SINO Lokshun KA800M User manual

KA800M Magnetic Scale
Operation Instructions
GUANGZHOU SINO DRO CO., LTD

Contents
1Safety Precautions...................................................................................................1
1.1 Applications ..................................................................................................................1
1.2 Precautions ....................................................................................................................1
1.3 Validity ..........................................................................................................................1
2Features and Specifications..................................................................................2
3Principle of Operation ..........................................................................................2
4Structure ................................................................................................................3
5Installation .............................................................................................................4
5.1 Priority of installation: ..................................................................................................4
5.2 Fine reference installation .............................................................................................5
5.3 Coarse reference installation .........................................................................................9
6Signal Cables .......................................................................................................12
7Troubleshooting...................................................................................................12

KA800M Magnetic Scale
1 Safety Precautions
This manual is designed for technicians concerning installation and commissioning.
Please read this manual carefully before use.
Unauthorized modification and operation will invalidate the warranty.
1.1 Applications
KA800M Magnetic Scale is a linear displacement sensor designed with a theoretical
measuring length of up to 100m. With an extremely high precision, the magnetic is mainly
applied to heavy lathes, as a position measuring device of a lathe. Showing the positions of
lathe moving parts through digital display, it facilitates the machining and improves the
precision of machining.
1.2 Precautions
Always follow safety rules and regulations when using the displacement sensor. Do take
measures to ensure that the sensor will not bring any danger to operator or devices like limit
switch and emergency stop switch.
1.3 Validity
The manual is only designed for KA800M magnetic scale.
For instructions of other sensors of KA series, refer to their corresponding manual.
The displacement sensor complies with 73/23/EEC directive for low-voltage
electric apparatus and 89/336/EEC directive for EMC.
We are certified with ISO 9001: 2000 by World-a British international certification
company.
1

KA800M Magnetic Scale
2 Features and Specifications
KA800M magnetic scale is a non-contact displacement measurement system, using detection
of magnetic signals, which features:
- High precision of up to ± 10µm / 300mm or ± 20µm / 1000mm,
- Measurement length of up to 3–100m,
- Low sensitivity to impact, vibration and contamination (e.g. dirt and petroleum),
- ease of maintenance due to high resistance to wear, and
- Robustness.
Specifications:
- Resolution: 1µm
- Output signal: RS422
- Operating voltage: 5V±5%
- Max. moving speed: 30m/min
- Operating temperature: -20–70℃
3 Principle of Operation
The read head is fixed on a part of the lathe, and does not move. When the KA800M body is
connected to the moving part of the lathe, the tape on the body records an alternating
magnetic field with north and south poles, while the two increment sensors of magnetic head
on the read head measures the alternating magnetic field.
Since the tape is not in contact with the magnetic head, the two increment sensors on the
entire magnetic head must be always located above the tape, which pick up the period of the
alternating magnetic field so that the controller can determine the distance. In order to
determine the direction of movement, an offset exists between these two increment sensors,
and the sine output signals of the sensors have a phase shift of 90°, which can be considered
as a sine and cosine signals. Both the signals are converted into A/B pulses by the magnetic
head, which is then sent to the controller (RS422) to generate differential signals. A phase
shift exists between the A and the B digital signals shifting periodically, so as to determine
the direction of sensor.
2

KA800M Magnetic Scale
4 Structure
KA800M magnetic scale mainly consists of the body and the reading head. The body
consists of the head section, the standard section and the end section (Fig. 4.1). Only one
head and end sections are provided, and the quantity of standard sections may vary as the
measuring length changes.
Head section
Body end cover Standard section
Sealing
End section
Sealing
Body end
cover
Read hea
d
Signal cable
Fig. 4.1 Structure of product
Screw
Body cover
Scale casing
The sections consist of casings of sections and body cover
secured by M3×8 hex socket cap screws (Fig. 4.2).
Dimensions of the structure are as shown in Fig. 4.3.
Note: L0 is the effective measuring length.
Fig. 4.2 Structure of body
Fig. 4.3 Dimensions of structure
3

