Waycon SX300 Series User manual

MANUAL
Draw Wire Sensor
SERIES SX300

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COPYRIGHT
This document is copyrighted by WayCon Positionsmesstechnik GmbH. Changes to, additions to and duplications of
this manual are prohibited without the prior written approval of WayCon Positionsmesstechnik GmbH.
SUBJECT TO CHANGE
WayCon Positionsmesstechnik GmbH reserves the right to change this document without notice.
VERSION NUMBER
4.0
STAND
08.07.2020
CONTACT
WayCon Positionsmesstechnik GmbH
Mehlbeerenstraße 4
82024 Taufkirchen
Phone.: [phone]
Fax: [phone]
Email: [e-mail]
Internet: www.waycon.biz
© WayCon Positionsmesstechnik GmbH

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TABLE OF CONTENT
1 GENERAL INFORMATION ������������������������������������������������������������������������������������������������������������������������������������������������������������4
1.1 Product identication....................................................................................................................................................................................................4
2 PRODUCT DESCRIPTION��������������������������������������������������������������������������������������������������������������������������������������������������������������4
3 TECHNICAL DATA �������������������������������������������������������������������������������������������������������������������������������������������������������������������������5
3.1 Technical Data Mechanic ..............................................................................................................................................................................................5
3.2 Technical Data Encoder.................................................................................................................................................................................................5
4 Safety Instructions ������������������������������������������������������������������������������������������������������������������������������������������������������������������� 10
4.1 Instructions for safe start-up ....................................................................................................................................................................................10
4.1.1 Flushing of transducer and cylinder............................................................................................................................................................10
4.1.2 Venting of transducer.......................................................................................................................................................................................10
4.1.3 Initial testing of encoder .................................................................................................................................................................................10
4.1.4 Initial testing of transducer ............................................................................................................................................................................10
4.2 Instructions for safe use.............................................................................................................................................................................................10
4.2.1 Operating medium............................................................................................................................................................................................11
4.2.2 Regular checks of screwed connections and leak tightness..............................................................................................................11
4.2.3 Double acting cylinders...................................................................................................................................................................................11
4.3 Instructions for safe handling..................................................................................................................................................................................11
5 INSTALLATION��������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 12
5.1 General Information Notes .......................................................................................................................................................................................12
5.1.1 Wiring and electrical connections................................................................................................................................................................12
5.1.2 Fixing devices and screws...............................................................................................................................................................................12
5.1.3 Mounting position and accessibility...........................................................................................................................................................12
5.1.4 Applying extra weight to the transducer..................................................................................................................................................12
5.2 Fixation of the wire at the piston............................................................................................................................................................................13
5.3 Mounting procedure instruction............................................................................................................................................................................13
5.8 Mounting of a rotary transducer with shaft........................................................................................................................................................15
5.9 Mounting of the Series M58.....................................................................................................................................................................................16
6 MAINTENACE AND SERVICE����������������������������������������������������������������������������������������������������������������������������������������������������� 17
6.1 Maintenance Plan.........................................................................................................................................................................................................17
6.2 Elimination of failures during operation..............................................................................................................................................................17
6.3 Encoder change............................................................................................................................................................................................................18
6.4 Disassembly of transducer .......................................................................................................................................................................................19
6.5 Changing o-ring seals of ange assembly ..........................................................................................................................................................23
6.6 Final work after dismantling.....................................................................................................................................................................................24
6.6.1 Storage...................................................................................................................................................................................................................24
6.6.2 Tightening torques for screws.......................................................................................................................................................................24
7 Spare parts �������������������������������������������������������������������������������������������������������������������������������������������������������������������������������� 24
7.1 Exploded view ...............................................................................................................................................................................................................24
7.2 Exploded view - encoder assembly and attachment parts...........................................................................................................................25
7.2.1 Part list - encoder assembly and attachment parts...............................................................................................................................25
7.3 Exploded view – ange assembly ..........................................................................................................................................................................25
7.3.1 Part list – ange assembly...............................................................................................................................................................................26
7.4 Exploded view – transducer housing....................................................................................................................................................................26
7.4.1 Part list – transducer housing........................................................................................................................................................................26
8 EXAMPLE TEST REPORT������������������������������������������������������������������������������������������������������������������������������������������������������������ 27

