GETOtec MAGIC User manual

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Assembly Instructions
MAGIC Distance Measuring System
MAGIC Encoders
MAGIC-PG

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Contents
1Information about this document......................................................................................... 5
1.1Applicability of these assembly instructions .....................................................................................5
1.2Symbols used .....................................................................................................................................5
2Safety .................................................................................................................................. 6
2.1Proper use ..........................................................................................................................................6
2.2Exclusion of liability in the event of alterations and improper use...................................................6
2.3Experienced personnel ......................................................................................................................6
2.4General safety information ................................................................................................................6
2.5Safety information for storage and transportation............................................................................7
2.6Safety information on handling current-carrying, live products.......................................................7
2.7Additional information........................................................................................................................8
3Product descriptions............................................................................................................ 9
3.1HIWIN MAGIC......................................................................................................................................9
3.2HIWIN MAGIC-PG ...............................................................................................................................9
3.3Connection........................................................................................................................................10
3.4Reference switch..............................................................................................................................10
3.5Scope of delivery ..............................................................................................................................11
4Assembly ........................................................................................................................... 12
4.1Assembly of the HIWIN MAGIC.........................................................................................................12
4.1.1Assembly of the magnetic and protective cover tape.............................................................12
4.1.2Assembly of the encoder.........................................................................................................13
4.2Assembly of the HIWIN MAGIC-PG ..................................................................................................13
4.2.1Assembly of the profile rails ...................................................................................................13
4.2.2Assembly of the magnetic scale and the protective cover tape .............................................13
4.2.3Assembly of the MAGIC-PG encoder.......................................................................................15
4.3Reference switch..............................................................................................................................16
5Electrical connection ......................................................................................................... 16
5.1Cable and connector ........................................................................................................................17
5.2Subsequent switching ......................................................................................................................18
5.3Voltage amplitudes...........................................................................................................................19
5.4Reference switch..............................................................................................................................20
6Putting into operation ........................................................................................................ 20
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7Maintenance ...................................................................................................................... 20
8Technical data ................................................................................................................... 21
8.1Dimensions.......................................................................................................................................21
8.1.1HIWIN MAGIC dimensions.......................................................................................................21
8.1.2HIWIN MAGIC-PG dimensions.................................................................................................22
8.2Technical data of the MAGIC encoder..............................................................................................23
8.3Technical data of the magnetic scale ..............................................................................................24
8.4Reference switch..............................................................................................................................25
9Spare parts and item numbers .......................................................................................... 26
9.1Item numbers of the individual parts...............................................................................................26
9.2Order code for PG linear guideway ..................................................................................................27
10Declaration of incorporation .............................................................................................. 28
4

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1 Information about this document
These assembly instructions are intended for planners, developers and operators of systems into which
the distance measuring systems described are to be integrated. They are also intended for people who
perform the following tasks:
•Transportation
•Assembly
•Electrical connection including connection to the higher-level control system
•Integration into a security system
•Retrofitting or upgrading
•Setup
•Putting into operation
•Operation
•Cleaning
•Maintenance
•Troubleshooting and error elimination
•Shutdown, disassembly and disposal
1.1 Applicability of these assembly instructions
These assembly instructions are applicable to HIWIN distance measuring systems with the following
product designations:
•HIWIN MAGIC
•HIWIN MAGIC-PG
1.2 Symbols used
WARNING
Warnings serve to protect people against concrete or possible dangers to life and health.
It is absolutely imperative that warnings are heeded.
NOTE NOTE
Notes serve to protect the distance measuring system or other components or provide hints for
efficient work processes.
i
INFO
INFOs offer helpful additional information about distance measuring systems or their environment.
5Work instructions are marked with the checklist symbol. The actions described must be carried out and
adhered to in the sequence given.
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2 Safety
This chapter serves the safety of everybody who is present in the area around mobile systems and
assembles, installs, connects, operates, maintains or disassembles the distance measuring
systems described.
2.1 Proper use
The HIWIN MAGIC is a magnetic distance measuring system for measuring tasks with linear movement
within an automated system. It is used, above all, in linear motors.
The distance measuring systems named may not be used outdoors or in hazardous areas where there
is a risk of explosions.
The distance measuring systems may only be used as described for the intended purpose.
2.2 Exclusion of liability in the event of alterations and improper use
No changes may be made to the distance measuring systems that are not described in these assembly
instructions. If it is necessary to change the design, please contact the manufacturer.
In the event of alterations or improper assembly, installation, putting into operation, operation,
maintenance or repair, the manufacturer assumes no liability.
Only original parts from HIWIN may be used as spare parts and accessories. Spare parts and
accessories not supplied by HIWIN are not tested for operation with HIWIN MAGIC distance measuring
systems and may compromise operational safety and reliability. The manufacturer accepts no liability
for damage caused as a result of using non-approved spare parts and accessories.
2.3 Experienced personnel
The distance measuring system may only be assembled, integrated into higher-level systems, put into
operation, operated and maintained by experienced personnel. Experienced is anyone who:
•has suitable technical training;
and
•has been trained to operate the machine by the machine operator, received instruction in the
applicable safety guidelines from the machine operator and can assess the risks to be expected;
and
•has read and understood these assembly instructions in their entirety and has access to them at
all times.
2.4 General safety information
•Before and during all assembly, disassembly or repair work, the distance measuring system or
complete system must be switched to zero current, and you must ensure that the power supply
cannot be restored by anyone else. Otherwise, there is a danger of death and injury.
•The distance measuring systems must not be used in hazardous areas where there is risk of explosions.

