EncoderWorks develops the AVS78E-021K5R0GI-0016 custom compatible replacement solution around explosion-proof SSI singleturn feedback where RS422 clock/data timing, 16-bit Gray code interpretation, K5 5 m radial cable mapping, preset input, counting-direction input, INOX grounding, and Ø12 mm clamping-flange coupling must remain aligned with the installed controller. The failure boundary is not only the 10–30 VDC supply, but also Pulse ± polarity, Data ± polarity, monoflop timing, clock pause, controller sampling edge, shield continuity, radial cable clearance, and explosion-proof certificate scope. Typical production lead time: 15 working days.
This model is used where the controller reads a 16-bit absolute singleturn position word through an SSI interface from a solid-shaft encoder with a clamping flange, radial cable exit, and stainless housing. A compatible replacement must preserve the Gray output code, SSI clock response, RS422 differential wiring, zero-set behavior, direction input logic, K5 cable execution, Ø12 mm shaft interface, housing bonding, and hazardous-area installation boundary.
System Limits
The first system boundary is the SSI timing and 16-bit Gray-code word structure. AVS78E-021K5R0GI-0016 must return the same 16-bit position value when the controller sends its clock sequence. If the replacement is supplied with Binary code, a 12-bit or 13-bit word, incorrect MSB / LSB handling, wrong sampling edge, insufficient clock pause, or mismatched monoflop behavior, the RS422 signals may still look stable while the controller calculates the wrong angle. Typical failures include fixed position offset, one-bit shift, unstable zero position, reversed direction, or incorrect value after preset.
The second boundary is the K5 radial cable, INOX grounding, and Ø12 mm clamping-flange installation. Pulse + / Pulse -, Data + / Data -, GND, supply, preset, counting direction, shield path, cable bend radius, side exit clearance, cable strain relief, and stainless housing bonding must match the installed wiring. A correct SSI encoder can still fail if the clock pair is reversed, the data pair is reversed, the preset line is triggered unintentionally, the direction input is held in the wrong state, the shield is terminated with high impedance, or the 5 m radial cable is routed close to motor or drive wiring. Mechanically, the Ø12 mm × 25 mm solid shaft, clamping flange, coupling alignment, axial load, radial load, and stainless housing fit must be checked together.
Wiring & Installation
Before replacement, confirm the full installed model code, SSI bit length, Gray code requirement, controller clock frequency, monoflop timing, clock pause, Pulse ± cable mapping, Data ± cable mapping, preset input use, counting-direction input state, K5 cable length, radial exit direction, INOX housing requirement, clamping-flange geometry, and Ø12 mm shaft interface. This K5 radial version should not be inferred from K2, KR, aluminum-housing, axial-cable, servo-flange, PROFIBUS, or other interface variants because the controller depends on clock/data timing rather than fieldbus addressing or network parameterization.
During installation, verify supply wiring, GND, differential clock pair, differential data pair, preset line, and counting-direction line before powering the system. Keep the 5 m SSI cable away from motor and drive wiring, maintain low-impedance shield and housing continuity, and avoid cable kinking, tensile load, or shearing load at the radial exit. The clamping flange should seat flat, and the coupling should not force the Ø12 mm shaft off center. Explosion-proof suitability must be confirmed against the installed hazardous-area requirement and certificate scope before shipment.
Custom Compatible Solution
- Match SSI RS422 behavior, 16-bit singleturn feedback, Gray output code, monoflop timing, and controller clock expectation
- Preserve Pulse ±, Data ±, supply, GND, preset input, counting-direction input, shield continuity, K5 radial cable routing, and INOX grounding
- Adapt the Ø12 mm × 25 mm solid shaft, clamping flange, K5 9-strand 5 m radial cable, stainless housing, and IP66 sealing boundary
- Review clock frequency, line length, sampling edge, cable route, housing bonding, coupling alignment, shaft load, hazardous-area certificate scope, and commissioning requirements before shipment
Key Data
| Item | Data |
|---|---|
| Model | AVS78E-021K5R0GI-0016 |
| Encoder type | Explosion-proof singleturn absolute rotary encoder |
| Interface | SSI |
| Electrical standard | RS422 |
| Supply voltage | 10–30 VDC |
| Output code | Gray |
| Singleturn resolution | 16 bit |
| Multiturn resolution | Not applicable |
| Total position structure | 16-bit absolute singleturn data |
| SSI timing boundary | Monoflop time and clock pause require controller-side confirmation |
| Connection | K5, 9-strand cable, 5 m |
| Cable exit | R, radial |
| Control inputs | Zero-set / preset and counting direction |
| Shaft / flange | Ø12 mm × 25 mm solid shaft, clamping flange |
| Housing material | I, stainless steel 1.4404 / AISI 316L |
| Protection class | IP66 sealing boundary requires confirmation against installed version |
| Hazardous-area boundary | ATEX / IECEx explosion-proof compliance requires confirmation against installed certificate scope |
| Key replacement checks | SSI clock frequency, Pulse ±, Data ±, Gray code, 16-bit word length, preset, direction input, shield continuity, K5 radial cable route, INOX grounding, Ø12 mm clamping-flange coupling |
