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DSG-DMG 维修售后NEWALL-DSG-DMG安装手册,标准说明书

型号
DSG-DMG

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详细信息

  • 维修售后NEWALL-DSG-DMG安装手册,标准说明书在本资料上方(或技术资料中)能下载带图的详细说明书
  • 维修及销售的主要有日本富特巴(FUTEBA)、三丰(Mitutoyo)、英国新和(NEWALL)、万濠(RATional)、怡信(Easson)、信和(Sino)、奥特嘉(oska)、朕衡(Zhen)、硕信(Soin)、必嘉(Bica)、艾莫特(AMOT)、意大利(Givi)等品牌.维修数显表范围:NEWALL球栅数显表维修DP8、E70、B60、Mitutoyo三丰品牌(KACOUNTER、QM-DATA200、KLD-200、EC-100),Rational万濠(WE6800-2、WE6800-3、WE6800E、DC3000),RSF-ELEKTRONIK,FAGOR(20I-M、30I-M),NEWALL新和(B60、E70、DP8),BICA-DRO,POWERN(PE2X、PE3X),HEIDENHAIN海德汉(ND780、ND522、ND523),NIKON尼康(DP-E1、SC2-E1、SC3-E1、QUADRA-CHEK200),CHFOIC(DRO-2M、DRO-3M、DRO-2L、DRO-2G、DRO-3E、JDS100B、DS401SM),SONY索尼(LH51、LH71、LH52、LH72),JENIX韩国东山,SUMTAK-FUTABA(FUTABA-PULSCALE、CMJ200),SINO诺信(SDS6-3V、SDS6-2V、SDS2MS),GSW-3A、GSW-3B、GSW-204、GSW-2B、GSW-2C,SOIN(SI2008-2B、SI2008-3B)
  • 维修售后NEWALL-DSG-DMG安装手册,标准说明书
  • 以上品牌和型号的数显表都能维修:数显表被雷击坏、接错电压被烧坏、数显表显示轴跳数,显示轴不显示、显示轴精度不准、显示轴闪烁、数显表按键不灵、数显表无信号等等。
  • ----------------------- Page 1-----------------------

    N NEWALL MEASUREMENT SYSTEMS LTD 

     

    DSG & DMG               Linear Encoders 


    ----------------------- Page 2-----------------------

    Contents 

     

                            CONTENTS 

     

                             1.0 Technical Specification 

     

                                   1.1   Bracketry 

                                   1.2   Preparation 

                                   1.3   Warnings 

     

                            2.0  Technical Specification 

     

                                  2.1    Output Signals 

                                  2.2    Resolution and Signal Period Options 

                                  2.3    DMG - EV and EM Interface Module 

     

                            3.0    DSG Encoder Assembly 

     

                            4.0  DMG Encoder Assembly 

     

                            5.0    Mounting The Digital Reader Head 

     

                                  5.1    DSG 

                                  5.2    DMG 

     

                            6.0 Mounting The Scale 

     

                                  6.1    DSG 

                                   6.1.1 Double End Mounting 

                                   6.1.2 Single End Mounting 

                                   6.1.3 Scales in excess of 2.5 meters 

                                  6.2    DMG Scale 

                                   6.2.1 Single End Mounting 

     

                            7.0    Fitting The Scale Guard 

     

                            8.0    Cable Routing 

     

                            9.0    Final Check 

     

                            Appendix A -- Mounting the Digital Reader Head 

                            Appendix B - DSG / DMG Digital -- Scale Support Brackets 

     

    1     Newall Measurement Systeewall Measurement Systems 


    ----------------------- Page 3-----------------------

                                                                                                                    Introduction 

     

     1.0        INTRODUCTION 

     

    This manual will provide connection and mounting instructions for Newall's DSG Digital and DMG Digital linear 

    encoders. It is important that you read and understand this manual prior to commencing the installation. 

     

    If, at any time, you have any questions relating to this manual or the installation, contact Newall or your local 

    authorised Newall 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 linear 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 beginning the installation the machine should be studied to determine where the Linear encoder(s) will be 

    fitted. Appendix A shows several different methods of mounting the Reader Head along with its brackets. 

     

    In order to reduce erroneous readers caused by machine wear, it is recommended that the Scale be fitted as close 

    to the machine lead screw or axial drive shaft as possible. 

     

    The actual overall scale length is approximay 258mm (10.1”) for DSG and 173mm (6.8") for DMG longer than 

    the stated scale travel. (e.g. if the travel length is 40” (DSG) the actual overall scale length of the scale will be 50”) 

     

    Outboard mounting of the scale support brackets will add approximay 20mm (3/4") to the effective scale travel. 

