ELGO Electronic EMAX2 Series User manual

Operation manual
SERIES EMAX2
Magnetic Absolute Length Measuring System with 0.01mm Resolution
Absolute measuring
Direct contact free measurement
Up to 10 m measuring length (20 m on request)
Resolution 0.01 mm
Changes of position are also recognized without voltage –
no calibration necessary
Automatically recognition of too big distance between sensor and
magnetic tape (LED indicator)
Additional incremental signals for dynamic drive mechanism available

Contents
2
1General............................................................................................................................ 3
1.1Information Operation Manual..............................................................................................3
1.2Explanation of Symbols .........................................................................................................3
1.3Statement of Warranties ........................................................................................................4
1.4Demounting and Disposal.....................................................................................................4
2Product Features................................................................................................................ 5
2.1Functional Principle ..............................................................................................................5
3Safety ............................................................................................................................... 7
3.1General Cause of Risks.........................................................................................................7
3.2Personal Protective Equipment ...............................................................................................7
3.3Conventional Use.................................................................................................................7
4Technical Data .................................................................................................................. 8
4.1Dimensions EMAX2 ..............................................................................................................9
4.2Dimensions EMAX2 with FW2080........................................................................................10
5Transport and Storage...................................................................................................... 11
5.1Safety Instructions for Transport, Unpacking and Loading.......................................................11
5.2Handling of Packaging Material...........................................................................................11
5.3Check of Transport .............................................................................................................11
5.4 Storage..............................................................................................................................11
6Installation / Commissioning............................................................................................. 12
6.1 Mounting of the Sensor Head ..............................................................................................12
6.2 Pin Connections .................................................................................................................13
6.3 Interfaces...........................................................................................................................14
6.3.1 RS422 Standard (Option 420) & RS232 (Option 230)...........................................................14
6.3.2 RS422 Adressable Version (Option A20) ..............................................................................15
6.3.3 Connection to a RS422 Master............................................................................................17
6.3.4 SSI - (Option SB0 or SG0)...................................................................................................17
6.3.5 CANopen - (Option CA0) ...................................................................................................18
6.3.6 CAN BASIC ELGO - (Option CN0)......................................................................................19
6.3.7 Sine Cosine Incremental Signals (Option SC50) ....................................................................21
6.3.8 Terminating Impedance ......................................................................................................22
7Options .......................................................................................................................... 23
7.1 Magnetic Tape ...................................................................................................................23
7.1.1 Handling ...........................................................................................................................23
7.1.2 Processing Note for Sticking ................................................................................................24
7.1.3 Resistance to Chemicals of the Magnetic Tape ......................................................................24
7.1.4 Sticking and Cutting ...........................................................................................................24
8Operation....................................................................................................................... 25
8.1 Offset................................................................................................................................25
9Interference..................................................................................................................... 25
9.1 Security..............................................................................................................................25
9.2Electrical Interference Suppression........................................................................................26
9.3Restart after Fault Clearance................................................................................................26
10Maintenance ................................................................................................................... 26
11Type Designation EMAX2.................................................................................................. 27
12Accessories ..................................................................................................................... 29
13Index .............................................................................................................................. 30

General
3
1General
1.1 Information Operation Manual
The manual contains important information regarding the handling of the indicator.
For your own safety please note all safety warnings and instructions.
Precondition for safe operation is the compliance with the specified safety and handling instructions.
Moreover, observe the existing local accident prevention regulation and general safety rules.
Please read the operation manual carefully before starting to work. The manual should be kept accessible at
anytime. The illustrations in the manual are for better representation of the facts they are not necessarily to
scale and can be slightly different to the actual construction.
1.2 Explanation of Symbols
Warning notices are characterised by symbols in the operation manual.
The notes will be introduced by signal words to express the magnitude of the danger.
Follow these advices in order to avoid accidents and injuries to persons and property.
Warning notices:
DANGER!
This symbol in connection with the signal word „Danger“ indicates an
immediate danger for the life and health of persons.
Failure to heed these instructions can result in serious damage to
health and even fatal injury.
WARNING!
This symbol in connection with the signal word „Warning“ indicates a
possible danger to the life and health of persons.
Failure to heed these instructions can result in serious damage to
health and even fatal injury.
ATTENTION!
This symbol in connection with the signal word „Caution“ indicates a
possibly dangerous situation.
Failure to heed these instructions can lead to minor injury or property
damage.
Specific safety instructions
DANGER!
...marks perilous situations by electricity. By non-observance of the
safety instructions the possibilities of death or severe injuries exist. The
operations have to be carried out only by an electrician.

