Hubner FG INOX Product guide

English
Translation of the original Operating and Assembly Instructions FG_INOX_MANUAL-en_R0
ID 76465
Operating and Assembly Instructions
Incremental Encoder FG INOX
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 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
3.3 Signal outputs...........................................................................................................11
4Overview additional options.........................................................................................11
4.1 Option S (overspeed switch).....................................................................................11
4.2 Option LWL (signal transmission using fiber optics)..................................................11
4.3 Type code.................................................................................................................12
5Transport, packaging and storage................................................................................13
5.1 Safety instructions for transport.................................................................................13
5.2 Incoming goods inspection........................................................................................13
5.3 Packaging / disposal.................................................................................................13
5.4 Storage of packages (devices)..................................................................................13
6Mounting 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 of incremental encoder..............................................................................15
6.6 Permissible mounting deviations...............................................................................17
6.7 Electrical connection and start up..............................................................................18
6.7.1 Preparing cables ..................................................................................................18

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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.........................................................................................................21
12Dimension drawings......................................................................................................22
13Connection diagrams ....................................................................................................26
13.1 Terminal box.............................................................................................................26

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1 General
1.1 Information about the Operating and Assembly instructions
These Operating and Assembly Instructions provide important instructions for working with the device.
They must be carefully read prior to starting all tasks, and the instructions contained herein must be
followed.
In addition, applicable local regulations for the prevention of industrial accidents and general safety
regulations must be complied with.
1.2 Scope of delivery
Incremental Encoder FG INOX, Operating and Assembly Instructions, declaration of conformity and
special tools for opening and closing the encoder according to ID. card.
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.
2 Safety
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 incremental encoder FG INOX has been designed and constructed exclusively for the intended
use described here.
The unit is used for measurement of rotations, for instance of electrical and mechanical drives and
shafts. The incremental encoders FG INOX with a housing made of V4A stainless steel has been
specially developed for speed measurements in conditions exposed to aggressive media.
In combination with their extremely robust construction they are ideally suitable for applications
exposed to extremely high levels of salt water (e.g., offshore) as well as acids and alkalis (e.g.,
chemical industry), where they offer a very high level of corrosion resistance.
The encoder housing and all external attachments are made of V4A stainless steel, the seals of Viton
and the nameplate of polyester. Before use in corrosive atmospheres, it is recommended to test the
corrosion resistance.
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
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 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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3 Technical Data
3.1 Type plate
The figure below shows an example of a type plate:
Without option S or fiber optics.
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

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3.2 Electrical and mechanical data
Pulse rates 1 … 2048 (preset selectable)
Connection data
Supply voltage 12 V … 30 VDC
No load-current ≤100 mA
Connection screw-type terminal Type Phoenix SPTAF 1
(0,25 mm² … 0,75 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 current per output 150 mA peak
Duty cycle 1 : 1 ± 5 %
Square wave displacement 0°, 90° 90° ± 5 %
Max. frequency 200 kHz
Start-up time < 100 ms
Encoder temperature range -25°C … + 85°C
Degree of protection
acc.DIN EN 60529 Sealing Mech. permissible speed Rotor moment of
inertia
Breakaway torque
IP66 with radial shaft
seal ≤6000 min -1 approx. 315 gcm² approx. 3,5 – 4,0 Ncm
Vibration resistance DIN EN 60068-2-6 / IEC 68-2-6
(10…2000 Hz) 10 g (=100 m/s²)
Shock resistance DIN EN 60068-2-27 / IEC 68-2-27
(6 ms) 100 g (=1000 m/s²)
Weight approx. 3,5 kg
Max. encoder shaft load Fa,max. (axial) = 100 N
Fr,max. (radial) = 120 N
Shaft dimensions 11j6 x 30 mm

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3.3 Signal outputs
Signal outputs
Basic channel 0° (A) and pulse channel
90° (B)
Reference pulse (N) one square-wave
pulse per revolution,
Each with inverted signals
4 Overview additional options
4.1 Option S (overspeed switch)
The incremental encoder FG INOX with option S has an insulated switching output. The switching
function is realized with a semiconductor, the switching speed is set in our factory (switching
hysteresis 10%).
If the set switching speed is exceeded, the switch opens.
It is recommended to save the switch circuit against an overcurrent with a fuse (0,5A).
Specification
Value
Deviation from switch: Accuracy of measurement: 2%
Switching time TSw :<3ms
Switch data 0…30V DC/max 500mA
Max. voltage drop at closed switch: 0,7V
4.2 Option LWL (signal transmission using fiber optics)
The signals 0°, 90° and marker pulse from the incremental encoder will be encoded and transmitted
via fiber optics cable. Fiber optic cable types 50/125 µm or 62,5/125 µm are available.