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1 GENERAL INFORMATION
1�1 Product identication
All transducers are marked with a label and a security note. Additionally the serial number is stamped into the transducer housing
nearby the test point. For any questions regarding the transducer or spare parts, please specify the type and serial number.
2 PRODUCT DESCRIPTION
The WayCon SX300 Draw Wire Series is designed for use in combination with hydraulic cylinders and measuring the cylinder
position. Especially designed for long stroke cylinders with pressurized housings to be anged directly to the cylinder head. By
giving feed back signals to a machine control unit, it is possible to control the position of a cylinder, to program specic movements
or to manage synchronous movements of several cylinders. Due to its small overall size, its short assembly time and its possible
customisation, this sensor technology is a cost-eective and exible solution for a wide range of industrial applications.
Typical Applications
►hydraulic gates for dam control
►synchronous run of more than one cylinder
►sluice gate control
►cylinder acceleration and speed control
►stroke control of fairground ride applications
spring set /wire retraction
mounting ange
lling pipe
rope xation clip
wire rope outlet
vent hole
rotation shaft
rotary encoder
connector
main housing
(pressurized)
wire rope capstan

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3 TECHNICAL DATA
Measurement range [m] 10 / 15
Linearity [%] ±0.05 (depending on the used encoder)
Sheave circumference [mm] 568.9
Operating temperature [°C] -20...+70
Hydraulic uid only non-hazardous uids (non-ammable, non-toxic), no gaseous media
Operating pressure [bar] 300 (30 MPa)
Testing pressure [bar] 400 (40 MPa)
Pressure port Minimess 1620
Piston travel speed [m/s] max. 2 (in air) 
Rope tension [N] start of measurement range: 10...11.5 (13...16.5)
end of measurement range: 29...31.5 (37...43)
Wire sag (calculated) [mm] <30
Connector orientation adjustable in 90° steps
Weight [kg] 61
Housing 2) 42CRMo4 (1.7228)
Draw wire stainless steel 1.4301, Ø 0.69 mm
Encoder requirements
[mm]
ange with stator coupling Ø 58
pitch circle diameter for xing screws 63
hollow shaft Ø 15
 identified laboratory value without hydraulic fluid
2) In case of outdoor use we recommend to varnish the housing additionally. Attention: Do not varnish moving parts (encoder shaft, coupling...)!
Output signal
Link to the encoder
SSI
8�5883�
6624�G322
CANopen
8�5888�
6622�2123
Probus-DP
8�5888�
6632�3113
EtherCAT
8�5888�
66B2�B212
Pronet
8�5888�
66C2�C212
4���20 mA
M58-SC-W-10-
420A-SR12
Linearity [%] ±0.05 (independent of the measurement range))
Resolution scalable
(via Software)
no yes no
Resolution standard [Pulses/mm]
[Bit]
14,4
13
14.4
13
-
12
Sensor element Multiturn-Absolute-Encoder with optical disc Multiturn-
magnetic
Connection connector M23,
radial, 12 pins
2 x connector
M12, radial
3 x connector
M12, radial
3 x connector M12, radial, 4 pins connector M12,
radial, 5 pins
Power supply [VDC] 10...30, reverse polarity protection of the power supply
Current consumption
(no load, 24 VDC) [mA] max. 50 max. 100 max. 120 max. 200 max. 30
Protection class IP67 IP65
Humidity max. 90 % relative, no condensation -
Temperature [°C] -40...+90 -40...+80 -40...+85 -40...+85
Special cables needed yes no
Link to manual - CANopen Probus-DP EthcerCAT Pronet 4...20 mA
Link to device le - EDS GSD XML GSDML -
3�1 Technical Data Mechanic
3�2 Technical Data Encoder

