GEL 2035 - Magnetic Absolute Rotary Encoder

Synchronous serial interface with heavy-duty clamping flange and clamping flange Synchronous serial interface with heavy-duty clamping
flange and clamping flange


Synchronous serial interface with heavy-duty clamping flange and clamping flange CANopen interface with semi hollow shaft

General

  • Magnetic absolute rotary encoder with a maximum total resolution of 24 bits in a compact design
  • Wear-free electronic gear with a high-performance li-ion buffer battery
  • Magneto-resistive scanning supplies unambiguous position values for every angular position via a synchronous serial interface or CANopen interface

Features

  • Total resolution 24 bits
  • Reset function via push-button or pin
  • Interfaces:
       - SSI or SSI and resolver
       - CANopen
  • Flange variants: heavy-duty clamping flange, clamping flange with tooth wheel adapter, semi hollow shaft
  • Protection class up to IP 69K

Advantages

  • IP 69K variant also withstands aggressive media or high-pressure cleaner applications due to stainless steel housing with two-chamber system
  • Heavy-duty clamping flange for high bearing loads
  • Appropriate for all standard applications and also for real heavy-duty applications

Fields of application

  • General mechanical engineering
  • Regenerative energies
  • Mobile machines

Description

Construction and design

The resilient encoder housing has a flange dimension of 58 mm and comprises anodised aluminium. The absolute rotary encoders in the series GEL 2035 are available with a clamping flange, heavy-duty clamping flange or clamping flange with tooth wheel adapter. A very compact redundant system is realised by combination with a resolver. The complete electrical isolation of the resolver from the magnetic absolute rotary encoder ensures true redundancy of the absolute position values. For integration into a CANopen network, the absolute rotary encoder GEL 2035 is available with a CANopen interface. This version is available in stainless steel as standard and is equipped with a semi hollow shaft. For use in extremely dusty, dirty or aggressive environments, the absolute rotary encoder GEL 2035 is available in an IP 69K variant. Compliance with protection class IP 69K is ensured by the robust stainless steel housing with radial cable gland and the two-chamber system.

Battery saving mode

In order to preserve the battery power, the encoder is delivered in battery saving mode. In this mode, the encoder is not active. Applying the power supply, activates the encoder which provides postion values. To extend battery life, this mode can be re-activated. In the following cases, activation of the saving mode is useful to save battery power:

  • Long-term shutdown of the plant without voltage supply.
  • Storage as spare part.
  • IDisassembly of the encoder, followed by long-term stor-
    age.
  • In case of a faulty encoder, before returning it to the fac-
    tory.
  • Protection class up to IP 69K

You have two alternatives to activate the battery saving
mode:
1. Using the PRESET push-button
     In de-energized state, push the PRESET push-button
     for at least 0.1 s.
2. Using the PRESET input
     In de-energized state, apply between PRESET input
     and GND a voltage of 3 V to 30 V for at least 0.1 s.
In battery saving mode the encoder is disabled. After
switching on the power supply, the encoder provides the
adjusted PRESET value independent of the position of the
encoder shaft (→page 6). Electronic adjustment of the
encoder is required. For this reason, battery saving mode
is recommended only in the cases mentioned above.


Sensing principle

The multiturn absolute rotary encoders in the series GEL 2035 provide an unambiguous position value for each angular position with a resolution of up to 24 bits. The single turn and multiturn stage each operate with a resolution of 12 bit. The multiturn stage is based on an electronic gear. A buffer battery ensures the function of the absolute rotary encoder also in case of power failure. Even if the rotary encoder moves in de-energised state, the current position value is accurately output immediately after power is switched on.

Interfaces

The absolute rotary encoder supplies the position values either in binary or gray code via a fast synchronous serial interface (SSI) or as per encoder profile DS406 via a CANopen interface.

