SphMic Installation Manual 12620.qxd
Contents
1. Outboard Scale Support Mounting NEWALL O Scale Supports Inverted o YN Pri suUe s g euJeJnsBej EMON OZ gNASONSHdS nae TMIN ooo 118 00 YU 131 00 Newall Measurement Systems 15 Appendix B Appendix B MICROSYN Newall leasurement Systems Ltd Leicester England O e Microsyn 2G O Outboard Scale Support Mounting NEWALL m Microsyn 2G a al O mmm Leicester England Scale Supports Inverted NEWALL wl Microsyn 2G Newall Measurement Systems Leicester England o Mj UR le 65 50 Fxg CTRS 75 00 16 Newall Measurement Systems Notes Newall Measurement Systems 17 Newall Measurement Systems Ltd Technology Gateway Cornwall Road South Wigston Leicester LE18 4XH United Kingdom Tel 44 0 116 264 2730 Fax 44 0 116 264 2731 E mail sales newall co uk e Web www newall co uk Newall Electronics Inc 1803 O Brien Road Columbus Ohio 43228 USA Tel 1 614 771 0213 Fax 1 614 771 0219 E mail sales newall com Web www newall com2. Fit the mounting block using the M6 USA 1 4 20 socket head cap screw and washer Check the alignment by gently sliding the scale through the head and in and out of the mounting block adjustments may be carried out by altering the M5 jacking screws When the alignment is complete secure the scale by inserting the M5 screw and washer through the mounting block and into the fixed end of the scale oO 8 Newall Measurement Systems Mounting the Scale 58 00 _ gt ya End Mounting Block TL Dy Jacking Screws M5 NEWALL Fixing Slot for M6 Screw Figure 5 4 Spherosyn Single End Mounting 5 1 3 Scales in Excess of 2 5 Metres 100 Traverse the machine to fullest extent of travel including hand winding past any electrical limits or trip dogs Insert the short blank length of Spherosyn tube into the Reader Head allowing for a sufficient amount of scale to project from the Reading Head in order to fit the scale mounting brackets Assemble the angle bracket to the scale clamp Refer to Figure 5 5 The jacking plate is included in each bracket kit this will only be required if the machine mounting face is not a machined surface Slide the assembly onto the scale allowing approximately I0mm clearance fr
3. Assemble the scale support link to the scale support pin leaving approximately 3mm 1 8 gap between the bottom of the pin shoulder and the top of the link Slide the link pin assembly onto the scale making certain that there is sufficient clearance between the Reader Head and the support link to prevent damage to the Reader Head cable Do not secure the support pin to the scale at this time Transfer punch through the support link and into the machine casting It is important that the support link be kept sguare to its mounting surface at all times Newall Measurement Systems 7 Mounting the Scale Remove the link pin assembly and the scale from the Reader Head Drill and tap M8 x 18mm deep USA 5 16 18 x 3 4 deep into the machine casting as marked by the transfer punch Fit the pillar s to the machine casting by using one of the methods shown in figure 5 3 The pillar shoulder fits square and flush to the machine surface Spherosyn Support Pillars Microsyn Support Pillars Machine Surface Machine Surface jo 4 om 8 2mm Jj 6mm US Flat Spacer Flat Spacer C Bore 6mmX3mm deep C Bore 8 4mmX5mm deep 9 32 X 1 8 deep Figure 5 3 Support Pillars A maximum of two support pillars may be screwed together to allow for sufficient adjustment of the scale If two pillars are insufficient to enable the scale to be mounted then additional brackets will be necessary T
4. Beijing Newall Technology Co Ltd Rm 2112 Ruicheng International No 71 Chaoyang Road Chaoyang District Beijing 100123 China Tel 86 10 858 44 817 Fax 86 10 858 44 827 E mail sales newall cn e Web www newall cn NEWALL A brand of CUSTOM SENSORS amp TECHNOLOGIES 023 12620 UK 0
5. Figure 5 1 Once the Reader Head is secured and correctly aligned the scale support brackets can now be fitted The scale support brackets consist of the support pin the support link and the pillar s Traverse the machine to its maximum position toward the non cable entry side of the Reader Head Maximum position means all available travel including hand winding past any electrical limits or trip dogs Carefully slide the blank scale or Spherosyn scale if less than 60 travel allowing for a sufficient amount of scale to project from the Reader Head in order to fit the scale support brackets Assemble the scale support link to the scale support pin leaving approximately 3mm 1 8 gap between the bottom of the pin shoulder and the top of the link Slide the link pin assembly onto the scale to approximately 5mm 0 2 away from the end of the Reader Head Transfer punch through the support link and into the machine casting It is important that the support link is kept sguare to its mounting surface at all times Remove the link pin assembly and the scale from the Reader Head Drill and tap M8 x 18mm deep USA 5 16 18 x 3 4 deep into the machine casting as marked by the transfer punch Fit the pillar s to the machine casting by using one of the methods shown in Figure 5 3 The pillar should fit sguare and flush to the machine surface SS a L 6 Newall Measurement Systems Mounting the Scale M A m