    (Refer to Appendix 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 6.4 and 6.10) 

     

    The moving member of the Linear Digital Encoder assembly can be either the Reader Head or the Scale. 

     

    Cable routing from the Reader Head should be examined (See Section 8).  Each Reader Head is provided with 

    either a 3.5 metre (11’) or 7 metre (22’) of armoured cable. Extension cables are available in 1 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. 

     

     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 responsibility 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 Linear Digital Encoders can withstand the rigorous 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               2 


    ----------------------- Page 4-----------------------

    Technical Specification 

     

           2.0 TECHNICAL SPECIFICATIONS 

     

           Construction: 

                              Housing                    Aluminium  

                              Cable                      6mm (¼" ) Fully interlocked Stainless Steel conduit armour 

                                                         9-way 'D-Type' connector, Heidenhein 12 pin or 9 pin round connector 

     

           Dimensions (reader head): 

                    DMG Digital 

                              Height                     35.0mm (1.378") 

                             Width                       75.0mm (2.953") 

                              Depth                      25.0mm (0.984") 

                             Weight                      0.640Kg (1.410lbs)          (max. inc. 3.5m cable) 

                    DSG Digital 

                              Height                     53.5mm (2.106") 

                             Width                       131.0mm           (5.157") 

                              Depth                      28.5mm (1.112") 

                             Weight                      0.858Kg (1.890lbs)          (max. inc. 3.5m cable) 

     

           Operating Voltage:                            5 VDC ± 5% 

     

           Supply Voltage Fluctuation:                   Within operating voltage range 

     

           Maximum Power Consumption:                    80mA + line receiver requirement 

     

           Operating Temperature:                        0 to 55°C 

     

           Storage Temperature:                          -20 to 70°C 

     

           Outputs:                                      Differential Quadrature via RS422 compatible 

                                                         line drivers @ 5V TTL levels, 1Vpp or 11µApp. 

     

           Maximum Output frequency:                      1,000,000 counts/sec (1Mhz) 

     

           Maximum cable length:                         20m (using Newall supplied cables) 

     

           Required Moving Force: 

                              DMG Digital                 10N 

                              DSG Digital                20N 

     

           Scale Type: 

                              DMG Digital                Carbon Fibre                5.64mm OD         (0.222") 

                              DSG Digital                Stainless Steel             15.24mm OD        (0.600") 

     

           Environmental Conditions:                     IP67 (fully submergible) according to IEC529. 

                                                         Exceeds NEMA Type 6 

     

           EMC Compliance:                               BS EN 50081-2      Electromagnetic Compatibility 

                                                                            Generic Emission Standard - Industrial Environment 

                                                         BS EN 50082-2      Electromagnetic Compatibility 

                                                                            Generic Immunity Standard - Industrial Environment 

     

                                                         NOTE:    NEWALL MEASUREMENT SYSTEMS LIMITED RESERVES THE  

     

                 Certificate No FM36096                  RIGHT TO CHANGE THE SPECIFICATION WITHOUT NOTICE 

     

    3      Newall Measurement Systeewall Measurement Systems 


    ----------------------- Page 5-----------------------

                                                                                                                    Output Signals 

     

     2.1 Out Signals 

     

     TTL Output Signal - Differential Quadrature 

     

     Newall TT Series Linear Encoders provide a differential quadrature output at RS422 TTL levels. 

     The distance between two successive edges of the combined pulse trains A and B is one measuring step (resolution). 

     

                                                                       Resolution 

     

                                         Signal Period 

     

    EV & EM - 1Vpp & 11µApp Output Signal  

     

    Newall EV & EM Series linear encoders provide differential sinusoidal output signals that are phase shifted by 90°, and 

    can provide 1Vpp or 11µApp signal levels depending on which model is selected. 

     

    1Vpp is available with 20μm signal period only  

     

    11μApp is available with 20μm or 40μm signal period 

     

    Assumes 120 Ohm termination resistor 

     

                                                                                                    Newall Measurement Systems            4 


    ----------------------- Page 6-----------------------

           2.2 Resolution and Signal Period Option 

     

          Both DSG - TT and DMG - TT are available, to order with a range of pre-programmed  

          resolutions as shown below. 

     

           Resolution       DSG - TT                 DMG - TT 

     

            1µm                     √                         √ 

            2µm                     √                         √ 

            5µm                     √                         √ 

            10µm                    √                         √ 

     

          Both DSG - EV / EM and DMG - EV / EM are available to order with the signal periods shown below. 

