Ifm Electronic GMBH Sensors, Networking and Control Technology For Automation Training Manual

ifm electronic gmbh
Sensors, networking
and control technology
for automation
Training manual
Shaft Encoders
Training manual for shaft encoders (September 2003)
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ifm electronic gmbh, VTD-STV department, Teichstr. 4, 45127 Essen, phone: +49 201/2422-0,
Internet: http://www.ifm-electronic.com
Contents:
1 Introduction........................................................................................................................ 6
1.1 Measuring systems........................................................................................................... ....... 6
1.1.1 Shaft encoders as a standard means of measuring .....................................................................6
1.2 Applications for shaft encoders ............................................................................................. .. 6
1.2.1 Rotational movement.................................................................................................................7
1.2.2 Linear movement .......................................................................................................................7
1.3 Application examples of shaft encoders................................................................................... 7
1.4 Digital signals............................................................................................................. ............. 8
1.5 Measuring device and measuring system ................................................................................. 9
2 Layout .............................................................................................................................. 10
2.1 On the contents ............................................................................................................. ....... 10
3 Techniques and methods of electronic linear measurement ............................................... 11
3.1 Analogue systems ............................................................................................................ ..... 11
3.1.1 Potentiometers.........................................................................................................................11
3.1.2 Resolvers ..................................................................................................................................11
3.1.3 Inductive principle ....................................................................................................................12
3.1.4 Magnetic principle ...................................................................................................................12
3.1.5 Capacitive principle ..................................................................................................................13
3.2 Digital systems ...................................................................................................................... 13
3.2.1 Mechanical shaft encoders .......................................................................................................13
3.2.2 Oscillator sensors .....................................................................................................................14
3.2.3 Inductive system.......................................................................................................................14
3.2.4 Photoelectric shaft encoders ....................................................................................................14
4 Shaft encoders of ifm electronic........................................................................................ 16
4.1 DIADUR method ............................................................................................................... .... 16
4.2 Shaft encoder types of ifm electronic..................................................................................... 17
5 Shaft encoders.................................................................................................................. 18
5.1 Incremental shaft encoders.................................................................................................. .. 18
5.1.1 Shape and design.....................................................................................................................18
5.1.2 Coded disc ...............................................................................................................................19
5.1.3 Resolution - mechanical ...........................................................................................................20
5.1.4 Signal generation .....................................................................................................................20
5.1.5 Pulse generation and analogue signals .....................................................................................23
5.1.6 Wiring of an incremental encoder ............................................................................................27
5.1.7 Detection of the direction of rotation for the direction of counting..........................................28
5.1.8 Pulse multiplication ..................................................................................................................29
5.2 Absolute shaft encoders..................................................................................................... ... 30
5.2.1 Resolution ................................................................................................................................32
5.2.2 Singleturn shaft encoders.........................................................................................................32
5.2.3 Multiturn shaft encoders ..........................................................................................................34
5.2.4 Code types...............................................................................................................................35
5.3 Comparison of absolute shaft encoders and incremental shaft encoders................................ 39
5.4 Data transmission ........................................................................................................... .......40
5.4.1 SSI interface on the shaft encoder ............................................................................................40
5.4.2 SSI interface programming via software ...................................................................................43
5.4.3 SSI controller ............................................................................................................................44
5.4.4 Profibus-DP interface................................................................................................................46
5.5 Accuracy of the shaft encoder ............................................................................................... 48
5.5.1 Dividing error ...........................................................................................................................49
5.5.2 Mark-to-space ratio..................................................................................................................49
5.5.3 Phase difference .......................................................................................................................49
6 Mechanical design ............................................................................................................ 51
6.1 Solid shaft encoders ........................................................................................................ ......51
6.1.1 Flange types for solid shaft encoders ........................................................................................52
6.2 Hollow shaft encoders ....................................................................................................... ....54
6.2.1 Mounting of hollow shaft encoders..........................................................................................55
7 Electrical connection ......................................................................................................... 56
7.1 Connection cable ............................................................................................................ ......56
7.2 Connector ................................................................................................................... ..........57
7.2.1 Sockets/coupling ......................................................................................................................58
7.3 Laying the cable ............................................................................................................ ........59
7.4 Earthing and screening ...................................................................................................... ....59
8 Mechanical data ............................................................................................................... 60
8.1 Maximum mechanical rotational speed ..................................................................................60
8.1.1 Mechanical rotational speed of the shaft encoder . ...................................................................60
8.2 Shaft load.................................................................................................................. ............61
8.3 Shock resistance and vibration resistance ...............................................................................62
8.4 Housing material ............................................................................................................ .......62
8.5 Protection rating........................................................................................................... .........62
8.6 Operating temperature ....................................................................................................... ...62
9 Electrical data ................................................................................................................... 64
9.1 Voltage supply.............................................................................................................. .........64
9.2 Voltage supply via the external evaluation electronics ............................................................65
9.3 Sensor cables for encoders.................................................................................................. ...65
9.4 Current consumption ......................................................................................................... ...66
9.4.1 Light-emitting diodes (LEDs) .....................................................................................................66
9.5 Current rating of the signal outputs.......................................................................................6 7
9.6 Signal frequency............................................................................................................ ........67
9.6.1 Signal frequency and mechanical rotational speed ...................................................................67
9.6.2 Signal frequency and cable length............................................................................................68
10 Overview shaft encoders................................................................................................... 70
11 Operating instructions ...................................................................................................... 71
12 Data sheet........................................................................................................................ 72
13 Accessories....................................................................................................................... 74
13.1 Couplings for solid shaft encoders......................................................................................... 74
13.2 Angle flanges.............................................................................................................. .......... 76
13.3 Bearing block .............................................................................................................. .......... 76
13.4 Isolating adapter .......................................................................................................... ......... 77
13.5 Pinion and rack ............................................................................................................ ......... 77
13.6 Resilient base ............................................................................................................. ........... 78
13.7 Measuring wheel ............................................................................................................ ...... 78
13.8 Fastening clamp .................................................................................................................... 80
13.9 Pulse divider, pulse stretcher.................................................................................................. 80
13.9.1 Pulse divider .............................................................................................................................81
13.9.2 Pulse stretcher..........................................................................................................................81
14 Mounting of shaft encoders.............................................................................................. 82
15 Calculation examples ........................................................................................................ 84
15.1 Linear measurement.............................................................................................................. 84
15.2 Switching frequency and mechanical rotational speed ........................................................... 84
16 Handling of shaft encoders ............................................................................................... 85
17 Applications...................................................................................................................... 86
18 Annex............................................................................................................................... 89
18.1 Competitors................................................................................................................ .......... 89
18.2 Glossary of technical terms................................................................................................ .... 89
19 Type key ........................................................................................................................... 93
19.1 Examples of the use of the type key ...................................................................................... 94
20 List of figures .................................................................................................................... 95
21 Index ................................................................................................................................ 98
22 Source ............................................................................................................................ 100
1 Introduction
In all areas of technology production and test processes are automated to
an increasing extent. If only end stops or reference points are to be
monitored, inductive or capacitive proximity switches or photoelectric
sensors are the preferred choice.
1.1 Measuring systems

Tools of automation The mechanical movements of robot arms, linear slides, rotary tables or
slides often have to be controlled numerically. Measuring systems for
lengths, angles and partial steps provide feedback about these movements
to the controller.
1.1.1 Shaft encoders as a standard means of measuring

Encoders are needed if high precision and short measuring times are
required and if the processing of the information is to be carried out by
means of electronic control systems.
In the following especially angular and linear measurement will be
discussed. There is a variety of measuring methods which will be briefly
described below.
Reliable Shaft encoders are standard units for angular and linear measurement. In
many manufacturing and production processes they are indispensable as
reliable transducers or pulse pickups.
Shaft encoders are used where precise detection of lengths, positions,
rotational speed, and angles is required.
Function Shaft encoders transform mechanical movements into electrical signals.
Resistant Shaft encoders have shown excelle nt performance in various applications,

even in harsh environments with shock, dirt, changing temperatures and
vibration. They are very reliable and have a long life.
Versatile The photoelectric measuring principle enables high measuring accuracy as
well as inexpensive versatile solutions which are especially adapted to
automation technology.
1.2 Applications for shaft encoders

Typical applications of linear measurement systems are woodworking
machines, machine tools, robots and handling machines, textile machines,
electronic scales, plotters and printers from the IT area as well as test
equipment.
Training manual Shaft encoders Page 6 of 100

1.2.1 Rotational movement
Encoders can be used without a lot of mechanical work being required
wherever rotating machine parts are present. Flange, fixing holes and
grooves enable easy connection to the rotating part.
1.2.2 Linear movement

Nearly every linear movement is connected with a rotational movement, for
example a feed function with the rota tion of a drive shaft. Furthermore a
linear movement can easily be transformed into a rotational movement on
the shaft encoder by means of a measuring wheel or a rack with a toothed
wheel.
Therefore encoders are often used for linear measurement. To convert a
rotational angle into a distance a conversion factor is required which results
from the geometry of the device as well as any transmission ratio or gear
reduction.
1.3 Application examples of shaft encoders
Figure 1, Linear measurement and synchronous movement monitoring
Figure 2, Detection of rotational speed and angle measurement

Figure 3, Bending systems and X-Y-recorders drawing tables
Figure 4, Level measurement and radar/aerial systems
Figure 5, Industrial robots
1.4 Digital signals

The measured values of angles or distances are in most cases required in
digitised form so that they can be further processed in electronics connected
downstream, e.g. a plc.
For this reason the measurement is carried out digitally. The measuring
system in the form of a shaft encoder assigns a digital output value to the
analogue measured value as a length or an angle.
Thus the output value of the shaft encoder represents the measured
quantity in defined digital steps.
Most digital length and angle measuring systems are based on standards
with a periodic structure. By using different principles of physics periodical
electrical signals are generated from which the measured value is derived.

1.5 Measuring device and measuring system
Measuring device The measuring disc and detection system of the encoder are also called
measuring device, sensor, transducer or encoder. They convert lengths or
angles into electrical signals.
Measuring system A measuring system consists of the complete measuring chain. It may
consist for example of a measuring disc, the scanning unit, the interpolation
electronics, and a counter.
The electronics and the counter can be integrated as interface electronics in
the measuring device or the electronics connected downstream.
For angle measurement the coupling between the machine shaft and the
measuring device is to be regarded as part of the measuring system as well.
ifm offers two different types of unit for the measurement of angles or
lengths:
incremental encoders
absolute encoders
Both the absolute and the incremental shaft encoders have advantages
when compared with each other. They can also be combined in one unit.

2 Layout
For a better understanding a few explanations regarding terms used in the
text will be given to make reading the text and finding information easier.
Keywords Keywords are indicated in the margin on the left, referring to the topic to be
dealt with in the following section.
What does FAQ mean? This stands for Frequently Asked Questions. This term is used for example in
the context of modern electronic media. Almost everybody starting to deal
with a new unit faces the same questions. Sometimes an FAQ precedes a
section instead of a keyword. To differentiate them from simple keywords,
they are written in italics.
2.1 On the contents

This manual is to provide basic information on shaft encoders. Important
terms and correlations are explained, state-of-the-art technology is
described and technical data of ifm-units are presented. This results in the
following structure.
Characteristics of the shaft encoders Other types of shaft encoders which are used are mentioned. Then follows a
general overview of different encoder systems. This is to facilitate the
correct classification of shaft encoders and to decide where they can be
used and where they cannot be used. The knowledge of these features,
their advantages and disadvantages is a prerequisite for their successful use.
ifm-units Here the data of ifm shaft encoders are stated and explained. Mechanical
design, electrical features and use are described. Some units are presented.
Applications A few applications with illustrations are briefly described.
Annex This manual is to help you with your self-study as well. Therefore important
terms are briefly explained again in the glossary of technical terms. The
points which are essential for ifm sha ft encoders are described in detail in
the chapters preceding the glossary. The index will help to look them up.
The type key for the ifm-specific units is briefly presented as well.
Much success! Everybody should have these basics to be able to benefit from the chance
this product offers and to use shaft encoders successfully.

3 Techniques and methods of electronic
linear measurement
Electronic signal processing mainly differentiates between the processing of
analogue and digital signals. The information which is supplied by the
different measuring systems is also differentiated.
It is divided into analogue and digital systems/signal transmitters.
3.1 Analogue systems
3.1.1 Potentiometers
Potentiometers consist of a slide made of resistance material and a wiper
contact.
The wiper is only ever in contact with a small area of the resistance coil or
surface. The position of the wiper contact results in a variable resistance
value.
Areas of application: Level measurement, measurement of valve positions,
temperature measurement by means of a bimetal spring.
Figure 6, Potentiometer
3.1.2 Resolvers
Resolvers are synchro generators which precisely indicate the current
position of the rotor. They belong to the group of absolute encoders. The
design of the unit is similar to an electric motor or generator.
Applications are robots and the military area (aeroplanes, tanks).
S4
sine
S2
R4
rotor
S1
R2 cosine
S3
Figure 7, Resolver

3.1.3 Inductive principle
The units (well-known are the versions from the company Novotechnik)
consist in principle of two ferrite cores which form a magnetic circuit
between which printed coils with two closed rings are turned.
Areas of application: Machine construction, conveyor technology, robots,
printing industry, packaging industry, foundries, and rolling mills.
A
M
U1 U2
Figure 8, Inductive principle (Novotechnik)
A: reference element
M: measuring element
3.1.4 Magnetic principle

Small permanent magnets are arranged on the circumference of a disc. The
Hall sensor placed in front converts the alternating magnetic fields into
electrical signals.

U
N
S
Figure 9, Magnetic principle
3.1.5 Capacitive principle

Two plates of a capacitor are moved in relation to each other on an axle.
The resulting capacitance provides information about the position of the
axle.
3.2 Digital systems
3.2.1 Mechanical shaft encoders

Mechanical shaft encoders generate a digital output signal. Switches or
contacts on a control shaft are activate d by cams. These units are also called
cam-operated switchgroups.
Areas of application: Conveyor systems with low resolution, transport belts
and washing machines.
Figure 10, Mechanical shaft encoder (cam-operated switchgroup)
A cam-operated switchgroup is free from wear and tear if the mechanical

switches from figure 10 are replaced by inductive proximity switches.

Figure 11, Cam-operated switchgroup wi th inductive proximity switches
3.2.2 Oscillator sensors

The oscillator sensors work according to the incremental principle and
transmit digital signals. Usually U-shaped sensors are used for non-contact
detection of a rack or a coded disc.
3.2.3 Inductive system

With this principle the teeth of a rotating toothed wheel are detected by
means of an inductive proximity switch.
Figure 12, Inductive system
3.2.4 Photoelectric shaft encoders

On the edge of a round metal or glass disc transparent slits (segments or
increments) are arranged.
Binary output signals are generated by means of through-beam sensors in
miniature format and subsequent electronics. The number of increments
determines the resolution of a full circle.

Figure 13, Incremental shaft encoder
The photoelectric shaft encoders are discussed in this manual.

