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
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 4of 32
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
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 7of 32
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
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 8of 32
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
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 9of 32
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
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 10 of 32
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

Assembly instructions Assembly
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4Assembly
Warning! Danger due to electrical voltage!
Dangerous currents may flow before and during assembly, disassembly and repair work.
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!
Observe the assembly instructions of the other system components (e.g. linear motor,
servo drive)!
Caution! Possible damage to the HIWIN MAGIC distance measuring system!
The measuring tape of the magnetic distance measuring systems must not be exposed to
strong magnetic fields. Magnetic dust can falsify the measuring signal or damage the
distance measuring system.
Keep the distance between the distance measuring systems and the permanent magnets
of linear motor axes!
Caution when using magnetic feet (dial gauge holders), e.g. to align the profile rails!
Avoid strong shocks (e.g. use of a hammer)!
Do not use the system in environments with magnetic dust (e.g. graphite dust)!
Caution! Possible damage to the HIWIN MAGIC distance measuring system!
Magnetic chips or other foreign objects may stick to the magnetic tape. This can destroy the
mechanics of the encoder.
Check the air gap between the scanning unit and the measuring standard (magnetic tape)
regularly and keep it free!
Note:
The magnetic tape is fixed to the rail with a high-performance adhesive (exclusively for sizes
HG_20, HG_25, QH_20 and QH_25). The adhesive can be dissolved by certain solvents. If the
adhesive loosens, the magnetic tape may bulge. This must be prevented with specific
measures (e.g. additional clamping of the magnetic tape at the ends).
HIWIN GmbH accepts no liability should a tape come loose from the rail that has not been
secured with the appropriate measures.
4.1 Mounting the HIWIN MAGIC
Fig. 4.1 Illustrates the assembly steps for the HIWIN MAGIC described below.
Fig. 4.1: Structure of the HIWIN MAGIC

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 12 of 32
4.1.1 Mounting the magnetic and cover strip
The magnetic tape can be mounted on a suitable flat surface chosen by the customer parallel to
the direction of movement on the fixed part of the system. The following criteria must be met:
Average roughness value Ra≤ 3.2 µm
Height deviation (parallelism) to the direction of travel of the encoder: ≤ 0.1 mm
Lateral parallelism deviation to the direction of travel of the encoder: ≤ 0.2 mm (ideally use
a reference edge)
The magnetic tape and the cover strip are provided with an adhesive film covered by a
protective tape.
Note:
Only remove the protective tape shortly before or during assembly!
Assembly steps:
Thoroughly clean the surface [1] on which the tape is to be mounted with alcohol or
isopropanol.
Note:
The mounting surface for the magnetic tape must be absolutely clean, dry and free of grease!
This is the only way to ensure a reliable adhesive bond!
Stick on the magnetic tape [2] and press it on using a mounting roller with a force of
approx. 250 N/cm2. Make sure that the tape is neither compressed nor overstretched.
Clean the surface of the magnetic tape as described above.
Stick the cover strip [3] onto the magnetic tape. Make sure that there are no bubbles under
the tape when gluing. Press on the cover strip with a mounting roller with a force of approx.
250 N/cm2.
The magnetic tape and the cover strip are mounted.
Note:
The adhesive strength is created under pressure. The final strength is achieved after approx.
48 hours at room temperature.
4.1.2 Mounting the encoder
Attach the encoder [4] to the moving part of the system so that the reference edge of the
encoder is flush with the edge of the magnetic tape. The reference edge of the encoder is
identified by a mark on the front.
The encoder is mounted.
Note:
The distance between the cover strip and the encoder must be 0.2 ±0.1 mm. The use of a
feeler gauge is recommended for setting the correct distance.
Make sure that the minimum cable bending radius of 40 mm is not undercut!

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 13 of 32
4.2 Mounting the HIWIN MAGIC-PG – HG and QH series
4.2.1 Assembly of the profile rails
Mount the linear guideways according to the “Linear guideways” assembly instructions.
4.2.2 Mounting the magnetic and cover strip
The magnetic and cover strip must be glued in place after the rails have been mounted.
Spare parts required to replace the pressure roller:
1 pc. 8-18-0011 Slide bearing
1 pc. 8-12-0144 Castor
Note:
Check the pressure roller inside the installation aid for any damage before use and replace it if
necessary. Uneven surfaces on the roller can deform and damage the magnetic tape during
installation.
Assembly steps:
Pull the block off the rail.
Note:
For this purpose, use the installation aid supplied to prevent balls from falling out.
Clean the groove thoroughly with alcohol or isopropanol so that it is free of grease and
dust.
Pull the adhesive foil off the magnetic tape. Insert the magnetic tape evenly into the groove
by hand with the adhesive surface facing the profile rail (see Fig. 4.2).
Fig. 4.2: Inserting the magnetic tape
Check in advance that the pressure roller inside the assembly tool is free of grease.
Pull the assembly tool onto the linear guideway using the supplied installation aid (see
“Linear guideways” assembly instructions).
Proceed with the assembly tool a few times along the entire length of the profile rail. Then
remove the assembly tool.

