Supporting Information

For internal use only

The information supplied in our data sheets is decisive!

Version 1.1

Supporting information on Lenord + Bauer's encoders encoder kits (MiniCoder) linear scales controllers
Contents:
1 Sensors 1.1 Survey for encoders 1.2. Signal pattern 1.3 Connectors and cable assignments 1.4 Obsolete appliances and their replacement types 1.5 Frequently asked questions 1.6 Unique features of encoder kits and encoders 2. Controllers 2.1 Survey for controllers 2.2 Frequently asked questions 2.4 Unique features of controllers 2.3 EcoPLC first steps 3. Demonstration products 3.1 Demonstration and test sheets for MiniCoders 3.2 Demo table on automation of motion (poster format) 4. Test devices
This information is supplied without any liability on our part! No liability accepted for printing and other errors! Author: Georg Sztefka Date: 09.06.2000

Lenord, Bauer & Co. GmbH Dohlenstrae 32 46145 Oberhausen (Germany) Phone +49 208 99 63 - 0 Fax +49 208 67 62 92 Internet: http://www.lenord.de E-Mail: info@lenord.de

Project Handling

 We will help you in the very beginning of a project!
 We will consult you to find the right products and their combination to meet

the specifications of your customer.

 By doing so we will learn together solving the customers problem.
 We will give you support in any stage of the project.

We suggest the following procedure to handle a project: Your inquiry by email or fax should contain: a project name to refer to the same problem general description of the machine a brief explanation of the application (number of axes, functionality, etc.) the specifications of your customer (speed, load, force, precession, inputs/outputs, bus systems, etc.) a drawing is always helpful We will answer by email or fax: further questions which you have to discuss with your customer (e.g. different resolution possible, speed really necessary, is a higher torque acceptable [price!]?) products with article code a drawing of the constellation with our products if necassary (products, cables, connector blocks, etc.) In practise we will need several iterations (questions and answers) to reach the last two points.

LB_OVE.XLS (Sensor overview)

1.1 Survey on linear encoders and encoder kits supplied by Lenord + Bauer Incremental systems (standard types, special types upon request)
Structural shape Mechanic coupling, measureing wheel or rod Precision pulse number / resolution Signal pattern and driver

standard shaft diameter

tacho, analogue output

radial shaft movement

axial shaft movement

shaft / hollow shaft

mounting method

GEL ITEM

radial shaft load

295 Encoder 294 295 294 293 292 260 219 209 208 207 108 107

Euro-flange Euro-flange Euro-flange Euro-flange Euro-flange Euro-flange synchro flange rectangular flange bearing block clamping flange synchro flange clamping flange synchro flange

D=115 mm D=115 mm D=115 mm D=115 mm D=115 mm D=115 mm D=90 mm D=60 mm D=58 mm D=58 mm D=58 mm D=58 mm D=58 mm

shaft shaft hollow shaft* hollow shaft* hollow shaft hollow shaft shaft shaft shaft shaft shaft shaft shaft *electr. isolated mat. measure

16 mm* 16 mm* 20 mm* 20 mm* 20 mm* 20 mm* 12 mm 16 mm* 16 mm* 10 mm 6 mm 10 mm 6 mm *only

250 N 250 N 1,5 mm 1,5 mm 3 mm 3 mm 200 N 500 N 500 N 200 N 200 N 60 N 40 N 0,2 mm 0,2 mm 0,5 mm 0,5 mm

E F K L M N T U V X 75 ... 256 K N 75 ... 256 N T V X 116-152, 195-256 K N 116-152, 195-256 N T V X 40 ... 10000 N T U V X A,B,C S 40 ... 10000 N T U V X A,B,C S 10 ... 10000 N T U V X A,B,C S 10 ... 5000 N T U V X 10 ... 5000 N T U V X 10 ... 5000 N T U V X 10 ... 5000 N T U V X 100,500,1000,1024,2500 N T* V alarm 100,500,1000,1024,2500 N T* V alarm *short circuit resistant 1s air gap

Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull* Push/Pull Push/Pull *perman. ...

248 Kit 247 245 244 243

flange with feather key pipe+flange+alignm. pin pipe flange with feather key pipe

50x15x30 mm D=26 mm D=28 mm 37,5 x 18,5 mm D=12 mm

toothed wheel toothed wheel toothed wheel toothed wheel t.wh./meas.rod

any any any any any

m=1...3,5 m=1...3,5 m=0.3 and 0.5 m=0.3 and 0.5 m=0.5 and 1

module, pitch

uncritical uncritical uncritical uncritical uncritical

600 m 600 m 20 m resp. 30 m 20 m resp. 30 m 30, 100 m

600 m E 700 m E F 100 m resp. 150 m K M N T 100 m resp. 150 m K M N T 150 m, 300 m L M N T

V V X V X

T,D,H (W)

Open Collect. Push/Pull* Push/Pull* Push/Pull* P,Q1,Q2 Push/Pull* *permanently

221 Scale 220

rod mounting block, etc. 85 x53x40 mm rod mounting block, etc. 86 x53x40 mm

measuring rod measuring rod

10 m 100 m

N T U V X N T U V X

Push/Pull* Push/Pull* *perman. ...

