Hubner FG 40, FG40 K-1024G-90G-NG, KK-1024G-90G-NG, K-1024S-N Operating And Assembly Instructions Manual

English

Operating and Assembly Instructions Incremental Encoder FG 40

Read the Operating and Assembly Instructions prior to assembly, starting installation and handling! Keep for future reference!

Translation of the original Operating and Assembly Instructions FG40_MANUAL-en_R12(2018-10-31)ID74490.doc ID 74490

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

Trademark

Brand names and product names are trademarks or registered trademarks of their respective owner. Protected trademarks bearing a ™ or ® symbol are not always depicted as such in the manual. However, the statutory rights of the respective owners remain unaffected.

Manufacturer / publisher

Johannes Hubner Fabrik elektrischer Maschinen GmbH Siemensstraße 7 35394 Giessen

Germany Phone: +49 641 7969 0 Fax: +49 641 73645 Internet: www.huebner-giessen.com

E-Mail: info@huebner-giessen.com

The manual has been drawn up with the utmost care and attention. Nevertheless, we cannot exclude the possibility of errors in form and content. It is strictly forbidden to reproduce this publication or parts of this publication in any form or by any means without the prior written permission of Johannes Hubner Fabrik elektrischer Maschinen GmbH. Subject to errors and changes due to technical improvements.

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Directory

1 General ............................................................................................................................ 5

1.1 Information about the Operating and Assembly instructions ....................................... 5

1.2 Scope of delivery ....................................................................................................... 5

1.3 Explanation of symbols .............................................................................................. 5

1.4 Disclaimer .................................................................................................................. 6

1.5 Copyright ................................................................................................................... 6

1.6 Guarantee terms ........................................................................................................ 6

1.7 Customer service ....................................................................................................... 6

2 Safety ............................................................................................................................... 6

2.1 Responsibility of the owner ........................................................................................ 6

2.2 Intended use .............................................................................................................. 6

2.3 Improper use .............................................................................................................. 7

2.4 Personnel ................................................................................................................... 7

2.5 Personal protective equipment ................................................................................... 7

2.6 Special dangers ......................................................................................................... 7

2.6.1 Electrical current .................................................................................................... 7

2.6.2 Rotating shafts / Hot surfaces ................................................................................ 7

2.6.3 Safeguarding against restart .................................................................................. 7

3 Technical Data ................................................................................................................ 8

3.1 Type plates ................................................................................................................ 8

3.2 Electrical and mechanical data ................................................................................... 9

3.2.1 For pulse rates (square wave pulses) ................................ .................................... 9

3.2.2 Output signals Sine / Cosine ................................................................................10

3.3 Type code .................................................................................................................14

3.3.1 For pulse rates (square wave pulses) ................................ ...................................14

3.3.2 For output signals Sine / Cosine ...........................................................................15

4 Transport, packaging and storage ...............................................................................16

4.1 Safety instructions for transport .................................................................................16

4.2 Incoming goods inspection ........................................................................................16

4.3 Packaging / disposal .................................................................................................16

4.4 Storage of packages (devices) ..................................................................................16

5 Mounting and commissioning ......................................................................................17

5.1 Safety instructions .....................................................................................................17

5.2 Technical information ................................................................................................17

5.3 Required tools ...........................................................................................................17

5.4 Mounting preparations ..............................................................................................18

5.5 Mounting B5 type (flange) incremental encoders ......................................................18

5.6 Mounting B35 type (flange and foot) incremental encoders .......................................20

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5.7 Mounting tolerances for construction type B5 and B35 ..............................................21

5.8 Attaching additional devices ......................................................................................22

5.9 Electrical connection and start up ..............................................................................24

5.9.1 Preparing cables ..................................................................................................24

5.9.2 Electrical connection .............................................................................................24

6 Dismantling ....................................................................................................................26

6.1 Safety instructions ................................................................ .....................................26

6.2 Dismantling the encoder ...........................................................................................26

7 Faults .............................................................................................................................. 27

7.1 Faults table ...............................................................................................................27

8 Inspections .....................................................................................................................28

8.1 Safety instructions ................................................................ .....................................28

8.2 Maintenance information ...........................................................................................28

8.3 Inspection schedule ..................................................................................................28

9 Disposal ..........................................................................................................................28

9.1 Disposal procedure ...................................................................................................28

10 Replacement parts .........................................................................................................28

11 Dimension drawings ......................................................................................................29

11.1 Construction type B5 (flange) ....................................................................................29

11.2 Construction type B35 (flange and foot) ....................................................................31

11.3 Construction type B5/B14 (flange with 2 shaft ends) .................................................33

11.4 construction type B35/B14 (flange and foot with 2 shaft ends) ..................................35

11.5 Mounting options .......................................................................................................37

11.6 Additional dimension drawings – electrical socket design .........................................39

12 Connection diagrams ....................................................................................................42

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WARNING!

