Elgo EMAX Series, EMAL Series Operating Manual

Operating Manual

SERIES EMAX / EMAL

Magnetic Absolute Linear Encoder with 10 µm resolution

 Absolute encoder with 10 µm resolution
 No referencing required (changes of position

are also recognized in the de-energized state)

 Wear free and contactless measurement
 Measuring length up to 10 m (EMAX) resp. 20 m (EMAL)
 Too large distances between sensor and magnetic tape

are automatically detected and signalized by an LED

 Sensor with fixed cable outlet or optionally with

M9 round connector on sensor housing

 Additional incremental or sine-cosine signals for

dynamic movement control available

 Available interfaces: SSI, CANopen, RS422, RS232

New: IO-Link acc. to IEC 61131-9

799000616 / Rev. 14/ 2019-01-17
Translation of the original operating manual

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Publisher

ELGO Electronic GmbH & Co. KG

Carl-Benz-Str. 1
D-78239 Rielasingen-Worblingen

Technical Support

 [phone] – 0
 [phone]

 [e-mail]

Document- No.

799000616

Document- Name

EMAX-EMAL-00-MA-E_03-19

Document- Revision

Rev. 14

Issue Date

2019-01-17

Copyright

© 2019, ELGO Electronic GmbH & Co. KG

Contents

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1 Contents

1 Contents ............................................................................................. 3

2 List of Figures: .................................................................................... 5

3 List of Tables: ..................................................................................... 5

4 General, Safety, Transport and Storage ........................................... 6

4.1 Information Operating Manual ............................................................................. 6

4.2 Explanation of Symbols ........................................................................................ 6

4.3 Statement of Warranties ....................................................................................... 7

4.4 Demounting and Disposal .................................................................................... 7

4.5 General Causes of Risk ........................................................................................ 7

4.6 Personal Protective Equipment ............................................................................... 7

4.7 Conventional Use ............................................................................................... 8

4.8 Safety Instructions for Transport, Unpacking and Loading .......................................... 8

4.9 Handling of Packaging Material ............................................................................ 8

4.10 Inspection of Transport ........................................................................................ 8

4.11 Storage ............................................................................................................. 8

5 Product Features ................................................................................ 9

5.1 Functional principle ............................................................................................. 9

6 Technical Data ................................................................................. 10

6.1 Identification .................................................................................................... 10

6.2 Dimensions Sensor Housing with Cable Outlet ...................................................... 10

6.3 Dimensions Sensor Housing with M9 round connector ............................................ 10

6.4 Dimensions Guide Carriage FW2080 .................................................................. 11

6.5 Technical Data Sensor ....................................................................................... 12

6.6 Technical Data Magnetic Tape ............................................................................ 13

7 Installation and First Start-Up ......................................................... 14

7.1 Operating Area ................................................................................................ 14

7.2 Installation of the Magnetic Tape ......................................................................... 15

7.3 Installation of the Sensor .................................................................................... 18

7.4 Offset Calibration ............................................................................................. 19

8 Interfaces ......................................................................................... 20

8.1 Interface SSI (option SB0 and SG0) ...................................................................... 20

8.2 Interface CANopen (option CA0) ......................................................................... 21

8.3 CAN BASIC ELGO (Option CN0) ........................................................................ 22

8.4 Termination Resistor .......................................................................................... 23

8.5 Interface RS422 (Option 420) & RS232 (Option 230) ............................................. 24

8.6 RS422 Addressable Version (Option A20) ............................................................. 25

8.7 Connection to a RS422 Master ........................................................................... 27

8.8 IO-Link Interface ............................................................................................... 28

Contents

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9 Optional Incremental Output .......................................................... 29