4 Shaft encoders of ifm electronic
ifm electronic offers shaft encoders which function according to the
photoelectric principle. In the past ifm electronic cooperated with different
partners.
Since 1990 ifm has been working with the company Heidenhain in
Traunreut.
4.1 DIADUR method

The number of increments (bright and dark fields) on the glass disc are of
vital importance for a high resolution of the encoder. The patented DIADUR
method of Heidenhain allows to apply very fine structures on a glass disc.
The DIADUR method is divided into six steps:
1. Cleaning of the glass disc (ultrasonic, without contact).

2. Application of photoresist, pre-dried, hardened.
Photoresist is a light-sensitive material which is applied in liquid form to
a carrier material in this case glass.
3. The so-called working originals (negatives) are pressed onto the glass
plate.
4. The complete glass surface is coated with chromium and exposed via a
mask.
5. The chromium is washed off with a chemical solution.
6. Chromium only adheres to the glass plate where the photoresist has
been exposed.
Due to the many manufacturing steps the production of a DIADUR glass

disc is very time-consuming.
The advantages of a DIADUR glass disc are:
Very good contour sharpness of the lines. This results in a very high
accuracy.
The glass disc is largely resistant to chemical and mechanical influences.
The system accuracy is approx. ± 1/20 grating mark for coded discs
with up to 5,000 increments and ± 12 seconds of an angle for coded
discs with more than 5,000 increments.

4.2 Shaft encoder types of ifm electronic
The following photos show the standard types of shaft encoders of ifm
electronic in alphabetical order referred to the ifm designation. The sizes
of the encoders in the photos are not to correct scale.
The designation of the individual shaft encoders always starts with a capital
"R". The second capital letter is the designation of the type. It refers to the
flange and the type of shaft. Example: RC stands for the type with round
flange and solid shaft.
RA, incr., hollow shaft RB, incr., solid shaft RC, incr., solid shaft
RM, abs. SSI, hollow shaft RM, abs., Profibus DP, solid shaft RM, abs., SSI, solid shaft
RN, abs., parallel, solid shaft R=, incr., hollow shaft RP, incr., hollow shaft
RU, incr., solid shaft RV, incr., solid shaft

5 Shaft encoders
Encoders convert mechanical movements like rotational or linear
movements (rotation and translation)into binary/digital voltage values. They
are transducers, mainly for rotational movements.
In connection with mechanical converters like measuring wheels or racks
incremental shaft encoders can also be used for linear measurements.
Shaft encoders function according to the principle of photoelectric detection
of the fine detection grids.
Most shaft encoders are round.
Even if the following information may seem superfluous: Shaft encoders
have to be driven mechanically from outside on the shaft.
Depending on the measuring and evaluation method a differentiation is
made between:
incremental shaft encoders

absolute shaft encoders
5.1 Incremental shaft encoders
5.1.1 Shape and design

The main components of an incremental shaft encoder are shown in figure
14. They are:
shaft (solid shaft or hollow shaft)

mounting flange
ball bearing
coded disc
detection system (LED, condenser/lens, detection grid, photo elements)
electronics for generating the signals
electrical connection (cable, connector)
housing cap

Figure 14, Incremental shaft encoder
AG: detection rid; PE: photo elements; TS: coded disc; ES: electrical signals;
RM: reference mark; KL: ball bearing; MF: mounting flange; WL: shaft; KD:
condensor
5.1.2 Coded disc

The core element of the encoder is the coded disc made of hardened and
special surface-coated glass, see 4.2. DIADUR-. It is the carrier for the
circular graduations or gratings.
Due to the special glass it is possible to operate the encoder also at high
temperatures without any major changes of the signal quality.
Increments On the outer edge of the coded disc there is the radial grid of lines and gaps
(light and dark fields).
These lines and gaps are called increments and they form the so-called
incremental track.
Measurement This incremental track forms the basis for the measurement of the encoder.
With one complete revolution of the coded disc as many electrical signals
are transmitted as there are increments on the coded disc.
The coded disc is fixed to a shaft which protrudes through the housing.
Figure 15, Coded disc with increments

5.1.3 Resolution - mechanical
The resolution is the number of physical light/dark fields on the coded disc
of the encoder which are provided as voltage pulses per revolution of the
coded disc.
The mechanical resolution of an encoder cannot be modified.
The number of increments on the coded disc depends on the resolution
required in the application.
For standard units there is a large variety of different resolutions per type. It
usually starts with five and first continues in small steps, later the distances
increase.
Standard resolutions The small incremental encoder RB for the voltage range of 10 30 VDC for
example is offered with the following resolutions in the ifm catalogue: 5,
10, 20, 25, 30, 40, 50, 60, 100, 125, 150, 200, 250, 360, 400, 500, 600
and 1,000.
A different resolution always means a different encoder and thus a different
article/order number.
The maximum resolution which can be shown optically as light dark fields
is 10,000 increments. The range of the resolution depends on the type.
Resolutions deviating from the standard are available on request.
5.1.4 Signal generation
5.1.4.1 Through-beam method

The signals are generated by means of the through-beam method. The
through-beam method is the principle of photoelectric detection of fine
detection grids. This detection principle can be compared to a miniaturised
photoelectric through-beam sensor.
Figure 16, Photoelectric detection, through-beam method
KD: condensor; AG: detection grid; TS: coded disc; PE: photo elements; RM:
reference mark.

5.1.4.2 Reference mark, zero index
The reference mark is on a second track next to the incremental track. Once
per revolution it generates a defined pulse, the so-called zero index, on a
separate channel.
5.1.4.3 Scanning plate
At a short distance opposite the rotatable coded disc with the increments
there is a fixed scanning plate. It has a grating on four fields and the
reference mark graduating on a further field.
0° 90°
180° 270°
Figure 17, Scanning plate, without reference mark grating
Grating period The four graduations of the sc anning plate are shifted against each other by
one-fourth of the grating period.
One grating period = 360 degrees / resolution.
The segments are adapted to the circle of the coded disc and therefore they
are slightly curved.
5.1.4.4 Condenser
All fields are penetrated by a parallel-orientated light beam which is emitted
by a light unit consisting of an LED and a convex lens (condenser).
Lichtquelle
Figure 18, Light source and condenser
With one rotation of the coded disc the light is interrupted periodically by
the light and dark fields and its intensity is detected by silicon photo diodes.
A photo element is assigned to each segment of the scanning plate.
5.1.4.5 Signal generation of the photo elements
Sine wave If a coded disc is rotated the photo elements for the incremental track
generate four sinusoidal current signals , each of which is electrically phase-
shifted by 90 degrees.

0° 90° 0° 90° 0° 90° 0° 90° 0° 90°
180° 270° 180° 270° 180° 270° 180° 270° 180° 270°
a b c d e
I3
I1
I2
I4
Figure 19, Sine wave of the photo elements
Sine curve I1: segment 0°

The photo element for the reference mark or the zero index generate a
signal peak.
The four sinusoidal photo-element signals are at first symmetrical to the
zero line.
5.1.4.6 Photo elements
The photo elements are connected in push-pull circuit thus creating two
output signals which are electrically phase-shifted by 90°.
3 4
1 2
Figure 20, Connection of the photo elements
DC component Due to the connection in push-pull circuit the DC component is suppressed.

The DC component is generated by scattered light of the adjacent fields of
the detection grid.
I3-I4
Ie1
I1-I2
Ie2
0° 90° 180° 270° 360°

Figure 21, Signal voltage

5.1.5 Pulse generation and analogue signals
5.1.5.1 Square-wave pulse trains

The sine curves I e1 and Ie2 are converted into square-wave pulse trains by
means of voltage comparators, thus generating two square-wave pulse
trains which are phase-shifted to each other by 90°.
Square-wave pulse train The square-wave pulse trains are amplified in the output stage of the
encoder and provided as electrical signals in the form of voltage pulses.
I3-I 4 Ie1
I1 -I2
Ie2
0° 90° 180° 270° 360°

180°
90° 180°
Figure 22, Pulse generation
90-degree-shift Due to the interaction of sc anning plate and coded disc the electrical 90-
degree shift from channel A to channel B has a mechanical origin. This
ensures that this shift remains the same for all rotational speeds of the
coded disc.
For simple counting operations it would be sufficient to only evaluate one
output channel, but only by means of the second signal output which is
shifted by 90 degrees it is possible to determine the direction of rotation or
counting (see 5.1.7).
5.1.5.2 Signal evaluation
As a standard an incremental shaft encoder provides three signal outputs:
Channel A, channel B and channel 0 (zero index).

A
UB
C D
E0 V0 T0
AS0 0
0
G
EA VA TA A
ASA
A
EB VB TB B
ASB
B
F
Figure 23, Signal generation, block diagram
A: shaft; B: scanning plate; C: coded disc; D: voltage supply; E: signal

outputs; AS 0, ASA and ASB: signal output stages with inverted and non-
inverted outputs; E 0: infrared reception transistor; F: condenser; G: light
source; T 0: pulse generation (Schmitt-trigger); V 0: direct-current amplifier.
The mark-to-space ratio of both output signals from channel A and channel
B is 1 : 1 at all times.
Signal sequence The sequence of voltage levels of the output channels of an incremental
shaft encoder is as follows:
1. LOW level (voltage value zero).

2. Voltage increase from LOW level to HIGH level (positive-going edge).
3. HIGH level (voltage value of the operating voltage).
4. Voltage drop from HIGH level to LOW level (negative-going edge).
If voltage is applied to the incremental shaft encoder it provides for each

channel the level value which results from the position of the coded disc. A
possible voltage change of a channel from no voltage to operating voltage
does not cause any counting operation in the subsequent evaluation
electronics.
5.1.5.3 Pulse diagram
The duration of the individual pulse (ON/OFF) depends on the rotational
speed of the coded disc. Thus it is not possible to indicate a time for the
pulse length.

180° 180°
90°
NI
90°
Figure 24, Pulse diagram channels A, B, and zero index (NI)
Therefore the duration of an individual pulse is fixed electrically to the value

360 degrees.
The ON pulse is present for the time of (electrically) 180 degrees, for the
remaining 180 degrees the pulse has the value zero.
The distance between channels A and B is electrically 90 degrees and
depends on the speed and direction of rotation of the coded disc.
Measuring step The measuring step is the angular value which results from the distance
between two edges of the two square-wave pulse trains of output A and
output B.
Without previous interpolation of the measured signals the measuring step
corresponds to the fourth part of the grating period (90 degrees) of the
radial gratings.
5.1.5.4 Zero index, channel 0
The zero index, also called zero pulse or reference mark, is generated only
once per revolution of the coded disc. On the complete circumference of
the index track there is only one segment.
The position of the reference mark on the coded disc is also determined
mechanically.
As can be seen in figure 24 the relative duration of the HIGH level of the
zero index is only half as long as that of channels A and B. Therefore the
input circuitry must have an input frequency for the evaluation of the zero
index which is four times higher than for the evaluation of channels A and
B. With a high number of revolutions of the encoder the length of the zero
index is shortened. The distance between the edges becomes shorter. In
case of "slow" evaluation electronics/plcs this can lead to the signal not
being detected even if the other channels can still be properly read.
The zero index can be used to define a switch point, to count the
revolutions or to synchronise a connected electronic counter.
In addition to the mechanical position of the zero index on the coded disc
the signal periods of channels A and B are used as reference values.
The standard zero index is 90° long see figure 24.For the ifm type RB for
the voltage range of 10 to 30 V DC the length of the index is 360°.

180° 180°
B
45°
NI
360°
Figure 25, Zero index 360 degrees long (NI), type RB, 10 30 V
Reference mark outside To facilitate the determination of the zero index its approximate position is
marked by a reference mark on the outside of some encoder types. For this
purpose there is an indentation on the flange near the shaft. The same
indentation is also on the front of the shaft.
If both indentations are matched, the signal for the zero index is present on
the output. For high resolutions the zero index is short and therefore
manual positioning is difficult.
5.1.5.5 Inverted output signals
For different encoders the three standard output signals (channels A, B and
zero index)are additionally provided in the inverted state.
The encoder then has six signal outputs in total: channel A and channel A-
negated1; channel B and channel B-negated as well as zero index and zero
index negated.
NI
NI
Figure 26, Pulse diagram with inverted channels (NI: Zero index)
Suppress interference Due to the inverted signals it is possible to evaluate the voltage difference.
Thus parasitic signals on long connect ion cables have almost no negative
effect.
Except for types RA and RB all HTL 2 shaft encoders provide the inverted
signals.
1
An expression like 'A-negated' is represented as an individual character or word by a line above the
character or word (see Figure 26).
2
HTL stands for high transistor logic. These are units with an operating voltage higher than 5 V DC.

5.1.5.6 Sinusoidal signals
For some incremental shaft encoders the sinusoidal voltages instead of the
square-wave pulse trains are provided for the channels A and B. They can
be processed in various ways in the input circuitry.
These two sinusoidal increment signals are also phase-shifted by 90 degrees.
y 1Vss
0° 90° 180° 270° 360°
x
Figure 27, Sinusoidal output signals (Vss = Vpp)
The reference mark signal for the zero index is also available in analogue
form. The voltage step has a nearly triangular shape of approx. 0.5 V.
1 Volt peak-peak (Vpp) If sinusoidal voltage signals are provided the voltage level is 1 Volt from
peak to peak.
Cable lengths of up to 150 m are possible.
The sinusoidal output signals can be digitised in an input circuitry
(comparator). They are specially suitable for pulse multiplication see
below. They can also be used with digital drives to monitor the rotational
speed even with very slow movements.
5.1.6 Wiring of an incremental encoder

The individual cores are differentiated by their colours and they have the
same meaning for all incremental shaft encoders of ifm electronic. The cores
which are available depend on the respective shaft encoder.
Wiring of an incremental shaft encoder:
brown channel A
green channel A inverted (A-negated)
grey channel B
pink channel B inverted (B-negated)
redzero index
black zero index inverted (zero index negated)
blue L+ (sensor)
white 0 V (sensor)
brown/green +U b (L+)
white/green U n (0 V)
lilac interference signal (inverted)
screen housing

5.1.6.1 Interference signal
Some encoders have an interference signal as additional signal output. The
interference signal indicates malfunctions of the shaft encoder like for
example breakage of the supply cores, failure of the light source, soiling of
the coded disc or the photo elements.
A square-wave pulse train indicates the malfunction. If the wire for the
interference signal has a LOW level, th ere is a malfunction. If the level is
HIGH the unit is operational.
For cable units the connection core (lilac) must be insulated if the
interference signal is not used, in order to avoid any short circuits. Unlike for
the useful signals, the output driver for the interference signal is not
protected against short circuits.
5.1.7 Detection of the direction of rotation for the

direction of counting
The electrical 90-degree shift between channels A and B in connection with
the dynamic signal changes is used by the subsequent evaluation electronics
like programmable logic controllers (plcs) or electronic up/down counters to
determine the direction of counting.
Signal change The signal changes and signal st ates of channels A and B of the shaft
encoder are decisive for the detection of the direction of rotation or
counting.
If the shaft encoder stands still there is no signal change. Input circuits
cannot (yet) decide which is the current direction of counting.
If voltage is applied to shaft encoders and evaluation/display electronics a
signal change can take place on one or more output channels, depending
on the position of the coded disc in the shaft encoder. However, this signal
change is suppressed as counting pulse by the evaluation electronics
because it was taken into account for the counting process before switching
off the supply voltage.
This ensures that the direction of counting is correctly determined when the
measuring system is switched on and the coded disc starts moving.
If the coded disc moves the positive signal change of channel A comes
before the positive signal change of channel B and vice versa, depending on
the mechanical direction of rotation.
B
Figure 28, Signal change
Phase discriminator The direction of rotation can easily be detected by means of a phase
discriminator in evaluation electronics by evaluating the phase position of
signal A to signal B.