Indicates a possibly dangerous situation that can result in death or serious injury if it is not avoided.

CAUTION!

Indicates a possibly dangerous situation that can result in minor injury if it is not avoided.

CAUTION!

Indicates a possibly dangerous situation that can result in material damage if it is not avoided.

NOTES!

Indicates useful tips and recommendations as well as information for efficient and trouble-free operation.

NOTES!

Do not use a hammer or similar tool when installing the device due to the risk of damage occurring to the bearings or coupling!

DANGER! Life-threatening danger due to electric shock!

Indicates a life-threatening situation due to electric shock. If the safety instructions are not complied with there is danger of serious injury or death. The work that must be executed should only be performed by a qualified electrician.

1 General

1.1 Information about the Operating and Assembly instructions

These Operating and Assembly Instructions provide important instructions for working with the device. They must be carefully read prior to starting all tasks, and the instructions contained herein must be followed.

In addition, applicable local regulations for the prevention of industrial accidents and general safety regulations must be complied with.

1.2 Scope of delivery

Incremental Encoder FG 40, Operating and Assembly Instructions.

1.3 Explanation of symbols

Warnings are indicated by symbols in these Operating and Assembly Instructions. The warnings are introduced by signal words that express the scope of the hazard. The warnings must be strictly heeded; you must act prudently to prevent accidents, personal injury, and property damage.

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NOTES!

Content information, text, drawings, graphics, and other representations are protected by copyright and are subject to commercial property rights. It is strictly forbidden to make copies of any kind or by any means for any purpose other than in conjunction with using the device without the prior written agreement of the manufacturer. Any copyright infringements will be prosecuted.

DANGER!

This section provides an overview of all the important safety aspects that ensure protection of personnel, as well as safe and trouble-free device operation. If these safety instructions are not complied with significant hazard can occur.

1.4 Disclaimer

All information and instructions in these Operating and Assembly Instructions have been provided under due consideration of applicable guidelines, as well as our many years of experience. The manufacturer assumes no liability for damages due to:

 Failure to follow the instructions in the Operating and Assembly Instructions  Non-intended use  Deployment of untrained personnel  Opening of the device or conversions of the device

In all other aspects the obligations agreed in the delivery contract as well as the delivery conditions of the manufacturer apply.

1.5 Copyright

1.6 Guarantee terms

The guarantee terms are provided in the manufacturer’s terms and conditions.

1.7 Customer service

For technical information personnel is available that can be contacted by telephone, fax or email. See manufacturer’s address on page 2.

2 Safety

2.1 Responsibility of the owner

The device is used in commercial applications. Consequently the owner of the device is subject to the legal occupational safety obligations and subject to the safety, accident prevention and environmental protection regulations that are applicable for the device’s area of implementation.

2.2 Intended use

The device has been designed and constructed exclusively for the intended use described here. Series FG 40 Incremental Encoders are used for measurement of rotations, for instance of electrical

and mechanical drives and shafts. Claims of any type due to damage arising from non-intended use are excluded; the owner bears sole

responsibility for non-intended use.

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DANGER! Life-threatening danger due to electrical shock!

There is an imminent life-threatening hazard if live parts are touched. Damage to insulation or to specific components can pose a life-threatening hazard. Therefore: Immediately switch off the device and have it repaired if there is damage to the insulation of the power supply. De-energize the electrical equipment and ensure that all components are connected for all tasks on the electrical equipment. Keep moisture away from live parts. Moisture can cause short circuits.

WARNING! Danger of injury due to rotating shafts and hot surfaces!

Touching rotating shafts can cause serious injuries.

