MiniCoder GEL Operating Instructions. Speed and position sensor optional with amplitude control

Transcription

1 MiniCoder GEL 2443 Speed and position sensor optional with amplitude control Operating Instructions D-02B-2443 (V3.1) Right to technical changes and errors reserved

2 Device manufacturer and publisher: Lenord, Bauer & Co. GmbH Dohlenstraße Oberhausen Deutschland Phone: Fax: Internet: info@lenord.de Doc. no. D-02B-2443 (V3.1) 2 GEL 2443

3 Lenord + Bauer Table of contents Table of contents 1 About these operating instructions About these Operating Instructions Validity Target group Abbreviations and glossary Symbols, marks and notes Identification of the speed sensor ID plate Type code Delivery scope Screen connection type Notes on how to avoid property damage or malfunctions Correct use Notes for operators and manufacturers Modifications and conversions Sources of hazards Measuring surface Air gap between measuring surface and target wheel Electrostatic discharge Contamination Target wheel Notes on electromagnetic compatibility Description MiniCoder Target wheel Handling Transport and storage Maintenance and cleaning Removing the sensor Disposal Assembly Safety instructions Mounting the sensor Adjusting the sensor Completing assembly Connecting the MiniCoder Faults Appendix Technical data Connection assignment Output signals Scale drawing Drilling and milling plan Manufacturer's declaration GEL

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5 Lenord + Bauer About these Operating Instructions 1 About these operating instructions 1 About these operating instructions 1.1 About these Operating Instructions These Operating Instructions are part of the product and describe how to use it safely. Please read the Operating Instructions carefully before you begin assembly. Keep the Operating Instructions for the entire service life of the product. Make sure that the Operating Instructions are available to personnel at all times. Pass the Operating Instructions on to each subsequent owner or user of the product. Insert all additions received from the manufacturer. To avoid property damage or malfunctions, read and observe the specifications provided in these Operating Instructions. 1.2 Validity These Operating Instructions apply to the standard design of the product. This includes all types that are n o t marked with a Y behind the product number in the type code. A product marked with Y is a customised design with a special assembly and/or modified technical specifications. Depending on the customised modification, additional or other documents may be valid. 1.3 Target group These Operating Instructions are intended for electrical specialists and mechanics who are authorised to mount and electrically connect devices and systems, to put them into operation, and to label them under the terms of safety-related standards, as well as machinery operators and manufacturers. GEL

6 1 About these operating instructions Abbreviations and glossary Lenord + Bauer 1.4 Abbreviations and glossary AC DC ESD EMC Measuring scale Alternating Current Direct Current Electrostatic Sensitive Devices Electromagnetic Compatibility General term for target wheel, toothed rack or slotted disk This guide describes the target wheel in more detail. Comments contained in this document also apply to other measuring scales. 1.5 Symbols, marks and notes The following symbols, marks and notes are used in these operating instructions to enable you to recognise certain information more quickly: page 6 Notes on how to avoid property damage Important information for understanding or optimising procedures Step to be carried out Page reference to another part of these operating instructions 6 GEL 2443

7 Lenord + Bauer ID plate 2 Identification of the speed sensor 2 Identification of the speed sensor 2.1 ID plate The following information is provided on the sensor: Type code 2 Serial number 3 Article code (customised design only) 2.2 Type code Signal pattern K Sin/Cos signals 1 Vpp Reference mark None N Flag M Groove Z Flag aligned with tooth (recommended) Amplitude control R With 1 Without Cable outlet R Radial G Axial Module Connection type K Open cable end (fixed length: 30, 150, 250 or 600 cm) A 17-pin straight connector B 17-pin angular connector Cable length Number in cm Temperature sensor cable (2 m) M Included None Separate screen connection on sensor E Mandatory 2443 GEL

8 2 Identification of the speed sensor Delivery scope Lenord + Bauer 2.3 Delivery scope The delivery scope includes the following components: MiniCoder with connection cable, packed in a protective ESD bag and protective foam packaging Distance gauge Shielding cover These operating instructions 2.4 Screen connection type Examples: Screen connector 2443xxxGxKxxx E 2 L M xxxGxAxxxME 1 L xxxGxBxxxME M23 8 GEL 2443