KA800M Magnetic Scale
5 Installation
5.1 Priority of installation:
(1) To install the magnetic scale, the scale shall be kept parallel with the lathe guide rail.
(2) The center of the measuring range of magnetic scale shall be located at the center of the
lathe travel. In addition, ensure that the actual measuring range of the magnetic scale is
at least 50mm greater than the maximum travel of the lathe.
(3) The magnetic scale shall be located as near as possible to the transmission screw rod of
lathe. Mostly, the magnetic scale will move together with the workbench after
installation, and the read head is fixed on the lathe, namely it is better that the wire does
not move.
(4) The magnetic scale shall be so installed that the operation of lathe is not blocked and
the instinctive functions of the lathe are not degraded.
(5) The magnetic scale shall be installed so that it will not be hit during machining, not
block the operation of any lathe handle, braking device or other projections, and not be
touched easily during workpiece loading or unloading.
(6) The magnetic scale shall be installed correctly as shown in Fig. 5.1 (with the read head
upwards and body downwards). Do not expose the sealing side on the body right to the
coolant injection of the lathe.
Fig. 5.1 Do not reverse!
Fine or coarse reference installation is optional according to the site conditions. Fine
reference installation means that the installation reference face on the lathe is installed by
machining, and coarse reference installation means that he installation reference face on the
lathe is not installed by machining.
4

KA800M Magnetic Scale
5 Installation
5.2 Fine reference installation
Steps of installation:
(1) Machining reference face: Select a suitable place for installation and installation
reference face. The installation reference face shall be machined to a roughness of
Ra6.3. Drill M6 screw holes on the installation reference face with intervals and
dimensions as shown in Fig. 4.3.
(2) Installation of scale casing: Install the casings of head, standard and end sections
accordingly to the reference face. Connect all casings with cylindrical pins, and apply
sealing rubber to the connections without any gap as shown in Fig. 5.2, so as to ensure
good sealing. After installation, correct the surface to a range within 0.1mm
horizontally and vertically as shown in Fig. 5.3.
Vertical
<0.1mm
m
Horizontal
<0.1mm
m
Sealing rubber Cylindrical pin
Fig.5.2Casingconnection Fig.5.3Correctionofsurface
(3) Installation of steel strip: Push the entire steel strip into the open slot as shown in Fig.
5.4. Push two Ф2.5 sealing strip orderly into the open slot, and press down the steel
strip to make it flat as shown in Fig. 5.5. After pressing down the steel strip securely,
clean the strip with acetone, alcohol or gasoline, so as to attach the tape securely.
Sealing strip
Jig
Jig moving
direction
Steel strip
Fig. 5.4 Installation of steel strip Fig. 5.5 Pressing down steel strip
5

KA800M Magnetic Scale
5 Installation
(4) Attachment of tape: Remove the backing as shown in Fig. 5.6, and attach the tape
straight on the specified position on the steel strip by clamping the tape with a jig. (Figs.
5.6 and 5.7)
Sticker
Tape
Stainless
steel strip Magnetic
material
Sticker Jig moving direction
Attachment
face
Fig.5.5Structureoftape Fig.5.6Useofjig
Jig moving direction
Tape Jig
Fig. 5.7 Attachment of tape
Note:
①Since the tape is one of the critical parts of magnetic scale, special attention shall be
paid during attachment, and the tape shall be kept straight to attach by fixing by a jig.
②The tape shall not be exposed to any impact from external magnetic field, and shall not
be in contact with a solenoid valve or other permanent magnetisms.
③Before attachment of tape protection strip, the tape shall be kept clean. If it is stained,
clean it with acetone, turpentine oil or soft plastic tool instead of gasoline.
(5) Attachment of tape protection strip: Attach a stainless steel protection strip over the
tape surface in the same way for attachment of tape, and secure the steel strip to the
casing of the head section with an M3×4 screw, with one end unfixed.
6

KA800M Magnetic Scale
5 Installation
(6) Installation of read head: Put the sealing strip through the Ф4 hole, with the toothed
edge upwards (Fig. 5.8). Install the connection base symmetrically on both sides of the
read head, with the base closely placed to the both contact face as shown in Fig. 5.9.
Fix the read head to the scale casing with a jig as shown in Figs. 5.10 and 5.11.
Installation
connection base
The
contact
face shall
be close
d
attached.
Sealing strip Read head
Fig. 5.8 Installation of sealing strip Fig. 5.9 Read head installed to the connection base
Supporting
the
installation
connection
base
securely
Jig
Installation
connection
base laid on
the scale
casing
Fig. 5.10 Positioning of jig Fig. 5.11 Side view
The ends of signal cable can be reversed. Since the read head cover is a symmetrical type,
the cover can be removed and installed reversely, so as to adjust the cable outgoing direction
(Fig. 5.12).
7