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•The distance measuring systems may only be used and operated indoors.
•The air gap between the encoder and the magnetic scale must be checked regularly and kept clear.
Magnetic chippings or other foreign materials can get left on the magnetic scale. This can
mechanically destroy the encoder.
2.5 Safety information for storage and transportation
The distance measuring systems are shipped in
suitable packaging. The systems must be left in this
packaging until they are built.
The distance measuring systems must be stored so
that they are dry and protected against shocks.
During storage and transportation, there may be no
heavy objects on the products.
The measuring scale of the magnetic distance
measuring systems must not be subjected to any
strong magnetic fields (keep it away from
permanent magnets of linear motor axes!). Strong
shocks (e.g. hammer blows) can also damage the
magnetization of the measuring scale.
NOTE
2.6 Safety information on handling current-carrying, live products
•Make absolutely certain that the system (e.g. linear motor axis) is properly grounded with the
PE rail in the control cabinet as reference potential. Without low-ohm grounding, safety is not
guaranteed.
•Power connections may be live even when the motor is not moving. Never loosen electrical
connections when energized. In unfavorable cases, electric arcs can form, causing injury and
damage to contacts.
•Heed the assembly instructions for the other system components (e.g. linear motor,
drive amplifier).
•The distance measuring sensor is operated at a low voltage, so there is not normally any risk
of injuries or fatalities from this alone.
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2.7 Additional information
Please read the installation explanation in chapter 10.
If you have any questions, please contact our sales organization:
Tel.: +49 (0)781 / 9 32 78-0
Fax: +49 (0)781 / 9 32 78-90
If you have questions about the documentation, suggestions or corrections, please send a fax to the
following fax number:
+49 (0)781 / 9 32 78-90

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3 Product descriptions
The magnetic distance measuring systems of the HIWIN MAGIC series are optimized for measuring the
distances traveled in linear movements and particularly on linear motor axes. They are particularly
suitable for use in harsh environmental conditions and are resistant to oil, dirt, vibrations and shocks.
The robust housing is electrically shielded, and signals are output in real time (see chapters 5and 8for
more information).
Two types are available:
•HIWIN MAGIC: type with separate encoder
•HIWIN MAGIC-PG: distance measuring system integrated in a linear guideway
The measuring scale of the magnetic measuring systems may not be subjected to any strong
magnetic fields (keep it well away from the permanent magnets of linear motor axes!).
Strong shocks
(e.g. hammer blows) can also damage the magnetization of the measuring scale.
NOTE
The system is not suitable for environments where there is magnetic dust (e.g. graphite dust).
These things can falsify the encoder signal or damage the distance measuring system.
3.1 HIWIN MAGIC
This distance measuring system consists of a separate encoder (figure 3.1) and
a magnetic scale (figure 3.2). The customer can select suitable positions for both
of these and install them.
Figure 3.1 MAGIC encoder Figure 3.2 MAGIC magnetic scale
3.2 HIWIN MAGIC-PG
For this type, the distance measuring system is integrated in a linear guideway. The complete unit is
referred to as a positioning guideway (PG).
The encoder is fitted to a standard block. It is suitable for HG-20 and HG-25 blocks. A magnetic scale is
integrated directly in a profile rail (see figure 3.3).
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Figure 3.3 Linear guideway with MAGIC-PG system
The magnetic scale is adhered to the rail using a high-strength glue. The effect of the glue can be
loosened by certain solvents. If this happens, the magnetic scale can bulge up. This must be prevented
by taking additional measures (e.g. additional clamping of the magnetic scale at the ends).
NOTE
HIWIN GmbH assumes no liability if a scale that was not secured by means of suitable measures should
come loose from the rail.
3.3 Connection
The distance measuring system is connected with the fixed cable mounted on the encoder to a superior
controller (e.g. amplifier). It is supplied with a low voltage of 5 V.
The cable can be delivered with open ends (see figure 3.4) or optionally converted finished with round
plug coupling (see figure 3.5).
Figure 3.4 Connection cable with open ends Figure 3.5 Cable with coupling (optional)
3.4 Reference switch
The MAGIC encoder delivers index signals at a distance of 1 mm. For the definition of a reference point,
a reference switch ("cam switch") is required.
For this purpose, HIWIN offers an inductive proximity switch (see figure 3.6).

