Hiwin MAGIC User manual

Assembly Instructions
HIWIN MAGIC Positioning Measurement Systems
www.hiwin.de

HIWIN GmbH
Brücklesbünd 2
D-77654 Offenburg
Phone [phone]
Fax [phone]
[email protected]
www.hiwin.de
All rights reserved.
Complete or partial reproduction
is not permitted without our permission.
These assembly instructions are protected by copyright.
Any reproduction, publication in whole or in part, modi-
fication or abridgement requires the written approval of
HIWIN GmbH.

Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Contents
Contents
1. Information about this document 4
1.1 Applicability of these assembly instructions 4
1.2 Symbols used 4
2. Safety 5
2.1 Proper use 5
2.2 Exclusion of liability in the event of alterations and improper use 5
2.3 Experienced personnel 5
2.4 General safety information 5
2.5 Safety information for storage and transportation 5
2.6 Safety information on handling current-carrying, live products 6
2.7 Additional information 6
3. Product descriptions 6
3.1 HIWIN MAGIC 6
3.2 HIWIN MAGIC-PG 7
3.3 Connection 7
3.4 Reference switch 8
3.5 Scope of delivery 8
4. Assembly 9
4.1 Assembly of the HIWIN MAGIC 9
4.2 Assembly of the HIWIN MAGIC-PG 10
4.3 Reference switch 13
5. Electrical connection 14
5.1 Cable and connector 14
5.2 Subsequent switching 15
5.3 Voltage amplitudes 16
5.4 Reference switch 16
6. Putting into operation 17
7. Maintenance 17
8. Technical data 18
8.1 Orientation of the HIWIN MAGIC-PG encoder 18
8.2 Dimensions 19
8.3 Technical data of the MAGIC encoder 21
8.4 Technical data of the magnetic scale 23
8.5 Technical data of the reference switch 24
9. Spare parts and article numbers 25
9.1 Article numbers of the individual parts 25
9.2 Order code for HIWIN MAGIC-PG linear guideway 26
9.3 Order code for HIWIN MAGIC 27
10. EC Declaration of Conformity 28

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Information about this document
1.2 Symbols used
The following symbols are used in these instructions.
1. Information about this document
These assembly instructions are intended for planners, developers and operators of systems into which the positioning
measurement 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 positioning measurement systems with the following product designa-
tions:
HIWIN MAGIC
HIWIN MAGIC-PG
Note: Notes serve to protect the positioning measurement system or other components or provide
hints for efficient work processes.
NOTE
Work instructions: Work instructions are marked with the checklist symbol. The actions described
must be carried out and adhered to in the sequence given.
Potentially dangerous situation!
Warnings serve to protect people against concrete or possible dangers to life and health.
It is absolutely imperative that warnings are heeded.
WARNING!

5
Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Safety
2. Safety
2.1 Proper use
The HIWIN MAGIC is a magnetic positioning measurement system for measuring tasks with linear movement within an
automated system. It is used, above all, in linear motors.
The positioning measurement systems named may not be used outdoors or in hazardous areas where there is a risk of explo-
sions. The positioning measurement 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 positioning measurement 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, 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 positioning measurement 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 positioning measurement system may only be assembled, integrated into higher-level systems, put into operation, oper-
ated 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 guide-
lines 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 positioning measurement system or complete system
must be switched to zero current, and you must ensure that the power supply cannot be restored by anyone else. Other-
wise, there is a danger of death and injury.
The positioning measurement systems must not be used in hazardous areas where there is risk of explosions.
The positioning measurement 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 positioning measurement systems are shipped in suitable packaging. The systems
must be left in this packaging until they are built.
The positioning measurement 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.
Note:
The measuring scale of the magnetic positioning measurement 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
This chapter serves the safety of everybody who is present in the area around mobile systems and as-
sembles, installs, connects, operates, maintains or disassembles the positioning measurement systems
described.
WARNING!