9 Lenord + Bauer Correct use 3 Notes on avoiding... 3 Notes on how to avoid property damage or malfunctions 3.1 Correct use The MiniCoder is intended solely for measurement tasks in the industrial and commercial sector. It can be used to measure, for instance, positions, angles or speeds. It is installed in a system and must be connected to special evaluation electronics, contained, for example in a speed control or a positioning control unit. All other uses shall be deemed incorrect. 3.2 Notes for operators and manufacturers Personnel training Make sure that the following requirements are met: Assembly, operation, maintenance and removal tasks are performed by trained and qualified skilled personnel or are checked by a responsible specialist. Personnel has received training in electromagnetic compatibility and in handling electrostatic-sensitive devices. Provide personnel with all applicable accident prevention and safety regulations. Make sure that personnel is familiar with all applicable accident prevention and safety regulations. 3.3 Modifications and conversions Unauthorised modifications or conversions may damage the product. Do not make any modifications or conversions to the product, with the exception of activities described in this documentation. 3.4 Sources of hazards The MiniCoder is a sensitive measuring instrument because the active, magnetic sensor element is located directly beneath the measuring surface. Mechanical damage can quickly cause the measuring system to fail Measuring surface The speed sensor is highly magnetic on its measuring surface. When it is brought close to metal objects, it can quickly make contact with them. For example, the measuring surface can be damaged if it touches the target wheel or as a result of other mechanical impact. Ensure that the measuring surface does not come in contact with other objects. GEL

10 3 Notes on avoiding... Sources of hazards Lenord + Bauer Air gap between measuring surface and target wheel If the air gap is too large, i.e. there is a too great distance between the measuring surface and the target wheel, the measuring signal can be lost. If the air gap is too small, the measuring surface may come in contact with the target wheel if this runs out of round. Large temperature fluctuations and varying coefficients of thermal expansion affecting the target wheel and mounting device may lead to critical air gap changes: An increased air gap has a negative effect on measurement accuracy (may lead to reduced signal amplitudes). A decreased air gap leads to overdriving and thus to possible pulse losses. Ensure that the air gap between the measuring surface and the target wheel is within the permissible range (see table page 18) Electrostatic discharge Electrostatic discharge can destroy the electronic components. Only touch the connector pins and connecting wires when wearing a suitable grounding device, such as an ESD wristband: Contamination The accumulation of ferromagnetic particles between the measuring surface and the teeth of the measuring scale may mean that the MiniCoder cannot clearly read the change from tooth to gap. Ensure by taking design measures that no contaminants enter the air gap. Ensure that target wheel and installation space are free from contamination and metal shavings Target wheel Mechanical inaccuracies in the tooth interval, tooth shape and curvature impair measurement accuracy. So that the teeth do not erode, only use the toothed wheel as a target wheel. In designs with a reference flag, the latter may not protrude beyond the addendum circle of the target wheel, to avoid contact between the reference flag and the measuring surface. 10 GEL 2443

11 Lenord + Bauer Notes on electromagnetic compatibility 3 Notes on avoiding... Ensure that the reference flag does not protrude beyond the toothed wheel. A reference mark (flag or groove) causes an imbalance, which may lead to the target wheel running out of round. If you produce the target wheel internally, compensate for the imbalance by attaching counter weights or boring balancing holes in the target wheel. In the case of a high number of revolutions and large target wheel, high centrifugal force affects the outer toothed rim. Vibrations also occur in the machine. Vibrations and high centrifugal force may cause reference flags to loosen. The number of revolutions at which vibrations critical for the target wheel occur, depends on the size and module of the target wheel and the condition of the machine. Ensure that the target wheel in the speed range in use complies with the permitted air gap tolerance levels. Ensure that the target wheel does not achieve a critical number of revolutions. If the target wheel is not placed symmetric to the measuring surface, measuring errors may occur. To guarantee that the minicode functions smoothly, this must be adjusted precisely. Place the MiniCoder symmetrically to the toothed wheel; the lines of symmetry must match. Comply with the limiting values provided ( page 18). If the target wheel runs out of round, the MiniCoder must be adjusted so the air gap tolerance is complied with (see table page 18). 3.5 Notes on electromagnetic compatibility To avoid influencing the certified electromagnetic compatibility (EMC) the following assembly information must be observed. Only use connectors with a metal housing or with a housing made from metallised plastic and shielded cables. Place the shielding on the connector housing if included in the shielding concept. Spread the shielding wide. Keep all unshielded lines as short as possible. Use large diameter grounding connections (for example, as a low induction ground strap or ribbon conductor) and keep them short. If there are potential differences between machine and electronic ground straps, make sure that no equalising currents can flow via the cable shielding. For this purpose, lay a large diameter voltage equalising cable or use cables with separate two-ply shielding. With cables with separate two-ply shielding, spread the shielding on one side only. GEL

