Magnetic Incremental Rotary Encoder Gel 2592

General information
  • Extremly robust rotary encoder with stainless steel housing for measuring rotational movements of machines and vehicles
  • Contactless magnetic scanning of an integrated target wheel
  • Rotary encoder with solid shaft (shaft diameter 16 mm) or with integrated hollow shaft coupling (diameter 20 mm)
  • Plug or cable outlet with customer-specific modifications available
  • Up to 5 sensors in one housing, three different signal patterns available
  • High electromagnetic compatibility and interference immunity
  • High temperature range -40 °C to +120 °C
  • Protection class IP 67
  • Voltage or current output
  • Vibration resistance up to 20 g
  • Solution individually tailored to the specific application, as up to 5 sensors can be integrated in one housing
  • Maintenance-free, durable operation in the harshest ambient conditions due to selected bearings and a magnetic measuring system
  • Highly resistant to condensation, spray, condensed water and aggressive chemical substances
Field of application
  • Rail vehicle industry
    - Traction monitoring
    - Electronic anti-skid protection
    - Motor rotational speed
    - Anti-slip protection
  • Machinery and motors
  • Heavy industry
  • Metallurgy
  • Composting plants
  • Sewage treatment plants



The precision encoders GEL 295x are designed as an modular, application-specific encoder system and consist of a housing component and modular sensor systems. All rotary encoders GEL 295x are manufactured to drawing or application description. The technical specifications may vary from the technical data given. The modified specifications and the pin layout are to be found on the customerspecific dimensional drawing.

Construction and design

The series GEL 295x rotary encoders are extremely robust sensors for the measurement of rotary movements or positions on machines and vehicles. Due to their high resistance to condensation, spray and condensed water, as well as the very wide temperature range from -40 ° to +120 °, they are particularly suitable for use in rail vehicles or in heavy industry.
The housing component is available with solid shaft or hollow shaft including an integrated flexible precision hollow shaft coupling. The resilent encoder housing with a standard flange size of 115 mm is made of stainless steel. The electrical connection of the sensor system is variable, using plug connectors or cable outlets.
A very large number of customer-specific requirements can be met using the modular sensor system.
The GEL 295x offers particular advantages especially in relation to redundancy and safeguarding against failures. The rotary encoder comprises up to five separate sensors.
A Y number is assigned to customer-specific designs, this letter is appended to the product identifier (GEL 295xYxxx).

Notes on mounting

The flexible high-precision hollow shaft coupling compensates eccentricities, axial impacts and vibrations. The precision encoders are designed to be mounted on an expansion shaft with a diameter of 20 g7 mm. The expansion shaft must contain an inside thread, e.g. M12, to accept a hexagon socket set screw, and must not project more than 15 mm into the hollow shaft coupling. The set screw is screwed in, with its hexagon socket first, into the direction of the expansion shaft. A centring flange ensures the exact positioning of the high-resolution encoder in the mounting device.g

The rotary encoder with solid shaft must be connected with the drive shaft via a flexible coupling. The flexible clamp coupling type KK 14 is recommended. The degree of axial offset between the shaft ends directly influences the degree of the phase displacement. In particular, this must be taken into account for systems with high pulse numbers.

Sensing principle

The rotary encoders work with differential, magnetic-fielddependent sensors and a precision target wheel. The sensors scan without contact the tooth structure of the target wheel and output a sine and cosine voltage. The integrated evaluation electronics converts the analog sensor signals into incremental output signals.
By interpolation of the integrated evaluation electronics, the sinusoidal signals can be converted into rectangular output signals.
In the basic version, signal pattern K, V and X are available (see table). On request we check the feasibility of other signal patterns.

Possible pulse numbers

The possible pulse numbers depend on the signal output. The version with sine/cosine differential signal provides 256 pulses per revolution, signal pattern is K (smaller pulse numbers on request).
For signal pattern V and X, 150 or 256 pulses are supplied and interpolated. Hence the following pulses are available:

Pulse numbers for signal pattern V and X

Input pulses Interpolation factor
1 2 3 4 5 6 8
150 150 300 450 600 750 900 1200
256 256 512 768 1024 1280 1536 2048
Output signal level

With signal pattern K 1 Vpp differential signals are output. The signal pattern V and X have HTL level (output voltage see "Technical data").

Available signal pattern

K Two sine-wave signals, phase- shifted by 90°, with inverse signals
V Two square-wave signals, phase- shifted by 90°
X Two square-wave signals, phase- shifted by 90°, with inverse signals

Technical data

Signal Pattern K V X
General data
Resolution 256 sin/cos Periods
150 to 2048(2) pulses per revolution
Precision short-wave (transformer and tooth forming error) 360° × 0.006 / pulse number
Precision long-wave (radial run-out) ± 0.015°
Electrical data
Supply voltage VS 5 V DC ± 5% 10 to 30 V DC
Current consumption without load ≤1.0 W
Output signals Difference signal Square wave siganl (2)
Output signal level 1 Vpp High: VS - 1 V, Low: < 1.0 V (3)
Maximum permissible cable length 100 m (observe voltage drop on supply line)
Mechanical data
Housing material stainless steel, X12CrMoS17-1,4104
Weight approx. 3 kg
Admissible coupling offset axial lateral ± 1.3 mm ± 0.2 mm
Speed range 0 to 6000 min -1
Bearing life cycle under radial load (with solid shaft) 100 N → 21.0.10⁹ revolutions
200 N → 15.0.10⁹ revolutions
250 N → 7.5.10⁹ revolutions
Bearing life cycle under axial load (with integrated hollow shaft coupling) 50 N → 130.4.10⁹ revolutions
75 N → 43.2.10⁹ revolutions
150 N → 7.2.10⁹ revolutions
Ambiant data
Working temperature range (DIN 32876) -40 °C to +85 °C
Operating and storage temperature range (DIN 32876) -40 °C to +120 °C
Protection class (EN 60529) IP 67 (hollow shaft side: corresponds to protection class of the engine or gear unit)
Vibration resistance (EN 60068-2-6) 200 m/s²
Shock resistance (EN 60068-2-27) 2000 m/s²
Electromagnetic compatibility (EMC) Industrial application: EN 61000-6-1 to 4 Rail vehicles: EN 50121-3-2
Insulation strength (according to EN 60439-1) 500 V AC

Connection assignment

Connection assignment- mating connector

Pin layout Pin Signal pattern K Signal pattern V, X Function
(= solder side of mating connector)
1 /Track 2 ¹ /Track 2 ¹ Track 2, inverse
2 ¯ ¯ not connected
3 ¯ ¯ not connected
4 ¯ ¯ not connected
5 Track 1 Track 1 Track 1
6 /Track 1 /Track 1 Track 1 inverse
7 ¯ ¯ not connected
8 Track 2 Track 2 Track 2
9 ¯ ¯ not connected
10 0V (GND) 0V (GND) Ground
11 ¯ ¯ not connected
12 VS 5 V DC VS 10 to 30 V Supply voltage

Connection assignment - cable outlet

Core colour Signal pattern K Signal pattern V, X Function
rot VS = 5 V DC VS = 10 to 30 V Supply voltage
blau 0V (GND) 0V (GND) Ground
gelb UA+ Track 1 Track 1
bUA- /Track 1 Track 1 inverse
weiß UB+ Track 2 Track-2
braun UB- /Track 2¹ Track 2,inverse

Precision rotary encoder with hollow shaft

Dimensional drawing - housing component with one sensor system


Assembly drawing and mating dimensions


Precision rotary encoder with solid shaft

Dimensional drawing - housing component with one sensor system


Dimensional drawing - Clamp coupling KK 14


Type code and accessories

Type code



Description Item number
Clamp coupling KK 14, inner diameter: 6 to 16 mm (specify shaft diameter) KK 14
Mating connector, M23, 12-pole, straight, IP 65 GG 126
Mating connector, M23, 12-pole, angled, IP 65 GW 126