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Safety/Product descriptions
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 unfavourable 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 positioning measurement sensor is operated at a low voltage, so there is not normally any risk of
injuries or fatalities from this alone.
WARNING!
2.6 Safety information on handling current-carrying, live products
2.7 Additional information
If you have any questions, please contact our sales organization:
Phone:+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
3. Product descriptions
The magnetic positioning measurement systems of the HIWIN MAGIC series are optimised for measuring the distances trav-
elled 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 5 and 8 for more information).
Two types are available:
HIWIN MAGIC: type with separate encoder
HIWIN MAGIC-PG: positioning measurement system integrated in a linear guideway
Note:
The measuring scale of the magnetic measurement 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.
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 positioning measurement system.
NOTE
3.1 HIWIN MAGIC
This positioning measurement 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

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Product descriptions
3.2 HIWIN MAGIC-PG
For this type, the positioning measurement 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, HG-25, QH-20 and QH-25 blocks. A magnetic scale is
integrated directly in a profile rail (see Figure 3.3).
3.3 Connection
The positioning measurement 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 3.3 Linear guideway with MAGIC-PG system
Figure 3.4 Connection cable with open ends Figure 3.5 Cable with coupling (optional)
Note:
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).
HIWIN GmbH assumes no liability if a scale that was not secured by means of suitable measures should come loose from
the rail.
NOTE

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Product descriptions
3.5 Scope of delivery
Depending on customer requirements, the positioning measurement 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 positioning measurement systems integrated in linear guideways as a complete system.
The standard scope of delivery and the optional accessories are shown in Table 3.1. 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.
Positioning measurement 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
Table 3.1 Overview of the standard scope of delivery and optional accessories
3.4 Reference switch
The MAGIC encoder delivers index signals at a distance of 1mm. 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).
Figure 3.6 Reference switch on mounting

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Assembly
4. Assembly
Note:
The measuring scale of the magnetic positioning measurement 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 positioning measurement system.
Note:
The numbers used for identification in the assembly instructions are also shown in the item overview in Section 9.1 in order
to make it easier to select individual parts.
NOTE
NOTE
4.1 Assembly of the HIWIN MAGIC
The following assembly steps for the HIWIN MAGIC are shown in Figure 4.1.
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 ≤ 3.2µm
Difference in height (parallelism) in relation to the direction of movement of the encoder: ≤ 0.1mm
Lateral parallel deviation in relation to the direction of movement of the encoder ≤ 0.2mm (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!
Before and during all assembly, disassembly or repair work on a linear motor axis, the positioning measure-
ment 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 positioning measurement sensor is operated at a low voltage, so there is not normally any risk of injuries
or fatalities from this alone.
WARNING!
Positive counting direction
[1]
[4] [3]
[2]
0.2 ±0.1
flush

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Assembly
4.2 Assembly of the HIWIN MAGIC-PG
The following assembly steps for the HIWIN MAGIC-PG are shown in Figure 4.2.
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
The magnetic scale and protective cover tape must be stuck on after the rails are installed.
Note:
Prior to use the pressure roller of the fitting tool has to be checked for possible damages and has to be replaced if neces-
sary. Unevenness on the roller might deform and damage the magnetic scale during assembly.
Parts required to replace the pressure roller:
1 pcs 8-18-0011 slide bearing
1 pcs 8-12-0144 roller
Assembly steps:
The profile rail must be fitted as described in the assembly instructions for linear guideways.
Pull the block from the rail (using the tool provided in order to prevent balls from falling out).
Clean the groove thoroughly with alcohol or acetone so that it is free of grease and dust.
Pull the adhesive film from the magnetic scale. Insert the magnetic scale in the groove by hand with the adhesive
surface against the profile rail.
NOTE
Assembly steps:
Clean the surface [1] to which the tape is to be fastened thoroughly with alcohol or acetone.
Note:
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.
Glue on the magnetic scale [2], and then use a mounting roller to press it on with a force of approx. 250N/cm2. Ensure
that the tape is neither compressed nor overstretched.
Clean the surface of the magnetic scale as described above.
Glue the protective cover tape [3] onto the magnetic scale. Make sure that no bubbles form under the tape during glu-
ing. 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.
NOTE
4.1.2 Assembly of the encoder
The encoder [4] is mounted on the moving part of the system, so that the stop edge of the encoder is flush with the edge of
the magnetic scale. The stop edge of the encoder is indicated by a mark on the front side.
Note:
The distance between the stainless steel protective cover tape and the encoder must be 0.2 ± 0.1mm.
It is advisable to use a feeler gauge to set the correct distance.
Make sure that the minimum cable bending radius of 40mm is not underrun.
NOTE

