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

9
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

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Product descriptions
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.
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 10.1, and the order codes for systems are shown in Section 10.3.
Distance measuring system MAGIC MAGIC-PG
Encoder Select cable length Select cable length
Magnetic scale
(incl. stainless steel protective 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
Table 3.1 Overview of the standard scope of delivery and optional accessories

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
4. Assembly
Danger from electrical voltage!
Before and during assembly, disassembly and repair work, dangerous currents may flow.
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!
XHeed the assembly instructions for the other system components (e.g. linear motor, drive amplifier)!
WARNING!
Damage to the HIWIN MAGIC distance measuring systems!
The measuring scale of the magnetic distance measuring systems must not be subjected to any strong magnetic fields!
Magnetic dust can falsify the encoder signal or damage the distance measuring system!
XKeep the distance measuring system away from permanent magnets of linear motor axes!
XExercise caution when using magnetic devices (gauge holders) to align the profile rails, for example!
XAvoid strong shocks (e.g. hammer blows)!
XDo not use the system in environments where there is magnetic dust (e.g. graphite dust)!
ATTENTION!
Damage to the HIWIN MAGIC distance measuring systems!
Magnetic chippings or other foreign materials can get left on the magnetic scale. This can mechanically destroy the
encoder.
XRegularly check the air gap between the encoder and the magnetic scale and keep it clear.
ATTENTION!
4.1 Assembly of the HIWIN MAGIC
The following assembly steps for the HIWIN MAGIC are shown in Fig. 4.1.
Fig. 4.1 Assembly of the HIWIN MAGIC
The magnetic scale is adhered to the rail using a high-strength glue (only for the HG-20, HG-25. QH-20 and QH-25
blocks). 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
Positive counting direction
[1]
[4] [3]
[2]
0,2 ±0,1
flush

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
4.1.1 Assembly of the magnetic and protective cover strip
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
≤
3.2 µm
|Difference in height (parallelism) in relation to the direction of movement of the encoder:
≤
0.1 mm
|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 strip are coated with an adhesive film covered by a protective tape.
Assembly steps:
XClean the surface [1] to which the tape is to be fastened thoroughly with alcohol or isopropyl alcohol.
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.
XGlue on the magnetic scale [2], and then use a mounting roller to press it on with a force of approx. 250 N/cm2.
Ensure that the tape is neither compressed nor overstretched.
XClean the surface of the magnetic scale as described above.
XGlue the protective cover strip [3] onto the magnetic scale. Make sure that no bubbles form under the tape during
gluing. Use a mounting roller to press the protective cover strip with a force of approx. 250 N/cm2.
 The magnetic scale and the cover strip have now been mounted.
The bond strengthens under pressure. The final strength is obtained after approx. 48 hours at room temperature.
NOTE
NOTE
4.1.2 Assembly of the encoder
XMount the encoder [4] 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.
 The encoder has now been mounted.
The distance between the stainless steel protective cover strip and the encoder must be 0.2 ± 0.1 mm.
It is advisable to use a feeler gauge to set the correct distance.
Make sure that the minimum cable bending radius of 40 mm is not underrun.
NOTE
4.2 Assembly of the HIWIN MAGIC-PG – HG and QH series
4.2.1 Assembly of the profile rails
XFit 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 strip
The magnetic scale and protective cover strip must be stuck on after the rails are installed.
Parts required to replace the pressure roller:
1 pcs 8-18-0011 slide bearing
1 pcs 8-12-0144 roller
Only remove the protective tape shortly before or during assembly!
NOTE
Prior to use, the pressure roller inside the fitting tool has to be checked for possible damages and has to be
replaced if necessary. Unevenness on the roller might deform and damage the magnetic scale during assembly.
NOTE

