Encoders for Extreme Environments

Encoders for Extreme Environments Head Office sales@atisystems.co.za - www.atisystems.co.za ATI Systems Committed to Quality Durban Branch 011 383 8300 031 303 1587 International: +27 11 383 8300 International: +27 31 303 1587 sales@atisystems.co.za - www.atisystems.co.za 159 Galjoen Rd, Wadeville, Germiston 10 Ballance Rd, Windermere, Durban Management System ISO 9001:2008 www.tuv.com

Product Family 300 Miniature 500 Robust 600 Industrial The model 300 series consists of robust a n d ex tremely reliable m i n i ature encoders, 30 mm in diameter and designed for installation in applications where limited space is at a premium. Versatile and modular are catchwords that differentiate the incremental encoders in the model 500 series. Fieldbus interfaces based on Ethernet, PROFIBUS or DeviceNet are examples of communication protocols used in automation. These interfaces are available on the 600 series of absolute coded encoders. 700 Compact 800 Heavy Duty 900 Premium The 700 series is a robust encoder with a compact design. With its short length, it is designed for filling the need for heavy duty encoders even in installations where space is limited. When the most robust, maintenance-free and cost-effective encoder solution is required, the model 800 series is the first choice of most engineers. The optional ADS (Advanced Diagnostic System) is a built-in system tailored to support c o n d i t i o n - b a s e d m a i n t e n a n c e, guaranteeing the reliability of the application. Machines are becoming more and more a d v a n c e d i n c l a s s i c i n d u s t r i a l applications. More complex motions need to be absolutely monitored in order to achieve full process control. The 900 series meets these increasing demands. 1000 Extreme There are many examples of extreme environments within the steel industry in the terms of temperature, mechanical forces, vibrations and shocks. The 1000 series is designed with exceptional d u r a b i l i t y, s u i t e d t o a n e x p o s e d environment. This due to the high encapsulation level which keeps the internal parts protected from dust and liquids. 4

The Best of Both Worlds An encoder operates on the threshold between mechanics and electronics, and these two worlds require completely different qualities of the encoder. On the electrical side, an encoder must offer the highest level of reliability, precision and accuracy. On the mechanical side, it must withstand powerful forces, vibrations and extreme temperatures. In a drive system, the encoder provides the link between motor and frequency converter. This document outlines the criteria to be considered when choosing a solution optimized for both worlds. The Function of an Encoder The encoder translates a mechanical movement to an electrical. The Principle Behind a Drive System 1. The motor shaft drives a load at a certain torque. Intentional speed adjustments may be required during operation; but also, unintentional changes in speed can occur, as the speed is affected by a number of factors, for instance, a variation in the load and by slip. 2. The encoder is mounted directly on the rotor and measures the real speed of the motor shaft. 3. The encoder sends a constant stream of feedback of the speed to the frequency converter. 4. The frequency converter interprets the encoder signals and calculates the necessary compensation for the speed. 5. The frequency converter regulates frequency and voltage, which control the speed of the stator s rotating magnetic field. Inside an Encoder The internal structure of an encoder is based on a rotating disc with a large number of measurement points around its circumference. With a pulse rate of 1,024 ppr, one revolution will provide 4,096 measurement points. This means that the encoder can detect a movement of 0.1 mechanical degrees and that an updated speed can be calculated 4,096 times during each revolution. This enables immediate compensation for deviations, so that the preferred speed can be maintained. 5 Electric motor Motor 4 1 Encoder Frequency converter 2 3 Stator rotating magnetic field Rotor rotating motor shaft 5

Electronics Absolute Position Encoders Absolute position encoders are offered with serial interfaces such as SSI and EnDat or with integrated fieldbus communication of various kinds, ready for installation in an existing fieldbus system. Available in the 1000, 600 and 500 series DRIVE-CLiQ is a registered trademark of Siemens. Increased Function and Safety Dual Solutions Two separate encoders can be integrated into one and the same cover. This solution provides added safety in the form of true redundancy, something required in critical applications where the risk of component faults must be avoided. The two outputs can also be connected to two separate systems with different functions, and there are solutions for combining an incremental and an absolute output in one and the same product. Available in the 1000, 800 and 500 series ADS Online ADS Online is an Advanced Diagnostic System that continuously monitors the encoder function. If the encoder is nearing the end of its life, a warning is transmitted, enabling action to be taken in good time before problems arise. This system is integrated into the encoder and is used in applications with high demands for reliability, for example, in motors for continuous operation at a paper mill. Available in the 800 series 6

