MiniCODER

Configurable rotational speed and

position sensor with rotational speed
GEL 2449
histogram

Technical information Version 2023-08-22

General
■ The measuring system comprises a MiniCODER and a
target wheel for attachment to machine shafts
■ Target wheels are to be ordered separately
■ The MiniCODER contactlessly scans the target wheel using
magnetoresistive sensors and acquires the direction of rota-
tion, rotational speed and position
■ The configurable MiniCODER records the minimum tempera-
ture, maximum temperature and rotational speed histogram;
it can be calibrated automatically using the testing and pro-
gramming unit
■ Safety integrated certificate

Features
■ Output signal 1 Vpp Differential signal (sin/cos)
■ Square-wave differential reference signal
■ Frequency range from 0 to 200 kHz (1)
■ Temperature range from -30 °C to +120 °C
■ Degree of protection IP 68 MiniCODER with tangential cable outlet

Advantages
■ Wear-free and electrically maintenance-free measuring
system
■ Low temperature drift and high signal quality
■ Highest immunity to interference due to fully screened metal
housing
■ Resistant to typical oils
■ Quick commissioning of the configurable MiniCODER in the
assembled state using the testing and programming unit
without the need to open the spindle
■ High design flexibility due to custom manufacture of
precision target wheels

Field of application
■ Position and rotational speed acquisition in machine tool
engineering

(1) At a cable capacitance of 5 nF

Right to technical changes and errors reserved.

DS22-2449

Internet: www.lenord.com Lenord, Bauer & Co. GmbH

E-Mail: info@lenord.de Dohlenstraße 32
Phone: +49 208 9963–0 46145 Oberhausen, Germany
Description

Design Signal pattern K

The MiniCODERs are intended to be used for the con- The output signals are two sinusoidal signals offset by 90°
tactless measurement of rotary and linear movements pre- for the detection of direction (tracks 1 and 2) and their
dominantly in machines, gears, motors or high-speed spin- inverse signals.
dles. They are manufactured using the latest micro The signal sequences are dependent on the direction of
system technology and are fully encapsulated, as such rotation
they are particularly resistant to shocks and vibration.
U1+
Measuring system
U1-
The measuring system comprises a MiniCODER and a tar-
get wheel. The system does not need dedicated bearings U2+
for this task, as the target wheel is mounted directly on the
machine shaft. U2-
The measuring system operates contactlessly and is main-
UN+
tenance and electrical wear-free. It acquires the direction
of rotation, rotational speed and position of the rotating UN-
machine shaft.
The target wheel is made of ferromagnetic material and is Clockwise output signals
to be ordered separately.
UN* Reference signal (reference track N)
The MiniCODER has a magnetic field that is changed by
the rotating target wheel. The sensor acquires the change
in the magnetic field and the integrated electronics convert Cable outlet MiniCODER
this information into appropriate output signals. The MiniCODER is available with the following cable out-
External electronics can read the output signals and deter- let:
mine the direction of rotation, rotational speed and position
of the machine shaft.
A defined air gap between the target wheel and
MiniCODER is required for the contactless measurement.
To make assembly easier, a corresponding distance gauge Tangential left
is included with the MiniCODER.
Optional extras
Reference mark
Configurable (P)
The MiniCODER can determine the position of a machine
shaft by acquiring a reference mark. The MiniCODER can be adjusted, analysed and config-
The position is output as an square-wave differential refer- ured using the testing and programming unit GEL 211CS0.
ence signal (reference track N).
The MiniCODER evaluates the following reference marks: Configuration of the MiniCODER via the connector
Tooth (Z). ■ Setting the sin/cos amplitudes without mechanical re-
adjustment of the air gap
■ Elimination of the offset and amplitude error for com-

Module pensating mounting tolerances

■ Definition of 7 rotational speed ranges for the activation
Possible modules: 1.0 and 0.4 . of the rotational speed histogram in the MiniCODER
■ Entry of a spindle serial number (allocation of the drive)
The MiniCODER must be ordered to suit the de-
sign of the reference mark and to suit the module In addition, various data is saved in the MiniCODER and
of the target wheel. can be read using the GEL 211CS0:
■ Rotational speed histogram for the analysis of the
drive's operating conditions
■ Number of startups
■ Minimum / maximum temperature in the MiniCODER
■ Item number and serial number of the MiniCODER
■ Total operating time and time since the last configura-
tion

2 DS22-2449 / (2023-08-22)
 Technical data

Technical data measuring system

GEL 2449 1 GEL 2449 4
Target wheel
Material Ferromagnetic steel
Width of the target wheel 10.0 mm
Reference mark Tooth (Z)
Module m(1) 1.0 0.4
Geometric data
Air gap permitted 0.50 mm ± 0.02 mm 0.20 mm ± 0.01 mm

