Magnetic absolute rotary encoder

GEL 235

Technical Information Version 01.11

General
 Absolute encoder with a total resolution up to 28 bit
 Measuring scale: metallic code disc
 Evaluation: nonius-principle

Features
 High resolution 28 bit
 Mechanical gear
 High accuracy ± 0,08°
 SSI, PROFIBUS DP, CANopen, 4 to 20 mA
 Sin/Cos differential signal
 ATEX zone 2/22 and stainless steel versions

Advantages
 Compact design
 Dew-point-proof
 Operating temperature from -40 °C up to +105 °C
 Protection class up to IP 67

Fields of application
 General engineering
 Renewable energy
 Mobile work machine
DS22-235

Internet: www.lenord.de Phone: +49 208 9963–0 Lenord, Bauer & Co. GmbH
E-Mail: [email protected] Fax: +49 208 676292 Dohlenstraße 32
46145 Oberhausen, GERMANY
General informationen

General Magnetic measuring principle

The absolute rotary encoder series GEL 235 delivers for The magneto-resistive scanning of a ferro-magnetic steel-
each angular position a unique position value via a digital disc offers significant advantages:
interface with a resolution up to 28 bit. The absolute rotary  suitable for all standard application and furthermore for
encoder series includes Singleturn (ST) with up to 16 bit and Real-Heavy-Duty use
Multiturn (MT) with 12 bit resolution via a mechanical gear.  withstands high shock / vibration level
 not influenced by dirt or oil mist
Compact design  long term stable temperature characteristics
 full functionality in the presence of condensation:
With a standard flange size of 58 mm the housing length for
dew-point-proof
ST and MT with mechanical gear is less than 50 mm.  no aging of the magnetic sensor elements
 withstand aggressive media
Robuste construction
 Resilient anodised aluminium housing, double-bearings Interface
 The 12 mm steel encoder shaft and the steel code disc The absolute rotary encoder supplies the position values in
form a single robust unit a binary or gray code by use of a fast SSI-interface. In ad-
 The temperature coefficient of all rotating parts is uniform dition high interpolateable Sin/Cos differential signals with
 Withstands high shock and vibration levels and high 1 Vpp are delivered. The programming of code, resolution,
accelerationrates counting direction and Preset values is optionally possible.
With 28 bit resolution and a high data rate up to 2 MHz for
Nonius-Algorithm (Vernier-Algorithm) SSI mode even highly dynamic motion processes are well
The measurement principle of the GEL 235 is based on the controlable. A connectable bus-cap enables the profiles
magnetic scanning of a code disc made of ferro-magnetic CANopen DS 406 and PROFIBUS DP ENCODER PROFIL
steel, the so called nonius-disc. Magneto-Resistive sensors V1.1. Integrated rotary selectors for the encoder ID and data
scan three tracks and deliver three corresponding sinusoidal rate, a switchable on terminal resistor and diagnostic LEDs
signals. The phase relation of those three sinusoidal signals supports a fast startup.
is unique with one revolution. Based of the Nonius-principle
this phase relation is evaluated and delivers with high reso-
lution and accuracy the absolute position.