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Assembly
Figure 4.2 Inserting the magnetic scale
Install the fitting tool on the profile rail using the tool provided. First check that the fitting toolʼs pressure roller 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.
Figure 4.3 Fitting tool for pressing down on the magnetic scale
Use alcohol or acetone to remove the grease from the surface of the magnetic scale.
Glue 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.
Grease rail and cover tape to prevent corrosion and dry operation of the end seal (thin lubricating film)
Pull 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.
NOTE

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Assembly
4.2.3 Assembly of the MAGIC-PG encoder
As shown in Figure 4.4, the encoder is delivered pre-assembled at the block. Shown is the default orientation. The assembly
steps below apply to all 4 possible orientations of the encoder (see also Section 8.1). For the assembly of the block on the
rail, please refer to the “Assembly Instructions Linear Guideways”.
[13]
[5]
[7]
Figure 4.4 MAGIC-PG encoder, pre-assembled at the block
[5] Encoder
[7] Screws
[13] Cover tape
The height of the encoder must be adjusted (please refer to Figure 4.4).
Remove the end seal [14] by loosening the screws [11].
Adjust the distance between the cover tape [13] and the MAGIC-PG encoder [5] to 0.2 ±0.1 mm. It is recom-
mended to use a feeler gauge to set the correct distance.
Fix the encoder by tightening the screws [7] with 1 Nm.
Fasten the end seal [14] onto the MAGIC-PG encoder [5] using screws [11], nuts [10] and lock washers [9]. Make sure
that the end sealʼs complete sealing lip lightly touches the outline of the profile rail.
Figure 4.5 Replacement of the MAGIC-PG encoder
[5]
[8]
[14]
[13]
[12]
[6]
[11] [9] [10]
[7][9]
4.2.4 Replacement of the MAGIC-PG encoder
Note:
To replace the MAGIC-PG encoder, the block with the MAGIC-PG encoder that should be replaced, has to be mounted on the
profile rail.
On the side where the MAGIC-PG encoder [5] should be replaced, remove the end seal [14] by loosening the screws [11].
Remove the defective MAGIC-PG encoder [5] by loosening the screws [7].
Do not disassemble the recirculation unit [8]!
[5] Encoder
[6] Profile rail
[7] Screw
[8] Recirculation unit
[9] Lock washer
[10] Nut
[11] Screw
[12] Magnetic scale
[13] Cover tape
[14] End seal
NOTE

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Assembly
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 2mm (see the technical data in Section 8.5).
Figure 4.6 Reference switch and cam switch (linear motor axis installation example)
The MAGIC-PG encoder can be mounted in two directions – depending on the desired counting direction and/or cable
outlet side. The counting direction is as shown in Section 8.1 if the cable is connected as in Table 5.1.
Fasten the new MAGIC-PG encoder [5] onto the recirculation unit [8] using the screws [7] and the lock washers [9] (see
Figure 4.5). Do not tighten screws [7] all the way
Adjust the distance between the cover tape [13] and the MAGIC-PG encoder [5] to 0.2 ±0.1 mm. It is recom-
mended to use a feeler gauge to set the correct distance.
Fix the encoder by tightening the screws [7] with 1 Nm.
Fasten the end seal [14] onto the MAGIC-PG encoder [5] using screws [11], nuts [10] and lock washers [9]. Make sure
that the end sealʼs complete sealing lip lightly touches the outline of the profile rail.
Note:
When assembling the MAGIC-PG encoder, ensure that you do not violate the connecting cableʼs minimum bending radius of
40 mm.
NOTE

