SICK MAX30N User manual

OPERATING INSTRUCTIONS
MAX®
Linear encoder

Product described
MAX® linear encoder
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
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 modi‐
fication, abridgment or translation of this document is prohibited without the express
written 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.
2O P E R A T I N G I N S T R U C T I O N S | MAX®8022793/1EFT/2021-12-15 | SICK
Subject to change without notice

Contents
1 About this document........................................................................ 6
1.1 Purpose of this document........................................................................ 6
1.2 Target audience........................................................................................ 6
1.3 Further information................................................................................... 6
1.4 Symbols and document conventions...................................................... 6
1.4.1 Warning levels and signal words............................................. 6
1.4.2 Information symbols................................................................ 6
2 Safety information............................................................................ 7
2.1 General notes............................................................................................ 7
2.2 Intended use............................................................................................. 7
2.2.1 Purpose of the device.............................................................. 7
2.3 Responsibility of user............................................................................... 7
3 Product description........................................................................... 9
3.1 Device variants......................................................................................... 9
3.2 Product identification............................................................................... 9
3.3 Construction and function........................................................................ 10
4 Mounting............................................................................................. 12
4.1 Preparation and installation of the encoder........................................... 12
4.2 Installation cavity for encoder housing................................................... 15
4.2.1 Installation cavity in cylinder base.......................................... 15
4.2.2 Insertion chamfer.................................................................... 16
4.2.3 Bore hole for M12 male connector system and cable gland 18
4.2.4 Bore hole for the retaining screw............................................ 21
4.3 Installation cavity for the piston and piston rod..................................... 23
4.3.1 Bore hole for piston................................................................. 23
4.3.2 Piston rod bore hole................................................................ 23
4.4 Encoder installation.................................................................................. 24
4.4.1 Mounting in the cylinder.......................................................... 24
4.4.2 Mounting M12 male connector system................................. 26
4.4.3 Mounting cable gland.............................................................. 27
4.5 Installation of position magnet................................................................ 28
4.6 Cylinder design......................................................................................... 29
4.7 Cylinder handling after encoder installation........................................... 29
4.7.1 Washing and drying the cylinder............................................. 29
4.7.2 Electrostatic painting of the cylinder...................................... 30
5 Electrical installation........................................................................ 31
5.1 Electrical connection................................................................................ 31
5.1.1 Connection diagram, pin assignment for 4-pin M12 male
connector................................................................................. 31
5.1.2 Connection diagram, pin assignment for 5-pin M12 male
connector................................................................................. 31
CONTENTS
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5.1.3 Connection diagram - cable or single strands....................... 31
5.1.4 Connection sequence.............................................................. 32
5.2 Connection diagram for vehicle electronics............................................ 32
6 Commissioning.................................................................................. 34
6.1 Tolerance considerations for the set point............................................. 34
6.2 Putting the encoder into operation.......................................................... 35
6.3 Select a suitable fuse............................................................................... 35
6.4 Set up the filter wiring - analog................................................................ 35
6.5 Power-up and output signal in the event of a fault................................. 35
6.6 Bus termination - digital........................................................................... 36
6.7 CAN bus protocols.................................................................................... 36
6.8 Communication objects........................................................................... 37
6.8.1 CANopen................................................................................... 37
6.8.2 SAE J1939................................................................................ 37
6.9 Configuration and system startup........................................................... 38
6.9.1 Configuring CANopen.............................................................. 38
6.9.2 Configuring SAE J1939........................................................... 40
6.9.3 System startup for CANopen................................................... 40
6.9.4 System startup for SAE J1939................................................ 41
6.9.5 Setting CANopen operating parameters................................ 41
6.9.6 Setting SAE J1939 operating parameters............................. 42
6.9.7 CANopen encoder data during operation............................... 42
6.9.8 SAE J1939 encoder data during operation............................ 43
6.9.9 CANopen error messages....................................................... 43
6.9.10 SAE J1939 error messages.................................................... 43
7 Maintenance...................................................................................... 44
7.1 Error table................................................................................................. 44
7.2 Checking the functioning of the encoder................................................ 44
7.3 Repairs...................................................................................................... 45
8 Transport and storage....................................................................... 46
8.1 Transport and storage conditions............................................................ 46
9 Decommissioning............................................................................. 47
9.1 Dismantling............................................................................................... 47
9.2 Disposal..................................................................................................... 47
10 Technical data.................................................................................... 48
10.1 MAX® Analog / PWM................................................................................ 48
10.2 MAX® Digital CANopen / SAE J1939...................................................... 51
10.3 Encoder dimensions................................................................................. 54
10.4 Position magnet dimensions.................................................................... 55
10.5 M12 flange dimensions........................................................................... 56
11 Annex.................................................................................................. 57
CONTENTS
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11.1 Accessories............................................................................................... 57
11.2 Specification of additional components................................................. 58
11.3 CE Declaration of Conformity................................................................... 59
CONTENTS
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1 About this document
1.1 Purpose of this document
In the following instructions, the MAX® linear encoder is referred to simply as “encoder”
or “device”.
