Bogen AKS16 Owner's manual

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AKS16 Ops Manual rev 2.1 (2023/12/20)
AKS16
Absolute Magnetic Sensing Head
INSTALLATION AND OPERATION INSTRUCTIONS

AKS16 Ops Manual rev 2.1 (2023/12/20)
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BOGEN Magnetics GmbH · Potsdamer Straße 12-13 · 14163 Berlin · Germany
Fon [phone] - 0 · Fax [phone] - 60 · [e-mail] · www.bogen-magnetics.com
Safety Instruction
Read these instructions carefully prior to installation and operation.
This manual is intended for professionals who perform the installation and the setup. The assembly
of the system requires knowledge of mechatronics and general health and safety regulations. Follow
all warnings and instructions for your own safety and the safety of your system.
These operating instructions apply to the incremental magnetic sensing head AKS16 in connection
with a magnetic scale for linear or rotary applications.
Risk of electric shock or short circuit!
Incorrect handling of electrical equipment can be fatal or cause damage to property.
Danger to life!
Unauthorized use of the system can be highly dangerous.
The magnetic position sensing heads must not be used in life-saving systems such as airplanes etc.
Risk of pinching
There is a risk of getting pinched between the sensing head and the magnetic tape. This can lead to injury or
mechanical damage. Avoid getting with your limbs and tools near the gap between the head and the tape while the
measuring system is in motion!
Dangers that may follow
Malfunctions of the measuring system can lead to further risks to the device or the system in which it is embedded.
When there is evidence that the measuring system is not working properly, it must be put out of operation and
secured against unauthorized use. The prescribed safety regulations must be observed for the use of position sensing
heads. In particular, measures must be taken to prevent dangers to people and property in the event of a failure.
This includes the installation of additional safety limit switches, emergency stop switches and the observance of the
required environmental conditions
Risk of damage for the magnetic layer
Magnetic tapes and sensing heads can be damaged by magnetic fields!
Apply only demagnetized tools for assembly and maintenance!
Improper storage of magnetic tape rolls can lead to magnetic interaction between the layers and thus to a reduction
of the measurement accuracy

AKS16 Ops Manual rev 2.1 (2023/12/20)
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Electromagnetic Compatibility
For the electrical connection it is essential that the electromagnetic compatibility (EMC) is guaranteed.
• System and control cabinet must be connected to the same ground potential.
• Use shielded cables. Connect the cabinet side of the cable shield with protective earth (PE).
• Avoid installing in close proximity to power lines.
• The nominal operating voltage (see datasheet) must be observed even if there is a voltage drop
along the supply line!
• Determine the place of installation so that inductive and capacitive interferences cannot aect the
sensor. By adequately routing the cable, interferences can be reduced.
Intended Use
The incremental magnetic sensing heads AKS16 are part of a highly accurate measuring system
consisting of magnetic scales and sensing heads capable of contactless position detection for linear
and rotary applications.
Fields of deployment:
• mechanical engineering
• automation
• medical engineering
• electrical engineering.
The system consists of a sensing head and a linear or rotating magnetic scale and can be incorporated
into various electronic systems. It can be congured according to the customer‘s demands. In
combination with a suitable analysis software absolute and relati-ve position and position changes
can be measured. In this way it is possible, for instance, to control machi-ne tools, determine torsional
forces or detect longitu-dinal expansions.
Fields of Deployment
• capital equipment,
• automation,
• medical engineering,
• electrical engineering.
A measurement solution consists of a sensing head and a linear or rotary magnetic scale and can
be incorporated into various electronic systems. It can be congured according to the customer‘s
specications. In combination with a suitable analysis software absolute and relative position and
position changes can be measured. In this way it is possible, for instance, to control machine tools,
determine torsional forces or detect longitudinal expansions.

AKS16 Ops Manual rev 2.1 (2023/12/20)
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Function and Properties
The magnetic position sensing heads AKS16 are suitable for non-contact, absolute and incremental
position measuring systems. The measuring function is realized by magnetic scanning.
The system has the following features:
• absolute and incremental encoder
• 16 to 18 bit absolute resolution
• 16 bit incremental resolution
• non-contact, quick position measurement
• single piece unit
• no wear from usage
• resistant to dust, cooling lubricant emulsion, oil, etc.
• dierent diameters and length oered
• radial, axial or linear reading.
Mode of Operation
The sensing head with its sensor is mounted on the machine part whose position is to be measured.
The measuring magnetic surface is mounted along the measuring distance. On the magnetic tape
alternating magnetic north and south poles are positioned with a regular distance. The magnetic hall
sensor cells in the sensing head are scanning the magnetic poles on the tape contact-free.
Permissive Linear and Rotation Speed
Please see AKS16 technical data sheet on our website: www.bogen-magnetics.com
Digital Absolute Output
The sensing head with digital absolute output signal converts the analog signals to an absolute
information in BISS-C or SSI.
Digital Incremental Output
The sensing head with digital incremental output signal converts the analogue signals into digital
A/B and Z pulses and transmits them to the controller. The two digital signals A and B are electrically
phase-shifted by 90°. The sign of the phase shift represents the direction of movement of the sensor.
Every change of A or B (rise to fall or vice versa) is a count for the period counter (up/down counter).
If signal A is preceding signal B, the counter increases. If signal B is preceding signal A, the counter
decreases. The Z pulse appears every time when passing the zero point. The controller thus knows
at all times the increment position, without having to query the sensing head periodically (real-time
capability). Therefore, after an interruption of the power supply the sensing head can still read its