Therefore:

Do not reach into moving parts/shafts or handle moving parts/shafts during operation. Close to protect from injury all access openings in flanges with the corresponding plug screw, and provided you exposed rotating components with protective covers. Do not open covers during operation. Prior to opening the covers ensure that all parts have come to a standstill. The encoder can become hot during prolonged use. In case of contact risk of burns is existing.

DANGER! Life-threatening danger if restarted without authorization!

When correcting faults there is danger of the power supply being switched on without authorization. This poses a life-threatening hazard for persons in the danger zone.

Therefore:

Prior to starting work, switch off the system and safeguard it from being switched on again.

2.3 Improper use

Do not use the device in potentially explosive areas. The device must not be subjected to mechanical loads in addition to its own weight and unavoidable vibration and shock loads that arise during normal operations.

Examples for non-permitted mechanical loads (incomplete list):

- Fastening transport or lifting tackle to the device, for example a crane hook to lift a motor.

- Fastening packaging components to the device, for example ratchet straps, tarpaulins etc.

- Using the device as a step, for example by people to climb onto a motor.

2.4 Personnel

Installation and commissioning as well as disassembly routines must be carried out by skilled technical staff only.

2.5 Personal protective equipment

Wear personal protective equipment such as safety shoes and safety clothing to minimise risks to health and safety when carrying out work such as installation, disassembly or commissioning. Adhere to all applicable statutory regulations as well as the rules and standards determined by the owner.

2.6 Special dangers

Residual risks that have been determined based on a risk assessment are cited below.

2.6.1 Electrical current

2.6.2 Rotating shafts / Hot surfaces

2.6.3 Safeguarding against restart

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Encoder with one terminal box

Encoder with 2 terminal boxes (redundant version)

Encoder with 2 sinusoidal signals

3 Technical Data

3.1 Type plates

Nameplates for different device variations are shown below

The type plate is located on the outside of the housing and contains the following information:

 Manufacturer, Address  Type, year of construction  CE marking  Serial number (S/N)  Commission number (C/N)  Pulse rate  Protection class  Power supply  No-load current  Outputs

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Pulse rates

Value

Standard pulse rates

500, 600, 1000, 1024, 1200, 2000, 2048, 2400, 2500

Special pulse rates

4000, 4096, 4800, 5000, 8192, 10000, 12000, 16000, 16384, 20000, 25000, 40000, 50000

(further pulse rates according to customers specification)

Connection data

Supply voltage

12 V … 30 V DC

No load-current

approx. 50 mA at 24 V

Outputs

Current limited, short-circuit proof push-pull line driver with integrated impedance adaptation for 30 to 140 Ω lines.

Pulse height (HTL)

approx. as supply voltage, output saturation voltage < 0.4 V at IL 30 mA

Output current

max. 150 mA at 24 V (observe derating)

Internal resistance

75 Ω bei 24 V

Slew rate

200 V / µs with CL 100 pF

Duty cycle

1 : 1 ± 3 % for standard pulse rates 1 : 1 ± 5 % for special pulse rates up to 25000 pulses

Square wave displacement 0°, 90°

90° ± 3 % for standard pulse rates 90° ± 5 % or special pulse rates up to 25000 pulses

Max. frequency

200 kHz, Higher max. frequency on request

Special output voltage 5V (TTL)

Pulse height

5V, RS422-compatible (TIA/EIA-Standard)

Supply voltage

12 … 30 V DC (optional: 5 V DC),

3.2 Electrical and mechanical data

3.2.1 For pulse rates (square wave pulses)

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Pulse rates

Value

Standard pulse rates

500, 600, 1000, 1024, 1200, 2000, 2048, 2400, 2500

Connection data

Supply voltage

5 V … 30 V DC

No load-current

Approx. 120 mA at 5 V, approx. 50 mA at 24 V

Max. frequency

200 kHz, higher max. frequency on request

Output signals

2 sinusoidal signals A and B each with inverted signals Reference pulse with inverted signal Signal amplitude 1 V pp / RL = 120 Ω Error signal and inverted signal Signal amplitude 5V