KA800M Magnetic Scale
5 Installation
Signal cable
Fig. 5.12 Cable direction reversion
Connect and fix the read head to the moving part of the lathe. General accessories provided
include: T-support A, B, C, D, and E, which are optional and used as a transition part for
connection between the read head and moving part of the lathe.
Remove the jig and the connection base of read head, and distribute the signal cabling.
(7) Test of magnetic scale
Connect the cable to the digital display, and switch on the power supply for the digital
display after they are securely connected, so as to check that the measurement of magnetic
scale is normal. Compare the read-out with a length reference, and perform further
installation. In case of failure, switch off the power supply, refer to the “Troubleshooting”
section (on page 12) for maintenance, and perform the further installation.
(8) Installation of Ф2 sealing strip: To install the strip, put the sealing strip through the
round rubber hole as shown in Fig. 5.13.
(9) Installation of scale body cover: Align the body cover with both ends of the scale
casing, and secure it with M3×8 screws in the same way as shown in Fig. 5.14.
(10) Installation of sealing strip: Close the sealing strip with toothed edge for dust
proofing as shown in Fig. 5.15.
(11) Installation of covers of both ends: Apply some sealant before fixing the end covers.
Apply sealant on the exposed position of the Ф2 sealing strip, so as to ensure a good
sealing effect as shown in Fig. 5.16.
8

KA800M Magnetic Scale
5 Installation
Sealing strip
Putting through the
round hole
Cylindrical pin
Fig. 5.13 Installation of sealing strip Fig. 5.14 Installation of body cover
Application of sealant
Self-tapping screw
Fig. 5.15 Installation of strip Fig. 5.16 Application of sealant
5.3 Coarse reference installation
Brackets are options specially designed for coarse reference installation.
Installation method: Install and adjust securely the brackets to the designated position on the
lathe bed, with each bracket corresponding to connection position of the magnetic scale.
Adjust to the brackets within 0.1mm horizontally and vertically on the installation reference
face by adjusting the screws. The method for bracket installation is as shown in Figs. 5.17
and 5.18.
9

KA800M Magnetic Scale
5 Installation
Adjusting screw
M5 X 16 Fixing screw
M6 X 20
Adjusting screw
M5 X 16
Scale casing
installation hole M5
Vertically
<0.1mm
Lathe bed
Bracket
Adjusting screw
M5 X 16 Horizontally
<0.1mm
Fig. 5.17 Installation method for bracket adjustment
Unit: mm
Full length of magnetic scale=L0+214
Locations of scale casing connection n+4 brackets
KA800M magnetic scale
Fig. 5.18 Installation dimensions and quantity of brackets
As shown in Fig. 5.18: X=L0+214-(47+1160+1200+47)=L0-2240
L0is the effective measuring length.
If X≥1900, L=X-n×1200 (700≤L≤1800).
10

KA800M Magnetic Scale
5 Installation
If 700≤X≤1800, X=L and n=0.
e.g. if the effective measuring length L0of the magnetic scale is 9000mm
X=L0-2240=9000-2240=6760
X=6760≥1900, L= X-n×1200, 700≤L≤1800
L=6760∵-n×1200, 700≤L≤1800
n=5∴, L=760mm
The quantity of brackets is n+4=9.
Steps of coarse reference installation:
(1) Installation of bracket: Drill M6 screw holes to install a bracket. For installation method
and dimensions, see Figs. 5.17 and 5.18.
(2) Installation of scale casing: Fix the scale casing on the bracket as shown in Fig. 5.19.
Fixing screw
M5 X 16
Scale casing
Bracket
Lathe bed
Closely attached
to installation
face
Fig. 5.19 Installation of scale casing
Steps (3)–(11) are the same as those of fine reference installation.
11

KA800M Magnetic Scale
6 Signal Cables
1 5
69
FG
(1) Pinout: See Table 6.1.
Table 6.1 Pinout
Pin No. 1 2 3 4 5 6 7 8 9
Signal
A
OV
B
Idle
Z
A +5V B Z
Color Black / Black FG Black Green Red Orange White
Orange White /
Green
/Black
(2) Length of cable
The length of standard cable is 5m.
7 Troubleshooting
Failure Cause Solution
Insufficient voltage Turn on the digital display and
check the LED for short
circuit, or check that the digital
display switch is turned on or
the power supply is connected.
Excessive voltage drop
Check the voltage
An operation voltage of
5V±5% shall be supplied to
the system.
of cables.
The digital display rec
distance information
(sometime
eives no
s) or the LED
flashes.
ic scale cable cified byAny magnet
unconnected
Connect cables as spe
the circuit diagram.
The clearance between the
magnetic and tape of this
distance is not as specified.
is shown.
Adjust the height of the
magnetic head, and manually
move it to the whole travel
until the information
No signal is produced at
certain measuring distance.
ged by
Replace the tape.
The magnetic pole of tape of
the distance is dama
strong magnetic field.
The linear error exceeds the
owable range. d and the tape is
excessive.
position of
magnetic head.
The clearance between the
magnetic hea
Correct the
all
12

GUANGZHOU SINO DRO CO., LTD
http://www.sino-ld.com
Service on-line:02081639851