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 14 of 32
Fig. 4.3: Mounting tool for pressing on the magnetic tape
Degrease the surface of the magnetic tape with alcohol or isopropanol.
Stick the cover strip onto the magnetic tape. Make sure that there are no bubbles under the
tape when gluing.
Press the cover strip on with the assembly tool as well.
Grease the rail and cover strip to prevent corrosion and dry running of the sealing lip (light
lubricating film)
Pull the block back onto the rail. Make sure that no balls fall out.
The magnetic tape and the cover strip are mounted.
Note:
The adhesive strength is created under pressure. The final strength is achieved after approx.
48 hours at room temperature.
4.2.3 Mounting the MAGIC-PG encoder
The encoder is delivered pre-assembled on the block as shown in Fig. 4.4. The standard
alignment is shown. The assembly steps apply to all 4 possible orientations of the encoder (see
“Linear motors and distance measuring systems” catalogue). To mount the block on the linear
guideway, please refer to the “Linear guideways” assembly instructions.
Fig. 4.4: MAGIC-PG encoder pre-mounted on the block
Table 4.1: MAGIC-PG – HG and QH series
Art. no. Name Art. no. Name
1 Cover strip 5 Lock washer
2
Screws
6
Nut
3 Wiper 7 Screws
4 Encoder
Note:
When mounting the MAGIC-PG encoder, make sure that the minimum cable bending radius of
40 mm is not undercut!

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 15 of 32
Assembly steps:
The MAGIC-PG encoder must be adjusted in height. Please refer to Fig. 4.4.
Dismantle the wiper [3] by loosening the screws [7].
Set the distance between the cover strip [1] and the MAGIC-PG encoder [4] to 0.2 ±0.1 mm.
To do this, loosen the screws [2]. The use of a feeler gauge is recommended for
adjustment.
Fix the encoder by tightening the screws [2] with 1 Nm.
Fasten the wiper [3] to the MAGIC-PG encoder using screws [7], nuts [6] and the lock
washers in such a way that the sealing lip rests lightly against the rail contour on all sides.
The MAGIC-PG encoder is mounted.
4.2.4 Replacing the MAGIC-PG encoder
Note:
To replace the MAGIC-PG encoder, the block on which the MAGIC-PG encoder is to be replaced
must be mounted on the profile rail.
Note:
The deflection unit [7] must not be disassembled!
Assembly steps:
On the side where the MAGIC-PG encoder [6] is to be replaced, remove the wiper [5] by
loosening the screws [4].
Disassemble the defective MAGIC-PG encoder [6] by loosening the screws [9].
Fig. 4.5: Replacing the MAGIC-PG encoder
Table 4.2: Replacement of MAGIC-PG encoder – HG and QH series
Art. no. Name Art. no. Name
1 Profile rail 6 Encoder
2 Magnetic scale 7 Deflection unit
3 Cover strip 8 Lock washer
4 Screws 9 Screws
5 Wiper 10 Nut

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 16 of 32
Note:
The new MAGIC-PG encoder can be mounted in two directions depending on the desired
counting direction and/or cable output side. The counting direction results as shown in the
“Linear motors and distance measuring system” catalogue when the cable is connected
according to Table 5.1.
Attach the new MAGIC-PG encoder [6] to the recirculation [7] with the screws [9] as well as
the lock washers [8] according to Fig. 4.5. Only lightly tighten the screws [9].
Set the distance between the cover strip [3] and the MAGIC-PG encoder [6] to 0.2 ±0.1 mm.
To do this, loosen the screws [9]. The use of a feeler gauge is recommended for
adjustment.
Fix the encoder by tightening the screws [9] with 1 Nm.
Fasten the wiper [5] to the MAGIC-PG encoder using screws [4], nuts [10] and lock washers
[8] in such a way that the sealing lip rests lightly against the rail contour on all sides.
The MAGIC-PG encoder is replaced.
4.3 Mounting the HIWIN MAGIC-PG – CG series
4.3.1 Assembly of the profile rails
Mount the linear guideways according to the “Linear guideways” assembly instructions.
4.3.2 Mounting the magnetic tape
Pull the block off the rail.
Note:
For this purpose, use the installation aid supplied to prevent balls from falling out.
Clean the groove thoroughly with alcohol or isopropanol so that it is free of grease and
dust.
Insert the magnetic tape with the black side facing upwards (see Fig. 4.6)
Fig. 4.6: Inserting the magnetic tape
The magnetic tape is mounted.
4.3.3 Mounting the cover strip
Note:
For assembled profile rails, the cover strip is delivered in the required length and with finished
ends according to Table 4.3.
Note:
We recommend using the assembly and disassembly tool from HIWIN for mounting the cover
strip. Information on the disassembly tool can be found in section 9.2 Assembly/disassembly
tool for cover strip.
Note:
Mounting the cover strip secures the magnetic tape underneath and protects it from soiling.