These operating instructions describe:
•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
•MAX® quickstart
•Technical information - interface description
MAX® product pages
•www.sick.com/MAX®
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
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 General notes
Should humans be 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 MAX® linear encoder is designed for position measurements in mobile hydraulic
applications (e.g. in hydraulic cylinders) and can be used to control the hydraulic com‐
ponents of self-driving mobile machines. The rugged housing offers optimum protection
against dust, climatic influences, vibrations, surrounding media, as well as electrical
and magnetic fields.
The device is a component and must be connected to a suitable electronic control unit.
The MAX® linear encoder fulfills the requirements of the following EMC standards:
MAX30N:
•EN ISO 14982:2009 and EN ISO 13766-1:2018
MAX48N/MAX48A/MAXH1A/F1A:
•EN ISO 14982: 2009 / EN 13309: 2010 / EN ISO 13766-1:2018
•EN 61000-6-2: 2005 / EN 61000-6-3: 2011
2.3 Responsibility of user
Designated users
see "Target audience", page 6.
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
supplied system documentation).
bIf you are not certain whether the device corresponds to the state defined
during project planning or in the supplied system documentation, please
contact 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.
SAFETY INFORMATION 2
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Read the operating instructions
bRead and follow the operating instructions in this document
bFollow all safety notes
bIf there is anything you do not understand, please contact SICK Customer Service
Retention of documents
These operating instructions:
bMust be made available for reference.
bMust be conveyed to new owners.
2 SAFETY INFORMATION
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3 Product description
3.1 Device variants
The device is currently available in these variants:
MAX30N MAX48N MAX48A
Each device variant is available with the following interfaces and connection types:
Analog PWM Digital
M12 male connector, 4-pin
3-wire connecting cable
M12 male connector, 5-pin
Output signals
•Analog (current, voltage)
•PWM (pulse width [%] / frequency [Hz])
•Digital (CANopen, SAE J1939)
NOTE
See product pages of the MAX® www.sick.com/MAX® or:
•MAX48N product information: 8021725
•MAX48A product information: 8025847
•MAX30N product information: 8024964
3.2 Product identification
Type code
Table 2: Type code (example)
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 description (example)
Position Meaning Description
1 Series M = Mobile
2 Technology A = Magnetostrictive
3 Installation type X = Integrated (hydraulic cylinder)
4 Size 48 = MAX48 diameter
30 = MAX30 diameter
5
6 Version N = radial cable routing/plug connector
A = axial cable routing/plug connector
7 Place holder -
8Pipe diameter /
damping / end cap
1 = 10 mm / 30 mm / flat
2 = 10 mm / 36 mm / flat
3 = 10 mm / 63 mm / flat
7 = 7 mm / 30 mm / flat1)
8 = 7 mm / 36 mm / flat1)
9 = 7 mm / 63 mm / flat1)
9 Supply voltage 1 = 12 VDC
2 = 24 VDC
PRODUCT DESCRIPTION 3
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1) MAX30 only
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Position Meaning Description
10 Communication inter‐
face
V = Voltage
A = Current
C = Digital CANopen (250 kbit)
J = Digital SAE J1939 (250 kbit)
P = pulse-width modulation, 5 V signal
11
12
Signal output 10 = current (4 ... 20 mA)
10 = voltage (0.50 ... 4.50 V)
21 = voltage (4.75 ... 0.25 V)
7F = CANopen (node ID 7F Hex)
FD = SAE J1939 (source address JD Hex)
B = pulse width (10 ... 90%)
D = frequency (250 Hz)
13 Connection type A = M12 4-pin analog / PWM
(1 = V DC; 2 = n.c.; 3 = GND; 4 = SIG)
B = M12 4-pin analog / PWM
(1 = V DC; 2 = SIG; 3 = GND; 4 = n.c.)
M= M12 4-pin analog
(1 = n.c.; 2 = V DC; 3 = GND; 4 = SIG)
K = analog cable connection / PWM 3-wire cable
C = M12 5-pin digital
(1 = n.c.; 2 = V DC; 3 = GND; 4 = CAN_HI; 5 = CAN_LO)
D = M12 5-pin digital
(1 = V DC; 2 = n.c.; 3 = GND; 4 = CAN_HI; 5 = CAN_LO)
14 Connector length A = strands, 60 mm
1 = connecting cable, 300 mm
15 Measuring range
Position measurement
in 1 mm steps
e.g., 0300 = 50 ... 300 mm
16
17
18
3.3 Construction and function
Construction of the device
123 4
Figure 1: MAX® design
1M12 connector system
2Encoder housing (electronics)
3Position magnet
4Pressure pipe
Male connector system:
The M12 male connector system requires very little time to attach. It is suitable for
applications in harsh environments up to IP69K (when using a suitable mating connec‐
tor).
