Renishaw HS20 Installation & User's Guide

Installation and user’s guide

M-8003-3192-05-A

HS20 installation guide

Document Information

Document number: M-8003-3192-05-A

Issue date: March 2019

Care of equipment

Renishaw HS20 laser encoder and associated products

are precision components and must therefore be treated

with care. For further information refer to Appendix B.

Changes to Renishaw products

Renishaw plc reserves the right to improve, change or

modify its products and documentation without incurring

any obligation to make changes to Renishaw equipment

previously sold or distributed.

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.

Trademarks

RENISHAW and the probe symbol used in the

RENISHAW logo are registered trade marks of Renishaw

plc in the United Kingdom and other countries.

apply innovation and names and designations of other

Renishaw products and technologies are trade marks of

Renishaw plc or its subsidiaries.

All other brand names and product names used in this

document are trade names, trade marks, or registered

trade marks of their respective owners.

Safety

The Renishaw HS20 laser is designed for integration into

the primary position feedback loop of a motion system.

It is essential that the system is installed in accordance

with the instructions in this installation guide and it is the

responsibility of the system integrator to ensure that, in the

event of a failure of any part of the Renishaw system, the

motion system remains safe.

In the case of motion systems with powers or speeds

capable of causing injury, it is essential that appropriate

safety protection measures are included in the machine

design. Further guidance on this can be found in

EN12100:2010 Safety of Machinery - General principles

for design - Risk assesment and risk reduction”. It is the

responsibility of the application integrator to ensure that the

complete machine or equipment complies with appropiate

standards. The user is also referred to Appendix D which

contains additional safety information.

Laser safety

DO NOT STARE DIRECTLY INTO THE BEAM

In accordance with EN60825-1, EN60825-2 and US

standards 21CFR 1040.10 and 1040.11 except for

deviations pursuant to Laser Notice no. 50, dated June

24, 2007. Renishaw HS20 lasers are Class 2 lasers and

safety goggles are not required, since the blink reaction of

a human will protect the eye from damage. Do not stare

into the beam or shine it into the eyes of others. It is safe

to view a diffuse-reected beam. Do not dismantle the unit

in any way; doing so may expose laser radiation in excess

of Class 2 limits. For further product and motion system

safety information refer to Appendix D.

Electrical safety

Do not remove any part of the housing; to do so may

expose a danger of high voltage electric shock. Defective

products should be returned to Renishaw for service.

Safety information

The following symbol is used in this manual wherever

important safety information is present.

!

Before proceeding with any electrical connection

or operation of the laser system, refer to the

General safety information in the introduction.

Warranty

Renishaw plc warrants its equipment provided that it

is installed exactly as dened in associated Renishaw

documentation.

FCC (USA only)

Information to the user (47CFR section 15.105)

NOTE: 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 HS20 installation guide,

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.

Information to user (47CFR section 15.21)

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.

EC compliance

Renishaw plc declares that the HS20 laser encoder

complies with the applicable directives, standards and

regulations.

HS20 Laser measurement system relevant patents and

patent applications

The following patents and patent applications relate to this

and other products:

EP 0397289

JP 2,630,345

US 5,026,163

EP 0668483

JP 3,502,178

US 5,638,177

GB 2337339B

DE 19980326 T1

US 6,473,250 B1

JP 3,388,738

US 5,341,702

JP 2001-194184A

US 6,934,641 B2

JP 2005-37,371

WEEE

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.

Packaging

components

Material 94/62/EC

code

94/62/EC

number

Outer box Cardboard - 70%

recycled material

PA P 20

Inserts Cardboard PA P 20

Bags Low density

polyethylene

LDPE 4

REACH

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

RoHS compliance

Compliant with EC directive 2011/65/EU (RoHS)

