Question 1

What sets POSIHALL apart from optical absolute and traditional battery-backed encoders? Why is "battery-free, gear-free" revolutionary?

Accepted Answer

Decision context: There are 3 approaches to multiturn absolute position measurement, with notable differences.

1) Battery + Gear (traditional optical absolute):
• Single-turn optical encoder + internal gears + lithium battery.
• Battery counts every revolution; stored multi-turn position in memory.
• Problem: Battery fails in 5-7 years, position lost during replacement — field recalibration required.
• Gears wear, accuracy degrades over time.
• Battery performance drops at low temperatures (<-20°C).

2) Optical True Absolute (gear-free):
• Multiturn-coded optical disk + LED + phototransistor.
• No battery, no gears.
• Problem: Optical disk is complex (binary-coded rings), expensive. Readings fail in dirty/oily environments. Mechanical impact breaks the disk.

3) POSIHALL (magnetic true absolute):
• Coded magnetic disk + Hall-effect sensors.
• No battery, no gears — genuine absolute technology.
• Magnetic principle unaffected by dirt/oil/ice.
• Impact-resistant.
• No battery replacement — 15+ years maintenance-free.
• Wide temperature range -40°C / +85°C (no battery limit).

POSIHALL's Revolutionary Nature:
Introduced to the industry by ASM in 2017. Patent-protected. Eliminated all limitations of previous solutions:
• Battery replacement → NONE (zero field maintenance)
• Gear wear → NONE (permanent accuracy)
• Optical fouling → NONE (magnetic principle is robust)
• Cold performance → STANDARD (-40°C compatible)

Industry Impact: POSIHALL has rapidly displaced battery-backed encoders in industry over the last 5-7 years — particularly in maintenance-cost-critical applications: crane winches, lifts, mobile machinery, and long-life industrial equipment.

Question 2

How do I choose between PH36 (compact), PH58 (standard), and PH68 (rugged)?

Accepted Answer

The 3 POSIHALL models offer the same core technology in different sizes and capacities. Decision follows 3 parameters: mounting space + max revolutions + shaft load capacity.

PH36 (Compact 36 mm):
• Size: 36 mm housing diameter — smallest in the family.
• Weight: 120 g (without cable) — lightest.
• Max turns: 31 revolutions (~31 × 360° = 11,160°).
• Shaft load: Low — small servo motors, OEM devices.
• Use: Compact servo motor backup, small machinery joint, OEM integration, office equipment.
• Insufficient when: >31 revolutions required or high mechanical load.

PH58 (Standard 58 mm):
• Size: 58 mm housing diameter — industry standard.
• Weight: 400 g (without cable).
• Max turns: 255 revolutions (~255 × 360° = 91,800°).
• Shaft load: Medium — industrial equipment standard.
• Use: Crane winches, lift platforms, lead screws, solar tracking, automatic doors.
• Most common choice — POSIHALL family's industrial reference model.

PH68 (Rugged 68 mm):
• Size: 68 mm housing diameter — largest in the family.
• Weight: 450 g (without cable).
• Max turns: 255 revolutions (same as PH58).
• Shaft load: High — larger bearings, for heavy industry.
• Use: Large cranes, heavy mobile-machinery joints, mining equipment, rotational towers.
• Advantage: Higher shaft radial/axial load capacity — where PH58 doesn't suffice.

Decision Steps:
1. Measure mounting space: Fits in 36 mm? → Consider PH36.
2. Calculate max revolutions:
• 1 m diameter crane drum + 50 m cable = ~16 revolutions → PH36 sufficient
• Lead screw 10 mm pitch + 2 m stroke = 200 revolutions → PH58 required
• Large lift 100 m height / 0.5 m drum circumference = 200 revolutions → PH58/PH68
3. Shaft load:
• Low radial/axial load on shaft → PH36/PH58 sufficient
• High load (mobile machinery vibration, heavy industry) → PH68

Rule of thumb:
• Compact + below 31 revolutions → PH36 (economical)
• Industry standard + within 255 revolutions → PH58 (reference)
• Heavy industry + high shaft load → PH68

Question 3

What is the tare function? How does it simplify POSIHALL field installation?

