SICK MAX48 Manual

TECHNICAL INFORMATION
MAX48
Non-contact position sensors

Product described
MAX48
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
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reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Purpose of this document........................................................................ 5
1.2 Target audience........................................................................................ 5
1.3 Further information................................................................................... 5
1.4 Symbols and document conventions...................................................... 5
1.4.1 Warning levels and signal words............................................. 5
1.4.2 Information symbols................................................................ 5
2 Safety information............................................................................ 6
2.1 General notes............................................................................................ 6
2.2 Intended use............................................................................................. 6
2.2.1 Purpose of the device.............................................................. 6
2.3 Responsibility of user............................................................................... 6
3 Product description........................................................................... 8
3.1 Product identification............................................................................... 8
3.2 Device variants......................................................................................... 8
3.3 Construction and function........................................................................ 9
4 Mounting............................................................................................. 11
4.1 Preparation for installing the sensor....................................................... 11
4.1.1 Installation cavity for the sensor............................................. 11
4.1.2 Installation cavity for the piston rod....................................... 11
4.1.3 Insertion chamfer.................................................................... 12
4.1.4 Bore hole for the retaining screw............................................ 12
4.1.5 Bore hole for the connector system....................................... 13
4.1.6 Piston for the position magnet................................................ 14
4.2 Installing the position magnet................................................................. 15
4.3 Location of the O-ring and support ring.................................................. 16
4.4 Installing the sensor in the cylinder........................................................ 16
4.4.1 Installing using an M12 connector system............................ 16
4.4.2 Installation using cable connector and screwed cable
gland......................................................................................... 18
4.5 Install the retaining screw........................................................................ 18
4.6 Cylinder handling after sensor installation............................................. 18
4.6.1 Washing and drying the cylinder............................................. 18
4.6.2 Electrostatic painting of the cylinder...................................... 19
4.6.3 Mounting the cylinder on mobile hydraulic machines.......... 19
4.6.4 Electrical and electrostatic interference................................ 19
5 Electrical installation........................................................................ 21
5.1 Electrical connection................................................................................ 21
5.1.1 Connection diagrams, pin assignment.................................. 21
5.1.2 Connection sequence.............................................................. 21
CONTENTS
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5.2 Connection diagram for vehicle electronics............................................ 22
6 Commissioning.................................................................................. 23
6.1 Commissioning the device....................................................................... 23
6.2 Select a suitable fuse............................................................................... 23
6.3 Set up the filter wiring.............................................................................. 23
6.4 Tolerance considerations for the set point............................................. 24
7 Transport and storage....................................................................... 26
7.1 Transport and storage conditions............................................................ 26
8 Maintenance...................................................................................... 27
8.1 Checking the device function................................................................... 27
8.2 Error table................................................................................................. 28
8.3 Repairs...................................................................................................... 28
9 Decommissioning............................................................................. 29
9.1 Dismantling............................................................................................... 29
9.2 Disposal..................................................................................................... 29
10 Technical data.................................................................................... 30
10.1 Analog MAX48.......................................................................................... 30
10.2 Dimensions of sensor............................................................................... 32
10.3 Dimensions of position magnet............................................................... 33
11 Annex.................................................................................................. 34
11.1 Accessories............................................................................................... 34
11.2 CE Declaration of Conformity................................................................... 34
CONTENTS
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1 About this document
1.1 Purpose of this document
In this document, the MAX48 position sensor is referred to simply as “device”.
This Technical Information describes:
•Device components
•Mechanical preparation of the device
•Electrical preparation of the device
•Necessary maintenance work for safe operation
1.2 Target audience
This document is intended for technicians (persons with technical expertise) tasked
with installing and maintaining the device.
These technicians must be trained on the device.
Only trained electricians are permitted to carry out work on the electrical system or
electrical assemblies.
1.3 Further information
•MAX48 Operating Instructions
Product web page for the MAX48
www.sick.com/MAX48
1.4 Symbols and document conventions
1.4.1 Warning levels and signal words
Important
Hazard which could result in property damage.