2 Lenord+Bauer DS22-235(01.11)
 Technical data

General
Incremental deviation < 0.01°
Accurary ± 0.08°
Electrical data
Operating voltage 10 to 30 V DC with reverse voltage protection
(option: 5 V - 5%, +25%)
Power consumption < 1.6 W, without load
Resolution Singleturn (ST) 8, 9, 10 to 16 Bit (measuring steps over 360°)
Resolution Multiturn (MT) 4, 8, 12 Bit (revolution, mechanical gear)
Interface SSI, PROFIBUS Encoder Profile V 1.1, CANopen Encoder
Profile DS406, 4–20 mA
Analogue output signal Sin/Cos difference signal 1 VPP, 64 periods per resolution
Mechanical data
Moment of inertia of the rotor 611.8·10-6 kgm2
Clamping flange Distance contact point : 5 mm
Shaft load (radial/axial)
at 1,000 min-1 = 160 N / 80 N,
at 6,000 min-1 = 100 N / 80 N
Synchro flange Distance contact point: 10 mm
Shaft load (radial/axial)
at 1,000 min-1 = 70 N / 50 N,
at 6,000 min-1 = 50 N / 40 N
Semi hollow shaft Distance contact point: 1 mm
Shaft load (radial/axial)
at 1,000 min-1 = 100 N / 20 N,
at 6,000 min-1 = 40 N / 20 N
Material anodised aluminium,
stainless steel 1.4104
Weight Singleturn aluminium: 300 g; stainless steel: 600 g
Weight Multiturn aluminium: 310 g; stainless steel: 620 g
Operating speed (limit value) Singleturn 12,000 min-1
Operating speed (limit value) Multiturn 10,000 min-1, 12,000 min-1(short time)
Operating torque < 3 Ncm
Bearing life cycle > 106 bei 1000 min-1
Shaft sealing ring (optional) Material: Viton, protection class: IP 67,
reduced operating speed: max. 6,000 min-1
Ambient data
Working temperature range -40 °C to +100 °C
Operating temperature range -40 °C to +105 °C (120 °C short time)
Storage temperature range -40 °C to +85 °C (depending on packing)
Protection class IP 64, IP 67 (optional)
Vibration protection (IEC 68, 2-6) 200 m/s2, 10 to 2,000 Hz
Shock protection (IEC 68, 2-27) 2000 m/s2, 11 ms
EMC EN 61000-6-1 to -4
Insulation strength Ri > 1 MΩ at 500 V AC
Relative humidity of air max. 100 %
Condensation permissible yes

DS22-235(01.11) Lenord+Bauer 3
Dimensioned drawing
basic encoder GEL 235

Synchro flange

3
D 6 10 12
3 * *
L 10 20 20
L 4
.1
±0
42
Ø

34
*
Ø 53.8
Ø 58

Ø 50

3x M
D

4/7
deep
46.5

0°
12
3x
Clamping flange

3
D 6 10 3 * *
L 10 20 L 10
,1
±0
48
Ø
34

*
Ø 36 g7
Ø 53.8
Ø 58

46.5

5°
3x M4 / 7 deep
0°
12
3x

Semi hollow shaft

7.5
3 * *
3
.1
±0
42
Ø
34

*
Ø 52
Ø 58

20°

1
5 +0.
Ø1
3x 1

46.5

3x
M
10 5d 3
eep
29

* see connection variants of the next page.

4 Lenord+Bauer DS22-235(01.11)
 Pin layout SSI, Sin/Cos

Connector- or cable outlet PRESET adjustment SSI

At any given rotary position the output signals can be set to
preset values. As default the singleturn is to set 2n-1and the
multiturn is set to half of its maximum value. The preset can
be set electrically by applying Vs to the Preset line for t > 100
ms (do not apply permanently). Alternatively, a preset push-
button is optionally available, recessed in the encoder base
(IP 67). This is to be pushed with a blunt pin for t > 100 ms.
By using the optional parameter kit, the preset values can
be freely defined.

PRESET

Connector- or cable layout

Counting direction
With view on the encoder shaft the position value increases
by rotating the shaft clockwise (CW) (default setting). By ap-
plying VS permanently to the CW/CCW line the position val-
ue will increase when rotating the shaft counter-clockwise.
CCW = increasing position values while turning the
encoder shaft clockwise
increasing position values while turning the
CW =
encoder shaft counter-clockwise

DS22-235(01.11) Lenord+Bauer 5
SSI

The absolute rotary encoder GEL 235 transmits its position Sin/Cos differential signal
date via a fast Synchron-Seriell-Interface (SSI) with up to
For realtime control high interpolateable Sin/Cos differential
2 MHzdata rate using binary or Gray Code. With increasing
signals 1 Vpp are supported.
data rate the allowed cable length using the SSI mode de-
creases (see table cable length) and a minimum pause time
of 16 µs is necessary before the next request for position
date can be started.