3 PRODUCT DESCRIPTION
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Encoder housing (electronics):
The housing is designed to be installed in a hydraulic cylinder and protects the electron‐
ics against external influences.
Position magnet:
The position magnet is the only moving component in the measuring device when
installed in the piston. The position magnet is located inside the piston and moves over
the pressure pipe without contacting it. The magnet field that is produced during this
process defines the current position of the piston.
Pressure pipe:
The pressure pipe is a pressure-resistant structure that is immersed into the cylinder
piston rod. 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
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
produced in the magnetostrictive device component (3). This travels to the converter
(5), and the electronics produce an electrical output signal.
The time interval between the current pulse and the detection of the structure-borne
sound wave is measured, thereby enabling 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.
PRODUCT DESCRIPTION 3
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4 Mounting
4.1 Preparation and installation of the encoder
The method of installation depends on the cylinder design. Installation is typically done
by inserting it into the cylinder pipe. The encoder housing is inserted into the cylinder
base. If the cylinder base is screwed or flanged to the cylinder pipe, installation via
the base side is also possible. This is particularly advantageous for extended stroke
lengths. Encoders with a flange housing (MAXFx) or with a screw-in housing (MAXHx)
are also inserted and fastened in the cylinder from the bottom side.
The encoder dimensions are listed in the technical data: see "Encoder dimensions",
page 54.
Recommended installation position:
MAX48N:
3
1 2
d1
30
(1.18)
>3
(0.12)
19.5 (0.77)
Ø 48f7
(1.89)
Ø 12 (0.47)
51.2
(2.02)
21.2 + 0.2
(0.83 + 0.01)
min. 10 (0.39)
Figure 3: Encoder installed in the hydraulic cylinder, MAX48N with M12 male connector system
1Measuring range
2Damping zone
3Hydraulic port
3
1 2
d1
30
(1.18)
>3
(0.12)
19.5 (0.77)
Ø 48f7
(1.89)
Ø 12 (0.47)
51.2
(2.02)
21.2 + 0.2
(0.83 + 0.01)
min. 10 (0.39)
Figure 4: Encoder installed in the hydraulic cylinder, MAX48N with connecting cable
1Measuring range
2Damping zone
3Hydraulic port
4 MOUNTING
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MAX48A:
1 2
3
30
(1.18)
19.5 (0.77)
51.2 (2.02)
21.2 + 0.2
(0.83 + 0.01)
> 3
(0.12)
min. 15 (0.59)
Ø 48H8
(1.89)
d1
Ø 12 (0.47)
Figure 5: Encoder installed in the hydraulic cylinder, MAX48A with M12 male connector system
1Measuring range
2Damping zone
3Hydraulic port
1 2
3
d1
30
(1.18)
>3
(0.12)
19.5 (0.77)
Ø 48H8
(1.89)
Ø 12 (0.47)
51.2
(2.02)
21.2 + 0.2
(0.83 + 0.01)
min. 15 (0.59)
Figure 6: Encoder installed in the hydraulic cylinder, MAX48A with connecting cable
1Measuring range
2Damping zone
3Hydraulic port
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MAX30N:
3
1 2
d1
32.5
(1.28)
21.5 (0.85)
Ø 31f7
(1.22)
55.2
(2.17)
22.7 + 0.2
(0.89 + 0.01)
min. 10 (0.39)
>3
(0.12)
Ø 12 (0.47)
Figure 7: Encoder installed in the hydraulic cylinder, MAX30N with M12 male connector system
1Measuring range
2Damping zone
3Hydraulic port
3
1 2
d1
32.5
(1.28)
21.5 (0.85)
Ø 31f7
(1.22)
55.2
(2.17)
22.7 + 0.2
(0.89 + 0.01)
min. 10 (0.39)
>3
(0.12)
Ø 12 (0.47)
Figure 8: Encoder installed in the hydraulic cylinder, MAX30N with connecting cable
1Measuring range
2Damping zone
3Hydraulic port
4 MOUNTING
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4.2 Installation cavity for encoder housing
4.2.1 Installation cavity in cylinder base
Fit dimensions and tolerances
Prepare an installation cavity for the encoder housing and electrical connection accord‐
ing to the following dimensions:
1 2
T1 T2T2 T3
d3 d2 d1
Figure 9: Dimensions for installation cavity of encoder housing
1Installation cavity for electrical connection
2Hydraulic port
Table 4: Installation cavity for the encoder housing and electrical connection
Type Installation cavity for elec‐
trical connection
Installation cavity for encoder
housing
Null zone
(d1) Ø(T1) depth (d2) Ø(T2) depth (d3) Ø(T3)
depth
MAX48N 32<=d1<=40 >=10 48 H8 21.2 +0.2 >=52 >=28
MAX48A 25<=d1<=40 >=15 48 H8 21.2 +0.2 >=52 >=28
MAX30N 26<=d1<=28 >=10 31 H8 22.7 +0.2 >=35 >=30
Mean roughness value of the surface: Ra < 0.8 mm
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1
2
3
4
Figure 10: Detailed view of installation cavity for encoder housing
1Bore hole for passing through the electrical connecting cable
2Installation cavity for encoder housing (d2 and T2)
3Threaded hole for the retaining screw
4Diameter (d1) and depth (T1) of electrical connection
4.2.2 Insertion chamfer
To ensure proper and secure installation of the device in the cylinder, a insertion
chamfer 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
cylinder bore hole to the insertion chamfer on the O-ring.
