Flux GMI-ROTARY Series User manual
GMI-ROT Series - Absolute Rotary Encoder
User Manual
FLUX GmbH - All rights reserved
Original instructions.
This Instruction Manual is provided to users of the GMI ROTARY ENCODERS for the
training of maintenance technicians and operators. Instructions, drawings, tables and
anything else contained in this manual are of a reserved nature and may not be reproduced
and/or published, neither completely nor in part, without specific written permission by the
company FLUX GmbH.
Technicians, maintenance personnel and operators are explicitly forbidden to spread the
news contained herein and to use this manual for purposes other than those strictly related
to the good preservation of the GMI ROTARY ENCODERS, its use and maintenance.
The company FLUX GmbH cannot be held responsible or liable for any injury caused by
incorrect use of this documentation. To avoid incorrect maneuvers which could cause
hazards to persons it is important that you read and understand all the documentation
supplied with the GMI ROTARY ENCODERS.
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Table of contents
1. General information 5
1.1. Introduction 5
1.2 Ownership of the information provided 5
1.3 Conventions and Definitions 5
1.3.1 Introduction 5
1.3.2 Terminological conventions 6
1.3.3 Definitions 6
1.3.4 Personal Protective Equipment and rules of conduct 6
1.3.5 Typographic conventions 6
1.4 Warranty 9
1.4.1 General conditions 9
1.4.2 Parts excluded from the warranty 9
1.4.3 Operations involving the invalidation of the warranty 10
1.5 Technical support 10
1.5.1 Request for support interventions 10
2. Description and proper use 11
2.1 Description of the ENCODER 11
2.2 How the Giant Magneto Impedance Principle works 14
2.3 Declaration of Conformity 14
2.4 Proper use 14
2.4.1 Improper use 15
3. Safety 16
3.1 Warnings about residual risks 16
3.1.1 Lifting and transport 16
3.1.2 Installation and connection 17
3.1.3 Use 19
3.1.4 Maintenance and demolition 22
4. Installation and commissioning 23
4.1 Environmental conditions of the installation site 24
4.2 Installation 25
4.2.1 Checks before installation 25
4.2.2 Mounting 25
4.3 Connection and commissioning 26
4.4 Storage of the ENCODER 27
5. Maintenance and Demolition 28
5.1 General maintenance instructions 28
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5.2 Debugging 30
5.3 Ordinary maintenance of the ENCODER 31
5.4 Extraordinary maintenance interventions 32
5.5 Decommissioning, disassembly and demolition 32
5.5.1 Decommissioning of the ENCODER 32
5.5.2 Disassembly 32
5.5.3 Demolition 33
6. Annexes 33
7. Revision history 34
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1. General information
1.1. Introduction
This instruction manual is an integral part of the GMI ROTARY ENCODERS (identified in this
document, with the term encoder) realized by the company FLUX GmbH. For this reason, it
must follow the encoder itself if it is transferred to a new user or owner.
This manual has been drawn to provide operators and technicians involved in the
maintenance of the encoder information and essential instructions to operate properly and
safely.
While showing all the attention and the instructions for the correct use of the encoder by the
operators or to allow maintenance personnel to intervene correctly, this manual assumes
that the use and maintenance personnel has a degree of education that allows them to
interpret the information reported.
1.2 Ownership of the information provided
This instruction manual contains proprietary information.
All rights are reserved.
This manual may not be reproduced or duplicated, in whole or in part, without the prior
written consent of the Manufacturer. The use of this document material is only allowed to the
customer to whom the manual was provided as support of the encoder and only for
purposes of installation, use and maintenance of the encoder the manual refers to.
The manufacturer declares that the information contained in this manual are congruent with
the technical specifications and safety devices of the encoder the manual refers to.
Drawings, diagrams and technical data are updated to the date of publication of this
document and are valid only for the encoder to which they were attached.
The Manufacturer reserves the right to make changes or improvements to this documentary
material without notice.
The Manufacturer assumes no liability for direct or indirect injury to people, things or animals
arising from the use of this document or of the encoder in conditions different than those laid
down.
1.3 Conventions and Definitions
1.3.1 Introduction
The instruction manual of the encoder was divided into chapters that allow, for each major
phase of the life of the encoder (transport, installation, use, setup, maintenance and
disposal), to facilitate the procurement of necessary information to the user of the encoder
itself.