General
4
Tips and recommendations:
NOTE!
Here you can see highlights, useful tips, information and
recommendations for efficient and trouble-free operation.
1.3 Statement of Warranties
The warranty conditions are in a separate document in the sales documents.
Guarantee
The producer guarantees the functional capability of the process engineering and the selected parameter.
The period of warranty is one year and begins with the date of delivery.
The warranty (1 year) is beginning with the date of purchase.
1.4 Demounting and Disposal
Unless otherwise authorized, dispose the item considering the safety and environmental instructions.
Before demounting
Disconnect the power supply
Secure against re-start
Disconnect supply lines physically and discharge remaining energy
Dispose operating supplies with respect to the environment
Disposal
Recycle the decomposed elements:
Collect metal scrap
Electronic components in electronic scrap
Recycle plastic parts
Dispose the rest of the components according to their material consistence
ATTENTION!
Wrong disposal Îdamage caused to the environment!
Electronic waste, electronic components, lubricants and operating
supplies are liable to treatment of hazardous waste.
Only approved specialized companies should perform disposal.
Local authorities and waste management facilities provide information about environmentally suitable
disposal.

Product Features
5
2Product Features
The series EMAX2 is an absolute length measuring system. Sensor and translator and interpolation unit are
together in one housing. The magnetic tape of series EMAB is paste up to a plain area. The EMAX2 can be
mounted with a max. distance of 1.5 mm. (2.0 mm sensor distance to the magnetic tape with reduced
measuring accuracy)
The absolute length measuring system has the following advantages:
no reference necessary
direct contact free measurement
distance between sensor and magnetic tape can be between 0.1... 2.0 mm
->distance OK = LED glow green
->distance not OK = LED glow red
up to 20 m measuring length (on request)
high resolution 0.01 mm
repeat accuracy +/- 1 increment
inured against dirt
The following interfaces are available (RS422, addressable RS422, RS232, SSI, CANopen (DS406), CAN
BASIC ELGO (CN0).
Typical applications are handling systems, conveyor and storage technology, hydraulic presses, stamping
machines, casting machines, linear slides, linear drives and pick and place systems.
The guided version is delivered completely with magnetic tape guide and guiding wagon.
2.1 Functional Principle
A Hall sensor and a magneto-resistive impedance measuring bridge are guided over a two-track magnetic
tape with a fine-interpolation trace and an absolute trace. Together with the sensor line the absolute track
provides an absolute value and the fine-interpolation trace provides together with the interpolation electronic
the measuring systems high resolution.
Interpolation trace
Not magnetised area
Absolute trace
Picture 1: Functional principle EMAX2
Pic. 2 shows two magnetic traces, with north pole and south pole magnetization. The fine interpolation trace
encloses alternately north and south pole traces with a distance of 5 mm, these are scanned with resistance
bridges and provide a resolution of 0.01 mm. The absolute value provides the sensor line with 16 single Hall
sensors, these sensors are scanning the code sections of the north and south poles. The absolute value on
the magnetic tape recurs every 10 m.
Interpolation trace
Not magnetised area
Absolute trace

