Hiwin MAGIC-01-14-EN-2207-MA User manual

Assembly instructions
HIWIN MAGIC Distance Measuring Systems
MAGIC-01-14-EN-2207-MA
www.hiwin.de

Assembly instructions Legal information
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 2of 32
Imprint
HIWIN GmbH
Brücklesbünd 1
D-77654 Offenburg, Germany
Phone [phone]
Fax [phone]
[email protected]
www.hiwin.de
All rights reserved.
Reprinting, even in part, is not permitted without our approval.
These assembly instructions are protected bycopyright. Written permission isrequired from
HIWIN GmbH for any duplication, publication in whole orin part, alterations orabridgement.

Assembly instructions Contents
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 3of 32
Contents
1General ........................................................................ 4
1.1 About these assembly instructions................................................ 4
1.2 Presentation and layout conventions used in these assembly instructions ............ 5
1.3 Warranty and liability ............................................................ 6
1.4 Manufacturer information ........................................................ 6
1.5 Product monitoring .............................................................. 6
2Basic safety information......................................................... 7
2.1 Proper use...................................................................... 7
2.2 Exclusion of liability in the event of alteration and improper handling ................. 7
2.3 Qualified personnel.............................................................. 7
2.4 General safety instructions ....................................................... 7
2.5 Safety instructions for storage and transport....................................... 8
2.6 Safety instructions for handling products carrying current and voltage................ 8
2.7 Further information.............................................................. 8
3Product descriptions ............................................................ 9
3.1 HIWIN MAGIC................................................................... 9
3.2 HIWIN MAGIC-PG................................................................ 9
3.3 Connections ................................................................... 10
3.4 Reference switch............................................................... 10
3.5 Scope of delivery............................................................... 10
4Assembly ..................................................................... 11
4.1 Mounting the HIWIN MAGIC ..................................................... 11
4.2 Mounting the HIWIN MAGIC-PG – HG and QH series ............................... 13
4.3 Mounting the HIWIN MAGIC-PG – CG series....................................... 16
4.4 Reference switch............................................................... 21
5Electrical connection ........................................................... 22
5.1 Cable and plug ................................................................. 22
5.2 Sequential control .............................................................. 23
5.3 Voltage amplitude .............................................................. 24
5.4 Reference switch............................................................... 24
6Commissioning ................................................................ 24
7Maintenance................................................................... 25
8Disposal....................................................................... 25
9Spare parts and accessories .................................................... 26
9.1 Article numbers of the individual parts ........................................... 26
9.2 Assembly/disassembly tool for cover strip........................................ 26
9.3 Order code for HIWIN MAGIC-PG linear guideway.................................. 27
9.4 Order code for HIWIN MAGIC .................................................... 29
10 Declaration of conformity....................................................... 30

Assembly instructions General
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1General
1.1 About these assembly instructions
These assembly instructions are intended for planners, developers and operators of systems
into which the described distance measuring systems are to be integrated. It is also addressed
to persons who carry out the following work:
Transport
Assembly
Electrical connection including connection to the higher-level control system
Integration into a safety system
Retrofitting or upgrading
Setup
Commissioning
Operation
Cleaning
Maintenance
Troubleshooting
Decommissioning, disassembly and disposal
1.1.1 Scope of these assembly instructions
These assembly instructions apply to HIWIN distance measuring systems with the following
product designations:
HIWIN MAGIC
HIWIN MAGIC-PG
1.1.2 Requirements
We assume that
Operating personnel are trained in the safe operation of the HIWIN MAGIC and MAGIC-PG
distance measuring systems and have read these assembly instructions and understood
their contents in full
Maintenance personnel maintain and repair the HIWIN MAGIC distance measuring systems
and MAGIC-PG in such a way that they present no danger to persons, the environment or
property
1.1.3 Availability
The assembly instructions must always be available to all persons working with or on the HIWIN
MAGIC and MAGIC-PG distance measuring systems.