Confidential, Georg Sztefka

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output amplifier

mounting size

device / kit

special

LB_OVE.XLS (Sensor overview)

Environmental conditions / impacts humidity protection condensed water outlet vibration protection option Ex-protection option housing material

Classic application rail vehicles mechanical engineering bulb/press manufacturing motors Ex-protection food industriy offshore metallurgy/mills wood processing plate processing heavy industry

Remarks

operation temperature

200g 20g -40...+120 C 200g 20g -40...+120 C 200g 20g -40...+120 C 200g 20g -40...+120 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -20...+85 C 100g 10g -10...+70 C 100g 10g -10...+70 C ... short circuit resistant

IP67 IP67 IP67 IP67 IP66 IP66 IP65 IP65 IP65 IP65 IP65 IP65 IP65

protection type

Vibration

shock

S S S S X X X X X X X

X X X X X X X

S S S S X X X X X X X X

stainless steel stainless steel stainless steel stainless steel plastic, metal flange

X X X X X X X X X X X X

X X X X X X X

X X X X

X X X X

X X X X

X X X X

Aluminium Aluminium S=Standard

X X X X X X

X X X X X X

X X X X

very robust very robust very robust very robust can directly be mounted on motor shaft end (bore in shaft required) Tandem combination, several devices mounted on one shaft high resolution extreme shaft load with robust mounting flange integrated in the bearing block for heavy loads (cog belt, small conveyor belts) extensive accessories (measruring wheel, supports, bearing blocks,couplings) extensive accessories (couplings) for less demanding applications for less demanding applications

295 294 295 294 293 292 260 219 209 208 207 108 107

200g 20g -20...+85 C 200g 20g -40...+135 C 200g 20g -40...+120 C 200g 20g -40...+120 C 200g 20g -40...+85 C short circuit resistant

IP68 IP68 IP68 IP68 IP67

S S Zinc S S X S S S S plastic S S IP65 connector side S=Standard

X X X X X

X X X

gear block manuf., vibration support, toothed wheel pumps, screwer simple mounting without adjustment, Option: Ex-protection pipe encoder for precision application very compact for precision application very compact and easily incorporable in many different ways

248 247 245 244 243

100g 10g -20...+85 C 100g 10g -20...+85 C ... short circuit resistant

IP66 IP66

plastic, hard chrome plated. meas. rod plastic, hard chrome plated meas. rod

X X

X X

X X X X

encapsulated system, very easy to mount encapsulated system, very easy to mount

221 220

Confidential, Georg Sztefka

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GEL ITEM

LB_OVE.XLS (Signal pattern)

1.2 Signal pattern

output voltage Ua or current Ia abbreviated designation former designation description Voltage supply Ub examples x=0,1,2 x=0,1,2 x=0,1,2 26x, 29x 26x, 29x 26x, 29x 247 269 247 247 247 269 26x 244, 245 243, 244, 245 243, 244, 245 all (excl. 247, 248) 243 x=0,1,2 26x, 29x 243 243 268, 269 x=0,1,2 243 26x, 29x 207-293 207-293 294 268 x=0,1,2 207-293 26x meaning tacho output - additional or exclusive tacho output - additional or exclusive tacho output - additional or exclusive like V-Signal but galvanically separated 1 track signal without inverse signal 1 track signal without inverse signal 1 Spursignal, plus inversem as X-signal but galvanically separated 1 tracksignal with constant pulse duration clockwise rotation: (1 track sign. def. pulse length, without inverse signal, 2nd output 0V) anti-clockwise rotation (1st output 0V 1 track sign. def. pulse length, without inverse signal) x=0,1,2 2 track signals, plus inversem, reference pot. Ub/2 2 track signals, without inverse, reference pot. Ub/2 reference groove reference flag groove detection like proximity switch 1 track signal with defined pulse length, without inverse signal start and end of toothing reference groove (direction signal, max. speed) reference flag 1 track signal defined impulse length, without inv. sign., 1 dir. sign., without inv. sign. 2 track signals, plus inverse signal 2 track signals, plus inverse signal 2 track signals, without inverse signal 2 track signals, plus inverse signal stop detector 2 track signals, plus inverse signal +F10 same as signal meaning S but keyboard ratio 1:1

A B C D D E F H H I

analogue analogue analogue rectangle rectangle rectangle rectangle rectangle monoflop monoflop

10-30 V 10-30 V 10-30 V 10-30 V 7-30 V 10-30 V 10-30 V 10-30 V 7-30 V 10-30 V

0 ... 20 mA 0 ... 20 mA 4 ... 20 mA approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub Ub

K L M N P P Q R R S S T U V W W X Z

sinusoidal sinusoidal rectangle rectangle rectangle monoflop rectangle pulse level pulse monoflop 5,20,100s, etc. rectangle rectangle rectangle rectangle level rectangle rectangle

5V 5V 5V

1 Vss 1 Vss approx. Ub

5 V, 10-35 V approx. Ub 5V approx. Ub 10-35 V 5V 5V 7-30 V 5V 10-35 V 5V 10-35 V 10-35 V 10-16,5 V 10-30 V 10-35 V 10-35 V approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub 5V approx. Ub approx. Ub approx. Ub approx. Ub approx. Ub

T and X are signal and connector compatible to competition products Note: E V X (E is integrated in V and V is integrated in U) Definition: With view on clockwise turning/revolving shaft track 1 is leading and track 2 is delayed by 90.