1

Contents

Section 1 - Operation overview Page: 3

Introduction Page: 4

General safety information Page: 4

Secondary fault protection measures Page: 5

Operation overview Page: 6

HS20 laser system components Page: 6

Storage and handling Page: 9

Machine requirements summary Page: 9

HS20 laser with long range linear optics Page: 10

HS20 laser with standard linear optics Page: 10

Typical HS20 installation Page: 11

Section 2 - Mechanical installation Page: 12

Space requirements for the HS20 Page: 13

Golden rules of mechanical installation. Page: 14

Mounting options for the HS20 laser head Page: 14

HS20 external dimensions and mounting holes Page: 16

HS20 mounting plate external dimensions and mounting holes Page: 17

HS20 alignment plate Page: 17

HS20 alignment plate adjustments Page: 18

Measurement retroreflector mounting detail Page: 19

Beam position relative to the laser, optics and ducting Page: 20

Beam protection ducting Page: 21

LS06 laser steerer Page: 22

Reference mark switch bracket and actuating cam Page: 23

Mounting the HS20 laser onto a machine Page: 24

Protecting the HS20 laser head Page: 26

Design of measurement retroreflector mounting Page: 26

Section 3 - Electrical installation and system configuration Page: 27

General Page: 28

System grounding (earthing) Page: 28

HS20 cables and connectors Page: 28

HS20 interface connector Page: 30

24V DC input connector Page: 31

HS20 diagnostic connector Page: 31

Powering down and disconnecting the HS20 Page: 32

Power requirements Page: 32

Output quadrature format Page: 32

2

Analogue quadrature - 1V analogue interface Page: 32

Signal strength Page: 33

Reference mark wiring Page: 34

HS20 configuration Page: 34

Configuration switch function Page: 35

Quadrature hysteresis Page: 35

Quadrature resolution selection Page: 36

Digital quadrature update rate Page: 37

Parity Page: 37

Error signal monitoring Page: 38

Status lines Page: 38

Section 4 - HS20 laser beam alignment Page: 39

HS20 laser beam alignment Page: 40

LS06 operation Page: 40

Alignment procedure Page: 41

Section 5 - System Integration Page: 45

System integration Page: 46

Reset input signal Page: 46

Operation of system on power-up Page: 46

HS20 diagnostic LEDs Page: 47

Pre HS20 feedback testing Page: 49

Switching machine control to HS20 feedback Page: 51

Machine under HS20 feedback testing Page: 52

APPENDIX A – System specification Page: 53

APPENDIX B - Maintenance Page: 54

APPENDIX C - Test sheets Page: 57

APPENDIX D - Safety information Page: 60

APPENDIX E – Laser steering mechanism Page: 63

APPENDIX F – Glossary Page: 64

APPENDIX G – HS20 laser head labels Page: 65

3

Section 1 - Operation overview

Contained in this section

Introduction

General safety information

Secondary fault protection measures

Operation overview

HS20 laser system components

HS20 laser head

Linear optics

HS20 beam protection ducting

Alignment plate kit

Alignment tool kit

LS06 laser steerer

Reference mark switch assembly

RCU compensator

Storage and handling

Machine requirements summary

HS20 laser with long range linear optics

HS20 laser with standard linear optics

Typical HS20 installation

4

Introduction

The Renishaw HS20 laser head provides linear position feedback for machine tools using laser

interferometry. The HS20 laser head has been designed to be rugged and reliable whilst operating 24

hours a day in a machine shop environment. Depending on the application, the HS20 laser head may

be connected directly to a motion control system, alternatively it may be connected via the RCU10

quadrature compensation unit. In case of the latter, please also refer to the RCU Manual (M-9904-

1122) which provides extensive information on system integration. Always refer to the manual for

information on the HS20 laser system.

This manual is separated into chapters to cover the standard installation of the HS20 laser system.

The chapters cover mechanical and electrical installation and integration of the system in the machine

controller. The appendices give further instruction on alignment diagnosis and system troubleshooting.

WARNING If this equipment is used in a manner not specied by the manufacturer, the

protection provided by the equipment may be impaired.

General safety information

The Renishaw HS20 laser encoder and compensator systems are designed for integration into the

primary position feedback loop of a motion system. It is essential that the system is installed in

accordance with the instructions in the installation manuals and it is the responsibility of the system

integrator to ensure that, in the event of a failure of any part of the Renishaw laser system, the motion

system remains safe.