Accepted Answer

The tare function is the feature that lets users set the sensor's "zero" position wherever they want during field installation. It's an important usability advantage that distinguishes POSIHALL from standard encoders.

Standard Encoder Problem:
Traditional absolute encoders fix "zero" during factory calibration. In field installation:
• Sensor mounts onto the shaft.
• The shaft's current position vs sensor's "zero" is a random angle.
• PLC reads this random value — meaningless.
• Solution: Define software offset on the PLC side (e.g., "true zero = sensor value + 127°"). Complex, error-prone.

Tare Function Solution:
On POSIHALL, a physical button or programming command says "current position = zero". The sensor stores the present angle as the new zero. All future readings reference this new zero.

Use Steps:
1. Sensor + shaft mounted.
2. Shaft set to the "zero-accepted" position (e.g., crane boom horizontal).
3. Tare command sent to POSIHALL (via M12 connector pin or programming software).
4. Sensor stores the current angle as zero.
5. PLC now measures from 0° — no software offset needed.

Advantages:
• Faster field installation: PLC programmer doesn't compute offsets.
• Fewer errors: No software-offset miscalculation, no wrong-position reporting risk.
• Easy service maintenance: After sensor replacement, re-tare for field calibration.
• Multi-installation: Same PLC code transfers to different sites without offset changes.

Tare vs Homing:
POSIHALL is an absolute encoder — no homing needed. The tare function changes the absolute reference — it redefines "zero". Different from homing in incremental encoders.

Typical Scenario: Crane boom is tared to zero in horizontal position. As the boom rises, positive values (e.g., 60° = 60°); as it lowers, negative values (e.g., -10°). PLC software is simple and clean. Even after a sensor swap, the new sensor is calibrated to the same reference via tare.

Question 4

How do I calculate which to choose between 31 turns (PH36) and 255 turns (PH58/PH68)?

Accepted Answer

Decision rule: calculate the maximum required rotation count. POSIHALL's "turns" value indicates how many full revolutions the sensor can retain absolute position for.

PH36 — 31 Turns:
~31 full revolutions (11,160°). Beyond this the sensor keeps working but "wraps to zero" — at the 32nd revolution the value approaches 0 again.

PH58 / PH68 — 255 Turns:
255 full revolutions (91,800°). Generous for most industrial applications.

Maximum Rotation Calculation:
How far does the measured part move per shaft revolution? From that:
• Linear motion: Shaft moves X mm per revolution. Total stroke / X = required revolutions.
• Rotary motion: Reduction ratio between shaft pulley and load.
• Helical motion (crane winch): Cable diameter + drum diameter × number of wraps.

Typical Calculation Examples:

Scenario 1 — Crane Winch:
• Drum diameter: 500 mm (circumference = π × 500 = 1,570 mm)
• Cable length: 30,000 mm (30 m)
• Wraps = 30,000 / 1,570 = ~19 revolutions
• PH36 (31 turns) sufficient ✓

Scenario 2 — Large Crane Winch:
• Drum diameter: 400 mm
• Cable length: 100,000 mm (100 m)
• Wraps = 100,000 / (π × 400) = ~80 revolutions
• PH58/PH68 (255 turns) required ✗ PH36

Scenario 3 — Lead Screw:
• Screw pitch: 5 mm/revolution
• Stroke: 1,000 mm (1 m)
• Revolutions = 1,000 / 5 = 200 revolutions
• PH58/PH68 required

Scenario 4 — Lift Platform:
• Drum diameter: 600 mm (circumference ~1,880 mm)
• Lift height: 50,000 mm (50 m, 14-storey building)
• Revolutions = 50,000 / 1,880 = ~27 revolutions
• PH36 sufficient ✓ (but PH58 preferred for industry standard)

