MICRO-EPSILON eddyNCDT SGS 4701 User manual

Operating Instructions
eddyNCDT SGS 4701

MICRO-EPSILON
MESSTECHNIK
GmbH & Co. KG
Koenigbacher Str. 15
94496 Ortenburg / Germany
Tel. [phone] / 168-0
Fax [phone] / 168-90
e-mail [email protected]
www.micro-epsilon.com
Digital Eddy-Current Measuring System for Spindle Growth System

eddyNCDT SGS 4701
Contents
1. Safety ........................................................................................................................................ 5
1.1 Symbols Used ................................................................................................................................................. 5
1.2 Warnings.......................................................................................................................................................... 5
1.3 Notes on CE Marking ...................................................................................................................................... 6
1.4 Intended Use ................................................................................................................................................... 6
1.5 Proper Environment......................................................................................................................................... 6
2. System Description .................................................................................................................. 7
2.1 Measuring Principle ......................................................................................................................................... 7
2.2 Electrical Runout.............................................................................................................................................. 8
2.3 Structure of the Measuring System................................................................................................................. 9
2.4 Glossary......................................................................................................................................................... 10
2.5 Technical Data ............................................................................................................................................... 11
3. Delivery .................................................................................................................................. 12
3.1 Unpacking, Included in Delivery.................................................................................................................... 12
3.2 Storage ......................................................................................................................................................... 12
4. Installation and Assembly...................................................................................................... 13
4.1 Precautions.................................................................................................................................................... 13
4.2 Sensor............................................................................................................................................................ 13
4.2.1 Frame Size 10 x 4 x 4 mm............................................................................................................ 13
4.2.2 Frame Size 12 x 10 x 4.5 mm ...................................................................................................... 14
4.3 Sensor Cable ................................................................................................................................................. 16
4.4 Controller ....................................................................................................................................................... 18
4.5 Connecting the Measuring System............................................................................................................... 19
4.6 Ground Concept............................................................................................................................................ 20
5. Operation ................................................................................................................................ 20
6. Liability for Material Defects.................................................................................................. 20
7. Service, Repair ...................................................................................................................... 21
8. Decommissioning, Disposal ................................................................................................. 21

eddyNCDT SGS 4701
Appendix
A 1 Clamping Flange Controller................................................................................................... 22
A 2 Tool Sensor Cable .................................................................................................................. 23
A 3 Optional Accessories............................................................................................................. 23
A 4 Notes for Electrostatic Discharge ......................................................................................... 24
A 5 Target Thickness .................................................................................................................... 25
A 6 Non-ferromagnetic Target ...................................................................................................... 26
A 7 Change from SGS4311 to SGS4701...................................................................................... 26

Page 5
Safety
eddyNCDT SGS 4701
1. Safety
System operation assumes knowledge of the operating instructions.
1.1 Symbols Used
The following symbols are used in these operating instructions.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate
injury.
Indicates a situation that may result in property damage if not avoided.
Indicates a user action.
iIndicates a tip for users.
Measure Indicates hardware or a software button/menu.
1.2 Warnings
Connect the power supply and the display/output device according to the safety regulations for electrical
equipment.
> Risk of injury
> Damage to or destruction of the controller and/or sensor
The supply voltage must not exceed the specified limits.
> Damage to or destruction of the controller and/or sensor
Avoid shocks and impacts to the sensor and controller.
> Damage to or destruction of the controller and/or sensor
Protect the cable against damage
> Failure of the measuring device

Page 6
Safety
eddyNCDT SGS 4701
1.3 Notes on CE Marking
The following apply to the measuring system eddyNCDT series SGS 4701:
- EU Directive 2014/30/EU
- EU Directive 2011/65/EU, “RoHS” category 9
Products which carry the CE mark satisfy the requirements of the EU directives cited and the European
harmonized standards (EN) listed therein. The EU Declaration of Conformity is available to the responsible
authorities according to EU Directive, article 10, at:
MICRO-EPSILON MESSTECHNIK
GmbH & Co. KG
Koenigbacher Str. 15
94496 Ortenburg / Germany
The measuring system is designed for use in industrial environments and meets the requirements.
1.4 Intended Use
- The measuring system eddyNCDT series SGS 4701 is designed for use in industrial areas. It is used
for displacement, distance and movement measurement
for temperature detection
position measuring of parts or machine components
- The measuring system must only be operated within the limits specified in the technical data, see 2.5.
- The system must be used in such a way that no persons are endangered or machines and other material
goods are damaged in the event of malfunction or total failure of the controller.
- Take additional precautions for safety and damage prevention in case of safety-related applications.
1.5 Proper Environment
Protection class: IP 67 (in plugged state) Humidity: 5 - 95 % (non-condensing)
Temperature range operation: Ambient pressure: Atmospheric pressure
Controller +10 ... +70 °C
(+50 ... +158 °F)
Temperature range
storage:
0 ... +70 °C
(+32 ... +158 °F)
Sensor/sensor cable 0 ... +90 °C (+32 ... +194 °F)