9.1 Incremental A/B Signals (TTL / HTL) ..................................................................... 29

9.2 Sine/Cosine Incremental Signals (Option SC50) .................................................... 29

10 Pin Assignment ................................................................................ 30

10.1 Connections of Housing with fixed Cable Outlet .................................................... 30

10.2 Connections of Housing with M9 Round Connector ................................................ 36

11 Disturbances, Maintenance, Cleaning ............................................. 37

11.1 Fault Clearance ................................................................................................ 37

11.2 Re-start after Fault Clearance .............................................................................. 37

11.3 Maintenance .................................................................................................... 37

11.4 Cleaning ......................................................................................................... 37

12 Type Designation ............................................................................. 38

12.1 Example of available Variants ............................................................................. 39

12.2 Accessories ...................................................................................................... 39

13 Index ................................................................................................ 43

Contents

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2 List of Figures:

Figure 1: Coding of the magnetic tape ....................................................................................................... 9

Figure 2: Dimensions of sensor with cable outlet ....................................................................................... 10

Figure 3: Dimensions of sensor with M9 round connector .......................................................................... 10

Figure 4: Dimensions of guide carriage FW2080 ...................................................................................... 11

Figure 5: Components of the magnetic tape ............................................................................................. 15

Figure 6: Handling ................................................................................................................................. 16

Figure 7: Tolerances ............................................................................................................................... 18

Figure 8: Mounting direction on magnetic tape ......................................................................................... 19

Figure 9: SSI - reading the data ............................................................................................................... 20

Figure 10: SSI - Gray / binary switchover ................................................................................................. 20

Figure 11: Bit rate and CAN identifier settings ........................................................................................... 21

Figure 12: Bit rate / address (option CN0) ................................................................................................ 22

Figure 13: Termination resistor ON / OFF ................................................................................................ 23

Figure 14: Set options on top of the housing ............................................................................................. 25

Figure 15: Connection to a RS422 Master ................................................................................................ 27

Figure 17: A/B - Inkrementalsignale (TTL / HTL) ........................................................................................ 29

Figure 18: Sine – Cosine Incremental Signals ............................................................................................ 29

3 List of Tables:

Table 1: Mounting tolerances .................................................................................................................. 18

Table 2: Bit rate and CAN-Identifier with option CA0 ................................................................................. 21

Table 3: Identifier Option CN0 ................................................................................................................ 22

Table 4: Bit rate and address settings (option CN0) .................................................................................. 22

Table 5: Bit rate RS422 (option420) and RS232 (option 230) ..................................................................... 24

Table 6: Addressable RS422 Option A20 ................................................................................................. 25

Table 7: Error messages of an addressable EMAX / EMAL .......................................................................... 27

Table 8: Characteristics values for option SC50 ........................................................................................ 29

Table 9: Connections of SSI interface cable 1 ........................................................................................... 30

Table 10: Connections of SSI interface cable 2 ......................................................................................... 30

Table 11: Connections of SSI interface with option M8F0, 8-pin M16 round connector ................................ 30

Table 12: Connections of SSI interface with option MCM0, 12-pin M16 round connector ............................ 31

Table 13: Connections of SSI interface with option D9M0, 9-pin D-SUB connector ...................................... 31

Table 14: Connections of SSI interface Option M8M0, 8-pin M16 round connector ..................................... 31

Table 15: Connections of CANopen interface (open cable ends) ................................................................ 32

Table 16: Connections of CANopen interface with option D9M, 9-pin D-SUB connector .............................. 32

Table 17: Connections of RS422 interface (open cable ends) ..................................................................... 33

Table 18: Connections of RS422 interface with option D9M0, 9-pin D-SUB connector ................................. 33

Table 19: Connection of RS422 interface option D9M5, 9-pin D-SUB connector ......................................... 33

Table 20: Connections of RS422 interface option M8M0, 8 pin M16 round connector ................................. 34

Table 21: Connections of RS232 interface (open cable ends) ..................................................................... 34

Table 22: Connections of RS232 interface with option D9M0, 9-pin D-SUB connector ................................. 34

