Operating Instructions

eddyNCDT SGS 4701

Digital Eddy-Current Measuring System for Spindle Growth System

MICRO-EPSILON
MESSTECHNIK
GmbH & Co. KG
Königbacher Strasse 15

94496 Ortenburg / Germany

Tel. +49 (0) 8542 / 168-0

Fax +49 (0) 8542 / 168-90
e-mail [email protected]
www.micro-epsilon.com
 Contents

1. Safety......................................................................................................................................... 5
1.1 Symbols Used.................................................................................................................................................. 5
1.2 Warnings........................................................................................................................................................... 5
1.3 Notes on CE Marking....................................................................................................................................... 6
1.4 Intended Use.................................................................................................................................................... 6
1.5 Proper Environment.......................................................................................................................................... 6

2. System Description................................................................................................................... 7
2.1 Measuring Principle.......................................................................................................................................... 7
2.2 Electrical Runout............................................................................................................................................... 8
2.3 Structure of the Measuring System.................................................................................................................. 9
2.4 Glossary.......................................................................................................................................................... 10
2.5 Technical Data................................................................................................................................................ 11

3. Delivery ................................................................................................................................... 12
3.1 Unpacking, Included in Delivery.................................................................................................................... 12
3.2 Storage .......................................................................................................................................................... 12

4. Installation and Assembly....................................................................................................... 13

4.1 Precautions..................................................................................................................................................... 13
4.2 Sensor............................................................................................................................................................. 13
4.2.1 Frame Size 10 x 4 x 4 mm............................................................................................................. 13
4.2.2 Frame Size 12 x 10 x 4.5 mm ....................................................................................................... 14
4.3 Sensor Cable.................................................................................................................................................. 16
4.4 Controller........................................................................................................................................................ 18
4.5 Connecting the Measuring System................................................................................................................ 19
4.6 Ground Concept............................................................................................................................................. 20

5. Operation................................................................................................................................. 21
6. Liability for Material Defects................................................................................................... 21
7. Service, Repair ....................................................................................................................... 22
8. Decommissioning, Disposal .................................................................................................. 22

eddyNCDT SGS 4701

Appendix
A1 Clamping Flange Controller................................................................................................... 23
A2 Tool Sensor Cable................................................................................................................... 24
A3 Optional Accessories.............................................................................................................. 24
A4 Notes for Electrostatic Discharge.......................................................................................... 25
A5 Target Thickness..................................................................................................................... 26
A6 Non-ferromagnetic Target....................................................................................................... 27
A7 Change from SGS4311 to SGS4701....................................................................................... 28

eddyNCDT SGS 4701

Safety

1. Safety
System operation assumes knowledge of the operating instructions.

1.1 Symbols Used

The following symbols are used in the instruction manual.
Indicates a hazardous situation which, if not avoided, may result in minor or moderate
injury.

Indicates a situation that may result in property damage if not avoided.

Indicates a user action.

i Indicates a tip for users.

Measure Indicates hardware or a software button/menu.

1.2 Warnings
Connect the power supply and the display/output device according to the safety regulations for electrical
equipment.
>> Danger of injury
>> Damage to or destruction of the controller and/or sensor

The supply voltage must not exceed the specified limits.

>> Damage to or destruction of the controller and/or sensor

Avoid shocks and impacts to the sensor and controller.

>> Damage to or destruction of the controller and/or sensor

Protect the cable against damage

>> Failure of the measuring device

eddyNCDT SGS 4701 Page 5

Safety

1.3 Notes on CE Marking

The following apply to the measuring system eddyNCDT series SGS 4701:
-- EU directive 2014/30/EC
-- EU directive 2011/65/EC, “RoHS” category 9
Products which carry the CE mark satisfy the requirements of the EU directives cited and the European
harmonized standards (EN) listed therein. The EU Declaration of Conformity is available to the responsible
authorities according to EU Directive, article 10, at:
MICRO-EPSILON Messtechnik GmbH & Co. KG
Königbacher Straße 15
94496 Ortenburg / Germany

The measuring system is designed for use in industrial environments and meets the requirements.