Confidential, Georg Sztefka

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LB_OVE.XLS (Pin layout)

1.3 Connector and cable layout/assignment for linear scales, encoders, encoder kits and testing devices
The L+B declaration for flat connectors is valid: Pin 1 located on top (vertical installation - top view on the mounted/plugged-in connector) Pin 1 located left-hand (horizontal installation - top view on the mounted/plugged-in connector)
description 4 pole 6 pole 6 pole 7 pole 9 pole circular connector 10 pole 10 pole 12 pole 12 pole 12 pole 9 pole rectangle 10 pole 8 pole Sub D 9 pole 6 pole 6 pole 6 pole 9 pole 9 pole cable 10 pole 10 pole 10 pole 12 pole 12 pole
pink black white brown purple yellow red blue 204T,V,X 205T,V,X 206T,V,X

track 1 /track 1 track 2 /track 2

A /A B /B

Ub Ground Sense GND-Sense tacho output Alarm

1.track /1.track 2.track /2.track N /N Us Us

90 /90 0 /0

B C

B C D

C B D F A

1 2 6 7

Us

D A

F A

5 3

B G C H D I F A

2 3 6 4 1

B G C H D I F A

C H B G D I F A

3 6 4 7 5 8 2 1

8 1 5 6 3 4 12 10

5 6 8 1 3 4 12 10 2 11 7

1 5 2 6 3 7 8 4

2 3 4 5 7 8 1 9 6 10

1 2 3 4 8 9 6 5

white

brown

yellow black

pink black white brown purple yellow

white brown pink black grey yellow red blue green

white white/brown green green/brown yellow yellow/brown red black

white brown pink black purple yellow red blue

pink black white brown purple yellow red blue

white brown pink black purple yellow red blue green red/blue

brown

white

white brown

grey

grey

yellow green

yellow green

red blue

red blue

pink

grey yellow/black

grey

265V 202V 207V 243T 204E,V 208V 205E,V 209V 206E,V 219V 262A,B,C,E,V,S 264E,V 266 267

266 268 269

205V

240 293T,U,V,X Hohner 204T,V,X 259 205T,V,X 266 206T,V,X 267X 268 269 291A,B,C,E,T,V,X

207T,V,X 220T,U,V 208T,V,X 221T,U,V 209T,V,X 219T,V,X 245K,T,V,X 107T,V 108T,V

210K Z1 EcoCon 202V 207V Phoenix KleZ2 EcoCon 204E,V 208V 205E,V 209V 206E,V 219V 262A,B,C,E,V,S

(244K,T) 201X 244K,T 247E,F,V,X 202X 294V,W 262A,B,C,T,X

107T,V 108T,V

207TUVX 291A,B,C, 294T,X 208TUVX 295K 209TUVX 219TUVX

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LB_OVE.XLS (Sensor replacements)

1.4 Obsolete types and their replacements

field of application and short description mech. replacement by 293 293 260 260 260 260 260 260 260 260 260 260 208 207 209 208 207 209 208 207

obsolete type

292 291 290 272 269 268 266 265 264 263 262 261 259 240 218 217 206 205 204 203 202 201 25

hollow shaft tandem encoder, can be combined with 290, 291, 292, 150 hollow shaft encoder hollow shaft encoder tacho, option pulse- and analogue output, 4 pole male connector Option stand still control 4 pole male connector same as 262 but suitable for Ex-protection area Tacho, 0 -0,5 rpm up to 0-10000 rpm, former signal pattern I, Z, R, W, (A_signal polarity switchable) synchro flange 70mm diameter sinusoidal encoder, flange same as 260, flat housing

not all signal pattern replaceable not all signal pattern replaceable not all signal pattern replaceable not all signal pattern replaceable not all signal pattern replaceable not all signal pattern replaceable 259 flange + 208 electronics possible

very flat encoder with sinusoidal 2Vss output at 20mA constant current supply, one track signal

Confidential, Georg Sztefka

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remarks

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______________________________________________