Note
Tips
1.4.2 Information symbols
Table 1: Information symbols
Icon Meaning
Important technical information for this product
Important information about electrical or electronic functions
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2 Safety information
2.1 General notes
Should persons be placed at risk, or operating equipment potentially be damaged in
the event of a malfunction or failure of the device, this must be prevented by means of
suitable protective devices, e. g., emergency shutdown systems.
If the device is not functioning correctly, it must be taken out of operation and secured
against unauthorized operation.
To guarantee proper operation of the device, please observe the following:
•Protect the device against mechanical stress during installation
•Do not open the device
•Connect the device with the correct polarity, supply voltage and control pulses
•Observe the permissible operating and ambient conditions for the device
•Regularly check the device for correct operation and document the results
2.2 Intended use
2.2.1 Purpose of the device
The MAX48 sensor is designed to take position measurements in mobile hydraulic
applications and therefore can be used to control the hydraulic components of con‐
struction machinery, e.g., in hydraulic cylinders. The rugged housing offers optimal pro‐
tection against dust, climatic influences, vibrations, surrounding media as well as
electrical and magnetic fields.
The device is an accessory and must be connected to a suitable electronic control unit.
2.3 Responsibility of user
Designated users
see "Target audience", page 5.
Correct project planning
•This document assumes that appropriate project planning has been carried out
before delivery of the device (e.g., based on the SICK application questionnaire),
and the device is in the required delivery state based on that planning (see sup‐
plied system documentation).
wIf you are not certain whether the device corresponds to the state defined
during project planning or in the supplied system documentation, please con‐
tact SICK Customer Service.
Special local conditions
In addition to the instructions in this Technical Information, follow all local laws, techni‐
cal rules and company-internal operating directives applicable at the respective device
installation location.
Read the technical information
•Read and follow the technical information in this document
•Follow all safety notes
•If there is anything you do not understand, please contact SICK Customer Service
2 SAFETY INFORMATION
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Retention of documents
This Technical Information:
bMust be made available for reference.
bMust be conveyed to new owners.
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3 Product description
3.1 Product identification
Type code
Table 2: Type code
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
M T X 4 8 N - 1 1 R 1 0 T T
Table 3: Type code Explanation
Position Meaning Value
1 Series M = Mobile
2 Technology A = Magnetostrictive
3 Installation type X = Integrated (hydraulic cylinder)
4 Size 48 = Housing diameter
5
6 Version N = Non-Safety
7 Place holder -
8 Diameter
Pressure pipe
1 = 10 mm / 30 mm damping
7 = 7 mm / 30 mm damping
9 Voltage supply 1 = 12 VDC
2 = 24 VDC
10 Electrical
Interface
V = Voltage
A = Current
11 Signal output 10 = Analog 4.00 ... 20.00 VDC
21 = Analog 4.75 ... 0.25 VDC
40 = Analog 1.00 ... 9.00 VDC
12
13 Connection type A = 4-pin analog (1 = VDC, 2 = n.c., 3 = GND, 4 = OUT)
B = 4-pin analog (1 = VDC, 2 = OUT, 3 = GND, 4 = n.c.)
M = 4-pin analog (1 = n.c., 2 = VDC, 3 = GND, 4 = OUT)
K = Analog cable/3-wire PWM
14 Connector length A = 60 mm M12
E = 100 mm M12
15 Measuring range
Position measurement
in 1 mm steps
e.g., 0300 = 50 ... 300 mm
16
17
18
3.2 Device variants
The device is available in the following variants:
•M12 male connector (4-pin) or 3-wire PUR cable
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3.3 Construction and function
Construction of the device
12 3 4
Figure 1: Construction of the MAX48
1M12 connector system
2Protective housing (electronics)
3Position magnet
4Pressure pipe
Connector system:
The M12 connector system requires very little time to attach. It is suitable for applica‐
tions in harsh environments up to IP69K (when using a suitable mating connector).
Protective housing (electronics):
The housing is designed to be installed in a hydraulic cylinder and protects the sensor
electronics against external influences.
Position magnet:
This is the only moving component in the measuring device when installed in the pis‐
ton. The position magnet is located inside the piston and moves over the pressure pipe
without contacting it. The magnet field thereby produced identifies the current position
of the piston.
Pressure pipe:
Pressure-resistant construction - is inserted in the piston rod of the cylinder. It contains
the hermetically protected magnetostrictive sensing element.