5.1.8 Pulse multiplication
Duplication By means of logic switching elements like AND and OR gates the rising and
falling square-wave pulse trains of channels A and B can be connected in
such a way that the output signals have a higher resolution than the one
determined by the mechanical division of the coded disc.
Due to the electrical processing times of the required logic gates it is not
possible to increase the number of pulses to any number in this case.
A
B &
_
>1
A
&
B
Figure 29, Duplication of the pulses
The circuitry from figure 29 can also be implemented with an exclusive-OR-

gate (XOR).
Due to the pulse multiplication with logic gates the electrical 90-degree shift
of channels A and B is lost.
If the 90-degree shift is required it makes sense to use a shaft encoder with
sinusoidal output signals see above.
Multiplication (logic gates) A further pulse multiplicat ion is possible with the respective electronics.
X1
X2
X3
X4
Figure 30, Pulse multiplication

Depending on which edge of a channel is evaluated the pulse trains shown
in figure 30 and the related pulse multiplication can be implemented.
Single evaluation Pulse train X1 represents a single evaluation. A reaction to the to the falling
edge of channel A takes place. The number of pulses has not increased.
Double evaluation Pulse train X2 is generated if there is a reaction both to the rising edge and
to the falling edge of channel A. It is a double evaluation with double
symmetrical number of pulses.
Triple evaluation A triple evaluation is shown in the pulse diagram X3. In addition to the
rising and falling edges of channel A it also evaluates the rising edge of
channel B. The pulse evaluation is triple, but asymmetric.
Quadruple evaluation Diagram X4 shows a quadrupl e evaluation. The rising and the falling edges
of both channels are evaluated. The number of pulses has quadrupled and it
is symmetrical.
In the limit ranges wrong pulses may occur. The phase position of the
channels must be observed exactly. The pulse length after the multiplication
is to be set in such a way that with maximum rotational speed the newly
generated pulses are about half as long as the original pulses of the output
channels. The short signal duration resulting from this causes higher
requirements as regards the electronics of the evaluation unit (plc or
counter).
Multiplication from sinusoidal signals For shaft encoders which generate sinusoidal signals of 1 V pp , a multiple
number of the mechanical resolution can be achieved (factor 10 and more)
by means of linear interpolation.
Pulse multiplication with sinusoidal signals as a basis has the advantage of
the electrical 90-degree shift between the output channels A and B being
maintained.
5.2 Absolute shaft encoders

Absolute measuring systems determine the current absolute position of the
measuring system in the form of clear code information by scanning the
coded disc. They signal this position to the subsequent electronics as coded
value in binary form.
The special advantage is that this position value is available unchanged
after a power failure. The exact position is also indicated if the encoder has
continued to turn when no power was available.
Wrong measurements due to wrong pulses and errors which add up are
mostly excluded.
Binary numerical values Absolute shaft encoders convert rotational movements or positions into
binary numerical values. Each angular position of the coded disc is provided
as a binary numerical value.
Binary figures consist of individual bits which can only take the values 1 or
0. For absolute shaft encoders the digital value 1 means that the level of
the signal wire is HIGH. Therefore the digital value 0 corresponds to the
LOW level.
With their HIGH and LOW levels all signal outputs of absolute shaft
encoders form a clear binary number. Th e prerequisite is of course that the
signal wires are in the correct order corresponding to their value.
The binary numerical value of an absolute shaft encoder consists of up to 13
bits. For each bit a separate signal wire is required.
Angular positions, movements and positions can be determined by means
of the binary numerical value.

Figure 31, Coded discs
Many tracks In contrast to incremental shaft encoders the coded disc of absolute shaft
encoders has considerably more tracks (see figure 31).
The graduation carrier of absolute shaft encoders consists of a coded disc
made of glass with several code tra cks. Each individual track corresponds to
one bit within the binary output value see above.
These absolute shaft encoders also work according to the principle of the
photoelectric detection of graduations.
Transparent and non-transparent zones are distributed in concentric circles
(= tracks)on the coded disc. On a fixed radial reading zone (photoelectric
sensors detect the tracks)an exactly determined sequence of light dark
fields results from each position of the disc.
One or several scanning plates are arranged at a short distance to the
rotatable coded disc. They have scanning fields which are assigned to the
coded tracks.
A light beam aligned in parallel illuminates each scanning plate. This light
beam is generated by an LED and a capacitor like in the case of the
incremental shaft encoder.
With the rotation of the coded disc the light beam is modulated and its
intensity is detected by the silicon photo elements.
Incremental signals For absolute shaft encoders which additionally provide incremental signals
four scanning fields are assigned to the finest track.
The four graduations of the scanning fi elds are shifted against each other by
one fourth of the grating period like in the case of the incremental shaft
encoders.

Figure 32, Photoelectric detection, through-beam method
LQ: light source; KD: condensor; TS: coded disc; PE: photo elements; AG:
scanning plate.
If voltage is applied to the absolute shaft encoder, the binary value which is
caused by the current position of the coded disc is immediately provided at
the output channels in the form of HIGH/LOW levels.
The number of tracks depends on the requested resolution, the distribution
of the light and dark segments on the type of coding selected.
Absolute shaft encoders are differentiated as follows:
Singleturn shaft encoders

Multiturn shaft encoders
5.2.1 Resolution
The resolution of absolute shaft encoders depends on the number of tracks.
Singleturn shaft encoders are available with resolutions of 256 (8 bits), 360,
512 (9 bits), 1,024 (10 bits), 2,048 (11 bits), 4,096 (12 bits), and 8,192 (13
bits). See also chapter 5.2.4 Coding.
Multiturn shaft encoders have up to 13 tracks and thus a resolution of
8,192 steps per revolution with 4,096 (12 bits) countable revolutions.
5.2.2 Singleturn shaft encoders

Singleturn shaft encoders are absolute shaft encoders. In contrast to the
incremental units they provide a coded numerical value for each angular
position.
After each complete revolution of the axle the numerical value starts with
the start value again.
If the rotational direction of the shaft changes the counting direction of the
output value changes as well.
Parallel data output Most singleturn shaft encode rs have a parallel data output where each track
of the coded disc is assigned a separate data wire. Therefore the number of
connection cores to be wired is very high.

Enable signal The data of the signal tracks ar e permanently provided by the shaft encoder
if there is a LOW signal or no voltage on the release channels A and B. If a
HIGH signal is applied to the release channels all signal outputs are of high
impedance and thus they are blocked.
Figure 33, Pulse diagram of the parallel interface
The signal outputs are assigned to two release channels see figure 33.The
number of tracks for the respective release channel is as follows:
Release channel A: tracks 3 to 10 8, 9 and 10-bit shaft encoders

tracks 7 to 12 11 and 12-bit shaft encoders
Release channel B: tracks 1 to 2 8, 9 and 10-bit shaft encoders
tracks 1 to 6 11 and 12-bit shaft encoders.
LSB and MSB Track 1 is the least significant bit (LSB), the last track with the highest index
number (e.g. bit 12) is the most significant bit (MSB).
If bit 1 (LSB) is not transmitted, the transmission error is smallest; if the last
bit (MSB) is not transmitted, the error is largest.
The designation of the connections as regards the core colours varies
depending on the number of bits.
Connection of a 10-bit shaft encoder:
brown Ub, plus, 10 - 30 V DC

yellow/brown sensor, plus, 10 - 30 V DC
white Ub, minus, 0 V
white/yellow sensor, minus, 0 V
green release channel A
yellow release channel B
white/grey bit 10 (MSB)
white/green bit 9
red/blue bit 8
grey/pink bit 7
lilac bit 6
black bit 5
red bit 4
blue bit 3
pink bit 2
grey bit 1 (LSB)
The respective connection is indicated on each shaft encoder.

Multiplex operation Due to the fact that the signal outputs are of high impedance because of
the LOW signal at the release channel it is possible to switch the output
signals in parallel with other shaft en coders. Therefore a plc for example can
operate several shaft encoders with the multiplex method.
In that case two or more shaft encoders are wired in parallel on the same
channels of the plc input card. Thus only 10 input channels are used for 10-
bit shaft encoders, irrespective of the number of encoders. The release
channels of the shaft encoders are triggered by means of the plc outputs.
To do this two output channels per shaft encoder are required. The signal
outputs of the individual shaft encoders are read by the plc during operation
either one after the other or on demand. It is important that only one shaft
encoder at a time is enabled.
Depending on the version of the shaft encoder either TTL signals or 24 V DC
signals are provided.
Direction of rotation and counting With shaft encoders it must be possible to differentiate the direction of
rotation. Therefore it has been determined that the direction of rotation is
always indicated looking at the front of the shaft of the encoder.
For the singleturn shaft encoder this means that rotation to the right is
clockwise if you look at the shaft.
In that case the direction of counting is ascending.
Direction of rotation clockwise counting up

Direction of rotation counter-clockwise counting down
5.2.3 Multiturn shaft encoders

Multiturn shaft encoders are also absolute shaft encoders. Like the
singleturn shaft encoders they prov ide a coded numerical value for each
angular position of the axle.
Multiturn shaft encoders have the same design for determining the position
within one revolution as singleturn shaft encoders.
In addition the number of completed revolutions of the axle is provided in a
further bit combination.
In order to distinguish between the number of revolutions permanent
magnets embedded in the discs are used which are connected to each other
via gears for gear reduction.
Detection is made via digital Hall-effect sensors.
Figure 34, Gear box with coded discs and Hall elements
HE: Hall element; CS: coded disc; GB: gear box.

The following diagram shows the pulse characteristics taking the example of
a (non-existent) multiturn shaft encoder with four bits for single turn and
three bits for multiturn.
y
15
0
15
Singleturn
0
0 - 15 15
0
15
0
15
0
15
0 0
15 15
0 0
15 15
0 0
0 1 2 3 4 5 6 7 0 1 x
Multiturn 0 - 7
Figure 35, Multiturn encoder, 4 bits singleturn, 3 bits multiturn
5.2.4 Code types

In control technology different types of code are used, e.g. Gray code, BCD
code or dual code as well as different variants.
5.2.4.1 Dual code (binary code)
With the dual code (binary) code each digit is assigned a certain value,
starting with 20 for the least significant position and 2 n-1 for the most
significant position.
The dual code can easily be processed from the technical point of view.
The optical detection, however, can lead to reading errors as the bit change
of several tracks is not carried out exactly time-synchronously or because
there is a bit change on several tracks at the same time (see figure 36,
values 7 and 8). This can lead to wrong allocations of the position.
Bit 1 (LSB)
Bit 2
Bit 3
Bit 4 (MSB)
Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Figure 36, Dual code

5.2.4.2 BCD code
The BCD code has a tetradic design. Each digit of a decimal number is
assigned a 4-digit dual figure (tetrad). The BCD code is mainly used if
decimal displays are to be triggered directly.
Four bits allow numerical values from 0 to 15. For the BCD coding the bits
from (binary) 0000 to I00I are required. The bit combinations of I0I0 to IIII
are not required because they represent the decimal numbers 10 to 15.
Therefore the efficiency of this code is not so high.
The figure 3600 is shown as follows:
3 6 0 0
0011 0110 0000 0000
Thus at least 14 bits are required beca use the two preceding zeros of the bit
combination are not required for the three.
The genuine binary code as well as th e Gray code only need 12 bits for the
same figure. 212 = 4,096 (211 = 2,048).
5.2.4.3 Gray code
Absolute shaft encoders often use the Gray code. The advantage is its
simple design: It is mirror symmetric and proceeds by one step, i.e. when
going from one position (number) to the next only one single bit changes.
This minimises the risk of possible reading errors during transmission and
further processing.
Bit 1 (LSB)
Bit 2
Bit 3
Bit 4 (MSB)
Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Figure 37, Gray code
A 4-digit code results in 2 4 = 16 combinations. As the genuine Gray code

counts from 0 to 2 n-1 these are the numbers 0 to 15 in the figure above.
A 12-digit code (2 12 = 4,096 combinations) performs a decimal count from
0 to 4,095.
The bit information read with the Gray code is converted into a binary code
by means of a suitable code converter. It can then be further processed. For
further processing of the signals code converters (e.g. code converter Gray
code dual code) or program modules in programmable controllers can be
used.
Reflectible Gray code The code values are provided in ascending direction if the shaft of the
encoder turns clockwise. As the Gray code is reflectible descending code
values can be generated as well with clockwise rotation of the shaft by
inverting the most significant bit (MSB).

5.2.4.4 Symmetrically cut Gray code (Gray excess code)
The Gray code proceeding by one step is for resolutions which can be
represented as the power of 2 (2, 4, 8, 16,... 256, 512 etc.).
If other resolutions, e.g. 360 or 1000 are to be implemented, the section
corresponding to the requested even-numbered area is taken from the Gray
code see figure 38 for the value 10. This ensures that the code proceeds
by one step.However, the represented section does not start at zero any
more, but it is shifted by a certain amount.
Bit 1 (LSB)
Bit 2
Bit 3
Bit 4 (MSB)
Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Gray Excess 10 Code
Bit 1 (LSB)
Bit 2
Bit 3
Bit 4 (MSB)
Value 0 1 2 3 4 5 6 7 8 9
Figure 38, Gray excess code
For the evaluation half of the differenc e between the original resolution and
the reduced resolution is deducted from the generated binary value.
Calculation for determining the start value for example with the value 360:
1. The next higher binary value above 360 is 512 (2 9).

2. The number 360 is deducted from this value, the result is 152.
3. This is divided by 2; the result is 76.
The range of numbers starts at 76 and ends at 435. This range from 76 to
435 is shown on the coded disc. The value 76 is converted internally and
provided as zero. Accordingly, the internal value 435 is provided as 359.