1.5 Frequently Asked Questions

How to carefully choose the appropriate Sensor or: Questions customers often ask.
When to use which signal pattern? The common signal pattern for 5V is the T-shape signal and the V-shape signal for 10-35 V supply (10-30 V for some appliances). In addition to the V-shape signals the X-signal pattern also offers inverse signals (same as T). When to use which housing type? In most cases the standard housing (GEL 107, 108, 207, 208, 209) is sufficient. The bigger housings of GEL 260 up to type GEL 293 offer a higher resolution. The GEL 293 is relatively flat device (small mounting depth) When to choose a MiniCoder? if non-contacting, i.e. wear-free, measuring is required if neither end of the shaft is free if conventional hollow-shaft encoders cannot comply with the shaft diameter in case of high speeds in case of high protection classes in case of high temperatures When better not to choose a MiniCoder? If, for instance, the radial shaft allowance/clearance exceeds the air-gap tolerance. Which MiniCoder model? The air-gap tolerance might be a criterion. See the respective table. Safety integrated for Sinumerik? The control (Sinumerik 840C/CE and 840D/DE) recognizes all encoder errors relevant to safety. We can supply you with a more detailed description regarding this subject. Which are the most important toothed-wheel sizes? The max. outside diameter is determined by the space available in the housing. The shaft diameter influences the inside diameter. Bear in mind the bearing clearance! Which precision can be achieved? The resolution of the revolution (number of teeth, module) and the tolerances (air gap, angle of installation) determine the precision. With an internal or external interpolation the precision is enormously increased by the factor of the interpolation. Some of our customers interpolate up to 2,000 times. Which phase errors can be tolerated? It depends on the interpolation factor. We have an application paper on this subject for the GEL 244. When to use an external interpolation? When long cables require a low signal slope (sinusoidal, cosine signal). When EMC related problems are to be expected. When a high precision is essential.

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______________________________________________ When better not to use an external interpolation? When a compact installation without additional wiring is of immediate importance. When to provide for a humidity protection? In case of temperature fluctuations. When to provide for a condensed-water outlet? In case of important temperature fluctuations in a humid environment. What has to be taken into account when using a condensed-water outlet? It must always be located at the deepest position, i.e. if the flange bores are used to fix the encoder, this must be taken into account to find the right position for the outlet (the customer must define the position of the outlet). Drawings for radial and axial installation are available (GEL 207 through 219 and 293, drawing nos. 293KW0001-000 and 207KW0002-001). When should I use a vibration protection? If the appliance must be shock-proof up to 200g and a protection against vibration is required which is correspondingly strong. How many pulses are necessary? As a rule, the required resolution of the angle of rotation or the detection of the smallest or biggest RPM determine the pulse number. Please note that high pulse numbers per revolution may result in very high signal frequencies in connection with high speeds. The line drivers must recharge the cable capacity correspondingly often. Furthermore, the cable capacity increases with the cable length. Each recharge increases the line drivers dissipation! Do also bear in mind the input frequency of the counter card. (EcoController accepts max. 200 kHz) What is an Euro flange (also named B10)? This is an encoder flange with the following size: centering shoulder 85h6 mm, scribed circle 100 mm, OD 115 mm. What is a servo flange? A servo flange is a flange for encoders: round flange with a diameter of 58 mm and circular groove for a clamping device. What is a clamping flange? Name of/Designation for an encoder flange: round flange for tightening. Which standards are applicable to encoders? DIN 32878, DIN 66348; DIN 66258; DIN IEC 625; DIN 1319

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______________________________________________

1.6 Unique characteristics: Sensors 1.6.1 Standard encoders for use under rough conditions in industry (207, 208, 209, 260, 293)
Thanks to their nature design and their magnetically and incrementally operating measuring systems the robust standard encoders are best suited for being used under roughest conditions in industry. By means of standard mounting flanges and due to the standard output signal patterns with various voltages their easy installation and integration into complex control tasks becomes possible.

Use where vibrations and impacts dominate

Tablet presses, jolters, screening machines, presses, extruders, concrete gravel machines, rolling machines, tunnel-driving technology, mining, conveyor belts, escalators a flexible coupling compensates for the shaft play (GEL 293: integrated) a toothed wheel made of steel tolerates strong, regular and process-dependent highfrequency vibrations as well as impacts on shaft and housinge the electronics is additionally protected by a potting compound protected against humidity

Outdoor applications (temperature and humidity)

Cranes, dockyards, drilling technique, outdoor use, filling plants, paper production the electronics is protected against humidity condensed water can be drained off via a specially provided condensed-water outlet no optical compo. which steam up at high humidity of air or in case of temp. fluctuations a regular removal is not required as in case of optical systems (dirt, humidity)

Unique characteristics
The unique characteristics result from the robust magnetic measuring principle. In case of heavy shock or intensive vibrations the measuring wheels of optical systems get deformed or broken, whereas the toothed wheel made of steel which is used in the magnetic system works trouble-free under such circumstances. When optical systems get steamed up in high humdity of air and in case of high temperature fluctuations they stop working. The magnetic measuring system, however, does even function, if the toothed wheel is dewed or dirty. The measuring system (not the electronics) even resists increased nuclear radiation. Further advantages: solid assembly base with 16-mm shaft and 500 N bearing load available the GEL 293 has a small front-to-back size 2 systems on one shaft are feasible with the tandem encoder

1.6.2 Heavy-duty encoder / railway encoder GEL 295

The GEL 295 is intended for use under roughest conditions and has therefore a massive stainless-steel housing. The magnetic incremental measuring sytem is entirely sealed and resists even extreme environmental influences.