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3�2 Dimensions
Flange type F1 (rod sealing) for SSI /PROF / CAT / CAN / NET
1:51:5
VENTILATION HOLE
POSITION OF ENCODER OUTPUT AND
PROTECTION CAP ROTATABLE IN STEPS OF 90°
Ra0,8
Ra0,8
encoder cap:
for SSI encoder: X = 71 mm
for Profibus encoder: X = 98 mm
for EtherCAT encoder: X = 98 mm
for CANopen encoder: X = 98 mm
106,5
146
222
99
Ø
X
SCREWED
SEALING PLU
G
30°
Ø
245
Ø
18
12-BORE
Ø
249
229
189,5
28
Ø
130 f7
Ø
279
Ø
1,5 x 45°
1,5 x 45°
35
115
150
196,5
MINIMESS 1620
2103-01-18.00
M10 EYE BOLT
DIN 580
22
65
157
3 TECHNICAL DATA

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Flange type F2 (piston sealing) for SSI / PROF / CAT/ CAN / NET
1:5
VENTILATION HOLE
POSITION OF ENCODER OUTPUT AND
PROTECTION CAP ROTATABLE IN STEPS OF 90°
FLANGE SEALING:
O-RING 123,42 x 3,53 (NBR)
AND BACK-UP RING
Ra0,8
Ra0,8
encoder cap:
for SSI encoder: X = 71 mm
for Profibus encoder: X = 98 mm
for EtherCAT encoder: X = 98 mm
for CANopen encoder: X = 98 mm
106,5
146
222
99
Ø
X
SCREWED
SEALING PLU
G
30°
Ø
245
Ø
18
12-BORE

249
229
189,5
28
Ø
130 f7
Ø
279
Ø
1,5 x 45°
1,5 x 45°
35
115
150
196,5
MINIMESS 1620
2103-01-18.00
M10 EYE BOLT
DIN 580
22
65
157
3 TECHNICAL DATA

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3 TECHNICAL DATA
Flange type F1 (rod sealing) for 4���20 mA
99
31
100
35
48,5
123,5
345,5
Ø
Ø

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Flange type F2 (piston sealing) for 4���20 mA
99
31
100
35
48,5
123,5
345,5
Ø
Ø
3 TECHNICAL DATA

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4 SAFETY INSTRUCTIONS
4�1 Instructions for safe start-up
Start-up is permitted only, if it is ensured that
1. all xings and connections have been installed correctly.
2. the plant / the components have been lled with the proper oil.
3. the laid piping and the hydraulic cylinder have been cleaned inside and were duly ushed prior to combining the system.
4�1�1 Flushing of transducer and cylinder
Before the application may be initially operated at full operating pressure and operating speed, all components must be ushed
thoroughly. Please refer to the cylinder instruction guidelines.
4�1�2 Venting of transducer
Before operation it is necessary to vent the transducer via the test point connection or the screwed sealing plug. Please make
sure that in both cases the used vent hole is the highest point of the transducer. Proper venting is indicated so that the oil is
free from bubbles and foaming. (Minimess and plug are interchangeable.)
4�1�3 Initial testing of encoder
Connect the encoder in a de-energized state only. Make sure that the operating voltage for the encoder is correct and the max.
permissible output current is not exceeded (see technical data). The operating voltage for encoder and succeeding device must
be turned on and o together. For setting up functions refer to the technical data chapter.
4�1�4 Initial testing of transducer
As soon as the operating temperature has reached the specic value, the plant must be shut down. After this all screw
connections must be checked and tightened, if necessary.
Note: Avoid that eyes and skin get in contact with the operating medium�
(Consult a physician, if required)�
Minimess test-point
screwed sealing plug
4�2 Instructions for safe use
The transducer may be used only xedly installed to a hydraulic cylinder in suitably safeguarded applications. Keep your plant
as clean as possible. This ensures you a trouble-free operation and a long service-life.
Please follow the instructions of all applicable manuals:
►this instruction manual
►hydraulic cylinder guidelines/manual
►encoder manual