Principle of operation
21
3
4
5
6
7
Figure 2: Schematic of the magnetostrictive measurement principle
1Magnet field of the current pulse
2Magnet field of the position magnet
3Magnetostrictive sensor component
4Current pulse
5Sound wave converter
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6Structure-borne sound wave
7Position magnet
The device operates on the magnetostrictive measurement principle that records the
actual path of a position magnet:
The radial magnet field (1) generated by the current pulse (4) interacts with the magnet
field (2) of the position magnet (7).
As a result of the interaction of the two magnet fields, a wave (ultrasonic) (6) is pro‐
duced in the magnetostrictive sensor component (3). This travels to the converter (5)
and the sensor electronics produce an electrical output signal.
The time interval between the current pulse and the detection of the structure-borne
sound wave is measured and enables the precise position of the magnet – which
changes as the cylinder moves – to be determined. As this measurement principle does
not require a reference point, no recalibration is necessary for this type of device.
The device is also maintenance-free as a result of the non-contact measurement.
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4 Mounting
4.1 Preparation for installing the sensor
4.1.1 Installation cavity for the sensor
The method of installation depends on the cylinder design. Generally, the sensor is
installed from the piston rod side. It is also possible to install the sensor from the head
side of the cylinder.
The sensor dimensions are listed in the technical specifications: see "Dimensions of
sensor", page 32.
Fit dimensions and tolerances
4 2
3 1
Figure 3: Dimensions of the sensor installation cavity
1Diameter for the housing
2Depth for the housing
3Diameter for the electrical connection
4Depth for the electrical connection
bPrepare an installation cavity for the sensor in accordance with the following
dimensions.
Table 4: Installation cavity for the housing and electrical connection
Type Installation cavity for housing Installation cavity for electrical connec‐
tion
1
Ø
2
Depth
3
Ø min. ... Ø max.
4
Depth
MAX48 48H8 21.2 mm + 0.2 d > 32.5 mm
d < 40 mm
≥ 10 mm
Mean roughness value of the surface: Ra < 0.8 mm.
4.1.2 Installation cavity for the piston rod
123
4 5
>3
(0.12)
Figure 4: Installation cavity for the piston rod and pressure pipe
1Null zone
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2Measuring range
3Damping
4Diameter of the pressure pipe
5Diameter of the piston rod bore hole
Table 5: Depth of the piston rod
1 = Null zone 30 mm
2 = Measuring range as per the applicable data sheet and selected
device variant
3 = Damping
bPrepare an installation cavity for the piston rod in accordance with the following
dimensions.
Table 6: Bore hole diameters for the pressure pipe and piston rod
4
Ø Pressure pipe
5
Ø Bore hole in the piston rod
Ø 7 mm Ø 10 mm
Ø 10 mm Ø 13 mm
NOTE
The total bore hole depth comprises the measuring range (S), the damping (D), and an
addition distance of 3 mm.
4.1.3 Insertion chamfer
To ensure proper and secure installation of the device in the cylinder, a insertion cham‐
fer must be provided.
NOTICE
Risk of damage to the device during installation
The device can be damaged by any sharp edges present at the transition from the cylin‐
der bore hole to the insertion chamfer on the O-ring.
bPrepare an insertion chamfer with a radius of 0.6 mm ... 1 mm at the end of the
cylinder bore hole.
20°
R 0.6
(0.06)
Figure 5: Insertion chamfer
4.1.4 Bore hole for the retaining screw
bPrepare a bore hole for the retaining screw in accordance with the following dimen‐
sions.
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6.25 ±0.1
(0.25) M5 x 8
Figure 6: Installation cavity for the retaining screw
45°
4
(0.16)
4.5
(0.18)
8.5
(0.33)
1
(0.04)
4.5
(0.18)
Figure 7: Position on the sensor
Permissible tightening torque for the retaining screw: 0.5 Nm ... 1.0 Nm. (based on the
max. permissible force on the housing surface)
4.1.5 Bore hole for the connector system
bPrepare an installation cavity for the connector system and flange plate in accord‐
ance with the following dimensions.