Temperature range
The storage temperature of -40°C up to 85°C is restricted by
Cable length the packaging material. A operating temperature range from
-40°C up to 100°C is permissible, in which a mounted
Using SSI protocol the allowed data rates are reduced as the encoder is not allowed to exceed this temperature range.
cable length increases. It is recommended that the wires of Within the allowed operating temperature range the func-
Clock ± and Data ± are each in twisted pair configuration tionality of the absolute rotary encoder is assured
each while the cable is shielded. (DIN 32878), specifically when the temperature is measured
at the encoder housing.
cable length / m clock rate / kHz The encoder temperature is affected by the installation
< 50 < 400 conditions (thermal conduction, thermal radiation), the self-
heating (bearing friction, electrical power dissipation) and
< 100 < 300 the environmental temperature.
< 200 < 200 Depending on the operating conditions of the encoder, the
< 400 < 100 working temperature of the encoder can be higher than the
environmental temperature.
Depending on the power supply from 5 V DC to 30 V DC a
self-heating of up to 10°C can occur. At high rotation speeds
> 5000 min-1 a self-heating caused by bearing friction of up
to 20°C is possible. If the encoder is operated close to its
maximum permissible specifications several parameters
can affect encoder self-heating. In this case the environ-
mental temperature has to be reduced by suitable methods
(cooling) to ensure that the maximum permissible working
temperature is not exceeded.
Technical data SSI
Output code binary, gray
Clock frequency max. 2 MHz
Transmission Max. 1,200 m depending on transmission rate
The immunity to interference high immunity to interference via symmetrical transmission
Direction of rotation adjustable, standard clockwise (CW) with view on the en-
coder shaft, increasing position values
Preset about input level, optional with pushbutton
Cable halogen-free PUR ( 6 x 2 AWG, shielded)

6 Lenord+Bauer DS22-235(01.11)
 CANopen

GEL 235 Bus cap for CANopen

(Example: Synchro flange with connector outlet; other flange and cable gland analogue)
20.5
15.6

.1
±0
42
Ø
X

°
120

10°
2x
5°
Ø 58

10°
ep
de
Z 4
/7
M
4
3
3
45
75

Technical data CANopen

Interface CANopen DS 406 with additional function
Cable diameter 8 mm
Connection Via bus cap as T-Connector, alternatively cable gland or
M12 plug, diagnostics LED, I/O DC-isolated (inductive cou-
pling)
Programmable function Resolution, Preset, offset, counting direction, speed output,
acceleration output, output of work areas relative to deter-
mined values, scalable step number (decimal/binary)
Output code binary
Data rate 50 kBit/s to 1 MBit/s adjustable via bus master or rotary se-
lector
Sensor-ID 0 to 99 adjustable via bus master
Terminal resistor Switchable via bus cap (both DIP-switches at ON)
Operating temperature -40 °C to 85 °C (short time 100 °C)

DS22-235(01.11) Lenord+Bauer 7
PROFIBUS DP

Technical data PROFIBUS DP

Interface PROFIBUS DP, Encoder Profile V 1.1
Cable diameter 8 mm
Connection Via bus cap as T-Connector, alternatively cable gland or
M12 plug, diagnostics LED, I/O DC-isolated (inductive
coupling)
Programmable function Resolution, Preset, offset, counting direction, speed output,
acceleration output, output of work areas relative to
determined values, scalable step number (decimal/binary)
Output code Binary
Data rate 9.6 kBit/s up to 12 MBit/s adjustable via bus master
Sensor-ID 1 to 125 adjustable via rotary selector
Terminal resistor Switchable via bus cap (both DIP-Switchers at ON)
Operating temperature -40 °C to 85 °C (for short time 100°C)

8 Lenord+Bauer DS22-235(01.11)
 Analogue interface 4 to 20 mA

Counting direction These positions are then permanently stored in the encoder.
With view on the encoder shaft the position value in- Pins that do not carry a signal must remain open or be earthed.
creases by rotating the shaft clockwise (CW).
Note: The counting direction can not be changed by the
user. If a different counting directing is necessary for the
application please contact Lenord + Bauer or you local
sales contact.

Teach-In function
The Teach-In function is a special start-up function that
can optionally be provided on the GEL 235. It can be
used to position the entire measurement range between
two freely chosen points. You specify the signal limits by
applying a high signal for at least 100 ms to the appro-
priate signal inputs at the Teach-In min and Teach-In
max positions.

Technical data analogue interface

Resolution internal 65,536 step per revolution,

4,096 revolutions
Interface resolution 16 bit (0.244 μA) in the range 4 to 20 mA
Measuring range max. 28 bit
Interface accurary ±15 μA typical (25 °C)

Pin assignment

PIN Signal Description

1 GND Ground
2 n. c.
3 T-Low Teach-In Min.
4 T-High Teach-In Max.
Analogue output
5 AOUT
(current)
6 GNDA Analogue ground
7 VS Operating voltage
8 n. c.