Table 23: Connections - cable outlet with 4-pin. M12 round connector ...................................................... 35

Table 24: Connections - open cable ends (standard) ................................................................................. 35

Table 25: Connections - 12-pin M12 round connector (RCM0) .................................................................. 35

Table 23: Connections of the 7-pin M9 round connector (male) ................................................................. 36

Table 24: Connections when using the DKA cable with open cable ends ..................................................... 36

Table 25: Connections IO-Link without cable / Table 26: Connections IO-Link with DKA cable .................... 36

Table 27: Example of available variants .................................................................................................... 39

Table 28: Accessories ............................................................................................................................. 39

General, Safety, Transport and Storage

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DANGER!
This symbol in connection with the signal word “Danger” indicates an immediate danger for the life and health of
persons. Failure to heed these instructions can result in serious damage to health and even fatal injury.

WARNING!
This symbol in connection with the word „Warning” means a possibly impending danger for the life and health of
persons. Failure to heed these instructions can result in serious damage to health and even fatal injury.

CAUTION!
This symbol in connection with the signal word “Caution” indicates a possibly dangerous situation. Failure to heed
these instructions can lead to minor injuries or damage of property.

DANGER!
This symbol in connection with the signal word “Danger” indicates an immediate danger for the life and health of
persons due to voltage.
Failure to heed these instructions can result in serious damage to health and even fatal injury. The operations may
only be carried out by a professional electrician.

NOTE!
…points out useful tips and recommendations as well as information for an efficient and trouble-free operation.

4 General, Safety, Transport and Storage

4.1 Information Operating Manual

This manual contains important information regarding the handling of the device. For your own safety and operational safety, please ob­serve all safety warnings and instructions. Precondition for safe operation is the compliance with the specified safety and handling instruc­tions. Moreover, the existing local accident prevention regulations and the general safety rules at the site of operation have to be observed.
Please read the operating manual carefully before starting to work with the device! It is part of the product and should be kept close to the
device and accessible for the staff at any time. The illustrations in the manual are for better demonstration of the facts. They are not neces­sarily to scale and can slightly differ from the actual design.

4.2 Explanation of Symbols

Special notes in this manual are characterized by symbols. The notes are introduced by signal words which express the magnitude of danger.
Please follow this advice and act carefully in order to avoid accidents, damage, and injuries.

Warning notes:

Special safety instructions:

Tips and recommendations:

Reference marks:

 Marks a reference to another chapter of this manual.

 Marks a reference to another chapter of another document.

General, Safety, Transport and Storage

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CAUTION!
Wrong disposal causes environmental damages!
Electronic scrap, electronic components, lubricants and other auxiliary materials are subject to special refuse and can
only be disposed by authorized specialists!

CAUTION!
Please read the operating manual carefully, before using the device! Observe the installation instructions! Only start
up the device if you have understood the operating manual. The operating company is obliged to take appropriate
safety measure.
The initial operation may only be performed by qualified and trained staff.
Selection and installation of the devices as well as their embedding into the controlling system require qualified
knowledge of the applicable laws and normative requirements on the part of the machine manufacturer.

PROTECTIVE CLOTHING
… is close-fitting working clothing with light tear strength, tight sleeves and without distant parts. It serves preliminari­ly for protection against being gripped by flexible machine parts.
Do not wear rings, necklaces or other jewellery.

PROTECTIVE GLOVES
…for protecting the hands against abrasion, wear and other injury of the skin.

PROTECTIVE HELMET
…for protection against injuries of the head.

4.3 Statement of Warranties

The producer guarantees the functional capability of the process engineering and the selected parameters.

4.4 Demounting and Disposal

Unless acceptance and disposal of returned goods are agreed upon, demount the device considering the safety instructions of this manual
and dispose it with respect to the environment.
Before demounting, disconnect the power supply and secure against re-start. Then disconnect the supply lines physically and discharge
remaining energy. Remove operational supplies and other material.
Disposal:
Recycle the decomposed elements: Metal components in scrap metal, Electronic components in electronic scrap, Recycle plastic compo­nents, dispose the remaining components according to their material consistence.