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correct absolute position on the scale.
Assembly and Installation
During assembly utmost cleanliness is required. Device parts have to be degreased thoroughly before
gluing. During installation the mounting tolerances and the position of the measuring point have to be
observed respectively implemented as stated in the datasheet.
Measurement Options
The AKS16 comes with two measurement options.
• option 1 is a sensing head with parallel orientation of AKS16 chip
• option 2 is a sensing head with perpendicular orientation of AKS16 chip.
Delivery Condition
The AKS16 is supplied with a connector Molex 501568-1207 or with a FFC as an alternative for Molex.
Programming Device
Introduction
Each AKS16 requires a calibration process in assembly. It is recommended that the calibration is
performed across the whole working range of the sensing solution.
The calibration process consists of an analog calibration where the dierent sensors in the sensing
head will be optimized for best performance and a nonius calibration where the sensing head is
optimized over the scale.
With the AKS16 software and hardware the parameters of an AKS16 sensing head can be changed
for a successful calibration. The software sets the sensing head parameters for the correct master-
nonius periods (16/15, 32/31, 64/63) and the operating measurement systems (linear, rotary radial,
rotary axial).

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To calibrate the sensing head you need:
Windows PC
AKS16 programming unit
cable for programming unit
(USB 2.0 type A connector / mini-B connector)
cable (9 pin serial cable / Molex or FFC)
System Requirements
The programming device can be connected to a Windows PC with a USB cable and operated with the
dedicated software. The software requires Windows Vista or later (32/64 Bit). Before the programming
device (programmer AKS16) can be connected the specic driver must be installed. Copy the software
to a local directory on your Windows PC. To install the driver execute the specic program.
• USB_Adapter_00052040_Driver.exe. Connecting the device (for the calibration setup).
• Mount the sensing head correctly per mechanical specications. It is required to place the sensing
head within the allowed mechanical tolerances (maximum displacement), see technical data
sheet.

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Both status LEDs (green and red) on the AKS16 sensing head will light up now if all devices are mounted
correctly. The pictures below show the nal stage of all connected cables and the programming device.
Programming Software
Please contact our sales department for software and application notes: [e-mail]

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Commissioning
Verify general system operation
After mounting the distance measuring system or after replacing the sensing head, verify general system
operation as follows:
• recalibrate the sensing head,
• switch on the supply voltage of the sensing head,
• move the sensing head along the entire measurement path or revolution,
• check that all signals are present at the output,
• check if the count direction matches the traversing/revolution direction. If this is not the case please
mark the checkbox in the main window of the software.
Maintenance
The functionality of the measuring system and all related components must be reviewed and recorded
regularly. For more information and data sheets go to our website www.bogen-magnetics.com
Appendix
Troubleshooting
If there are signs of interference or malfunctioning, the measurement system must be put out of operation
and secured against unauthorized use.

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FAQs
Q: Can I connect a sensor after I have chosen my desired sensor parameters?
A: Yes, in case the user wants to choose the parameters first and then calibrate the sensor the
software will allow this order.
Q: Can I connect a dierent sensor after I have calibrated the rst sensor?
A: Yes, the software has been developed to perform this scenario. The software will disconnect the
sensor automatically after performing a calibration. The user can freely disconnect the cables and
reconnect a new sensor if desired.
Q: How can I choose calibration duration?
A: Calibration duration represents a time variable. The duration should cover at least four pole pairs
for successful calibration.
Example: If the AKS16 is used with a 1.28 mm Pole Pitch Linear Scale”then four pole pairs are 8 * 1.28 = 10.24
mm. This is the absolute minimum calibration distance. If the sensor is moving along the scale with a speed
of 5 mm per second, then the calibration duration is distance / speed = 10.24 / 5 = 2.048 seconds. Thus we
choose the nearest bigger calibration duration available in the given parameters, that is 2.1875 seconds.
Q: Can I connect a sensing head for 1.28 mm and 1.5 mm pole pitch with the same programming unit and
software?
A: Yes. The software recognizes the different pole pitches and performs the right actions. The
programming unit can handle both pole pitches.
Q: Can I connect an AKS16 and AKS17 with the same programming unit/software?
A: The programming unit and the software are able to work with both sensing heads.