     

           Signal Period      DSG - EV      DSG - EM      DMG - EV       DMG - EM 

     

                20µm              √              √             √              √ 

                40µm                             √                            √ 

     

          2.3 DMG - EV and EM Interface Module 

     

          When DMG-EV or DMG-EM linear encoders are supplied, an interface module is included 

          that provides 1Vpp or 11μApp output signals.  

     

          1Vpp SVV Interface module (Part Number 600-83640) 

     

          11μApp SVM Interface module (Part Number 600-83650) 

     

    5     Newall Measurement Systeewall Measurement Systems 


    ----------------------- Page 7-----------------------

                                                                                               Encoder Assembly 

     

    3.0       DSG ENCODER ASSEMBLY 

     

       Item      Description                   Qty 

                                                             Item      Description                   Qty 

     

         1       DSG Digital Reader Head         1 

         2       DSG Scale                       1             6       Support Pillar Long             2 

         3       Scale Support Link              2             7       Scale Cover                     1 

         4       Scale Anchor Pin                2             8       M5 x 20 Hex Head                6 

         5       Support Pillar Short            2             9       M8 x Socket Button Head         2 

     

    4.0       DMG ENCODER ASSEMBLY 

     

       Item      Description                   Qty             Item      Description                   Qty 

     

         1       DMG Digital Reader Head         1               8       Scale Cover                     1 

         2       DMG Scale                       1               9       M3 Spring Washer                1 

         3       Support Link                    2               10      M3 x 16 SHCS                    1 

         4       Anchor Pin                      1               11      M3 x 12 SHCS                    4 

         5       Support Pin                     1               12      M4 x 5 Nylon Set Screw          1 

         6       Support Pillar Short            2               13      M6 x 10 Socket Button Head      2 

         7       Support Pillar Long             2 

     

                                                                                     Newall Measurement Systems         6 


    ----------------------- Page 8-----------------------

    Mounting the Digital Reader Head 

     

             5.0       MOUNTING THE DIGITAL READER  

                       HEAD 

     

             5.1       DSG Digital 

     

             Mount the Digital 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 5.1) 

     

                                          Figure 5.1 - Alignment of the DSG Digital Reader Head 

     

             Final adjustments can be carried out by use of laminated shims, which are included with each transducer assembly. 

             Each layer of shim is equivalent to 0.05mm (0.002"). 

     

             5.2       DMG Digital 

     

             Mount the Digital 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 5.2) 

     

                                        Figure 5.2 - Alignment of the DMG Digital Reader Head 

     

    7     Newall Measurement Systeewall Measurement Systems 


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                                                                                                            Mounting the Scale 

     

    6.0         MOUNTING THE SCALE 

     

    6.1        DSG 

     

    6.1.1      Double End Mounting 

     

    Note:      Refer to section 6.1.3 for mounting scales in excess of 2.5 meters. 

     

    Each end of the DSG Scale is different and can be identified by the pan head screw at the 'tensioner end' and a nylon 

    snap rivet at the 'fixed end'. 

     

                                                        Figure 6.1 - DSG Scale 

    NOTES: 

     

    (A)        Erroneous readings will occur if the Digital Reader Head is allowed to travel beyond the Effective  

    Travel Limits.  (Refer to Figure 6.1) 

     

    (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 Figure 6.1) 

     

    (C)        When mounting scales in the vertical plane the tensioner end should be positioned at the top. 

     

    Once the Digital 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 DSG Scale through the Digital Reader Head, 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 approximay 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 approximay 5mm (0.2") away from the end of the Digital Reader Head. 

     

    Transfer punch through the support link and into the machine casting.  It is important that the support link is kept 

    square to its mounting surface at all times. 

     

    Remove the link/pin assembly and the scale from the Digital 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 6.3. The pillar should fit square and flush to the machine surface. 

     

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    ----------------------- Page 10-----------------------

    Mounting the Scale 

     

               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/pin assembly onto the pillar and pass the scale through the Digital 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 Digital 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 READINGS WILL 

                                        OCCUR IF THIS WARNING IS NOT FOLLOWED.  REFER TO FIGURE 6.2 

     

                                                  Figure 6.2 - DSG Reader Head and Bracket Alignment 

     

                Remove the scale from the Digital 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 scale support pin leaving approximay 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 Digital 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 

               square to its mounting surface at all times. 

     

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                                                                                                        Mounting the Scale 

     

    Remove the link/pin assembly and the scale from the Digital 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 6.3. The pillar shoulder fit square and flush to the machine surface. 