ALWAYS EX-STOCK Incremental Encoders - Industrial Duty - 500 Series Industrial Blind-Hollow Shaft Encoders with Operation and 1,5 m Radial Cable Outlet 56 392911-04 392911-12 392911-07 392911-52 392911-08 392911-18 Description RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 500 ppr RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 1000 ppr RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 1024 ppr RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 2000 ppr RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 2048 ppr RHI 503 56, HS Ø12 mm HTL Cable Radial 1,5 m 2500 ppr Industrial Blind-Hollow Shaft Encoders with 5 Vdc Operation and 1,5 m Radial Cable Outlet 518540-17 518540-08 518540-01 518540-11 518540-07 518540-14 Description RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 500 ppr RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 1000 ppr RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 1024 ppr RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 2000 ppr RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 2048 ppr RHI 503 56, HS Ø12 mm 5 Vdc TTL Cable Radial 1,5 m 2500 ppr 56 Industrial Shaft Encoders with Operation with 1,5 m Radial Cable Outlet 63 515398-20 515398-06 515398-50 515398-11 515398-29 515398-28 Description RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 500 ppr RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 1000 ppr RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 1024 ppr RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 2000 ppr RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 2048 ppr RSI 503 63, Synchro Ø6 mm HTL Cable Radial 1,5 m 2500 ppr Industrial Shaft Encoders with 5 Vdc Operation with 1,5 m Radial Cable Outlet 63 513678-04 513678-14 513678-07 513678-19 513678-06 513678-13 Description RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 500 ppr RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 1000 ppr RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 1024 ppr RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 2000 ppr RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 2048 ppr RSI 503 63, Synchro Ø6 mm 5 Vdc TTL Cable Radial 1,5 m 2500 ppr 7

Ruggedized Hollow Shaft Incremental Encoder - 500 Series 56 57 58 59 Short Description: General Information Ÿ Ÿ Ÿ Ÿ 6 Short-circuit protected outputs IP67 at housing, IP 66 at shaft inlet 5 Vdc or 9...30 Vdc Shock and vibration protected Suitable Applications: Ÿ Standard to demanding industrial applications Encoder Data Type Operating temperature Ingress protection class At shaft inlet Vibration (55 to 2000 Hz) Shock (6ms) Cover Material Accuracy and Resolution Line count Dividing error Channel separation Measuring steps RHI 503-40 C.. +70 C IP 67 according to IEC 60529 IP 66 according to IEC 60529 2 < 300 m/s according to IEC 60068-2-6 (1) 2 < 2000 m/s according to IEC 60068-2-27 Aluminium, coated and chromated or anodized 1..5000 ppr ± 50 el 90 ± 25 el 4 x Line count 5001..10 000 ppr ± 90 el 90 ± 45 el Connection Option Electrical Option Cable Function Colour PIN S00 SOO inverted S90 S90 inverted Sref Sref inverted + E Volt 0 Volt STATUS Housing Yellow Black Green White Brown Violet Red Blue Grey Shield 12 pin EML 5 6 8 1 3 4 12 10 7 Chassis Power supply 5 V ± 10% 9-30 V Polarity protected No Output signals Short circuit protected Current consumption Max consumption Output load (Max) Out frequency (Max) Uhigh at 10 ma load Ulow at 10 ma load Cable length (Max) STATUS output High level Low level 1 TTL 45 ma 75 ma ± 20 ma 300 khz > 3.0 V < 0.4 V 50 m Encoder OK Warning / Failure 1 TTL output to the RS-422 standard when differential transmission is used HTL 50 ma at 24 Vdc 75 ma ± 40 ma 300 khz > +EV - 2.0 V < 1.15 V 200 m @ 50k Hz Encoder OK Warning / Failure RS-422 25 ma at 24 Vdc 40 ma ± 20 ma 300 khz > 3.0 V < 0.4 V 1 km (TIA/EIA-422-B) Encoder OK Warning/Failure Output Signals Ordering Information (Tick your Choice) S00 S00 S90 S90 S REF S REF Clockwise, seen from shaft side 360 el.(1 period) 90 el.(channel separation) Type Flange Shaft (1) Electronics Connection Connection direction Line count Supply Output HS THS RHI 503 56, HS Ø8mm 5Vdc TTL Cable Axial/Radial Radial 1..5000 57, THS Ø10mm 9-30Vdc HTL 8 pin M12 Axial/Radial Radial 5001..10000 58, HS Ø12mm RS-422 12 pin EML Axial/Radial Radial 59, THS Ø14mm 8 pin PT Axial/Radial Radial 6 pin MS Axial (1) Possible combinations: 5 Vdc/TTL, /HTL or /RS-422 HS Holow-shaft THS Through going hollow-shaft Please specify line count and cable length when ordering Ordering example: RHI 503 58 Ø 10 5 Vdc 1024 ppr TTL 12 pin EML Radial 8

