Hubner FG 2 Series Product guide

English
Translation of the original operating and assembly instructions FG2_MANUAL-en_R8(2016-08-11)ID70199.doc
ID 70199
Operating and Assembly Instructions
Incremental Encoder FG 2
Read the Operating and Assembly Instructions prior to
assembly, starting installation and handling!
Keep for future reference!

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Trademark
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]
E-Mail: [e-mail]
www.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.
Copyright © Johannes Hubner
Fabrik elektrischer Maschinen GmbH
All rights reserved.

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Directory
1General............................................................................................................................ 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
2Safety............................................................................................................................... 6
2.1 Responsibility of the owner ........................................................................................ 6
2.2 Personnel................................................................................................................... 6
2.3 Intended use.............................................................................................................. 7
2.4 Improper use.............................................................................................................. 7
2.5 Personal protective equipment................................................................................... 7
2.6 Special dangers......................................................................................................... 8
2.6.1 Electrical current.................................................................................................... 8
2.6.2 Rotating shafts / hot surfaces................................................................................ 8
2.6.3 Safeguarding against restart.................................................................................. 8
3Technical Data ................................................................................................................ 9
3.1 Type plate.................................................................................................................. 9
3.2 Electrical and mechanical data..................................................................................10
4Overview additional options .........................................................................................11
4.1 Option S (overspeed switch).....................................................................................11
4.2 Option LWL (signal transmission using fiber optics)..................................................11
4.3 Option AKK (double pulse output).............................................................................11
4.4 Type code.................................................................................................................12
5Transport, packaging and storage ...............................................................................13
5.1 Safety instructions for transport.................................................................................13
5.2 Goods inward inspection...........................................................................................13
5.3 Packaging / disposal.................................................................................................13
5.4 Storage of packages (devices)..................................................................................13
6Installation and commissioning....................................................................................14
6.1 Safety instructions.....................................................................................................14
6.2 Technical information................................................................................................14
6.3 Required tools...........................................................................................................14
6.4 Mounting preparations ..............................................................................................15
6.5 Mounting the encoder ...............................................................................................15
6.6 Mounting tolerances..................................................................................................17

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6.7 Electrical connection and start up..............................................................................18
6.7.1 Preparing cables ..................................................................................................18
6.7.2 Electrical connection.............................................................................................18
7Dismantling....................................................................................................................19
7.1 Safety instructions.....................................................................................................19
7.2 Dismantling the encoder ...........................................................................................19
8Faults..............................................................................................................................20
8.1 Faults table...............................................................................................................20
9Inspections.....................................................................................................................21
9.1 Safety instructions.....................................................................................................21
9.2 Maintenance information...........................................................................................21
9.3 Inspection schedule ..................................................................................................21
10Disposal..........................................................................................................................21
10.1 Disposal procedure...................................................................................................21
11Replacement parts.........................................................................................................22
12EC-Declaration of Incorporation...................................................................................23
13Dimension drawings......................................................................................................26
14Connection diagrams ....................................................................................................32
14.1 Terminal box.............................................................................................................32
14.2 Connection cable......................................................................................................33

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1General
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 2, 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.
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.

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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
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.
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.
2Safety
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.
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 Personnel
Installation and commissioning as well as disassembly routines must be carried out by skilled technical
staff only.

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2.3 Intended use
The device has been designed and constructed exclusively for the intended use described here.
Series FG 2 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.
For UL and CSA:
For the use in NFPA 79 applications only.
Option S
The FG 2 with option S has in addition to the incremental output a switching output.
The incremental encoder FG 2 with option S has been designed and constructed exclusively for the
intended use described here.
Series FG 2 with option S Incremental Encoders are used for speed monitoring, for instance of
electrical and mechanical drives, hoisting gear and conveying machines.
The FG 2 with option S is a device, which generates a switching signal for a superior control system.
This is realized with opening of a switch contact.
Claims of any type due to damage arising from non-intended use are excluded; the owner bears sole
responsibility for non-intended use.
2.4 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.
2.5 Personal protective equipment
For tasks such as assembly, disassembly or commissioning the use of personal protective equipment
such as safety footwear and protective work clothing is required.
The regulations specified by the owner and that are locally specified apply.

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2.6 Special dangers
Residual risks that have been determined based on a risk assessment are cited below.
2.6.1 Electrical current
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.
2.6.2 Rotating shafts / hot surfaces
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.
2.6.3 Safeguarding against restart
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.

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3Technical Data
3.1 Type plate
Below are some nameplates for different device models shown.
Without option S or LWL
With option S
The type plate is located on the outside of the housing and contains the following information:
Englisch
Deutsch
Manufacturer, address
Hersteller, Anschrift
Type:Incremental Encoder, Year of manufacture
Typ: Inkrementaler Drehgeber, Baujahr
CE mark
CE-Kennzeichnung
Serial number (S/N)
Seriennummer (S/N)
Pulse rate
Impulszahl
Degree of protection
Schutzart
Supply voltage
Versorgungsspannung
Outputs
Ausgänge
Max. speed
Max. Drehzahl
Switching speed
Schalterdrehzahl

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3.2 Electrical and mechanical data
Pulse Rates
1024, 2048
Connection data
Supply voltage
12 V…30 VDC Ripple max. 10 %
For UL and CSA Class 2 supplied
No load-current
approx. 50 mA at 24 V
Connection
screw-type terminal Type Phoenix ZFKDS 1,5-W-5,08
(0,25 mm² - 1,5 mm²)
Connection
(Option fiber optic)
St-fiber optic plug
Outputs
Current limited, short-circuit proof push-pull line driver
Pulse height (HTL)
approx. as supply voltage
output saturation voltage < 0.4 V at IL30 mA
Output current per output
150 mA peak
Internal resistance
75 Ωat 24 V
Slew rate
200 V / µs with CL100 pF
Duty cycle
1 : 1 ± 5 %
Square wave displacement 0°, 90°
90° ± 5 %
Max. frequency
200 kHz
Encoder temperature range
-25°C … + 85°C
(UL/CSA: max. +70°C)
Degree of protection acc.DIN EN
60529
Sealing
Rotor moment of
inertia
Breakaway
torque
IP 66
(UL and CSA Type 1)
with radial shaft seal
approx. 100 gcm²
approx. 3 Ncm
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)
200 g (=2000
m/s²)
Max. encoder shaft load
Fa, max. (axial) = 100 N
Fr, max. (radial) = 120 N
Shaft dimensions
11j6 x 30 mm
Weight
approx. 2 kg
Signal outputs
Basic channel 0° (A) and pulse channel 90° (B)
Reference pulse (N) mechanically defined; one
square-wave pulse per revolution
Each with inverted signals