Technical data GEL 2449

Electrical data
Supply voltage UB 5 V DC ± 5%
(polarity reversal protected, overvoltage protected)
Current consumption (without load) ≤ 50 mA
Output signal level 1 Vpp Differential signal
Output signal Two sinusoidal signals offset by 90° and their inverse sig-
nals, short-circuit-proof; square-wave reference signal
Output frequency 0 to 200 kHz (2)
Power consumption without load ≤ 0.3 W
Mechanical data
Housing material Die cast zinc
Weight 100 g
Cable data (Cable version —)
Cabel construction 9 x 0.15 mm2 [26 AWG]
Number of cores x core cross-section
Cable diameter 5 mm
Minimum bending radius 25 mm
Maximum permitted cable length 100 m (3)
Ambient data
Working temperature range 0 °C to +70 °C
Operating and storage temperature range -30 °C to +120 °C
Degree of protection IP 68
Dielectric strength 500 V AC; as per DIN EN 61439-1:2012-06
Electromagnetic compatibility Electromagnetic emissions
DIN EN 61000-6-4:2011-09; DIN EN 61000-6-3:2011-09
Electromagnetic immunity
DIN EN 61000-6-2:2006-03; DIN EN 61000-6-1:2007-10
Vibration resistance 200 m/s2 (EN 60068-2-6:2008-10)
Shock resistance 2000 m/s2 (EN 60068-2-27:2010-02)
MTTF 4,405,286 h at 55 °C
FIT 227 10-9 h-1 at 55 °C
Approvals
European Economic Area Conformity in accordance with
EMC Directive 2014/30/EU

(1) Further modules upon request

(2) At a cable capacitance of 5 nF
(3) Pay attention to voltage drop on the power supply cable

DS22-2449 / (2023-08-22) 3
Elektrical Connection

On the standard versions of the MiniCODER, the screen on the connection cable
■ is connected to the MiniCODER housing
■ is connected to the connector housing in metallised connectors
■ is connected to a connector pin in plastic connectors

Cable outlet MiniCO-

Cable version Connection type
DER

L = cable length

Cable outlet MiniCODER

Cable outlet MiniCODER
L (tangential left)

Cable versions for temperature sensor

Cable version
— (without temperature sensor cable)

L
M (2-core temperature sensor cable, 2 m long)

Cable data
— TEFLON cable 2 × 0.14 mm2 [26 AWG]
— Outside diameter: 2.8 mm (± 0.1) L
— Minimum bending radius: 20 mm
N (4-core temperature sensor cable, 2 m long)

Cable data
— ETFE cable 4 × 0.14 mm2 [26 AWG]
— Outside diameter: 3.5 mm (± 0.2) L
— Minimum bending radius: 7 mm
P (6-core temperature sensor cable, 2 m long)

Cable data
— ETFE cable 6 × 0.14 mm2 [26 AWG]
— Outside diameter: 3.5 mm (± 0.2) L
— Minimum bending radius: 7 mm

4 DS22-2449 / (2023-08-22)
 Elektrical Connection

Connection types
Connection type Notes
J (12-pin male connector) Not available with temperature sen-

M12x1
sor cable!
Cable lengths available:
52.3 030 / 050 / 150 / 250 / 600
L
K1) (flying lead) Not available with temperature sen-
sor cable!

22
1
Cable lengths available:
5.15 030 / 050 / 150 / 250 / 600
L
M (17-pin panel-mounting socket, angled, EMC screening, strain relief and
with pin contacts) sealing, IP 67 (connected)

56
M23x1
42
L
N (17-pin panel-mounting socket with pin EMC screening, strain relief and
M23x1

contacts) sealing, IP 67 (connected)

36
L
P (10-pin female connector) Not available with temperature sen-
sor cable!
22

1
Cable length available to the cen-
5.15 timetre!
L
U (12-pin coupling with pin contacts) Not available with temperature sen-
sor cable!
M23x1

57
L
Z (10-pin male connector) Not available with temperature sen-
sor cable!
19.5

Cable lengths available:

120 / 200 / 250
55.8
L
1) The delivery takes place with connected test plug from Lenord+Bauer.