1.4 Intended Use

-- The measuring system eddyNCDT series SGS 4701 is designed for use in industrial areas. It is used
ƒƒ for displacement, distance and movement measurement
ƒƒ for temperature detection
ƒƒ position measuring of parts or machine components
-- The measuring system must only be operated within the limits specified in the technical data, see Chap.
2.4.
-- The system must be used in such a way that no persons are endangered or machines and other material
goods are damaged in the event of malfunction or total failure of the controller.
-- Take additional precautions for safety and damage prevention in case of safety-related applications.

1.5 Proper Environment

Protection class: IP 67 (in plugged state) Humidity: 5 - 95 % (non-condensing)
Operating temperature: Ambient pressure: Atmospheric pressure
Controller +10 ... +70 °C Storage temperature: 0 ... +70 °C
(+50 ... +158 °F) (+32 ... +158 °F)
Sensor/sensor cable 0 ... +90 °C (+32 ... +194 °F)

eddyNCDT SGS 4701 Page 6

System Description

2. System Description
2.1 Measuring Principle
The eddyNCDT series SGS 4701 (Non-Contacting Displacement Transducers) measuring system operates on
the basis of eddy currents without making physical contact. It is used for measurements on objects consisting
of electrically conducting materials which have ferromagnetic or non-ferromagnetic properties.
High frequency alternating currents flow through a coil cast in a sensor housing. The electromagnetic field
from the coil induces eddy currents in the electrically conducting target, causing the alternating current
resistance of the coil to change. This change of impedance delivers an electrical signal proportional to the
distance of the target from the sensor.
The eddyNCDT SGS 4701 conditions the sensor signals user-fairly at a bandwidth of 2,000 Hz. Thus a
so-called spindle monitoring is also still possible at numbers of revolutions up to 120,000 rpm. The spindle
growth itself can be detected at even higher numbers of revolutions.
Monitoring an axial expansion requires subsequent individual filtering by the user. Micro-Epsilon recommends
averaging or filtering across several revolutions in order to record only the relative expansion during a defined
period. During an unfiltered/non-averaged measurement, effects such as those within a single revolution also
become visible; this can cause incorrect interpretations.
In order to achieve highly accurate measurements, it is imperatively necessary that one (or more) sample(s)
item under test is / are provided by the customer.

eddyNCDT SGS 4701 Page 7

System Description

2.2 Electrical Runout

Ferromagnetic metals can have areas with different magnetizations called Weiss domains; these in turn
dampen the sensor’s eddy current field differently. Even with constant distance between sensor and target,
different distance values can occur. The domains can be reproduced, but show unrealistic axial runout devia-
tions within one revolution.
If the eddyNCDT SGS4701 is to be used for recording an axial runout measurement, start-up behavior or
a so-called spindle monitoring, it is possible to compare with non-ferromagnetic metal. Because of their
material properties, non-ferromagnetic metals offer the advantage that they do not show any such effects and
therefore should be used for such measuring tasks.
Non-ferromagnetic metals on average have less mechanical strength; this means that the selection of materi-
als is of crucial significance.
AlZnMgCu1,5 (3.4365)

Proposed materials
AlMg1SiCu
Inconel, NiCr19NbMo (2.4668)
Bronze in general
i Consider the material strength.

More details are available in the annex, see Chap. A 6.

eddyNCDT SGS 4701 Page 8

System Description

2.3 Structure of the Measuring System

The eddyNCDT series SGS 4701 is developed for recording the thermal and mechanical expansion of high-
speed milling spindles. This enables the active compensation of the axial spindle expansion via e. g. a CNC
machine tool.
The SGS 4701 consists of a sensor, a sensor cable and a controller which can be factory calibrated for
ferromagnetic or non-ferromagnetic measurement objects. Miniature sensors enable it to be installed directly
in the spindle, where the measurements take place, typically on the labyrinth-ring of the spindle. As well as
measuring linear expansion, the temperature of the sensor is also detected and output. The compact control-
ler can be installed on the spindle housing via a flange or directly in the spindle.