A
511 0
435 76
256
Figure 39, Cut Gray code for the value 360
The designation for the code shown in figure 39 is:

512 Gray excess 76 code.
With the mechanical resolution only even numbers are possible for the cut
Gray code like for the normal Gray code.
The cut Gray code (also called "reduced Gray code", e.g. 10 Gray excess 3
code) is used if the advantages of a code proceeding by one step are to be
used but if resolutions are required which do not correspond to a power of
2. When choosing the resolution it has to be considered that the value can
be divided by 2 without any remaining fraction.
Other resolutions result in the following positions:
76 to 436 with a required resolution of 360

152 to 872 with a resolution of 720 and
12 to 1,012 with a resolution of 1,000.
With the Gray code or cut Gray code the individual bits have no value, like
for example with the dual code where each bit combination is directly
assigned a decimal number by the power of 2.
5.2.4.5 Decadic Gray excess-3-code
This is a combination of the BCD code and the Gray code.
Each individual decade is coded in the Gray code in such a way that it
counts up to the number 13 starting with the number 3. Following that the
second decade starts with the number 3 and the first decade counts down
etc.
The decimal Gray excess-3-code is a code proceeding by one step and it is
mirror-symmetric.
A disadvantage is that the conversion is very complex from the point of view
of the hardware as well as from the point of view of the software.

5.2.4.6 Comparison of different code types
E D C B A E D C B A
0 0
1 D C B A 1
2 0 2
3 1 3
4 2 4
5 3 5
6 4 6
7 5 7
8 6 8
9 7 9
10 8 10
11 9 11
12 12
Decadic Gray-
13 excess-3-Code 13
14 14
15 15
16 16
17 D C B A 17
18 0 18
19 1 19
20 2 20
21 3 21
22 4 22
23 5 23
24 6 24
25 7 25
26 8 26
27 9 27
28 28
BCD- Code
29 29
30 30
31 31
Dual- Code Gray- Code
Figure 40, Code types
The table shows that only the Gray code and the dual code fully use all
possibilities, i.e. there are 2 n combinations. With the Gray excess code there
are bit combinations which cannot be used.
5.3 Comparison of absolute shaft encoders and

incremental shaft encoders
Absolute shaft encoders provide the actual position value immediately after
they are switched on or after a power failure.
Multiturn shaft encoders can in addition detect the number of revolutions.
Thus these absolute shaft encoders have a very wide measuring range.
With incremental shaft encoders on the other hand the plant would maybe
have be set manually to the basic position or to a reference point.
The complexity as regards connection and evaluation is higher for absolute
shaft encoders than for incremental shaft encoders. Absolute shaft encoders
are also more expensive.

5.4 Data transmission
As mentioned before absolute shaft encoders provide a data word the
length of which depends on the resolution. If there is a separate signal
output for each track this is called parallel data transmission.
Many cores In order to transmit the inform ation to the evaluation unit a cable which
provides one core for each channel has to be laid. For a multiturn shaft
encoder with 12 bits for singleturn and 12 bits for multiturn this would
result in 24 cores for the data cable.
The respective number of signal inputs is also required at the evaluation
electronics, e.g. a plc. With high-re solution units this leads to the well-
known wiring problems:
high susceptibility to interference,

high cable costs,
high installation complexity,
thick, inflexible cables.
For singleturn shaft encoders with a maximum of 13 bits data this

complexity can still be justified. In this case parallel data transmission is still
often used.
With the 5 V unit multiplex operation with 8 and 4 channels is also possible.
This does not reduce the cabling, but inputs on the evaluation unit or the
plc.
5.4.1 SSI interface on the shaft encoder

A multiturn shaft encoder can detect 4,096 revolutions (12 bits) with a
resolution of 8,192 steps (13 bits). If these data were to be transmitted in
parallel 12 + 13 = 25 data wires would be required and in addition the
wires for the voltage supply and the sensor.
Figure 41, SSI interface unit RM
Few cores Therefore serial data transmission is offered for multiturn shaft encoders.
For this purpose the unit has an SSI interface (synchronous-serial interface
EIA RS422A or RS485). Only four data cores are required for the data
transmission.
In contrast to the parallel interface this one requires fewer components and
it is less susceptible to interference. Considerably fewer wires than with the
parallel interface are needed for the transmission. Furthermore considerably
longer cables are possible.
These shaft encoders have the following connections in addition to the
voltage supply and sensor monitoring:

Clock and clock inverted
TTL-compatible signals for data and data inverted
Two sinusoidal increment signals (A and B), 1 Vpp
Independent of the unit the data are transmitted either in the dual code or
in the Gray code.
Figure 42, SSI, pulse diagram for singleturn shaft encoders
Figure 43, SSI, pulse diagram for multiturn shaft encoders
The times for T, t1 and t2 shown in the diagrams above must be observed.
They are:
Clock T: 0.9 µs to 11 µs
t1: greater than 0.45 µs
t2: max. 0.4 µs.
Function In quiescent condition the clock and data wires are HIGH. The clock is
generated by the evaluation electronics (e.g. SSI controller). The first falling
clock edge signals the start of the data transmission the current measured
value is stored.
Data transfer is carried out with the first rising clock edge. With the
following rising clock edges the data ar e transmitted bit by bit, starting with
the MSB. The transmission of a complete data word requires n + 1 rising
clock edges (n = resolution in bits). Thus 25 clock edges are required for a
24-bit shaft encoder.
After the transmission of a complete data word the data output remains
LOW and the clock output remains HIGH until the shaft encoder is ready to
transmit the next measured value (t3 see figure 43).
If during this time there is a new request for data output (clock) the data
which have already been provided are provided again.
In this case the data output is LOW between the LSB of the first data
transmission and the MSB of the second data transmission.

If the data output is interrupted (clock = high for t >= t3) a new measured
value is stored with the next clock edge.
The input circuitry reads the data with the rising clock edge.
The standard signal length is 25 bits (without parity bit), but a version with
24 bits (or with parity bit) is available on request.
In addition to the values for the absolute position incremental data can be
transmitted as a sine wave in parallel.
A
360° el.
B
A 0
B 0
90° el. C
Figure 44, SSI interface, incremental signal shape
The size of the incremental signals is 1 Vpp for a terminating resistor of

approximately 120 . The signals for the channels A and B are almost
sinusoidal and are also shifted by 90 degrees.
The number of increments is limited to 512 per revolution.
The evaluation of the serial data of multiturn shaft encoders can be carried
out by subsequent electronics the SSI controller.
serial parallel
multiturn SSI plc
RM controller
24 V DC
+ –
power supply
Figure 45, SSI interface, block diagram
The data are updated synchronously with the readout cycle. Thus the data
are as current as the time distance between two readouts. Therefore a
periodic readout of the shaft encoder is recommended.
After a longer readout break and simultaneous rotation of the encoder
shaft the data content of the first readout may be obsolete and should be
ignored.
Connection of a multiturn shaft encoder with SSI interface:

black n. c. (not connected)
red n. c.
green n. c.
brown n. c.
brown Ub, plus, 10 - 30 V DC
lilac clock
yellow clock - negated
white/green Ub, minus, 0 V
screen housing
blue/black channel B (+)
red/black channel B (-)
grey data - negated
green/black channel A (+)
yellow/black channel A (-)
pink data
5.4.2 SSI interface programming via software

Different multiturn shaft encoders with SSI interface can be parameterised
via PC (ifm types RM6110 and RM6113). The required programming of the
shaft encoder is carried out with a special software via a standard PC.
The programming software is for programming as well as for checking the
set values. This is especially necessary if units are replaced.
Figure 46, SSI programming software
Before setting up new or replaced programmable shaft encoders the correct

setting always has to be checked. If the factory setting remains unchanged
this may cause serious malfunctions of the plant.

Figure 47, SSI programming software, connection
The programming cable which is available as accessory connects the shaft

encoder directly with the COM interface of the PC and serves for voltage
supply if the shaft encoder has not yet been connected to a controller/plc.
The setting possibilities and operation of the software are very extensive and
can be found in the detailed operating instructions supplied with the
products.
The following features can be set/programmed for example:
Output format of the position values in dual or Gray code

Transmission format of the data in a triangular structure (SSI) or
synchronous-serial right-justified (see chapter 18.2 Glossary of technical
terms).
Direction of rotation for ascending position values.
Singleturn resolution up to max. 8,192 positions per revolution.
Multiturn resolution up to max. 4,096 distinguishable revolutions.
Offset and preset values.
It is also possible to check the shaft encoder by means of the software.
5.4.3 SSI controller

The SSI controller enables the connection of absolute shaft encoders with
SSI interface to a plc.
shaft encoder evaluation electronics

+5V R2 R1
line
driver C2 data + C1
data - C1
C2 R2 R1
R1 R2 +5V
C1 clock +
C1 clock -
R1 R2
Figure 48, SSI interface, circuit example

The controller converts the serially tra nsmitted Gray-coded data word of the
shaft encoder into parallel binary or BCD-coded information.
In addition it provides the following functions:
Monitoring function for voltage errors,

Transmission errors (wire break) and incorrect operation
Virtual zero point, i.e. the zero point can be defined new at any
position
Scaling factors, i.e. the number of steps, the resolution, can be freely
selected between 1 and 4096, the number of revolutions can be
selected between 1 and 4096 by duplicating, thus 2, 4, 8, 16,....
The direction of rotation can be inverted.
Code type, i.e. a choice between BCD and Hex code.
Parity, i.e. a choice between an encoder with or without parity bit.
Figure 49, SSI controller
The pulse frequency for absolute shaft encoders is 100 kHz. The data
frequency for binary coded data is 1 kHz, 0.6 kHz in the BCD code.
LSB outputs LSB outputs

singleturn multiturn
D 00 D 01 D 02 D 03 D 04 D 05 D 06 D 07 D 08 D 09 D 10 D 11 D 12 D 13 D 14 D 15 D 16 D 17 D 18 D 19 D 20 D 21 D 22
STR RST OEN DAV PYB D 30 D 29 D 28 D 27 D 26 D 25 D 24 D 23

24 V UN n.c. n.c. UP-S D D T T
SSI-encoder-input outputs
supply multiturn
Figure 50, SSI controller, connections
Outputs D00 - D15 for singleturn:
D00 (=LSB) to D11 (=MSB) with output in binary code

D00 (=LSB) to D15 (=MSB) with output in BCD code
Outputs D16 - D30 for multiturn:
D16 (=LSB) to D27 (=MSB) with output in binary code

D16 (=LSB) to D30 (=MSB) with output in BCD code
STR (strobe) input for the signal to call the current encoder value. With a
HIGH-LOW edge to STR the last complete encoder value in the
output buffer is provided to the plc.
RST (reset) input for external setting of the zero position.
OEN (output enable) input for external switching signal which releases or
blocks the data outputs (for the use of several controllers on one
plc). HIGH releases the data outputs, LOW blocks them. If this input
is not connected to the plc the data outputs are permanently free.
DAV (Data-valid) If the strobe signal calls the data, these data are valid if
the output DAV is HIGH. In case of a LOW signal the following
errors might have occurred:
Transmission error of the SSI module
Measured values above the programmed resolution
PYB (output for the internal parity information) The parity is formed
from singleturn and multiturn by means of the complete data word.
In case of an even sum of all HIGH outputs including the parity
output this output is HIGH.
5.4.4 Profibus-DP interface

Profibus is a further alternative to avoid having to use many cores for data
transmission of a multiturn or singleturn shaft encoder.
Figure 51, Profibus DP shaft encoder, type RM
Instead of an SSI interface or parallel outputs the shaft encoder has an

interface for Profibus DP. The shaft encoder operates as a slave alongside
other components on the bus. The expression "DP" stands for decentralized
peripherals.
Profibus is a manufacturer-independent, open fieldbus standard determined
by the international standards EN 50170 and EN 50254.
Profibus enables the communication of units of different manufacturers.
It is suited for time-critical applications as well as for complex tasks. Further
technical and manufacturer- independent information is available on the
internet at http://www.profibus.com .

DP in shaft
gateway encoder
DP out
24 V DC
+ –
power
supply
Figure 52, Profibus DP
Absolute shaft encoders with Profibus DP interface are distinguished by their

certification by the Profibus user organisation (PNO) and are therefore
suitable for unrestricted use in all Profibus DP networks.
This means among other things that all possible baud rates, the complete
address range and the unit characteristics are supported according to the
Profibus unit profile for shaft encoders.
The shaft encoder is configured in the Profibus system by means of the so-
called device data base file (GSD) for MS Windows. The file can be
downloaded free of charge from the internet at http://www.ifm-
electronic.com or http://www.profibus.com.
The assignment of the addresses and the setting of the terminating
resistance are carried out on the unit. The address of the unit can be set
from 3 to 126. It is not possible to set the address via the Profibus master.
B
B A B A
5 5
0 0
PROFIBUS- DP
+Up B/A
-0 V BUS
B/A
BUS
Figure 53, Profibus, addressing and terminating resistor
The data are transmitted in the dual code. The programming interface has a
transmission rate of max. 12 MBaud 3.
The programming possibilities according to the Profibus profile for shaft
encoders class 2 are for example:
3
MBaud = megabaud

counting direction of the code values
resolution
zero point
limit position HI and LO
motion indication
separation multiturn and singleturn shaft encoder
Furthermore the following diagnostic possibilities according to the Profibus

shaft encoder profile class 2 are available:
alarms
warnings
status
serial number of the shaft encoder.
Manual A comprehensive manual is supplied with the unit. It describes the

installation and configuration possibilities.
These are for example:
General information about the Profibus technology.
Unit installation as regards cabling, addressing, terminating resistor and
GSD file.
Unit configuration consisting of en coder class, operating parameters,
data exchange, diagnostic information.
Configuration of the DP-Profibus encoder on a Siemens plc type S7-
CPU 315-2 DP, version STEP7 V5.X.
5.5 Accuracy of the shaft encoder

There are three types of accuracy as regards a shaft encoder:
dividing error
mark to space ratio
phase difference
The accuracy of a shaft encoder is indicated in electrical degrees or as part

of the grating period.
The accuracy of the provided signal sequence of a shaft encoder mainly
depends on the following conditions:
1. Error of the radial gratings of the coded disc.

2. Error in the grating of the detection grid.
3. Eccentricity of the coded disc to the shaft.
4. Radial runout of the bearing.
5. Deviations due to the coupling with rotor couplings (solid shaft
encoder).
6. Interpolation error during further processing of the measured signals.

5.5.1 Dividing error
The dividing error is described as a deviation of any edge to its exact
geometric position. It indicates the greatest deviation of the nominal
distance between two pulse edges of one or several pulse channels. The
dividing error consists of a mechanical rotational error and the electronic
repeatability.
It does not add up with several revolutions of the shaft encoder.
The dividing error is very important with positioning applications which are
to be carried out during one revolution of the shaft encoder.
5.5.2 Mark-to-space ratio

The mark-to-space ratio describes the ratio between the rising and the
falling pulse edges. It is important for the calculation of the actually required
limit input frequency of the input circuit of the evaluation electronics. The
accuracy value is indicated for each shaft encoder.
360°
A
Figure 54, Mark-to-space ratio
Range A in Figure 54 indicates the location of the variation range.
5.5.3 Phase difference

The phase difference describes the variation of two subsequent edges of the
two channels A and B by their nominal distance. This distance is to be 90
degrees electrically. The maximum possible deviation is indicated in the data
sheet.
360°
A
90°
Figure 55, Phase difference
The area A in figure 58 indicates the variation range. For resolutions up to

5,000 the accuracy is ± 1/20 grating period. This is also valid for a detection
frequency of one to two kHz and at room temperature.