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______________________________________________

Extreme outdoor applications

Rail vehicles (motor-speed detection, anti-spin and anti-skid protection, traction check, master encoder for brake energy restore) shock-proof > 100g, vibration-proof > 30g, use when the temperatures are high (-40 - 120 C = -40....248 F) use in high humidity of air (magnetic system, sealed system) use in water (IP 68)

Extreme indoor applications

Used in blast furnaces insensitive to high temperatures, gases, vibration

Use in corrosive areas

Sewage treatment plants, composting plants insensitive to high temperature resists aggressive gases (e.g. ammonia) humidity-proof

Use in special or security areas

Drive technology up to 6 redundant or functionally independent measuring systems in one housing

1.6.3 Linear scale GEL 221

The linear scale GEL 221 is an incremental magnetically operating measuring system with a high resolution and a high absolute precision. The most outstanding advantage of this robust and self-guided measuring system is the fact that it can be mounted easily without any additional adjustment. Its main characteristics are: protection class IP66 easy installation because of a distant-tolerant drag plate high temperature range may be shortened according to your needs absolute accuracy of measurement is higher than that of analogue systems resolution 10m and 100 m for GEL 220 (0.00039 inches and 0.0039 inches) dynamics (0 up to 200kHz)

Use in clean rooms or in a sanitary environment

Food processing industry, chemical industry smooth and easy-to-clean surface moisture-proof the measuring rod is hard-chromium plated and therefore resistent against many types of liquids and gases

Use in areas where vibrations and moisture occur

Presses, wood processing
09.06.00 page 9 Confidential

______________________________________________ oil-resistant shock- and vibration-proof dew-point-proof

Unique characteristics
The unique characteristics are due to the robust magnetic measuring system. In case of heavy shock or intensive vibrations the measuring rods of optical systems get deformed or broken, whereas the rolled measuring rods made of steel which are used in the magnetic system work trouble-free under such circumstances. Optical systems stop working if they get dirty and steamed up should the humidity of air and the temperature fluctuations be high. The magnetic measuring system even functions in places where dew occurs and in dirty areas.

1.6.4 MiniCoder (243, 244, 247)

The MiniCoders are incremental pulse generators not having a joint housing for measuring system and measuring scale. They are designed for being built directly into machines where they become an integral part of the machine itself or of the measuring equipment. Due to the their direct incorporation into the machine both axes become free for the user. The main characteristics are: extremely small and compact encoder kits for the detection of position, speed and direction contactless magnetic measuring principle oil, dirt and humidity do not influence the precisely measured values dew-point-proof compression-proof up to 100 bar temperature range - 40...+120 degrees Centrigrade (-40....248 F) pulse number variable through toothed-wheel diameter and module sine-shaped or square-shaped signals at the output shock- and vibration-proof thanks to a fully sealed electronics measuring frequency 0 Hz up to 200 kHz (GEL 243, GEL 244) 0 Hz up to 25 kHz (GEL 247)

Use in the field of machine building (GEL 243, GEL 244)

Main spindles, piston rods, motors, pumps, ventilators Application whereever the use of hollow-shaft encoders with extremely large shaft diameters or resolvers with large inner diameters is not economical or does not make sense from the technical point of view. high precision (applies in particular to the GEL 244) because of toothed wheels made of steel high angle accelerations and speeds can be achieved the GEL 244 has got a high protection class IP 68 on the measuring and connection side the GEL 243 has got a high protection class IP 67 only on the measuring side (connection side IP 65)

Use in motor car construction (GEL 247)

Rail vehicles, motors, pumps, ventilator, brakes
Confidential page 10 09.06.00

______________________________________________ robust design high protection class IP68 use under roughest ambient conditions detection from standstill up to maximum speed

Unique characteristics
The unique characteristics result from the robust magnetic and small measuring system which can be flexibly mounted even if the shaft diameters are large. pressure-sealed systems thanks to their small compact size they can be incorporated into machines dirt, oil and humidity do not influence the result of measurement the measuring scale may have any size at all (e.g. external rim of fan impellers)

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This page has been left blank intentionally.

Confidential

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LB_OVE.XLS (Controller overview)

2.1 Survey on controllers supplied by Lenord + Bauer (standard types, special types upon request)
main characteristics separated (Display+Keypad not inside the housing) working concept stearing output technology functions power supply communication interfaces encoder input programs

operation terminal (display+keypad+housing)

incremental path to analog converter

RS232 RS485 RS422 CAN Profibus Interbus max. incremental counter frequency

compact (CPU+Keypad+Display)

4xxx* 7xxx*, 73+74 73xx* 74xx* 76xx* 131* 83xx 86xx 8810 80xx 81xx 2000 2100 ND31**

