Hubner FGH 41 Product guide

Translation of the original operating and assembly instructions
Issue: 2022-09-08
ID 78427
English
Operating and assembly instructions
Incremental hollow shaft encoder with functional safety
FGH 41 in hollow shaft design
certified according to EN 61508 part 1-7:2010 / IEC 62061:2015 SIL CL2 and
EN ISO 13849-1: PL d
and according to EN 61508 Part 1-7:2010 / IEC62061:2015 SIL CL3 and
EN ISO 13849-1: PL e
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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Trademarks
Loctite®is a registered trademark of Henkel AG & Co. KG, Düsseldorf. 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.
Copyright
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 Hübner Fabrik elektrischer
Maschinen GmbH. Content information, text, drawings, graphics, and other representations are
protected by copyright and are subject to commercial property rights. Duplications of any kind
that are not combined with use of the machine are prohibited without manufacturer's written
consent. Actions to the contrary make damage compensation mandatory.
Copyright© Johannes Hübner Fabrik elektrischer Maschinen GmbH
Change reservation
The manual has been drawn up with the utmost care and attention. Nevertheless, we cannot
exclude the possibility of errors in form and content.
All rights, subject to errors and changes due to technical improvements reserved.
Font styles
Italic or bold font styles are used for the title of a document or are used for highlighting.
Courier-New font displays text, which is visible on the screen and software/software menu
selections.

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Contents
1 General Information ........................................................................................................... 6
Applicability................................................................................................................................ 6
Abbreviations and terms used....................................................................................................6
General functional description....................................................................................................7
1.3.1 Main Features...............................................................................................................9
1.3.1.1 Variant 1 (FGH 41 SIN/COS) .....................................................................................9
1.3.1.2 Variant 2 (FGH 41 TTL/HTL)......................................................................................9
1.3.2 Principle of the safety function.......................................................................................9
2 Basic safety instructions................................................................................................. 10
Explanation of symbols and notes............................................................................................ 10
General risks when using the product....................................................................................... 11
Intended use............................................................................................................................11
Non-intended use.....................................................................................................................12
Safety functions of the fail-safe processing unit........................................................................12
2.5.1 Mandatory safety checks / measures ..........................................................................13
Warranty and liability................................................................................................................ 14
Declaration of Conformity......................................................................................................... 14
Organizational measures ......................................................................................................... 14
Personnel selection and qualification; basic obligations............................................................14
Safety information.................................................................................................................. 16
3 Transport, packaging and storage.................................................................................. 17
Safety instructions for transport................................................................................................ 17
Incoming goods inspection....................................................................................................... 17
Packaging (disposal)................................................................................................................ 17
Storage of packages (devices)................................................................................................. 18
4 Technical Data.................................................................................................................. 19
Safety...................................................................................................................................... 19
Electrical characteristics........................................................................................................... 20
4.2.1 General....................................................................................................................... 20
4.2.2 Device-specific............................................................................................................21
Ambient conditions................................................................................................................... 22
Mechanical characteristics FGH 41.......................................................................................... 23
Type code................................................................................................................................ 24
Type plate................................................................................................................................ 24
5 Assembly.......................................................................................................................... 25
Safety instructions.................................................................................................................... 25
Technical notes........................................................................................................................ 26
Required tools..........................................................................................................................26
Mounting preparations .............................................................................................................26
Mounting of FGH 41, (hollow shaft design)............................................................................... 27
Dismantling the FGH 41........................................................................................................... 29
6 Installation / Preparation for Commissioning................................................................. 30
Electrical connection Terminal box connection .........................................................................30
EMC requirements................................................................................................................... 31
EMC conform wiring schemes..................................................................................................32
6.3.1 Connection scheme 1 ................................................................................................. 32
6.3.2 Connection scheme 2 ................................................................................................. 32

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6.3.3 Connection scheme 3..................................................................................................33
Ground connection –measuring system...................................................................................34
Cable specification...................................................................................................................34
Permitted cable length..............................................................................................................35
6.6.2 Square wave incremental-signals (TTL/HTL)...............................................................36
Connection instructions for plug connection..............................................................................37
7 Incremental interface........................................................................................................37
Variant 1, analog incremental signals (SIN/COS)......................................................................38
Variant 2, square - wave incremental signals (TTL/HTL)...........................................................39
8 Connection diagram..........................................................................................................40
9 Replacing the Measuring System ....................................................................................41
10 Checklist..........................................................................................................................42
11 Maintenance....................................................................................................................43
12 Accessories.....................................................................................................................44
Draw-off-tool...........................................................................................................................44
Mating connector....................................................................................................................44
13 Dimension drawings.......................................................................................................45
FGH 41 T (hollow shaft design) ..............................................................................................45
FGH 41 K (hollow shaft design)..............................................................................................47
FGH 41 K (with torque bracket) ..............................................................................................48

