Hiwin MAGIC User manual

Assembly Instructions
HIWIN MAGIC Distance Measuring System
www.hiwin.de

HIWIN GmbH
Brücklesbünd 1
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 Distance Measuring System
MAGIC-01-11-EN-1907-MA
Contents
Contents
1. General information..................................................................................................................... 4
1.1 About these assembly instructions 4
1.2 Depictions used in these assembly instructions 4
1.3 Warranty and liability 6
1.4 Manufacturer’s details 6
1.5 Copyright 6
1.6 Product monitoring 6
2. Basic safety notices.............................................................................................................. 7
2.1 Intended use 7
2.2 Exclusion of liability in the event of alterations and improper use 7
2.3 Qualified personnel 7
2.4 General safety information 7
2.5 Safety information for storage and transportation 7
2.6 Safety information on handling current-carrying, live products 8
2.7 Further 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
4.2 Assembly of the HIWIN MAGIC-PG – HG and QH series 13
4.3 Assembly of the HIWIN MAGIC-PG – CG series 17
4.4 Reference switch 21
5. Electrical connection............................................................................................................22
5.1 Cable and connector 22
5.2 Subsequent switching 23
5.3 Voltage amplitudes 24
5.4 Reference switch 24
6. Commissioning....................................................................................................................25
7. Maintenance .......................................................................................................................25
8. Disposal .............................................................................................................................25
9. Technical data .....................................................................................................................26
9.1 Orientation of the HIWIN MAGIC-PG encoder 26
9.2 Dimensions 27
9.3 Technical data of the MAGIC encoder 31
9.4 Technical data of the magnetic scale 33
9.5 Technical data of the reference switch 34
10. Spare parts and accessories .................................................................................................35
10.1 Article numbers of the individual parts 35
10.2 Mounting/removing tool for cover strip 35
10.3 Order code for HIWIN MAGIC-PG linear guideway 36
10.4 Order code for HIWIN MAGIC 37
11. EC Declaration of Conformity.................................................................................................38

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
General information
1. General information
1.1 About these assembly instructions
These assembly instructions are intended for planners, developers and operators of systems into which the distance measur-
ing system 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
1.1.1 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
1.1.2 Requirements
We assume that
|operating personnel are trained in the safe operation practices for HIWIN distance measuring systems MAGIC and
MAGIC-PG and have read and understood these assembly instructions in full;
|maintenance personnel maintain and repair the HIWIN distance measuring systems MAGIC and MAGIC-PG in such a
way that they pose no danger to people, property or the environment.
1.1.3 Availability
These assembly instructions must remain constantly available to all persons who work with or on the HIWIN distance
measuring systems MAGIC and MAGIC-PG.
1.2 Depictions used in these assembly instructions
1.2.1 Instructions
Instructions are indicated by triangular bullet points in the order in which they are to be carried out.
Results of the actions carried out are indicated by ticks.
Example:
XFix the encoder by tightening the screws [7] with 1 Nm.
XFasten the end seal [14] onto the MAGIC-PG encoder [5] using screws [11], nuts [10] and lock washers [9]. Make
sure that the end seal’s complete sealing lip lightly touches the outline of the profile rail.
 The MAGIC-PG encoder has now been mounted.

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
General information
1.2.2 Lists
Lists are indicated by bullet points.
Example:
Two types are available:
|HIWIN MAGIC: type with separate encoder
|HIWIN MAGIC-PG: distance measuring system integrated in a linear guideway
|…
Imminent danger!
Noncompliance with the safety notices will result in serious injury or death!
DANGER!
Potentially dangerous situation!
Noncompliance with the safety notices runs the risk of serious injury or death!
WARNING!
Potentially dangerous situation!
Noncompliance with the safety notices runs the risk of slight to moderate injury!
CAUTION!
Potentially dangerous situation!
Noncompliance with the safety notices runs the risk of damage to property or environmental pollution!
ATTENTION!
1.2.3 Depiction of safety notices
Safety notices are always indicated using a signal word and sometimes also a symbol for the specific risk (see Section 1.2.4,
“Symbols used”).
The following signal words and risk levels are used:
1.2.4 Symbols used
The following symbols are used in these assembly instructions:
Table 1.1 Warning signs
Substance hazardous to the
environment!
Warning of dangerous electrical voltage!
1.2.5 Information
NOTE
Describes general information and recommendations.

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
General information
1.3 Warranty and liability
The manufacturer’s “General conditions of sale and delivery” apply.
1.4 Manufacturer’s details
Address HIWIN GmbH
Brücklesbünd 1
D-77654 Offenburg
Phone +49 (0) 781 / 9 32 78 - 0
Technical customer service +49 (0) 781 / 9 32 78 - 77
Fax +49 (0) 781 / 9 32 78 - 90
Technical customer service fax +49 (0) 781 / 9 32 78 - 97
E-mail [email protected]
Website www.hiwin.de
Table 1.2 Manufacturer’s details
1.5 Copyright
These assembly instructions are protected by copyright. Any reproduction, publication in whole or in part, modification or
abridgement requires the written approval of HIWIN GmbH.
1.6 Product monitoring
Please inform HIWIN, the manufacturer of the HIWIN distance measuring systems MAGIC and MAGIC-PG of:
|Accidents
|Potential sources of danger in the distance measuring systems MAGIC and MAGIC-PG
|Anything in these assembly instructions which is difficult to understand

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Basic safety notices
2. Basic safety notices
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.
WARNING!
2.1 Intended 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, 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 Qualified personnel
The distance measuring system may only be assembled, integrated into higher-level systems, put into operation, operated
and maintained by qualified personnel. Qualified personnel are those 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
Danger of serious or fatal injuries!
XBefore and during all assembly, disassembly or repair work, the distance measuring system and/or the higher-level
system must be disconnected from the power supply, and you must ensure that the power supply cannot be restored
by anyone else!
XThe distance measuring systems must not be used in hazardous areas where there is risk of explosions!
XThe distance measuring systems may only be used and operated indoors!
WARNING!
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.

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Basic safety notices
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
The distance measuring sensor is operated at a low voltage, so there is not normally any risk of injuries or
fatalities from this alone.
NOTE
2.6 Safety information on handling current-carrying, live products
2.7 Further information
If you have any questions, please contact our sales organisation:
Phone:+49 (0) 781 / 9 32 78-0
Fax: +49 (0) 781 / 9 32 78-90
If you have questions, suggestions or corrections concerning the documentation, please send a fax to the following number:
+49 (0) 781 / 9 32 78-90

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Product descriptions
3. Product descriptions
The magnetic distance measuring systems of the HIWIN MAGIC series are optimised for measuring the distances travelled in
linear movements and particularly on linear motor axes. They are particularly suitable for use in harsh environmental condi-
tions 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 9 for more information).
Two types are available:
|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 scale (Fig. 3.2). The customer can
select suitable positions for both of these and install them.
Fig. 3.1 MAGIC encoder Fig. 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, HG-25, QH-20 ,QH-25, CG-20 and CG-25 blocks. A magnetic
scale is integrated directly in a profile rail (see Fig. 3.3).
Fig. 3.3 MAGIC-PG system for HG and QH blocks Fig. 3.4 MAGIC-PG system for CG blocks

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Product descriptions
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 Fig. 3.5) or optionally converted finished with round plug coupling (see Fig.
3.6).
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 Fig. 3.7).
Fig. 3.5 Connection cable with open ends
Fig. 3.6 Cable with coupling (optional)
Fig. 3.7 Reference switch on mounting