96x96 144x144 48X96 48X96 144x144

X X X X X

1 5-30 1-2 1-9 1 5 1 5 2 10

X X X X

X X X X X X

X X X X X X X X X X X X

X X X X X X X X* X X X X

* **

250 280

660

740 780 780 750 8x0

X *** X X X X X X X X X X

X* 144x144 X 1-3 0,3*-3 144x288 X 1-6 1-6 168x168 X** DIN hatrail X 1 1-5 DIN hatrail X 1-6 0,3*-6 X 1 0,25** 70x275x267 X 1 0,25** 70x275x267 X 1 1 100x371x180

X X X X

X X X X X X X

10 X 10 40 30 35 50 X X X X X X (X) (X) (X) X

*410=contact/440=analog

X X X X X X X X X 19 X X X 19 X X 80 85 X 80 15 90 X X* (X) X* X**

X X X X X X X X X X X X X X X X X X X X X X X X* X X* X X

20 X X X 20 X X X X X 5 X X 5 X X 20 X X X X X X X X X X X X X X X X X X X X X

8 100 32 800 1 (6) 1 6 32 1600

100 X X X X X 99 7168 100 X X X X X 99 6416 100 X X 100 P P S S S S X S S S X S S S 4 96 99 6416 1 255* 99 **

*180 permanently stored ** dynamically recalculated

*discontinued model **with KG-2 housing

*0,3ms only for camshaft gear **0,5 without internal interpolation *83xx/86xx controller **80xx/81xx controller

*24V for electronics and 230-480V for amplifier **24V for electronics and 230V for amplifier

X = fixed during manufacturing S = switchable after 1998 P= programmable

**510=contact/540=analog ***10=contact/60=analog *LogiPanel

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max. amount of motion tasks

circular interpolation

SSI incremantal 5V 24V absolut parallel amount of programs

elec. camshaft gear

fast/slow switching

speed feed forward

free programming

synchronization

GEL Item

cycle time / ms

controlled axis

relay contacts

housing / mm

rotating knife

positioning

coil winder

flying saw

cam profil

transistor

CAN bus

AC 115V

AC 230V

DC 24V

AC 18V

analog

ramps

LB_OVE.XLS (Decision structure)

2.2 Guide for a decision

How many axes? freely programmable one-axis-positioning MMI

camshaft gear

multipleaxes positioning (slave-slave with one virtual master) linear interpolation circle interpolation

master-slave synchronization

operating and observing operating terminal PC O&O software

compact device

rotating knife

independent

coil winder

flying saw

cam profil

special functions

8000 8100 x 8300 x 8600 x LD2000 LD2100

x x x

x x x x x x

x x x

x x x

x x x

x x (x) x x x x (x) (x) (x) x x x x x x x x x x x

x x x x x x

x x x x

Confidential, Georg Sztefka

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LogiPanel

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LB_OVE.XLS (Controller questions)

2.3 Package of questions Item GEL

ND31 4000 7000 83xx 86xx 80xx 81xx 2000 2100 8810 8819

question
y y Can the inputs be used for start, stop and referencing? How can we influence the cutting length? Feedback of the slave possible by an external encoder and can it be switched?
8820

answer

y y y y y y y y y y y y y y

By different cam profiles or changing the last section's length

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______________________________________________

2.4 Unique characteristics: Controllers 2.4.1 EcoControllers

The EcoController is a compact digital controller for the automation of motion. A jerk-free and smooth starting or run-out with highest possible acceleration is achieved by the feedback of the actual position and a speed input control. The fast control is already programmed and ready for use and only the parameters of the drive and the encoder must be set. Every position or path can be run with a defined speed taking advantage of the motor rating. The compact design and the fact that the EcoController is mounted on top hat rails a common technique in the construction of switch cabinets - makes it even attractive for small machines. The EcoController's unique characteristics are as follows: easy mounting on top hat rails easy and excellent handling thanks to a separate Operating Terminal a counting card for the scanning of positions is already integrated (max. 2, SSI and/or incremental) integrated analogue outputs (max. 2) for the drive control controls up to 6 axes with one unit (actuator and initiator via CAN bus) standard interfaces (RS 232 and RS 485) for PC and Operating Terminal various bus systems can be used (CAN, PROFIBUS, INTERBUS)

2.4.2 Standard applications in compact and dynamic machines

Positioning, flying saw (cutting to size), rotating cutter, synchronisation control (electronic gear), electronic camshaft gear, coilling controller ready programmed positioning routines integrated interpolations for standard applications only the parameterization of the drive and the encoder remain to be carried out easy-to-operate via a local Operating Terminal and/or PC absolute synchronization control with compensation of the control deviation

2.4.3 Applications with camshaft gears (sequencing control)

Mechanic camshaft gears are rigid and only offer useful results at a certain speed. With an electronic camshaft gear, on the other hand, dynamic cams can be programmed, which offer shorter or longer displacement of the electronic cams dependent on the machine's cycle time or speed. freely programmable dynamic cams variable machine speeds short cycle times of the cam control several programmes can be established

2.4.4 General applications in compact and dynamic machines (EcoPLC)

Special machines, general automation of standard production machines freely programmable according to IEC 1131 standard plus integrated positioning routines

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______________________________________________ inputs and outputs are freely programmable positioner plus logic functions individually designed control elements (free allocation of keys and any desired text in various languages)

2.4.5 Unique characteristics

The unique characteristics are a result of the compact design and functionality, latter offering not only positioning routines but also simple logic functions. easy and rapid commissioning easy operating + observing via Operating Terminal and/or PC loadable operating system with flash technology

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2.5 EcoPLC first steps 2.5.1 Case A: PC + 1 Eco + 1 Operating Terminal

Which cables are required? GEL 89022 (PC/Eco), GEL 89019 (Eco/Terminal) Where are they to be placed? Voltage supply Switch on RS232 inteface: e.g. COM2 at PC to plug C at Eco plug B at Eco to plug B at the Operating Terminal Eco: e.g. N1 and N2 for 24V AC Terminal: e.g. A1 and A2 for 24V AC Select the correct controller address at the terminal At the Eco prepare the start/stop input (terminal J8): First apply 0 V or leave open, otherwise the Eco starts without a program and shows an error (system error no. 1 = no program). After this incident, switch the Eco off and then on again. In case the Eco is not switched off, programs will not really be loaded and are not saved into memory. Communication refer to the User Manual, chapter 3.1.3

2.5.2 Case B: PC + 2 Ecos + 1 Operating Terminal PC communication with the Ecos has to be effected via RS 485 (bus from PC to the Ecos) if all Ecos in one project shall be programmed via PC. In case the PC will be integrated in the bus system of the RS 485 communication it is not necessary (see case of RS 232 connection) to switch the communication cable from Eco to Eco in order to load programs and parameters.
Is the RS485/RS232 converter required? In case the PC interfaces do not provide a RS 485 connection, a converter is necessary in oder to manage all Ecos of one project. With a RS232 interface only one Eco can be managed via PC. In this case you have to disconnect Eco 1 and connect Eco 2 for programming. GEL 89025 or GEL 89026 (PC/converter), GEL 89015 (converter/Eco), GEL 89019 (Eco/Terminal) Slave Eco to Slave Eco: GEL 89016 EED (which application case?) Master Eco to Slave Eco: GEL 89016 SED (master and slave axis in different devices) Wiring of cables? Where are they to be placed? The wiring of cables is described in the corresponding chapters in the manuals. Ready-made cables can be ordered. GEL 89025: RS232 inteface, e.g. COM2 at PC to converter GEL 89015: converter to plug B at Eco (not C Framing Error) GEL 89016 EED/SED: Plug B at Eco1 to plug B at Eco2 GEL 89019: plug B at Eco to plug B at the Operating Terminal Which DIP connector adjustment? SW1.1 ON (B1.1 in parallel to B2.1); SW5 ON (RS485, OFF = RS422)

Which cables are necessary?

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______________________________________________ Voltage supply First switching on Ecos: e.g. N1 and N2 for 24V AC Terminal: e.g. A1 and A2 for 24V AC At the Eco prepare the start/stop input (terminal J8): First apply 0 V or leave open, otherwise the Eco starts without a program and shows an error (system error no. 1 = no program). After this incident, switch the Eco off and then on again. In case the Eco is not switched off, programs will not really be loaded and are not saved into memory. At the Operating Terminal the correct controller address has to be selected. The Ecos have to be connected subsequently to the PC interface resp. to the converter. Then load the parameters. This is important because the individual device address has to be assigned to the Eco prior to be connected to the bus system. Devices with the same addresses on a RS485 bus connection cannot be identified thus leading to bus conflicts/errors. Normal switching on Connect all equipment parts to the RS485 bus (PC probably via converter)

2.5.3 Case C: PC + 2 Ecos + 2 Operating Terminals Equal to case B (see previous section), but exception is that the connection line from Eco to Eco must not connect Ser3! In this case one terminal is assigned to each Eco.
Connection Eco / Eco Connection PC converter/Eco Disconnect Pin 9 and Pin 5 of cable GEL 89016 EED/SED! One Operating Terminal cable has to be removed temporarily. Thus, the connecting line to the PC converter can be connected to a free Eco B connector. Here, a special cable with two connectors connected in parallel enables an additional bus connection.

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3 Demo products
3.4 MiniCoder demo panels
You can buy or rent each device from LENORD+BAUER, please contact us.

GEL 243

GEL 244

GEL 247

GEL 248

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3.5 EcoController poster panel

MiniCoder GEL 244 (2 )

EcoController GEL 8110

Operator Terminal GEL 8810

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4 Testing devices
You will find below a copy of the original document of the follwing testing devices:

GEL 210 T/X, for encoders with rectangular outputs GEL 210 K, for encoders with sinusoidal outputs

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GEL 210 T/X

Test device for encoders with rectangular output

09/99

Fields of application:
display high signal (red) display low signal (green) (other LEDs accordingly)

This device serves to check encoders with square-wave signal-outputs with the following signal shapes:
T, TN

TRACK 1

TRACK 2

GND
TRACK 1 TRACK 2 N

operating voltage current consumption V, VN, X, XN operating voltage current consumption

UB = 5 V DC + 5 % max. 35 mA UB = 10 ... 30 V 40 ... 80 mA

UB

ON
8 6 11 5 4 9 1 7 12 10 2 3

Functioning:
connector for encoder

voltage supply (4-mm socket connectors)

Each signal output of the encoder is checked for its ability to deliver a valid high or low signal. This is acknowledged by either the red or the green LED. One output is loaded with approx. 2.8 kW against 0 V and against UB. The low level must not be higher than 20 % of the operating voltage. High level must be at least 80 % of the operating voltage. If the signal levels are not correct or there is no output signal at all (e.g. a failure of contact), the corresponding LED is off. For the signal shape V there is no display for the inverse signals (lower row of LEDs).

Caution:
The encoder to be tested needs to be fed via the testing device GEL 210.

Lenord, Bauer & Co. GmbH Dohlenstrae 32 46145 Oberhausen Germany

Phone +49-208-99 63-0 Fax +49-208-67 62 92 E-Mail: info@lenord.de Internet: http://www.lenord.de

Pin layout, Type code

Pin layout

Type code
210
encoder supply
+

XX TX-

description signal pattern square-wave signal 5 V and their inverse signals square-wave signal 10 ... 30 V with reference signal

UB
X, V 10 ... 30 V +5V+5% T

US
10 ... 30 V +5V+5%

reference earth

V
8 6 11 5 4 9 1 7 12 10 2 3

VN

T X

TN XN

track 1 track 1 track 2 track 2 N N

This information is supplied without liability. Printing and other errors excepted.

GEL 210 K

Operating instructions

Testing device for encoder with sinusoidal outputs

Field of application:
Alignment of MiniCoders GEL 244 K, KN, KM Testing of various encoders with sinusoidal outputs Floating measuring

Function:
With the testing device the sine and cosine wave signals of the encoder are checked for admissible signal levels. The 3-digit LC display (background lightened) displays the following measurands: amplitude of sine and cosine track (voltage) offset values of both signal tracks (voltage) phase deviation between signal tracks with respect to 90 (degree) correct function of reference track (voltage) Changing the measurement range is effected by means of the laterally installed push button (with each actuation the measurement range is scrolled down). The active range is indicated by the respective LED.

Connections (see drawing on the next page):

The encoder is to be wired to a 10-pole terminal strip (screw contacts) and to be connected to the testing device (unique orientation). Voltage supply to the testing device is effected either via the included mains adapter (5 V, stabilized) or by means of a 5 V supply connected to a 2-pole terminal strip.

Technical data:
Operating voltage Supply current without sensor Operating temperature Frequency range Dimension (WHD) Weight excl. mains adapter 5 VDC 5% < 100 mA +10 +40 C 0.1 4 kHz 8415730 mm 200 g

Measuring units and tolerances (admissible range):

1. Amplitude (peak to peak) Track A 2. Amplitude (peak to peak) Track B 3. Offset Track A 4. Offset Track B 0.800 1.100 VPP 0.800 1.100 VPP -0.060 +0.060 VDC -0.060 +0.060 VDC

Measuring error of testing device:

Amplitude (peak to peak) Tracks A and B Amplitude (zero peak) Track N Offset Tracks A, B, N Phase mismatch relative to 90 2% (0.12 kHz) 10% (0.12 kHz) 0.2% 0.2

5. Phase mismatch relative to 90 between Tracks A and B -5.00 +5.00 degree 6. Amplitude (zero peak) Track N 7. Offset Track N > 0.200 V -0.400 - 0.100 VDC

This information is supplied without liability. Printing and other errors excepted!
Lenord, Bauer & Co. GmbH Dohlenstrae 32 46145 Oberhausen (Germany) Phone. +49 (0) 208-99 63-0 Fax +49 (0) 208-67 62 92 E-Mail: info@lenord.de Internet: http://www.lenord.de

05/99

GEL 210 K

Connection diagram:
NC

GND UNUN+
NC

blue yellow grey green black pink brown white red

UBUB+ UAUA+ +5 V

Amplitude Spur A Amplitude Spur B Offset Spur A Offset Spur B

Messbereichstaster

Phase Spur A zu B Peak Referenzspur Offset Referenzspur

(Messbereichstaster = measuring range push button, Spur = track)

+5 Volt ext.

alternatively:
GND +5 V

DS12-210K

GEL 210 K

Measurements (assembly errors):

Air gap error

UA+, UA-

Amplitude Track A:

0.800 1.100 VPP

UB+, UB-

Amplitude Track B:

0.800 1.100 VPP

Offset error

UA+, UA-

Offset Track A:

-0.060 +0.060 VDC

UB+, UB-

Offset Track B:

-0.060 +0.060 VDC

Phase error

UA+, UB+

Phase Track A to Track B (deviation from 90):

-5.00 +5.00 degree

Zero mark Measuring of the reference track (N) amplitude and offset for monitor purposes only. For correction the zero mark must be adjusted mechanically. Amplitude (zero peak) Track N: Offset Track N:
DS12-210K

> 0.200

V -0.400 -0.100 VDC

3