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4�2�1 Operating medium
During operation the maximum oil temperature must not exceed +70 °C! Continuous monitoring is indispensable.
If necessary, a cooling system must be provided. The operating medium must be checked for contamination or ageing in regular
intervals, so that it can be exchanged in time. Relling only with compatible oil. Please refer to the hydraulic cylinder guidelines.
The use of the sensor is only permitted with non-hazardous hydraulic uids (not-ammable, non-toxic).
4�2�2 Regular checks of screwed connections and leak tightness
Tightening of screwed connections is part of the regular maintenance. A constant maintenance must be independently and
suciently ensured by the user of the application. The main housing of the transducer, the rotating shaft sealing and the ange
connection between transducer and cylinder have to be checked regularly on leak tightness.
4�2�3 Double acting cylinders
Do not use the SX300 in combination with a double acting cylinder.
Note: The responsibility of performing a regular maintenance service rests with the operator
of the facility� WayCon will not carry out any maintenance service, neither in the course
of new installation nor in the course of warranty or guarantee services!
4�3 Instructions for safe handling
According to the weight of the transducer a suitable lifting device (crane) must be used for installation. Care must be taken that
the applied belts are designed in such a way that loosening during handling as well as any possible damage of the transducers
is impossible.It is not allowed, to lift the hydraulic cylinder at the eye bolt of the transducer. Be aware of the Minimess test-point
near by the eye bolt.
Note: It is not allowed to lift the hydraulic cylinder at the transducer lifting device (eye bolt)�
It is also not allowed to use the eye bolt of the transducer to do any positioning of the
hydraulic cylinder at� Please refer to the hydraulic cylinder guidelines�
test-point
eye bolt
4 SAFETY INSTRUCTIONS

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5 INSTALLATION
5�1 General Information Notes
The installation of the transducer to the hydraulic cylinder must be done by trained and qualied tters only.
5�1�1 Wiring and electrical connections
To avoid damage due to wrong wiring we strongly recommend to do the electrical connection according to the wiring
instructions of the encoder.
All existing safety devices for electrical installations have to be ready for operation and must be checked regularly.
►Before setting in operation, connect all required strands as per data sheet. To prevent short-circuits, neatly insulate the ends
of all strands which are not required.
►When pre-assembling the mating connector, comply with any instructions accompanying the connector.
►Our recommendations regarding cable lengths:
• in case of asymmetrical transmission, i.e. inverted signals are not used, cable length max. 10 m.
• in case of symmetrical transmission (e.g. to RS 422), cable length max. 50 m (cable with twisted pairs of wires).
►Plug in or pull out mating connector at the encoder only when encoder is de-energized.
►Make certain that the operating voltage is correct and the max. permissible output current is not exceeded (see data sheet).
►The operating voltage for encoder and succeeding device must be turned on and o together.
ln order to maintain CE-Conformity the EMC installation conformity must be followed. Shielded cables should be used or control
lines. The cable shield should, if possible be connected fully enclosed (360º) by shielded connectors or cable bushings. This has
to be done at the encoder and transmission end.
►The protection earth should be put with low impedance on both face and back of the encoder and the transmission end.
►In case of earth loop problems, the protection earth of the encoder side has to be removed. On this occasion the encoder
should be placed electrically isolated opposite the actuation.
►The encoder lines should run separately from cables with high noise levels. Consumers with high disturbance levels, e.g.
frequency converters, solenoid valves, contactors etc. should not be connected to the same voltage supply. Otherwise, a
suitable voltage ltering has to be installed.
Note: Please refer to the additional encoder instruction guidelines�
5�1�2 Fixing devices and screws
The bolts, nuts and stud bolts used for xing the transducer to the cylinder must be at least of quality 8.8. Please refer to the
cylinder manual.
5�1�3 Mounting position and accessibility
Generally the transducer can be installed in any mounting position desired. However the mounting position shall be chosen in such a way that
a good accessibility with respect to later maintenance is ensured. For proper ventilation the testpoint or screwed sealing plug must be the
highest point of the sensor.
5�1�4 Applying extra weight to the transducer
The transducer must always be installed in such a way to the cylinder that no extra load is applied to the transducer. This means that no other
parts or holders are allowed to be xed to the transducer. If an additional housing is required, it must be xed directly to the hydraulic cylinder,
not to the transducer.
Note: The transducer must always be installed to the cylinder in such a way that no
extra load is applied to the transducer� This means that no other parts or
holders are allowed to be xed to the transducer� Do not move or lift the
cylinder by exercising force to the transducer�

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5�2 Fixation of the wire at the piston
Use a suitable xation for the wire inside the cylinder. WayCon recommends to install a“clipxation”unit, that is screwed into
the piston. It is available as accessory.
Note: Because the rope must be extracted vertically from the sensor (maximum
variation from the vertical is 3°), it is very important to chose the wire xation
point at the piston in its center� If the wire gets extracted at an inclination the
durability of the wire is reduced considerably and a wire breakage will be
unavoidable in the end�
Piston wire xation
clip fixation
rope clip
hydraulic cylinder housing
piston
Clipxation M8
hex nut M14, DIN439
6
Ø 3,5
40
36,5
max. 28 3
30
M 8
13
Clipxation M14
hex nut M14, DIN439
11
Ø 4
50
45
max. 28
M 14
3,1
22
36,5
5 INSTALLATION
5�3 Mounting procedure instruction
Please make sure that the SX300 has the correct
measurement range, before starting the installation.
In order to calculate the correct measurement range
the pre-extraction (distance between the piston and
the sensor, while the piston is in its end position = the
closest to the SX300; picture 1) has to be deducted from
the nominal measurement
range. The result is the actual usable measurement
range.
As a result the nominal measurement range of the SX300
has to be greater than the cylinder stroke + the pre-
extraction + reserve (picture 2).
If the calculation of the measurement range was done
incorrectly, a tearing of the wire rope may happen! picture 2
cylinder
stroke
pre-
extraction
bottom
position
piston
top
position
piston
pre-
extraction
top
position
piston
picture 1

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The wire xation unit has to be screwed into the piston of the cylinder and locked
with counter nut.
Note:
Use screw locking device. If it is not possible to work through the cylinder head
bore, you have to take o the cylinder head (please refer to the cylinder manual).
Install 3 stud bolts at the cylinder head.
It is necessary to use stud bolts on the underside of the Sensor ange, as
conventional screws (e.g. according to DIN 912) cannot be mounted for space
reasons.
Note:
Studshaveto be greased with MoS2during assembly,unless otherwise described.
Please follow the operating instructions for the cylinder.
Move the transducer near the cylinder bore. Use a crane if necessary. Remove the
red protective cap at the cable outlet of the sensor. Open the rope clip, guide the
rope through the hole and hang the rope clip in the clip xation. Finally, close the
rope clip again.
Note: Do not let the draw wire snap! If the draw wire retracts freely into the
sensor, it can cause injury and damage the device. Take care when unhooking
and retracting the draw wire into the sensor. Avoid leading the draw wire over
edges or corners.
Move the transducer toward the cylinder head and insert the stud bolts through
the bores in the ange.
Note:
Avoid leading the rope over edges or corners. Be careful not to damage the
O-ring. Do not operate the sensor if there are buckles or damages in the draw
wire. Tearing the draw wire may cause injury or damage to the sensor.
Mount the xing screws through the ange and tighten them crosswise with a
torque of 100 Nm in the rst step.
Note:
The fastening screws must be greased with MoS2 during assembly, unless
otherwise described. Please follow the operating instructions for the cylinder.
5 INSTALLATION

5�8 Mounting of a rotary transducer with shaft
Note:
It is mandatory that the rotary transducer has a clamping ange of 36 mm,
shaft Ø10 mm and shaft length of 20 mm
Step 1:
Mount the coupling onto the shaft of the rotary transducer. Make sure to
leave a gap of 4 up to 5 mm between coupling and rotary transducer ange.
Step 2:
Mount the rotary transducer onto the adapter ange with three DIN912 M4x20 screws.
Use the bores as shown.
Step 3:
Mount the adapter ange with the rotary transducer onto the SX300.
To x, use four DIN912 M8x55 screws and four spacer sleeves 8x14x35.
Step 4:
Secure the coupling to the SX300 shaft by tightening the two setscrews.
Use a torque of 2 up to 2.5 Nm.
Attention: Do not apply excessive force!
Step 5:
Fix the protection cap with three M8x90 (for Series Encoder M58) screws.
Make sure that the opening leaves the connector output free.
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5 INSTALLATION
Screw the nuts onto the stud bolts at the bottom of the ange. Tighten the bolts
and nuts crosswise to the specied torque. Observe the following values if the
manual of the cylinder does not prescribe a torque:
• 145 Nm for M16, quality 8.8
• 215 Nm for M16, quality 10.9
• 250 Nm for M16, quality 12.9
Note:
The nuts must be greased with MoS2 during assembly, unless otherwise specied.
Please follow the operating instructions for the cylinder�

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5 INSTALLATION
5�9 Mounting of the Series M58
Example: SX300-15-M420AT, cylinder stroke 9�5 m
Nominal measurement range SX300: 15 m
Output signal: 4...20 mA
The output signal is approx. 4 mA while the wire rope is retracted.
The output signal is approx. 20 mA while the wire rope is extracted.
The wire rope gets connected to the piston, while the piston is in its
top position (picture 1). In case this pre-extraction would be 1 m, the output
signal would be 5.07 mA. As the cylinder stroke is 9.5 m, the output signal at the
pistons bottom position would be 15.2 mA.
In this example the wire rope would be totally extracted for 10.5 m.
For this reason a SX300 with a nominal measurement range of 10 m would not
be sucient, although the cylinder stroke is only 9.5 m.
Note:
Please use for teaching of the rotary transducer the manual of the Series M58 (Link)
pre-
extraction
top
position
piston
picture 1
picture 2
cylinder
stroke
pre-
extraction
bottom
position
piston
top
position
piston
Protection cap completely mounted.
Draw wire sensor SX300 with the completely mounted rotary transducer

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6 MAINTENACE AND SERVICE
6�2 Elimination of failures during operation
In spite of correct installation, normal use and regular maintenance, there may be failures in mechanical or electrical matters.
Please refer to following table:
Fault Cause of trouble Repair
Leakage Leakage above ange connection Exchange o-ring between transducer ange and cylinder head,
check seal face at cylinder/transducer
Leakage above transducer housing Dismantle, exchange o-ring of transducer housing, exchange
of all sealings is recommended!
Leakage above rotating shaft
either on spring side or encoder
side
Dismantle, check rotating shaft for damage, new rotating
shaft, new seal, new bearing, exchange of all sealings is
recommended!
Leakage of ange, ange adapter
and ange
Dismantle ange and lling pipe, check o-rings and back-up
rings of lling pipe, check o-rings of M12 screws, exchange
of all sealings is recommended!
No encoder output signal in general No supply Check connector and wiring.
Wrong or broken connection Check connection, check encoder, change encoder
Supply over-voltage Check supply, check encoder, change encoder
Piston moves without change of
signal and without transducer shaft
rotation
Broken wire inside cylinder Dismount transducer from cylinder, dismantle transducer,
check springs, new spring set, new wire set, new rotating shaft
and seal
Piston moves without change of
signal and without encoder rotation
Encoder hollow shaft loose Tighten the hollow shaft onto the rotation shaft of the
transducer
High hysteresis in output signal Encoder stator coupling broken or
loose
Check encoder stator coupling, change if necessary
Note: We highly recommend to carry out all repairs by transducer specic skilled and
trained tters only�
Proper maintenance includes the regular check of the operating medium, check for leakages, check of encoder xation and the
output signal control.
6�1 Maintenance Plan
This maintenance plan gives you a general outline about the recommended intervals of servicing the SX300. The need for
replacing certain components strongly depends on the application and the environmental conditions that the SX300 is used in.
For example a SX300 that performs 50 full strokes per day and is exposed to wind and weather, should obviously be serviced
more often, than a sensor that is installed indoors and used only once or twice a day.
Action Description Interval every Responsible
Checking for oil leaks Detailed examination of the housing for signs
of leaking hydraulic oil. (Special attention on
Minimess and sealing plug)
6 months Service technician
Checking for damage in the protection
coating
Detailed examination of the housing for signs of
chipped areas, or rust
6 months Service technician
Recommended replacement of the
spring package
full stroke per day : 1/10/25
more than 50 full strokes per day
10/6/5 years
3 years
specially trained and
WayCon certied personnel
Checking of encoder Detailed examination of the encoder for signs of
wear, rust, moisture ingress etc.
6 months Service technician
Checking of electrical connection Detailed examination of the cable for signs of
damage of the insulation, cable gland etc.
6 months Service technician
Replacement of the measurement cable necessary only in case of a cable break WayCon technician