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4.3 Type code
FG
INOX
AK
1024
G
90G
NG
S
Incremental encoder
Housing of V4A stainless steel
Connections
AK: Terminal box
AL: Terminal box with connector for ST-compatible fiber optic
plug
Pulses per
rotation
1 … 2048 (preset selectable)
Basic version
Basic channel 0° (A)
Pulse channel 90° (B)
Each with inverted signals (not for LWL see chapter 4.2)
NG: Reference pulse with inverted signal
S: Option S

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5 Transport, packaging and storage
5.1 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.
5.2 Incoming goods inspection
Check delivery immediately upon receipt for completeness and possible transport damage.
Inform theforwarder directly on receipt of the goods about existing transport damages (prepare pictures
for evidence).
5.3 Packaging / disposal
The packaging is not taken back and must be disposed of in accordance with the respective statutory
regulations and local guidelines.
5.4 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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6 Mounting and commissioning
6.1 Safety instructions
NOTES!
Observe the safety instructions contained in Chapter 2 when installing or working on the
device!
Personnel
Installation and commissioning must be carried out by skilled technical staff only.
6.2 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 12 dimension drawings)!
Deep groove ball bearings
FG INOX 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.
6.3 Required tools
·Open-end spanner: wrench size 10 (e.g. DIN 894)
·Face spanner
·Flat-blade screwdrivers:
·Assembly grease
·Loctite®243 (medium strength threadlocker)

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6.4 Mounting preparations
1. Ensure all accessories are available (please refer to Chapter 12 Dimension drawings).
NOTES!
Earth cable is 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!
6.5 Mounting of incremental encoder
NOTES!
For a mounting example please refer to dimension drawing HM 20 M 114476 (Chapter 12).
Fig. 1
1
9
2
10
3
12 13
468
5
14
11
15
7
close
open

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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!
We recommend our zero-backlash, torsion-resistant coupling HK5 to attach the
incremental encoder. Please refer to the catalogue Torsion Resistant Couplings for
Encoders.
3. Secure the coupling hub on the (motor) shat with a grub screwor 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 (7) points downwards
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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6.6 Permissible mounting deviations
NOTES!
Angle misalignment and parallel displacement between the (motor) shaft and the encoder
shaft are mounting errors and should be kept as small as possible.
Mounting errors
- Cause radial forces to act on the encoder shaft.
- Reduce the service life of the bearings and the coupling.
- Degrade the quality of the signals (harmonic content).
Mounting tolerances for our zero-backlash, torsion-resistant couplings HK5 and HKD5:
Coupling Axial offset Angular error Parallel offset
HK 5 ± 1 mm 0.5° -
HKD 5 ± 1.5 mm 0.5° 0.5 mm

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6.7 Electrical connection and start up
NOTES!
You must observe applicable EMC guidelines when routing cables!
6.7.1 Preparing cables
1. Strip cable insulation. The cable for the signal and supply line is shielded.
2. Crimp wire-end ferrules.
6.7.2 Electrical connection
1. Open the terminal box cover (15, Fig.1) with a special key by turning it counterclockwise. The
terminal box cover has a right-hand thread.
CAUTION!
Do not allow moisture to enter the terminal box when the cover is open!
2. Remove the cap of the cable gland (7, Fig. 1).
3. Feed the cable into the terminal box trough the cable gland.
NOTES!
The signal cable shielding can be connected directly to the housing via the EMC cable
gland. To achieve an effective shielding the cable shield must also be connected in the
electrical cabinet.
4. Tighten the cable gland and blanking plugs using a spanner.
NOTES!
Prior to delivery cable glands and blanking plugs are tightened finger tight only. To ensure
that the terminal box is reliably sealed tighten all cable glands and blanking plugs before
starting up for the first time.
5. Use a spanner to tighten the cable gland until the cable is securely clamped and properly sealed.
NOTES!
Prevent lateral pulling forces acting on the cable and plugs so as not to impair the degree
of protection of the cable gland.
6. Connect the supply voltage, the signal cable and possibly option S (please refer to the connection
diagrams, Chapter 12).
CAUTION!
Do not apply supply voltage to the signal outputs, as this will destroy the device!
7. Close the terminal box cover.
NOTES!
Before closing the terminal box cover check and if necessary clean both seal surfaces
and the gasket.

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7 Dismantling
7.1 Safety instructions
Personnel
Dismantling must be carried out by skilled technical staff only.
WARNING!
Observe the safety instructions contained in Chapter 2 when inspecting or working on
the device!
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!
7.2 Dismantling the encoder
Remove all electrical cables from the device before dismantling. To dismantling the encoder follow the
instructions given in Chapters 6.5 in the reverse order.

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8 Faults
8.1 Faults table
Faults Possible cause Remedy
Switch does not close
(only by option S)
No supply voltage
Control: LED in the terminal box
does not shine
Check connection cable and
supply voltage
Error LED does not shine:
Rotation speed above the
switching speed
Adjust the suitable rotation
speed
Error LED is shining:
Evaluation of rotation speed is
faulty.
Disconnect power supply and
switch on again
Moisture in the terminal box
Soiled terminal box gasket or
seal surfaces Clean terminal box gasket and seal surfaces
Damaged terminal box gasket Replace terminal box gasket
Cable gland/blanking plug not
tightened Tighten cable gland/blanking plug
Unsuitable cable for cable gland Use suitable cable and cable
glands
No output signals
Supply voltage not connected Connect supply voltage
Connection cable reversed Wire correctly
Output signals subject to
interference
Unsuitable cable Use data cable with conductors
arranged as twisted pairs and
common shield
Cable shield not connected Connect cable shield at both
ends
Cable routing not EMC
compliant Observe applicable EMC guidelines when routing cables
Signal interruptions
Signal end stage overloaded Check pin assignment; observe
connection diagram
Do not assign unused outputs
Outputs short-circuited Do not connect outputs with
supply voltage or GND
Contact Hubner-Service (page 2) if none of the remedies listed above provides a solution)!