Resolution

1024 signal periodes

Duty cycle

1 ± 0,1

Phase shift A, B

90° ± 1°

3.2.2 Output signals Sine / Cosine

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Protection class acc. to

DIN EN 60529

Sealing

Permissible speed

Rotor moment of inertia

Breakaway torque

IP65

Standard

≤ 6000 min

-1

510 gcm²

6 Ncm

IP66

with labyrinth seal

≤ 6000 min -1

580 gcm²

6 Ncm

IP66/IP67

with axial shaft seal

≤ 4000 min -1

510 gcm²

8 Ncm

IP66/IP67

with radial shaft seal (for special applications, e.g. wet areas in rolling mills)

≤ 3000 min -1

510 gcm²

9 Ncm

Encoder temperature ranges

Standard

0°C… + 70°C

Special temperature ranges

-25°C… + 85°C

-40°C… + 85°C

-5°C… + 100°C

Special output voltage 5V (TTL)

Pulse height

5V, RS422-compatible (TIA/EIA-Standard)

Supply voltage

12… 30 V DC (optional: 5V DC)

Vibration resistance

DIN EN 60068-2-6 / IEC 68-2-6 (10 … 2000 Hz)

20 g (=200 m/s²)

Shock resistance

DIN EN 60068-2-27 / IEC 68-2-27 (6 ms)

150 g (=1500 m/s²)

Max. encoder shaft load

Fa, max. (axial) = 100 N Fr, max. (radial) = 120 N

Shaft dimensions

11j6 x 30 mm (standard) 14j6 x 30 mm (optional)

Weight

Type AK Type K Type KK

approx. 2,8 kg approx. 3,1 kg approx. 3,6 kg

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Signal outputs

Basic version

Basic channel 0° (A) and pulse channel 90° (B) Internal system diagnostics with error output (ERROR) Each with inverted signals

Option N

Reference pulse (N) mechanically defined; one square-wave pulse per revolution; with inverted signal

Option 2F

Twice as many pulses as basic channel by combining the 0° and 90°channels

Option B

Rapid direction of rotation detection at each edge of the 0° and 90°channels

Can be combined with Option F

Option B2

Rapid direction of rotation detection at each edge of the 0° and 90° channels; additional standstill recognition

Option B3

Rotation-dependent output signals. This option supports counter cards with separate UP/DOWN pulse inputs. Basic channel signals are issued at option output 1 when rotation is clockwise and at option output 2 when rotation is counterclockwise.

Option S

Electronic overspeed switch with two independently programmable switching points

See separate Operating and Assembly

Instructions EGS® 40

Fiber optic option

As an alternative to conventional signal transmissions via copper cables encoder signals can also be transmitted via fiberoptic cables.

Max. frequency 100 kHz

N N

The signal sequence 0°, 90° applies for clockwise rotation seen from the drive shaft direction. To obtain the same signal sequence for counter clockwise rotation the clamp 0°, 90° has to be connected see connection diagram.

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Signal outputs for output signals sine / cosine

Basic channel 0° (A) and pulse channel 90° (B).

Reference pulse (N) mechanically defined; one square-wave pulse per revolution; with inverted signal

Each with inverted signal. Internal system diagnostics with error

output (ERROR).

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40 K 1024

90G

Incremental encoder

Series

connections, radial design

K: Terminal box R: Burndy®-plug C: Connection cable L: Fiber optic connection S: 15-pole EMC industrial plug

KK: 2 terminal boxes, i.e. redundant version or with option S further combined connections available

connections, axial design

AK: Terminal box AR: Burndy®-plug AC: Connection cable

Pulses per revolution

Basic signal output

Basic channel 0° (A) Pulse channel 90° (B) Each with inverted signals

NG: Option reference pulse with inverted signal N2: Reference pulse, mechanically fixed with

LED check (red) for display of reference pulse

2F: Option 2F B: Option B B2: Option B2 B3: Option B3

S: Option S Options see pages before

3.3 Type code

3.3.1 For pulse rates (square wave pulses)

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40 K 1024

Incremental encoder

Series

connections, radial design

K: Terminal box R: Burndy®-plug C: Connection cable L: Fiber optic connection S: 15-pole EMC industrial plug

KK: 2 terminal boxes, i.e. redundant version

Resolution

1024 signal periods per revolution

Output signals

2 sinusoidal signals A and B each with inverted signals

NG: Option reference pulse with inverted signal

3.3.2 For output signals Sine / Cosine

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CAUTION! Material damage caused by improper transport!