6
Picture 2: Coding

Safety
7
3Safety
3.1 General Cause of Risks
This chapter gives an overview about all important safety aspects to guarantee an optimal protection of
employees.
Non-observance of the instructions mentioned in this operation manual can result in hazardous situations.
3.2 Personal Protective Equipment
Employees should wear protective clothing during installation of the device to minimize the risk of accidents.
Change into protective clothing before beginning the work process. Also observe any labels in the operating
area regarding protective clothing.
Protective clothing:
Safety working clothing
... is close-fitting
... is tear proof
... has tight sleeves without distant parts
Also wear no rings, necklaces or other jewellery.
Protective gloves
... For protecting the hands against abrasion and cuts.
3.3 Conventional Use
The ELGO length measuring system EMAX2 is for the limited purpose as described in this manual:
CAUTION!
Danger through non-conventional use!
Non-intended use and non-observance of this operation manual
can lead to dangerous situations.
Therefore:
Use EMAX2 only as described
Strictly follow this manual
Avoid in particular:
Remodelling, refitting or changing of the device or parts of it with
the intention to alter functionality or scope of the device.
ELGO is not liable for any damages resulting from improper use of the product.
The operator is liable for all damages during non-conventional use.

8
4Technical Data
Mechanical Data
Measuringprinciple absolute
Repeataccuracy +/‐1increment
Systemaccuracyinµmat20°C
+/‐(150+20xL)(typedesign.010)
+/‐(50+20xL)(typedesign.F10)
L=effectivemeasuringlength
Distancefromthesensorto
magnetictape max.1.5mm,2.0mmwithreducedaccuracy
Basicpolepitch5mm
Sensorhousingmaterial zincdiecasting
HousingdimensionsSensor:LxWxH=75x24x26mm
Sensorwithguidecarriage:LxBxH=100x34x48mm
NecessarymagnetictapeMeas.length10m:AB20‐50‐10‐2‐R‐11
Meas.length20m:AB20‐50‐10‐2‐R‐12
Max.measuringlengthEMAX:upto10m
EMAL:upto20m
Cableconnectionopencableend
WeightEMAX2:ca.100gwithoutcable
cable:ca.60gpermeter
Ambient Temperature
Storagetemperature‐25…+85°C
Operationtemperature‐10…+70°C
(‐25…+85°C)onrequest
ProtectionclassIP40(Standard)
IP65(OptionV)
Electrical Data
Powersupply10…30VDC+/‐10%
Periodicandrandomdeviation10‐30V:<10%
Currentconsumptionmax.150mA
InterfacesSSI‐Interface,CANopen(DS406),CANBASICELGO(CN0),
RS422,addressableRS422
Resolution0.01mm
Max.outputfrequency 4m/s
Sensorcable1.5mstandardcablelength,othersonrequest,
dragchaincompliant
Technical Data

Technical Data
9
4.1 Dimensions EMAX2
Seitenansicht
26,00
15,00
24,00
15,00
2,00
26,00
15,00
24,00
0,93 10,00
* The amount of decode switches is depending on the interface
Front view Rear view

Technical Data
10
4.2 Dimensions EMAX2 with FW2080
Side view
22,00
16,50
83,50
4,00
Ø8,00
Ø4,50
4,50
Top view
5,00
10,00
16,50
83,50
80,00
3,00
Ø3,50
Ø6,00
95,00
24,00
43,00
5,00
12,00
48,00
R 4,00
Front view
20,00
8,00
13,00 22,00
11,50 25,00
6,00
8,00
1,50

Transport and Storage
11
5Transport and Storage
5.1 Safety Instructions for Transport, Unpacking and Loading
ATTENTION!
Professional transport only.
Do not throw, hit or fold the package.
5.2 Handling of Packaging Material
Adverts for proper disposal refer to chapter demounting and disposal.
5.3 Check of Transport
Examine delivery immediately after receiving for completeness and transport damages.
In case of externally recognizable transport damages:
Do not accept the delivery or do accept under reserve
Note extent of damages on the transportation documents or on the delivery note
File complaint immediately
NOTE!
Claim any damages you recognize as soon as possible. The claims for
damage must be filed in the lawful reclaim periods.
5.4 Storage
Store device only under following conditions:
Do not store outside
Keep dry and dust-free
Do not expose to aggressive media
Protect from direct sun light
Avoid mechanical shocks
Storage temperature: -25 °C up to +85 °C
Relative humidity: 80 % non-condensing
Inspect packages regularly if stored for an extensive period of time (> 3 months)

