Hubner FG 40 Series Product guide

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

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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............................................................................................................................ 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 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
3Technical 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
4Transport, 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
5Mounting 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
6Dismantling....................................................................................................................26
6.1 Safety instructions.....................................................................................................26
6.2 Dismantling the encoder ...........................................................................................26
7Faults..............................................................................................................................27
7.1 Faults table...............................................................................................................27
8Inspections.....................................................................................................................28
8.1 Safety instructions.....................................................................................................28
8.2 Maintenance information...........................................................................................28
8.3 Inspection schedule ..................................................................................................28
9Disposal..........................................................................................................................28
9.1 Disposal procedure...................................................................................................28
10Replacement parts.........................................................................................................28
11Dimension 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
12Connection diagrams ....................................................................................................42

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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 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.
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 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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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
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 plates
Nameplates for different device variations are shown below
Encoder with one terminal box
Encoder with 2 terminal boxes (redundant version)
Encoder with 2 sinusoidal signals
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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3.2 Electrical and mechanical data
3.2.1 For pulse rates (square wave pulses)
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 IL30 mA
Output current
max. 150 mA at 24 V (observe derating)
Internal resistance
75 Ωbei 24 V
Slew rate
200 V / µs with CL100 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),

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3.2.2 Output signals Sine / Cosine
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°

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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
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.
N
N

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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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3.3 Type code
3.3.1 For pulse rates (square wave pulses)
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

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3.3.2 For output signals Sine / Cosine
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

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4Transport, packaging and storage
4.1 Safety instructions for 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 Incoming goods inspection
Check delivery immediately upon receipt for completeness and possible transport damage.
Inform the forwarder directly on receipt of the goods about existing transport damages (prepare
pictures for evidence).
4.3 Packaging / disposal
The packaging is not taken back and must be disposed of in accordance with the respective statutory
regulations and local guidelines.
4.4 Storage of packages (devices)
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 commissioning
5.1 Safety instructions
Personnel
Installation and commissioning must be carried out by skilled technical staff only.
NOTES!
Observe the safety instructions contained in Chapter 2 when installing or working on the
device!
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 fulfil degree of protection requirements the diameter of the connection cable must correspond to
that of the cable gland (please refer to Chapter 11 dimension drawings)!
Deep groove ball bearings
FG incremental encoders are fitted with maintenance-free, greased "for-life" deep groove bearings.
Bearings must be changed by the manufacturer only. Opening the encoder renders the guarantee null
and void.
Screw retention
We recommend using Loctite®243 threadlocker (medium strength) on all fastening screws to prevent
loosening.
5.3 Required tools
Spanners: 10 mm, 22 mm, 24 mm
Allen keys: 2 mm, 3 mm
Flat-blade screwdrivers:
Assembly grease
Loctite®243 (medium strength threadlocker)

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5.4 Mounting preparations
1. Ensure all accessories are available (please refer to Chapter 11 Dimension drawings).
NOTES!
Fastening screws and earth cable are not included in the range of supply.
2. Preparing the place of attachment: Clean the (motor) shaft, centering, bolting surfaces and
fastening threads; check for damage. Repair any damage!
5.5 Mounting B5 type (flange) incremental encoders
NOTES!
For a mounting example please refer to dimension drawing HM 09 M 57 263a (Chapter 11.1).
)
1
9
2
10
3
12
13
4
7
6
15
8
5
14
17
11
16
Figure 1: FG 40 construction type B5

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1. Lightly grease the (motor) shaft (1) and centering (9).
2. Fit coupling (2) onto (motor) shaft.
NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!
3. Secure the coupling hub on the (motor) shat with a grub screw or cheese head screw (10)
(depending on the coupling type).
4. Fasten the intermediate flange (3) to the motor using the fastening screws (12).
NOTES!
If possible, fit the intermediate flange in a manner that ensures the screwed sealing plug
(14) points downwards!
5. Lightly grease the encoder shaft (5) and centering (4).
6. Fit the encoder (8) into both the centering (4) and coupling hub at the same time.
NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!
NOTES!
If possible, fit the device in a manner that ensures the cable gland points downwards
Exchange the position of the cable gland (16) and the blanking plug (15), if necessary.
7. Secure the encoder with 4-6 screws (6) evenly distributed around the circumference of the flange.
8. Remove the sealing plug (14) from the access bore (13) to the coupling.
9. Secure the coupling hub on the encoder shaft with a grub screw or cheese head screw (11)
(depending on the coupling type).
NOTES!
To carry out this task, it may be necessary to turn the (motor) shaft to the correct
position.
10. Replace the sealing plug (14) to seal the access bore to the coupling.

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5.6 Mounting B35 type (flange and foot) incremental encoders
NOTES!
B35 type encoders can be attached by means of a flange (B5, please refer to Chapter 5.5) or
foot (B3):
For a mounting example please refer to dimension drawing HM 09 M 102 240a (Chapter 11.2).
1. Lightly grease the (motor) shaft (1).
2. Fit coupling (2) onto (motor) shaft.
NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!
NOTES!
We recommend our zero-backlash, torsion-resistant double-joint coupling HKD5 to
attach B35 type encoders. Please refer to the catalogue Torsion Resistant Couplings for
Encoders.
3.Secure the coupling hub on the (motor) shaft with a grub screw or cheese head screw (10)
(depending on the coupling type).
1
2
10
11
17
16
18
20
19
5
Figure 2: FG 40 construction type B35