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1.3.2 Terminological conventions
ENCODER: it is the term used in this instruction manual to indicate the GMI ROTARY
ENCODERS.
PPE: it refers to Personal Protective Equipment.
1.3.3 Definitions
USER
Any person (entrepreneur/business) who uses the ENCODER or who entrusts the use or
related operations to prepared people.
OPERATOR
Personnel, generally without specific expertise, performing the operations necessary for the
use of the encoder and the cleaning of the encoder itself and the place where it is installed; if
necessary they can make simple adjustments or measures to restore the encoder operation.
MAINTAINER
Qualified Technician that can intervene on any mechanical part to make the adjustments,
repairs and maintenance operations required.
The maintenance technician must have sufficient experience in the mechanical, electrical
and control engineering fields; typically is not enabled to carry out work on electrical systems
in the presence of voltage.
MANUFACTURER'S TECHNICIAN
Specialized technician expert provided by the manufacturer of the ENCODER to perform
complex nature operations in particular situations or when agreed with the user.
1.3.4 Personal Protective Equipment and rules of conduct
For each of the operations described in this manual, are indicated the PPE to use (possibly
in addition to those that the personnel is required to wear in the place of installation of the
encoder) and the rules of conduct that allow to safeguard the operators themselves.
1.3.5 Typographic conventions
The graphic setting of this instruction manual is such as to allow easy recognition of its
content; in this context, for example, the instructions are associated to lists, as follows:
●This symbol identifies a generic bulleted list or a bulleted list consisting of simple actions
(the order in which the actions are presented is not binding but recommended);
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1. This identifies a numbered list explaining a complex procedure (the order in which the
actions are presented is binding to safely and correctly perform the operation under
consideration).
The bold text is used to highlight words, phrases or parts of the procedure.
In addition, to ensure a more in-depth knowledge of the ENCODER and of the instructions
for its correct and safe use, the text of this instruction manual is accompanied by indications
that complete it, by providing additional information, attention needed or particularly
significant hazards to consider. At this proposal, the following notation is used:
NOTE: indicates notes, warnings, hints and other points on which the
attention of the reader is drawn or completes the explanation
with more information.
WARNING: it indicates situations or tasks in which there is a possibility of
damage to the ENCODER, to the related equipment or to the
environment.
DANGER: it indicates situations or tasks that must be performed or
information to which particular attention must be paid to
avoid injury.
In this paragraph shall be shown the graphical symbols used in this manual to indicate the
need to wear particular PPE.
It indicates the need to use appropriate head protection to perform the
operation described.
It indicates the need to use suitable protective gloves to perform the operation
described (possibly dielectrics gloves to perform electrical operations).
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It indicates the need to use suitable protective shoes to perform the operation
described.
Below are the graphic symbols used in this manual to indicate residual hazards and risks for
the described operation.
Indicates the risk related to the presence of suspended loads
Indicates the risk associated with the presence of forklifts and other means of
transporting goods
Indicates the risk related to the possible crushing of lower and upper limbs
Indicates the risk related to the presence of possible unevenness / obstacles
on the ground
Indicates the risk related to the presence of high temperature surfaces
(> 45 ° C)
Indicates the risk related to the presence of live parts
Indicates the risk related to the presence of electromagnetic fields
Indicates the risk related to the presence of moving parts that can cause
mechanical injuries
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Indicates the possible fire risk
1.4 Warranty
1.4.1 General conditions
The manufacturer, the company FLUX GmbH, provides the ENCODER and equipment
produced by the same Manufacturer free from defects in materials and workmanship for a
period of two years unless it is otherwise writtenly agreed in a separate contract.
During the warranty period, the manufacturer undertakes to remove in the time it takes the
noticeable faults and defects in materials or workmanship in the event of a malfunction or
breakage; this provided that the ENCODER has been installed with the assistance of
technicians of the manufacturer and it has been used correctly in accordance with the rules
of conduct and maintenance described in this manual.
Defective parts under warranty will be repaired or replaced free of charge by the
manufacturer, if it is proven their defect at the origin.
Freight or shipping costs unless otherwise specified in the contract of sale, as well as travel
expenses relating to the intervention of technicians of the manufacturer at the headquarters
of the user are regulated in the contract of sale.