Observe the symbols and information on the packaging:

 Do not throw - risk of breakage  Keep dry  Do not expose to heat above 40 °C or direct sunlight.

Keep dry

Keep packages dry and free from dust; protect from moisture.

Protect against heat

Protect packages from heat above 40 °C and direct sunlight.

NOTES!

Turn the shaft of the device every 6 month to prevent the bearing grease solidifying!

4 Transport, packaging and storage

4.1 Safety instructions for transport

4.2 Incoming goods inspection

Check delivery immediately upon receipt for completeness and possible transport damage. Inform the forwarder directly on receipt of the goods about existing transport damages (prepare

pictures for evidence).

4.3 Packaging / disposal

The packaging is not taken back and must be disposed of in accordance with the respective statutory regulations and local guidelines.

4.4 Storage of packages (devices)

If you intend to store the device for a longer period of time (> 6 months) we recommend you use protective packaging (with desiccant).

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NOTES!

Observe the safety instructions contained in Chapter 2 when installing or working on the device!

NOTES!

Do not use a hammer or similar tool when installing the device due to the risk of damage occurring to the bearings or coupling!

5 Mounting and commissioning

5.1 Safety instructions

Personnel

Installation and commissioning must be carried out by skilled technical staff only.

5.2 Technical information

Ambient temperature

The max. permissible ambient temperature depends on the speed and degree of protection of the device, the signal frequency, the length of the signal cable and the place of installation (please refer to Chapter 3.2).

Degree of protection

To fulfil degree of protection requirements the diameter of the connection cable must correspond to that of the cable gland (please refer to Chapter 11 dimension drawings)!

Deep groove ball bearings

FG incremental encoders are fitted with maintenance-free, greased "for-life" deep groove bearings. Bearings must be changed by the manufacturer only. Opening the encoder renders the guarantee null and void.

Screw retention

We recommend using Loctite® 243 threadlocker (medium strength) on all fastening screws to prevent loosening.

5.3 Required tools

 Spanners: 10 mm, 22 mm, 24 mm  Allen keys: 2 mm, 3 mm  Flat-blade screwdrivers:  Assembly grease  Loctite® 243 (medium strength threadlocker)

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NOTES!

Fastening screws and earth cable are not included in the range of supply.

NOTES!

For a mounting example please refer to dimension drawing HM 09 M 57 263a (Chapter 11.1).

1 9 2

10 3 12

13 4 7 6 15 8 5

Figure 1: FG 40 construction type B5

5.4 Mounting preparations

1. Ensure all accessories are available (please refer to Chapter 11 Dimension drawings).

2. Preparing the place of attachment: Clean the (motor) shaft, centering, bolting surfaces and fastening threads; check for damage. Repair any damage!

5.5 Mounting B5 type (flange) incremental encoders

)

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NOTES!

You must be able to mount the coupling without force. Ream out the bores of used couplings, if necessary!

NOTES!

If possible, fit the intermediate flange in a manner that ensures the screwed sealing plug (14) points downwards!

NOTES!

You must be able to mount the coupling without force. Ream out the bores of used couplings, if necessary!

NOTES!

If possible, fit the device in a manner that ensures the cable gland points downwards Exchange the position of the cable gland (16) and the blanking plug (15), if necessary.

NOTES!

To carry out this task, it may be necessary to turn the (motor) shaft to the correct position.

1. Lightly grease the (motor) shaft (1) and centering (9).

2. Fit coupling (2) onto (motor) shaft.

3. Secure the coupling hub on the (motor) shat with a grub screw or cheese head screw (10) (depending on the coupling type).

4. Fasten the intermediate flange (3) to the motor using the fastening screws (12).

5. Lightly grease the encoder shaft (5) and centering (4).

6. Fit the encoder (8) into both the centering (4) and coupling hub at the same time.

7. Secure the encoder with 4-6 screws (6) evenly distributed around the circumference of the flange.

8. Remove the sealing plug (14) from the access bore (13) to the coupling.

9. Secure the coupling hub on the encoder shaft with a grub screw or cheese head screw (11) (depending on the coupling type).

10. Replace the sealing plug (14) to seal the access bore to the coupling.

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NOTES!

B35 type encoders can be attached by means of a flange (B5, please refer to Chapter 5.5) or foot (B3): For a mounting example please refer to dimension drawing HM 09 M 102 240a (Chapter 11.2).