All dimensions stated in millimeters

DS22-2449 / (2023-08-22) 5
Elektrical Connection

Pin assignments

Connection type J
12-pin male connector Pin Signal / function
(plug-in view)
1 U1+ Signal track 1
2 U1– Inverse signal track 1
3 UN+ Signal reference track N
4 0V GND
5 UB + 5 V supply voltage
5 4
6
11 3 6 U2+ Signal track 2
7
12 10 2
8 7 U2– Inverse signal track 2
9 1
8 UN– Inverse signal reference track N
9 Not used
10 U Sense 5 V Sense
11 Not used
12 Not used

External sense regulation is required with long power supply cables!

Connection type K
Flying lead Pin Core colour Signal / function
(10-pin female connector1))
(plug-in view)
1 red UB + 5 V supply voltage
2 white U1+ Signal track 1
3 brown U1– Inverse signal track 1
4 pink U2+ Signal track 2
5 black U2– Inverse signal track 2
1
6 green U Sense 5 V Sense
7 grey UN+ Signal reference track N
8 yellow UN– Inverse signal reference track N
9 blue 0V GND
10 Not used
1) The delivery takes place with connected test plug from Lenord+Bauer.

If a test and programming device is to be used for the function test, then the test plug must not be removed!

6 DS22-2449 / (2023-08-22)
 Elektrical Connection

Connection type M and N

17-pin panel-mounting socket Pin Signal / function
with pin contacts
(plug-in view)
1 U1+ Signal track 1
2 U1– Inverse signal track 1
3 UN+ Signal reference track N
4–6 Not used
7 0V GND
8 Not used
9 Not used
10 UB + 5 V supply voltage
11 U2+ Signal track 2
12 U2– Inverse signal track 2
13 UN– Inverse signal reference track N
14 Not used
15 0V GND (jumper pin 7)
16 U Sense 5 V Sense
17 Not used

Connection type M and N: Additional assignments on connection of a temperature sensor cable

17-pin panel-mounting socket with pin con-
Core colour Pin Signal / function
tacts
2-core temperature sensor cable brown 8 Temp +
(Cable version M)
blue 9 Temp –
4-core temperature sensor cable brown 8 Temp1 +
(Cable version N)
white 9 Temp1 –
green 4 Temp2 +
pink 14 Temp2 –
6-core temperature sensor cable brown 8 Temp1 +
(Cable version P)
white 9 Temp1 –
grey 6 Temp2 +
yellow 5 Temp2 –
green 4 Temp3 +
pink 14 Temp3 –

DS22-2449 / (2023-08-22) 7
Elektrical Connection

Connection type P
10-pin female connector Pin Signal / function
(plug-in view)
1 UB + 5 V supply voltage
2 U1+ Signal track 1
3 U1– Inverse signal track 1
4 U2+ Signal track 2
5 U2– Inverse signal track 2
1
6 U Sense 5 V Sense
7 UN+ Signal reference track N
8 UN– Inverse signal reference track N
9 0V GND
10 Not used

Connection type U
12-pin coupling with Pin Signal / function
pin contacts
(plug-in view)
1 U2– Inverse signal track 2
2 U Sense 5 V Sense
3 UN+ Signal reference track N
4 UN– Inverse signal reference track N
5 U1+ Signal track 1
5 4
6
11
3 6 U1– Inverse signal track 1
7 2
12 10 7 Not used

8 9 1 8 U2+ Signal track 2

9 Not used
10 0V GND
11 0V GND (jumper pin 10)
12 UB + 5 V supply voltage

8 DS22-2449 / (2023-08-22)
 Elektrical Connection

Connection type Z
10-pin male connector Pin Signal / function
(plug-in view)
1 U2+ Signal track 2
2 U2– Inverse signal track 2
3 Screen
4 UB + 5 V supply voltage
4
8 1
5 5 U1+ Signal track 1
9 2
10
6
3 6 U1– Inverse signal track 1
7
7 0V GND
8 UN+ Signal reference track N
9 UN– Inverse signal reference track N
10 Not used

Sense regulation not possible!

DS22-2449 / (2023-08-22) 9
Dimensional drawing

Dimensional drawing – cable outlet tangential left

23

17.5
13.4
ø 3.8
Ø 5 -0.3

18
29

3 +0.05

All dimensions stated in millimeters

General tolerance ISO 2768 –mK

10 DS22-2449 / (2023-08-22)
 Hole pattern and installation dimensions, air gap table

Hole pattern and installation dimensions

1.5 -0.2

A
ø 3 H7 P
ø 0.05 M AB
ø 3 H7

3.9

10.9
d
3
xM B
3.35 ±0.05

2
23 ±0.05
TRef

TSig
ra

b S
90° ±6‘
a
g

All dimensions stated in millimeters

a Width of the signal track
b Distance of mounting surface to target wheel: depending on geometry of target wheel (for example width of signal track)
d Air gap: depending on target wheel module (see air gap table→ page 11)
g Width of the target wheel
ra = da/2 (with da = Outside diameter of the tooth wheel)
A Mounting fixture
P Positioning pins M3
S Center line machine shaft / target wheel
TRef Reference track (target wheel)
TSig Signal track (target wheel)