Scenario 5 — Solar Panel Tracking (2-axis):
• Azimuth: 0° → 270° (~0.75 rev) → PH36 amply sufficient
• Tilt: 0° → 90° (~0.25 rev) → PH36 amply sufficient
• PH36 economical for both axes

General Decision:
• Below 30 turns → PH36 (economical)
• 30-255 turns → PH58 (industry standard)
• 200+ turns + heavy shaft load → PH68 (rugged)
• Beyond 255 turns → POSIHALL family insufficient, alternative solutions (POSIWIRE + magnetic encoder combination) should be considered.

Extra Turn Needs: POSIHALL maxes at 255 turns. For more, consult ASM; in some applications POSIWIRE WS100M (50 m linear) + magnetic absolute encoder combo is used.

Question 5

What does it mean that POSIHALL technology is used as a "magnetic absolute encoder" within POSIWIRE and POSITAPE? Same technology?

Accepted Answer

Yes — POSIHALL is also the absolute encoder technology integrated into linear sensors (POSIWIRE, POSITAPE). ASM launched POSIHALL as a standalone product in 2017, then from 2018 onwards added this technology to the POSIWIRE and POSITAPE families as a "magnetic absolute encoder" option.

Same Technology, Three Sensor Lines:

1) POSIHALL (Standalone Rotary):
• A separate product — full absolute rotary encoder with its own housing, mounting, outputs.
• Battery-free absolute technology.
• Up to 255 turns (PH58/PH68) or 31 turns (PH36).

2) POSIHALL Integration in POSIWIRE:
• POSIWIRE cable-extension sensors are typically potentiometer-based.
• Premium models (e.g., WS10 with magnetic absolute encoder option, WS21, WS61, WS100M) use POSIHALL technology inside.
• When ordering a WS model, selecting the "magnetic absolute encoder" output places POSIHALL electronics inside.
• Advantage: battery-free absolute linear position, alternative to optical encoders.

3) POSIHALL Integration in POSITAPE:
• All POSITAPE steel-tape sensors use POSIHALL magnetic absolute encoder standard.
• WB10ZG, WB12, WB61, WB85, WB21, WB100M and WBT (integrated tilt) models — all POSIHALL-based.
• This is the foundation of POSITAPE's 0.05 mm resolution and wear-free operation.

Why Important?
POSIHALL technology is ASM's primary differentiator. Across the portfolio:
• Rotary absolute measurement (POSIHALL standalone page)
• Linear absolute measurement (POSIWIRE option)
• Linear absolute + outdoor robust (POSITAPE standard)
• Hydraulic cylinder + Position + Inclination (POSITAPE WBT, POSIWIRE WST)

Patent Protection:
POSIHALL is patent-protected — no 1:1 equivalent at other manufacturers. Some competitors offer similar magnetic-absolute approaches, but the combination of 255 turns + 16-bit + battery-free is unique in industry.

Typical Decision:
• Rotary position only → POSIHALL directly
• Linear position + absolute value → POSIWIRE or POSITAPE (POSIHALL inside)
• Position + Inclination → POSITAPE WBT or POSIWIRE WST (POSIHALL + MEMS gyro)

IMB Electric engineering support verifies the right POSIHALL-based solution for your system.

Question 6

POSIHALL output interface selection: Voltage / 4-20 mA / SSI / CANopen / J1939 — which for which PLC system?

Accepted Answer

The POSIHALL family supports all modern industry-standard output interfaces. Choice depends on the format supported by your PLC's input card.

1) Analog 0.5-10 V Voltage:
• Industry-standard analog. Most PLC analog input cards support it.
• Limit: Voltage drop introduces errors over 100 m cable.
• POSIHALL specific: 16-bit internal resolution + analog conversion → 12-14 bit effective resolution at the output.
• Use: Standard factory interior, fixed installation.