NOTES!

You must be able to mount the coupling without force. Ream out the bores of used couplings, if necessary!

NOTES!

We recommend our zero-backlash, torsion-resistant double-joint coupling HKD5 to attach B35 type encoders. Please refer to the catalogue Torsion Resistant Couplings for

Encoders.

Figure 2: FG 40 construction type B35

5.6 Mounting B35 type (flange and foot) incremental encoders

1. Lightly grease the (motor) shaft (1).

2. Fit coupling (2) onto (motor) shaft.

3. Secure the coupling hub on the (motor) shaft with a grub screw or cheese head screw (10) (depending on the coupling type).

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NOTES!

Use shims (19) to achieve the correct vertical alignment to the base plate (20).

Observe information in Chapter 5.7about mounting errors and max. permissible mounting tolerances!

NOTES!

Angle misalignment and parallel displacement between the (motor) shaft and the encoder shaft are mounting errors and should be kept as small as possible.

Mounting errors

- Cause radial forces to act on the encoder shaft.

- Reduce the service life of the bearings and the coupling.

- Degrade the quality of the signals (harmonic content).

Coupling

Axial offset

Angular error

Parallel offset

HK 5

± 1 mm

0.5°

HKD 5

± 1.5 mm

0.5°

0.5 mm

4. Align the encoder shaft (5) to the (motor) shaft and insert into the coupling hub.

5. Fasten encoder foot with 4 M6 hexagon head screws (18).

6. Secure the coupling hub on the encoder shaft with the grub screw or cheese head screw (11) (depending on the coupling type).

5.7 Mounting tolerances for construction type B5 and B35

Mounting tolerances for our zero-backlash, torsion-resistant couplings HK5 and HKD5:

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NOTES!

Encoders in construction type B5/B14 have a second shaft end with integrated coupling half (1) and a B 14 flange (2) on the non-drive end onto which it is possible to fit an additional device with a B5 flange, for example an incremental encoder, absolute shaft encoder or an overspeed switch. A second coupling half with elastomer ring (5, Figure

4), which is available as an accessory, is required to fit an additional device. Installation example see dimension drawing HM 09 M 102 245 (Chapter 11.5). This design option makes it possible to combine up to four devices.

CAUTION!

Do not remove the housing cover secured with Torx screws! These devices are not equipped with a second shaft end.

NOTES!

The fastening screws (4) can be used later to secure the additional device (7).

NOTES!

Ensure no liquids or dirt are allowed ingress into the device when the cover plate is removed. Mount the cover again, if you experience installation delays.

Figure 3:

5.8 Attaching additional devices

When supplied ex works the second shaft end is protected by a cover plate (3) secured with 6x M6x20 hexagon head screws (4).

1. Loosen the hexagon head screws (4).

2. Remove the cover plate (3).

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WARNING!

If no second device is added ensure the cover plate is fitted to protect and cover the second shaft end.

NOTES!

The correct distance between both coupling halves has now been set.

6 7 5

4 7 2

Figure 4:

Figure 5:

3. Slide on the coupling half (5) with elastomer ring up to the collar of the shaft of the additional device (7), and secure by tightening the grub screw (6).

4. Mount the attachment (7) to the B 14 flange (2) of the rotary encoder.

5. Fix the attachment (7) with 6 x hex bolts M6 x 20 – 8.8. For this step the mounting screws (4) of the cover can be used.

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NOTES!

You must observe applicable EMC guidelines when routing cables!

CAUTION!

Do not allow moisture to enter the terminal box when the cover is open!

NOTES!

The signal cable shielding can be connected directly to the housing via the EMC cable gland. A coil spring integrated in the cable gland ensures all-round contact is made with the bare cable shielding to ensure a good shield connection. This type of shield connection should be preferred.

Alternatively, if equipotential boning currents are anticipated it is possible to connect the cable shielding to a shield terminal in the terminal box. A capacitor between the shield terminal and the encoder housing prevents the flow of equalizing current.

To achieve an effective shielding the cable shield must also be connected in the electrical cabinet.

NOTES!

Prior to delivery cable glands and blanking plugs are tightened finger tight only. To ensure that the terminal box is reliably sealed tighten all cable glands and blanking plugs before starting up for the first time.