If the resolution is above 5,000 the accuracy is indicated in angular seconds.
It is approximately ± 12 angular seconds.
The accuracy of the absolute position values is indicated in the technical
data sheet of the respective unit.

6 Mechanical design
Shaft encoders are differentiated as regards their type of mechanical
coupling. There are solid shaft encoders and hollow shaft encoders with
different types of flange for mechanical fixing.
For the electrical connection there are cable units and connector units, in
exceptional cases also units with terminal chamber (e.g. absolute shaft
encoder type RM for Profibus connection).
6.1 Solid shaft encoders

Solid shaft encoders are coupled to the machine by means of shafts with a
diameter of 6 mm or 10 mm and the respective mechanical couplings. The
coupling has to compensate for the vibrations and shocks from the
machine.
Figure 56, Solid shaft encoder
The shaft at the end of which the coded disc is mounted inside the shaft
encoder, is guided by two ball bearings.
Ball bearing Depending of the flange size the shafts are in most cases designed in such a
way that the same ball bearings can be used for different shaft diameters.
The diameter of the shaft in the ball bearing is 10 mm, but outside the shaft
only has a diameter of 6 mm.
The shaft encoder has two ball bearings positioned behind each other on
the shaft in the flange. The ball bearings are closed in order to meet the
respective protection rating, i.e. the balls cannot be seen from outside.
There is an additional seal in front of the ball bearing.
If the mounting tolerances and the maximum rotational speed are observed
the ball bearings have an average lifetime of between 25,000 and 120,000
operating hours.

Figure 57, Ball bearing (K) with sealing ring (D)
The ball bearings are particularly important because their mechanical design
is decisive for the smooth running of the shaft.
This is especially interesting in cases where the drive for the encoder shaft
does not have a high torque or if a high protection rating is required for the
shaft encoder. For this reason the starting torque is indicated in the data
sheet.
Starting torque It is the minimum impact on the shaft required to start a rotational
movement of the shaft from standstill.
The value of the starting torque is smaller than 1 Ncm (Newton centimetre)
and it is indicated for room temperature.
The flange is for the mechanical fixing of solid shaft encoders.
6.1.1 Flange types for solid shaft encoders

The flange The flange of a shaft encoder is a precise aluminium injection-moulded part.
Outside it has the respective profile with the corresponding threaded blind
holes for fixing.
The inside is for the ball bearings for the shaft, for fixing the housing cap as
well as fixing and positioning the LEDs for the through-beam method.
Figure 58, Flange with threaded holes (G)

The units are distinguished by their individual flange versions. The following
flange types are standard:
1. Clamp flange
2. Synchro flange
3. Round flange
Figure 59, Flange types (1, 2, 3 see above)
The diameter of the flange and the position of the mounting threads are
standardised.
Figure 60, Clamp, synchro and round flange
In addition to the flange types mentioned above there is also a square

flange.
6.2 Hollow shaft encoders

Hollow shaft encoders have their own bearing and a coupling at the stator
side. They can be mounted directly on the machine without any special
coupling.

Figure 61, Hollow shaft encoders
With an angular acceleration of the shaft the stator coupling must only
withstand the torque resulting from the bearing friction. The special stator
coupling is the basis for a high natural frequency of the coupling and
enables relatively high amplification in the control circuit. The coupling at
the stator side allows axial movements of the driving shaft.
The maximum permissible axial movement is for types
RO ± 1 mm
RA ± 0.5 mm
RP ± 1.5 mm.
The mechanical connection to the shaft is established by tapping off the

drive. The hollow shaft of the encoder is put onto this shaft.
Additional fixing possibilities on the housing ensure protection against
rotation and a secure fit of the housing.
Due to the special patented bearing inside the shaft encoder vibrations are
compensated for.
The hollow shaft versions differ depending on the encoder type. They can
be continuous or open on one side (blind hole).
The dimensions of the hollow shaft are designed to fit common sizes very
precisely. In most cases they have the tolerance H7 according to DIN ISO
286 T2. Common dimensions for the inner diameter are:
6 mm (6 mm to 6.012 mm)
20 mm (20 mm to 20.021 mm)
50 mm (50 mm to 50.025 mm)

Figure 62, Hollow shaft encoder, cut-away view
The mounting of the hollow shaft on the shaft of the drive is carried out by
means of one or two set screws (n) or a clamping ring.
Depending on the type the driving shaft must protrude far enough into the
hollow shaft (indication in the data sheet).
The shaft of hollow shaft encoders is also only for the transmission of the
rotational movement.
The use of hollow shaft encoders is cheaper in comparison with solid shaft
encoders because additional couplings , mounting devices and other fixing
components are not needed. The required mounting space is smaller than
for encoders with solid shaft.
6.2.1 Mounting of hollow shaft encoders

Hollow shaft encoders are mounted by means of a stator coupling.
Figure 63, Stator coupling for hollow shaft encoder

7 Electrical connection
The electrical connection of shaft encode rs can be carried out by means of a
connection cable or a connector.
7.1 Connection cable

The connection cable at the unit is one or two metres long. Cable lengths of
10 m are also available. At the end of the cable a short section of the
insulation is stripped. The cores do not have any wire end ferrules.
Cable length If a plug and socket connection wi th a suitable extension lead (cross-section,
screening) is used, a max. length of 100 m for the 5-V version and 50 m for
the 10 to 30 V version is possible.
The cable material is polyurethane (PUR) or polyvinyl chloride (PVC),
depending on the unit.
The PUR cable is more resistant to oil, hydrolysis and microbes.
Bending radius The permissible bending radii of the connection cables generally depend on
the diameter and the material.
Guide values for PUR cables with 5 or 6 mm and PVC cables with 5 or 8
mm:
r 20 mm if flexed once,
r 75 mm if flexed continuously.
Screening All connection cables of the shaft encoders are screened (metal mesh
screening). The screen of the connection cable is fixed internally to the
housing cap. The individual connection cores are not screened.
Temperature ranges Depending on the cable version the encoder cables can be used in the
following temperature ranges:
for firmly laid cables -30° C to 85° C.

for frequent flexing -10° C to 85° C.
If the cable has a restricted resistance to hydrolysis and microbes, it can be

used at up to 100°C for stationary and moving applications.
Figure 64, Cable entry axial (A) and radial (R)
The cable entry at the unit can be axial or radial.

It is implemented by means of a cable gland in most cases. Small shaft
encoders do not have a cable gland for reasons of space. In this case the
cable entry is radial.
Figure 65, Cable entry for small units
The cable entry of a small encoder, like shown in figure 68, allows axial as
well as radial connection.
Some shaft encoders have a connection cable with cable plug. These units
have a cable with a plug mounted at the end.
Figure 66, Cable plug
7.2 Connector
The size of the connector on the unit, the number of pins and their
connection depend on the unit version.

Figure 67, Connector unit
In many cases it is a 12-pole connection.
9
1 8
10 12
2 7
3 6
4 5
11
Figure 68, Pin connection of a plug
The pin connection of the plug at the unit is described in detail in the data
sheet.
7.2.1 Sockets/coupling
Suitable sockets for the connection of connector units are offered as
accessories.
The data sheets of the shaft encoders with connector specify the type of
connector so that the suitable sockets (coupling with cable) or the suitable
couplings for wiring can be selected from the ifm range of accessories.
A typical designation for a connector is for example ifm 1001.2.
Figure 69, Coupling, electrical
The couplings are rated for operation with DC voltage and have a voltage
range of 4.5 V DC to 30 V DC. The temperature range is 40 degrees
Celsius to +140 degrees Celsius. The couplings have the protection rating IP
67. In many cases the housing material is brass with a plastic sheathing.

7.3 Laying the cable
Connectors or terminal boxes with metal housing should be used for
mounting and no other signals should be led through these components.
The housing of the encoder, connector, terminal box, and evaluation
electronics should be connected with each other via the screening of the
cable.
The screening should have as low an inductance as possible (short, large
surface) and must be connected in the area of the cable entry. The
screening system as a whole must be connected to protective earth.
The connection cables should be laid separately from any sources of
interference (e.g. cables of motors, solenoid valves etc.) In general, a
minimum spacing of 20 cm is sufficient.
Connections or plugs should not be disconnected while live.
7.4 Earthing and screening

On a cabled unit the screen is directly connected to the encoder housing.
Figure 70, Earthing and screening
The screen connected at the encoder should be led directly to the evaluation
electronics and be earthed there. This ensures the best possible screening
against interference from outside.

8 Mechanical data
Shaft encoders are a combination of high-quality mechanics and electronics.
With the respective design they can be considered as precise measuring
instruments. For this reason the mechanical data are very important.
In principle, incremental and absolute shaft encoders have the same
mechanical design. The individual components differ in detail. There are
differences as regards the coded discs, the number of photo elements and
the internal evaluation electronics.
8.1 Maximum mechanical rotational speed

The maximum mechanical rotational speed indicated in the data sheet is
stated for permanent operation at the highest temperature.
It assumes that the connection between the driving shaft and the encoder
has no considerable offset.
The maximum rotational speed of the complete system of encoder and
evaluation electronics is influenced by three factors:
mechanical rotational speed of the shaft encoder

limit frequency/maximum output frequency
maximum input frequency of the evaluation electronics.
8.1.1 Mechanical rotational speed of the shaft encoder

The maximum permissible mechanical rotational speed is indicated in the
data sheet. It results from the mechanical load of the encoder. For most
units it is between 10,000 and 12,000 revolutions per minute. Exceptions
are hollow shaft encoders with a maximum of 3,000 or 6,000 revolutions
per minute.
8.1.1.1 Limit frequency / maximum output frequency of the shaft
encoder
This is an electrical value for the output stages of the shaft encoder see
below.
The mechanical rotational speed and the maximum output frequency of the
signal outputs are in direct correlation with the number of pulses provided
per revolution. This means that the rotational speed during operation must
not exceed the maximum permissible mechanical rotational speed of the
shaft encoder and that the rotational speed must not become so high that it
exceeds the maximum permissible output frequency of the output stage
because of the number of increments.
Example:
A shaft encoder has 5,000 increments per revolution and a maximum
output frequency of 250,000 Hertz. Thus the shaft encoder may only be
operated with max. 50 revolutions per second (3,000 min-1) even if it is rated
for 10,000 min -1 so that the maximum output frequency is not exceeded.

8.1.1.2 Maximum input frequency of the evaluation electronics
For the input electronics there are usually details about the maximum
frequency taking into account the number of signal edges to be evaluated.
In case of pulse duplication or multiplication the pulse length is reduced
accordingly. Furthermore the phase difference error must be taken into
account.
The influences described above should be checked for the concrete
application in order to determine the suitability of the shaft encoder. Due to
the tolerances a shaft encoder and ev aluation electronics should be chosen
which can process at least 1.5 times the frequency.
5000 pulses/rev. 2500 pulses/rev.

350
300
250
1000 pulses/rev.
200
150
500 pulses/rev.
100
50 250 pulses/rev.
0 2000 4000 6000 8000 10000 12000

rot. speed [min-1]
Figure 71, Rotational speed and switching frequency
8.2 Shaft load

The shaft of an encoder is made of stainless steel. The maximum mechanical
shaft load is indicated for the outer end of the shaft, i.e. the place with the
highest possible leverage.
The load of the shaft influences the b earing. Indirectly the shaft load always
means the load of the bearing.
Figure 72, Shaft load, axial (A) and radial (R)
Typical values are:
axial 10 N (Newton), 20 N, 40 N
radial 20 N, 60 N.

Depending on the ball bearing The shaft load mainly depends on the design of the bearing. Small units
with small ball bearings have lower values for the permissible load. The
values for each shaft encoder are indicated in the data sheet.
8.3 Shock resistance and vibration resistance

The shock resistance indicates the highe st permissible value of an impact or
shock which may occur for a short time. For ifm units this value is 100 g for
a time of 11 ms (g = gravitational acceleration); type RB is an exception,
however. In this case the shock resistance is 30 g for 11 ms.
Acceleration To determine this value the units are connected and mounted according to
their specified use (e.g. by means of the fixing holes on the front of the
flange). The units are tested in a drop-test machine by dropping them and
bringing them to a gentle stop. The acceleration is 100 g (30 g for type RB).
The amplitude at which vibration of the unit dies out (attenuation factor)
must stop after 11 ms.
Despite these high values impacts or shocks with a hammer etc., for
example for aligning the system during installation must be avoided.
Vibration A value is also indicated for vibrations at which the encoder does not show
any malfunction or is not destroyed in continuous operation. For ifm units
this value is 10 g for the frequency range of 55 to 2,000 Hz.
The acceleration values indicated in the technical data sheet of the shaft
encoder do not impair the function of the units. They can reduce the
accuracy, however.
8.4 Housing material

All shaft encoders have a metal housing. The shaft is made of stainless steel,
the flange and the cap are made of aluminium.
8.5 Protection rating

ifm shaft encoders are supplied with the protection rating IP 64 as a
standard. This value refers to the shaft entry, not to the housing with cable
entry or flange connector. For types RB, RC, RU, and RV the protection
rating IP 66 with an additional sealing of the shaft is available on request. It
has to be taken into account that the units are slightly stiffer due to the
specially sealed bearings.
The singleturn shaft encoders have IP 65.
The housing (cap), the cable entry and the flange sockets meet the
requirements of IP 67.
8.6 Operating temperature

Shaft encoders may be used at operating temperatures starting at 30
degrees Celsius up to +100 degrees Celsius. The temperature range
depends on the type of unit.
The operating temperature range indicates the limit temperatures of the
mounting environment at which the nomin al technical data of the encoders
are observed (DIN 32 878).
Incremental shaft encoders with solid shaft have the widest temperature
range. Hollow shaft encoders have the smallest temperature range.
Storage temperature Often the storage temperature is also indicated in the data sheet. This is the
ambient temperature during storage or transport of the unit in the box.

9 Electrical data
In general the current consumption of the shaft encoder increases slightly
after approx. 5 to 6 years see below.
9.1 Voltage supply

Incremental and absolute shaft encoders are only operated with DC voltage.
There are two versions:
1. TTL voltage range, 5 V DC ± 0.5 V and

2. HTL voltage range, 10 V - 30 V including residual ripple.
After the transient condition of the supply voltage the tolerances indicated
have to be observed.
Ub
Upp
5.25 V
5.0 V
4.75 V
typ. 500 ms
Figure 73, Transient condition of the TTL voltage
Uss = Upp
Figure 73 shows that it can take up to 500 ms until the supply voltage is
within the tolerances.
The voltage level of the output pulses depends on the supply voltage.
Internal operating voltage The internal operating volt age of the shaft encoder is ensured by built-in
voltage regulators. The output pulses are not concerned by this.
This means that operation of the shaft encoder is maintained even with a
poor supply voltage (voltage dips, high residual ripple). The signal outputs,
however, depend on the voltage characteristic of the supply voltage.
The shape of the output pulses in case of poor supply voltage can lead to
the subsequent evaluation electronics not detecting all pulses.
Residual ripple The figure below shows that pulse 2 is below the HIGH level of the
controller and can therefore not be detected/counted.
1 2 3
Figure 74, Residual ripple of the signal outputs
For linear measurement the pieces to be measured become too long.