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Figure 3.6 Reference switch on mounting
3.5 Scope of delivery
Depending on customer requirements, the distance measuring systems MAGIC and MAGIC-PG are
offered in different forms and with different scope.
Individual components can be supplied to retrofit existing linear guideway systems.
In addition, HIWIN offers the distance measuring systems integrated in linear guideways as a complete
system.
Table 3.1 shows the standard scope of delivery and the optional accessories. The item numbers of the
individual parts are given in section 9.1, and the order codes for systems are shown in section 9.2.
Table 3.1 Overview of the standard scope of delivery and optional accessories
Distance measuring system MAGIC MAGIC-PG
Encoder Select cable length Select cable length
Magnetic scale (incl. stainless steel
protective cover tape) Select length Select length
Type of encoder with coupling Optional Optional
Reference switch Optional Optional
Screw set for MAGIC-PG Not suitable Standard scope of
delivery
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4 Assembly
Before and during all assembly, disassembly or repair work on a linear motor axis, the distance
measuring system, the linear motor and the associated systems and controls must be
disconnected from the power source, and it must be ensured that the power supply cannot be
restored by anyone else. Otherwise, there is danger of death and significant danger of injury.
The distance measuring sensor is operated at a low voltage, so there is not normally any risk of
injuries or fatalities from this alone.
NOTE The measuring scale of the magnetic distance measuring systems must not be subjected to any
strong magnetic fields (keep it away from permanent magnets of linear motor axes!).
Exercise caution when using magnetic devices (gauge holders) to align the profile rails,
for example!
Strong shocks (e.g. hammer blows) can also damage the magnetization of the measuring scale.
The system is not suitable for environments where there is magnetic dust (e.g. graphite dust).
These things can falsify the encoder signal or damage the distance measuring system.
i
The numbers used for identification in the assembly instructions are also shown in the item overview in
chapter 9 in order to make it easier to select individual parts.
4.1 Assembly of the HIWIN MAGIC
Figure 4.1 shows the assembly steps described below for the HIWIN MAGIC.
4
Positive counting direction
2 3
1
Figure 4.1 Assembly of the HIWIN MAGIC
4.1.1 Assembly of the magnetic and protective cover tape
The magnetic scale can be mounted on a suitable, even surface selected by the customer parallel to the
movement direction on the fixed part of the system. The following criteria must be met:
•Mean surface roughness Ra≤3.2 μm
•Difference in height (parallelism) in relation to the direction of movement of the encoder: ≤0.1 mm

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•Lateral parallel deviation in relation to the direction of movement of the encoder: ≤0.2 mm
(ideally use stop edge)
The magnetic scale and the cover tape are coated with an adhesive film covered by a protective tape.
Only remove the protective tape shortly before or during assembly!
NOTE
5Assembly steps:
¾Clean the surface [1] to which the tape is to be fastened thoroughly with alcohol or acetone.
The surface used for the magnetic scale must be absolutely clean, dry and grease-free!
This is the only way to ensure a reliable bond is obtained.
¾Glue on the magnetic scale [2], and then use a mounting roller to press it on with a force of approx.
250 N/cm2. Ensure that the tape is neither compressed nor overstretched.
¾Clean the surface of the magnetic scale as described above.
¾Glue the protective cover tape [3] onto the magnetic scale. Make sure that no bubbles form under
the tape during gluing. Use a mounting roller to press the protective cover tape with a force of
approx. 250 N/cm2.
NOTE The bond strengthens under pressure. The final strength is obtained after approx. 48 hours at
room temperature.
4.1.2 Assembly of the encoder
The encoder [4] is mounted on the moving part of the system so that it moves in the middle above the
magnetic scale. The encoder can be aligned with the magnetic scale with the help of the milled
recesses on the front sides.
The distance between the stainless steel protective cover tape and the encoder must be 0.2 ±0.1 mm.
It is advisable to use a feeler gauge to set the correct distance.
NOTE
Make sure that the minimum cable bending radius of 40 mm is not underrun.
4.2 Assembly of the HIWIN MAGIC-PG
Figure 4.2 shows the assembly steps described below for the HIWIN MAGIC-PG.
4.2.1 Assembly of the profile rails
Fit the profile rails as described in the assembly instructions for the linear guideways.
4.2.2 Assembly of the magnetic scale and the protective cover tape
One-piece T-shaped rails (threaded holes from below) are generally shipped with the magnetic scale
and protective cover tape already installed. In the case of R-shaped rails consisting of one or more
parts (bored holes from above) and T-shaped rails consisting of several parts, the magnetic scale and
protective cover tape must be stuck on after the rails are installed.
5
Assembly steps:
¾The profile rail must be fitted as described in the assembly instructions for linear guideways.
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¾Pull the block from the rail (using the tool provided in order to prevent balls from falling out).
¾Clean the groove thoroughly with alcohol or acetone so that it is free of grease and dust.
¾Pull the adhesive film from the magnetic scale. Insert the magnetic scale in the groove by hand
with the adhesive surface against the profile rail.
Figure 4.2: Inserting the magnetic scale
¾Install the fitting tool on the profile rail using the tool provided. First check that the fitting tool's
runner wheel is free of grease. Run the fitting tool along the whole length of the profile rail a
number of times. Then remove the fitting tool.
Figure4.3: Fitting tool for pressing down on the magnetic scale
¾Use alcohol or acetone to remove the grease from the surface of the magnetic scale.
¾Glue the cover tape onto the magnetic scale. Make sure that no bubbles form under the tape during
gluing. Press the cover tape down using the fitting tool.
¾Grease the rail again to prevent corrosion.
¾Pull the block onto the rail again. Ensure no balls fall out while you are doing this.
NOTE The bond strengthens under pressure. The final strength is obtained after approx. 48 hours at
room temperature.

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8
9
7
6
3
5
2
11
12 13
11 Positive
Counting
Counting direction
for cable outlet
on the other side
positive
Counting
Counting direction
for cable outlet
on the other side
10
Figure 4.4 Assembly of the HIWIN MAGIC-PG
4.2.3 Assembly of the MAGIC-PG encoder
5¾On the side where the MAGIC encoder [7] should be mounted, remove the metal scraper [6] by
loosening the screws. Do not disassemble the deflection unit [9]!
¾Screw the headless screw [8] into the threaded hole of the deflector.
¾Place the MAGIC housing on the deflector. The housing can be mounted in two directions -
depending on the desired counting direction and/or cable outlet side. The counting direction is as
shown in figure 4.4 if the cable is connected as in table 5.1. Do not tighten screws [13] all
the way (underlay lock washers [11]).
¾The height of the encoder must be adjusted. There must be a distance of 0.2 ±0.1 mm between
the cover tape and the encoder. It is advisable to use a feeler gauge to set the correct
distance. Then tighten the screws [13] all the way.
¾Fasten the metal scraper onto the MAGIC housing using screws [10] and nuts [12] (use lock
washers [11]). The block must also be on the rail in order to guarantee a correct alignment of the seal.
When fitting the encoder and glider, ensure that you do not violate the connecting cable's
minimum bending radius of 40 mm.
NOTE
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4.3 Reference switch
The reference switch is generally fitted to the fixed part of the system, and a cam switch is fitted to the
moving part.
The distance between the cam switch and switch must not be more than 2 mm (see the technical data
in section 8.4).
Figure 4.5
Reference switch and cam switch
(linear motor axis installation example)
5 Electrical connection
Make absolutely certain that the system (e.g. linear motor axis) is properly grounded with the PE
rail in the control cabinet as reference potential. Without low-ohm grounding, safety is not
guaranteed.
Power connections may be live even when the motor is not moving. Never loosen electrical
connections when energized. In unfavorable cases, electric arcs can form, causing injury and
damage to contacts.
Heed the assembly instructions for the other system components (e.g. linear motor,
drive amplifier).
The distance measuring sensor is operated at a low voltage, so there is not normally any risk of
injuries or fatalities from this alone.
Do not operate the sensor with a voltage other than the one specified. This can destroy it.
NOTE

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5.1 Cable and connector
The maximum length of the cable for the encoder is 5 meters. It has a single shield and is not suitable
for a cable carrier.
Up to a length of 5 meters, the drop in voltage is minimal and the encoder meets the EMC requirements
of EN 61000-4-4, test severity level 3. This covers immunity to electrical fast transients.
A high-quality 8-wire cable must be used as the extension cable ( V1+, V1- / V2+, V2- and V0+, V0- as
a twisted pair with double shielding) or A, A
¯and B, B ¯and Z, Z ¯with digital signals to RS 422.
It is also recommended when using the sensor near a source of EMC interference, such as a linear
motor, to keep the sensor cable as short as possible. As a general rule, the shorter the cable, the less
sensitivity there is to interference.
Up to a cable length of 500 mm, when the connector described and the prescribed extension cable are
used and the encoder housing is insulated from the machine frame with an insulation level of greater
than 4kV to EN61000-4-4, test severity level 4 is reached.
Table 5.1 shows the assignment of the open cable ends as well as of the optionally available round
connector. Figure 5.1 shows the design of this connector.
In order to prevent EMC interference in the encoder signal, the encoder extension cable must
be shielded and the shielding must be in full contact across the connectors. High-quality,
fully-shielded connectors must be used.
Table 5.1 Cable and connector assignments
Color of the encoder
cable
Round connector
pin no. Signal
Brown 4 and 5 5 V power supply
White 12 and 13 GND / 0 V
Green 9 V1 + / A
Yellow 1 V1 – / A
¯
Blue 10 V2 + / B
Red 2 V2 – / B
¯
Purple 3 Ref + / Z
Gray 11 Ref – / Z
¯
Connector housing Shielding
NOTE

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When the encoder is connected as in table 5.1, the counting direction (with a moving encoder) is as
specified in the assembly instructions (see figures 4.1 and 4.2).
If you wish to have a positive counting direction in the opposite direction, when connecting to the
electronic evaluation system, you must switch "A" with "B and "A
¯with "B ¯".
Figure 5.1
Pin assignment of the round connector
5.2 Subsequent switching
Figures 5.3 and 5.4 show the recommended switching of the subsequent electronic components for the
individual channels for the analog and digital encoders.
Figure 5.3 Recommended switching of the subsequent electronic components
for sin/cos 1Vpp output
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Figure 5.4 Recommended switching of the subsequent electronic components for digital TTL output
5.3 Voltage amplitudes
The output voltage of the encoder (1 Vpp) depends on its distance from the magnetic scale. Figure 5.4
shows the relationship between amplitude and reading distance.
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8
Leseabstand in mm
Spannungs-
amplitude
in V
Recommended
range
for the
reading
di t
Figure 5.4 Voltage amplitude by reading distance
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5.4 Reference switch
The reference switch must be connected according to figure 5.5.
Explanation of symbols
+ Power supply "+"
- Power supply "0V"
A Switch output/opener (NC)
Wire colors
BN Brown
BK Black
BU Blue
Figure 5.5 Circuit diagram of the optional reference switch
6 Putting into operation
Heed the assembly instructions for the other system components (e.g. linear motor, drive amplifier).
NOTE
5When putting the distance measuring system into operation, you must adhere to the following sequence:
¾Connect the encoder.
¾Connect the power supply (5 V).
Do not exceed the operating voltage. This can destroy the encoder.
¾Check the output signal with an oscilloscope, for example.
7 Maintenance
Before and during all maintenance work on a linear motor axis, the distance measuring system,
the linear motor and the associated systems and controls must be disconnected from the power
source, and it must be ensured that the power supply cannot be restored by anyone else.
Otherwise, there is danger of death and significant danger of injury.
The distance measuring system works on a non-contact basis and thus requires no maintenance.
However, it must be checked regularly for soiling and, if necessary, cleaned with a suitable cleanser
(e.g. alcohol). Dirt particles between the encoder and the measuring scale can destroy the distance
measuring system.
Grease the steel parts again to prevent corrosion.
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8 Technical data
8.1 Dimensions
8.1.1 HIWIN MAGIC dimensions
Figure 8.1 Scale drawing of the HIWIN MAGIC encoder
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