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
Fig. 4.2 Inserting the magnetic scale
XFirst check that the pressure roller inside the fitting tool is free of grease.
XSlide the fitting tool onto the profile rail using the assembly aid provided.
XRun the fitting tool along the whole length of the profile rail a number of times. Then remove the fitting tool.
Fig. 4.3 Fitting tool for pressing down on the magnetic scale
XUse alcohol or isopropyl alcohol to remove grease from the surface of the magnetic scale.
XGlue the cover strip onto the magnetic scale. Make sure that no bubbles form under the tape during gluing.
XPress the cover strip down using the fitting tool.
XGrease rail and cover strip to prevent corrosion and dry operation of the end seal (thin lubricating film)
XPull the block onto the rail again. Ensure no balls fall out while you are doing this.
 The magnetic scale and the cover strip have now been mounted.
The bond strengthens under pressure. The final strength is obtained after approx. 48 hours at room temperature.
NOTE
Assembly steps:
XPull the block from the rail.
Using the assembly aid provided in order to prevent balls from falling out.
NOTE
XClean the groove thoroughly with alcohol or isopropyl alcohol so that it is free of grease and dust.
X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 (see Fig. 4.2).

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
4.2.3 Assembly of the MAGIC-PG encoder
As shown in Fig. 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 9.1). For the assembly of the block on the
rail, please refer to the Assembly Instructions “Linear Guideways”.
Fig. 4.4 MAGIC-PG encoder, pre-assembled at the block
Assembly steps:
The height of the encoder must be adjusted (please refer to Fig. 4.4).
XRemove the end seal [3] by loosening the screws [7].
XAdjust the distance between the cover strip [1] and the MAGIC-PG encoder [4] to 0.2 ±0.1 mm. It is recommended to
use a feeler gauge to set the correct distance.
XFix the encoder by tightening the screws [2] with 1Nm.
XFasten the end seal [3] onto the MAGIC-PG encoder [4] using screws [7], nuts [6] and lock washers [5]. 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.
[1]
[3]
[4]
[2] [5]
[7]
[6]
Positive counting direction
Pos. Designation Pos. Designation
1Cover strip 5Lock washer
2Screws 6Nut
3End seal 7Screws
4Encoder
Table 4.1 MAGIC-PG – HG and QH series
When assembling the MAGIC-PG encoder, ensure that you do not violate the connecting cable’s minimum bend-
ing radius of 40mm.
NOTE

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
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 9.1 if the cable is connected as in Table 5.1.
XFasten the new MAGIC-PG encoder [6] onto the recirculation unit [7] using the screws [9] and the lock washers [8]
(see Fig. 4.5). Do not tighten screws [9] all the way
XAdjust the distance between the cover strip [3] and the MAGIC-PG encoder [6] to 0.2 ±0.1mm. It is recom-
mended to use a feeler gauge to set the correct distance.
XFix the encoder by tightening the screws [9] with 1Nm.
XFasten the end seal [5] onto the MAGIC-PG encoder [6] using screws [4], nuts [10] and lock washers [8]. Make sure
that the end seal’s complete sealing lip lightly touches the outline of the profile rail.
NOTE
 The MAGIC-PG encoder has now been replaced.
4.2.4 Replacement of the MAGIC-PG encoder
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.
Do not disassemble the recirculation unit [7]!
Assembly steps:
XOn the side where the MAGIC-PG encoder [6] should be replaced, remove the end seal [5] by loosening the screws [4].
XRemove the defective MAGIC-PG encoder [6] by loosening the screws [9].
NOTE
NOTE
Pos. Designation Pos. Designation
1Profile rail 6Encoder
2Magnetic scale 7Recirculation unit
3Cover strip 8Lock washer
4Screws 9Screws
5End seal 10 Nut
Table 4.2 Replacement of MAGIC-PG encoder – HG and QH series
Fig. 4.5 Replacement of the MAGIC-PG encoder
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[8]
[9]
[10]