12 3 Notes on avoiding... Notes on electromagnetic compatibility Lenord + Bauer Machine 2 GEL Evaluation electronics 4 Control lines 5 Voltage equalising cable (only in the case of extreme levels of interference) 5 4 The sensor is part of a machine or machinery; include the voltage equalisation for the sensor in the overall shielding concept. Lay signal and control lines separately from the power cables. If this is not possible, use pairs of twisted and shielded wires and/or lay the encoder line in an iron pipe. Make sure that surge protective measures have been carried out externally (EN ). 12 GEL 2443

13 Lenord + Bauer MiniCoder 4 Description 4 Description The measuring unit consists of the MiniCoder (sensor) and a precision target wheel for mounting on shafts. It provides a space-saving solution for measuring rotational movements on gears, machines, motors and high-speed spindles without making contact. In terms of electromagnetic immunity, the special metallic coating on the MiniCoder provides a high level of protection. 4.1 MiniCoder Parts 1 Separate screen cable 2 Connector cable 3 Flange 4 Measuring surface 5 Distance gauge 6 Shielding cover (prepared) Function The MiniCoder is secured to the mounting device with the flange (3). The sensitive sensor system is located behind the measuring surface (4). For easy adjustment, a corresponding distance gauge is supplied in different strengths depending on target wheel module The strength is printed on the distance gauge mm strength for module mm strength for module 0.5 The integrated electronics are supplied with power by means of the connection cable (2). The separate screened connection cable (1) is mounted at a suitable point on the mounting device, ensuring earthing. To improve electromagnetic immunity, the supplied shielding cover (6) should also be mounted. GEL

14 4 Description MiniCoder Lenord + Bauer The MiniCoder has a magnetic field which is changed by the rotating target wheel. The sensor system records the change in the magnetic field and the integrated electronics transform these changes to sinusoidal output signals The output signals are two 90 shifted sinusoidal signals for direction detection (tracks 1 and 2) and their inverse signals, optionally with a reference pulse (track N). All signals are forwarded to the separate electronics via the connection cable. The output frequency of the signals is between standstill (0 Hz) and a maximum of 200 khz. If the MiniCoder is equipped with amplitude control, it corrects amplitudal fluctuations caused by changes in measuring distance and temperature. This MiniCoder does not require readjustment. The power supply for the MiniCoder, the evaluation of the number of pulses and the establishment of the control circuit requires separate electronics. Der MiniCoder ist mit einem separat herausgeführten Schirmanschlusskabel ausgestattet. The MiniCoder is delivered with a separate screen connection cable. The screen cable can be connected separate (1) or with one mounting screw on the flange (2). N N 1 Separate earthing (recommended) 2 Near-sensor earthing (earthing via the nearby mounting screw) 14 GEL 2443

15 Lenord + Bauer Target wheel 4 Description 4.2 Target wheel You can order suitable target wheels to be manufactured according to your specifications from Lenord + Bauer. If you produce your own target wheel, please note the following: Use steel toothed wheels with involute toothing and module 0.3 or 0.5 Mechanical inaccuracies in the tooth interval, tooth shape and curvature impair measurement accuracy. If you wish to measure a reference signal (depending on the MiniCoder type), fix a reference mark to the toothed wheel. If the toothed wheel runs out of round, the MiniCoder must be adjusted so the admissible air gap tolerance is complied with (see table). Reference marks Reference marks may occur in the form of a groove or a flag. Depending on the reference mark, you may need to use a different type of MiniCoder (see type code). The flag must be made of ferromagnetic material and may not protrude beyond the gearwheel of the target wheel. D > J > GEL 2443xN: Flag sits between two teeth (h = 4 mm, b = 0.5 mm) GEL 2443xZ: Flag sits precisely on one tooth GEL 2443xM: Groove sits between two teeth (t = 1 mm, b = 1.2 mm for module 0.3 b = 1.6 mm for module 0.5) Reference marks cause imbalance. In the case of a high number of revolutions, high centrifugal force afffects the outer toothed rim. For this reason, we recommend compensating for this imbalance by boring balancing holes in the target wheel or attaching counter weights. The positions of the reference mark determines the phasing of the zero or reference signal with regard to the track signals. Using GEL 214 interpolation electronics by Lenord + Bauer, reference marks (flag or groove) should be locating directly between two teeth. If you are using a different form of evaluation electronics, please observe the manufacturer's notes. GEL