Temperature ranges

High precision SMD components are used in the absolute rotary encoder. Despite careful selection, thermal ageing of these components cannot be excluded. For this reason the encoder should be stored at a temperature from -40°C to +85°C. Operating temperatures of -40°C to +85°C are allowed, an installed absolute rotary encoder is not allowed to exceed this temperature range. The function of the absolute rotary encoder is ensured within the operating temperature range allowed, (DIN 32878); here it is the temperature at the encoder housing that applies. The temperature of the absolute rotary encoder is affected by the installation situation (thermal conductance, thermal radiation), the heating caused by the absolute rotary encoder (bearing friction, electrical power loss) and the ambient temperature. The operating temperature may be higher than the ambient temperature depending on the operation of the absolute rotary encoder. Depending on the supply voltage the heating caused by the encoder can be up to 10°C. At high operating speeds >5,000min-1 the heating caused by the encoder can be up to 20°C due to the bearing friction. If the absolute rotary encoder is operated close to the limits of the specifications allowed, the ambient temperature must be reduced by suitable means (cooling) such that the operating temperature range allowed is not exceeded.


Technical data


General
Absolute accurary (DIN 32876) 0.8°
Repeatability < 0.01°
Step number per revolution 4096 steps per revolution (12 Bit)
Numbers per revolution 4096 revolution(12 Bit)
Electrical data
Operating voltage 10 to 30 V DC with reverse voltage protection
Power consumption 0,3 W, without load
Resolution single turn 12 Bit
Resolution multiturn 12 Bit (electronic gear)
Digital interfaces SSI (Gray / binary)
CANopen Encoder Profil DS406
Analogue interface Resolver signal
Mechanical data
Moment of inertia of rotor 611.8 x 10-6 kgm2
Material Aluminium anodised,
stainless steel
Weight single turn Stainless steel: 450 g(1)
Weight multiturn Aluminium: 300 g (SSI), 450 g (SSI+resolver) stainless steel: 600 g(2)
Operating speed (limit value) single turn 12,000 min-1
Operating speed (limit value) multiturn 10,000 min-1,12,000 min-1(short-term)
Operating torque < 3 Ncm
Bearing life cycle > 105hat1000min -1
Shaft sealing ring (optional) Material: Viton, protections class IP 67 / IP 69K
Environmental data
Working temperature range -40°C to +85°C
Operating temperature range -40°C to +85°C
Storage temperature range -40°C to +85°C
Protection class according to DIN 60529 IP 67, IP 69K
Vibration resistance (DIN EN 60068-2-6) 200 m/s2,10to2,000Hz
Shock protection (DIN EN 60068-2-27) 2000 m/s2,11ms
EMC EN 61000-6-1 to 4
Insulation strength Ri > 1 MΩ, at a testing voltage of 500 V AC
Relative humidity max. 99 %
Condensation permissible,
according to DIN EN 60068-2-30 Part 2 of 1999
Clamping flange
Shaft load (radial/axial) 120 N / 90 N at 1000 min-1
Heavy-duty flange
SShaft load (radial/axial) 120 N / 90 N at 1000 min-1
Semi hollow shaft
Shaft load (radial/axial) 75 N / 70 N at 1000 min-1


Dimensional drawings



Dimensional drawing GEL 2035 SSI
Clamping flange / heavy-duty flange
Clamping flange / heavy-duty flange

Clamping flange with tooth wheel adapter
Clamping flange with tooth wheel adapter

All dimensions stated in mm


Dimensions drawings

Dimensional drawing GEL 2035 SSI - with protection class IP 69K
Clamping flange; stainless steel 1.4305
Clamping flange stainless steel 1.4305

All dimensions stated in mm


Dimensional drawings GEL 2035 - CANopen
Semi hollow shaft; single turn; stainless steel 1.4101
Semi hollow shaft single turn stainless steel 1.4101

All dimensions stated in mm

Synchronous serial interface

The synchronous serial interface transfers the position data at a clock frequency of up to 2 MHz. Prior to further position sampling, a minimum clock pulse space of 25 μs must be met.