bPrepare an insertion chamfer with a radius of 0.6 mm at the end of the cylinder
bore hole.
4 MOUNTING
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MAX48N and MAX48A
1
23
6.25 ±0.1
(0.25)
21.2 +0.2
(0.83) (0.01)
T1
20°
Ø 48 H8
(1.89)
d1
R 0.6
(0.02)
1.5
(0.06)
Ra 3.2
(0.13)
Ra 0.8
(0.03)
Figure 11: Introduction chamfer MAX48N and MAX48A
1Retaining screw
2Installation cavity for encoder housing
3Installation cavity for electrical connection
MAX30N
1
23
9.25 ±0.1
(0.36)
1.5
(0.06)
22.7 +0.2
(0.89) (0.01)
T1
Ra 3.2
(0.13)
20°
Ra 0.8
(0.03)
Ø 31 H8
(1.22)
d1
R 0.6
(0.02)
Figure 12: Introduction chamfer MAX30N
1Retaining screw
2Installation cavity for encoder housing
3Installation cavity for electrical connection
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4.2.3 Bore hole for M12 male connector system and cable gland
4.2.3.1 M12 flange type S
1.8 (0.07) x45°
12 (0.47)
19 (0.76)
20 (0.79) M12 x1
4x M3
Ø 12.2 ±0.1
(0.48)
14 (0.55)
Ø 3.3 (0.13)
Figure 13: M12 flange type S installation situation
Prepare an installation cavity for the male connector system and flange plate in accord‐
ance with the following dimensions:
Ø 12.2 ±0.1
(0.48)
21.0 ±0.2
(0.83 ±0.01)
21.0 ±0.2
(0.83 ±0.01)
Ø 12.2 ±0.1
(0.48)
4xM3
14.0
(0.55)
14.0
(0.55)
8.0
(0.31)
5.5
(0.22)
Ø 0.1
A
A4x
Figure 14: Prepare an installation cavity for the male connector system and flange plate M12
flange type S
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4.2.3.2 M12 flange type L
R 15.5 (0.61)
10 (0.39)
21 (0.83)
24 (0.94) M12 x1
4x M4
Ø 16 (0.63) H7
17 (0.67)
Ø 4.4 (0.17)
Figure 15: M12 flange type L installation situation
Prepare an installation cavity for the male connector system and flange plate in accord‐
ance with the following dimensions:
17.0
(0.67)
4xM4
16H7
(0.63)
17.0
(0.67)
10.5 (0.41)
7.0
(0.28)
min. 5.0
(0.20)
1.5 ±0.25
(0.06 ±0.01)
Ø 16 H7
(0.63)
15°
26.0 ± 0.2
(1.02 ±0.01)
A
Figure 16: Prepare an installation cavity for the male connector system and flange plate M12
flange type L
4.2.3.3 Cable gland
M12x1.5
6.5
(0.26)
25
(0.98)
Figure 17: Cable gland
Cable gland with M12 x 1.5 connection thread, polyamide V0 terminal insert in accord‐
ance with UL94, NBR O-ring, NBR molded seal, width across flats 14
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Prepare an installation cavity for the cable gland according to the following dimen‐
sions:
NOTICE
Prepare bore hole with thread and plane surface in accordance with figure 18
M12 x 1.5
(0.06)
Ø 10.5
(0.41)
12 (0.47)
20 (0.79) ± 0.2 (0.01)
20 (0.79) ± 0.2 (0.01)
Figure 18: Preparation for cable gland installation hole
Figure 19: For installation with cable gland
4 MOUNTING
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