6. most over looked aspect of fitting the Encoder is proper cable routing Dangling and loose cables can be snagged or broken causing irreparable damage Care should be taken in order to ensure that the cables are secured to the machine and that cable loops do not interfere with any part of the machine or the Encoder movements P clips and thread forming screws are provided to route the cables from the Reader Head to the digital readout unit Note The armoured cable is an integral part of the Reader Head If the cable becomes damaged then it would have to be replaced complete with the Reader Head If extension cables are used do not allow the plug and socket junction to lie in the swarf tray or in the direct flow of coolant or oil In order to avoid problems associated with electrical noise and interference do not allow the cables to lie across electrical motors fuse boxes or electrical pumps 8 0 FINAL CHECK Prior to putting the Encoder into operation slowly traverse the machine axis to both extents of its travel checking at all times that the cables are secure and that machine over travel cannot occur Newall will not accept responsibility for Encoder malfunction caused by over travel or damaged cables 14 Newall Measurement Systems Appendix A _ _ lt lt lt lt lt 88988888 Appendix A SPHEROSYN NEWALL O o
7. the Reader Head together with its bracket s to the machine and secure the assembly parallel with axis travel to within 0 05mm 0 002 Refer to Figure 4 1 Figure 4 1 Alignment of the Spherosyn Reader Head Final adjustments can be carried out by use of laminated shims which are included with each encoder assembly Each layer of shim is equivalent to 0 05mm 0 002 42 Microsyn Figure 4 2 Alignment of the Microsyn Reader Head Mount the Reader Head together with its bracket s to the machine and secure the assembly parallel with axis travel to within 0 05mm 0 002 Refer to Figure 4 2 Newall Measurement Systems 5 Mounting the Scale 5 0 MOUNTING THE SCALE 5 1 Spherosyn 5 1 1 Double End Mounting Note Refer to section 5 1 3 for mounting scales in excess of 2 5 metres Each end of the Spherosyn Scale is different and can be identified by the red cap screw at the tensioner end and a nylon snap rivet at the fixed end EFFECTIVE TRAVEL LIMITS ae JOOOO FIXED END TENSIONER END Figure 5 1 Spherosyn Scale NOTES A Erroneous readings will occur if the Reader Head is allowed to travel beyond the Effective Travel Limits Refer to Figure 5 1 B The pre load on the balls are factory set via the set screw at the tensioner end Do not tamper with or adjust the set screw as this will alter the calibration and accuracy specification of the scale Refer to
8. NEWALL Spherosyn amp Microsyn Linear Encoders Installation Guide Contents CONTENTS 1 Introduction I I Bracketry 1 2 Preparation l 3 Warnings 2 _ Spherosyn Encoder Assembly 3 Microsyn Encoder Assembly 4 Mounting the Reader Head 4 1 Spherosyn 4 2 Microsyn 5 Mounting the Scales and Support Brackets 5 1 Spherosyn 5 1 1 Double End Mounting 5 1 2 Single End Mounting 5 1 3 Encoders in Excess of 2 5 metres 5 2 Microsyn 5 2 1 Single End Mounting 6 Mounting the guard 7 _ Cable routing 8 Final check APPENDICES SSS _ _ _ s gt I sz 2 _ Newall Measurement Systems Introduction 1 0 INTRODUCTION This manual will provide mounting instructions for Newall s Spherosyn and Microsyn Linear Encoders It is important that you read and understand this manual prior to beginning the installation If at any time during the installation you should have any questions contact Newall or your local authorised representative 1 1 Bracketry Due to the variety of machine types and applications it will be necessary to design make and fit custom brackets for the encoder assembly If bracketry is needed make certain they are rigid enough not to allow any flexing or distorting while the machine is in operation Newall offers a variety of bracket kits to aid in the installation Contact Newall or your local authorised representative for details 1 2 Preparation Prior to