Principle of the serial data transmission [gray code (25 bits), RS 422 / RS 485 standard]

   f       >40kHz
   T       Length of the clock signal period (= 1/clock frequency)
   Tp     Clock pulse space,
            between the clock sequences TP At least 25 μs

Direction of rotation

The encoder can output increasing position values on the clockwise or counter clockwise rotation of the shaft. The direction of rotation can be selected by using the CW/CCW input (counting direction).

Cable length

With the synchronous serial interface protocol the transmission rate allowed drops with increasing cable length. A screened, twisted pair cable is recommended for the signal cables (± CLOCK and ± DATA).

Cable length [m] < 50 < 100 < 200 < 400
Clock frequency [kHz] < 400 < 300 < 200 < 100

PRESET function

The output signals can be set to a PRESET value from any position value. As supplied the encoder is set to half the maximum resolution. The PRESET is set electronically if the supply voltage UB is briefly t > 100 ms applied to the PRESET input (do NOT apply continuously). Other PRESET values are available upon request. As an alternative there is a PRESET push-button recessed into the base of the housing (IP 67). The PRESET pushbutton can be operated using a pin ( t > 100 ms).

Synchronous serial interface

Pin layout - SSI (SD)
M23 connector, 12-pin

PIN Signal Description
1 GND Earth
2 DATA+ Output: Differential data signal in accordance with RS 485
3 CLOCK+ Input: Differential clock signal in accordance with RS 485
4-6 - Not used
7 CW/CCW Direction of rotation
8 UB Operating voltage
9 Preset Electronic adjustment
UB , t > 100 ms
10 DATA- Output: Differential data signal in accordance with RS 485
11 CLOCK- Input: Differential clock signal in accordance with RS 485
Pin layout - cable gland with IP69K
Flying lead

Core colour Signal Description
blue GND Earth
brown DATA+ Output: Differential data signal in accordance with RS 485
grey/pink CLOCK+ Input: Differential clock signal in accordance with RS 485
grey CW/CCW Direction of rotation
red UB Operating voltage
pink Preset Electronic adjustment
UB , t > 100 ms
white DATA- Output: Differential data signal in accordance with RS 485
red/blue CLOCK- Input: Differential clock signal in accordance with RS 485


Synchronous serial interface


Resolver
A resolver is integrated into the rotary encoder GEL 2035 SR. This supplies a redundant position signal within a turn.
Resolver configuration

R1, R2 Primary (rotor)
S1 to S4 Secondary (stator)
Technical data of resolver
Input voltage 7 V rms
Primary ER1-R2= Esinωt
Secondary ES1-S3=KER1-R2 Cosθ, K = conversion ratio ES2-S4=KER1-R2 Sinθ
Input frequency 10 kHz (max. permissible deviation ± 5 %)
Conversion ratio 0.5 ± 5 %
Precision (measurement errors) ± 10
Zero potential max. 20 mV rms
Phase separation Nominally 0°
Speed ripple max. 1.5 % at 1,500 min-1
Insulation resistance 100 M Ωat 500 V DC
Input current max. 80 mA

Pin layout - synchronous serial interface with resolver (SR)
Connector M23, 17-pin

PIN Signal Description
1 R1 Resolver signal
2 R2 Resolver signal
3 S4 Resolver signal
4 S3 Resolver signal
5 CW/CCW Direction of rotation
6-7 - Not used
8 Clock- Differential clock signal in accordance with RS 485
9 Data- Differential data signal in accordance with RS 485
10 GND Earth
11 UB Operating voltage,
12 PRESET Electronic adjustment
UB ,t>100ms
13 S2 Resolver signal
14 S1 Resolver signal
15 Clock+ Differential clock signal in accordance with RS 485
16 Data+ Differential data signal in accordance with RS 485
17 - Not used