DS22-235(01.11) Lenord+Bauer 9
GEL 235 Ex

General information GEL 235 Ex The following evidence must be furnished: the maximum surface
The absolute rotary encoder GEL 235 may be used only temperature of the plant may not exceed 2/3 of the minimum
in zones 2 and 22. The mechanical and electrical values flashpoint of the ambient dust/air mixture. The maximum surface
stipulated in the GEL 235 operating instructions – quan- temperature of the equipment may not rise to within 75 K of the
tities such as temperature, maximum load current, max- glow temperature of a thick layer of dust. Provided that all the
imum voltage and mechanical load – may on no ac- mechanical and electrical values stipulated for the GEL 235 are
count be exceeded. The GEL 235 may be operated only complied with, the surface temperature of the housing will not be
within its approved protection rating. The plant operator higher than +85°C. The maximum surface temperature measured
is obliged to perform a risk assessment, for which he or at the cable connection is 80°C.
she will need to know the minimum flashpoint of any
dust and dust/air mixtures that may be present.

Mechanical data
Material anodised aluminium
Weight Singleturn 300 g
Weight Multiturn 310 g
Operating speed (limit value) Singleturn 6,000 min -1
Operating speed (limit value) Multiturn 6,000 min -1
Umgebungsdaten
Working temperature range -20 °C to 50 °C
Operating temperature range -20 °C to 50 °C
Storage temperature range -20 °C to 50°C
Explosion control Ex II 3G Ex nA II T6
Ex II 3D Ex td A22 IP67 T85°C
-20 °C ≤ Ta ≤ 50 °C

Cable connection (SSI interface)

Reduction of type code

Features Possible variations

Interface SG, SB, CO, DP
Resolution per revolution no reduction
Revolution Multiturn no reduction
Flange, Shaft no reduction
Outlet, Position B, K, Q
Cable length no reduction
IP class, pushbutton 3, 4

The significance of the type codes may be seen from the code overview provided. Explosion proof encoders must always
have a 1 in the last position of the type code.

10 Lenord+Bauer DS22-235(01.11)
 GEL 235 stainless steel

Technical data GEL 235 stainless steel

Mechanical data
Material stainless steel 1.4104
Weight singleturn 600 g
Weight multiturn 620 g

Cable connection (SSI interface)

Reduction of type code by stainless steel

Features Possibel variations

Interface SG, SB, CO, DP
Resolution per revolution no reduction
Revolution multiturn no reduction
Flange, shaft B, D, E, F
Outlet, position B, K, Q
Cable length no reduction
IP class, pushbutton 3, 4 (only SG, SB)

The significance of the type codes may be seen from the code overview provided. The stainless steel encoders must always
have a 2 in the last position of the type code. The dimension drawing of stainless steel variants conform to standard variant.

DS22-235(01.11) Lenord+Bauer 11
Type code GEL 235

Interface
AN Analogue output
CO CANopen DS 406
DP PROFIBUS DP
SG SSI Gray
SB SSI binary
TB SSI binary 5 V
TG SSI Gray 5 V
Resolution per revolution
08 8 bit, 256 steps/revolution
09 9 bit, 512 steps/revolution
10 10 bit, 1024 steps/revolution
11 11 bit, 2048 steps/revolution
12 12 bit, 4096 steps/revolution
13 13 bit, 8192 steps/revolution
14 14 bit, 16384 steps/revolution
15 15 bit, 32768 steps/revolution
16 16 Bit, 65536 steps/revolution
Number of revolutions
00 Only singleturn (ST)
04 04 bit, 16 revolutions
08 08 bit, 256 revolutions
12 12 bit, 4096 revolutions
Flange, Shaft
A Clamping flange, D = 6 / L = 10 mm
B Clamping flange, D = 10 / L = 20 mm
C Synchro flange, D = 6 / L = 10 mm
D Synchro flange, D = 10 / L = 20 mm
E Semi hollow shaft, D = 15 / T 25 mm
F Clamping flange, D = 12 / L = 20 mm
Electrical interface
A Cable cap axialflex®, axial
B Cable gland, axial
D 12-pole connector outlet, Typ M 23, axial
E 12-pole connector outlet, Typ M 23, radial
K CANopen, bus cap with cable gland
L CANopen, bus cap with connector outlet
Q PROFIBUS DP, bus cap with cable gland
P PROFIBUS DP, bus cap with connector outlet
S Connection cap, 4 to 20 mA with M12-connector outlet
Connector/Cable
B 1 meter cable length
C 3 meter cable length
D 5 meter cable length
E 10 meter cable length
S Connector outlet / without cable
Protection class, Preset-pushbutton
1 Protection class IP 64
2 Protection class IP 64, Preset-pushbutton
3 Protection class IP 67
4 Protection class IP 67, Preset-pushbutton
Option
0 None
1 Ex zone 2/22
2 Edelstahl
235 _ _ _ _ _ _ _ _ _ _ _

