Hubner Ex FG 40 Product guide

English
Translation of the original Operating and Assembly Instructions ExFG40_Manual_En_R7(2020-11-02)ID77099.docx
ID 77099
Operating and Assembly Instructions
Incremental Encoder Ex FG 40
with Ex approval
Read the Operating and Assembly Instructions prior to
assembly, starting installation and handling!
Keep for future reference!

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Manufacturer / Publisher
Johannes Hübner Phone:[phone]
Fabrik elektrischer Maschinen GmbH Fax: [phone]
Siemensstr. 7 Internet: www.huebner-giessen.com
35394 Giessen / Germany E-Mail: [e-mail]
Further current information on this product series can be found online in our
Service Point.
Simply scan the QR Code and open the link in your browser.

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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
1General.......................................................................................................................... 6
1.1 Information about the Operating and Assembly Instructions................................................... 6
1.2 Scope of delivery...................................................................................................................... 6
1.3 Explanation of symbols............................................................................................................ 7
1.4 Disclaimer................................................................................................................................. 8
1.5 Copyright.................................................................................................................................. 8
1.6 Guarantee terms...................................................................................................................... 8
1.7 Customer service..................................................................................................................... 8
2Safety............................................................................................................................ 8
2.1 Responsibility of the owner...................................................................................................... 8
2.2 Intended use ............................................................................................................................ 9
2.3 Improper use.......................................................................................................................... 10
2.4 Personnel............................................................................................................................... 10
2.5 Personal protective equipment .............................................................................................. 10
2.6 Special dangers ..................................................................................................................... 11
2.6.1 Electrical current ........................................................................................................... 11
2.6.2 Rotating shafts / Hot surfaces ....................................................................................... 11
2.6.3 Safeguarding against restart ......................................................................................... 11
2.6.4 Danger of explosion....................................................................................................... 11
3Technical Data.............................................................................................................12
3.1 Type plates............................................................................................................................. 12
3.2 Electrical and mechanical data .............................................................................................. 13
3.3 Type key................................................................................................................................. 16
3.3.1 For pulse rates (square wave pulses) ............................................................................ 16
3.3.2 For output signals Sinus / Cosinus................................................................................. 17
3.3.3 For output signals Sinus / Cosinus –pulse rates (square wave pulses) ........................ 18
4Transport, packaging and storage.............................................................................19
4.1 Safety information concerning transport ................................................................................ 19
4.2 Goods inward inspection........................................................................................................ 19
4.3 Packaging (disposal).............................................................................................................. 19
4.4 Storing packages (devices).................................................................................................... 19
5Mounting and commisioning......................................................................................20
5.1 Safety instructions.................................................................................................................. 20
5.2 Technical information............................................................................................................. 20
5.3 Mounting preparations ........................................................................................................... 21
5.4 Mounting B5 type (flange)...................................................................................................... 21
5.5 Mounting tolerances for Construction Type B5...................................................................... 23
5.6 Electrical connection and start up.......................................................................................... 23
5.6.1 Preparing cables ............................................................................................................ 23
5.6.2 Electrical connection ..................................................................................................... 24
6Dismantling..................................................................................................................25
6.1 Safety instructions.................................................................................................................. 25

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6.2 Dismantling the encoder ........................................................................................................ 25
7Faults ...........................................................................................................................26
7.1 Faults table............................................................................................................................. 26
8Inspections..................................................................................................................27
8.1 Safety instructions personnel................................................................................................. 27
8.2 Maintenance information........................................................................................................ 27
8.3 Inspection schedule ............................................................................................................... 27
9Disposal.......................................................................................................................27
10 Repair...........................................................................................................................28
11 Replacement parts ......................................................................................................28
12 EU-Declaration of Conformity ....................................................................................29
13 EU-type examination certificate .................................................................................31
14 Dimension drawings ...................................................................................................34
15 Connection Diagrams .................................................................................................35

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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.
These Operating and Assembly Instructions have been written to enable the owner to safely and
properly transport, assemble, commission and maintain the explosion-protected device.
We reserve all rights to make technical changes to the device described in the instructions below.
Drawings and images are simplified representations. Due to improvements and modifications it is
possible that they differ in some minor details from the device supplied. Technical data and
dimensions are not binding. They are provided for information purposes only and are not guaranteed
characteristics. The customer will be informed immediately if modifications affect devices already
supplied.
Due to the wide variety of application conditions, these Operating and Assembly Instructions can only
take into consideration general application conditions to maintain clarity and oversight. In special
cases, such as in unusual ambient conditions or when particularly stringent safety regulations apply
certain operating characteristics must be agreed with the manufacturer or the distributor.
Caution!
Read and observe the information contained in the assembly, operating and maintenance
documentation, connection diagram and Safety Data Sheet before transporting,
assembling, commissioning or maintaining the device!
Retain the safety instructions and the Operating and Assembly Instructions for future reference!
The first installation work MUST ONLY be carried out by personnel who are able to
provide verification of special training to work on Ex certified machinery.
1.2 Scope of delivery
Incremental Encoder Ex FG 40, Operating and Assembly Instructions.