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 17 of 32
Clean the cover strip with a suitable cleaning agent.
Place the cover strip on the profile rail
Fig. 4.7: Cover strip with finished ends and distance LS
Table 4.3: Strip end distance
Size Distance LS[mm]
15 5.0
20 8.0
25 9.5
30 10.0
35 10.0
45 11.0
55 12.0
65 14.5
Maintain distance Lsin accordance with Table 4.3.
Starting from one side, clamp the cover strip onto the profile rail over a length of approx. 15
cm.
Press down the cover strip fold on the reference side of the profile rail.
Starting from the front side, press on the second fold of the cover strip.
Fig. 4.8: Fitting the beginning of the tape
The cover strip is resting flush on the upper side of the profile rail.

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 18 of 32
Fig. 4.9: Correctly and incorrectly fitted cover strip
Place the assembly tool on the front side. (See Fig. 4.10)
Push the assembly tool over the entire rail.
Fig. 4.10: Mounting the cover strip using the assembly tool
Carefully bend the two strip ends of the cover strip with a rubber hammer.
Fig. 4.11: Bending over the strip ends
The cover strip has been mounted.

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 19 of 32
4.3.4 Mounting the MAGIC-PG encoder
The encoder is delivered pre-assembled on the block as shown in Fig. 4.12. The standard
alignment is shown. The assembly steps apply to all 4 possible orientations of the encoder (see
“Linear motors and distance measuring systems” catalogue). To mount the block on the linear
guideway, please refer to the “Linear guideways” assembly instructions.
Fig. 4.12: MAGIC-PG encoder pre-mounted on the CG block
Table 4.4: MAGIC-PG – CG series
Art. no. Name Art. no. Name
1 Screws A 5 Screws B
2 Encoder 6 Wiper screw
3 Encoder housing 7 Wiper
4 Cover strip
Note:
When mounting the MAGIC-PG encoder, make sure that the minimum cable bending radius of
40 mm is not undercut!
Note for MAGIC CG_45:
The encoder must be mounted on the same side of the rail as the magnetic tape (the
magnetic tape is not centred in the rail).
An additional cover is mounted on the encoder housing [3].
Assembly steps:
Dismantle the wiper [7] by loosening the screws [6].
Loosen screws A [1] and B [5].
The encoder [2] can now be moved.
Set the distance between the cover strip [4] and the MAGIC-PG encoder [2] to 0.2 ±0.1 mm.
The use of a feeler gauge is recommended for adjustment.
Fix the encoder by tightening screws A [1] and B [5].
Note:
Tighten the screws with a torque of 1 Nm.
Attach the wiper [7] to the MAGIC-PG encoder using screws [6] so that the sealing lip rests
lightly against the rail contour on all sides.
The MAGIC-PG encoder is mounted.

Assembly instructions Assembly
HIWIN MAGIC Distance Measuring Systems MAGIC-01-14-EN-2207-MA Page 20 of 32
4.3.5 Replacing the MAGIC-PG encoder
Fig. 4.13: Replacing the MAGIC-PG encoder (CG)
Table 4.5: Replacing the MAGIC-PG encoder – CG series
Art. no. Name Art. no. Name
1 Screws A 5 Screws B
2 Encoder 6 Wiper screw
3 Encoder housing 7 Wiper
4 Cover strip
Assembly steps:
Loosen and remove screws A [1] and B [5].
Remove the MAGIC-PG encoder [2].
Note:
The new MAGIC-PG encoder can be mounted in two directions depending on the desired
counting direction and/or cable output side. The counting direction results as shown in the
“Linear motors and distance measuring system” catalogue when the cable is connected
according to Table 5.1.
Insert the new MAGIC-PG encoder [2] into the housing [3].
Fasten the new MAGIC-PG encoder [2] with screws A [1] and B [5]. Only lightly tighten the
screws.
Set the distance between the cover strip [4] and the MAGIC-PG encoder [2] to 0.2 ±0.1 mm.
The use of a feeler gauge is recommended for adjustment.
Fix the encoder by tightening screws A [1] and B [5].
Attach the wiper [7] to the MAGIC-PG encoder using screws [6] so that the sealing lip rests
lightly against the rail contour on all sides.
The MAGIC-PG encoder is replaced.