CANopen interface

Pin layout - CANopen
M12 connector
A-coded


Pin/socket layout
Pin Bus IN Bus OUT
1 CAN_GND CAN_GND
2 +VSIN +VSOUT
3 GND GND
4 CAN_H CAN_H
5 CAN_L CAN_L
Technical data CANopen
Device profile CANopen DS406 with additional function
Cable diameter 8 mm
Programmable parameters Resolution, PRESET, offset, counting direction, speed, acceleration and rotational speed output, range output referred to pre-defined values, scalable number of steps (decimal/binary)
Output code Binary
Baud rate 50 kbit/s ... 1 Mbit/s can be set via bus master
Sensor ID 0 ... 99, can be set via bus master
Terminating resistor To be provided externally
Operating temperature -40 ... +85 °C (shorttime 100 °C)


Type code

Type code GEL 2035




Type code restrictions



SSI (interface: SD)
Feature Possible variant
Number of revolutions 12
Flange/shaft B,G,H
Outlet R
Connector/cable S

SSI and resolver (interface: SR)
Feature Possible variant
Number of revolutions 12
Flange/shaft B
Outlet F
Connector/cable S
CANopen (interface: CO)
Feature Possible variant
Number of revolutions 00 (single turn only)
Flange/shaft R
Outlet B
Connector/cable S

Protection class IP 69K (IP: 5)
Feature Possible variant
Interface SD
Number of revolutions 12
Flange/shaft B
Outlet C
Connector/cable B,C,D,E


Accessories

Torque support FB23504


Bushing
Order no. D
POM Brass
RH 23501 RH 23504 8 mm
RH 23502 RH 23505 10 mm
RH 23503 RH 23506 12 mm


Clamp couplingKK 14
A Coupling half
B Involute annular gear

d1(1) d1(1) d1/d2
KK 14 6 ... 16 6 ... 16 6/6; 8/8; 10/10;12/12; 16/16
Torque support FB23505
(standard with semi hollow shaft)


Metal coupling MK 8 / MK 12
MK 8     Material: X12CrNi18-8 (V2-A)
MK 12    Material: ST

A B D d1(1) d1(1) d1/d2
MK 8 35 5 21 5 ... 12 5 ... 12 6/6; 8/8; 10/10;12/12; 16/16
MK 12 50 7 26 6 ... 15 6 ... 15 12/12


Clamping elements KL200
(3 pieces)


Accessories

Ordering overview for mounting accessories

Description Item number
Torque support, hard(*) FB 23504
Torque support, soft(*) FB 23505
Bushing, 8 mm, POM (polyoxymethylene) RH 23501
Bushing, 10 mm, POM (polyoxymethylene) RH 23502
Bushing, 12 mm, POM (polyoxymethylene) RH 23503
Bushing, 8 mm, brass RH 23504
Bushing, 10 mm, brass RH 23505
Bushing, 12 mm, brass RH 23506
Clamping elements (3 pieces) KL 200
Metal coupling, inside diameter: 5 to 12 mm (state shaft diameter) MK 8
Metal coupling, inside diameter: 6 to 15 mm (state shaft diameter) MK 12
Clamp coupling KK14, inside diameter: 6 to 16 mm (state shaft diameter) KK 14
(*)The GEL 2035 with semi hollow shaft is supplied as standard with a soft torque support FB 23505 mounted. If the alternative torque support FB 23504 is to be mounted, it must be stated on the order.


Ordering overview for connection accessories

Description Item number
M23 mating connector, 12-pin straight GG 126
M23 mating connector, 17-pin straight FS 11311
CANopen mating connector, M12, 5-pin socket , A-coded FS 3020
CANopen, mating connector, M12, 5-pin plug, A-coded FS 3021
CANopen connection cable 10 m, 5-pin plug / flying lead with ferrules BK 2100
CANopen connection cable 2 m, 5-pin plug / flying lead with ferrules BK 2101
CANopen connection cable 10 m, 5-pin socket / flying lead with ferrules BK 2102
CANopen connection cable 2 m, 5-pin plug / flying lead with ferrules BK 2103
CANopen connecting cable 10 m, 5-pin socket/plug BK 2104
CANopen connecting cable 10 m, 5-pin socket/plug BK 2105
CANopen terminating resistor M12 FS 3040