Installation dimensions for standard target wheels

Dimension ZAZ ZFF
g 10 8.6
a1/2 6 4.6
aN 4 4 ZAZ
b 4 ± 0.2 4.7 ± 0.2 ZFF
b
aN
a1/2
g

Air gap table

Type Module m Air gap permitted d
1 1.0 0.50 mm ± 0.02 mm
4 0.4 0.20 mm ± 0.01 mm
To make assembly easier, a corresponding distance gauge is included with the MiniCODER.

DS22-2449 / (2023-08-22) 11
Type code

Type code
Signal pattern
K Sin/cos signals 1 Vpp
Reference mark
Z Reference tooth (tooth on tooth)
Optional extras
P Configurable
Cable outlet MiniCODER
L Tangential, cable outlet left
Module (1)
1 Scanning of target wheels with module m = 1.0
4 Scanning of target wheels with module m = 0.4
Connection type
J 12-pin male connector (only cable lengths 030 / 050 / 150 / 250 / 600 available)
K Flying lead(2) (only cable length 030 / 050 / 150 / 250 / 600 available)
M 17-pin panel-mounting socket, angled, with pin contacts
N 17-pin panel-mounting socket with pin contacts
P Test connector (10-pin female connector), cable length can be selected to the centimetre
U 12-pin coupling with pin contacts
Z 10-pin male connector (only cable length 120 / 200 / 250 available)
Cable length L(3)
030 0.3 m
050 0.5 m
120 1.2 m
150 1.5 m
200 2.0 m
250 2.5 m
600 6.0 m
Cable version for temperature sensor (2 m)
– Without cable for temperature sensor
M With 2-core temperature sensor cable (only for connection type M, N)
N With 4-core temperature sensor cable (only for connection type M, N)
P With 6-core temperature sensor cable (only for connection type M, N)
2449 _ _ _ _ _ _ _ _ _ _

Technical information on MiniCODERs with other signal patterns is available on the Internet at www.lenord.com
or can be requested from our Support (support@lenord.de) .

(1) Further modules upon request

(2) The delivery takes place with connected test plug from Lenord+Bauer.
(3) Other cable lengths upon request; maximum cable length: 6.0 m

12 DS22-2449 / (2023-08-22)
 Use in safety applications

Fault detection has a major influence on the availability of Safety Integrated

safety functions. This task must be realised by the control
MiniCODERs with sin/cos signals (signal pattern K) have
system, as fault detection is not integrated into the sensor.
been checked according to Safety Integrated by the IFA in
Safety of the overall system conjunction with Siemens Sinumerik control systems.
The assessment of the safety of the drive train
and the machine can only be undertaken by the IFA assessment
machine manufacturer taking account the rele- (IFA test report number 2013 23874):
vant directives, standards and safety regulations. "The sensor is suitable for providing two independent
items of speed information. Due to the fault detection in
MTTFd(1) the Sinumerik control systems, it is only necessary to use
one sensor for safety applications."
It is assumed that only 50 % of the hardware failures on
electronic components are hazardous failures. For MTTFd- Control systems from other manufacturers
figures it is therefore typically possible to assume twice the
MTTF figure(2) For control systems from other manufacturers with a safety
(sources: EN ISO 13849-1:2008 (D); Annex C, section 5.2 function, fault detection must be undertaken in the control
Semiconductors; EN 61800-5-2:2007, Annex B, section system as in the Sinumerik:
3.1.3 Anteil sicherer Ausfälle (Portion of safe failures)). ■ Faults in the sensor function are detected in the down-
The expected operating temperature must be taken into stream control system by monitoring the differential
account in this assumption. sin/cos signals. For this purpose the amplitudes, the
frequency, the offset or the phase on the sin/cos signals
PFHd(3) should be checked for plausibility.
■ Mechanical slip or detachment of the target wheel from
The performance level and SIL level do not relate to the the shaft in operation or at standstill should, for exam-
reliability of sub-components but to the availability of safety ple, be excluded by a connection with a shaped fit.
functions. Some measures for fault detection by control systems
The MTTFd figures for the sensors are used in these cal- on the usage of sinusoidal sensor signals are listed in
culations. DIN EN 61800-5-2 Table 16 for electrical power drive sys-
Characteristics tems with adjustable rotational speed.