9. aximum of two support pillars may be screwed together to allow for sufficient adjustment of the scale If two pillars are insufficient to enable the scale to be mounted then additional brackets will be necessary These brackets must be sufficiently rigid to eliminate any axial movement of the scale Loosely fit the support link pin assembly onto the pillar and pass the scale through the Reader Head and into the support pin While gently sliding the scale forward and back 25 50mm 1 2 through the support pin carefully tighten the hex screws on the support link ensuring that the scale slides smoothly through the Reader Head and into the support pin If any interference is detected then fully loosen the hex screws on the support link and repeat this step Note Do not force the Scale through the Support Pin IMPORTANT WARNING THE CENTRE LINE BORE OF THE READER HEAD MUST BE IN DIRECT ALIGNMENT WITH THE CENTRE LINE BORE OF THE SUPPORT PIN PERMANENT DAMAGE TO SCALE AND OR ERRONEOUS READER WILL OCCUR IF THIS WARNING IS NOT FOLLOWED REFER TO FIGURE 5 2 Support Pin Bore Centre Line Reader Head Bore Reading Head Centre Line Figure 5 2 Reader Head and Bracket Alignment Remove the scale from the Reader Head and traverse the machine to its full extent in the opposite direction Full extent means hand winding past electrical limits
10. beginning the installation the machine should be studied to determine where the Encoder s will be fitted For best results it is recommended that the Encoder be fitted as close to the machine lead screw or axial drive shaft as possible Spherosyn Overall Length Travel 258mm 10 2 Microsyn Overall Length Travel 173mm 6 8 Outboard mounting of the scale support brackets will add approximately 20mm 3 4 to the stated travel Refer to Appendix A amp B For a more compact installation scale travels of 300mm 12 or less may be fitted by supporting one end of the scale only by use of a single end mounting block Refer to Figure 5 4 and 5 10 The moving member of the Encoder assembly can be either the Reader Head or the Scale Cable routing from the Reader Head should be examined See Section 7 Each Reader Head is provided with either a 3 5 metre l 7 metre 22 or 10 metre 33 of armoured cable Extension cables are available in metre 3 2 metre 6 3 5 metre 11 5 5 metre 16 5 and 10 metre 32 lengths Contact Newall or your local authorised representative for details For Encoders larger trhan I 500mm 60 travel a setup tube blank scale is recommended 1 3 Warnings If for any reason the machine axis travel is greater than the actual scale travel it is recommended that mechanical stops are fitted to the machine to avoid damage caused by over travel Newall will not accept respons
11. cking screws When the alignment is complete secure the scale by inserting the M3 screw and spring washer through the mounting block and into the fixed end of the scale Ff 25 00 j End Mount Block fi E NEWALL m Microsyn 2G Newall Measurement Systems Ltd Leicester England Jacking Screws M3 Fixing Slot for M5 Screw Figure 5 10 Microsyn Single End Mounting 6 0 FITTING THE SCALE GUARD Each Encoder includes a protective guard This aluminium guard is intended to protect the scale from impact damage The guard can be attached to the machine casting or by means of the scale support pillars Refer to Figure 6 1 To fit the guard to the support pillars measure and mark off the distance between the centre of each pillar For Spherosyn drill two 8 5mm 3 8 for Microsyn 7mm 9 32 holes at either end of the guard The guard can be attached to the pillars by using the button head screws provided After the guard is attached move the machine axis to both extents of its travel ensuring that the guard does not interfere with or rub against the Reader Head Newall Measurement Systems 13 Fitting the Scale Guard Cable Routing Final Check Figure 6 1 Fitting the Scale Guard example shown using a Spherosyn Scale 7 0 CABLE ROUTING The most important and the
12. hese brackets must be sufficiently rigid to eliminate any axial or radial movement of the scale Loosely fit the support link pin assembly onto the pillar and pass the scale through the Reader Head and into the support pin While gently sliding the scale forward and back 25 50mm I 2 through the support pin carefully tighten the hex screws on the support link ensuring that the scale slides smoothly through the Reader Head and into the support pin If any interference is detected then fully loosen the hex screws on the support link and repeat this step Repeat the above steps at the other end of the machine Then carefully slide the Spherosyn Scale through the support pin through the Reader Head and into the opposite support pin Tighten the hex screws on the anchor pins 5 1 2 Single End Mounting Note The maximum total length of the scale must not exceed 610mm 24 when using a single end mounting kit The single end mounting kit is sold separately ask for UK part number 600 63610 USA part number 294 23010 Remove the white rivot from the fixed end of the scale After the Reader Head has been installed slide the scale through the Reader Head and insert the fixed end of the scale into the single end mounting block Refer to Figure 5 4 Once the position for the single end mounting block has been determined mark the machine casting using the slot in the mounting block as the guide Drill and tap M6 x 12mm deep USA 1 4 20 x 1 2