For the construction of the ENCODER, the manufacturer uses materials, organs and
mechanisms of the type, condition and quality, deemed at its sole discretion, appropriate to
the functions that the ENCODER needs to perform; in pursuing a policy of constant
development and updating of the product, the manufacturer reserves the right to modify both
the functional and aesthetic characteristics, to make any changes in the design of any
functional organ or accessory, or to suspend the manufacture and supply, without
commitment to inform and without incurring in any obligation.
In addition, the company FLUX GmbH reserves the right to make any structural or functional
changes, in addition to changing the supply of spare parts and accessories without having to
notify anyone and for any reason whatsoever.
1.4.2 Parts excluded from the warranty
The warranty does not cover wear parts and all utensils and any consumables supplied by
the manufacturer together with the ENCODER.
1.4.3 Operations involving the invalidation of the warranty
Any attempt to disassemble, modify or tamper any component of the ENCODER by the user
or by unauthorized personnel will result in invalidation of the warranty and will hold the
manufacturer harmless from any liability for damages to persons or property caused by such
tampering.
The manufacturer is not responsible and the warranty is void in the following cases:
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●improper uses of the ENCODER;
●use that does not comply with the requirements of the regulations in force in the country
of use;
●ENCODER installation in conditions other than those specified in this document;
●connections which do not comply with the specifications outlined in this document;
●total or partial non-compliance with the instructions in this manual;
●incorrect or missing maintenance;
●use of non-original spare parts or not specified by the manufacturer.
1.5 Technical support
With regard to the maximum exploitation of the performance provided by the ENCODER and
extraordinary maintenance operations, this manual does not replace the experience of
trained and qualified installers, users and maintenance personnel.
In this case, the Company's Technical Support Service provides:
●telephone support regarding the characteristics and the simplest interventions that can
be performed on the ENCODER;
●sending of specific technical documentation;
●training interventions of the user's personnel assigned to the ENCODER;
●interventions to modify the ENCODER (on request only).
WARNING: In case of doubts about the correct interpretation of the
instructions contained in this Instruction manual, contact the
Technical Support Service to obtain the NECESSARY
clarifications.
1.5.1 Request for support interventions
To contact the Technical Support Service, contact:
FLUX GmbH
Hans Steininger Gasse 16,
5280 Braunau am Inn, Austria
Tel: +43 7722 20764
www.flux.gmbh
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2. Description and proper use
2.1 Description of the ENCODER
GMI ROTARY ENCODERS from FLUX GmbH offers motor feedback solutions for a wide
range of applications, fitting optimally in designs that require precise positioning with
exacting velocity and torque control.
The position sensor technology (Giant Magnetic Impedance) and encoder architecture,
developed and manufactured by FLUX, are the result of 40+ years experience in encoder
development and manufacturing.
It addresses in a purposeful and compact manner motion control feedback design
requirements calling for:
●Precise position feedback;
●Hollow shaft implementation;
●High positioning accuracy;
●High position stability / low noise;
●Zero backlash / hysteresis;
●Insensitivity to external electrical noise;
●Insensitivity to environmental pollution (IP67);
●Low signal latency.
GMI ROTARY ENCODERS are the ideal choice for a wide range of applications including:
●machine tools;
●semiconductor manufacturing;
●cobots and robots;
●satcomm;
●medical;
●gimbals;
●motors (torque, direct drive, servo, dc brushless);
●automated guided vehicles (AGV).
The following are the main technical characteristics of the GMI ROTARY ENCODERS
covered by this Instruction manual. More details on this, dimensions and tolerances are
shown in the dedicated technical data sheet attached to this document or on the website
www.flux.gmbh.
The ‘GIM-ROT’ series of rotary encoders incorporates the FLUX patented GMI (Giant
Magneto Impedance) position sensor to deliver high performance feedback as part of a
closed loop motion control system.
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Performance achievements:
●Resolution up to 22 bits / revolution;
●Accuracy to ± 0.005° (± 18 arc seconds);
●Liberal mounting tolerance; to axial ± 0.4 mm and to radial ± 0.3 mm;
●Axial stack-up as small as 8 mm including air-gap;
●High ratio of inner diameter (through hole) to outer diameter.