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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 reached per 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 complies with the ATEX-EU directive 2014/34/EU for potentionally explosive atmospheres
and with the IECEx-Scheme.
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 devices area of implementation.

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2.2 Intended use
The device is in accordance with equipment category 2G (use above ground gas) and equipment
category 2D (use above ground dust) designed and constructed.
Equipment category 2G and 2D: Ex-labeling: II 2G Ex db IIC T6-T5
II 2D Ex tb IIIC T85°C
- Conforms to standard: EN IEC 60079-0: 2018
IEC 60079-0 Ed.7.0
Equipment-General requirements
EN 60079-1:2014
IEC 60079-1 Ed.7.0
Equipment protection by
flameproof closures „d“
EN 60079-31:2014 / IEC 60079-31 Ed.2.0
Equipment dust ignition protection by
enclosure „t“
- Type of protection: db, tb
- Temperature class: T6-T5, T85°C
- Group of equipment: II
- Explosive gas group: IIC, IIIC
- Device protection level: Gb, Db
The operation in other explosive atmospheres is not permissible.
EU –Type examination certificate see Chapter 13
The temperature class corresponds to the speed and the ambient temperature. The permissible values
are shown in the table.
Device
category
Temperature class
Degree of
protection
max. speed
Ambient temperature
2G
T6
IP66
6000 rpm
-40°C … 55°C
2G
T5
IP66
6000 rpm
-40°C … 60°C
2D
T85°C
IP66
6000 rpm
-40°C … 55°C
The incremental encoder Ex FG 40 can be used in saline environments e.g. on offshore drilling rigs.

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It is not permissible to make any alteration to equipment that is used in potentially explosive
environments. Repairs may only be carried out by authorized authorities provided by the
manufacturer. Contravention invalidates the EX approval.
Attend the standard EN 60079-14 / IEC 60079-14 during mount and operation.
The device must be operated in accordance with the stipulations of the Operating and
Assembly Instructions. The relevant laws, regulations and standard for the planned
application must be observed.
Operation of the device is only permissible when…
-the details on the type label of the device match the on-site conditions for the permissible Ex
area in use (group of equipment, equipment category, zone, temperature class or maximum
surface temperature),
-the details on the type label of the device match the electrical supply network,
-the maximum permissible input power is not exceeded,
-the permissible ambient temperature is not exceeded,
-the device is undamaged (no damage resulting from transport or storage), and
-it has been checked that there is no explosive atmosphere, oils, acids, gases, vapors,
radiation etc. present during installation.
-all openings of the housing are closed (also cable-gland).
-the permissible speed is not exceeded.
2.3 Improper use
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.
WARNING!
Operation in the vicinity of strongly charge-generating processes must be avoided.
Charging takes place by friction, contact with charged liquid, spray charging.
Typical processes are:
- running drive belts
- pneumatic conveying of bulk material
- fast multiphase flow of liquids
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.

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2.6 Special dangers
Residual risks that have been determined based on a risk analysis 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.
2.6.4 Danger of explosion
WARNING!
The device can be used in potentionally explosive atmospheres of equipment category
2G (Zone 1 and 2) und 2D (Zone 21 and 22). The operation in other explosive
atmospheres is not permissible.

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3Technical Data
3.1 Type plates
Below are some nameplates for different device models and signs shown.
The type plate is located on the side of the housing and contains the following information:
Manufacturer, address
Type
Y = Year of construction
mark
S/N = Serial number
ID = ID number
PPR = Number of pulses ( 1Vpp = Sinus periodes)
IP = Degree of protection
Power supply
Ex-marking
QR-Code

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3.2 Electrical and mechanical data
Pulse rates (square wave signals)
Value
Standard pulse rates
500, 600, 1000, 1024, 1200, 1300, 2500
Resolution enhancement by signal
interpolation
Interpolation factors: 1, 2, 4, 8, 10, 20, 25
(Example. : Basic-pulse rate 1024
x Interpolation factor 8
= Resolution 8192 )
Connection data
Supply voltage
12…30 VDC, ripple max. 10%
No load-current
approx. 50 mA at 24 V
Maximum current consumption
approx. 250 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 hight (HTL)
approx. as supply voltage, output saturation voltage < 0.4 V at
IL30 mA
Internal resistance
75 Ωat 24 V
alternative pulse hight (TTL)
5V, RS422-compatible (TIA/EIA-Standard)
Slew rate
200 V / µs with CL100 pF
Duty cycle
1 : 1 ± 3 % for standard pulse rates
1 : 1 ± 5 % for pulse rates by signal interpolation
Square wave displacement 0°, 90°
90° ± 3 % for standard pulse rates
90° ± 5 % pulse rates by signal interpolation
Max. frequency
200 kHz, higher max. frequency on request
Signal outputs
Basic channel 0° (A) and pulse
channel 90° (B).
Internal system diagnostics with error
output (ERROR).
Each with inverted signal.
Reference pulse (N) mechanically
defined; one square-wave pulse per
revolution; with inverted signal.