9.2 Voltage supply via the external evaluation
electronics
Many application systems consist of an electronic counter or another
evaluation unit (e.g. speed monitor). In such cases the voltage supply of the
shaft encoder is often carried out directly via an internal power supply of the
evaluation unit (sensor supply).
If this is the case it must be ensured that the performance of the power
supply of the evaluation electronics is capable of supplying the required
energy to the shaft encoder.
If the evaluation unit does not provide sufficient power this can result in the
problems with the output pulses described above or the evaluation
electronics is damaged due to overload.
External power supply If the sensor supply of th e evaluation unit is not sufficient an additional
external power supply must be used for the supply of the shaft encoder.
When wiring the three units encoder (D), evaluation unit (A) and power
supply (N) it must be ensured that the power supply is not switched directly
in parallel to the sensor supply see figure below.
Such cases can lead to compensating currents flowing due to the different
internal resistances of the two power supplies. This can damage one of the
units.
Reference level In all cases, however, the negati ve connections of all units involved have to
be connected to each other in order to get a common reference point.
Ub Ub
D N A
- + - +
A B B A
Figure 75, Encoder supply with external power supply
The output voltage of the power supply (N) should have the same level as
the sensor supply of the evaluation unit (A) and it should be within the
operating voltage range of the shaft encoder.
9.3 Sensor cables for encoders

Long supply cables can lead to insufficient voltage supply of the shaft
encoder due to the inherent resistance of the cables. Via the sensor cables
the external electronics can detect the voltage at the encoder and adjust it
by a suitable control unit if necessary.
If the sensor cables are not needed, they can be connected in parallel with
the respective supply cable in order to reduce the voltage drop.
The sensor cables are designated as 'sensor' in the data sheet and on the
type label.

9.4 Current consumption
The current consumption of a shaft encoder consists of the current which is
required for the actual operation of the shaft encoder (basic consumption)
and the current which flows via the output stages of the shaft encoder to
the evaluation electronics.
Basic consumption The current consumption of a shaft encoder is not constant. It increases
with time because the luminosity of the LED(s) has to be re-adjusted for the
through-beam method and it depends of course on the number of pulse
outputs being triggered at the same time.
The data sheet only indicates the current consumption which corresponds to
the basic consumption of the shaft encoder. These are typical values, e.g. 95
mA (max. 150 mA). The value in brackets is the highest value for the current
consumption. It can be reached if the LEDs have been re-adjusted up to the
highest value (see below).
Maximum current consumption Absolute shaft encoders have a higher current consumption than
incremental shaft encoders.
In many cases only one value is indicated in the data sheet the highest
possible value. When dimensioning a power supply the highest value for the
current consumption of the shaft encoder(s) should always be calculated
with.
9.4.1 Light-emitting diodes (LEDs)

In the past miniature incandescent lamps were used in shaft encoders. The
lighting area of an incandescent lamp is larger than with LEDs and the
luminosity does not decrease so much in the course of time as in the case of
LEDs.
Disadvantages of the incandescent lamp These incandescen t lamps generated white light. The luminous efficiency
was low in comparison to the power consumption; the susceptibility to
failure was high.
LED As the performance of LEDs increased considerably in the past they are now
being used in shaft encoders. For this purpose they are aged. This ageing
ensures that the luminosity does not decrease very much any more.
In addition the luminosity of the LED is automatically re-adjusted
electronically if it ages nevertheless or if the coded disc is soiled.
Therefore the current consumption of the unit increases with time.
Due to the use of LEDs which are bigger and more luminous it has recently
been possible to illuminate all photo elements with only one LED and one
convex lens (condenser).
Therefore the advantages of the LED, i.e. low current consumption, long life
and vibration-resistant operation can also be used in the design of shaft
encoders.
9.5 Current rating of the signal outputs

The current rating of the signal outputs indicated in the data sheet always
refers to one individual signal output.
The standard maximum current rating is
20 mA for TTL output stages

50 mA for HTL output stages.
For hollow shaft encoders there may be the exception that the HTL output
stage can only be rated with 20 mA.

This is similar for absolute shaft encoders with parallel signal outputs. In this
case the maximum current rating per output is 20 mA, or 6 mA if there are
many signal wires.
The output stages for the signal outputs of HTL shaft encoders are short-
circuit protected. However, they are not protected against reverse voltages.
The voltage supply of these shaft encoders is reverse-polarity protected, but
the signal outputs are not.
TTL without protection TTL shaft encoders are the most sensitive shaft encoders as regards wrong
wiring. The signal outputs are not short-circuit protected and not protected
against reverse voltage and the supply voltage is not reverse-polarity
protected.
The required protective functions, for example a reverse-polarity protection
diode cannot be implemented because the minimum levels for TTL-
operation might not be reached due to the voltage drops connected with
this.
The HIGH level is above 2.5 V; the LOW level is below 0.7 V.
9.6 Signal frequency
9.6.1 Signal frequency and mechanical rotational speed

The current signal frequency for incremental shaft encoders results from the
product of resolution and mechanical rotational speed. It must not exceed
the maximum possible switching frequency indicated in the data sheet in
order not to saturate the unit.
Especially with shaft encoders with high resolutions it may happen that the
maximum permissible switching frequency is exceeded, but not the
maximum permissible mechanical rotational speed. Therefore it must be
checked in each application if the signal frequency to be expected is not too
high.
Evaluation electronics to which a shaft encoder is connected must of course
be rated for the signal frequencies to be expected.
The following diagram shows which rotational speed is permissible for a
given resolution.
Y
160 kHz 300 kHz
12000
10000
5000
2000
50 kHz
1000
500 1000 2000 5000 10000 X
Figure 76, Resolution and rotational speed
The x-axis in figure 76 shows the resolution, the y-axis the rotational
speed.The designations of the three graphs show the maximum possible
output frequency of the output stage of the shaft encoder.

9.6.2 Signal frequency and cable length
If the cable length to the evaluation unit for units with TTL output stage is
to be longer than 100 m it has to be taken into account that the maximum
output frequency of the shaft encoder cannot be reached any more.
In any case the supply voltage of 5 V DC at the shaft encoder should be
ensured. Via the sensor cables the external electronics can detect the
voltage at the encoder and adjust it by a suitable control unit if necessary.
y
300
250
200
150
100
80
60
50
40
30
x
Figure 77, Cable length and output frequency, TTL
The x-axis in figure 77 shows the output frequency in kHz; the y-axis shows
the cable length in metres.
For shaft encoders with HTL-output stage there is an additional

dependence on the supply voltage:
y
300
200
120 Up= 15 V
100
80
60
50 Up= 24 V
30
20 Up= 30 V
12
10
x
Figure 78, Cable length and output frequency, HTL
The x-axis in Figure 78 also shows the output frequency in kHz; the y-axis
shows the cable length in metres.
With decreasing supply voltage (U p) for the shaft encoder the maximum
output frequency decreases as well.

10 Overview shaft encoders
Experience has shown that the types offered as standard solutions are
sufficient for most positioning problems.
There is a choice of different units, depending on which resolution is
required, which force is to be applied to the bearing of the shaft and how
cable and connector entry are to be designed.
Incremental shaft encoders

Operating Flange Output Switching
Shaft Max. rot. Option
Type Resolution voltage (type / Ø in signals frequency in kHz
(Ø in mm) speed (min-1) connector
(TTL/HTL) mm) (optional) (TTL/HTL)
RB 5 1,000 5 / 10 30 R / 36.5 6 TTL, HTL 300/160 10,000 yes
RC 40 512 5 / 10 30 R / 58.0 6 TTL, HTL 300/160 12,000 yes
RU 48 10,000 5 / 10 30 S / 58.0 6 TTL, HTL 300/160 12,000 yes
RV 50 3,600 5 / 10 30 K / 58.0 10 TTL, HTL 300/160 12,000 yes

6, open on
RA 10 1,000 5 / 10 30 - / 36.5 TTL, HTL 300/160 12,000 yes
one side
10, open on
RO 100 5,000 5 / 10 30 - / 58.0 TTL, HTL 300/160 12,000 yes
one side
20, open on
5/- TTL 300 6,000 yes
one side
RP 1,000 3,600 - / 877.0
50, open on
- / 10 30 HTL 160 3,000 yes
one side
Flange types: R = round flange; S = synchro flange, K = clamp flange. Shaft types: V = solid shaft; H = hollow shaft
Absolute shaft encoders

Flange Shaft Output
Operating Incremental Max. rot. Option
Type Resolution (type / Ø in (type / Ø in signals
voltage signals speed (min-1) connexctor
mm) mm) (optional)
256 4,096
HTL / Gray no 10,000 yes
parallel
RN 10 30 S / 58 V / 10
1,024 8,192
SSI / Gray 1 Vpp / 512 12,000 yes
serial
8,192 x 4,096
10 30 S / 58 V / 6 / 10 SSI / Gray 1 Vpp / 512 12,000 yes
serial
max. 8,192 x 4,096

10 30 K / 58 V / 6 / 10 SSI / Gray 1 Vpp / 512 12,000 yes
serial, programmable
RM
max. 8,192 x 4,096
S / 58
programmable, 10 30 V / 6 / 10 Profibus - 12,000 yes
K / 58
Profibus
H / 12
8,192 1 Vpp
10 30 H / 58 (open on one SSI / Gray 10,000 yes
serial / 512
side)
Flange types: R = round flange; S = synchro flange, K = clamp flange. Shaft types: V = solid shaft; H = hollow shaft

11 Operating instructions
All shaft encoders are supplied with detailed operating instructions.
Observing the indicated conditions ensures permanent safe use of the unit.
Figure 79, Operating instructions, example
The operating instructions are available in several languages (German,

English and French).

12 Data sheet
The data sheets of shaft encoders provide clear and nearly complete
information about the technical data of a shaft encoder. In addition to the
important data like article number, type designation, resolution, and output
function they contain a technical drawing, a pulse diagram and the
connecton.
Figure 80, Data sheet of the shaft encoder RV1009

Figure 81, Data sheet of the shaft encoder RM6001

13 Accessories
Shaft encoders can be mounted easily and operated safely with the
corresponding accessories. ifm offers a wide range of accessories.
13.1 Couplings for solid shaft encoders

Incremental shaft encoders (types RC, RU and RV) have their own bearing
rated for up to 60 N (radial at the shaft end) for speeds up to 6,000
revolutions per minute. Due to this load capacity it is possible to mount
these encoders directly on mechanical transmission elements such as
toothed wheels, frictional wheels or pulleys.
If the encoders are subjected to higher strain, it is recommended to use a
coupling for the shaft-side connection of the drive.
The coupling compensates for production and mounting tolerances as well
as temperature influences and misalignment between encoder shaft and
driving shaft. Thus the bearing of the shaft encoder is not subjected to any
additional external stress.
The coupling has to meet high demands. It has to be designed in such a
way that it withstands the radial and axial forces and transmits the
rotational movement without any major delay.
Figure 82, Flexible coupling
While in the case of torsion-proof but flexible shaft couplings axial shaft
displacement only generates static forces in the coupling, radial and angular
displacement results in alternating stress, restoring forces and torques which
can strain the shaft bearing of the encoder.
There are three different alignment errors when mounting the couplings:

a
Figure 83, Axial, radial and angular displacement
The maximum permissible displacement is indicated in the data sheets of

the couplings. Displacement types:
axial displacement : ± 0.4 mm

radial displacement a: ± 0.25 mm
angular displacement : ± 3.5 degrees.
These values are valid for 23°C room temperature. The values for radial,
angular and axial displacement are maximum values which must not all be
reached at the same time during operation.
The life of a coupling depends on to what extent the permissible tolerances
are used.
Grub screw Couplings can be fixed by means of clamping screws or grub screws (set
screw with hexagon socket or slot).
For clamping, the front faces of the coupling are slotted. The slot is pressed
together on the shaft by means of a through bolt.
The grub screws clamp directly onto the shaft. Depending on the material of
the screw and the tightening torque indentations on the shaft may occur.
Therefore couplings with grub screws for fixing are mainly used on shafts
with a flat.
Different axle diameters Often the hub bore holes in both front faces of the couplings have the same
size, e.g. 6 mm.
There are also versions with different bore holes for a better adaptation to
the machine or to the drive. On one side of the coupling there is e.g. a 10-
mm bore hole, on the other side a 6-mm bore hole.

Figure 84, Flexible coupling with different bore holes
In addition to the flexible coupling with its excellent mechanical

characteristics the spring disc coupling has a further advantage: it is
electrically isolating.
Figure 85, Spring disc coupling
13.2 Angle flanges

There are different versions. Their bore holes are designed for the different
flanges of the shaft encoders.
Figure 86, Angle flange, example
The angle flanges have a height of 80 mm to 100 mm, a width of 90 mm to

110 mm and a depth of 40 mm.
13.3 Bearing block

The bearing block provides a further mounting possibility for hollow shaft
encoders. It can withstand high radial stress of the shaft.
It is recommended especially for the use with measuring wheels, pulleys or
chain wheels. It prevents overload of the encoder bearing.

Figure 87, Bearing block with angle flange
The bearing block has two different sha fts. The smaller shaft with a flat on
the right in figure 87 has a diameter of 10 mm.The shaft on the left has a
diameter of 12 mm.
High resistance The maximum permissible rotational speed is 6,000 min -1. The shaft can be
loaded with 200 N axial and 200 N radial. Thus the shaft load is many times
higher than for shaft encoders.
A matching angle flange is offered as a further accessory.
13.4 Isolating adapter

The isolating adapter is for shaft encoders with synchro flange. It consists of
plastic (PBTP) and provides mechanical as well as isolation protection.
Figure 88, Isolating adapter
The cap has a diameter of 63 mm. The diameter of the flange is 82 mm.
The depth is 38 mm.
13.5 Pinion and rack

A pinion on the shaft of the encoder in connection with a rack enables
direct transmission of linear movements.
Figure 89, Pinion

The pinion has 20 teeth and a circumference of 50 mm. It is designed for an
axle diameter of 6 mm. A pinion with a bore hole of 10 mm is also available.
Figure 90, Rack
The rack is 5 mm thick and it is available in lengths of 500 mm and 1,000

mm. Fixing holes have to be drilled by the user.
If possible the rack should be mounted with the teeth downwards. Thus
malfunctions due to dust or chips can be avoided. Measuring wheels and
pinions are usually mounted directly on the encoder shaft without a flexible
coupling.
13.6 Resilient base

In order to protect shaft encoders ag ainst mechanical overload due to the
use of pinions and racks the units can be mounted on a resilient base.
A B
Figure 91, Resilient base
13.7 Measuring wheel

Measuring wheels are available with circumferences of 200 mm and 500
mm. The measuring wheel with a circumference of 200 mm is available for
shaft diameters of 6 or 10 mm, the measuring wheel with a circumference
of 500 mm only for a shaft diameter of 10 mm.