Operating temperature
FIT [10-9 h-1] (4) MTTF [h] (2)
[°C]
55 227 4,405,286

(1) Mean time to failure "dangerous"

(2) Mean time to failure
(3) Probability of dangerous failure per hour
(4) Failure in time; i.e. failures per 109 hours

DS22-2449 / (2023-08-22) 13
Explanations about the target wheel

Target wheels example, to change automatically a tool in a milling spindle

or grinding spindle.
For the measurement of rotary movements, MiniCODERs
The selection of the reference mark is defined by the size
form a unit together with target wheels. The target wheel
and rotational speed of the target wheel used, as both
size and the related diameter depend directly on the mod-
parameters have an effect on the forces acting on the
ule and the number of teeth.
reference mark.
Standard target wheels
Reference mark Z – tooth on tooth
Standard target wheels are available on short delivery
These target wheels are made from one piece.
times from stock. For specifications and designs see
“Technical information ZAx / ZFx (DS51–ZAx/ZFx)”.
Module
Custom target wheels The module is a tooth parameter for target wheels and de-
scribes the relationship between the number of teeth and
Custom target wheels are manufactured individually to
the diameter of the target wheel. Given the same number
customer requirements. Please send us a design drawing
of teeth, the smaller the module, the smaller the outside
of your target wheel to info@lenord.de. diameter.
The MiniCODER must be ordered to suit the de-
Reference mark
sign of the reference mark and to suit the module
The MiniCODER can detect the reference mark in the form of the target wheel.
of a tooth. The acquired reference signal can be used
for referencing the position. This feature is necessary, for

Z = Reference mark – tooth

14 DS22-2449 / (2023-08-22)
 Accessories

Testing and programming unit

■ Testing Lenord+Bauer sensors with sin/cos output 1 Vpp, for example, MiniCODER
■ Transmitting the data via WLAN or Ethernet to mobile terminal devices (for example, tablet, PC)
■ Display of the data in a web browser, independent of the operating system

■ Used for checking the signals for compliance with adjustable tolerance limits
- sin/cos signals (amplitude, offset, phase offset)
- Reference signal (amplitude, offset, position and width)
- Target wheel (damage, concentricity, quality of the teeth)
■ Defining and saving different tolerance limits

■ Used for the configuration of the MiniCODER

- Automatic calibration of the sin/cos signals
- Configuring/reading the operating hours counter (rotational speed histogram)
- Saving the 7 configured speed ranges of the operating hours counter in one record;
Possible to save several records in the GEL 211

Accessories

Item number: Identifier:

PK211C-244XK-E Configuration kit (Ethernet), consisting of:

■ Testing and programming unit GEL 211CS04E2M
■ Sensor connection cable GG211
■ Power supply unit 5 V, ZB211CB
■ Operating instructions D-71B-211CS0
■ Case, XW1303

PK211C-244XK-W Configuration kit (WLAN), consisting of:

■ Testing and programming unit GEL 211CS04W2M
■ Sensor connection cable GG211
■ Power supply unit 5 V, ZB211CB
■ Operating instructions D-71B-211CS0
■ Case, XW1303

GG211-JAE Adapter cable GEL 211 for MiniCODER with connection type Z

GG211-12POL-M12 Adapter cable GEL 211 for MiniCODER with connection type J

GG211-12POL-M23 Adapter cable GEL 211 for MiniCODER with connection type U

GG211-17POL-M23 Adapter cable GEL 211 for the connection of the Precision-Box GEL SDA10

DS22-2449 / (2023-08-22) 15
Information about the square-wave reference signal

A control system evaluates the zero transitions on the rising and falling edge of the reference signal to determine the
width and position of the reference signal.

U
[mV]

U1 UN U2
500

U1 = U1+ - U1-
U2 = U2+ - U2-
0
UN = UN+ - UN-

-500

-90° 0° +90° φ

The square-wave reference signal is dependent on

— the width and shape of the reference mark
— the position of the reference mark in relation to the teeth on the signal track
— the module of the precision target wheel

The following applies for the square-wave reference signal:

■ The amplitude of the reference signal is independent of the air gap and in the ideal case set to +500 mV.
■ The offset level in relation to the quiescent voltage is fixed at -500 mV to provide a large signal to noise ratio.

The reference signal correspond to the common specifications for reference signals on the usage of 1 Vpp interface.

If you have any questions, please contact our Service department.

You will find the Service department on the internet at www.lenord.com.

16 DS22-2449 / (2023-08-22)
 Your notice

DS22-2449 / (2023-08-22) 17
Your notice

18 DS22-2449 / (2023-08-22)
 Your notice

DS22-2449 / (2023-08-22) 19
20 DS22-2449 / (2023-08-22)