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Output signals Sinus / Cosinus
Value
Pulse rates
500, 600, 1000, 1024, 1200, 1300, 2500
Connection data
Supply voltage
12…30 VDC, ripple max. 10%
No load-current consumption
approx. 50 mA at 24 V
Maximum current consumption
approx. 200 mA at 24 V
Signalamplitudes
1 V pp / RL= 120 Ω
Duty cycle
1 : 1 ± 3 %
Phase shift 0°, 90°
90° ± 3 %
Max. frequency
200 kHz, higher max. frequency on request
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 signal.
Internal system diagnostics with
error output (ERROR).

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Encoder temperature range
See table page 9
Supply voltage
12…30 VDC
Protection class
acc. to
DIN EN 60529
Sealing
Permissible
speed
mechanically
Rotor
moment of
inertia
Breakaway torque
IP66
With radial shaft seal
acc. table
approx. 773
gcm²
approx. 3,5 Ncm
Vibration resistance
DIN EN 60068-2-6 / IEC 68-2-6 (10 … 500 Hz)
20 g (=200 m/s²)
Shock resistance
DIN EN 60068-2-27 / IEC 68-2-27 (6 ms)
100 g (=1000 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 AKK
approx. 3,9 kg
approx. 4,0 kg

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3.3 Type key
3.3.1 For pulse rates (square wave pulses)
Ex FG
40
AK
1024
AH
1024
AH
Incremental encoder with Ex certification
Series
Connections, axial design
AK: One system with terminal strip
AKK: Two systems with terminal strip
System 1:
Standard pulse rates respectively resolution
enhancement by signal interpolation
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
AH: HTL-signals 0°, 90°, N, Err
AT: TTL-signals 0°, 90°, N, Err
System 2:
Standard pulse rates respectively resolution
enhancement by signal interpolation (same standard
pulse rates as system1, interpolation can be selected
freely).
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
AH: HTL-signals 0°, 90°, N, Err
AT: TTL-signals 0°, 90°, N, Err

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3.3.2 For output signals Sinus / Cosinus
Ex FG
40
AK
1024
SH
1024
SH
Incremental encoder with Ex certification
Series
Connections, axial design
AK: One system with terminal strip
AKK: Two systems with terminal strip
System 1:
Number of pulses
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
SH: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal HTL
ST: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal TTL
System 2:
Number of pulses same as system 1
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
SH: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal HTL
ST: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal TTL

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3.3.3 For output signals Sinus / Cosinus –pulse rates (square wave pulses)
Ex FG
40
AKK
1024
SH
1024
AH
Incremental encoder with Ex certification
Series
Connections, axial design
AKK: Two systems with terminal strip
System 1:
Number of pulses
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
SH: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal HTL
ST: Sin, Cos, marker pulse 1 V pp-signals; Error-Signal TTL
System 2:
Standard pulse rates respectively resolution
enhancement by signal interpolation (same standard
pulse rates as system1, interpolation can be selected
freely).
See page 13
Output signals
Each with inverted signals
Supply voltage each 12 … 30V
AH: HTL-signals 0°, 90°, N, Err
AT: TTL-signals 0°, 90°, N, Err

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4Transport, packaging and storage
4.1 Safety information concerning transport
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.
4.2 Goods inward inspection
Check the delivery immediately upon receipt for transit damage or short delivery.
Inform the carrier immediately on receipt if you determine that damage has occurred during transit (take
photos as proof).
4.3 Packaging (disposal)
The packaging is not taken back; dispose of according to the respective valid statutory provisions and
local regulations.
4.4 Storing packages (devices)
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.
If you intend to store the device for a longer period of time (> 6 months) we recommend you use
protective packaging (with desiccant).
NOTES!
Turn the shaft of the device every 6 month to prevent the bearing grease solidifying!

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5Mounting and commisioning
5.1 Safety instructions
NOTES!
Observe the safety instructions contained in Chapter 2 when installing or working on the
device!
NOTES!
Dirt penetrating inside the encoder can cause short circuits and damage the optical
sensing system.
Absolute cleanliness must be maintained when carring out any work on the open housing
cover.
NOTES!
Adhesive fluids can damage the optical sensing system and the bearings. Dismounting
an encoder, secured to a shaft by adhesive may lead to the destruction of the unit.
WARNING!
Couplings must be approved for explosive environments when using the encoder in
potentially explosive environments The use of standard couplings is not permissible.
Personnel
Installation and commissioning must be carried out by skilled technical staff only.
5.2 Technical information
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!
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 fulfill degree of protection requirements the diameter of the connection cable must correspond to that
of the cable gland.
Deep groove ball bearings
The Incremental Encoder Ex FG 40 is fitted with maintenance-free, greased "for-life" deep groove ball
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.