*GMI-ROT-055 (size 55mm) with radial mounting rotor version (-C11)
MODEL
Encoder Stator
Encoder Rotor
Thickness
(2)
Resolution
Accuracy
IP
OD
ID
min OD (1)
max ID (1)
GIM-ROT-055
55 mm
26.2 mm
39 mm
25 mm
7.5 mm
20 bit/r.
± 0.010° /± 40”
IP67
GIM-ROT-069
69 mm
40.2 mm
53 mm
39 mm
7.5 mm
20 bit/r.
± 0.008° /± 30”
IP67
GIM-ROT-080
80 mm
51.2 mm
64 mm
50 mm
7.5 mm
21 bit/r.
± 0.007° /± 25”
IP67
GIM-ROT-096
96 mm
67.2 mm
80 mm
66 mm
7.5 mm
22 bit/r.
± 0.005° /± 20”
IP67
(1) Achievable minimum or maximum dimensions. See datasheet for possible combinations.
(2) Minimum thickness at nominal air-gap for Axx option. See datasheet for more options and details.
GMI-ROT size (OD)
55 mm
69 mm
80 mm
96 mm
System data
Type
Axial, frameless, true absolute Giant Magneto Impedance encoder
GMI Technology - FLUX GmbH proprietary
Standard resolution
20 bits
20 bits
21 bits
22 bits
Standard accuracy
(no calibration required)
±0.010°
±0.008°
±0.007°
±0.005°
±36”
± 30”
±25”
±18”
±180 µrad
±140 µrad
±120 µrad
± 90 µrad
Hysteresis
none
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Repeatability
1 resolution count
Position update rate and
signal latency
Real-time
Standard maximum
speed
6’000 rpm (higher on request)
Electrical data
Supply voltage
(at encoder connector)
Option 5V: typ. 5 Vdc
Min. 4.35 Vdc. Max. 6 Vdc
Polarity protection
Yes
Current Consumption
(w/o output terminations)
max. 150 mA @ 5 Vdc (Option 5V)
2.2 How the Giant Magneto Impedance Principle works
Encoder rotor
(1) Metal carrier
(2) Absolute magnetic ring
Encoder stator
(3) GMI layer
(4) Absolute GMI sensor
(5) Metal housing and evaluation electronic
The magnetic field of the grating ring (2) generates in the thin metal foil (3) areas with
variable electrical a.c. impedance. The variation of the generated a.c. impedance is
converted to an electrical signal by the GMI sensor (4). The GMI sensor (4) is connected to
the evaluation electronic (5) which converts the electrical signal in digital position.
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2.3 Declaration of Conformity
Each ENCODER is followed by the dedicated Declaration of conformity to the applicable
Community Directives, that are:
-2014/30/EU Directive - Electromagnetic Compatibility Directive (EMC)
-2011/65/EU Directive - RoHS Directive, as amended by the Commission Delegated
Directive (EU) 2015/863.
Every Declaration of Conformity is available on the website www.flux.gmbh.
Each specific ENCODER shows, engraved on it, the relevant Type and Serial Number, so
that it can be easily reconnected to the Declaration of Conformity.
2.4 Proper use
The intended use of every GMI ROTARY ENCODER from FLUX GmbH is the measurement
of rotation and position of a mechanical system equipped with a rotating part (in general of a
rotating shaft), in an industrial type application that guarantees at all times and modalities the
compliance with the technical specifications shown on the dedicated technical data sheets
attached to this document, according to the specific encoder type, in particular respecting
the electrical data and the maximum mechanical speed.
Every GMI ROTARY ENCODER has been designed and built to be installed and to work
indoors and protected from atmospheric agents.
Every GMI ROTARY ENCODER is designed and built to work in environments where there
is not a potentially explosive atmosphere, and the GMI ROTARY ENCODER itself cannot
generate a potentially explosive atmosphere if properly used.
Because the product must be integrated into a complex system, the safety of people must be
ensured by solutions concerning the system itself. Before using the product, it is necessary
to carry out a risk assessment with regard to the actual conditions of use. Based on the
outcome of the assessment, the necessary safety measures must be implemented.
The use of the GMI ROTARY ENCODER for operations in contravention to those listed
above could result in personal injury or damage to GMI ROTARY ENCODER and are
therefore considered improper uses for which FLUX GmbH is not responsible.