Figure 92, Measuring wheel
Measuring wheels are either completely made of aluminium, the tread is

knurled axially (strongly roughened); or they are made of plastics with
different surfaces. These can be: rubber, smooth plastic or grooved plastic.
Non-slip For choosing the measuring wheel it is important that the wheel can move
on the surface without any slip.
Examples:
Surface of the measuring distance: Coating of the measuring wheel:,

Glass Rubber
Metal Rubber
Wood possibly aluminium
rubber aluminium
Figure 93, Measuring wheels, rubber, plastic, smooth aluminium,

roughened aluminium
A disadvantage of rubber is the wear due to abrasion and that the

temperature resistance is not very high.

A
B
C
Figure 94, Measuring wheel on moving arm
If a measuring wheel is used it may also be recommendable to place the

shaft encoder on a resilient base.
13.8 Fastening clamp

These small discs are for fastening shaft encoders with synchro flange.
Figure 95, Fastening clamp
The diameter is only 12 mm. They are 5.5 mm thick. The bore hole has a
diameter of 4.2 mm. The lip is 3 mm thick.
13.9 Pulse divider, pulse stretcher

With pulse dividers and pulse stretchers high frequencies or short pulses can
be adapted to low input frequencies of evaluation systems and controllers.
They modify high signal frequencies or short pulses in such a way that they
can be detected by standard inputs of plcs or electronic counters. The use of
a pulse divider thus eliminates the need of fast input cards of a plc.
Furthermore the pulse divider can be used as level converter of TTL or HTL
signals.
13.9.1 Pulse divider

The pulse sequence of incremental shaft encoders can be very fast,
depending of the resolution and rotational speed. The input frequency of
the standard inputs of a plc or an electronic counter is maybe not high
enough to detect all pulses of the shaft encoder.
By using a pulse divider the high frequency of the signal outputs of the shaft
encoder can be divided so that it can be detected by the plc. The
disadvantage is that the accuracy is reduced.

shaft encoder
E 80102
plc
Figure 96, Pulse divider E80102, connection
Depending on the version of the pulse divider the division ratio of the input
to the output can be freely selected between 1 and 255 (E80102) or it is
fixed to 10:1 (E80100).
13.9.2 Pulse stretcher

The pulse stretcher converts short input pulses into output pulses with a
constant length.
Figure 97, Pulse stretcher E80110
The input pulse (IN) length of the pulse stretcher must be at least 0.2 ms.
The pulse length on the output (OUT) is 25 ms. There must be at least 28
ms between the input pulses.

14 Mounting of shaft encoders
The mounting of shaft encoders is especially important. Misalignment
between drive and encoder shaft can considerably impair the operation of
the shaft encoder.
B A
C D
Figure 98, Figure 98: Mounting with coupling
The shaft encoder can be mounted by means of:
Mounting holes on the front face of the shaft encoder.

Fastening clamps
Clamping.
Figure 99, Mounting with fastening clamp
Not the cap Solid shaft encoders must never be fixed outside the flange. The housing
cap is made of aluminium and can be deformed relatively easily. It provides
no secure hold.
Hollow shaft encoders are mounted directly on the driving part, the hollow
shaft being connected to the driving shaft.

Figure 100, Hollow shaft encoder with shaft open on one side
3. SW 3
4x M4
Figure 101, Hollow shaft encoder with continuous hollow shaft

15 Calculation examples
15.1 Linear measurement
To calculate the resolution, the circumference of the pinion or the
measuring wheel and the requested resolution have to be known.
Example:
A pinion with a circumference of 50 mm is used, the required resolution is
0.1 mm.
With each 0.1 mm-step a pulse is to be generated, this results in a total of
500 pulses for one complete revolution. The shaft encoder in this example
needs to have a resolution of 500 increments.
For the resolution in millimetres the following applies: Number of
increments = circumference (in millimetres).
15.2 Switching frequency and mechanical

rotational speed
Correlations between maximum mechanical rotational speed, switching
frequency and resolution:
Note: With a high resolution the electrical switching frequency is quickly
exceeded.
The indication of the maximum mechanical rotational speed only refers to
the mechanical load of the shaft encoder.
Example: Encoder RU1045, type RU-5000-I05/L2
Max. mechanical rotational speed: 12,000 min -1 = 200 s-1
Maximum switching frequency (electr.): 300 kHz
A maximum resolution of 5,000 pulses and maximum mechanical rotational
speed result in a switching frequency of:
200 s1 X 5,000 = 1,000,000 Hz = 1 MHz.
Thus the maximum possible switching frequency of this shaft encoder is
exceeded by more than three times.

16 Handling of shaft encoders
Better not ...
Figure 102, No overvoltage, do not align with a hammer
Figure 103, Do not clamp into the vice, do not drill into the shaft
Figure 104, Do not saw or grind the shaft

17 Applications
Shaft encoders are used in the following industries for example:
Metallurgical, milling and steelworks equipment

Plant and apparatus construction in general (e.g.hydraulics,
pneumatics, welding systems, presses, stamping machines, drilling
machines)
Machine tools
Transfer lines
Special machines
Surface treatment machines
Processing machines for wood, paper, plastics
Printing and labelling machines
Mounting systems
Big antenna systems
Industrial robots
Conveyor and transport systems
Construction of lifts, escalators
Roller shutter doors
Stacking systems
Cranes and lifting systems
Figure 105, Measuring wheel for linear measurement
Incremental shaft encoders in connection with a counter enable automatic

cutting of e.g. sheets of veneer to a specified length.

Figure 106, High-lift shelves
In this case multiturn shaft encoders are used to enable exact positioning of
the transport system and automatic loading and unloading.
To ensure safe data transmission via longer distances multiturn shaft
encoders with SSI interface are used.

Figure 107, Robots
Absolute shaft encoders are used for the precise control of the movement
of industrial robots and automatic handling systems. They guarantee further
processing e.g. after a power failure without any problems, thus making
complex returning to a reference point superfluous.
Figure 108, X-Y-Z-milling system
The individual positions and travel lengths of an automatic machining

system are detected by incremental encoders with up to 10,000 pulses per
revolution. This allows resolutions up to 0.01 mm.

18 Annex
18.1 Competitors
There are many competitors on the market for shaft encoders with an
optical principle. Heidenhain, Hengstler, Stegmann, Balluff, IVO, TWK, T2R,
Litton and Baumer are some of the most important ones.
18.2 Glossary of technical terms

Starting torque The starting torque of a shaft encoder is the torque required to cause the
shaft to change from the off position to a rotational movement.
Absolute shaft encoder Encoder which provides cl ear, coded information for each measuring step.
Scanning frequency The number of signal periods per second. The maximum scanning frequency
limits the speed of incremental systems.
Alarm signal It serves to monitor the shaft encoder as regards malfunctions, e.g. disc
breakage, soiling, short circuit of the signal wire, and insufficient supply
voltage.
Analogue signal A signal which continuously changes its level.
Complementary Output stage where the inverted signals are provided as well. Electrically the
I/O levels are transmitted in the form of voltage differences between two
wires. Thus the useful signal (the difference) remains uncorrupted, as
interference usually occurs on both wires.
ASCII The name ASCII stands for ´American Standard Code for Information
Interchange´. It is a code standardised in the USA to represent alphanumeric
characters. Originally based on a 7-bit coding it enabled the representation
of 128 characters. Extended to 8 bits it became the standard code on small
computers. Due to this extension 128 characters became possible which are
nowadays partly used as checksum or to represent country-specific
characters.
The ASCII code is currently the standard code to store unformatted text
files.
ASIC User-specific IC.
Resolution Number of measuring steps (gratings) within a measuring range.
Axial load Maximum load of the encoder shaft in axial direction looking at the front
face of the shaft in the direction of the flange.
Baud rate Speed of the data transmission (bits per second).
BCD Binary-coded-decimal; binary representation of a decimal number (one
decade).
Bimetal A bimetal strip consists of two different metals which have a different
expansion at different temperatures. Both metal strips are bonded together.
These bimetal strips can also be used to manufacture temperature meters.
Binary Two logic states (yes/no, ON/OFF, HIGH/LOW). Basis for dual computer
systems.
Binary code The basis for each binary code is a so-called binary system, i.e. a system with
only two states, for example ON/OFF, true/false, 0 Volt/5 Volts or the binary
code 1/0.
The binary code is a code which only works with two characters: the binary
zero and the binary one. The basic unit is the bit, a storage place which can
only take the values 0 or 1. Eight such bits combined are called byte. Thus
one byte can represent 256 characters.
Bit Abbreviation for "binary digit"; smallest information unit of a binary system
the value of which can be I or 0 (yes/no decision).
Byte Sequence of 8 bits. One byte has 8 bits.

Data transmission, parallel Each individual track has one data wire. The data are either constantly
available or they are provided via an enable signal. Example: With a
resolution of 4096 steps (12 bits) there are 12 wires.
Dual The expression "dual" refers to the representation of numbers.
Code Format of the data transmission.
Data valid Output for checking the validity of data.
Data bus System of wires for parallel or serial electronic data transmission.
Data transmission, synchronous-serial With transmission in this format all data are transmitted in succession on
one data wire. Only 4 cable cores are required: Clock, clock negated, data
and data negated. In the case of shaft encoders with synchronous-serial
interface, the inverted data are provided as well to increase the noise
immunity. Depending on the clock frequency cable lengths of up to 100 m
are possible.
DC Direct voltage
DIN Deutsche Industrie-Norm (German industrial standard).
Revolution, maximum mechanical Maximum permissible revolution of the encoder shaft. The maximum value
is stated in the data sheet together with the other mechanical data.
Dual code Natural binary code, code often used with absolute shaft encoders.
EBCDIC This abbreviation stands for 'Extended Binary Coded Decimal Interchange
Code'. It is used on mainframes to represent characters. This code was
introduced by IBM in 1965 and has not changed up to now.
EEPROM Also E2-PROM. Abbreviation for "Electrically Erasable Programmable Read-
Only Memory".
EMC Electromagnetic compatibility.
Enable Control input via which the data outputs can be enabled.
EPROM "Erasable Programmable Read-Only Memory"; read-only memory which is
erasable with UV light and can therefore be rewritten.
Flange socket Connector which is mounted directly on the encoder housing.
Encoder monitoring see alarm signal
Encoder supply The supply voltage to be supplied to the shaft encoder.
Encoder accuracy Deviation between the actual position and the measured position.
Gray-Code The Gray code is a different way of representing the binary code. The basis
is that two adjacent bit combinations must not differ in more than one bit
(0 or 1). This is an advantage especially if as many data as possible are to be
stored. A further benefit is the possibility to detect errors in the transmission
of such codes more easily because ad jacent characters may only differ in
one position (valid for Ub of 24 V DC and maximum current rating).
HTL output Abbreviation for ´High Threshold Level´. The output level is more than 21
Volts. The counterpart is the TTL output.
Interpolation electronics It converts a sinusoida l period into several square-wave pulse trains by
means of an additional division, thus achieving a considerably higher
measuring resolution.
LSB Least Significant Bit
Mbaud Megabits per second. Information about a data transmission speed.
MSB Most Significant Bit
Multiturn shaft encoder The multiturn shaft encoder does not only count the resolution of a
revolution but also the number of revolutions.
Parity bit (even) A parity bit (check bit) is added to the transmitted data in order to achieve
an even number of bits.
PC Personal computer.
PUR Standard cable material (polyurethane) for all shaft encoders with more than
three output signals. According to VDE 0672 the PUR cables are resistant to
oil as well as hydrolysis and microbes.

PVC Standard material for the sheathing. In order to avoid cable break PVC
cables must not be moved if the temperature falls below -5 °C.
Radial load Maximum load of the encoder shaft in radial direction (parallel to the flange
at the outer end of the shaft).
RS422/485 Interfaces for serial data transmission with values according to the EIA
standard.
RS422 Standardised interface for unidirectional point-to-point connection.
RS485 Like RS422, but as bidirectional bus interface.
Interface Interface point with defined connections, signals and signal sequences.
Protection rating IP 50 Complete protection against contact with live parts or internal moving parts.
Protection against harmful dust deposits. The ingress of dust is not
completely prevented but dust must not penetrate in such quantity as to
impair the operation. No special protection against ingress of water.
Protection rating IP 64 Complete protection against contact with live parts or internal moving parts.
Protection against the ingress of dust and splashing water. Water splashed
onto the equipment from any direction shall have no harmful effect.
Protecting rating IP 65 Complete protection against contact with live parts or internal moving parts.
Protection against the ingress of dust and water jets. A water jet from a
nozzle, aimed at the equipment from any direction shall have no harmful
effect.
Protecting rating IP 66 Complete protection against contact with live parts or internal moving parts.
Protection against the ingress of dust and powerful water jets. Water must
not penetrate the equipment in harmful quantities in case of temporary
powerful water jets.
Singleturn encoder The singleturn encoder resolves a mechanical revolution of the shaft into a
number of code values corresponding to the resolution. A code value is
assigned to each angular position within a revolution.
Shock resistance Maximum permissible short-time value of a shock load.
Interference signal For 10 to 30 V shaft encoders with axial or radial flange connectors this
signal is on PIN 7. It can be used for monitoring the encoder. In case of a
problem the signal changes from HIGH to LOW level.
Synchronous-serial right-justified format Like with the triangular format (see below) the shaft encoder always
provides data bits via 25 clock pulses also in this case. In case of a scaling,
however, the 'zeros' are always put before the complete position
information.
Triangular format (SSI) For SSI transmission of the position values a differentiation is made between
multiturn (12 bits) and singleturn (13 bits). Therefore data bits are always
read over 25 clock pulses, but the data content may vary. The resolution of
the multiturn reduced by means of a scaling is filled with preceding 'zeros'.
In case of a reduced singleturn resolution the 'zeros' are added at the end.
TTL output "Transistor-transistor-logic" on a 5- Volt basis. The counterpart is the HTL
output.
Operating temperature Temperature range at whic h all electrical and mechanical data are met.
Vibration The value of a periodical oscillation at which the unit does not show any
malfunction or is not destroyed when in permanent operation. It is stated in
g for the frequency range 58 2000 Hz.
Virtual zero point The SSI controller enables the user to set a zero point independently of the
shaft encoder.
Shaft load The shaft load is the maximum permissible load on the shaft, referred to the
shaft end at maximum mechanical revolution and 20°C operating
temperature.

Angular second Angle sizes are stated in degrees. One angular second is the 3,600 th part of
a degree. A full circle with 360 degrees therefore has 1,296,000 angular
seconds.

