Giovenzana FGR1 User manual

Strawinskylaan 1105
1077 XX Amsterdam, The Netherlands
INTRODUCTION .................................2
Terms of use....................................2
Special conditions for a safe usage.................2
TECHNICAL CHARACTERISTICS ................... 3
Technical data ..................................3
Microswitch technical data........................3
Main components ...............................4
Dimensions.....................................5
INSTALLATION ..................................6
Limit switch installation ..........................6
Wiring and cams adjustment ......................8
Microswitches wiring.............................9
ACCESSORIES / SPARE PARTS ...................10
Pinions (PA66 - water cutting) ....................10
Pinions (PA66 - molded) .........................11
Camshapes....................................12
Oldham coupling ...............................13
MAINTENANCE AND REPAIR TERMS
AND CONDITIONS ..............................14
Maintenance...................................14
CERTIFICATIONS ...............................14
FGR1
EN
instruction manual
MT-FGR1-EN / 28.06.2021
Rev. 4
ROTARY GEAR LIMIT SWITCH
Before use, read this booklet carefully to
acquaint yourself with the features of the
product. This booklet is an integral part of
the product and therefore must be kept until
the product is dismissed.
Giovenzana International B.V. reserves the
right to change the features and data shown
in this document at any time and without
notice. This document cannot therefore be
considered a contract with third parties.
Rotary gear limit switches FGR are designed
and manufactured according to IEC
international standard and EN European
regulations.
Any improper installation or any tampering
of the device may cause serious personnel
injury or property damage, therefore, the
installation and maintenance must be
performed by specialized and authorized
personnel.
The use of this device is not allowed in
environment with a potentially explosive
atmosphere or in presence of corrosive
substances and in salt spray.
They are suitable for use in industrial
environment with machinery monitoring and
protection purpose.
Available in 3 variations:
• base fixing
• flanged fixing
• rear shaft

2GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
INTRODUCTION
Terms of use
Special conditions for a safe usage
GIOVENZANA INTERNATIONAL B.V.
Terms of use
Special conditions for a safe usage
The FGR rotary gear limit switch is a device used to
control the number of turns or the rotation/direction
angle of industrial and building machines.
A typical application is the rolling shutter door,
overhead cranes or tackles etc. The unit, throught a
gear system and cams transmission, controls 2 or
more microswitches so, after a determined number of
revolutions, it can prepare the motor to start or stop run.
The microswitches have a calibration screw that
operates independently on each cam; so it can calibrate
the opening and closing of each micro according the
functional requirements needed.
The system gear transmission allows you to choose
different ratios with the main shaft.
The equipment must be installed only if it is completely
intact and unbroken. The product must be installed
according to the applicable code of practice, national
regulations and laws and / or international standards as
well as in compliance with the present instructions.
Do not change anything inside or outside the
equipment.
Low mechanical risk
The equipment is suitable for resisting impact energies
up to 4 J.
When impacts of energy are likely greater than 4 J,
additional mechanical protection is required around the
plastic case.
Potential electrostatic risk
The equipment is intended for fixed use and the user
must not frequently touch the equipment in service
(except for maintenance).
To avoid the potential electrostatic charge, it is
necessary to perform the following instructions during
the installation and service of the FGR:
• Do not install under direct air or other gas flow. If
these requirements cannot be met, additional external
direct flow protection is required.
• Install only when the relative humidity of the
environment is greater than 30% (stable, always or
for a long time) or in an environment with a humidity
control system.
• The metal parts of the casing must be connected
to the equipotential system in accordance with the
instructions in paragraph “Connection of earthing or
bonding conductors”.
• Do not rub the plastic cover insistently. If cleaning is
required (e.g. to remove dust) only manual operations
with wet materials are allowed.
Conditions
• The inner components (cam MFI micros, mounting
brackets, etc.) are mounted in order to guarantee the
type of protection.
• Any modification is forbidden.
• Do not remove any components or micro even if they
are not used.
Types of protection
• Every screw shall be tightened with the tightening
torque according to this document, to maintain the
degree of protection IP.
• Additional holes and/or entries into enclosure are
forbidden, the only entries in the enclosure shall be
made by Giovenzana (see the information reported in
clause 1 of this document).
• The type of protection and minimum degree of
protection (IP code) of the entries into enclosure
or cable glands shall be in accordance with the
equipment marking.
• Any entry of the enclosure, the mounting of the entries
into enclosure or cable glands shall be carried out to
maintain the level of protection of the equipment.
Connection of earthing or bonding conductors
The equipment shall be earthed in accordance with the
relevant code of practice. The equipment is provided by
internal connection terminal for earthing.
If the reference standards applicable for the installation
require an external equipotential connection or these
become necessary for other reasons, connect the
equipotential conductor to the external earth terminal,
identified with the earthing symbol.
The conductors used for the earth and equipotential
connection must be equipped with an eye lug. Install
each conductor according to the following instructions:
• Place the eyelet in contact with the threaded hole of
the internal or external earth terminal, positioned on
the metal box.
• Place a Grover washer or non-loosening washer
between the eye lug and the clamp screw.
• Tighten the ground terminal screw with a tightening
torque of 1.7 N×m (15 lb×in). On the internal earth
screw add some threadlocker. Tightening the screw
ensures electrical continuity.
INTRODUCTION
GIOVENZANA INTERNATIONAL B.V.
Terms of use
Special conditions for a safe usage
The FGR rotary gear limit switch is a device used to
control the number of turns or the rotation/direction
angle of industrial and building machines.
A typical application is the rolling shutter door,
overhead cranes or tackles etc. The unit, throught a
gear system and cams transmission, controls 2 or
more microswitches so, after a determined number of
revolutions, it can prepare the motor to start or stop run.
The microswitches have a calibration screw that
operates independently on each cam; so it can calibrate
the opening and closing of each micro according the
functional requirements needed.
The system gear transmission allows you to choose
different ratios with the main shaft.
The equipment must be installed only if it is completely
intact and unbroken. The product must be installed
according to the applicable code of practice, national
regulations and laws and / or international standards as
well as in compliance with the present instructions.
Do not change anything inside or outside the
equipment.
Low mechanical risk
The equipment is suitable for resisting impact energies
up to 4 J.
When impacts of energy are likely greater than 4 J,
additional mechanical protection is required around the
plastic case.
Potential electrostatic risk
The equipment is intended for fixed use and the user
must not frequently touch the equipment in service
(except for maintenance).
To avoid the potential electrostatic charge, it is
necessary to perform the following instructions during
the installation and service of the FGR:
• Do not install under direct air or other gas flow. If
these requirements cannot be met, additional external
direct flow protection is required.
• Install only when the relative humidity of the
environment is greater than 30% (stable, always or
for a long time) or in an environment with a humidity
control system.
• The metal parts of the casing must be connected
to the equipotential system in accordance with the
instructions in paragraph “Connection of earthing or
bonding conductors”.
• Do not rub the plastic cover insistently. If cleaning is
required (e.g. to remove dust) only manual operations
with wet materials are allowed.
Conditions
• The inner components (cam MFI micros, mounting
brackets, etc.) are mounted in order to guarantee the
type of protection.
• Any modification is forbidden.
• Do not remove any components or micro even if they
are not used.
Types of protection
• Every screw shall be tightened with the tightening
torque according to this document, to maintain the
degree of protection IP.
• Additional holes and/or entries into enclosure are
forbidden, the only entries in the enclosure shall be
made by Giovenzana (see the information reported in
clause 1 of this document).
• The type of protection and minimum degree of
protection (IP code) of the entries into enclosure
or cable glands shall be in accordance with the
equipment marking.
• Any entry of the enclosure, the mounting of the entries
into enclosure or cable glands shall be carried out to
maintain the level of protection of the equipment.
Connection of earthing or bonding conductors
The equipment shall be earthed in accordance with the
relevant code of practice. The equipment is provided by
internal connection terminal for earthing.
If the reference standards applicable for the installation
require an external equipotential connection or these
become necessary for other reasons, connect the
equipotential conductor to the external earth terminal,
identified with the earthing symbol.
The conductors used for the earth and equipotential
connection must be equipped with an eye lug. Install
each conductor according to the following instructions:
• Place the eyelet in contact with the threaded hole of
the internal or external earth terminal, positioned on
the metal box.
• Place a Grover washer or non-loosening washer
between the eye lug and the clamp screw.
• Tighten the ground terminal screw with a tightening
torque of 1.7 N×m (15 lb×in). On the internal earth
screw add some threadlocker. Tightening the screw
ensures electrical continuity.
INTRODUCTION
GIOVENZANA INTERNATIONAL B.V.
Terms of use
Special conditions for a safe usage
The FGR rotary gear limit switch is a device used to
control the number of turns or the rotation/direction
angle of industrial and building machines.
A typical application is the rolling shutter door,
overhead cranes or tackles etc. The unit, throught a
gear system and cams transmission, controls 2 or
more microswitches so, after a determined number of
revolutions, it can prepare the motor to start or stop run.
The microswitches have a calibration screw that
operates independently on each cam; so it can calibrate
the opening and closing of each micro according the
functional requirements needed.
The system gear transmission allows you to choose
different ratios with the main shaft.
The equipment must be installed only if it is completely
intact and unbroken. The product must be installed
according to the applicable code of practice, national
regulations and laws and / or international standards as
well as in compliance with the present instructions.
Do not change anything inside or outside the
equipment.
Low mechanical risk
The equipment is suitable for resisting impact energies
up to 4 J.
When impacts of energy are likely greater than 4 J,
additional mechanical protection is required around the
plastic case.
Potential electrostatic risk
The equipment is intended for fixed use and the user
must not frequently touch the equipment in service
(except for maintenance).
To avoid the potential electrostatic charge, it is
necessary to perform the following instructions during
the installation and service of the FGR:
• Do not install under direct air or other gas flow. If
these requirements cannot be met, additional external
direct flow protection is required.
• Install only when the relative humidity of the
environment is greater than 30% (stable, always or
for a long time) or in an environment with a humidity
control system.
• The metal parts of the casing must be connected
to the equipotential system in accordance with the
instructions in paragraph “Connection of earthing or
bonding conductors”.
• Do not rub the plastic cover insistently. If cleaning is
required (e.g. to remove dust) only manual operations
with wet materials are allowed.
Conditions
•
The inner components (cam MFI micros, mounting
brackets, etc.) are mounted in order to guarantee the
type of protection.
•
Any modification is forbidden.
•
Do not remove any components or micro even if they
are not used.
Types of protection
•
Every screw shall be tightened with the tightening
torque according to this document, to maintain the
degree of protection IP.
•
Additional holes and/or entries into enclosure are
forbidden, the only entries in the enclosure shall be
made by Giovenzana (see the information reported in
clause 1 of this document).
•
The type of protection and minimum degree of
protection (IP code) of the entries into enclosure
or cable glands shall be in accordance with the
equipment marking.
•
Any entry of the enclosure, the mounting of the entries
into enclosure or cable glands shall be carried out to
maintain the level of protection of the equipment.
Connection of earthing or bonding conductors
The equipment shall be earthed in accordance with the
relevant code of practice. The equipment is provided by
internal connection terminal for earthing.
If the reference standards applicable for the installation
require an external equipotential connection or these
become necessary for other reasons, connect the
equipotential conductor to the external earth terminal,
identified with the earthing symbol.
The conductors used for the earth and equipotential
connection must be equipped with an eye lug. Install
each conductor according to the following instructions:
• Place the eyelet in contact with the threaded hole of
the internal or external earth terminal, positioned on
the metal box.
• Place a Grover washer or non-loosening washer
between the eye lug and the clamp screw.
• Tighten the ground terminal screw with a tightening
torque of 1.7 N×m (15 lb×in). On the internal earth
screw add some threadlocker. Tightening the screw
ensures electrical continuity.
INTRODUCTION
GIOVENZANA INTERNATIONAL B.V.
Microswitch technical data
Operating temperature -25 ... +85°C
Minimum life expectancy mechanical
electrical
one million of cycles
half million of cycles
Rated thermal current Ith 8 A
Rated insulation voltage Ui 250 V
Rated impulse withstand voltage Uimp 1500 V
Rated operating current le resistive load
inductive load
8 A - 250 V
3 A - 250 V
Pollution degree 2
Protection against electric shock class II
Terminals
The microswitches installed can have one of the three types of terminals illustrated below:
6.3×0.8 faston screws M3 for wire 1.5 mm² screws M3 for wire 1.5 mm²
with plate protection

3GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
TECHNICAL CHARACTERISTICS
Technical data
Case thermoplastic glass fiber reinforced
Ratio 1:12 - 1:33 - 1:50 - 1:75 - 1:100 - 1:150 - 1:200 - 1:400
Direct ratio 1:50 - 1:75 - 1:100
Protection class IP65
Shaft type - steel
- double overhang shaft version available
Fixing type base
front (flanged version)
Microswitches up to 4
Cam block self-lubricating with transparent support for easier cam viewing
Cable entry M20 or M16 (max 4)
Temperature - operating: -25 ... +70°C
- storage: -30 ... +70°C
Options - 5 cam shape options
- 20 pinion options
Microswitch technical data
GIOVENZANA INTERNATIONAL B.V.
Microswitch technical data
Operating temperature -25 ... +85°C
Minimum life expectancy mechanical
electrical
one million of cycles
half million of cycles
Rated thermal current Ith 8 A
Rated insulation voltage Ui 250 V
Rated impulse withstand voltage Uimp 1500 V
Rated operating current le resistive load
inductive load
8 A - 250 V
3 A - 250 V
Pollution degree 2
Protection against electric shock class II
Terminals
The microswitches installed can have one of the three types of terminals illustrated below:
6.3×0.8 faston screws M3 for wire 1.5 mm² screws M3 for wire 1.5 mm²
with plate protection

4GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
Main components
3
2
6
7
9
12
13
11
14
B
8
4
1
3
5
4
10
A
1 Cover
2 Base
3 Cover fixing screws
4 Holes for fixing the limit switch (M5)
5 Front shaft
6 M20 knockout
7 M16 knockout
8 Cable gland M16
9 Sealing ring
10 Cams unit
11 Cams
12 Cam adjustment locking screw
13 Cam adjustment screws
14 Microswitches
A Flange for front fixing of the limit
switch (where provided)
B Double shaft (where provided)

5GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
Dimensions
Flanged fixing
Base fixing
5011.5
14
27.3 123
(200.3) 90
125 94.8
45
106
3571
Ø 12 h 7
16.5
(A) (A)
103.5
79
6.2
10.7
10
Ø 4
50
10
Ø 4
(A) (A)
103.5
79
27.3 123
(200.3) 90
125140 94.8
106
3571
6.5
120
(B)
(B)
49 71
12
45
16.5
6.2
10.7
Ø 12 h 7
11.5
14

6GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
Rear shaft
50
10
Ø 4
27.3 123
(200.3)
12550 94.8
106
3571
Ø 12 h 7 Ø 12 h 7
90
45
11.5 11.5
14 14
16.5
(A) (A)
103.5
79
6.2
10.7

7GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
INSTALLATION
Limit switch installation
79
103.5
120
49
2 × M6
4 × M6 4 × M6
Fixing points for basic configuration Fixing points for flanged configuration
Base
configuration
fixing
Flanged configuration fixing

8GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
GIOVENZANA INTERNATIONAL B.V.
Microswitches wiring
The FGR rotary gear limit switch can be equipped with 2 or more microswitches among those shown below.
The wiring of the microswitches can be carried out to obtain an NO contact, an NC contact or both.
NO NC
To wire the microswitches it is
necessary to use fastons suitable
for a 6.3×0.8 mm contact.
1
2
4
NO
1
2
4
NC
To wire the microswitches it is
necessary to strip the end of the
cable (1.5 mm²) and screw it
into the terminal (M3 screws).
1
2
4
NO
1
2
4
NC
To wire the microswitches it is
necessary to strip the end of the
cable (1.5 mm²) and screw it
into the terminal (M3 screws).
1
2
4
NO
1
2
4
NC
ATTENTION
The following procedures show an FGR limit switch
with 4 microwsitches but remain valid for any other
configuration.
ATTENTION
It is strictly forbidden to unscrew the screws
indicated in the figure. Their removal can
compromise the operation of the limit switch
and therefore cause serious damages to
things and people during use.
Limit switch wiring
1b
1a
2a
2b
2c
3b
3a
1Unscrew the 2 screws (a) and remove the cover (b).
2Remove the cable gland (a) and loosen the sealing nut
(b) to facilitate the insertion
of the cable (c).
3Insert the cable (a) into the cable gland (b).
ATTENTION
TO CARRY OUT THE FOLLOWING OPERATIONS, THE LIMIT SWITCH COVER MUST BE REMOVED. ON THE COVER ARE
PLACED VERY IMPORTANT INFORMATION CONCERNING THE LIMIT SWITCH YOU ARE INSTALLING. THE COVER
MUST BE REASSEMBLED ON THE CORRESPONDING BODY. REASSEMBLING THE COVER ON A NON-CORRESPONDING
BODY CAN LEAD TO AN INCORRECT INTERPRETATION OF THE LIMIT SWITCH OPERATION AND THEREFORE CAUSING
SERIOUS DAMAGE TO THINGS AND PEOPLE DURING USE.

9GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
Microswitches wiring
GIOVENZANA INTERNATIONAL B.V.
Microswitches wiring
The FGR rotary gear limit switch can be equipped with 2 or more microswitches among those shown below.
The wiring of the microswitches can be carried out to obtain an NO contact, an NC contact or both.
NO NC
To wire the microswitches it is
necessary to use fastons suitable
for a 6.3×0.8 mm contact.
1
2
4
NO 1
2
4
NC
To wire the microswitches it is
necessary to strip the end of the
cable (1.5 mm²) and screw it
into the terminal (M3 screws). 1
2
4
NO 1
2
4
NC
To wire the microswitches it is
necessary to strip the end of the
cable (1.5 mm²) and screw it
into the terminal (M3 screws). 1
2
4
NO 1
2
4
NC
4a
4b
4c
4d
5a
5b
5Fix the cable gland (a) and then tighten the sealing nut (b).
4Insert the cable (a) into the base of the limit switch (b) passing it also through the lock nut
(c) and taking care not to let the cable sheath
(d) protrude too much.

10GIOVENZANA INTERNATIONAL B.V. - MT-FGR1-EN / 28.06.2021 - Rev. 4
GIOVENZANA INTERNATIONAL B.V.
Pinions (PA66 - water-cut)
Z M Dp De Di a d L α
16020051 12 20 240 280 193.2 20 23.4 31.42 20°
16020052 17 14 238 266 205.24 14 16.38 21.99 20°
16020053 10 22 220 264 168.52 22 25.74 34.56 20°
16020054 12 18 216 252 173.88 18 21.06 28.27 20°
16020055 13 16 208 240 170.56 16 18.72 25.13 20°
16020056 17 10 170 190 146.6 10 11.7 15.71 20°
16020057 13 6 78 90 63.96 6 7.02 9.42 20°
16020070 16 19 304 336 266.56 16 18.72 25.13 20°
Z Number of teeth
M Diametral pitch
Dp Pitch circle diameter
De External diameter
Di Internal diameter
a Addendum
d Dedendum
L Tooth width
αPressure angle
1. Screw M6×16 + lock washer
Ø 4 mm
2. Elastic pin 4×24
1
2
Pinions thickness: 10 mm
For the installation of the water-cut pinions, the wheel coupling sleeve is required (code 16020050).
Ø 25
Ø 4
M4
26Ø 34
33
6Ø 12
H8
Ø 45
(*)
De
L
Dp
Di
Ø 3.8
(*)
Ø 34
Ø 24.6
1a
1b
2a
2c
2b
C4
C1
C2
C3
M4
M1
M2
M3
3
4b
4a
4c
5
6
Cams adjustment ATTENTION
The procedure implies that the FGR has already
been coupled to the gearmotor of the system to be
monitored.
2The cam pack shown in this procedure is equipped with 4 microswitches (a). The correspondence
between calibration screws (b), cams (c) and
microswitches (a) is shown in the diagram.
3Loosen the main screw to release the calibration
mechanism.
4Adjust each cam (a) with the calibration screws (b). The cam must rotate until the microswitch trips (c).
ATTENTION
The direction of rotation of the
calibration screw corresponds
to direction of rotation of the
cam.
1After having wired the limit switch (a) and connected the cables to the microswitches (b), proceed to
adjust the cams as follows.
6Close the limit switch cover by tightening the screws.
TIGHTENING TORQUE
1.6-1.8 N×m
14.2-15.9 lb×in
TIGHTENING TORQUE
1.8-2.2 N×m
16-19.5 lb×in
5At the end of the operation, tighten the main screw to lock the calibration
mechanism.