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14
14
8
(0.31)
5.5
(0.22)
21 ±0.2
(0.38 ±0.01)
Ø 12.2 ±0.1
(0.48)
M 3x8
A
AØ 0.1
4x
Figure 8: Dimensions of the flange plate bore holes
14 (0.55)
21 (0.83)
Ø 12.2 (0.48)
Ø 48 H8
(1.89)
d
21.2 +0.2
(0.83 +0.01)
min. 10
(0.39)
1.5 (0.06)
20°
R 0.6
(0.06)
Figure 9: Dimensions of the connector system bore hole
4.1.6 Piston for the position magnet
bPrepare an installation cavity for the position magnet in accordance with the fol‐
lowing dimensions.
1.5
(0.06)
1.1 H13
(0.04)
13.2 +0.1
(0.52)
Ø 17.5 +0.1
(0.69)
Ø 19 H11
(0.75)
Ø 12
(0.45)
Figure 10: Dimensions of the position magnet installation cavity
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4.2 Installing the position magnet
Table 7: Fit dimensions for the piston
1 Magnet 17.4 x 10.6 x 12.0
2 Corrugated ring OD: 16.5 - 17.4
ID: 13.5 - 14
3 Circlip DIN 472 - 18 x 1
Diameter of the position magnet bore hole 13.2 + 0.1
Depth of the position magnet bore hole 10.7 + 0.1
Sequence of work steps:
NOTICE
•The position magnet must not rub against the pressure pipe.
•Observe the operating pressures: see "Technical data", page 30.
3 2 1 4
Figure 11: Installation of the position magnet
1Corrugated spring washer
2Position magnet
3Circlip
4Piston
1. Prepare the piston for installation of the magnet: see "Piston for the position mag‐
net", page 14.
2. Mount the corrugated spring washer.
3. Mount the position magnet.
4. Mount the retaining ring.
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4.3 Location of the O-ring and support ring
1
2
Figure 12: O-ring and support ring
1Support ring
2O-ring
The O-ring and support ring are pre-installed as shown in the figure and prevent oil from
penetrating into the connector area.
4.4 Installing the sensor in the cylinder
4.4.1 Installing using an M12 connector system
The M12 connector system has an enclosure rating of IP69K and is pre-assembled
ready for installation.
NOTE
When selecting the mating connector, ensure that it also has an enclosure rating of
IP69K.
Figure 13: Installation steps
1. Lubricate the O-ring and support ring.
2. Guide the connector system and its connecting cables carefully through the cylin‐
der wall.
Figure 14: Tensile load at edges
NOTICE
Risk of damage to the connecting cables during installation.
Tensile loads and sharp edges can damage the stranded wires and connecting
cables of the connector system.
bAvoid tensile loads and look out for sharp edges when installing the connec‐
tor system.
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3. Carefully insert the device into the cylinder.
4. Mount and engage the contact carrier in the flange plate.
NOTE
When mounting the contact carrier in the flange, ensure the lug of the contact car‐
rier is aligned correctly.
5. Press the flange plate into the bore in the cylinder wall.
6. Fasten the flange plate using suitable screws or rivets.
7. Use a specially prepared sleeve (e.g., made from polyamide) to locate the device in
its final position.
8. If necessary, carefully tap in the device and sleeve using a mallet.
Figure 15: Load-bearing surfaces
NOTICE
Risk of damage to the device during installation.
Forces acting on the load-bearing features of the housing can damage the device.
bDo not apply any load on the pressure pipe or behind the head of the device
when mounting the sensor.
1
222
1Oil inlet
2Areas requiring lubrication
9. Lubricate the indicated areas via the oil inlet.
Recommended screws for mounting the M12 flange
The screws should be selected so that no collision with the coupling nuts of the con‐
nected mating connectors can occur, e.g.,:
•M3 socket head cap screw with flat head
•DIN 912 hexagon socket head cap screw
•ISO 14580 Torx screw
•DIN 84 slotted-head screw
•Comparable Phillips head screws or self-tapping screws
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A soluble screw locking adhesive should be used when installing the screws.
Alternatively, the flange plate can be fastened using DIN 6660 button-head rivets.
4.4.2 Installation using cable connector and screwed cable gland
For devices with a cable connection, a protection class rated (preferably IP68) metallic
cable gland should be used for sealing and strain relief. The cable glands should also
be protected against damage by surrounding them with metal profiles (e.g. U-steel).