Installation / Commissioning
12
6Installation / Commissioning
6.1 Mounting of the Sensor Head
NOTE!
The distance between sensor and tape is monitored and indicated by
the LED on the sensor.
->distance OK =LED glow green
->distance not OK =LED glow red
For mounting the sensor head two 3M screws have to be used
Tolerances for distance and angle must be observed. (see pic. 3).
Parallel adjustment:
mid of sensor = mid of tape
+/- 0.5 mm
0.1
–
1.5 mm
Distance between sensor
and tape
C
B
A
A
, B , C = 0° +/- 0.5°
Fig. 3: Mounting and affinity tolerance
Mounting direction of EMAX2 sensor to magnetic tape:
Sensor and magnetic tape have to be mounted to the same direction (direction of arrow):
The provided pole searcher film allows to determine the respective pole pitches when lying on the tape. From
that the following installation direction results:
Magnetic tape EMAX Sensor Cable Pic. 4 Sensor/Magnetic tape
fine interpolation trace
not magnetised area
absolute trace
Markers on tape and sensor are additionally indicators for the mounting direction.
EMAX2 in combination with FW2080 has markers placed on sensor and guide rail.

Installation
/
Commissioning
13
6.2 Pin Connections
Signal
cable
Function RS422
(420, A20)
Function RS422
(420, A20)
Incremental HTL
Option RS232
(230)
Option RS232
(230)
Incremental HTL
Option RS232
(230)
Incremental TTL
white 0 V / GND 0 V / GND 0 V
/
GND 0 V
/
GND 0 V / GND
brown + 10-30 VDC + 10-30 VDC + 10-30 VDC + 10-30 VDC + 10-30 VDC
yellow TX + RX + RX RX RX
orange TX - TX - TX TX TX
green RX + RX + - - channel B inv.
violet RX - RX - - - channel A inv.
grey - channel A - channel A channel A
black - channel B - channel B channel B
shield PE* PE* PE* PE* PE*
Signal
cable
Option SSI
(SG0, SB0)
Option SSI
(SG0, SB0)
Incremental HTL
Option CAN
(CA0, CN0)
Option CAN
(CA0, CN0)
Incremental HTL
Option CAN
(CA0, CN0)
Incremental TTL
white 0 V / GND 0 V / GND 0 V
/
GND 0 V
/
GND 0 V / GND
brown + 10-30 VDC + 10-30 VDC + 10-30 VDC + 10-30 VDC + 10-30 VDC
yellow TX Data + TX Data + CAN high CAN high CAN high
orange TX Data - TX Data - CAN low CAN low CAN low
green CLK Clock + CLK Clock + - - channel A inv.
violet CLK Clock - CLK Clock - - - channel B inv.
grey - channel A - channel A channel A
black - channel B - channel B channel B
shield PE* PE* PE* PE* PE*
Signal
cable
Option SSI
(SG0, SB0)
Sine/Cosine
SC50
Option SSI
(SG0, SB0)
Incremental TTL
Function RS422
(420, A20)
Sine/Cosine
SC50
Function RS422
(420, A20)
Incremental TTL
white 0 V / GND 0 V / GND 0 V
/
GND 0 V
/
GND
brown + 10-30 VDC + 10-30 VDC + 10-30 VDC + 10-30 VDC
grey TX Data + TX Data + TX + TX +
pink TX Data - TX Data - TX - TX -
yellow CLK Clock + CLK Clock + RX + RX +
green CLK Clock - CLK Clock - RX - RX -
blue Sine + channel A Sine + channel A
red Sine - channel A inv. Sine - channel A inv.
black Cosine + channel B Cosine + channel B
violet Cosine - channel B inv. Cosine - channel B inv.
shield PE* PE* PE* PE*
*) Connect shield only at the device!