5.9 Electrical connection and start up

5.9.1 Preparing cables

1. Strip cable insulation.

2. Crimp wire-end ferrules.

5.9.2 Electrical connection

1. Open the terminal box cover (16, Fig.1).

2. Remove the cap of the cable gland (17, Fig. 1).

3. Feed the cable into the terminal box trough the cable gland.

4. Tighten the cable gland and blanking plugs using a spanner.

5. Use a spanner to tighten the cable gland until the cable is securely clamped and properly sealed.

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NOTES!

Prevent lateral pulling forces acting on the cable and plugs so as not to impair the degree of protection of the cable gland.

CAUTION!

Do not apply supply voltage to the signal outputs, as this will destroy the device!

NOTES!

To achieve a good shielding effect the cable shield be kept as short as possible.

NOTES!

Before closing the terminal box cover check and if necessary clean both seal surfaces and the gasket.

CAUTION!

Ensure when closing the terminal box cover that no cable becomes jammed.

6. Connect the supply voltage and signal cable (please refer to the connection diagrams, Chapter

11).

7. Applicable to alternative shield connection only: fit cable lug to cable shield and connect to the shield terminal (please refer to the connection diagrams, Chapter 12).

8. Close the terminal box cover.

9. Secure earth cable to earth terminal (7).

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WARNING!

Observe the safety instructions contained in Chapter 2 when inspecting or working on the device!

NOTES!

Do not use a hammer or similar tool when installing the device due to the risk of damage occurring to the bearings or coupling!

6 Dismantling

6.1 Safety instructions

Personnel

Dismantling must be carried out by skilled technical staff only.

6.2 Dismantling the encoder

Remove all electrical cables from the device before dismantling. To dismantling the encoder follow the instructions given in Chapters 5.5 and 5.6 or 5.8 in the reverse order.

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

Faults

Possible cause

Remedy

Moisture in the terminal box

Soiled terminal box gasket or seal surfaces

Clean terminal box gasket and seal surfaces

Damaged terminal box gasket

Replace terminal box gasket

Cable gland/blanking plug not tightened

Tighten cable gland/blanking plug

Unsuitable cable for cable gland

Use suitable cable and cable glands

No output signals

Supply voltage not connected

Connect supply voltage Connection cable reversed

Wire correctly

Output signals subject to interference

Unsuitable cable

Use data cable with conductors arranged as twisted pairs and common shield

Cable shield not connected

Connect cable shield at both ends

Cable routing not EMC compliant

Observe applicable EMC guidelines when routing cables

Signal interruptions

Signal end stage overloaded

Check pin assignment; observe connection diagram

Do not assign unused outputs

Outputs short-circuited

Do not connect outputs with supply voltage or GND

Contact Hubner-Service (page 2) if none of the remedies listed above provides a solution)!

7 Faults

7.1 Faults table

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

WARNING!

Skilled technical staff only are permitted to inspect the device and its installation. Observe the safety instructions contained in Chapter 2 when inspecting or working on

the device!

Interval

Inspections

Yearly

Inspect the coupling for damage and ensure it is free of play

Ensure the fastening screws are properly tightened

Ensure cable connections and connection terminals are securely seated

Following approx 16 000 … 20 000 hours of operation / higher levels of continuous load

Check deep groove ball bearings are running smoothly and listen for running noises

Replacement parts

Comment

Cover

Cover for the 2nd shaft end or for the hollow shaft bore (gAS)

Cable gland

M 20 x 1.5

Terminal box cover

Including flat seal and screws

Feather key

Specify shaft dimensions or feather key dimension

Programming cable and software

Screw plug

For closing the access to the coupling

8 Inspections

8.1 Safety instructions

8.2 Maintenance information

The device is maintenance-free. However, to guarantee optimum fault-free operations we recommend that you carry out the following inspections.

8.3 Inspection schedule

9 Disposal

9.1 Disposal procedure

The manufacturer is not obliged to take back the device. The device is classed as electronic equipment and subject to the WEEE Directive; observe local,

country-specific laws when disposing of the device. For information on environmentally sound disposal please contact your local authority or a specialist

disposal company.

10 Replacement parts

The replacement parts listed below can be obtained via the service address on page 2.