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Electrical connection
5. Electrical connection
Note:
Do not operate the sensor with a voltage other than the one specified. This can destroy it.
5.1 Cable and connector
The maximum length of the cable for the encoder is 5 meters. 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.
For HIWIN linear motor axes, and in general for all highly dynamic applications we recommend our pre-assembled extension
cables that are specifically designed for dynamic use in drag chains. The high-quality 8-wire cables (each: V1+, V1– / V2+,
V2– and V0+, V0– and B, B
¯and Z, Z ¯with digital signals to RS 422 as a twisted pair with double shielding) are shipped with a
round connector (coupling, female) on one side or customer-specific.
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 500mm, 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.
Note:
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.
NOTE
NOTE
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 unfavourable 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 positioning measurement sensor is operated at a low voltage, so there is not normally any risk of injuries
or fatalities from this alone.
WARNING!
Colour of the encoder cable Round connector pin no. Signal
Brown 4 and 5 5V power supply
White 12 and 13 GND/ 0V
Green 9V1+/ A
Yellow 1V1–/ Ā
Blue 10 V+/ B
Red 2V–/ B
¯
Purple 3Ref+/ Z
Gray 11 Ref–/Z
¯
Connector housing Shielding
Table 5.1 Cable and connector assignments

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Electrical connection
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 Figure 4.1 and Figure 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 “Ā” with “B
¯”.
1
212
11
10
9
8
7
6
5
4
313
14
15 16
17
Figure 5.1 Pin assignment of the round connector
5.2 Subsequent switching
Figure 5.2 and Figure 5.3 show the recommended switching of the subsequent electronic components for the individual chan-
nels for the analog and digital encoders.
Figure 5.2 Recommended switching of the subsequent electronic components for sin/cos 1VPP output
Figure 5.3 Recommended switching of the subsequent electronic components for digital TTL output
A-channel
V1-channel
B-channel
V2-channel
Reference-channel
V0-channel
GND
GND GND
GND
V1+
V1–
V0+
V0–
V2+
V2–
R4
47
47
3
2
3
2
6
U1 6
U2
R2 R6
R5
R7
R8
R1
R3
–
+
47
3
2–
+
–
+
120Ω
120Ω
120Ω
Z1
Z3
Z2
R14
R12
R11
R9 U3 6
R10
R13 +5V
4,7k 4,7k
A-channel B-channel
Reference-channel
GND
RS422
+5V
GND
RS422
+5V
GND
RS422
+5V
B
B
–
120Ω
Z1
A
A
–
Z
Z
–
120Ω
Z0
120Ω
Z2

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Electrical connection
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 0.1
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
0.2 0.3 0.4 0.5 0.6 0.7
0.8
Reading Distance [mm]
Recommended range
for the reading distance
Voltage Amplitude [V]
R
ecommen
d
e
d
range
f
or the readin
g
distanc
e
BN
BK
BU
Ā
Figure 5.4 Voltage amplitude by reading distance
5.4 Reference switch
The reference switch must be connected according to Figure 5.5.
Explanation of symbols
+Power supply “+”
–Power supply “0V”
Ā Switch output/opener (NC)
Wire colours
BN Brown
BK Black
BU Blue
Figure 5.5 Circuit diagram of the optional reference switch

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Putting into operation/Maintenance
6. Putting into operation
Note:
Read the assembly instructions for the other system components (e.g. linear motor, drive amplifier).
When putting the positioning measurement system into operation, you must adhere to the following sequence:
Connect the encoder.
Connect the power supply (5 V).
Do not exceed the operating voltage. This can destroy the encoder.
Check the output signal with an oscilloscope, for example.
NOTE
7. Maintenance
The positioning measurement 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 positioning measurement system.
Grease the steel parts again to prevent corrosion.
Before and during all maintenance work on a linear motor axis, the positioning measurement 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.
WARNING!