Fig. 1 Typical installation with Fig. 2 Measuring system consisting

measurement on the labyrinth ring of sensor and controller

Due to its compact size, the measurement technology (paired electronics and sensor) is fully integrated into
the spindle head.

eddyNCDT SGS 4701 Page 9

System Description

2.4 Glossary
SMR Start of measuring range.
Minimum distance between sensor front and target
MMR Midrange
EMR End of measuring range (start of measuring range + measuring range)
Maximum distance between sensor front and target
MR Measuring range
U [V]
U [V]
9.5 9.5

%
5
Signal

rea ity±
.a ar
Lin e
Lin

Displace-
0.5 0.5 Temp.
ment
0 0
100 600 µm 0 90 °C
Target
Sensor
Measuring range

SMR

eddyNCDT SGS 4701 Page 10

System Description

2.5 Technical Data

Sensor system SGS4701
Measuring range 500 µm (option 250 µm 2))
Offset 100 µm (option 50 µm 2))
Linearity ±2 µm
Resolution 1) 0.5 µm
Bandwidth 2000 Hz
Target ferromagnetic / non-ferromagnetic
Minimum target diameter 6 mm (option 3.5 mm 2))
Sensor 0 ... +90 °C (+32 ... +194 °F)
Operating temperature
Controller +10 ... +70 °C (+50 ... +158 °F)
Sensor ±150 ppm FSO/°C (MMR)
Temperature stability
Controller ±500 ppm FSO/°C (MMR)
Temperature Sensor +10 ... +80 °C (+50 ... +176 °F)
compensation range Controller +10 ... +70 °C (+50 ... +158 °F)
Supply voltage 12 ... 32 VDC
Displacement 0.5 - 9.5 V � 100 - 600 µm (option 50 - 300 µm 2))
Analog out Temperature 0.5 - 9.5 V (� 0 ... +90 °C)
Load resistor ≥ 10 kOhm
Protection class Sensor / controller IP 67 (in plugged state)
EMU04(10x/11x/14x/15x) 12 x 10 x 4.5 mm³
Dimensions
EMU04(12x/13x/16x/17x) 10 x 4 x 4 mm³
Diameter Ø 1.13 mm
Length 1000 mm (400 - 1500 mm on request)
Sensor cable
Min. bending radius 12 mm
Coating FEP

eddyNCDT SGS 4701 Page 11

Delivery

Sensor system SGS4701

Shock DIN EN 60068-2-27
(50 g, 6 ms, 3 cycles in each direction)
Vibration DIN EN 60068-2-6
(20 g, 10 - 3000 Hz)
FSO = Full Scale Output; MMR = Midrange
1) Static at midrange (MMR)
2) For OEM modifications: sensor with 250 μm measuring range and 50 μm SMR distance

3. Delivery
3.1 Unpacking, Included in Delivery
1 SGS 4701(xxx)
1 Test report
1 Instruction manual
Check the delivery for completeness and shipping damage immediately after unpacking.
If there is damage or parts are missing, immediately contact the manufacturer or supplier.
Optional accessories are available in the appendix.

3.2 Storage
Storage temperature: 0 ... +70 °C (+32 ... +158 °F)
Humidity: 5 - 95 % (non-condensing)

eddyNCDT SGS 4701 Page 12

Installation and Assembly

4. Installation and Assembly

4.1 Precautions
No sharp or heavy objects should be allowed to affect the cable sheath of the sensor cable, the power supply
cable and the output cable.
Check all plug-in connections for firm seating before starting operation.
Destruction of the
controller by electro- 4.2 Sensor
static discharge via
4.2.1 Frame Size 10 x 4 x 4 mm
the sensor. Please
observe the notes Sensors with integrated cable with miniature connector
regarding electro- EMU04(121)-C100 standard
static discharge, see Potting
Chap. A 4. Sensor coil
Sensors with integrated cable with open ends
(.39 .008)

(.06 ±0.002)
10 -0.2

1.5±0.05
EMU04(160)-C150 standard

0
4 -0.03 C = Cable length in cm
Cable lengths between 40 … 150 cm are possible in 10 cm
0.2 -0.05 x 45°

(.099)

increments.
)

2.5
-0.002
4 edges

0
0

(0.008

4 0-0.03
0
(.16 -0.0011 )

Fig. 3 Dimensional drawing

Dimensions in mm (inches), not to scale

eddyNCDT SGS 4701 Page 13

Installation and Assembly

4.2.2 Frame Size 12 x 10 x 4.5 mm

6 (.24) ø 1.13 Sensors with integrated cable with miniature connector
(.04 dia) EMU04(102)-C100 standard

ø 2.
(.1 d 5 Sensors with integrated cable with open ends
ia) EMU04(140)-C150 standard

12 (.47)
C = Cable length in cm
Cable lengths between 40 … 150 cm are possible in 10 cm
(.06±0.002)
1.5±0.05

4.5 ±0.05 increments.