In motion systems with powers or speeds capable of causing injury, safety protection measures must

be included in the design. It is recommended that satisfactory operation of these protection measures

is veried before the feedback loop is closed. The following are examples of safety protection

measures that can be used. It is the sole responsibility of the system integrator to select appropriate

measures for their application.

1. The HS20 quadrature will go into a tristate condition (open circuit) under fault conditions. The

equipment receiving this quadrature (RCU or machine controller) must detect the tristated

condition and stop the axis moving. All status lines should be connected so that the HS20

condition is monitored and the following actions should be initiated:

- /UNSTABLE - Whilst /UNSTABLE asserted low, the machine motion must be disabled.

- /BEAM_BLOCKED - Whilst /BEAM_BLOCKED is asserted low, the machine motion must be

disabled.

- /BEAM_LOW - Machining can continue, however the source of the alarm should be

investigated and maintenance performed.

- /OVERSPEED - Whilst /OVERSPEED is asserted low the machine motion must be disabled.

2. The axis must include physical limit switches which, when tripped, will stop axis motion before

damage occurs (soft limits alone are insufcient). Note that in the case of thermally compensated

systems, positional corrections of several hundred ppm are possible. This should be taken into

account when dening the relative positions of soft and hard axis limits.

3. Cable breakage detection (encoder disconnect). The position feedback is provided as differential

line driven pairs. Failure in the cable or of the line drivers can be detected by checking these

differential pairs are always being driven in opposing states. If the lines are not in opposing

states, the motion must be stopped.

!

5

4. Motor torque monitoring. If the motor torque exceeds an expected limit, the axis of motion must

be stopped.

5. The machine must include an emergency stop button.

6. Following error detection. If the difference between the controller demand position and the axis

feedback position exceeds an expected limit, the axis motion must be stopped.

7. Guards, viewing windows, covers and interlocks may be used to prevent user access to

hazardous areas, and to contain ejected parts or materials.

8. If the machine includes an independent tacho (velocity) feedback system, this should be cross-

checked with the position feedback. For example, if the tacho indicates the axis is moving, but

the position feedback doesn’t, the axis motion must be stopped.

9. In the case of synchronised parallel motion systems (for example twin rail gantry drive systems),

the relative positions of master and slave axes should be monitored. If the difference in their

positions exceeds an expected limit, axis motion must be stopped.

Important note: In the case of measures 6 to 9, the limits need to be selected carefully depending on

the application and the type of position compensation selected to avoid false alarms.

For further advice, consult the appropriate machinery safety standards.

Secondary fault protection measures

It is the responsibility of the system integrator to ensure that in the event of a failure of any part of the

Renishaw Laser System that the motion system remains safe. In the case of motion systems with

powers or speeds capable of causing injury, secondary protection measures must be included in the

design. Refer to the General Safety Information in the Introduction for details of suitable secondary

safety measures. It is recommended that such secondary measures be tested during system

integration by deliberately introducing single faults into the system. (Obviously such tests need to be

carried out carefully to ensure injury cannot occur if such secondary systems fail to operate)

6

Operation overview

The HS20 laser head can be incorporated into the position control loop of any motion-control system

that can be congured to accept digital or analogue quadrature format encoder signals. The laser

head can be tted as a direct replacement for linear encoder systems both in OEM and retrot

applications.

HS20 laser scale kit

The following is a list of the major components, and their basic function:

HS20 laser head

Part No: A-8003-6000

The HS20 laser head is a class II (maximum

output power < 1mW) visible helium/neon

laser source with integrated fringe detection

and processing circuitry. The HS20 can be

congured for digital output resolutions of

79, 158, 316, 633nm or analogue 1Vpp sin/cos

signals of 316nm. The HS20 laser head is

powered from 24V DC. One HS20 laser head

is required per axis. The HS20 may be used

with either standard (up to 30m) or long range

optics (up to 60m).

Linear measurement optics

There are two types of linear optics are available: standard (up to 30m) and long range (up to 60m)

See gure 1 and 2 (page 10) for typical setup examples.

Standard optics for applications with an axis length of up to 30m.