Installation
/
Commissioning
14
6.3 Interfaces
6.3.1 RS422 Standard (Option 420) & RS232 (Option 230)
The measuring system EMAX2 has RS422 interface.
The data transmission has the following format:
9600 Baud / 1 Start Bit / 8 Data Bits / 1 Stop Bit / No Parity
Data protocol:
The actual value is transmitted with 9600 Bit/s, 8 Data bits, 1Stop bit, without parity bit in the following
format:
02h STX
xxh ABS data MSB
xxh ABS data
xxh ABS data LSB
03h ETX
00h
0Dh
The scanned absolute position is shown binary with 0,01 mm resolution in the 3 ABS data bytes.
Standard
9600 Baud, 8 Data Bit, 1 Stop Bit, no parity
7 Byte, 02 MSB MSB-1 LSB 03 00 0D
binary position value
STX ETX
Other protocols on request:
RS422: Addressable version is optionally available (see next page).
Signal cable
154500003
8-pin M16 cable box with
ELGO standard SSI-
interface ( M8F0)
1 white 0 V / GND
2 brown
V
CC
3 yellow Data (+)
4 orange Data (-)
5 green Cloc
k
(+)
6 violet Cloc
k
(-)
7 (n.c.) -
8 (n.c.) -

Installation / Commissioning
15
6.3.2 RS422 Adressable Version (Option A20)
Protocol of an addressable EMAX2 version 1.4
The device address can be adjusted by a decoding switch which is located behind
a protection cap on the top of the sensor housing:
LED Terminating Address Baud rate
impedance
General format of a message to the EMAX:
0x02 Byte1 Byte2 Byte3 0x03
STX check ETX
0x02 (STX) starts a message
0x03 (ETX) close the message
Byte3 (check) is the arithmetic sum of 0x02(STX), Byte1 and Byte2.
ETX is not included in the checksum
0x04 characterizes the message as position-request
i is the address of the requested EMAX2 (i = 0x0b... 0x7f).
The position value consists of 3 byte:
PosLow (bit 0… bit 7), PosMid (bit 8… bit15), PosHigh (bit16...bit23).
Bit 0 has the value10 μm. Position-values are always smaller than 0xffff00.
Please note: The last byte is no ETX, like in all the other messages, but the EMAX2 address.
Position
A
ddress
0 0B
1 0C
2 0D
3 0E
4 0F
5 10
6 11
7 12
8 13
9 14
A
15
B 16
C 17
D 18
E 19
F 1A
General format of a message from the EMAX:
0x02 Byte1 Byte2 Byte3 Byte4
STX
Position-request from the EMAX with address i:
Message to the EMAX
0x02 0x04 i check 0x03
STX check ETX
A
nswer of the requested EMAX:
0x02 PosHigh PosMid PosLow EMAX-Address

Installation
/
Commissioning
16
Interrogation of the address of an EMAX2:
Connect always only a single EMAX2 to be interrogated via RS422/RS232 converter to COM port of a PC.
Note: The combination 0xff 0xff does not appear in normal mode for position answers of EMAX2 (directly
after STX) It is a sign for a special message not a position (in this case with 0x0b <= i <=0x7f it is the
answer to the interrogation of the address).
Negative answer: If one of the described operations failed for some reasons, EMAX2 gives a negative answer
with a concerning error code.
Description of the error messages of an addressable EMAX2:
Code Description
0x04 Wrong succession of bytes sent to EMAX2 for example if the 4. byte after the STX is no ETX or the
byte after STX is not 0x04, 0x05 or 0x06.
0x05 Receive Error: Error concerning the interface
(for example if there has been sent a message with a wrong baud rate etc.)
0x06 Invalid EMAX address – appears after trying to assign an address smaller 0x0b or bigger 0x7f to
EMAX2.
0x07 EMAX2 has forgotten its address - check of internal redundant stored address of EMAX2 failed, this
error message is sent at power up immediately if an error in reading EEPROM is detected or if the
internal redundant stored address does not fit.
0x08 Internal store error of address in EEPROM.
0x09 Error in calculation of position (No tape, tape damaged or to big distance)
0x0a Check-Sum-Error - Chec
k
-Sum of a message sent to EMAX2 is wrong
Message to the EMAX:
0x02 0x05 0x05 0x0c 0x03
STX address request check ETX
A
nswer of the EMAX:
0x02 0xff 0xff i 0x03
STX EMAX address ETX
EMAX answers:
0x02 0xff 0xff Err 0x03
STX 0xff 0xff Error Code ETX
With Err = 0x04... 0x0a