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
4.3 Assembly of the HIWIN MAGIC-PG – CG series
4.3.1 Assembly of the profile rails
XFit the profile rails as described in the assembly instructions for the linear guideways
4.3.2 Assembly of the magnetic scale
XPull the block from the rail.
Fig. 4.6 Inserting the magnetic scale
4.3.3 Mounting the cover strip
Fig. 4.7 Cover stripe with finished ends and distance LS
In the case of fully assembled profile rails, the cover strip is delivered in the required length and with finished
ends in accordance with Table 4.3.
NOTE
XClean the cover strip with a suitable cleaning agent.
XCenter the cover strip on the profile rail
For removal of the cover strip we recommend the use of the mounting and removing tool from HIWIN. See Sec-
tion 10.2 for information on the removing tool.
NOTE
By the installation of the cover strip, the magnetic tape underneath is secured and protected against dirt.
NOTE
L
S
Using the assembly aid provided in order to prevent balls from falling out.
NOTE
XClean the groove thoroughly with alcohol or isopropyl alcohol so that it is free of grease and dust.
XPull the adhesive film from the magnetic scale. Insert the magnetic scale in the groove by hand with the adhesive
surface against the profile rail (see Fig. 4.6)
 The magnetic scale and the cover strip have now been mounted.

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
Table 4.3 Dimension LS of cover strip end
XAdhere to the distance LSaccording to Table 4.3.
XClip the cover strip onto the profile rail, starting from one side, over a length of approx. 15 cm.
XPress down the fold of the cover strip first on the reference side of the profile rail.
XPress down the second fold of the cover strip starting from the front
Fig. 4.8 Starting to mount the cover strip
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
XPlace the mounting tool on the front side of the rail (see Fig. 4.10)
XSlide the mounting tool over the entire rail
 The masking tape rests flush on the upper side of the profile rail.
Fig. 4.9 Correctly and incorrectly installed cover strip
Fig. 4.10 Mounting the cover strip using the HIWIN mounting tool

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
XCarefully bend the two ends of the cover strip with a rubber mallet.
 The cover strip has been mounted
4.3.4 Assembly of the MAGIC-PG encoder
As shown in Fig. 4.12, 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 9.1). For the assembly of the block on the
rail, please refer to the Assembly Instructions “Linear Guideways”.
Fig. 4.11 Bending the cover strip ends
Fig. 4.12 MAGIC-PG encoder, pre-assembled on the CG block
[2]
[1]
[5]
[7]
[4]
[6]
[3]
Positive counting direction
When assembling the MAGIC-PG encoder, ensure that you do not violate the connecting cable’s minimum bend-
ing radius of 40mm.
NOTE
Pos. Designation Pos. Designation
1Screw A 5Screw B
2Encoder 6End seal screw
3Encoder housing 7End seal
4Cover strip
Table 4.4 MAGIC-PG – CG series

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Assembly Instructions
HIWIN MAGIC Distance Measuring System
MAGIC-01-11-EN-1907-MA
Assembly
4.3.5 Replacement of the MAGIC-PG encoder – CG series
Assembly steps:
XLoosen and remove screws A [1] and B [5].
XRemove the MAGIC-PG encoder [2].
Fig. 4.13 Replacement of the MAGIC-PG encoder – CG series
XFasten the end seal [7] to the MAGIC-PG encoder with the end seal screws [6] so that the sealing lip is slightly in
contact with the rail contour on all sides.
 The MAGIC-PG encoder has been mounted.
Tighten the screws with a torque of 1 Nm.
NOTE
Pos.Nr. Designation Pos.Nr. Designation
1Screw A 5Screw B
2Encoder 6End seal screw
3Encoder housing 7End seal
4Cover strip
Table 4.5 Replacement of the MAGIC-PG encoder – CG series
[2]
[1]
[5]
[7]
[4]
[6]
[3]
Assembly steps:
XRemove the end seal [7] by loosening the screws [6].
XLoosen screws A [1] and B [5].
 The encoder [2] can now be moved.
XSet 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.
XFix the encoder by tightening the screws A [1] and B [5].
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 9.1 if the cable is connected as in Table 5.1.
NOTE