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Fault / Error Message Possible cause Measures
Could not connect the sensor. Failed
communication to BiSS master, check the
connected interface.
Cables are not connected correctly. Please check cables connecting adapter and
sensor.
Another program may be using the adapter.
Please close any other application that may use
the adapter. If the problem still exists perform a
PC restart.
Could not connect the sensor. BiSS
communication failed. Check wire connection and
power supply.
Another program may be using the adapter.
Please close any other application that may use
the adapter. If the problem still exists perform a
PC restart.
Power supply for the adapter is too weak.
Please make sure that the PC can provide
enough power on the USB port. If not, you have to
provide external power.
Contacts are poorly shielded. Use shielded cables and ensure proper
contacting.
Install FTDI interface driver. The adapter driver is not installed.
Please install the driver software corresponding
to your adapter. If the problem still exists a
restart may be necessary.
Calibration failed, rotation speed is too slow for
calibration. Velocity or duration are not high enough. Increase velocity or calibration duration.
Calibration failed, rotation speed is too fast for
calibration. Velocity or duration exceed the limits. Decrease velocity or calibration duration.
Calibration successful but rotation speed is too
slow to acquire one complete turn. A full scale calibration was not performed.
This warning can be ignored when the user
is not using the full scale measurement area.
Otherwise it is recommended to repeat the
calibration with higher velocity or higher duration
and cover all the scale.
Calibration failed, invalid calibration data cycle
count.
Very noisy environment.
Please make sure that the cables are shielded
and that there is no interference in your
application.
The magnetic poles are damaged in some
places. Replace the magnetic nonius scale.
Please check the air gap between the sensor and
the magnetic scale. The air gap must be 0.4 mm. The sensor position is out of tolerance.
Please verify the air gap and X, Y mechanical
position of the sensor to match the tolerance
discussed in installation tolerance.
Please check X, Y position of the sensor on the
magnetic scale or the optimum calibration.
Nonius calibration failed. Please reposition the
sensor and press “Retry”.
The sensor position is out of tolerance.
Please verify the air gap and X, Y mechanical
position of the sensor to match the tolerance
discussed in installation tolerance.
Very noisy environment. Make sure that the cables are shielded and that
there is no interference in your application.
The magnetic poles of the scale are damaged
in some places. Replace the magnetic nonius scale.
Could not connect the sensor. Unable to detect
the slave. Please connect compatible AKS16. Wrong sensor. Make sure that the sensor option matches your sensor.
Analog parameters are all 0 and in the error
textbox you have the following message: “The
analog electrical phase error is very big. Please
check the current sensor configurations and
positions.”
The sensor is badly positioned. The software
and the sensor cannot calibrate this big error.
Reposition the sensor acording to the datasheet.
Make sure that the master mark on the sensor is
aligned with the master track on the ring.
You have good analog calibration but bad nonius
calibration.
Wrongly aligned sensor to the ring. Make sure that the master mark on the sensor is
aligned with the master track on the ring.
Wrong ring size. Make sure that the ring matches the “Size”
parameter.

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EU Declaration of Conformity
According to EU regulation for Electromagnetic Compatibility 2004/108/EU and European Standard
for Electromagnetic Compatibility EN 61326-1:2006 (EMC)
BOGEN Magnetics GmbH
Potsdamer Str. 12-13
14163 BerlinGermany
declares that
Magnetic Sensing Head AKS16, manufactured since 2015,
complies with the above-mentioned regulations and standards.
BOGEN Magnetics GmbH reserves the right to make changes, without notice, in the products, including software, described or contained herein in order to improve design and/or performance.
Information in this document is believed to be accurate and reliable. However, BOGEN Magnetics GmbH does not give any representations or warranties, expressed or implied, as to the accuracy
or completeness of such information and shall have no liability for the consequences of use of such information. BOGEN Magnetics GmbH takes no responsibility for the content in this document if
provided by an information source outside of BOGEN products. In no event shall BOGEN Magnetics GmbH be liable for any indirect, incidental, punitive, special or consequential damages (including
but not limited to lost prots, lost savings, business interruption, costs related to the removal or replacement of any products or rework charges) irrespective the legal base the claims are based
on, including but not limited to tort (including negligence), warranty, breach of contract, equity or any other legal theory. Notwithstanding any damages that customer might incur for any reason
whatsoever, BOGEN product aggregate and cumulative liability towards customer for the products described herein shall be limited in accordance with the General Terms and Conditions of Sale of
BOGEN Magnetics GmbH. Nothing in this document may be interpreted or construed as an oer to sell products that is open for acceptance or the grant, conveyance or implication of any license
under any copyrights, patents or other industrial or intellectual property rights. Unless otherwise agreed upon in an individual agreement BOGEN products sold are subject to the General Terms and
Conditions of Sales as published at www.bogen-magnetics.com.