2) Analog 0.5-4.5 V (Automotive standard):
• Automotive standard, optimised for mobile-machinery controllers (Bosch, Sauer-Danfoss).
• 0 V = error indicator (easy fault detection on PLC).
• Use: Off-road vehicles, tractors, excavators, crane boom angle.

3) Analog 4-20 mA Current (3-wire):
• Most robust analog option, noise-immune up to 1000 m.
• Use: Long distance, noisy industrial environments.

4) Programmable + Tare Function Analog:
• Voltage or current output range is user-programmable.
• Tare function (detailed in Q3) — "zero" position set during field installation.
• Use: When flexible field calibration is needed.

5) Redundant Analog (PH58, PH68):
• Two independent analog output channels — for functional safety (SIL).
• PLC compares both channels; alarms on deviation.
• Use: Lift safety, crane load charts, medical-device angle feedback.

6) SSI 16-bit Digital:
• Synchronous Serial Interface. Absolute position with nanosecond accuracy.
• 16-bit resolution = 65,536 steps/revolution + revolution count (32-bit total).
• Requires PLC SSI input card (Siemens SM338, Allen-Bradley 1756-SSI, ABB).
• Use: Precision CNC, robotics, fast feedback.

7) CANopen + Redundant CANopen:
• Automotive/industrial CAN bus standard. 127 sensors per bus.
• Redundant variant: second channel via a second CAN bus — for functional safety.
• Use: Mobile machinery, automotive ECU, multi-point monitoring.

8) SAE J1939:
• Heavy-vehicle standard — trucks, tractors, off-highway.
• Use: Construction machinery, heavy industrial mobile equipment.

Decision Table:
• Standard factory interior → 0-10 V Analog
• Long distance + noise → 4-20 mA
• Mobile machinery + automotive → 0.5-4.5 V or CANopen
• Heavy vehicle (tractor, excavator) → SAE J1939
• Precision CNC + robotics → SSI 16-bit
• SIL functional safety → Redundant Analog or Redundant CANopen (PH58/PH68)
• Flexible field calibration → Programmable + Tare

Important Note: POSIHALL is factory-configured to a specific output at shipment — no field update. Verify your PLC card format at order time.

Question 7

Crane winch and lift platform applications — what's the POSIHALL installation architecture?

Accepted Answer

The most common industrial applications of POSIHALL are crane winch position and lift platform height monitoring. In both, absolute position is critical — the system must know where it is even after power-off, no homing required.

Crane Winch Architecture:

Scenario: Port crane, 30 m cable, 500 mm drum diameter, ~19 cable wraps.

Sensor Selection: PH36 (31 turns sufficient) — compact, economical.

Installation:
1. PH36 mounts on the crane's side cover (fixed structure).
2. Sensor shaft connects to the drum shaft via coupling (M5 flexible coupling recommended).
3. As the drum rotates, the sensor rotates — counts each full turn.
4. Tare to zero: When the cable is fully wound (empty hook up), the sensor is tared.
5. As the cable unwinds, positive value = cable length (turns × drum circumference).

Output: 4-20 mA (long distance — cabin to control room ~50 m).

PLC Algorithm:
• Position = (POSIHALL turn count) × 1,570 mm (drum circumference)
• Height feedback: displayed in the control room
• Maximum height alarm: triggers above 25 m
• Dual function: position + load-chart calculation (with POSIROT angle sensor)

Lift Platform Architecture:

Scenario: 14-storey lift, 50 m height, 600 mm drum diameter, ~27 revolutions.

Sensor Selection: PH36 (31 turns sufficient) or PH58 (industry standard, preferred for safety).

Installation:
1. PH58 mounts above the motor, motor shaft connects to sensor shaft via coupling.
2. As the motor rotates, the lift moves; sensor tracks position continuously.
3. Tare: Sensor is tared with the lift at ground floor (reference point).
4. As the lift rises, sensor value increases positively → height (revolutions × 1,880 mm drum circumference).