(0.18 ±0.05)

(.07)
-0.005 1.75
0.3x45°
(0.012x45°)

10 -0.027
(0.39 -0.0002
-0.001
)

Fig. 4 Dimensional drawing

Dimensions in mm (inches), not to scale

eddyNCDT SGS 4701 Page 14

Installation and Assembly

Start of measuring range

For each sensor a minimum distance to the target must
Sensor Target
be maintained. This avoids a measurement uncertainty
due to the sensor pressing on the target and mechanical
damage to the sensor/ target. Measuring range

Fig. 5 Start of measuring range (SMR), the smallest dis- SMR

tance between sensor face and target

Measuring area
The minimum measuring area must have a diameter of

Measuring area
6 mm or greater for an eddy-current sensor. Optional
sensors are available with a minimum area diameter of Sensor

ø ≥ 6 mm
3.5 mm. If you underrun the minimum measuring area nor
reproducibly measurements are possible.

Fig. 6 Minimum measuring area for eddy-current sensor

eddyNCDT SGS 4701 Page 15

Installation and Assembly

4.3 Sensor Cable

Operating temperature -40 ... +90 °C

(.06 ± .008)
1.44 ± 0.2
Mating life 20 cycles
3 ± 0.2 5.3 ± 0.3
Cable retention 12.74 N
(.12 ± .008) (.21 ± .02)
Inner conductor silver-coated annealed copper wire
Min. bending radius 12 mm
Outer conductor silver-coated annealed copper wire
Dielectric core FEP
Jacket FEP
Fire resistance VM-1
Fig. 7 Dimensional drawing sensor cable,
dimensions in mm (inches), not to scale
Sensor cable lengths between 40 … 150 cm are possible in 10 cm increments.
Lay the sensor cable in such a way that no sharp-edged or heavy objects can affect the cable sheath.
Do not kink the cable. Details to the sensor cable are listed in the appendix, see Chap. A 4.
Sensor Bending radius: Controller
R ≥ 12 mm

Fig. 8 Minimum bending radius for sensor cable

Do not shorten the sensor cable. Loss of functionality. Removing the connector is only permitted behind the
plug-sided crimp when using the solder connections.
Remove the sensor cap from the controller.
Open the cable gland on the controller.

eddyNCDT SGS 4701 Page 16

Installation and Assembly

Run the sensor cable through the sensor

cap and the cable gland. i Avoid a strong cable bending.

Sensor Sensor cable Sensor cap Cable gland Controller

Bend up the green cable seal easily and insert the sensor cable.
Connect the sensor cable to the controller, see Fig. 9.

Solder connection Plug connection

Shield

Signal

Solder the sensor cable to the connection Connect the sensor cable to the female
board. connector.

i Connector mating life is 20 cycles.

Close the cable gland.

Push the sensor cap onto the controller housing until it snaps in place.
Fig. 9 Connection sensor cable
eddyNCDT SGS 4701 Page 17
Installation and Assembly

4.4 Controller
M12x1

94.2 ±0.1 (3.71 ± .004)

Mounting area
102.2 ±0.5 (4.02 ± .02)

ø 12 -0.1
(.47 dia. -.004)
Do not clamp the
controller outside the
installation area. The
controller may be
damaged. WS8
(ca. 8)
( .31)

Fig. 10 Dimensional drawing of controller, dimensions in mm (inches), not to scale

The controller is mounted laminar with a circumferential clamping on housing or with an optional clamping
flange.

eddyNCDT SGS 4701 Page 18

Installation and Assembly

4.5 Connecting the Measuring System

Provide the power supply for the controller.
Connect the 8-pin M12 connector to the controller with a power supply 24 VDC.