Installation / Commissioning
17
6.3.3 Connection to a RS422 Master

6.3.4 SSI - (Option SB0 or SG0)
Principle of the function: If the clock is not interrupted for the time Tm-T/2 (output of further 25 periods), the
shift register clocks once again the same data value (error recognition in evaluation).
Some encoders contain a Power Failure Bit (PFB):
With EMAX the PFB is always „low“.
Read out of the data (2 times with 25 clocks):
Not inverted SSI Clock
PFB = Power failure bit
T = Cycle duration of clock pulse
Tm = Mono flop time > 15 μs
By using the decoding switch, which is located behind a protection cap on the top of the sensor, the data
format of the SSI interface can be changed over with the help of a micro screwdriver from Binary code to
Gray code.
LED Gray / Binary code
Position Code
F Binary
0 Gray
Switch position:
0 ÆGray code
1 ÆBinary code
Colour Function
Green RX
V
iolet RX-
Yellow TX
Orange TX-
Brown +24VDC
White 0 V (GND)

Installation / Commissioning
18
6.3.5 CANopen - (Option CA0)
Interface / Protocol:
As standard the EMAX2 measuring system is equipped with a CANopen standard interface DS406, when
ordering option CA0.
The following identifiers are given:
CAN - Identifier
(4 Byte telegram)
180 (16) = Identifier
First 4 bytes = Position (resolution 0.01 mm), bit rate 250 KB/s
The CAN-Identifier can be adjusted in the range of 181 (16) to 18F (16) by a decoding switch, which is located
behind a protection cap on the top of the sensor housing:
LED Terminating Address Baud rate
impedance
Position CAN Identifie
r
0 1fe
1 181
2 182
3 183
4 184
5 185
6 186
7 187
8 188
9 189
A
18A
B 18B
C 18C
D 18D
E 18E
F 18F

Installation / Commissioning
19
6.3.6 CAN BASIC ELGO - (Option CN0)
Interface / Protocol:
On request the EMAX2 measuring system is equipped with a CAN interface with ELGO CAN standard
protocol.
The following identifiers are given:
80 (16) + EMAX address = Identifier to request the absolute position
10 (16) + position of decoding switch = Identifier contains absolute position of the
device (4 byte telegram) EMAX2 (resolution 0.01 mm)
4Byte acknowledgement telegram
The address can be adjusted in the range
of 0 (16) to F (16) by a decoding switch,
which is located behind a protection cap
on the top of the sensor housing
The bit rate can be adjusted by a decoding switch,
which is located behind a protection cap on the top
of the sensor housing
LED Terminating Address Baud rate
impedance
Status:
X
= 0 Æwithout erro
r
X
= 1 Æerror magnetic tape
Position Bit rate
0 500 kBit/s
1 250 kBit/s
2 125 kBit/s

Installation / Commissioning
20
A/B – Incremental Output
(Option HXXX or TXXX)
Optionally two 90° phase shifted square wave channels are available (shaft encoder compatible) with HTL-or
TTL-output level (push/pull)
The EMAX resolution (at 4 edge triggering) can have the following amounts:
2.5 μm; 5 μm; 10 μm; 25 μm (for each pulse edge)
Incremental signals
H2N5 Incremental square wave signals HTL with 2.5 μm resolution
H005 Incremental square wave signals HTL with 5 μm resolution
H010 Incremental square wave signals HTL with 10 μm resolution
H025 Incremental square wave signals HTL with 25 μm resolution
T2N5 Incremental square wave signals TTL with 2.5 μm resolution
T005 Incremental square wave signals TTL with 5 μm resolution
T010 Incremental square wave signals TTL with 10 μm resolution
T025 Incremental square wave signals TTL with 25 μm resolution