13. ibility for Scale and Reader Head damage caused by machine over travel Both the Reader Head and the Scale are precision made components and it is important that they are handled with care By design the Encoders can withstand the rigours of the harsh workshop environment However permanent damage can occur through bending or severe impact It is important that the Scale be kept at least 13mm 0 5 away from any magnetic bases on indicators or magnetic chucks Newall Measurement Systems 3 Encoder Assembly 2 0 SPHEROSYN ENCODER ASSEMBLY lt 2 5m 100 M8 5 16 18 in USA Item Description Qty Item Description Qty Spherosyn Reader Head 6 Support Pillar Long 2 2 Spherosyn Scale 7 Scale Cover 3 Scale Support Link 2 8 M5 x 20 Hex Head 6 4 Scale Anchor Pin 2 9 M8 x Socket Button Head 2 5 Support Pillar Short 2 10 Spacer Washer 2 3 0 MICROSYN ENCODER ASSEMBLY M6 1 4 20 in USA Item Description Qty Item Description Qty l Microsyn Reader Head 8 Support Link 2 2 Microsyn Scale 9 M3 x 12 Hex Screw 4 3 Scale Anchor pin 10 M3 x 12 SHCS 4 4 M3 x 16 SHCS ll M6 x 10 Socket Button Head 2 5 M3 Spring Washer 12 Support Pillar Short 2 6 Scale Support Pin 13 Support Pillar Long 2 7 M4 x 5 Nylon Set Screw 14 Spacer Washer 2 15 Scale Cover 4 _ Newall Measurement Systems Mounting the Reader Head 4 0 MOUNTING THE READER HEAD 4 1 Spherosyn Mount
14. icrosyn encoders include a set up bar The set up bar is of the same diameter as the Microsyn Scale and will be used to align the brackets to the Reader Head ANCHOR PIN UPPORT PIN PILLA L S CU SUPPORT LINK Figure 5 8 Microsyn Scale Support Bracket Traverse the machine to its maximum position toward the non cable entry side of the Reader Head Maximum position means all available travel including hand winding past any electrical limits or trip dogs Carefully slide the Microsyn Scale set up bar through the Reader Head allowing for sufficient scale to project from the Reader Head in order to fit the scale support brackets Assemble the support link to the anchor pin leaving approximately 3mm 1 8 gap between the bottom of the anchor shoulder and the top of the link Slide the link anchor assembly onto the scale set up bar to approximately 5mm 0 2 away from the end of the Reader Head Transfer punch through the support link and into the machine casting It is important that the support link be kept sguare to its mounting surface at all times Remove the link anchor assembly and the scale set up bar from the Reader Head Drill and tap M6 x 12mm deep hole USA 1 4 20 x 1 2 into the machine casting as marked by the transfer punch Fit the pillar s to the machine casting by using one of the methods shown in Figure 5 3 The pillar shoulder fits sgua
15. me Transfer punch through the support link and into the machine casting It is important that the support link be kept square to its mounting surface at all times Remove the link pin assembly and the scale from the Reader Head Drill and tap M6 x 12mm deep USA 1 4 20 x 1 2 deep into the machine casting as marked by the transfer punch Fit the pillar s to the machine casting by using one of the methods shown in Figure 5 3 The pillar shoulder fit square and flush to the machine surface Loosely fit the support link pin assembly onto the pillar and pass the scale set up bar through the Reader Head and into the support pin While gently sliding the set up bar forward and back 25 50mm 1 2 through the support mounting carefully tighten the screws on the support link ensuring that the scale set up bar slides smoothly through the Reader Head and into the support pin If any interference is detected then fully loosen the screws on the support link and repeat this step IMPORTANT WARNING THE CENTRE LINE BORE OF THE READER HEAD MUST BE IN DIRECT ALIGNMENT WITH THE CENTRE LINE BORE OF THE SUPPORT PIN PERMANENT DAMAGE TO SCALE AND OR ERRONEOUS READER WILL OCCUR IF THISWARNING IS NOT FOLLOWED REFER TO FIGURE 5 9 Anchor Pin Bore Centre Line Readi H seading neag Reader Head Bore Centre Line Figure 5 9 Reader Head and Bracket Alignmen
16. ng position for the bracket assembly Newall Measurement Systems 9 Mounting the Scale SCALE CLAM BRACKE JACK PLATE Figure 5 5 Long Scale Support Bracket Assembly 5 1 4 Center Supports for Scales in Excess of 2 5 Metres 100 Travel See data sheet supplied with center supports kit 600 84605 5 2 Microsyn Scale There are two accuracy grades of the Microsyn Encoder 5um and lOum The 5um scale can be identified by the black end plug fitted at the tensioner end The lOum scale has an anodised clear plug fitted at the tensioner end The fixed end of the scale has an M3 tapped hole which will be fitted to the anchor pin when installed EFFECTIVE TRAVEL LIMITS URZLLL FIXED END Figure 5 7 The Microsyn Scale NOTES A Erroneous readings will occur if the Microsyn Reader Head is allowed to travel beyond Effective Travel Limits Refer to Figure 5 7 B The pre load on the balls are factory set via the set screw at the tensioner end Do not tamper with of adjust the set screw as this will alter the calibration and accuracy specification of the scale and void the warranty 10 Newall Measurement Systems Mounting the Scale M The scale support brackets kit consists of the Anchor Pin Support Pin Support Link and Pillar s Refer to Figure 5 8 In order to avoid the risk of damage to the scale during installation all M