i Optional accessories:
PC4701-10 power supply and output cable, 10 m long, with 8-pin. female connector respectively with
free ends.
Connect the measurement signal display respectively control unit to the controller.
PIN Comment Color PC4701-10
1 Ground white 5
6 4
2 12 ... 32 VDC brown
Displacement signal green 8
3 7 3
(0.5 ... +9.5 V) at 100 ... 600 μm
Temperature signal yellow 1 2
4 (0.5 ... +9.5 V) at 0 ... +90 °C
5 NC gray
8-pin. male connector
6, 7 internally assigned pink, blue controller, view on pin
8 NC red side

Screen Housing -

Fig. 11 Pin assignment for signal output

eddyNCDT SGS 4701 Page 19

Installation and Assembly

4.6 Ground Concept

Sensor
+12 ... 32 VDC

GND
SGS4701 Controller

SGS4701 Housing Shield

PE PE

eddyNCDT SGS 4701 Page 20

Operation

5. Operation
The system is ready for operation. There are no adjustments which must be done by the user.
MICRO-EPSILON recommends to let the system warm up for about 30 minutes.

6. Liability for Material Defects

All components of the device have been checked and tested for functionality at the factory. However, if de-
fects occur despite our careful quality control, MICRO-EPSILON or your dealer must be notified immediately.
The liability for material defects is 12 months from delivery. Within this period, defective parts, except for
wearing parts, will be repaired or replaced free of charge, if the device is returned to MICRO-EPSILON with
shipping costs prepaid. Any damage that is caused by improper handling, the use of force or by repairs or
modifications by third parties is not covered by the liability for material defects. Repairs are carried out exclu-
sively by MICRO-EPSILON.
Further claims can not be made. Claims arising from the purchase contract remain unaffected. In particular,
MICRO-EPSILON shall not be liable for any consequential, special, indirect or incidential damage. In the inter-
est of further development, MICRO-EPSILON reserves the right to make design changes without notification.
For translations into other languages, the German version shall prevail.

eddyNCDT SGS 4701 Page 21

Service, Repair

7. Service, Repair
If the sensor, controller or sensor cable is defective: MICRO-EPSILON MESSTECHNIK
-- Please send us the affected parts for repair or GmbH & Co. KG
exchange. Königbacher Straße 15
If the cause of a fault cannot be clearly identified, 94496 Ortenburg / Germany
please send the entire measuring system to:
Tel. +49 (0) 8542/ 168-0
Fax +49 (0) 8542 / 168-90
[email protected]
www.micro-epsilon.com
8. Decommissioning, Disposal
Disconnect the power supply and output cable on the controller.
Disconnect the sensor cable between sensor and controller.
Incorrect disposal may cause harm to the environment.
Dispose of the device, its components and accessories, as well as the packaging materials in compli-
ance with the applicable country-specific waste treatment and disposal regulations of the region of use.

eddyNCDT SGS 4701 Page 22

Appendix| Clamping Flange Controller

Appendix
A1 Clamping Flange Controller

(.50)
12.8
2.8 (.11)
Mounting area

20 (.79)
ø2 15 (.59)
(.1 7.
1d
ia.
)
15 (.59)
20 (.79)

Dimensions in mm (inches), not to scale

eddyNCDT SGS 4701 Seite 23

Appendix| Tool Sensor Cable

A2 Tool Sensor Cable

1.5
0.6 (.06)
3.2 (.13)
(.02)

4.7 (.19)

6 (.24)
3.6 (.14)

(1.1)
2.7
15 (.59)
47 (1.85)
50 (1.97)
1.5 (.06)

Fig. 12 MML extraction tool H2.5 & H2.0, part number R302309000
Dimensions in mm (inches), not to scale

A3 Optional Accessories

PC4701-10 Power supply and output cable, 10 m long, with 8-pin. female connector
respectively with open ends
PC4701-10/dragchain Power supply and output cable, 10 m long, with 8-pin. female connector
respectively with open ends, for use with drag cable

eddyNCDT SGS 4701 Seite 24

Appendix| Notes for Electrostatic Discharge

A4 Notes for Electrostatic Discharge

Electrostatic discharge (ESD) may lead to the destruction of the controller when
-- connecting the sensor cable to the open controller,
-- handling the sensor.
The working practices listed below reduce and avoid any electrostatic discharge:
-- Wear a grounding bracelet that is conductive connected to an earthing point.
-- The table surface should be conductive and connected to the earthing point.
-- Wear appropriate shoes, ESD working clothes on the upper part of the body and the arms in order to
avoid any static charging.