Assembly instructions General
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1.2 Presentation and layout conventions used in these assembly
instructions
1.2.1 Instructions for actions
Instructions for actions are provided in sequential order and identified with a triangle symbol.
The results of the actions are accompanied by a tick symbol.
Example:
Fix the encoder by tightening the screws [7] with 1 Nm.
Fasten the wiper [14] to the MAGIC-PG encoder using screws [11], nuts [10] and lock
washers [9] in such a way that the sealing lip rests lightly against the rail contour on all
sides.
The new encoder is mounted.
1.2.2 Lists
Lists are identified through the use of bullet points.
Example:
It is available in two versions:
HIWIN MAGIC: type with separate encoder
HIWIN MAGIC-PG: distance measuring system integrated in a linear guideway
…
1.2.3 Presentation of safety information
Safety notices are always indicated by a signal word and sometimes with a hazard-specific
symbol (see section 1.2.4 Symbols used).
The following signal words/hazard levels are used:
Danger! Immediate danger!
Failure to follow this safety instruction will result in severe or fatal injury!
Warning! Potentially dangerous situation!
Failure to follow this safety instruction could result in severe or fatal injury!
Attention! Potentially dangerous situation!
Failure to follow this safety instruction could result in moderately severe or minor injury!
Caution! Potentially dangerous situation!
Failure to follow this safety instruction could result in damage to property or the environment!
1.2.4 Symbols used
The following symbols are used in these assembly instructions and on the linear axes:
Warning symbols
Warning of dangerous
electrical voltage!
Environmentally
hazardous substance!
1.2.5 Information
Note:
Provides general information and recommendations.

Assembly instructions General
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1.3 Warranty and liability
The manufacturer's "General Terms and Conditions of Sale and Delivery" apply.
1.4 Manufacturer information
Address HIWIN GmbH
Brücklesbünd 1
77654 Offenburg, Germany
Telephone +49 (0) 781 / 9 32 78 - 0
Technical customer service team +49 (0) 781 / 9 32 78 - 77
Fax +49 (0) 781 / 9 32 78 - 90
Technical customer service team fax +49 (0) 781 / 9 32 78 - 97
E-mail [e-mail]
Internet www.hiwin.de
1.5 Product monitoring
Please inform HIWIN, as the manufacturer of the HIWIN MAGIC and MAGIC-PG distance
measuring systems, about:
Accidents
Possible sources of danger on the MAGIC and MAGIC-PG distance measuring systems
Any unclear information in these assembly instructions

Assembly instructions Basic safety information
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2Basic safety information
Warning! Danger due to strong magnetic fields!
This chapter is for the safety of everyone who works with, assembles, installs, operates,
maintains or disassembles the distance measuring systems. Failure to comply with the
following information could be dangerous!
2.1 Proper use
HIWIN MAGIC is a magnetic distance measuring system for positioning tasks with linear
movement within an automated system. It is mainly used in linear motors. The named distance
measuring systems must 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 alteration and improper
handling
No changes whatsoever may be made to the distance measuring systems that are not
described in these assembly instructions. If a modified design is necessary, please contact the
manufacturer.
The manufacturer accepts no liability in the event of modifications or improper assembly,
installation, commissioning, operation, maintenance or repair.
Only original HIWIN parts are permitted as spare parts and accessories. Spare parts and
accessories not supplied by HIWIN have not been tested for operation with HIWIN MAGIC
distance measuring systems and may impair operational safety. The manufacturer accepts no
liability for damage caused by the use of non-approved spare parts and accessories.
2.3 Qualified personnel
The distance measuring system may only be installed, integrated into higher-level systems,
commissioned, operated and maintained by competent personnel. A qualified person is one
who
Has suitable technical training
and
Has been instructed by the machine operator in operation and the valid safety guidelines
and can assess the dangers to be expected
and
Has read through these assembly instructions in full and understood them and has access
to the assembly instructions at all times
2.4 General safety instructions
Warning! Danger of serious or fatal injuries!
Before and during all assembly, disassembly or repair work, the distance measuring
system or the higher-level system must be de-energised and it must be ensured that the
mains connection cannot be re-established by other persons!
The distance measuring systems must not be used in potentially explosive atmospheres.
The distance measuring systems may only be used and operated indoors.