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6�3 Encoder change
Unplug the encoder and remove the protection cap.
Note:
►Hollow shaft encoder. Do not apply radial force to the encoder.
The rotating shaft and stator coupling could get damaged.
►The protection cap may vary depending on the encoder design.
Loosen the clamp screw of the hollow shaft.
Remove the 2 encoder xation screws. Pull the encoder carefully o in
axial direction.
Installation in reverse order.
►Loosen hollow shaft screw before installing the encoder onto the shaft.
►Use screw locking device (e.g. Loctite 243) for the encoder xation screws
►The connector orientation can be chosen in 90 degree steps.
Note:
Please refer to the encoder guidelines supplied by the
encoder manufacturer and delivered with the encoder/transducer.
Important Note:
The procedures that are described in following chapters (including disassembly and
assembly of the transducer) may only be carried out by specially trained persons�
Special knowledge about draw wire transducer technology is necessary which can not
be generally assumed by hydraulic tters�
Non-observance can have severe consequences and lead to
►injury
►expensive standstills of operation
►loss of occupational safety
►loss of warranty
encoder
xaton screws
connector
protection cap
6 MAINTENACE AND SERVICE

- 19 -
6�4 Disassembly of transducer
Beforedismantling,removetransducerfromthecylinder(seechapterinstallation).
Loosen 16 pcs. main housing screws and take 14 pcs. completely out.
Leave 2 pcs. opposite wise lightly tightened.
Loosen 4 pcs. spring housing screws with holding the spring housing against
the spring torque. Turn back the spring set and pull out the wire rope of the
transducer at the same time.
Note:
Only by transducer specic trained persons. The stored energy of the spring may
lead to injuries when being mishandled.
As soon as the wire rope is completely pulled out, the springs can be turned back
to zero torque. Remove spring set with holding back the center spring hook to
avoid a uncontrollable spring roll o.
Note:
Only by transducer specic trained persons. The stored energy of the spring
may lead to injuries when being mishandled. Sucient energy is stored into the
spring even if the spring set is turned to zero torque.
Remove encoder (see chapter 6.2). Loosen 2 screws of the encoder adapter and
remove it in axial direction.
Note:
Do not bend or apply radial force to the rotation shaft and encoder adapter. The
rotation shaft and seal could be damaged.
Remove the last 2 screws from the main housing. Remove the main housing cap
in axial direction without tilt. Remove the o-ring.
Note:
The main housing cap must not be cant. Be aware of the rotation shaft and do
not apply radial force to the shaft. The rotation shaft and seal could be damaged.
6 MAINTENACE AND SERVICE

- 20 -
Cut the wire close to the transducer and turn the rotating shaft until thewire is
completely inside the sensor housing. Loosen the wire capstan clamp.
Note:
Do not try taking out the wire capstan before cutting the wire. Narrow wire rope
gap!
The wire capstan is now released and can be taken out of the main housing.
Pull out the capstan and remove the 3x18 cylinder bolt as well as the shim ring
(e. g. 6x12x0,2).
Note:
Any assembly only with new wire rope set.
Pull out the rotation shaft to the spring housing side.
Note:
Only by transducer specic trained persons. Do not bend or apply radial force to
the rotation shaft. The rotation shaft and seal could be damaged.
Beforeassembling thetransducerchange rotatingshaft seals (2 pcs.)and bearings
(2 pcs.) installed in the main housing and main housing cap. Check rotation
shaft against axial run out, wear and abrasion. Check surface against notches and
scratches. Change rotation shaft if necessary.
Note:
A worn out rotation shaft could damage new pressure seals
immediately.
Feed the new wire rope through the wire outlet of the main housing.
Note:
Only use a pre-assembled new wire rope set. Check transducer housing parts,
seal face and o-ring groove against damage and dirt.
6 MAINTENACE AND SERVICE