16 5 Handling Transport and storage Lenord + Bauer 5 Handling 5.1 Transport and storage The MiniCoder is delivered packed in polystyrene to prevent damage to the sensitive measuring surface. Do not remove the MiniCoder from its protective packaging until shortly before assembly. If packaging is damaged, check the sensor for any visible damage. A damaged sensor may not be mounted. Store the product in the original manufacturer packaging. 5.2 Maintenance and cleaning The sensor contains no maintenance parts. Do not try to repair a faulty sensor. Let required repairs only be carried out by LENORD + BAUER or by a representative authorised by LENORD+BAUER. Check the sensor for damage regularly. Replace a faulty sensor. Check the correct position of the sensor Cleaning the sensor In case of contamination clean the sensor with water or a non-corrosive commercial cleaning agent. Never use a high-pressure cleaner. Avoid allowing water, dirt or other substances to enter the open parts when the connector has been detached. 5.3 Removing the sensor Disconnect the sensor and release the connection cable. Insert the distance gauge in the air gap to avoid damaging the measuring surface. Loosen and remove all mounting screws. Carefully remove the sensor and the distance gauge from the mounting device. 5.4 Disposal Faulty sensors should be disposed of in accordance with regional regulations for electrical and electronic devices. 16 GEL 2443

17 Lenord + Bauer Safety instructions 6 Assembly 6 Assembly 6.1 Safety instructions Only touch the connector pins and connecting wires when wearing a suitable grounding device, such as an ESD wristband to avoid damaging the electronic components due to electrostatic discharge (see page 10). Only take the sensor out of the protective packaging just before assambly. Ensure that the measuring surface does not come in contact with other objects to avoid damaging the sensitive measuring surface Mounting the sensor Tools and aids (not included in the delivery scope): 2 screws M4 with washer and spring washer 1 screw M4 with washer and spring washer to mount the screen connection cable Digital testing device (e.g. GEL 210K Test device for encoders with sinusoidal outputs by Lenord + Bauer) Torque wrench Preparing the assembly Carry out all necessary bore holes in the mounting plate as shown in the drilling and milling plan ( page 25). Check the length of the cable and shorten it if required. If you are using the screen cable for near-sensor earthing, shorten the cable to mm and crimp a new ring terminal. Bend the shielding cover at the prepared folding edges. Clean the mounting area and screen connection area of the sensor and the mounting device as well as the mounting screws thoroughly to achieve a good electrical conductivity. Do not use cleaning agents which could damage the surface coating. GEL

18 6 Assembly Adjusting the sensor Lenord + Bauer Securing the sensor Attach the shielding cover (2) and 2 screws M4 (1) with spring washers to the sensor. Use washers if applicable. If using the separate screen cable for near-sensor earthing, replace the washer on the concerning screw with the cable lug of the screen cable. Insert the sensor carefully in the machine by using the distance gauge, to ensure a sufficiently large air gap. Secure the MiniCoder only slightly, that you can still adjust it. If using the separate earthing, mount the lug of the screen cable with a mounting screw on the bore hole provided. 6.3 Adjusting the sensor Use a digital testing device for adjusting the sensor (e. g. GEL 210K Testing device for encoders with sinusoidal outputs by Lenord + Bauer). When adjusting the target wheel, watch out for the toothed wheel running out of round and critical spacing changes caused by large temperature fluctuations. d d a a R d h h a a R Distance (9.5 ± 0.5 mm) Distance of reference mark (6 mm) Air gap Width of the target wheel (> 4.0 mm) Air gap table Module Air gap d, adjusting characteristic Tolerance mm ± 0.02 mm mm ± 0.03 mm For proper functioning, verify that the sensor and the target wheel are aligned symmetrically. 18 GEL 2443

19 Lenord + Bauer Completing assembly 6 Assembly For proper functioning, ensure that the air gap between the measuring surface and the target wheel is within the permissible range ( page 18). Connect the MiniCoder correctly to the testing device in accordance with the connection assignment (see section page 22). Note the operation instructions of the testing device. Check whether the output signals are in the measuring range. Correct the position of the sensor if necessary (see Influence of mounting position on output signals, page 24). Turn the target wheel slowly and observe the output signal on the testing device. 6.4 Completing assembly Tighten both mounting screws with a maximum torque of 1 Nm. Replace the distance gauge (1). Keep the distance gauge for future disassembly or readjustment. 6.5 Connecting the MiniCoder Note the minimum bending radius to avoid damaging the connection cable if bent too sharply (see Technical data page 21f). Lay the cable while taking the Notes on electromagnetic compatibility into account (see page 11). Connect the MiniCoder correctly in accordance with the connection assignment (see section page 22). GEL

