and, if necessary, adhere the remaining scale manually. Apply firm finger pressure via a clean lint-free cloth along the length of the scale after application to ensure complete adhesion. 10 Clean scale using Renishaw scale cleaning wipes (A ) or a clean, dry, lint-free cloth. 11 Fit end covers. START Allow 24 hours for complete adhesion of scale before fitting datum clamps. Ensure the adhesive wicks along the entire length of cut-out. 25

28 Readhead mounting and installation Mounting brackets The bracket must have a flat mounting surface, enable conformance to the installation tolerances, allow adjustment of the rideheight of the readhead, and be sufficiently stiff to prevent deflection of the readhead during operation. It must not be able to work itself loose due to vibrations. For the RESOLUTE Functional Safety readhead mounting: u The recommended screw type is M3 x 0.5 and must comply with: ISO 4762/DIN 9 grade 10.9 minimum/ansi B18.3.1M. u The recommended thread engagement is 6 mm. u Torque to Nm. u The use of a thread locking compound is recommended. u The readhead to interface 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. u Cable rolling radius must be >20 mm when the cable is routed through moving trunkings/a cable chain. u Route the cable away from operating environments that will exceed the EMC limits defined EN 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 L shaped aperture under the optical centre of the readhead to allow normal LED function during set-up procedure. Adjust the readhead to maximize the signal strength around the full axis rotation to achieve a Green or Blue LED. Readhead set-up LED and DRIVE-CLiQ interface STATUS LED status Blue Green Orange Red Yaw 0 ±0.5 Installation The information relating to all scale types and mounting options is listed. The builder/installer/maintainer/ repairer must apply the instructions for the product being installed as defined by this installation guide. The following general conditions must be observed during installation: u Observe ESD handling precautions when handling the cable connectors u Cleaning mating surfaces before mounting the rotary or linear scales Storage and handling DO ensure that protection is provided for both scale and readhead when transporting a machine with that equipment already installed. DO store scale in a cool dry place out of direct sunlight and in it s original packaging prior to installation. When stored on a reel ensure that the backing tape is facing out. DO allow scale to acclimatize to installation environment prior to installation. DO store at <95% RH DO operate at <80% RH DO store between -20 C and +70 C DO operate between 0 C and +70 C Maintenance and cleaning DO use Renishaw (A ) alcohol wetted scale wipes to clean the readhead optics and scale, available from your Renishaw representative. Or - use a clean, dry, lint-free cloth. Or - use only the following solvents sparingly with a wetted lint-free cloth: - Propan-2-ol (iso-propyl alcohol) CH 3 CHOHCH 3 Roll 0 ±0.5 Pitch 0 ±0.5 - n-heptane CH 3 (CH 2 ) 5 CH 3 DO NOT use the following aggressive solvents to clean the scale: - Acetone CH 3 COCH 3 - Chlorinated solvents - Methylated spirits NOTE: Flashing of set-up LED indicates scale reading error. Flashing state is latched. Rideheight 0.8 ±0.15 mm 26

29 Linear scale technical specifications RELA Form Mounting Datum fixing Material Accuracy (at 20 C) Coefficient of thermal expansion at 20 C Maximum length Mass 1.6 mm x 14.9 mm (H x W) Adhesive backing tape (nominal thickness 0.2 mm) RGG-2 epoxy (A ) datum point ZeroMet. High stability low-expansion nickel-iron alloy Certified to ±1 μm for lengths up to 1 m (includes slope and linearity). ±1 μm/m for lengths >1 m to 1.5 m. Calibrated traceable to International Standards 0.75 ± 0.35 μm/m/ C 1.5 m 184 g/m RSLA Form Mounting Datum fixing Material Accuracy (at 20 C) Coefficient of thermal expansion at 20 C Maximum length Mass 1.5 mm x 14.9 mm (H x W) Adhesive backing tape (nominal thickness 0.2 mm) RGG-2 epoxy (A ) datum point Hardened and tempered martensitic stainless steel ±1.5 μm up to 1 m ±2.25 μm from 1 m to 2 m ±3 μm from 2 m to 3 m ±4 μm from 3 m to 5 m (includes slope and linearity) calibration traceable to International Standards 10.1 ± 0.2 μm/m/ C 5 m 172 g/m RTLA-S Form Mounting Datum fixing Material Accuracy (at 20 C) Coefficient of thermal expansion at 20 C Maximum length Mass 0.4 mm x 8 mm (H x W) (including adhesive) Adhesive backing tape (nominal thickness 0.2 mm) Datum clamp (A ) secured with Loctite 435 Hardened and tempered martensitic stainless steel ±5 μm/m, calibration traceable to International Standards 10.1 ±0.2 μm/m/ C 21 m.2 g/m 27

30 System configuration Electrical connections RESOLUTE grounding and shielding Readhead Siemens DRIVE-CLiQ connection Outer shield DRIVE-CLiQ interface DRIVE-CLiQ cable For high speed applications, it is recommended to use similar cable lengths for each readhead to ensure the readings are simultaneous and achieve the highest accuracy. The DRIVE-CLiQ cable is a proprietary part and is not supplied by Renishaw plc. Readhead Readhead Outer shield Dual head DRIVE-CLiQ interface Siemens DRIVE-CLiQ connection DRIVE-CLiQ cable Outer shield 28

31 RESOLUTE Functional Safety Siemens DRIVE-CLiQ Serial Comms Power supply (DRIVE-CLiQ system) 24 V 1.8 W maximum (75 24V), 24 V as per DRIVE-CLiQ specification 24 V power is provided by the DRIVE-CLiQ network NOTE: The Renishaw DRIVE-CLiQ interface must be powered from a 24 V dc supply complying with the requirements for SELV of standard IEC BS EN Ripple 200 mvpp frequency up to 500 khz Sealing (readhead) IP64 (interface) IP67 Acceleration (readhead) Operating 500 m/s², 3 axes Shock (readhead and interface) Non-operating 1000 m/s², 6 ms, 3 axes, ½ sine Maximum acceleration of scale 2000 m/s 2 with respect to readhead NOTE: This is the worst case figure that is correct for the slowest communications clock rates. For faster clock rates, the maximum acceleration of scale with respect to the readhead can be higher. For more details, please contact your local representative. Interface output Function Power DRIVE-CLiQ communications Shield M Signal 24 V 0 V RX+ RX- TX+ TX- Pin M ( A code) Case Vibration (readhead) Operating 300 m/s 2, 3 axes, 55 Hz to 2000 Hz (interface) Operating 100 m/s 2, 3 axes, 55 Hz to 2000 Hz Mass Readhead 18 g Cable 32 g/m Interface 218 g M x 10 Readhead cable Maximum readhead cable length Connector tightening torque Single shielded, outside diameter 4.7 ± 0.2 mm Flex life >20x10 6 cycles at 20 mm bend radius UL recognised component Readhead to DRIVE-CLiQ interface 10 m (Refer to Siemens DRIVE-CLiQ specifications for maximum cable length from interface to controller) M 4 Nm The RESOLUTE encoder system has been designed to meet the requirements of IEC BS EN : 2008, but must be correctly integrated to achieve EMC compliance. In particular, attention to shielding arrangements is essential. 29