     

                                                  Figure 6.3 - 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. These 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 Digital 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 Digital 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. 

     

    Carefully slide the DSG Scale through the support pin, through the Digital Reader Head and into the opposite support 

    pin. FULLY TIGHTEN THE SUPPORT PIN HEX SCREW AT THE FIXED END OF THE SCALE, BUT ONLY 'SNUG 

    UP' THE HEX SCREW ON SUPPORT PIN AT THE TENSIONER END. 

     

    6.1.2      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 separay, ask for UK part number  

               600-63610, USA part number LBK01. 

     

    Remove the nylon pan head screw from the tensioner end of the scale. 

     

    After the Digital Reader Head has been installed slide the scale through the Digital Reader Head and insert the 

    tensioner end of  the scale into the single end mounting block.  (Refer to Figure 6.4) 

     

    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”).  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 tensioner end of the scale. 

     

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    ----------------------- Page 12-----------------------

    Mounting the Scale 

     

                                                           Figure 6.4 - DSG Single End Mounting  

     

             6.1.3        Scales in Excess of 2.5 meters 

     

             Traverse the machine to fullest extent of travel including hand winding past any electrical limits or trip dogs. 

     

             Insert the short blank length of DSG tube into the Digital Reader Head, allowing for a sufficient amount of scale to 

             project from the Digital Reading Head in order to fit the scale mounting brackets. 

     

             Assemble the angle bracket to the scale clamp (Refer to Figure 6.5).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 approximay 10mm clearance from the end of the Reader Head. 

     

             Mark the position of the jack plate (if required) 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 Digital 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 Digital Reader Head as near to the 

             bracket assembly as possible. Slide the blank tube through the Digital Reader Head into the scale clamp.Adjust the 

             brackets into position and carefully tighten the screws. Check that the blank tube slides through the Digital 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 DSG blank tube into the Digital Reader Head, assemble the remaining scale bracket assembly including the 

             jacking plate (if required) and slide onto the tube. 

     

             Set the outside edge of the scale clamp level with the mark that indicates the overall length of the DSG Scale and 

             mark the fixing position for the bracket assembly. 

     

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    ----------------------- Page 13-----------------------

                                                                                                      Mounting the Scale  

     

                                      Figure 6.5 - Long Scale Support Bracket Assembly 

     

    For scales which are mounted in the horizontal position, spring loaded scale supports are included and should be 

    positioned according to Table 1. 

     

    Once the locations for the supports have been determined, the DSG Reader Head should be positioned in the location 

    where the first support is to be fitted. Assemble the support unit including the jack plate if required. Mark the position 

    for the fixing screws, drill and tap (M8 for the jack plate or M6 for the angle bracket). Ensure that the angle bracket has 

    sufficient movement utilising the two slots to allow for adjustment in the vertical plane.  It is important that the top 

    face of the angle bracket is set to 58.5mm (2.3”) from the bottom machined face on the DSG Reader Head. 

     

                                 Figure 6.6 - DSG Long Scale Mounting and Support Details 

     

                                                                                             Newall Measurement Systems            12 


    ----------------------- Page 14-----------------------

    Mounting the Scale 

     

                Length      No off Scale          FROM FIXING  BRACKET                Mid Position of  Left Side Position  Right Side Position 

                              Supports        Left Side (A)        Right Side (B)       Travel (B)        of Travel (C)       of Travel (C) 

     

                  2500mm          2              850mm                 850mm                -                   -                   - 

     

                  3000mm          2              1100mm                1100mm               -                   -                   - 

     

                  3500mm          2              1350mm                1350mm               -                   -                   - 

     

                  4000mm          2              1500mm                1500mm               -                   -                   - 

     

                  4500mm          3              1125mm                1125mm            2250mm                 -                   - 

     

                  5000mm          3              1250mm                1250mm            2500mm                 -                   - 

     

                  5500mm          3              1350mm                1350mm            2750mm                 -                   - 

     

                  6000mm          3              1500mm                1500mm            3000mm                 -                   - 

     

                  6500mm          4              1300mm                1300mm               -                650mm               650mm 

     

                  7000mm          4              1400mm                1400mm               -                700mm               700mm 

     

                  7500mm          4              1500mm                1500mm               -                750mm               750mm 

     

                  8000mm          4              1600mm                1600mm               -                800mm               800mm 

     

                  8500mm          5              1410mm                1410mm            4250mm              1410mm              1410mm 

     

                  9000mm          5              1500mm                1500mm            4500mm              1500mm              1500mm 

     