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System Description
eddyNCDT SGS 4701
2. System Description
2.1 Measuring Principle
The eddyNCDT series SGS 4701 (Non-Contacting Displacement Transducers) measuring system operates on
the basis of eddy currents without making physical contact. It is used for measurements on objects consisting
of electrically conducting materials which have ferromagnetic or non-ferromagnetic properties.
High frequency alternating currents flow through a coil cast in a sensor housing. The electromagnetic field
from the coil induces eddy currents in the electrically conducting target, causing the alternating current
resistance of the coil to change. This change of impedance delivers an electrical signal proportional to the
distance of the target from the sensor.
The eddyNCDT SGS 4701 conditions the sensor signals user-fairly at a bandwidth of 2,000 Hz. Thus a
so-called spindle monitoring is also still possible at numbers of revolutions up to 120,000 rpm. The spindle
growth itself can be detected at even higher numbers of revolutions.
Monitoring an axial expansion requires subsequent individual filtering by the user. Micro-Epsilon recommends
averaging or filtering across several revolutions in order to record only the relative expansion during a defined
period. During an unfiltered/non-averaged measurement, effects such as those within a single revolution also
become visible; this can cause incorrect interpretations.
In order to achieve highly accurate measurements, it is imperatively necessary that one (or more) sample(s)
item under test is / are provided by the customer.

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System Description
eddyNCDT SGS 4701
2.2 Electrical Runout
Ferromagnetic metals can have areas with different magnetizations called Weiss domains; these in turn
dampen the sensor’s eddy current field differently. Even with constant distance between sensor and target,
different distance values can occur. The domains can be reproduced, but show unrealistic axial runout devia-
tions within one revolution.
If the eddyNCDT SGS4701 is to be used for recording an axial runout measurement, start-up behavior or
a so-called spindle monitoring, it is possible to compare with non-ferromagnetic metal. Because of their
material properties, non-ferromagnetic metals offer the advantage that they do not show any such effects and
therefore should be used for such measuring tasks.
Non-ferromagnetic metals on average have less mechanical strength; this means that the selection of materi-
als is of crucial significance.
Proposed materials
AlZnMgCu1,5 (3.4365)
iConsider the material strength.
AlMg1SiCu
Inconel, NiCr19NbMo (2.4668)
Bronze in general
More details are available in the annex, see A 6.

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System Description
eddyNCDT SGS 4701
2.3 Structure of the Measuring System
The eddyNCDT series SGS 4701 is developed for recording the thermal and mechanical expansion of high-
speed milling spindles. This enables the active compensation of the axial spindle expansion via e. g. a CNC
machine tool.
The SGS 4701 consists of a sensor, a sensor cable and a controller which can be factory calibrated for
ferromagnetic or non-ferromagnetic measurement objects. Miniature sensors enable it to be installed directly
in the spindle, where the measurements take place, typically on the labyrinth-ring of the spindle. As well as
measuring linear expansion, the temperature of the sensor is also detected and output. The compact control-
ler can be installed on the spindle housing via a flange or directly in the spindle.
Fig. 1 Typical installation with
measurement on the labyrinth ring
Fig. 2 Measuring system consisting
of sensor and controller
Due to its compact size, the measurement technology (paired electronics and sensor) is fully integrated into
the spindle head.

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System Description
eddyNCDT SGS 4701
2.4 Glossary
SMR Start of measuring range.
Minimum distance between sensor front and target
MMR Midrange
EMR End of measuring range (start of measuring range + measuring range)
Maximum distance between sensor front and target
MR Measuring range
0
0.5 0 0.5
9.5
600 µm
9.5
Linearity ±5 %
0 90 °C
Target
U [V]
Signal
U [V]
Temp.
Displace-
ment
Measuring range
SMR
Lin. area
100
Sensor