The use of the single GMI ROTARY ENCODER in contravention to those listed above can
be carried out only after having consulted in writing the manufacturer FLUX GmbH and upon
authorization.
2.4.1 Improper use
The GMI ROTARY ENCODERS should not be used improperly. In particular are considered
improper uses:
●use the ENCODER in deviation from what is indicated in this manual;
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●use the ENCODER in deviation from the technical specifications shown on the
dedicated technical data sheets attached to this document, according to the specific
encoder type;
●use the ENCODER in deviation from the electrical data, according to the specific
encoder type;
●use the ENCODER in deviation from the maximum mechanical speed, according to the
specific encoder type;
●use the ENCODER as a life support device;
●install and use the ENCODER in a potentially explosive atmosphere.
WARNING: in case of different intended use it is essential to consult in
advance FLUX GmbH.
3. Safety
3.1 Warnings about residual risks
In order to avoid any dangerous conditions for persons or damage to the encoder caused by
residual risks, that are those risks that remain despite all the measures taken, or potential
not evident risks, the manufacturer recommends to operators, maintainers and all personnel
involved in ENCODER operations to follow the instructions indicated in the following pages.
WARNING: always respect the signs and indications on the plates applied
to the ENCODER and operate exclusively according to the
instructions provided in this manual.
3.1.1 Lifting and transport
Residual risks during lifting and transport
During lifting and transport there are risks related to:
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●operations on the ENCODER by unqualified, untrained, uninformed, or improperly
equipped personnel;
●incorrect selection or incorrect use of the means of transport and handling of the
encoder;
●crushing of handling personnel;
●impact or fall of ENCODER components, damaging the ENCODER itself and its
protections;
●unhealthy postures or excessive effort for operators involved in the transport and
handling of ENCODER components .
PPE required
Attention to follow during lifting and transport
During lifting and transport, it is necessary to follow the precautions described in this
paragraph.
●Designate for these operations only personnel qualified and trained on handling
procedures and able to choose and use safely the means of lifting and transporting,
more suited to the condition.
●Do not lift, for any reason, the various parts of the ENCODER by grasping them by
non-structural elements (for example, cables or sheaths);
●Make sure that there are no persons in the vicinity of the area where the lifting, moving
operations are in course, and always keep a safe distance.
3.1.2 Installation and connection
Residual risks during installation and connection
During installation and connection there are risks related to:
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●operations on the ENCODER by unqualified, untrained, uninformed, or improperly
equipped personnel;
●contact with live elements;
●possible electric shocks, fire, general explosions due to the ignition of the electric arc;
●impact, crushing or dragging and trapping during the handling of the ENCODER on the
installation site;
●impact, crushing, shearing, entrapment due to the motion of the axes controlled by the
ENCODER, even when stopped or due to gravity;
●tripping or falling due to wiring;
●the ENCODER can locally generate electric and magnetic fields, which can lead to
anomalies in sensitive devices;
●damage to the ENCODER during installation and connection.
PPE required
Attention to follow during installation and connection
During installation and connection, it is necessary to follow the precautions described in this
paragraph.
●Follow the safety instructions given in Paragraph 3.1.1 - Lifting and Transport during the
necessary handling operations of the ENCODER components.
●Use auxiliary equipment and, in any case, any other machinery, tool or utensil only after
having understood the indications given in the relevant Use and Maintenance Manuals
or after having followed specific and formalized training.
●Choose an installation site which:
-provide enough space for normal use as well as for maintenance of the
ENCODER, including space for any peripheral equipment;
-allows you to correctly make the connections necessary for the operation of
the ENCODER;
-has the characteristics described in Paragraph 4.1 Environmental conditions
of the Installation Site.
●With regard to electricity, connect the grounding system before any other connection
to the power distribution line.
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●The manufacturer of the final system in which the ENCODER will be incorporated must
comply with all current regulations regarding the grounding of the system and verify the
correct execution at the end of the installation.
●Make sure that no injuries or material damage can occur due to the rotating elements.
●Follow the installation procedure reported on the dedicated technical data sheets
attached to this document, according to the specific ENCODER configuration.
●Install the ENCODER in applications that ensure compliance with the technical
specifications shown on the dedicated technical data sheet attached to this document,
according to the specific ENCODER configuration.
