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

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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: [phone]
Fax: [phone]
Internet: www.huebner-giessen.com

E-Mail: [e-mail]

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.

Copyright © Johannes Hubner
Fabrik elektrischer Maschinen GmbH
All rights reserved.

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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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FG

40 K 1024

G

90G

NG

2F

S

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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FG

40 K 1024

S

N

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