19 Type key
May 2004

19.1 Examples of the use of the type key
A type key is often also described as 'talking type key' because the most
important technical data can be read from the type designation by means of
the type key.
Once fixed, the type key may reach its limits with an increasing variety of
unit types. In that case a completely new type key must be created. in
general it is useful only to work with the article number. All organisational
processes at ifm electronic use the article number.
A shaft encoder with the article number RU6071 has the type designation
RU-0100-I24/L2E.
If the type key is known this type designation provides the following
information:
Position: 1 2 3-7 8 9 10 - 11 12 13 14 15
R U - 0100 - I 24 / L 2 E
Position 1: shaft encoder

Position 2: solid shaft encoder 58 mm with synchro flange
standard 6 mm shaft
Positions 3 7: 100 increments
Position 8: reserve
Position 9: incremental output signals
Positions 10 -11: 10 30 V DC
Position 12: reserve
Position 13: cable entry axial
Position 14: 2 m cable length
Position 15: protection rating IP66
Another shaft encoder with the article number RM 1102 has the type
designation RM-8192-E05/R5B.
Position: 1 2 3-7 8 9 10 - 11 12 13 14 15
R M - 8192 - E 05 / R 5 B
Position 1: shaft encoder

Position 2: multiturn shaft encoder 58 mm
Positions 3 -7: max. 8192 (25 bits) steps per revolution, 4096
revolutions
Position 8: reserve
Position 9: Profibus interface, connection to gateway
Positions 10 -11: 5 V DC (TTL, from the gateway)
Position 12: reserve
Position 13: cable entry radial with cable plug ifm 1001.1
Position 14: 5 m cable length
Position 15: 10 mm shaft

20 List of figures
Figure 1, Linear measurement and synchronous movement moni toring ....................................................................7
Figure 2, Detection of rotational speed and angle measurem ent...............................................................................7
Figure 3, Bending systems and X-Y-recorders drawing tables ....................................................................................8
Figure 4, Level measurement and radar/aerial systems ..............................................................................................8
Figure 5, Industrial robots .........................................................................................................................................8
Figure 6, Potentiometer ..........................................................................................................................................11
Figure 7, Resolver....................................................................................................................................................11
Figure 8, Inductive principle (Novotechnik) ..............................................................................................................12
Figure 9, Magnetic principle....................................................................................................................................13
Figure 10, Mechanical shaft encoder (cam-operated switchgr oup)..........................................................................13
Figure 11, Cam-operated switchgroup with inductive proximit y switches................................................................14
Figure 12, Inductive system .....................................................................................................................................14
Figure 13, Incremental shaft encoder ......................................................................................................................15
Figure 14, Incremental shaft encoder ......................................................................................................................19
Figure 15, Coded disc with increments ...................................................................................................................19
Figure 16, Photoelectric detection, through-beam method .....................................................................................20
Figure 17, Scanning plate, without reference mark grating.....................................................................................21
Figure 18, Light source and condenser....................................................................................................................21
Figure 19, Sine wave of the photo elements ...........................................................................................................22
Figure 20, Connection of the photo el ements.........................................................................................................22
Figure 21, Signal voltage.........................................................................................................................................22
Figure 22, Pulse generation.....................................................................................................................................23
Figure 23, Signal generation, block diagram ...........................................................................................................24
Figure 24, Pulse diagram channels A, B, and zero index (NI)....................................................................................25
Figure 25, Zero index 360 degrees long (NI), type RB, 10 30 V .............................................................................26
Figure 26, Pulse diagram with inverted channels (NI: Zero index) ............................................................................26
Figure 27, Sinusoidal output signals (Vss = Vpp)......................................................................................................27
Figure 28, Signal change.........................................................................................................................................28
Figure 29, Duplication of the pulses ........................................................................................................................29
Figure 30, Pulse multiplication.................................................................................................................................29
Figure 31, Coded discs............................................................................................................................................31
Figure 32, Photoelectric detection, through-beam method .....................................................................................32
Figure 33, Pulse diagram of the parallel interface........ ............................................................................................33
Figure 34, Gear box with coded discs and Hall elements .........................................................................................34
Figure 35, Multiturn encoder, 4 bits singleturn, 3 bits mu ltiturn..............................................................................35
Figure 36, Dual code ...............................................................................................................................................36
Figure 37, Gray code...............................................................................................................................................36
Figure 38, Gray excess code ....................................................................................................................................37
Figure 39, Cut Gray code for the value 360 ............................................................................................................38
Figure 40, Code types .............................................................................................................................................39
Figure 41, SSI interface unit RM ..............................................................................................................................40
Figure 42, SSI, pulse diagram for singleturn shaft encode rs.....................................................................................41
Figure 43, SSI, pulse diagram for multiturn shaft encoders ......................................................................................41
Figure 44, SSI interface, incremental signal shape ...................................................................................................42
Figure 45, SSI interface, block diagram ...................................................................................................................42
Figure 46, SSI programming software .....................................................................................................................43
Figure 47, SSI programming software, connection ..................................................................................................44
Figure 48, SSI interface, circuit example ..................................................................................................................44
Figure 49, SSI controller ..........................................................................................................................................45
Figure 50, SSI controller, connections......................................................................................................................45
Figure 51, Profibus DP shaft encoder, type RM .......................................................................................................46

Figure 52, Profibus DP .............................................................................................................................................47
Figure 53, Profibus, addressing and terminating resistor ..........................................................................................47
Figure 54, Mark-to-space ratio ................................................................................................................................49
Figure 55, Phase difference .....................................................................................................................................49
Figure 56, Solid shaft encoder .................................................................................................................................51
Figure 57, Ball bearing (K) with sealing ring (D) .......................................................................................................52
Figure 58, Flange with threaded holes (G) ...............................................................................................................53
Figure 59, Flange types (1, 2, 3 see above) ...........................................................................................................53
Figure 60, Clamp, synchro and round flange...........................................................................................................53
Figure 61, Hollow shaft encoders ............................................................................................................................54
Figure 62, Hollow shaft encoder, cut-away view .....................................................................................................55
Figure 63, Stator coupling for hollow shaft encoder................................................................................................55
Figure 64, Cable entry axial (A) and radial (R) ..........................................................................................................56
Figure 65, Cable entry for small units ......................................................................................................................57
Figure 66, Cable plug ..............................................................................................................................................57
Figure 67, Connector unit .......................................................................................................................................58
Figure 68, Pin connection of a plug .........................................................................................................................58
Figure 69, Coupling, electrical .................................................................................................................................58
Figure 70, Earthing and screening ...........................................................................................................................59
Figure 71, Rotational speed and switching frequency.......... ....................................................................................61
Figure 72, Shaft load, axial (A) and radial (R) ...........................................................................................................61
Figure 73, Transient condition of the TTL voltage ....................................................................................................64
Figure 74, Residual ripple of the signal outputs .......................................................................................................64
Figure 75, Encoder supply with external power supply ..... .......................................................................................65
Figure 76, Resolution and rotational speed..............................................................................................................68
Figure 77, Cable length and output frequency, TTL.................................................................................................68
Figure 78, Cable length and output frequency, HTL ................................................................................................69
Figure 79, Operating instructions, example .............................................................................................................71
Figure 80, Data sheet of the shaft encoder RV1009 ................................................................................................72
Figure 81, Data sheet of the shaft encoder RM6001 ...............................................................................................73
Figure 82, Flexible coupling .....................................................................................................................................74
Figure 83, Axial, radial and angular displacement....................................................................................................75
Figure 84, Flexible coupling with different bore holes ..............................................................................................76
Figure 85, Spring disc coupling................................................................................................................................76
Figure 86, Angle flange, example ............................................................................................................................76
Figure 87, Bearing block with angle flange..............................................................................................................77
Figure 88, Isolating adapter.....................................................................................................................................77
Figure 89, Pinion .....................................................................................................................................................77
Figure 90, Rack .......................................................................................................................................................78
Figure 91, Resilient base ..........................................................................................................................................78
Figure 92, Measuring wheel ....................................................................................................................................79
Figure 93, Measuring wheels, rubber, plastic, smooth aluminium, roughened alum inium .......................................79
Figure 94, Measuring wheel on moving arm ...........................................................................................................80
Figure 95, Fastening clamp......................................................................................................................................80
Figure 96, Pulse divider E80102, connection ...........................................................................................................81
Figure 97, Pulse stretcher E80110 ...........................................................................................................................81
Figure 98, Figure 98: Mounting with coupling.........................................................................................................82
Figure 99, Mounting with fastening clamp..............................................................................................................82
Figure 100, Hollow shaft encoder with shaft open on one side ...............................................................................83
Figure 101, Hollow shaft encoder with continuous hollow shaf t .............................................................................83
Figure 102, No overvoltage, do not align with a hammer........................................................................................85
Figure 103, Do not clamp into the vice, do not drill into th e shaft ...........................................................................85
Figure 104, Do not saw or grind the shaft...............................................................................................................85

Figure 105, Measuring wheel for linear measurement.............................................................................................86
Figure 106, High-lift shelves ....................................................................................................................................87
Figure 107, Robots..................................................................................................................................................88
Figure 108, X-Y-Z-milling system .............................................................................................................................88

21 Index
9 E
90-degree-shift 22 Earthing 57
Electrical connection 54
A Electrical data 61
Enable signal 32
Absolute shaft encoders 29 external evaluation electronics 62
Acceleration 60
Accessories 70 F
Accuracy of the shaft encoder 47
Angle flanges 72 FAQ 10
angular displacement 71 Fastening clamp 76
Applikationen 82 Flange types 50
axial displacement 71
G
B Grating period 20
Ball bearing 49 Gray code 35
BCD code 35 Gray excess code 36
Bearing block 72 Grub screw 71
Binär-Code 34
H
C Hall-effect sensors 33
Calculation examples 80 Handling 81
Capacitive principle 13 Hollow shaft encoders 51
Clamp flange 51 Housing material 60
Code types 34 hro flange 51
Coded disc 18 HTL voltage range 61
Condenser 20
Connection 32 I
Connection cable 54
Connector 55 Incremental shaft encoders 17
counting 33 Increments 18
Couplings 70 Inductive principle 12
Current consumption 63 Inductive system 14
Current rating 63 input frequency 59
Interference signal 27
D Inverted output signals 25
Isolating adapter 73
Data sheet 68
Data transmission 39 L
DC component 21
Decadic Gray excess-3-code 37 Laying the cable 56
Detection of the direction 27 LED 63
DIADUR 18 Light-emitting diodes 63
DIADUR method 15 Limit frequency 58
Direction of rotation 33 Linear measurement 80
Dividing error 47 Linear movement 7
Dual-Code 34 LSB 32

M Round flange 51
Magnetic principle 12
mark-to-space 23
S
Mark-to-space ratio 48 Scanning plate 20
Measuring step 24 screening 57
Measuring wheel 74 Sensor cables 62
Mechanical data 58 Shaft encoders 17
Mechanical rotational speed 58 Shaft load 59
Mechanical shaft encoders 13 Shock resistance 60
Mounting 53 Signal evaluation 22
Mounting of shaft encoders 78 Signal frequency 64
MSB 32 Signal generation 19
Multiplex operation 33 Signal generation of the photo elements 20
Multiturn shaft encoders 33 Singleturn shaft encoders 31
Sinusoidal signals 26
O Sockets/coupling 56
Solid shaft encoders 49
Operating instructions 67 Square-wave pulse trains 22
Operating temperature 60 SSI controller 43
Oscillator sensors 14 SSI interface 39
Standard resolutions 19
P Starting torque 50
stator coupling 52
Phase difference 48 Storage temperature 60
Phase discriminator 27 system accuracy 15
Photo elements 21
Photoelectric shaft encoders 14
photoresist 15
T
Potentiometers 11 technical terms 85
Profibus-DP interface 45 Through-beam method 19
Protection rating 60 transducer 9
Pulse diagram 23 TTL voltage range 61
Pulse divider 76 Type key 88
Pulse multiplication 28
pulse stretcher 76
V
R Vibration 60
vibration resistance 60
rack 73 Voltage supply 61
radial displacement 71
Reference mark 20 W
Reference mark outside 25
Reflectible Gray code 35 Wiring 26
Residual ripple 61
Resilient base 74 Z
Resolution 19, 31
Resolvers 11 zero index 20
Rotational movement 7

22 Source
Some diagrams and figures were taken from literature/catalogues of the
company Heidenhain.
THE END

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1.1 Measuring systems

1.1.1 Shaft encoders as a standard means of measuring

Function Shaft encoders transform mechanical movements into electrical signals.

Resistant Shaft encoders have shown excelle nt performance in various applications,

1.2 Applications for shaft encoders

Training manual Shaft encoders Page 6 of 100

1.2.2 Linear movement

1.3 Application examples of shaft encoders

Figure 1, Linear measurement and synchronous movement monitoring

Figure 2, Detection of rotational speed and angle measurement

Training manual Shaft encoders Page 7 of 100

Figure 4, Level measurement and radar/aerial systems

Figure 5, Industrial robots

1.4 Digital signals

Training manual Shaft encoders Page 8 of 100

Training manual Shaft encoders Page 9 of 100

2.1 On the contents

Training manual Shaft encoders Page 10 of 100

3.1 Analogue systems

Training manual Shaft encoders Page 11 of 100

3.1.4 Magnetic principle

Training manual Shaft encoders Page 12 of 100

Figure 9, Magnetic principle

3.1.5 Capacitive principle

3.2 Digital systems

3.2.1 Mechanical shaft encoders

Figure 10, Mechanical shaft encoder (cam-operated switchgroup)

A cam-operated switchgroup is free from wear and tear if the mechanical

Training manual Shaft encoders Page 13 of 100

3.2.2 Oscillator sensors

3.2.3 Inductive system

Figure 12, Inductive system

3.2.4 Photoelectric shaft encoders

Training manual Shaft encoders Page 14 of 100

The photoelectric shaft encoders are discussed in this manual.

Training manual Shaft encoders Page 15 of 100

4.1 DIADUR method

1. Cleaning of the glass disc (ultrasonic, without contact).

Due to the many manufacturing steps the production of a DIADUR glass

Training manual Shaft encoders Page 16 of 100

RU, incr., solid shaft RV, incr., solid shaft

Training manual Shaft encoders Page 17 of 100

incremental shaft encoders

5.1 Incremental shaft encoders

5.1.1 Shape and design

shaft (solid shaft or hollow shaft)

Training manual Shaft encoders Page 18 of 100

5.1.2 Coded disc

Figure 15, Coded disc with increments

Training manual Shaft encoders Page 19 of 100

5.1.4 Signal generation

5.1.4.1 Through-beam method

Figure 16, Photoelectric detection, through-beam method

Training manual Shaft encoders Page 20 of 100

Figure 18, Light source and condenser

Training manual Shaft encoders Page 21 of 100

Figure 19, Sine wave of the photo elements

Sine curve I1: segment 0°

Figure 20, Connection of the photo elements

DC component Due to the connection in push-pull circuit the DC component is suppressed.

0° 90° 180° 270° 360°

Training manual Shaft encoders Page 22 of 100