Further literature for the prevention of electrostatic phenomenon:

-- EN 61340-5-1 Protection of electronic components against electrostatic phenomenon - General require-
ments
-- EN 61340-5-2 Protection of electronic components against electrostatic phenomenon - User manual
-- VDE publications 71 Electrostatics, reasons, effects, protective measures

eddyNCDT SGS 4701 Seite 25

Appendix| Target Thickness

A5 Target Thickness
The principle of eddy current displacement measurement requires a minimum thickness for stable results.
This minimum thickness depends on the target material used and the sensor frequency.
The default system works at a carrier frequency of 1 MHz.
2000
µr =1
1000

2.4668
1.4301
Skin depth [µm]
µr =10

1.4571
Lead
3.4365 Magnesium

Bronze
Brass
µr =100
Aluminium
Copper

100
Gold
Silver

µr =1000

1.4005
Nickel

1.1141
µr =10,000
10
100 10 1 0.1
Electrical conductivity [Mega Siemens / m]

Fig. 13 Skin depth at 1 MHz compared to electrical conductivity

i When measuring the path at variable temperatures, the minimum target thickness is three times the skin
depth.

eddyNCDT SGS 4701 Seite 26

Appendix| Non-ferromagnetic Target

A6 Non-ferromagnetic Target
The list below includes recommendations for ways in which you may be able to switch to a non-ferromagnet-
ic target.
-- Use a non-ferromagnetic stainless steel, such as 1.4571,
-- Use alloys, such as AlZnMgCu1,5 (3.4365); consider the lower mechanical tensile strength,
-- Apply non-ferromagnetic coats that are about 1 mm thick to the original target,
ƒƒ Apply bronze by laser welding,
ƒƒ Electroplate with copper and subsequently gold plate because of oxidation,
ƒƒ Shrink non-ferromagnetic metals in combination with gluing.
AlZnMgCu1,5 (3.4365)

Proposed materials
AlMg1SiCu
Inconel, NiCr19NbMo (2.4668)
Bronze in general
i Consider the material strength.

eddyNCDT SGS 4701 Seite 27

Appendix| Change from SGS4311 to SGS4701

A7 Change from SGS4311 to SGS4701

Tips and notes for a successful change between the model series.

SGS4311 SGS4701

With a size of 4.5 x 10 x 12 mm, the

sensors are compatible in terms of their
construction.
The sensors for the SGS4701 controller can-
not be exchanged. Sensor, sensor cable and
controller are matched to each other.
When the sensor, the cable or the controller
are defect, a replacement system is required.

The controller is mounted close to the spin-

dle. Consider some space for it.

Components of the SGS4311 are not com-

patible with the SGS4701 series.

Voltage output 1.0 ... 9.0 V It is necessary to adapt the output scaling Voltage output 0.5 ... 9.5 V
for 150 ... 550 µm in the software/customer control system. for 100 ... 600 µm

The sensor cable length is permanently

defined for each system and must not be
changed.

eddyNCDT SGS 4701 Seite 28

Appendix| Change from SGS4311 to SGS4701

SGS4311 SGS4701

Bandwidth 100 Hz It is necessary to adapt the averaging Bandwidth 2000 Hz

process in the software/customer control
system.
Cable length of max. 12 m at voltage
output
Optional accessories:
-- Supply and output cable
PC4701-10 or
PC4701-10/ for use with drag cable

You can assemble a power and output

cable yourself using a conventional M12
connector.
Cable length > 12 m
Micro-Epsilon recommends to convert the
output signal from voltage to current.

eddyNCDT SGS 4701 Seite 29

MICRO-EPSILON MESSTECHNIK GmbH & Co. KG
X9751318-A061038MSC
Königbacher Str. 15 · 94496 Ortenburg / Germany
MICRO-EPSILON MESSTECHNIK
Tel. +49 (0) 8542 / 168-0 · Fax +49 (0) 8542 / 168-90
[email protected] · www.micro-epsilon.com
*X9751318-A06*