Part No: A-8003-0440

The kit includes:

• two retroreectors & clamp screws

• one beamsplitter

• two targets

7

Long range optics kit

Part No: A-8003-2222

For applications with an axis length up to 60m.

The kit includes:

• one retroreector, clamp screws & target

• one long-range retroreector & target

• one beamsplitter

• one long range periscope

One set of linear optics is tted to each axis.

HS20 beam protection ducting

The beam protection ducting system can be used with

either the long range or short range linear optics, to

protect the beam path from debris and coolant, whilst

also providing a stable thermal environment for the

laser measurement beam.

Although the Renishaw ducting system is primarily

designed for long range applications, certain harsh

operating environments and those with frequent rapid

temperature changes or environments that could

generate thermal gradients may also require the

ducting system to be tted even at relatively short axis

lengths.

Please refer to the HS20 beam protection ducting

installation manual (M-8003-5184) for further details

about kit contents, part numbers ordering and

installation.

Alignment plate kit

Part No: A-8003-2362

An alignment plate has been specially designed

to ease HS20 laser alignment on larger machines.

This plate, in combination with the three

adjustment feet tted to the HS20 laser head,

provide the user with both horizontal and vertical

plane translation and rotation adjustments. The

plate is supplied in kit format and includes a

clamp block for external linear optic mounting.

8

HS20 adjuster tool kit

Part No: A-8003-2401

The HS20 laser head has three adjustment feet to provide

translation and rotation during laser alignment. Ease of

alignment is achieved by tting a tool to each adjuster foot

throughout the alignment process.

LS06 laser steerer

Part No: A-8003-2898

The laser steering mechanism or ‘beam steerer’ is an alignment aid for the

HS20 laser scale. The device allows easy adjustment of both the pitch and

yaw of the laser beam. and can greatly simplify system alignment.

The LS06 provides an angular adjustment range of 0.6 mrads.

Reference mark switch assembly

Part No: A-8003-2380

An optical or mechanical reference mark switch is typically used to

determine the home position of each machine axis. Renishaw can

supply a mechanical reference switch that is compatible with RCU.

The assembly consists of a switch, which is repeatable to ±2µm and

a cable gland, which accepts cables with nominal outside diameter of

4to8 mm.

The reference mark switch assembly is an optional extra. One

reference mark switch should be used per axis.

RCU compensator kit

The RCU10 compensates for environmental variations during

use of the HS20 laser system. Air and material temperature

is measured and compensated through remote sensors. One

RCU10 compensator is required for each HS20 laser system.

RCU10 compensation units are available with or without an

integral pressure sensor (RCU10-PX-XX and RCU10-XX-XX

respectively). One RCU10-PX-XX is used per machine.

Refer to the RCU manual M-9904-1122 for full details.

9

Storage and handling

The HS20 laser encoder can be stored at temperatures between -20 °C and +70 °C (-4 °F and

+158°F). Do not store the HS20 laser encoder in conditions of high humidity or otherwise subject it to

conditions which may cause condensation to form on the optics.

Renishaw’s HS20 laser encoders and associated equipment are precision optical and electronic tools

used for obtaining precise measurements and must therefore be treated with appropriate care.

Ensure protection is provided for both the HS20 and the associated optics when transporting a

machine with the equipment already installed. Refer to Appendix B for maintenance and cleaning

instructions.

Machine requirements summary

The following denes the minimum requirements, which must be provided to successfully install the

HS20 laser head.

• The machine controller must accept digital encoder feedback inputs of RS485/422 format

differential AquadB or analogue sin/cos (1Vpp).

• The straightness of travel of any axis to which HS20 is to be tted must be within ±0.5mm to

maintain beam alignment.

• If beam protection ducting is required there must be sufcient clearance.

• The mounting location for the HS20 laser heads must remain within 0 to 40 °C (32 to 104 °F).

• The beam path must be reasonably thermally stable. Otherwise suitable beam protection (such as

HS20 beam protection ducting) must be used.

• Access is required to a 24V DC power supply for each HS20 laser head.