Local authorities and waste management facilities provide information about environmentally sound disposal.

Safety

4.5 General Causes of Risk

This chapter gives an overview of all important safety aspects to guarantee an optimal protection of employees and a safe and trouble-free
operation. Non-observance of the instructions mentioned in this operating manual can result in hazardous situations.

4.6 Personal Protective Equipment

Employees have to wear protective clothing during the installation of the device to minimize danger of health.
Therefore: Change into protective clothing before performing the works and wear them throughout the process.
Additionally observe the labels regarding protective clothing in the operating area.

Protective clothing:

General, Safety, Transport and Storage

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CAUTION!
Danger through non-conventional use!
Non-intended use and non-observance of this operating manual can lead to dangerous situations.
Therefore:

 Only use the device as described
 Strictly follow the instructions of this manual

Avoid in particular:

 Remodelling, refitting or changing of the construction or single components with the intention to alter the

functionality or scope of the device.

CAUTION! Transport the package (box, palette etc.) professionally. Do not throw, hit or fold it.

NOTE!
Claim any damage immediately after recognizing it. The claims for damage must be filed in the lawful reclaim peri­ods.

4.7 Conventional Use

The product described in this manual was developed to execute safety-related functions as a part of an entire assembly or machineThe
ELGO-device is only conceived for the conventional use described in this manual.
The ELGO EMAX / EMAL linear encoders only serve to measure lengths.

Claims resulting from damages due to non-conventional use are not possible.
Only the operator is liable for damages caused by non-conventional use.

4.8 Safety Instructions for Transport, Unpacking and Loading

4.9 Handling of Packaging Material

Notes for proper disposal: 4.4

4.10 Inspection of Transport

Check the delivery immediately after the receipt for completeness and transport damage.
In case of externally recognizable transport damages:

 Do not accept the delivery or only accept under reserve.
 Note the extent of damages on the transportation documents or delivery note.
 File complaint immediately.

4.11 Storage

Store the device only under the following conditions:

 Do not store outside
 Keep dry and dust-free
 Do not expose to aggressive media
 Protect from direct sun light
 Avoid mechanical shocks
 Storage temperature (6) needs to be observed
 Relative humidity (6) must not be exceeded
 Inspect packages regularly if stored for an extensive period of time (>3 months)

Product Features

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fine interpolation track
non-magnetized area

absolute track

N

S N S N S

N N N NS S S S N N N NS S S S N NS S

S N S N S

Magnetic tape EMAX / EMAL Cable outlet

fine interpolation track
non-magnetized area

absolute track

N

S N S N S

N N N NS S S S N N N NS S S S N NS S

S N S N S

Magnetic tape EMAX / EMAL Round connector

Sensor with cable outlet:

Sensor with M9 round connector:

5 Product Features

The series EMAX / EMAL is an absolute length measuring system. Sensor and translator and interpolation unit
are together in the same compact housing. The magnetic tape of series EMAB is paste up to a plain area. The
EMAX / EMAL encoders can be mounted with a maximum distance of 1.5 mm to the magnetic tape. With a
reduced measuring accuracy the sensor distance can be up to 2.0 mm.

The only difference between EMAX and EMAL is the maximum measuring length:

 EMAX up to 10 m
 EMAL up to 20 m

SSI, CAN, RS232, RS422 and IO-Link are available as interfaces for the EMAX / EMAL sensors.
For more information about the interfaces see section  8.

Typical applications are handling systems, conveyor and storage technology, hydraulic presses, stamping ma­chines, casting machines, linear slides, linear drives and pick and place systems.

Two different designs are possible as sensor housings:

1. sensor housing with fixed cable outlet (see  6.2)

2. sensor housing with M9 round connector (see  6.3)

For versions with fixed cable outlet, a guide carriage and a guide rail are available (see accessories  12.2).