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System Description
eddyNCDT SGS 4701
2.5 Technical Data
Sensor system SGS4701
Measuring range 500 µm (option 250 µm 2))
Offset 100 µm (option 50 µm 2))
Linearity ±2 µm
Resolution 1) 0.5 µm
Bandwidth 2000 Hz
Target ferromagnetic / non-ferromagnetic
Minimum target diameter 6 mm (option 3.5 mm 2))
Operating temperature Sensor 0 ... +90 °C (+32 ... +194 °F)
Controller +10 ... +70 °C (+50 ... +158 °F)
Temperature stability Sensor ±150 ppm FSO/°C (MMR)
Controller ±500 ppm FSO/°C (MMR)
Temperature
compensation range
Sensor +10 ... +80 °C (+50 ... +176 °F)
Controller +10 ... +70 °C (+50 ... +158 °F)
Supply voltage 12 ... 32 VDC
Analog out
Displacement 0.5 - 9.5 V �100 - 600 µm (option 50 - 300 µm 2))
Temperature 0.5 - 9.5 V (�0 ... +90 °C)
Load resistor ≥ 10 kOhm
Protection class Sensor / controller IP 67 (in plugged state)
Dimensions EMU04(10x/11x/14x/15x) 12 x 10 x 4.5 mm³
EMU04(12x/13x/16x/17x) 10 x 4 x 4 mm³
Sensor cable
Diameter Ø 1.13 mm
Length 1000 mm (400 - 1500 mm on request)
Min. bending radius 12 mm
Coating FEP

Page 12
Delivery
eddyNCDT SGS 4701
Sensor system SGS4701
Shock DIN EN 60068-2-27
(50 g, 6 ms, 3 cycles in each direction)
Vibration DIN EN 60068-2-6
(20 g, 10 - 3000 Hz)
FSO = Full Scale Output; MMR = Midrange
1) Static at midrange (MMR)
2) For OEM modifications: sensor with 250 µm measuring range and 50 µm SMR distance
3. Delivery
3.1 Unpacking, Included in Delivery
1 SGS 4701(xxx)
1 Test report
1 Operating instructions
Carefully remove the components of the measuring system from the packaging and ensure that the
goods are forwarded in such a way that no damage can occur.
Check the delivery for completeness and shipping damage immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or supplier.
Optional accessories are available in the appendix, see A 3.
3.2 Storage
Temperature range storage: 0 ... +70 °C (+32 ... +158 °F)
Humidity: 5 - 95 % (non-condensing)

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Installation and Assembly
eddyNCDT SGS 4701
4. Installation and Assembly
4.1 Precautions
No sharp or heavy objects should be allowed to affect the cable sheath of the sensor cable, the power supply
cable and the output cable.
Check all plug-in connections for firm seating before starting operation.
4.2 Sensor
4.2.1 Frame Size 10 x 4 x 4 mm
Sensor coil
Potting
10
-0.2
(.39
-0.08
)
1.5
±0.05
(.06
±0.002
)
4
2.5
(.099)
4 edges 0.2
(0.008
)x 45°
0 -0.05
0
-0.03
0 -0.03
(.16 )
0
-0.0011
(.16
)
0 -0.0011
0 -0.002
4
Sensors with integrated cable with miniature connector
EMU04(121)-C100 standard
Sensors with integrated cable with open ends
EMU04(160)-C150 standard
C = Cable length in cm
Cable lengths between 40 … 150 cm are possible in 10 cm
increments.
Fig. 3 Dimensional drawing
Dimensions in mm (inches), not to scale
Destruction of the
controller by electro-
static discharge via
the sensor. Please
observe the notes re-
garding electrostatic
discharge, see A 4.

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Installation and Assembly
eddyNCDT SGS 4701
4.2.2 Frame Size 12 x 10 x 4.5 mm
6 (.24)
12 (.47)
1.75 (.07)
4.5 ±0.05
(.18 ±0.0002)
0.3x45°
0.012x45°
ø 1.13
(.04 dia)
1.5
±0.05
(0.6
±0.002)
10
-0.005
-0.027
M2.5
2.5 (.1 dia)
(.39)
-0.0002
-0.001
Sensors with integrated cable with miniature
connector
EMU04(102)-C100 standard
Sensors with integrated cable with open ends
EMU04(140)-C150 standard
C = Cable length in cm
Cable lengths between 40 … 150 cm are possible
in 10 cm increments.
Fig. 4 Dimensional drawing
Dimensions in mm (inches), not to scale

Page 15
Installation and Assembly
eddyNCDT SGS 4701
Start of measuring range
For each sensor a minimum distance to the target must
be maintained. This avoids a measurement uncertainty
due to the sensor pressing on the target and mechanical
damage to the sensor/ target.
Target
Measuring range
SMR
Sensor
Fig. 5 Start of measuring range (SMR), the smallest dis-
tance between sensor face and target
Measuring area
The minimum measuring area must have a diameter of
6 mm or greater for an eddy-current sensor. Optional
sensors are available with a minimum area diameter of
3.5 mm. If you underrun the minimum measuring area nor
reproducibly measurements are possible.
Measuring area ø ≥ 6 mm
Sensor
Fig. 6 Minimum measuring area for eddy-current sensor