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

With radial terminal box

HM 08 M 57 221a

FG 40 AK

With axial terminal box

HM 08 M 57 024a

11 Dimension drawings

Further dimension drawings on our website or on request.

11.1 Construction type B5 (flange)

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 KK

Redundant version

HM 08 M 57 223a

FG 40 K

Mounting example for construction type B5

with flange and coupling HK 522

HM 09 M 57 263a

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

With radial terminal box

HM 08 M 57 222a

FG 40 KK

Redundant version

HM 08 M 57 224a

11.2 Construction type B35 (flange and foot)

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

Mounting example for construction type B35

With coupling HKD 522

HM 09 M 102 240a

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

Construction type B5/B14

(flange with 2 shaft ends)

HM 09 M 102 541

11.3 Construction type B5/B14 (flange with 2 shaft ends)

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 KK

redundant version

HM 09 M 102 549

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

construction type B35/B14

(flange and foot with 2 shaft ends)

HM 09 M 102 280

11.4 construction type B35/B14 (flange and foot with 2 shaft ends)

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 KK

redundant version

HM 09 M 101 548

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 K

FG 40 K with coupled unit

HM 09 M 102 245

11.5 Mounting options

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 KK

FG 40 KK with coupled unit

HM 09 M 102 627

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 R/RR

additional dimension drawing

electrical socket design FG 40 R/RR

HM 09 M 102 270

11.6 Additional dimension drawings – electrical socket design

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 L/LL

additional dimension drawing

electrical socket design FG 40 L/LL

HM 09 M 103063

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40 S/SS

additional dimension drawing

electric connection implementation FG 40 S/SS

15 pole EMC

HM 12 M 105755

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

Standard

Terminal box

FG 40

Standard without reference pulse

Terminal box

12 Connection diagrams

Shielding:

The shield of the signal cable can be connected directly to the housing of the encoder by the cable gland. Alternatively the shield of the signal cable can be connected to K11 via a capacitor(10nF / 500V) to the housing of the encoder.

10 pole printed circuit spring terminal block type Phoenix ZFKDS

Connection data: wire section 0,2-1,5 [mm²]

Alternative Shielding

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

Socket insert view

Shield: The shield of the signal cable is

directly to be connected with the socket housing.

Crimping tool: Burndy® No. MR 8 GE 5

FG 40

Standard

Burndy® plug

Connection cable

6x2x0,56 twin-standard, shielded

Type: HE-2LVCC-CY AWG 20b acc. to VDE 0881

Cross-section: 0,56 mm² Temperature: -20 °C to + 105 °C Outside dia: 10,1 mm

shield is connected to casing

other cables- / temperature ranges on request

FG 40

Standard

Connection cable

Crimp contacts for cross-sectional data of wire from 0,52 up to 1,5 mm²

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

Option 2F

Terminal box

FG 40

Option B

Terminal box

12 pole printed circuit spring terminal block type Phoenix ZFKDS

Connection data: Wire section 0,2-1,5 [ mm² ]

Shielding:

The shield of the signal cable can be connected directly to the housing of the encoder by the cable gland. Alternatively the shield of the cable can be connected to K13 via a capacitor (10nF / 500V) to the housing of the encoder.

Alternative Shielding

10 pole printed circuit spring terminal block type Phoenix ZFKDS

Connection data: Wire section 0,2-1,5 [ mm² ]

Shielding:

Alternative Shielding

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

Option B2

Terminal box

FG 40

Option B3

Terminal box

12 pole printed circuit spring terminal block type Phoenix ZFKDS

Connection data: Wire section 0,2-1,5 [ mm² ]

Shielding:

Alternative Shielding

10 pole printed circuit spring terminal block type Phoenix ZFKDS

Connection data: Wire section 0,2-1,5 [ mm² ]

Shielding:

Alternative Shielding

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

connection sheme PN 109-470

terminal box

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

connection sheme PN 109-415

EMC industrial plug

FG 40

connection sheme 649 Option S

Burndy plug

Incremental Encoder FG 40

FG40_MANUAL-en_R12(2018-10-31)ID74490.doc

FG 40

connection sheme 148 400b

Sine /cosine output

Hubner FG 40, FG40 K-1024G-90G-NG, KK-1024G-90G-NG, K-1024S-N Operating And Assembly Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual