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MotionPLC GEL 8240


General information

The controllers have an integrated PLC, field bus systems and multi-axis control with a maximum of 11 controlled axes (max 3 with ± 10 V and max. 8 with CAN bus). 64 axes altogether can be controlled via the CAN bus (without feedback). Additional inputs and outputs permit several CAN REMOTE I/Os with up to 64 inputs or outputs per node and up to 64 node addresses.
The standard CoDeSys programming environment runs in parallel with the multi-axis control and offers full transparency for all parameters. Parametrization of all 7 axes is effected by a PC tool and offers menu-guidance for comfortable setting of the usual parameters.
The standard programming environment in acc. with IEC 61131-3 includes a library of ready-made and powerful technology functions for terminal programming and automatic motion control.
Up to four different communication channels are available with one interface enabling all conventional field bus systems (PROFIBUS-DP, DeviceNet,...) to be used.
The field bus modules can be retrofitted or replaced at any time without the need to modify the PLC program.

Characteristics of MotionPLCs

  • Hardware
    - RAM: 1 MByte in total
    - NVRAM: 8 kBytes in total
    - Flash: 1 MByte in total
    - free memory space for PLC applications: 256 kBytes
  • 2 CAN bus-interfaces (servoconverter,
    CAN REMOTE I/O module)
  • 2 asynchronous interfaces (one optionally RS 232 or RS
    485, one RS 422)
  • High noise immunity due to electrically isolated digital and analogue inputs and outputs
  • 3 encoder inputs (SSI, incremental, 5 V / 24 V)
  • Short projecting times due to ready-made functional
    blocks and pre-configured inputs and outputs

MotionPLC - Description

In- and outputs
GEL 8240 GEL 8241
Digital inputs 22 30
Digital outputs 15 15
Analogue inputs 1 3
PT100 inputs 0 4
Analogue outputs 3 3
Key panel

Rear view

Technical data

GEL 8240 GEL 8241
Electrical Data
Supply voltage 19 to 30 V DC
Current consumption 1 A max. (depending on interface)
Serial interfaces
(communication or programming)
2 with adjustable baud rate
COM1: RS232C or RS422/485 COM2: RS232C
CAN bus interfaces 2 (CANopen, CANlink)
Field bus interface 1 extension slot for PROFIBUS-DP, InterBus-S or
DeviceNet (other ones upon request)
Encoder inputs (actual value inputs, galvanically separated)
Encoder inputs 3 incremental or absolute (5 V or 24 V, SSI)
freely combinable
Max. input frequency 200 kHz
Encoder supply loading 24 V, 900 mA / 5 V, 600 mA in total
Outputs (galvanically separated)
Digital outputs Red LED status indicator
9 x 24 V, 30 mA,
6 x 24 V, 500 mA;
Analogue outputs 3 x ± 10 V, max. 10 mA, resolution 2 mV
Inputs (galvanically separated)
Digital Inputs Green LED status indicator
22 x 24 V    |    30 x 24 V
Analogue inputs (max. 10 bit resolution) 1, switchable (0 to 10 V
or 0 to 20 mA)
3, switchable (0 ... 10 V
or 0 ... 20 mA)
PT100 inputs 4 (- 40 ºC to + 350 ºC)
Ambient data
Working temperature 0 ºC to + 50 ºC
Operating temperature -20 ºC to + 50 ºC
Storage temperature -20 ºC to + 70 ºC
Rel. atmospheric humidity ≤ 95%, no condensation
Protection class frontside IP 65
backside IP 20
EMC EN 61000-6-2 and 4(1)
Mechanical Data
Housing material Stahlblech, verzinkt
front panel: aluminium with edge protection
Anzeige LC display, 240 x 64 pixesl with LED background
(visible area: 133 mm x 39 mm)
Weight Approx. 1.7 kg

Connection assignment

overview terminal_strips_E

Connection assignment

terminal_strips_I1toV terminal_strips_I5toI6 terminal_strips_Q

PLC programming environment

IEC 1131-3 is an international standard for programming languages adapted to stored-program control units. The programming languages realized in CoDeSys are in conformity with the requirements of the standard. They can be mixed whenever needed and are partially convertible.

action_pos1 action_pos2 action_pos3 action_pos4 action_pos6 action_pos5
Instruction list (IL)

An instruction list (German: Anweisungsliste AWL) is composed of a sequence of instructions. Each instruction begins in a new line and consists of an operator and - depending on the type of operation - of one or several operands separated by

Ladder diagram (LD)

The ladder diagram (German: Kontaktplan KOP), too, is a graphics-oriented programming language which is basically similar to an electrical circuit. It consists of a series of networks. A network is limited on the right and left side of the plan by a vertical current path. In between, there is a circuit comprising contacts, inductances and connecting lines.

Function block diagram (FBD)

The function block diagram (German Funktionsplan FUP) is another graphics-oriented programming language. It is organized by lines and uses a list of networks, each containing a structure representing respectively a logical or an arithmetical expression, the recall of a function block, a jump or a return instruction.

Structured text (ST)

The structured text is a series of instructions which can be executed - as in the higher programming languages - depending on a condition ( „IF..THEN..ELSE “) or iteratively (WHILE..DO).

Sequential function chart (SFC)

The sequential function chart (German: Ablaufsprache AS) is a graphics-oriented language to describe the sequential execution of different actions in a program.

Continuous Function Chart Editor (CFC)

The essential difference with regard to the FBD is the free arrangement of function blocks. CFC is a useful enlargement of the IEC 1131-3 standard.

Operating software

Technological cam-plate function

  • Curve modification without set-up times
  • Reduced jerking during movements due to harmonic and
    cycloid curve shapes
  • Engagement and disengagement of the slave axis
  • Virtual master function:
    permits displacement of the curve drive
  • Dynamic adaptation of curve shapes:
    lengthening, shortening, etc.

Within the scope of supply

BB2100K operating software

curve editor

The BB2100K operating software can be used to define the desired curve characteristics on a PC. The PC is connected to the MotionCard via the serial interface. The parameter editor for the servo-converter LD 2000 can also be started out of this program. Other program characteristics:

  • System parameter editor

  • Oscilloscope function
  • Setting of range signals via mouse-click

Curve editor example

  • Individual programming due to free editing of program texts

  • Assistance with the analysis of curves (position, speed, acceleration and torque)
  • Graphics-aided editing of parameters for special applications (e.g. rotating cutter and flying saw)
Available on our homepage
bb2100k.exe Curve editor BB2100K for operation and monitoring of
servo-converter LD 2000 with cam-plate module.
ld2000.exe Start-up software for servo-converter LogiDrive LD

Application example

Application of adhesive on a car door

An glue dispenser with a three-axis portal equipped with servo drives and amplifiers is controlled by the MotionPLC in such a way that the tool follows a trajectory in three dimensions which has been fixed beforehand by a small number of essential tool center points in the teach-in mode.


Control components communication interlink

The PC tool for contour tracking


Teach-in example

Control panel cut out

Control panel cut out

Order details

Type code
Accessories (included in scope of supply)
Item-no. Description
GEL 89042 Counterplug set (only for GEL 8240)
GEL 89043 Counterplug set (only for GEL 8241)
BG 4622 14 hex screws M3 x 10, 14 cable bride, 2 earting terminals, 14 toothed lock washers
BG 4623 6 hex screws M4, 6 washers, 6 spring washers, 2 earthing terminals
CD GEL 824 CD-ROM GEL GEL 824 (inklusive Handbuch als pdf-Datei)
Accessories (optional)
GEL 89022 Connection cable RS 232 C between PC and MotionController
GEL 89130 Fieldbus module (PROFIBUS-DP)
GEL 89131 Fieldbus module (InterBus-S)
GEL 89132 Fieldbus module (DeviceNet)
GEL 89133 Fieldbus module (Ethernet)
GK 2063 Mounting frame: 6 hex screws M3 x 10 and 6 toothed lock washers
DS-12-824x Manual GEL 824x (printed)
Mounting frame GK 2063