                  9500mm          5              1580mm                1580mm            4750mm              1580mm              1580mm 

     

                  10000mm         6         1420mm & 2840mm       1420mm & 2840mm           -                710mm               710mm 

     

                  10500mm         6         1500mm & 3000mm       1500mm & 3000mm           -                750mm               750mm 

     

                  11000mm         6         1570mm & 3140mm       1570mm & 3140mm           -                785mm               785mm 

     

                                                                            Table 1 

     

               6.2         DMG Scale 

     

                                                                   Figure 6.7 - The DMG Scale 

     

               NOTES: 

     

               (A)        Erroneous readings will occur if the DMG Digital Reader Head is allowed to travel beyond  

                          Effective Travel Limits.  (Refer to Figure 6.7) 

     

               (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. 

     

               (C)        When mounting scales in the vertical plane the tensioner end should be positioned at the top. 

     

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                                                                                                               Mounting the Scale 

     

    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 DMG Linear Digital Encoders include a set 

    up bar. The set up bar is of the same diameter as the DMG Scale and will be used to align the brackets to the Digital 

    Reader Head. 

     

                                                  Figure 6.8 - DMG Scale Support Bracket 

     

    Traverse the machine to its maximum position toward the non-cable entry side of the Digital Reader Head.  Maximum 

    position means all available travel, including hand winding past any electrical limits or trip dogs. 

     

    Carefully slide the DMG Scale set-up bar through the Digital Reader Head, allowing for sufficient scale to project from 

    the Digital Reader Head in order to fit the scale support brackets. 

     

    Assemble the support link to the anchor pin leaving approximay 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 approximay 5mm (0.2") away from the end of the Digital 

    Reader Head. 

     

    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/anchor assembly and the scale set-up bar from the Digital 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 6.3. The pillar shoulder fits square 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 Digital 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 Digital 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 Digital  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 approximay 3mm (1/8") gap between the bottom of the 

    mounting shoulder and the top of the link.  (Refer to Figure 6.8) 

     

                                                                                                     Newall Measurement Systems               14 


    ----------------------- Page 16-----------------------

    Mounting the Scale 

     

              Slide the link/pin assembly onto the scale set-up bar making certain that there is sufficient clearance between the Digital 

              Reader Head and the support link to prevent damage to the Digital 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 

              square to its mounting surface at all times. 

     

              Remove the link/pin assembly and the scale from the Digital 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 6.3. 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 Digital 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 Digital 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 READINGS WILL 

                                      OCCUR IF THIS WARNING IS NOT FOLLOWED.  REFER TO FIGURE 6.9 

     

                                                   Figure 6.9 - DMG Reader Head and Bracket Alignment 

     

              Carefully slide the DMG Scale through the support pin, ensuring the fixed end is inserted first, through the Digital 

              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. 

     

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                                                                Mounting the Scale / Fitting the Scale Guard 

     

    6.2.1      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 6.10). The DMG single end mounting kit is sold 

    separay, as for UK part number 600-65340, US part number LBK02 (for DSG & DMG) and LBK03 (for DMG only). 

     

    Note:      The maximum total length of scale not exceed 450mm  (18") when using the single end  

               mounting block. 

     

    Once the Digital 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 6.10) 

     

    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 jacking 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. 

     

                                           Figure 6.10 - DMG Single End Mounting 

     

    7.0        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 7.1) 

     

    To fit the guard to the support pillars, measure and mark off the distance between the centre of each pillar.  For DSG 

    drill two 8.5mm (3/8"), for DMG 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 Digital Reader Head. 

     

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    Fitting the Scale Guard / Cable Routing / Final Check 

     

                                  Figure 7.1 - Fitting the Scale Guard (example shown using a DSG Scale) 

     

           8.0 CABLE ROUTING 

     

           The most important and the 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 Digital Reader Head to the 

           digital readout unit. 

     

           Note:       The armoured cable is an integral part of the Digital 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. 

     

           9.0         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. 

     

    17     Newall Measurement Systeewall Measurement Systems 


    ----------------------- Page 19-----------------------

                                                                                  Appendix A 

     

    Appendix A -- Mounting the Digital Reader Head 

     

                                                                   Newall Measurement Systems 18 


    ----------------------- Page 20-----------------------

    Appendix B 

     

             Appendix B - DSG Scale Support Brackets 

     

      19  Newall Measurement Systeewall Measurement Systems 


    ----------------------- Page 21-----------------------

                                                                                  Appendix B 

     

    Appendix B - DMG Digital Scale Support Brackets 

     

                                                                   Newall Measurement Systems  20 

     

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