When installing connector plugs on devices with a cable connector, please consider the
following:
•Enclosure rating: (preferably IP68)
•Connector housing:
Metal or impact-resistant plastic (check media resistance)
•Protect against external influences: enclose the cable sheath and male connector
•Prevent fluid ingress: the cable sheath should ideally be coated with sealing com‐
pound at offset locations
•Polarity: ensure correct polarity
•Male connector with screw terminals:
Apply ferrules and clamp all strands in the ferrule
•Soldered connections: no projecting strands or “cold joints”
•Crimp contacts: use a suitable tool to produce a gas tight crimp
•ESD protection: protect workplaces and persons from electrostatic discharge
•Prevent fluid ingress:
Use suitable caps to seal the male connector after installation
•Screwed cable glands: protect by enclosing within steel profiles
4.5 Install the retaining screw
The retaining screw prevents the sensor housing from moving in the axial direction. A
DIN 913 M5x10 threaded pin with tapered head should be used for this purpose. Use a
soluble screw locking adhesive when installing the threaded pin.
NOTICE
Risk of damage to the device during installation.
The screw must only rest in the slot and not be tightened too hard.
bTighten the screws with a torque of 0.5 Nm ... 1.0 Nm.
4.6 Cylinder handling after sensor installation
4.6.1 Washing and drying the cylinder
To protect the connecting cable and male device connector from ingress of cleaning
agents, please observe the following:
Sensors with M12 connector system
•Drying temperature: max. 90 °C
•Pressure of the cleaning fluid: ≤ 5 bar
•Protective cap: use the supplied plastic protective cap
•In case of higher pressures: use a metallic protector
•Protection class: IP69K
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Sensors with cable connector / installed male device connector
•Cable connectors / male device connector: protect against ingress of cleaning
agents using suitable sheathing
•Screwed cable glands: protect against ingress of moisture
4.6.2 Electrostatic painting of the cylinder
The electrostatic painting process uses very high voltages (up to 100 kV) which can
damage the electronics of the sensor integrated into the cylinder. To avoid damage,
observe the following when painting the cylinder:
•To avoid electrical isolation of the piston rod and the cylinder/sensor housing, do
not the suspend the cylinder by the piston rod
•Clean off all lacquer and other residues from the hanging devices in the paint
shop, all connectors used to short-circuit the connecting wires, and all connec‐
tions to the paint shop earth
Painting of cylinders with an integrated sensor and M12 connector system or installed
male device connector
To protect the sensor electronics, use metal protective caps that meet the following
requirements:
•The cap must not be made from aluminum
•The cap must be made from a permanently electrically-conductive material
•The cap must have an M12x1 thread
•The cap must be screwed on until it contacts the flange plate on the connector
as desired
•Always use a torque of ≥ 5 Nm to tighten the cap
•Make sure no paint particles get onto the thread or
pin contacts
Any paint particles on the outside of the cap will not impair the sensor.
A suitable cap can be purchased from the manufacturer as an accessory: see "Acces‐
sories", page 34.
Painting of cylinders with an integrated sensor and cable connector or third-party con‐
nector
Cylinders with an integrated sensor and cable connector cannot be electrostatically
painted because the cable connector is not protected against over voltages. Reliable
electrostatic painting is only possible when using a combination of M12 connector sys‐
tem and protective cap.
4.6.3 Mounting the cylinder on mobile hydraulic machines
When mounting the cylinder on mobile hydraulic machines, ensure no male connectors,
cables or cable ends can be damaged in the process.
4.6.4 Electrical and electrostatic interference
Insulation tests
When performing insulation tests on mobile hydraulic machines, disconnect all sensor
connection cables to avoid damage from high voltages.
Welding
Welding currents may be produced when carrying out welding work on nearby compo‐
nents. Welding currents can damage the sensor pipe or the sensor electronics.
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The following must also be observed when welding:
•Disconnect all sensor connections during welding
•Never fasten the grounding point to the piston rod or cylinder pipe
•Never perform welding work directly on the cylinder
•Never perform welding work near a cylinder if it has a built-in sensor
•Welding currents and similar effects can also arise at any bearing location on the
machine
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