Page 16
Installation and Assembly
eddyNCDT SGS 4701
4.3 Sensor Cable
Operating temperature -40 ... +90 °C
5.3 ± 0.3
(.21 ± .02)
1.44 ± 0.2 (.06
± .008)
3 ± 0.2
(.12 ± .008)
Mating life 20 cycles
Cable retention 12.74 N
Inner conductor silver-coated annealed copper wire
Min. bending radius 12 mm
Outer conductor silver-coated annealed copper wire
Dielectric core FEP
Jacket FEP
Fire resistance VM-1
Fig. 7 Dimensional drawing sensor cable,
dimensions in mm (inches), not to scale
Sensor cable lengths between 40 … 150 cm are possible in 10 cm increments.
Lay the sensor cable in such a way that no sharp-edged or heavy objects can affect the cable sheath.
Do not kink the cable. Details to the sensor cable are listed in the appendix, see A 4.
Sensor Bending radius:
R ≥ 12 mm
Controller
Fig. 8 Minimum bending radius for sensor cable
Do not shorten the sensor cable. Loss of functionality. Removing the connector is only permitted behind the
plug-sided crimp when using the solder connections.
Remove the sensor cap from the controller.
Open the cable gland on the controller.

Page 17
Installation and Assembly
eddyNCDT SGS 4701
Run the sensor cable through the sensor
cap and the cable gland. iAvoid a strong cable bending.
Sensor Sensor cable Sensor cap Cable gland Controller
Bend up the green cable seal easily and insert the sensor cable.
Connect the sensor cable to the controller, see Fig. 9.
Solder connection Plug connection
Shield
Signal
Solder the sensor cable to the connection
board.
Connect the sensor cable to the female
connector.
iConnector mating life is 20 cycles.
Close the cable gland.
Push the sensor cap onto the controller housing until it snaps in place.
Fig. 9 Connection sensor cable

Page 18
Installation and Assembly
eddyNCDT SGS 4701
4.4 Controller
94.2 ±0.1 (3.71 ± .004)
M12x1
(ca.8)
(.31)
Ø12 -0.1
(.47 dia. -.004)
102.2 ±0.5 (4.02 ± .02)
Mounting area
WS8
Fig. 10 Dimensional drawing of controller, dimensions in mm (inches), not to scale
The controller is mounted laminar with a circumferential clamping on housing or with an optional clamping
flange.
Do not clamp the
controller outside the
installation area. The
controller may be
damaged.

Page 19
Installation and Assembly
eddyNCDT SGS 4701
4.5 Connecting the Measuring System
Provide the power supply for the controller.
Connect the 8-pin M12 connector to the controller with a power supply 24 VDC.
iOptional accessories:
PC4701-10 power supply and output cable, 10 m long, with 8-pin. female connector respectively with
free ends.
Connect the measurement signal display respectively control unit to the controller.
Pin Comment Color PC4701-10
5
64
3
2
1
7
8
8-pin. male connector
controller, view on pin
side
1 Ground white
2 12 ... 32 VDC brown
3Displacement signal
(0.5 ... +9.5 V) at 100 ... 600 µm
green
4Temperature signal
(0.5 ... +9.5 V) at 0 ... +90 °C
yellow
5 NC gray
6, 7 internally assigned pink, blue
8 NC red
Screen Housing -
Fig. 11 Pin assignment for signal output

Page 20
Operation
eddyNCDT SGS 4701
4.6 Ground Concept
+12 ... 32 VDC
GND
Shield
PE PE
Sensor
SGS4701 Controller
SGS4701 Housing
5. Operation
The system is ready for operation. There are no adjustments which must be done by the user.
MICRO-EPSILON recommends to let the system warm up for about 30 minutes.
6. Liability for Material Defects
All components of the device have been checked and tested for functionality at the factory. However, if de-
fects occur despite our careful quality control, MICRO-EPSILON or your dealer must be notified immediately.
The liability for material defects is 12 months from delivery. Within this period, defective parts, except for
wearing parts, will be repaired or replaced free of charge, if the device is returned to MICRO-EPSILON with
shipping costs prepaid. Any damage that is caused by improper handling, the use of force or by repairs or
modifications by third parties is not covered by the liability for material defects. Repairs are carried out exclu-
sively by MICRO-EPSILON.
Further claims can not be made. Claims arising from the purchase contract remain unaffected. In particular,
MICRO-EPSILON shall not be liable for any consequential, special, indirect or incidental damage. In the inter-
est of further development, MICRO-EPSILON reserves the right to make design changes without notification.
For translations into other languages, the German version shall prevail.