Safety Requirements:
• SIL-2 functional safety typically required for lifts.
• Redundant CANopen selected → PH58/PH68 supports it.
• Two independent channels compared in PLC; deviation > 100 mm triggers safe lift stop.

Floor Recognition: PLC computes floors from position:
• Ground: 0 m → floor 0
• 3 m → floor 1
• 6 m → floor 2
• ...
• 42 m → floor 14

Because POSIHALL provides absolute value, floor definitions are persistent — after power loss the lift stops exactly at the last floor, no homing required.

Maintenance Advantage: PH58 is battery-free → 15+ years maintenance-free. Service teams don't need annual battery replacement. With traditional battery-backed encoders, this annual maintenance cost is 200-400 EUR.

Question 8

What are the POSIHALL warranty, calibration, and IMB Electric regional support conditions?

Accepted Answer

Warranty: ASM Sensor offers a 2-year manufacturer warranty on all POSIHALL models. Out-of-warranty cases:
• Mechanical impact damaging housing or shaft
• Excessive shaft load (radial/axial limit exceeded)
• Use outside datasheet limits (temperature, IP, magnetic interference)
• Unauthorised opening or repair
• Excessive shaft torque due to wrong coupling

Calibration: POSIHALL is a battery-free absolute encoder — no mechanical wear. Calibration interval is very long, typically 10-15 years. For field verification:
• Tare the sensor to zero.
• Rotate shaft to a known angle (e.g., 180° half turn).
• Sensor value must stay within ±2° (datasheet linearity).
• If multi-turn tests are performed, turn count must increase correctly.
• IMB Electric provides accredited calibration services in Türkiye (TÜRKAK scope).

Battery-Free Advantage: POSIHALL's most important differentiator is no annual battery-replacement requirement. With traditional battery-backed absolute encoders:
• Battery replacement interval: 5-7 years
• Replacement cost (part + labour): 200-500 EUR/sensor
• Position loss risk during replacement → field recalibration required

All of these costs disappear with POSIHALL. 10-year total cost of ownership with POSIHALL is 30-50% lower than battery-backed encoders.

Sensor Replacement: POSIHALL electronics are long-life. Typical failure mode is mechanical impact (housing damage) or excessive magnetic interference (mounting near a large transformer).

Spare Stock: IMB Electric maintains PH36/PH58/PH68 spare stock in Türkiye. 24-48 hour delivery available for emergency spares.

IMB Electric Regional Support:
IMB Electric is listed for Türkiye on ASM Sensor's official global distribution network, with authorisation extending to Türkiye + the Middle East + North Africa + Western Asia.

Regional services:
• Stock delivery (İstanbul İkitelli OSB)
• Fast quotation (24-48 hours)
• Accredited calibration and repair (TÜRKAK scope)
• Application-based engineering support — housing diameter + turns + output interface selection, redundant-channel consulting for SIL projects
• Local management of warranty processes
• Turkish + English + Arabic (for the Middle East) technical documentation
• Field training (on request) — tare function usage, PLC integration

Contact: info@imbelectric.com · +90 212 544 59 59 · imbelectric.com

About the POSIHALL® — Multiturn Absolute Magnetic Encoders series

01What sets POSIHALL apart from optical absolute and traditional battery-backed encoders? Why is "battery-free, gear-free" revolutionary?

02How do I choose between PH36 (compact), PH58 (standard), and PH68 (rugged)?

03What is the tare function? How does it simplify POSIHALL field installation?

04How do I calculate which to choose between 31 turns (PH36) and 255 turns (PH58/PH68)?

05What does it mean that POSIHALL technology is used as a "magnetic absolute encoder" within POSIWIRE and POSITAPE? Same technology?

06POSIHALL output interface selection: Voltage / 4-20 mA / SSI / CANopen / J1939 — which for which PLC system?

07Crane winch and lift platform applications — what's the POSIHALL installation architecture?

08What are the POSIHALL warranty, calibration, and IMB Electric regional support conditions?