Ruggedized Solid Shaft Incremental Encoder - 500 Series Short Description: 51 63 61 52 General Information Ÿ Ÿ Ÿ Ÿ Ÿ 6 Short-circuit protected outputs IP67 at housing, IP 66 at shaft inlet 5 Vdc or 9...30 Vdc Shock and vibration protected Robust housing for harsh environments Suitable Applications: Ÿ Standard to demanding industrial applications Encoder Data Type Operating temperature Ingress protection class At shaft inlet Vibration (55 to 2000Hz) Shock (6ms) Cover Material Accuracy and Resolution Line count Dividing error Channel separation Measuring steps RSI 503-40 C.. +70 C IP 67 according to IEC 60529 IP 66 according to IEC 60529 2 < 300 m/s according to IEC 60068-2-6 (1) 2 < 2000 m/s according to IEC 60068-2-27 Aluminium 1..5000 ppr ± 50 el 90 ± 25 el 4 x Line count 5001..10 000 ppr ± 90 el 90 ± 45 el Connection Option Electrical Option Cable Function Colour PIN S00 SOO inverted S90 S90 inverted Sref Sref inverted + E Volt 0 Volt STATUS Housing Yellow Black Green White Brown Violet Red Blue Grey Shield 12 pin EML 5 6 8 1 3 4 12 10 7 Chassis Power supply 5 V ± 10% 9-30 v Polarity protected No 1 Output signals TTL HTL Short circuit protected Current consumption Max consumption Output load (Max) Output frequency (Max) Uhigh at 10 ma load Ulow at 10 ma load Cable length (Max) STATUS output High level Low level 45 ma 75 ma ± 20 ma 300 khz > 3.0 V < 0.4 V 50m Encoder OK Warning / Failure 1 TTL output to the RS-422 standard when differential transmission is used 50 ma at 24 Vdc 75 ma ± 40 ma 300 khz > +EV - 2.0 V < 1.15 V 200 m @ 50 khz Encoder OK Warning / Failure RS-422 25 ma at 24 Vdc 40 ma ± 20 ma 300 khz > 3.0 V < 0.4 V 1 km (TIA/EIA-422-B) Encoder OK Warning/Failure Output Signals Ordering Information (Tick your Choice) S00 S00 S90 S90 S REF S REF Clockwise, seen from shaft side 360 el.(1 period) 90 el.(channel separation) Type RSI 503 Flange Shaft (1) Electronics Connection Connection direction Line count Supply Output HS 51, LI58 Ø8 round 5 Vdc TTL Cable 2 Axial /Radial 1..5000 63, Synchro Ø6 with face HTL 8 pin M12 2 2 Axial /Radial 5001..10000 61, Clamping Ø10 round RS-422 12 pin EML 2 2 Axial /Radial 52, LL68 Ø10 with face 8 pin PT 2 Axial/Radial 6 pin MS 2 Axial 10 pin MS 2 Axial/Radial (1) Possible combinations: 5 Vdc/TTL, /HTL or /RS-422 (2) Not available on flange option - 52, LL68 HS Hollow-shaft THS Through going hollow-shaft Please specify line count and cable length when ordering Ordering example: RSI 503 63 Ø 6ro 5 Vdc 1024 ppr TTL 8 pin PT Axial 9

Flat Pancake Design - 700 Series Compact Design The 700 series is compact and robust. The series features large hollow shafts up to 25.4 mm, which means that it can often be mounted directly on the motor s shaft without an intermediate adapter for shaft reduction. This characteristic contributes to minimising the overall build length, and at the same time facilitates mounting. Despite its compactness, the encoder is designed for the tough environments where a typical Leine & Linde product is used. Mechanically it features a dual set of heavy duty bearings and a well-encapsulated enclosure. Electronically it is built for reliability in tough environments where it is subjected to vibrations and electrical disturbances. Resolution Incremental Pulses Per Revolution: 10 ppr 50 ppr 100 ppr 150 ppr 200 ppr 256 ppr 300 ppr 360 ppr 400 ppr 500 ppr 512 ppr 600 ppr 720 ppr 800 ppr 900 ppr 1000 ppr 1024 ppr 1200 ppr 1250 ppr 1800 ppr 2000 ppr 2048 ppr 2400 ppr 2500 ppr 3072 ppr 4000 ppr 4096 ppr 4800 ppr 5000 ppr 6350 ppr 10000 ppr Electronics Output Interfaces (Supply Voltage): HTL (5-30 Vdc) HCHTL () T T L ( 5 V d c ) RS422 () 1 Vpp (5 Vdc) Flange Torque bracket (120º) Tether arm (with insulation) Shaft Through-Going Hollow Shafts with Insulation: Ø25 mm Ø20 mm Ø16 mm Ø14 mm Ø12 mm Connection M23 connector 12 pin (CCW) MS connector 10 pin MS connector 7 pin Cable (free length) 10

Flat Pancake Design - 700 Series Mechanics Model CHI 703 with Torque Bracket and 10 Pin MS Connector Model CHI 703 with Tether Arm and 12 Pin M23 Connector Model CHI 703 with Tether Arm and 7 Pin MS Connector Model CHI 703 with Tether Arm and 7 Pin MS Connector Model CHI 703 with Torque Bracket and 12 Pin M23 Connector 11

Flat Pancake Design - 700 Series Electronics Key Code Square Wave Signals CHI 703 S00 S00 C H I 7 0 3-0 - S90 S90 S REF S REF Model 703 = Standard Shaft 12 = Ø12 mm through-going hollow shaft 14 = Ø14 mm through-going hollow shaft 16 = Ø16 mm through-going hollow shaft 20 = Ø20 mm through-going hollow shaft 25 = Ø25 mm through-going hollow shaft 01 = Ø1 inch through-going hollow shaft 58 = Ø5/8 inch through-going hollow shaft 34 = Ø3/4 inch through-going hollow shaft Sine Wave Signals Sine waves are an alternative form of output signal. The analogue signal produces a unique amplitude for each position on the wave, allowing interpolation and very high resolutions. The interface 1 Vpp is often used in safety-critical applications where detection are required of extremely small movements. Flange 2 = Torque bracket 120 9 = Tether arm with insulation Electronics 1 = TTL (supply 5 Vdc, output 5 Vdc) 5 = HCHTL (supply, output ) 6 = HTL (supply 5-30 Vdc, output 5-30 Vdc) 7 = RS422 (supply, output 5 Vdc) 9 = Sinusoidal 1 Vpp (supply 5 Vdc, output 1 Vpp) Connection 2 = M23 connector 12 pin (CCW) 7 = MS connector 7 pin 8 = MS connector 10 pin 9 = Cable (specify length upon order) Resolution 10, 50, 100, 150, 200, 256, 300, 360, 400, 500, 512, 600, 720, 800, 900, 1000, 1024, 1200, 1250, 1800, 2000, 2048, 2400, 2500, 3072, 4000, 4096, 4800, 5000, 6350, 10000 ppr Sinusodial 1 Vpp: 1024, 2048 ppr Other resolutions available upon request. Output Interfaces (Supply Voltage): Interface Supply Output signal Suitable for Max frequency Max cable length TTL RS422 HTL HCHTL 5 Vdc 5 Vdc Low frequencies over short cables 200 khz 50 m at 50 khz 5 Vdc High frequencies over long cables 200 khz 1000 m at 200 khz 5-30 Vdc 5-30 Vdc High frequencies over medium-length cables 200 khz 100 m at 100 khz Medium frequencies over long cables 200 khz 350 m at 100 khz 12

Mill Duty Encoders - 800 Series Quality Into Every Detail Enclosure Robust cover with ingress protection class IP67 for protection against dust and liquids. Verified for use in salt water environments. Model available with ATEX/IECEx certification for hazardous environments. Shaft and Flange Robust shaft sealing verified for IP66. O-ring for tight sealing of the hollow shaft to its mating shaft. Hollow shafts for fixing with an axial screw. Shaft dimensions: Ø12 mm, Ø16 mm, Ø17 mm taper. Solid shaft Ø11 mm with key nut, and B10 Euro flange, for fixing with a shaft coupling. Throughgoing hollow shaft with dimensions Ø 25 mm or Ø1 inch. Bearings Insulated peek insert to protect the bearings from shaft currents. Model available with ceramic bearings for increased insulation and prolonged lifetime. Heavy duty bearings allow the encoder to be placed in the most demanding environments, where it can be subjected to shock and vibrations daily without losing quality or accuracy. and two galvanically insulated electronic circuits. The dual output signals can be used in two separate systems for different functions, or for achieving redundant signals. Programmable Speed Switch The 800 series can be bought with Overspeed, which is the Leine & Linde speed switch solution with four programmable relays for the settings of your choice. Built-in Condition Monitoring Models can be equipped with the advanced diagnostic system ADS Classic or ADS Online, which can monitor the basic encoder functions and ambient parameters. Avoid all unforeseen breakdowns! Relevant Certifications Models available certified for use in hazardous areas, ATEX/IECEx zone 1/21, or 2/22. Functional safety certified encoders available up to risk level SIL2 and PLd, category 3. Shock, vibrations, and temperature resistance High accuracy code discs and robust electronics verified for powerful shocks, vibrations, and extreme temperatures. Stable and Easy Mounting Torque bracket available in a variety of orientations, for fixing of the torque arm. Separate back cover for connection of cable wires to screw terminals. Ample space for easy handling when connecting the cables. M23 connector or pre-mounted cable with or without flying connector available. Protected Against Electronic Interference Short-circuit protection and polarity protection as standard. Overvoltage protection for protection against voltage peaks on the supply, for example due to lightning strokes. Earthing strap to conduct currents away from the encoder cover. Resolution Wide range of different pulse rates available from 1 to 10 000 ppr. Output Signals Square wave signal output with 6 channels for differential transmission and reference pulse for relative position. Available with a big number of output signals according to market standards, like HTL, TTL, RS422, or 1 Vpp, as well as High Current HTL for transmission over long cables. Dual output models are available, with double scanning sensors 13

Mill Duty Encoders - 800 Series Mechanics - Mill Duty Encoders 850 Solid Shaft Encoder with B10 Euro Flange. 861 Hollow Shaft Encoder. 855 Dual solid shaft encoder with B10 Euro flange. Redundant scanning sensors and two separate electronic circuits with galvanically insulated outputs. 865 Dual hollow shaft encoder. Redundant scanning sensors and two separate electronic circuits with galvanically insulated outputs. Ceramic bearings available as special option. 14

Mill Duty Encoders - 800 Series Hollow Shaft Heavy Duty Encoders 751282-09-861 750729-03-861 751282-02-861 750729-12-861 750901-01-861 750901-03-861 Pulse Rate 1024 1024 2048 2048 2048 1024 Supply Voltage Other Resolutions Available on Request ADS None None None None Shaft Size 12 mm 16 mm 12 mm 16 mm 16 mm 16 mm Available with Shaft Heavy Duty Encoders 750728-02 750728-11 1066902-02 1066902-03 Pulse Rate 1024 2048 1024 2048 Supply Voltage Other Resolutions Available on Request ADS No No Shaft Size 11 mm with B10 Tacho Flange 11 mm with B10 Tacho Flange 11 mm with B10 Tacho Flange 11 mm with B10 Tacho Flange Available with 15

Absolute Encoders - Industrial Duty - 600 Series Robustness in its Essence Sustainable Market leading vibration and shaft load resistance. Encapsulation Ingress protection class IP67 for protection against dust and liquids. Verified for use in salt water environments. Resolution High sing-leturn and multi-turn resolution versions of the encoder available. Shaft and Flange Ÿ Hollow shaft, either blind or through-going for fixing with a stator coupling. Shaft dimension: Ø12 mm. Ÿ Solid shaft, either round or face for fixing with a flange of either synchro or clamping type. Shaft dimensions: Ø6 mm, Ø10 mm and Ø12 mm. Material Ÿ Anodized aluminium or Ÿ Stainless steel A4, AISI 316L/EN 1.4404 Explosion-Protection (Optional) II 3 G Ex ec IIC T4 Gc X II 3 D Ex tc IIIC T135C Dc X Connection Ÿ M23 or M12 connectors Ÿ Cable glands or pre-mounted cable 16

Absolute Encoders - Industrial Duty - 600 Series Mechanics - Industrial Duty Encoders ISA 608 with Synchro Flange and Pre-Mounted Cable ISA 638 with Clamping Flange and 3 x M12 Connector IHA 608 with Stator Coupling and M23 Connector IHA 608 with Stator Coupling and 3 x Cable Gland ISA 608 with Clamping Flange and 1 x M12 Connector 17

Absolute Encoders - Industrial Duty - 600 Series Profibus DP 884765-01 884373-01 Description IHA 608 58, HS Ø12 mm 9-36 Vdc SPB M12 Radial 25 bit ISA 608 61sp Ø10 mm 9-36 Vdc SPB M12 Radial 25 bit IHA Profinet 810339-01 810327-01 Description IHA 608 58, HS Ø12 mm 9-36 Vdc ProfiNet M12 Radial 25 bit ISA 608 61sp Ø10 mm 9-36 Vdc Profinet M12 Radial 25 bit DeviceNet 823669-01 823667-01 Description IHA 608 58, HS Ø12 mm 9-36 Vdc SCD Cable Radial 25 bit ISA 608 61sp Ø10 mm 9-36 Vdc SCD M12 Radial 25 bit ISA SSI 816012-01 821383-01 Description IHA 608 58, HS Ø12 mm 9-36 Vdc SSG 17 pin EML Radial 25 bit ISA 608 61sp Ø10 mm 9-36 Vdc SSG 17 pin EML Radial 25 bit EnDat 818634-01 810206-01 Description IHA 608 58, HS Ø12 mm 9-36 Vdc SENB 17 pin EML Radial 25 bit ISA 608 61sp Ø10 mm 9-36 Vdc SENB 17 pin EML Radial 25 bit 18

Extra Heavy Duty Absolute Encoders - 900 Series Absolute Confidence 1. Lifetime Reliability Year After Year The most important factor when it comes to encoder lifetime is the size of the bearings. They will rotate millions of revolutions during many years in operation. By using bearings twice the size compared to similar encoders on the market, the 900 series is made to serve a long life in operation. Reliability is to know that the encoder will do its job, always. 2. Temperature and Moisture Full Performance in all Environments The 900 series is designed to perform in the most demanding environments. Some encoders end up in outdoor applications where they must withstand intense cold during the winter, while others are installed in metal processing applications where they are exposed to extreme heat. Moisture is another climate factor, whether it be rain and snow or hot water and steam. In some applications the encoder is exposed to dramatic fluctuations where the temperature may change in seconds. Withstanding this is a matter of details and caring for each component of the encoder. The mechanics are produced with strict demands on tolerances to offer a perfect fi t. The cover is treated with an anodization to keep a smooth surface also when exposed to salt water. The shaft sealings are specified to at least IP66 even after years in operation. The bearings are selected with a grease that withstands temperatures well above the limits of the encoder. Care is given when selecting each specific electronic component to be sure it fulfills the stringent requirements. When the full design is put together it is tested to its limits, in order to be sure that everything performs together. Once again it s about reliability to know that it will work even at exceptional conditions. To suit different shaft sizes, the 900 series offers both hollow shafts and solid shafts in several different dimensions and with special features such as taper shaft, keyway or key nut. Leine & Linde offers interfaces for electronic integration, whether it is serial, over a fieldbus or as incremental pulses. If required, combinations of absolute and incremental outputs from the same unit are possible. 5. Installation Handling the Encoder Thanks to the compactness of the inductive scanning, the bearings are twice the size compared to similar heavy duty encoders on the market. All without increasing the total size of the encoder. This will make the 900 series fi t, without having to redesign the installation where another heavy duty encoder has been used. The 900 series is available with connectors or pre-mounted cables. Or, if preferred, cable glands for terminal connection on site easily accessed on the back of the encoder and with the encoder s internal parts always enclosed by a protection cover. For more information, see code keys on page 12-13. Bearing Scale 1:1 3. Vibration and Shock Designed to Endure Market standard encoders have their most sensitive point in the optical scanning components for detection of shaft position. This may be a problem in heavy duty applications like metal processing where an encoder is subject to high continuous vibrations and instant shocks. Thanks to the inductive scanning principle a solution with top-notch robustness without compromising on resolution and accuracy is achieved. The 900 series is based on components which are extra resistant to harsh treatment and provides a solution where robustness is in its essence. At the same time it offers a high resolution output of 19 bit single-turn and 16 bit multi-turn. 4. Flexibility in Design Easy to Integrate To fit the machine, a big variety of interfaces, both mechanical and electrical, are provided. 19

Extra Heavy Duty Absolute Encoders - 900 Series Mechanics - Absolute Encoders Hollow Shaft with 2 x M12 Connectors Keywayed Hollow Shaft with 1 x M23 Connector Euro-Flange with 3 x M12 and 1 x M23 Connectors Taper Hollow Shaft with 1 x M20 Cable Gland Euro-Flange with 3 x M16 Cable Glands Keywayed Hollow Shaft with 3 x M16 and 1 x M20 Cable Glands 20

Extra Heavy Duty Absolute Encoders - 900 Series Electronics Profibus The 900 series supports the encoder profiles 3.062 (DVP0) which contains functions such as preset, scaling and code sequence. Profinet PROFINET can in general be described as Ethernet-based PROFIBUS DP communication and contains functions such as preset, scaling, code sequence, slave-to-slave and isochronous data exchange. EtherCat With no underlying subsystems EtherCAT has a fast Industrial Ethernet technology and is therefore suitable in applications where cycle time down to 31,25 μs is required. The encoder interface supports CANopen over EtherCAT according to CiA 301 and the device profile CiA 406. With objects for position value, speed, and acceleration, the encoder provides a wide usability for fast EtherCAT control systems. EtherNet/IP conformance tested TM EtherNet/IP is an Industrial Ethernet network that combines standard Ethernet technologies with Common Industrial Protocol, CIP. The EtherNet/IP encoders support the device profile 0x22 with available features such as preset, velocity, speed and acceleration limits, code sequence and scaling. DRIVE-CLiQ DRIVE-CLiQ is an Ethernet-based protocol from Siemens. With a speed of 100 Mbit/s and a cycle time of 31.25 μs, DRIVE-CLiQ has the performance required for the most demanding applications. Components with DRIVE-CLiQ are automatically configured with each other since every component has an electronic label. The encoders are supplied with specially adapted connectors, with power supply and data in the same connector. SSI Synchronous Serial Interface is a digital point-to-point interface. It provides unidirectional communication at speeds up to 1.0 MHz by the use of only four wires. EnDat 2.2 The EnDat 2.2 interface is a digital, bidirectional interface for encoders. It is capable of transmitting position values from absolute encoders, as well as reading and updating information stored in the encoder. Output Interfaces (Supply Voltage): Interface Supply Output signal Suitable for Max frequency Max cable length TTL RS422 HCHTL 5 Vdc 5 Vdc Low frequencies over short cables 200 khz 50 m at 50 khz 5 Vdc High frequencies over long cables 200 khz 1000 m (TiA/EIA-422-B) Medium frequencies over long cables 200 khz 350 m at 100 khz Resolution The 900 series is available with high resolutions for absolute position data up to 19 bit single-turn and 16 bit multi-turn. Depending on the communication protocol the receiving electronics may have limitations on how much data it can handle. For incremental outputs any resolution may be selected between 1 and 32768 PPR. 21

Extra Heavy Duty Absolute Encoders - 900 Series Key Code Absolute Encoder Models 901 and 903 9 0 0 0 Model 3 = Standard 1 = Extra robust (ceramic bearings) Shaft 2 = Hollow shaft 12 mm 6 = Hollow shaft 16 mm 7 = Hollow shaft 17 mm taper (only model 901) 0 = Hollow shaft 20 mm with keyway (only model 901) 1 = Solid shaft 11 mm with key nut 4 = Solid shaft 14 mm with key nut Flange 0 = No torque bracket (hollow shaft) 2 = Torque bracket 120 (hollow shaft) 3 = Torque bracket 330 (hollow shaft) 8 = Euro-fl ange B10 (solid shaft) Output Electronics 111 = SSI singleturn 112 = SSI singleturn 114 = SSI singleturn 121 = SSI multiturn 122 = SSI multiturn 124 = SSI multiturn 212 = EnDat 2.2 singleturn 214 = EnDat 2.2 singleturn 222 = EnDat 2.2 multiturn 224 = EnDat 2.2 multiturn 311 = PROFIBUS singleturn 315 = PROFIBUS singleturn 321 = PROFIBUS multiturn 325 = PROFIBUS multiturn 331 = PROFIBUS multiturn 335 = PROFIBUS multiturn 415 = DRIVE-CLiQ singleturn 416 = DRIVE-CLiQ singleturn 425 = DRIVE-CLiQ multiturn 426 = DRIVE-CLiQ multiturn 515 = EtherCAT 525= EtherCAT 615 = PROFINET 625 = PROFINET 715 = EtherNet/IP 725 = EtherNet/IP Resolution 13 bit with HTL 2048 ppr 13 bit with HTL 2048 ppr 13 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 19 bit with 1 Vpp 32 ppr 19 bit with 1 Vpp 32 ppr 19 + 16 bit with 1 Vpp 32 ppr 19 + 16 bit with 1 Vpp 32 ppr 19 bit 19 bit 19 + 12 bit 19 + 12 bit 15 + 16 bit 15 + 16 bit 19 bit 19 bit 19 + 15 bit 19 + 15 bit 19 bit 19 + 16 bit 19 bit 19 + 16 bit 19 bit 19 + 16 bit Connection Type 1 x M20 cable gland Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin 1 x M20 cable gland Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin 3 x M16 cable gland 3 x M16 cable gland 3 x M16 cable gland 1 x M12 connector 1 x M12 connector + 1 x temp input for connection with external temperature sensor 1 x M12 connector 1 x M12 connector + 1 x temp input for connection with external temperature sensor 22

Extra Heavy Duty Absolute Encoders - 900 Series Key Code Combination Encoder Models 921 and 923 9 2 Model 3 = Standard 1 = Extra robust (ceramic bearings) Shaft 6 = Hollow shaft 16 mm 7 = Hollow shaft 17 mm taper (only model 921) 0 = Hollow shaft 20 mm with keyway (only model 921) 1 = Solid shaft 11 mm with key nut 4 = Solid shaft 14 mm with key nut Flange 0 = No torque bracket (hollow shaft) 2 = Torque bracket 120 (hollow shaft) 3 = Torque bracket 330 (hollow shaft) 8 = Euro-fl ange B10 (solid shaft) Absolute Output Electronics 111 = SSI singleturn 112 = SSI singleturn 114 = SSI singleturn 121 = SSI multiturn 122 = SSI multiturn 124 = SSI multiturn 311 = PROFIBUS singleturn 315 = PROFIBUS singleturn 321 = PROFIBUS multiturn 325 = PROFIBUS multiturn 331 = PROFIBUS multiturn 335 = PROFIBUS multiturn 615 = PROFINET 625 = PROFINET 715 = EtherNet/IP 725 = EtherNet/IP Resolution 13 bit with HTL 2048 ppr 13 bit with HTL 2048 ppr 13 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 13 + 12 bit with HTL 2048 ppr 19 bit 19 bit 19 + 12 bit 19 + 12 bit 15 + 16 bit 15 + 16 bit 19 bit 19 + 16 bit 19 bit 19 + 16 bit Connection Type 1 x M20 cable gland Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin 1 x M20 cable gland Pre-mounted cable, specify length xx m 1 x M23 connector 17 pin 3 x M16 cable gland 3 x M16 cable gland 3 x M16 cable gland Incremental output Electronics (Supply / Output) 91 = HCHTL (9-30 V / 9-30 V) 92 = HCHTL (9-30 V / 9-30 V) 93 = RS422 (9-30 V / 5 V) 94 = RS422 (9-30 V / 5 V) 95 = TTL (5 V / 5 V) 96 = TTL (5 V / 5 V) Connection Type 1 x M23 connector 12 pin 1 x M20 cable gland 1 x M23 connector 12 pin 1 x M20 cable gland 1 x M23 connector 12 pin 1 x M20 cable gland Incremental Resolution 1-32768 ppr Other options may be available upon request. 23

Safety for Drives - FSI 800 SIL2/PLd Certified Heavy Duty Incremental Encoders Achieve functional safety SIL2 and PLd category 3 in accordance with EN ISO 13849-1 with the FSI 800 series from Leine & Linde. These functionally safe heavy duty incremental encoders are made with a slip-free shaft or hollow-shaft construction. Simplify Machine Design The square wave signals are monitored internally in the FSI 800 series encoders. If faults are detected, the encoder signals will enter safe state, or indicate faults via the status output. Thanks to the integrated safety solution, a second encoder or sensor for redundancy will no longer be needed for a functionally safe installation. This will save space and reduce the need for cables, which even further decreases the system s vulnerability to environmental factors, disturbances, wear and tear. The FSI 800 series fulfills the mechanical fault exclusion requirement due to the slip-free solution for the shaft installation. The FSI 862 hollow shaft encoder contains a guiding pin which requires a matching adapter shaft to be mounted. The FSI 850 shaft encoder has a key nut on to the shaft ensuring safe mounting in couplings with keyway. Handling Cables Over 300 Metres Up until now, the only single encoder solution available on the market has been using a 1Vpp signal, which is not appropriate in these harsh environments, due to its weak signal of 5 Vdc. Therefore, the solution is the FSI 800 series with HCHTL signals for, which also meets the demand for long cables (over 300 metres). This is perfectly designed for critical applications such as those in the steel and the paper industry, where production runs for 24 hours per day, seven days a week, protected in accordance with the requirements for SIL2/PLd, category 3, machinery directive in related C-standard. 24

Safe Motion - FSI 900 FSI 900 More Than a Safe Absolute Encoder Make sure that speed, acceleration, and end positions keep within safe limits in a functionally safe manner, certified in accordance with SIL2/PLd category 3. The FSI 900 is more than an absolute encoder, proving how Leine & Lindes technical solutions focus on the user conditions and needs. FSI means Functional Safety Integrated. FSI 900 monitors rotating movement, and acts immediately to make sure none of the userconfigured limits will be exceeded. Together with the integrated failsafe relay outputs, the FSI 900 is more than an encoder. It s a safety system all in one package. The FSI 900 is mounted on a motor shaft, winch drum, drill, roll drum, wheel or wind turbine. To achieve the safety functions required in its application, the FSI is based on an absolute encoder. The safe absolute scanning reads out unique values for every position, not even losing its position when the machine is restarted. Movement cannot go unnoticed. FSI Monitor Simplifies Installation The FSI 900 is used for defining and monitoring safe speed, end limits, acceleration, or standstill. Safe limits are configured by a simple and clear process in the software, FSI Monitor. The configuration is made on site by the safety coordinator, so that risk for errors is minimized. The installation is facilitated by the fact that no separate components need manual configuration, thanks to the product s failsafe relay outputs. The built-in programmability makes the product extremely flexible, as the safe functions can be set up all according to the needs of the user. Part of the Control System But Manages Safe Functions Separately Up until now, the only single encoder solution available on the market has been using a 1Vpp signal, which is not appropriate in these harsh environments, due to its weak signal of 5 Vdc. Therefore, the solution is the FSI 800 series with HCHTL signals for, which also meets the demand for long cables (over 300 metres). This is perfectly designed for critical applications such as those in the steel and the paper industry, where production runs for 24 hours per day, seven days a week, protected in accordance with the requirements for SIL2/PLd, category 3, machinery directive in related C-standard. 25

1000 Series Equipped for Extreme Environments In many applications within metal, mining and marine industries the demands on the equipment is exceptional. The machines are subject to exposure from mechanical loads, vibrations and shock in an environment of dust, liquids and high temperatures. They handle advanced machinery with utmost safety demands and economical value failure may never be an option. Such conditions require components of extraordinary durability, ready to meet extreme challenges in the field. 26

LEINE LINDE - Encoder Accessories Accessories 01300320+01300330 DZ260 GV210 FU252 00208002 00208014 00208010 00208015 01209153 ATITORQ 01209032 01209140 01209141 Description Optical transmission incremental encoders High electromagnetic disturbances Transmission of signals over long distances Where galvanic insulation is required Speed Monitor to control Overspeed, Underspeed, Standstill and Direction of Rotation Incremental encoder switch and splitter of encoder signals Converter frequency to Analog/Serial for speed signals Measuring wheel with 500 mm circumference and PU-Surface Measuring wheel with 500 mm circumference and burled rubber surface Measuring wheel with 200 mm circumference and PU-Surface Measuring wheel with 200 mm circumference and burled rubber surface Spring-loaded bracket for mounting shaft encoder with Synchro flange to measuring wheel For hollow shaft encoders. Isolated torque arm with adjustable bar For Hollow Shaft encoder. Spring loaded for industrial duty encoders Insulating bore reducer to reduce 12 mm hollow shaft encoder to 10 mm. Made from PEEK. Insulating bore reducer to reduce 14 mm hollow shaft encoder to 12 mm. Made from PEEK. Connectors Profibus 586299-02 586238-01 586281-01 586287-01 584398-01 584401-01 Profinet 586299-02 586238-01 586243-01 584404-01 Devicenet 586293-01 586299-01 584412-01 584417-01 SSI/EnDat 01209085 Description Supply M12 4 pin Female A-Coded Connector Supply M12 4 pin Female A-Coded Connector with 5m Open Ended Cable Bus M12 5 pin Male B-Coded Connector Bus M12 5 pin Female B-Coded Connector Bus M12 5 pin Male B-Coded Connector with 5m Open Ended Bus M12 5 pin Female B-Coded Connector with 5m Open Ended Supply M12 4 pin Female A-Coded Connector Supply M12 4 pin Female A-Coded Connector with 5m Open Ended Cable Bus M12 4 pin Male D-Coded Connector Bus M12 4 pin Male D-Coded Connector, Male-Male 5m cable Bus M12 5 pin Male A-Coded Connector Bus M12 5 pin Female A-Coded Connector Bus M12 5 pin Male A-Coded Connector with Open Ended Cable Bus M12 5 pin Female A-Coded Connector with Open Ended Cable M23 17 pin Female Connector 27