Overview of features:

 no referencing required
 direct wear free and contactless measurement
 allowed distance range between sensor and magnetic tape: 0.1 ... 1.5 mm

 Distance not ok = red LED on

 measuring length up to 10 m (EMAX) resp. 20 m (EMAL)
 high resolution 10 µm
 repeat accuracy +/- 1 increment
 very resistant against dirt

5.1 Functional principle

A Hall sensor and a magneto-resistive impedance measuring bridge are guided over a two-track magnetic tape
with a fine-interpolation trace and an absolute track. Together with the sensor line the absolute track provides
an absolute value and the fine-interpolation trace provides together with the interpolation electronic the measur­ing systems high resolution.

The fine interpolation track encloses alternately north- and south-pole tracks with a distance of 5 mm. These are
scanned with resistance bridges and provide a resolution of 0.01 mm. The absolute value provides the sensor
line with 16 single Hall sensors; these sensors are scanning the code sections of the north and south poles. The
absolute value on the magnetic tape recurs every 10 m with an EMAX resp. every 20 m with an EMAL system.

Figure 1: Coding of the magnetic tape

Technical Data

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14.1

22.5

30.9

37.1

63.5

19.6 4.4

75

66

67.5

7.5

20.6

1.7

Ø 3.3 Ø 6.8

184

4

40

67

Ø approx. 9

Ø approx. 11

14.5

24

26

70

75

60

2x45°

20.25

Ø 3.3

1.5x45°

20

22

SW10

5.5

39

15.5

5.8

Ø 1.2

6 Technical Data

6.1 Identification

The type label serves for the identification of the unit. It is located on the housing of the sensor and gives the
exact type designation (=order reference, see type designation) with the corresponding part number.
Furthermore, the type label contains a unique, traceable device number.
When corresponding with ELGO always indicate this data.

6.2 Dimensions Sensor Housing with Cable Outlet

Figure 2: Dimensions of sensor with cable outlet

6.3 Dimensions Sensor Housing with M9 round connector

Figure 3: Dimensions of sensor with M9 round connector

Technical Data

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REMARK!

The accessorial guide carriage FW2080 ( 12.2) is only available for
the housing version with a fixed cable outlet ( 6.2).

83.5

16.5

10

5

5

48

43

12 24

3

R=4

80

Ø 4.5

Ø 8

4.5

20

4

34

1.5

6

8

8

22

25

Ø 3.5

Ø 6

100

Top view:

Side view:

Rear view:

6.4 Dimensions Guide Carriage FW2080

Figure 4: Dimensions of guide carriage FW2080

Technical Data

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EMAX / EMAL (standard version)

Mechanical Data

Measuring principle

absolute

Measurement

linear

Repeat accuracy

±1 Increment

System accuracy in µm at 20°C
(L = measuring length in meters)

±(150 + 20 x L) (standard 010  12)
±(50 + 20 x L) (option F10  12)

Distance sensor / magnetic tape

max. 1.5 mm (2.0 mm with reduced measuring accuracy)

Basic pole pitch

5 mm

Sensor housing material

with cable outlet: zinc die cast
with M9 connector: aluminium

Sensor housing dimensions

a) Version with cable outlet: W x B x H = 75 x 24 x 26 mm,
resp. a) with FW2080 ( 12.2): W x B x H = 100 x 34 x 48 mm
b) Version with M9 connector: W x B x H = 75 x 22 x 39 mm

Required magnetic tape

EMAX: AB20-50-20-R-11
EMAL: AB20-50-10-R-12

Maximum measuring length

EMAX up to 10 m
EMAL up to 20 m

Connections

Version with cable outlet: open cable ends (more options  12)
Version with M9 connector: via DKA cable (accessories  12.2)