17. om the end of the Reader Head Mark the position of the jack plate if reguired or the angle support bracket Drill and tap the necessary fixing holes and assemble the bracket to the machine Remove the blank tube and the bracket assembly from the Reader Head Drill and tap M8 x 18mm USA 5 16 18 x 3 4 fixing holes Fit the jack plate if required and secure to the machine Assemble the scale clamp and the angle bracket to the jack plate but do not secure Traverse the Reader Head as near to the bracket assembly as possible Slide the blank tube through the Reader Head into the scale clamp Adjust the brackets into position and carefully tighten the screws Check that the blank tube slides through the Reader Head and into the scale clamp smoothly without any fouling or interruption Remove the blank tube and traverse the machine to the full extent in the opposite direction Remember the full extent is the absolute maximum travel up to the mechanical dead stops Check the overall length of the actual scale and measure from the outside edge of the scale clamp already fitted to the machine and mark the position of the scale on to the machine Slide the Spherosyn blank tube into the Reader Head assemble the remaining scale bracket assembly including the jacking plate if reguired and slide onto the tube Set the outside edge of the scale clamp level with the mark that indicates the overall length of the Spherosyn Scale and mark the fixi
18. re and flush to the machine surface A maximum of two support pillars may be screwed together to allow for sufficient adjustment of the scale If two pillars are insufficient to enable the scale to be mounted then additional brackets will be necessary These brackets must be sufficiently rigid to eliminate any axial movement of the scale Loosely fit the support link anchor assembly onto the pillar and pass the scale set up bar through the Reader Head and into the anchor pin While gently sliding the scale set up bar in and out of the anchor pin carefully tighten the cap screws on the support link ensuring that the scale set up bar slides smoothly through the Reader Head and into the anchor pin If any interference is detected then fully loosen the cap screws on the support link and repeat this step Remove the scale set up bar from the Reader Head and traverse the machine to its full extent in the opposite direction Full extent means hand winding past electrical limits Assemble the scale support link to the support pin leaving approximately 3mm 1 8 gap between the bottom of the mounting shoulder and the top of the link Refer to Figure 5 8 Newall Measurement Systems 41 Mounting the Scale Slide the link pin assembly onto the scale set up bar making certain that there is sufficient clearance between the Reader Head and the support link to prevent damage to the Reader Head cable Do not secure the support pin to the scale at this ti
19. t Carefully slide the Microsyn Scale through the support pin ensuring the fixed end is inserted first through the Reader Head and into the anchor pin Using the M3 x 16 skt cap screw and spring washer secure the scale to the anchor pin It is important that the nylon set screw on the support pin be only pinched to the scale at the tensioner end DO NOT OVER TIGHTEN THE NYLON SET SCREW ON THE SUPPORT PIN 12 Newall Measurement Systems Mounting the Scale Fitting the Scale Guard M 5 2 1 Single End Mounting For installations requiring a lower profile assembly there is an alternative method for fixing the scale at one end only by way of the single end mounting block assembly Refer to Figure 5 10 The Microsyn single end mounting kit is sold separately part number 600 65340 Note _ The maximum total length of scale should not exceed 450mm 18 when using the single end mounting block Once the Reader Head has been installed slide the scale through the head and insert the fixed end of the scale into the single end mounting block Refer to Figure 5 10 Once the position for the single end mounting block has been determined mark the machine casting with the slot in the block Drill and tap a M5 x 12mm deep hole Fit the bracket using the M5 skt head cap screw and washer Check the alignment by gently sliding the scale through the head and in and out of the mounting block adjustments may be carried out by altering the M3 ja
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