12 Lenord+Bauer DS22-235(01.11)
 Type code GEL 235

Reduction of type code by explosion proof

Features Possible variations

Interface SG, SB, CO, DP
Resolution per revolution no reduction
Revolution Multiturn no reduction
Flange, Shaft no reduction
Outlet, Position B, K, Q
Cable length no reduction
IP class, pushbutton 3, 4

The significance of the type codes may be seen from the code overview provided. Explosion proof encoders must always
have a 1 in the last position of the type code.

Reduction of type code by stainless steel

Features Possible variations

Interface SG, SB, CO, DP
Resolution per revolution no reduction
Revolution multiturn no reduction
Flange, shaft B, D, E, F
Outlet, position B, K, Q
Cable length no reduction
IP class, pushbutton 3, 4 (only SG, SB)

The significance of the type codes may be seen from the code overview provided. The stainless steel encoders must always
have a 2 in the last position of the type code. The dimension drawing of stainless steel variants conform to standard variant.

Reduction of type code by GEL 235 (standard)

Features Possible variations

PRESET pushbutton SG, SB, TB, TG

DS22-235(01.11) Lenord+Bauer 13
Accessories GEL 235

14 Lenord+Bauer DS22-235(01.11)
 Accessories

Type code for GEL-235-specific/mounting material

Part number Description

FB23504 Torque support, hard1
FB23505 Torque support, soft1
RH23501 Bushing, 8 mm, POM
RH23502 Bushing, 10 mm, POM
RH23503 Bushing, 12 mm, POM
RH23504 Bushing, 8 mm, brass
RH23505 Bushing, 10 mm, brass
RH23505 Bushing, 12 mm, brass
MF23501 Mounting flange
MF23502 Mounting flange
GG126 12-pole counter-connector for SSI, straight
upon request 12-pole counter-connector for SSI, 90° offset
upon request 8-pole M12 counter-connector for analogue interface

1The GEL 235 with the flange option semi hollow shaft will be always delivered with the torque support FB 23505. If an
alternative torque support (e.g. FB 23504) is needed it has to be mentioned on the order form.
For further accessories please look at our technical information for the encoder accessories program.

DS22-235(01.11) Lenord+Bauer 15
CANopen and PROFIBUS DP accessories

Order number Description

BK 2100 CANopen connection cable 10 m, 5-pol. connector, open cable end with end splice
BK 2101 CANopen connection cable 2 m, 5-pol. connector, open cable end with end splice
BK 2102 CANopen connection cable 10 m, 5-pol. socket, open cable end with end splice
BK 2103 CANopen connection cable 2 m, 5-pol. socket, open cable end with end splice
BK 2104 CANopen connection cable 10 m, 5-pol. socket/connector
BK 2105 CANopen connection cable 2 m, 5-pol. socket/connector
FS 3016 Mating connector, 5-pol. socket, PROFIBUS DP, B-coded
FS 3017 Mating connector, 5-pol. connector, PROFIBUS DP, B-coded
FS 3020 Mating connector, 5-pol. socket, CANopen, A-coded
FS 3021 Mating connector, 5-pol. connector, CANopen, A-coded
FS 3024 PROFIBUS DP connection cable 10 m, 5-pol. connector, open cable end with end splice
FS 3025 PROFIBUS DP connection cable 10 m, 5-pol. socket, open cable end with end splice
FS 3026 PROFIBUS DP connection cable 2 m, 5-pol. connector, open cable end with end splice
FS 3027 PROFIBUS DP connection cable 2 m, 5-pol. socket, open cable end with end splice
FS 3028 PROFIBUS DP connection cable 2 m, 5-pol. Socket / connector
FS 3040 Terminal resistance CANopen M12

Subject to technical modifications and typographical errors.

The latest version can be downloaded at www.lenord.de .

16 Lenord+Bauer DS22-235(01.11)