Sensor cable

Version with cable outlet: 1.5 m standard length (others upon request)
Version with M9 connector: no cable (accessorial part, see  12.2)

Weight

Sensor approx. 100 g without cable, (cable approx. 60 g/m)

Electrical Data

Supply voltage

+ 10 … 30 VDC

Residual ripple

10 … 30 V: <10%

Power input

max. 150 mA

Interfaces

SSI, CAN, RS422, RS232 oder IO-Link acc. to IEC 61131-9

Resolution

0.01 mm

Speed

max. 4 m/s

Conditions

Storage temperature

-20 °C … +85 °C

Operation temperature

-10 °C … +70 °C
(-25 °C … +85 °C upon request)

Humidity

max. 95 %, not condensing

Protection Class

IP40 (standard)
IP65 (option V)

6.5 Technical Data Sensor

Technical Data

- 13 -

Magnetic Tape AB20-50-20-2-R-11 and AB20-50-20-2-R-12

Coding

absolute, dual track system

Pole pitch

5 mm

Operation temperature installed

−20 °C … +65 °C
(−20°C … +80°C when using without adhesive tape, options „B“ or „D“)

Storage temperature uninstalled

Short-term: −10°C … +60°C
Medium-term: 0°…+40°C
Long-term: +18°C
(−20°C … +80°C when using without adhesive tape, options „B“ or „D“)

Gluing temperature:

+18°C … +30°C

Relative humidity

max. 95 %, non-condensing

System accuracy in µm at 20°C
(L = measuring length in meters)

±(150 + 20 x L) (standard 010  12)
±(50 + 20 x L) (option F10  12)

Material carrier tape

Precision Strip Steel 1.4310 / X10CrNi 18-8 (EN 10088-3)

Double-faced adhesive tape

3M-9088 (observe instructions), others on request

Dimensions

20 mm (±0.3 mm) x 1.8 mm (±0.1 mm)

Length expansion coefficient

 16 x 10-6 1/K

Thermal length expansion

∆L[m] = L[m] x [1/K] x ∆[K]
(L = tape length in meters, ∆ = relative temperature change)

Available measuring lengths

EMAX: max. 10 m
EMAL: max. 20 m
min. 0.2 m

Weight magnetic tape

ca. 62 g/m (incl. magnetic tape and cover tape)

Tape imprint

ELGO standard, printing color black, digit height >= 5 mm

Influence of external magnets

External magnetic fields must not exceed 64 mT (640 Oe; 52 kA/m) on
the surface of the magnetic tape as this could damage or destroy the code
on the tape.

Protection class

IP65

6.6 Technical Data Magnetic Tape

The magnetic tape consists of two components:

 The actual magnetic tape which carries the position information
 A mechanical stainless steel back iron

Installation and First Start-Up

- 14 -

CAUTION
Please read the operating manual carefully before using the device! Strictly observe the Instal­lation instructions! In case of damage caused by failure to observe this operating manual, the
warranty expires.

ELGO is not liable for any secondary damage and for damage to persons, property or assets.

The operator is obliged to take appropriate safety measures. The first start-up may only be
performed by staff that has been trained and authorized by the operator.

WARNING!
Do not use the device in explosive or corrosive environments!
The device must not be installed close to sources of strong inductive or capacitive interference
or strong electrostatic fields!

CAUTION!
The electrical connections must be made by suitably qualified personnel in accordance with
local regulations.

The device may be designed for switchboard mounting. During work on the switchboard, all
components must be de-energized if there is a danger of touching the energized parts!
(protection against contacts)

Wiring works may only be performed in the de-energized state!

Thin cable strands have to be equipped with end sleeves!

Before switching on the device, connections and plug connectors have to be checked!

The device must be mounted in a way that it is protected against harmful environmental influ­ences such as splashing water, solvents, vibration, shock and severe pollution and the operat­ing temperature must not be exceeded.

7 Installation and First Start-Up

7.1 Operating Area