18
Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Technical data
8. Technical data
8.1 Orientation of the HIWIN MAGIC-PG encoder
According to the order code (see Section 9.2) the HIWIN MAGIC-PG encoder is available in the orientations 1 to 4. Without a
statement about the required orientation the encoder is delivered by default (orientation 1).
For more blocks on one rail or on a pair of rails the encoder is mounted to block 1 on rail 1 (see Figure below). If a non-
standard orientation is needed, it has to be defined on the MAGIC-PG project planning sheet (www.hiwin.de).
Orientation 2
Rail 1
Rail 2
Orientation 4
Block 1
Block 1
Block 2
Block 2
Block n
Block n
...
...
Orientation 1
Orientation 3
Stop edge

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Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Technical Data
Signal cable
Counting direction
Ø 5.3
Sensor position Magnetic scale
incl. protective cover tape
2-M3 × 0.5p-thru
14
45
11.5
385.3
± 0.1
10 ± 0.1
1
12
(Distance)
1.85 ± 0.15
0,2 ± 0.1
Align the reference
edge of the encoder
flush with the
magnetic scale
L
B1
L1
B
H1
H
Unit: mm
8.2 Dimensions
8.2.1 HIWIN MAGIC dimensions
Figure 8.1 Scale drawing of the HIWIN MAGIC encoder
8.2.2 HIWIN MAGIC-PG dimensions
Figure 8.2 Scale drawing of the HGH20CA block including the MAGIC-PG housing
Figure 8.2 shows an HGH20CA / HGH25CA block. It is also possible to use the modules with HG20, HG25, QH20 and QH25
block sizes (long type and flange type, see the “Linear Guideways” catalogue). The overall dimensions then change accord-
ingly. The dimensions of all block sizes are shown in Table 8.1.
HG_20C HG_20H HG_25C HG_25H QH_20C QH_20H QH_25C QH_25H
L118.0 132.7 123.0 143.6 115.7 130.4 122.4 143.0
L1 41.5 41.5 39.0 39.0 39.0 39.0 39.0 39.0
B44.0 44.0 48.0 48.0 44.0 44.0 48.0 48.0
B1 43.0 43.0 46.4 46.4 43.0 43.0 46.4 46.4
H30.0 30.0 40.0 40.0 30.0 30.0 40.0 40.0
H1 4.6 4.6 5.5 5.5 4.6 4.6 5.5 5.5
Unit: mm
Table 8.1 Dimensions of the block sizes including MAGIC-PG housing

20
Assembly Instructions
HIWIN MAGIC Positioning Measurement System
MAGIC-01-8-EN-1606-MA
Technical data
8.2.3 PG-rail dimensions
Rail with groove, mounting from above
Rail with groove, mounting from below
Series/Size d
[mm]
D
[mm]
h
[mm]
HR
[mm]
WR
[mm]
P
[mm]
Max. length
[mm]
Max. length
E1= E2[mm]
E1/2 min
[mm]
E1/2 max
[mm]
Weight
[kg/m]
HGR20R G1 6.0 9.5 8.5 17.5 20.0 60.0 4,000 3,900 7 53 2,05
HGR25R G1C 6.0 9.5 8.5 22.0 23.0 60.0 4,000 3,900 7 53 3,05
Series/Size S h
[mm]
HR
[mm]
WR
[mm]
P
[mm]
Max. length
[mm]
Max. length
E1= E2[mm]
E1/2 min
[mm]
E1/2 max
[mm]
Weight
[kg/m]
HGR20T G1 M6 10.0 17.5 20.0 60.0 4,000 3,900 7 53 2,13
WR
HR
Ød
ØD
h
P E2 E1
L
Table 8.2 Dimensions of HGR_R G1
Table 8.3 Dimensions of HGR_T G1
h
S
H
R
WR
PE2 E1
L
Series/Size Screw size Torque [Nm]
HGR20R G1 M5 × 16 9
HGR20T G1 M6 13
HGR25R G1C M5 × 20 9
Table 8.4 Tightening torques of the mounting bolts according to ISO 4762-12.9