10

HS20 laser with long range linear optics

Figure 1 - HS20 with long range linear optics

HS20 laser with standard linear optics

Figure 2 - HS20 with standard linear optics

Measurement retroreector

(long range)

Interferometer assembly

(long range)

Interferometer assembly

Measurement retroreector

LS06 beam steerer

11

Typical HS20 installation

Figure 3 - Typical HS20 installation

12

Section 2 - Mechanical installation

Contained in this section

Space requirements for the HS20

Golden rules of mechanical installation

Mounting options for the HS20 laser head

HS20 external dimensions and mounting holes

HS20 mounting plate external dimensions and mounting holes

HS20 alignment plate

HS20 alignment plate adjustments

Measurement retroflector mounting detail

Beam position relative to the laser, optics and ducting

Beam protection ducting

Reference mark switch bracket and actuating cam

Mounting the HS20 laser onto a machine

Fitting the baseplate to the machine

Fitting the alignment plate to the baseplate

Fitting the optical plate to the alignment plate

Fitting the HS20 laser

Protecting the HS20 laser head

Design of the measurement retroflector mounting

13

Space requirements for the HS20

Before mechanical installation of the HS20 can be performed a mounting location must be decided.

The position should be chosen by consideration of the following:

Clearance required to adjust

HS20:

Minimum 250mm (10 in) above the HS20 laser head

Clearance required to adjust

alignment plate:

Minimum 150mm (6 in) on each side

Figure 4 - Space requirements for HS20

Beam path requirements To enable the measurement retroreector to travel unimpeded down

the full length of the axis requires the clearances detailed below:

Standard linear optics kit:

With ducting: Minimum 60 mm x 60 mm (2.4 in x 2.4 in)

Without ducting: Minimum 50mm x 50mm (2 in x 2 in)

Long range optics kit:

With ducting: Minimum 130 mm x 160 mm (5.2 in x 6.3 in)

Without ducting: Minimum Ø 90mm (Ø 3.6 in)

14

Golden rules of mechanical installation

The HS20 system provides position feedback of changes in linear distance between a reference

and target optic. Any movement in the HS20 laser, or interferometer assembly has the potential to

cause measurement errors or the signal strength to drop. Follow these ‘golden rules’ to help prevent

mechanical installation issues during use.

• Ensure all components are rigidly located with the recommended fixings. A lack of rigidity

between the optics and the machine will result in measurement errors.

• Lock the alignment plate position after alignment to prevent creep when the system is in use.

• Do not touch the glass surfaces of the optics as this will reduce signal strength.

This section covers mounting the alignment plate, HS20 and the measurement optics.

Mounting options for the HS20 laser head

There are two typical mounting methods for the HS20, detailed below. The application will generally

govern the most practical method of mounting the HS20. Both options assume that the HS20 is

mounted on the HS20 alignment plate.

1. Mounting directly to the machine rail with the HS20 laser beam parallel to the axis travel.

Figure 5 - Direct mounting onto machine rail

15

2. Mounting on a concrete plinth off the machine (as shown below). Although concrete has a

coefcient of expansion that is similar to steel, the structure’s thermal mass will provide a far

greater degree of laser alignment stability than a support fabricated from steel. Again the HS20

laser beam will run parallel to the axis travel.

Figure 6 - Plinth mounting arrangement

When designing the mounting scheme for the HS20 laser system the main criteria should be rigidity

and stability of both the laser and the linear optics. It is important that the mounting scheme ensures

the laser beam alignment remains stable to within ±0.5 mm at the far end of the axis. This is easy

to achieve on short axis machine axes, but on very long machine axes, the stability of the mounting

scheme becomes crucial. Under these conditions it is strongly recommended that the Renishaw

alignment plate is used since it has been designed to accommodate the small expansion of the HS20

laser during preheat without disturbing beam alignment.

16

HS20 external dimensions and mounting holes

This section details the key external dimensions along with the locations of mounting holes.

(All dimensions are in mm)

25.5

22

26

10

15

377

15

16.5

23

59

114

17

57

79

347

355

96

Figure 7 - Key dimensions for HS20 laser head

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Renishaw HS20 Installation & User's Guide

Renishaw HS20 Installation & User's Guide

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