Assembly instructions Basic safety information
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2.5 Safety instructions for storage and transport
The distance measuring systems are delivered in suitable packaging. The systems must be left
in these until they are installed.
The distance measuring systems must be stored in dry areas protected from impacts.
No heavy objects may be placed on the products during storage and transport.
Note:
The measuring tape of the magnetic distance measuring systems must not be exposed to
strong magnetic fields (keep a distance to permanent magnets of linear motor axes!). Strong
vibrations (e.g. a blow with a hammer) can also damage the magnetisation of the measuring
tape.
2.6 Safety instructions for handling products carrying current and
voltage
Note:
Since the sensor is operated with a low voltage, it alone does not normally pose a risk of injury
or death.
2.7 Further information
If you have any questions, please contact our sales organisation:
Tel.: +49 (0) 781 / 9 32 78-0
Fax: +49 (0) 781 / 9 32 78-90
For questions regarding the documentation, suggestions and corrections, please send a fax to
the following fax address:
Tel.: +49 (0) 781 / 9 32 78-90

Assembly instructions Product descriptions
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3Product descriptions
The magnetic distance measuring systems of the MAGIC series are optimised for measuring
the distances travelled in linear movements and particularly on linear motor axes. They are
particularly well-suited for use in harsh environments and are insensitive to oil, dirt, vibration
and shock.
The rugged housing is electrically shielded, the signal output is in real time (for details see
chapter 5 Electrical connection and “Linear motors and distance measuring systems”
catalogue).
It is available in two versions:
HIWIN MAGIC: type with separate encoder
HIWIN MAGIC-PG: distance measuring system integrated in a linear guideway
3.1 HIWIN MAGIC
This distance measuring system consists of a separate encoder (fig. 3.1) and a magnetic
tape(fig. 3.2). Both can be mounted by the customer in suitable positions of their choice.
Fig.
3.1: MAGIC encoder
Fig.
3.2: MAGIC magnetic tape
3.2 HIWIN MAGIC-PG
In this version, the distance measuring system is integrated into a linear guideway. The total
unit is then called the positioning guideway (PG).
The scanning unit is attached to a standard guide carriage, it is suitable for blocks of sizes
HG_20, HG_25, QH_20, QH_25, CG_20, CG_25, CG_30, CG_35 und CG_45. The measuring
standard is integrated directly into a profile rail in the form of a magnetic tape (see Fig. 3.3).
Fig.
3.3: MAGIC-PG system for HG and QH series
Fig.
3.4: MAGIC-PG system for CG series

Assembly instructions Product descriptions
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3.3 Connections
The distance measuring system is connected to a higher-level control system (e.g. servo drive)
with the cable permanently mounted on the encoder. It is supplied with a low voltage of 5 V.
The cable can be supplied with open ends (see Fig. 3.5) or optionally pre-assembled with a
round plug coupling (see Fig. 3.6).
Fig.
3.5: Cable with open ends
Fig.
3.6: Cable with coupling (optional)
3.4 Reference switch
The MAGIC encoder provides index signals at intervals of 1 mm. A reference switch ("cam
switch") is required to define a zero point.
HIWIN offers an inductive proximity switch for this purpose (see Fig. 3.7).
Fig. 3.7: Reference switch on bracket
3.5 Scope of delivery
Depending on customer requirements, the MAGIC and MAGIC-PG distance measuring systems
are offered in different forms and scopes.
Individual components can be supplied for retrofitting existing linear guide systems. HIWIN also
offers the distance measuring systems installed in linear guides as a complete system.
The standard scope of delivery and the optional accessories are shown in Table 3.1. You will
find the order code for systems in section 9 Spare parts and accessories.
Table 3.1: Overview of standard scope of delivery and optional accessories
Distance measuring system MAGIC MAGIC-PG
Encoder Select cable length Select cable length
Magnetic tape (including cover
strip)
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