20 7 Faults Lenord + Bauer 7 Faults Fault Possible causes Remedy Output signal is non-existent / too low Counting direction is not correct Electrical connection faulty Wrong air gap between measuring surface and target wheel Measuring surface and/ or target wheel damaged Assignment of tracks interchanged Check that all electrical connections between the sensor and the power supply and evaluation electronics are correct and that the contacts are secure and dry. Check that the required value is met in all (climatic) conditions, valid for one full rotation of the wheel. Check the position of the sensor and readjust it if necessary ( page 18). Insert the distance gauge before readjusting the sensor! Use a torque wrench to check that the mounting screws on the sensor flange are tightened with a torque of 60 Ncm. Replace the damaged component. Determine the cause of the damage and remedy it. Check the connections of the track signals and interchange them if necessary. 20 GEL 2443

21 Lenord + Bauer Technical data 8 Appendix 8 Appendix 8.1 Technical data Electrical Data Output level 1 V SS (difference signal) Output signal two 90 phase-shifted sinusoidal signals and their inverse signals, short-circuit proof; optionally with reference pulse Output frequency 0 to 200 khz (1) Offset (static) ± 20 mv Amplitude tolerance -20% to +10% Amplitude ratio U TR1 /U TR2 0.9 to 1.1 Supply voltage U S 5 V DC ± 5% Power consumption without load 0.3 W Mechanical Data Module of the target wheel 0.3 / 0.5 Admissible air gap 0.15 mm ± 0.02 mm with module mm ± 0.03 mm with module 0.5 Width of the target wheel min. 4.0 mm Material of the target wheel Ferromagnetic steel Max. admissible cable length 100 m (observe the voltage drop on the power line) Working temperature -30 C to +85 C Operating and storage temperature -40 C to +120 C Protection class IP 68 Electromagnetic compatibility EN to 4 (2) Insulation stability 500 V, according to EN Vibration resistance 200 m/s 2, according to DIN EN Shock resistance 2000 m/s 2, according to DIN EN Weight 30 g Housing Polyphenylensulfid (PPS), fibre reinforced (1) at a line capacity of 5 nf (2) The normative limit values are met if mounting and connection jobs are carried out properly. Coaxial earthing of the MiniCoder connection cable (e.g. on the free cable end) and keeping the separate screen connection line as short as possible will additionally improve noise immunity. GEL

22 8 Appendix Connection assignment Lenord + Bauer Mechanical Data Connection Core x cross section 9 x 0.15 mm 2 Outer diameter (O.D.) mm Min. bending radius 25 mm Separate screen connection line for nearsensor earthing (1) 8.2 Connection assignment Connection side view (solder/crimp side of the mating plug) Screening is not connected inside the MiniCoder. Lead colour Pin Signal / function White 1 U 1+ Track 1 Brown 2 U 1 /Track 1 Grey 3 U N+ Reference track Blue 7 0 V GND 8 ϑ+ Temperature + (brown) 9 ϑ Temperature (blue) Red 10 U S + 5 V supply voltage Rose 11 U 2+ Track 2 Black 12 U 2- /Track 2 Yellow 13 U N- /Reference track 15 0 V GND Green 16 U Sense 5 V Sense Wire strap to pin 7 (1) e.g. using one fixing screw 22 GEL 2443

23 Lenord + Bauer Output signals 8 Appendix 8.3 Output signals Signal for clockwise rotation of the target wheel (1) U [mv] U N 500 U 1 U 2 U 1 = U 1+ U 1 0 U 2 = U 2+ U 2 U N = U N+ U N -500 φ (1) Viewing on the MiniCoder mounting plate (see illustration page 14) GEL

24 8 Appendix Output signals Lenord + Bauer Influence of mounting position on output signals Nominal output signal (1) Measuring range Air gap 7 ) +! #! 8 Amplitude of track 1: 290 to 400 mv (AC) 7 Offset and amplitude tracking, + 8 ) + 7 Offset of track 1: 20 to +20 mv (DC) 7 7 Offset of track 2: 20 to +20 mv (DC) 7 7, + 8 ) + 7 Amplitude ratio: U 1 / U 2 = 0,9 to 1,1 Reference track position Reference track: centered between tracks 1 and 2 (U 1 and U 2 ) (1) Measurement of parameters with a commercial testing device 24 GEL 2443

25 Lenord + Bauer Scale drawing 8 Appendix 8.4 Scale drawing Axial cable outlet Radial cable outlet Ø Ø All dimensions stated in mm 8.5 Drilling and milling plan r a = d a /2 (d a = tip diameter of the target wheel) 8.6 Manufacturer's declaration The manufacturer's declaration in accordance with EMC directive 2004/108/EC can be found on the Internet at GEL

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