GETOtec MAGIC User manual

GETOtec
Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
Assembly Instructions
MAGIC Distance Measuring System
MAGIC Encoders
MAGIC-PG

GETOtec
Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
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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
HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010 3

GETOtec
Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
4HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010
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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Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
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GETOtec
Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
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.
HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010 5
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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.
HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010 7

GETOtec
Schwindstraße 9 Telefon: [phone] [email protected]
D-80798 München Telefax: [phone] www.getotec.de
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8HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010
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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D-80798 München Telefax: [phone] www.getotec.de
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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).
HIWIN_Montageanleitung_MAGIC_V1.1_EN.doc - 10/2010 9

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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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