●Install the ENCODER in applications that ensure compliance with the mounting
tolerances, according to the specific ENCODER configuration.
●Install the ENCODER in applications that ensure compliance with the electrical data,
according to the specific ENCODER configuration.
●Install the ENCODER in applications that ensure compliance with the maximum
mechanical speed, according to the specific ENCODER configuration.
●Do not use the conduits as protective conductors, but a protective conductor inside the
conduit.
●The cross-section of the protective conductor must comply with the standards in force.
Do not consider cable shields to be equivalent to a protective conductor.
●Prevent foreign bodies from getting inside the product.
●Check that the gaskets and cable glands are correctly seated in order to prevent
pollution due, for example, to sedimentation and humidity.
●Do not touch unprotected components or live parts.
●Carry out the assembly (using screws with adequate tightening torque) so that the
ENCODER does not come off even in the event of strong acceleration or repeated
shocks.
●Each system in which the ENCODER is used must be subjected to a risk assessment
and an accurate functional check before operation.
●Do not use the ENCODER as a load-bearing element.
●Protect the pipes of the connections to the energy sources by means of rigid sheaths or
suitable cable ducts.
●Do not place the ENCODER in the immediate vicinity of very hot surfaces, flammable or
heat sensitive components.
●Perform the required interventions using standard work tools and paying the utmost
attention to elements that could lead to stumbling or causing cuts and bruises.
●The ENCODER cannot be used until the ENCODER itself is tested: the presence of any
assembly or installation error could lead, in fact, to serious accidents for the operators.
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Before proceeding with the testing and initial start-up of the ENCODER, check that the parts
do not show physical damage due to impacts, tears or abrasions and that all the connections
have been made correctly and without the possibility of disconnection.
3.1.3 Use
Residual risks during use
During use there are risks related to:
●use of the ENCODER by unqualified, untrained, uninformed, or improperly equipped
personnel;
●contact with rotating parts, which can cause injury and capture edges of clothing and
hair;
●contact with hot or overheated parts during and at the end of processing:
-of the ENCODER itself, even in the event of malfunctions;
-of moving parts, even in the event of malfunctions;
●the ENCODER can locally generate electric and magnetic fields, which can lead to
anomalies in sensitive devices;
●contact with live parts in case of incorrect maintenance;
●possible electric shocks, fire, general explosions due to the ignition of the electric arc;
●projection of material in case of:
-breakage of the working elements, with projection of part of them;
-incorrect positioning of the ENCODER;
-presence of materials / foreign bodies on the working parts or on the
ENCODER.
PPE required
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Attention to follow during use
During use, it is necessary to follow the precautions described in this paragraph.
●Do not try to reach drives, even if in stop condition.
●Operate the ENCODER only if all the protection and safety devices are intact.
●Observe all safety and danger warnings.
●Wear all the necessary PPE, regularly checking its integrity (immediately reporting the
PPE is no longer able to perform the specific task).
●Do not use the ENCODER in conditions other than those indicated in the Intended Use
paragraph.
●Use the ENCODER ensuring compliance with the technical specifications shown on the
dedicated technical data sheets attached to this document, according to the specific
ENCODER configuration.
●Use the ENCODER ensuring compliance with the mounting tolerances, according to the
specific ENCODER configuration.
●Use the ENCODER ensuring compliance with the electrical data, according to the
specific ENCODER configuration.
●Use the ENCODER ensuring compliance with the maximum mechanical speed,
according to the specific ENCODER configuration.
●Always wait for any overheated parts to cool before intervening on the ENCODER.
●Keep people wearing devices such as heart pacemakers away from the ENCODER.
●Do not try to reach any moving parts. Do not try to reach drives, even if in stop condition.
●Do not intervene on the ENCODER without having read this manual completely and
carefully.
●Use auxiliary equipment and, in any case, any other machinery, tool or utensil only after
having understood the indications given in the relevant Use and Maintenance Manuals
or after having followed specific and formalized training.
●Immediately report abnormal operating situations.
●Do not perform any intervention (including cleaning) with the ENCODER in action or
electrically powered or near hot surfaces.
●Do not try to make the ENCODER perform unauthorized operations (refer to the Proper
use paragraph).
●Do not install or place equipment / pipes / channels on the ENCODER.
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