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1 General Information
These operating and assembly instructions contain the following topics:
General functional description
Basic safety instructions with declaration of the intended use
Characteristics
Assembly
Installation/Commissioning
Error causes and remedies
These operating and assembly instructions are supplemented by other documentation such as
product data sheets, dimension drawings, connection diagrams, prospects, etc.
The scope of delivery includes the incremental hollow shaft encoder FGH 41 and the operating
and assembly instructions.
The operating and assembly instructions may be requested separately.
Applicability
These operating and assembly instructions apply exclusively for the following measuring
system series with incremental-interface and functional safety:
FGH 41
The measuring system stands out due to 2 variants which are distinguished in the chapter
“Main features” on page 9.
The products are labelled with affixed nameplates and are components of a system.
The following documentation therefore also applies:
operator’s operating instructions specific to the system
these operating and assembly instructions
Abbreviations and terms used
FGH 41
Incremental hollow shaft encoder
DCavg
Diagnostic Coverage
Average diagnostic coverage
ESD
Electro Static Discharge
EU
European Union
EMC
ElectroMagnetic Compatibility
Functional
safety
(FS)
Part of the overall system safety, which depends on the correct functioning
of safety-related systems for risk reduction. Functional safety is ensured
when each safety function is executed as specified.
Fault
exclusion
Compromise between the technical safety requirements and the theoretical
possibility of an error occurring
HTL
High-Threshold-Logic
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics Engineers
ISO
International Standard Organisation
MTTFd
Mean Time To Failure (dangerous) Mean time until dangerous failure

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PFDav
Average Probability of Failure on Demand
Average probability of failure of a safety function with low demand
PFH
Probability of Failure per Hour
Operating mode with high requirement rate or continuous demand.
Probability of dangerous failure per hour.
PFHD
Probability of a dangerous Failure per Hour
Average probability of a dangerous failure per hour according to
ISO 13849-1.
PL
Performance Level, according to ISO 13849-1: Discrete level, which
specifies the capability of safety-related parts of a control to execute a safety
function under foreseeable conditions.
SIL
Safety Integrity Level, according to IEC 62061: Four discrete levels (SIL1 to
SIL4). The higher the SIL of a safety-related system, the lower the
probability that the system cannot execute the required safety functions.
SIS
Safety Instrumented System: is used to protect a dangerous process and
reduce the risk of an accident. Process instruments are a constituent of a
Safety Instrumented System. This comprises the essential components of a
complete safety-relevant process unit:
Sensor, fail-safe processing unit (control) and actuator
SCS
Safety Computer System with control function
STP
Shielded Twisted Pair
TTL
Transistor-Transistor-Logik (RS422)
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik (Association
for Electrical, Electronic and Information Technologies)
Repeat test
(proof test)
Repetitive test to detect hidden dangerous failures in a safety-related system.
General functional description
The rotary measuring system FGH 41 is a safe and incremental position measuring system.

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The measuring system has been designed so that it can be used in systems which require the
following safety functions according to EN 61800-5-2:
Safe Direction (SDI)
Safe Stop 1 (SS1)
Safe Stop 2 (SS2)
Safe Operating Stop (SOS)
Safely Limited Speed (SLS)
Safe Speed Range (SSR)
Safe Speed Monitor (SSM)
Safely-Limited Acceleration(SLA)
Safe Acceleration Range (SAR)
Safely-Limited Position (SLP)
Safely-Limited Increment (SLI)
Safe Cam (SCA)
The measuring system as a sensor is always part of a safety chain.
The following shaft designs can be used for the mechanical coupling:
Hollow shaft
Depending on the safety functions safety-related differences arise:
SIL3/PLe/Kat.3,
in conjunction with velocity oriented safety functions
SIL2/PLd/Kat.3,
in conjunction with positioning oriented safety functions
see chapter „Safety “ -> „functional safety“ on page 19.

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1.3.1 Main Features
The entire system electronics has a discrete design. Neither microcontrollers nor
programmable logic elements are contained in the system electronics. There is no interpolation
or signal multiplexing. All signal lines are led separately within the electronics.
1.3.1.1 Variant 1 (FGH 41 SIN/COS)
Incremental interface with analog output signals SIN±, COS± and Ref±; output level
1 Vss.
The safety-evaluated measuring system is designed for the implementation of safety-related
functions in relation to speed and direction of rotation. In the downstream fail-safe processing
unit an ideal error detection also occurs through evaluation of the annulus relationship
“SIN(x)2+ COS(x)2= 1”.
The reference signals N, Nare not evaluated from a safety viewpoint and may not be used for
safety-oriented purposes.
1.3.1.2 Variant 2 (FGH 41 TTL/HTL)
Incremental interface with digital square-wave output signals 0°, 0°, 90°, 90° und N, N, output
level in TTL or HTL logic.
The safety-evaluated measuring system is designed for the implementation of safety-related
functions in relation to speed and direction of rotation.
An internal signal monitor constantly checks the annulus relationship
"SIN(x)2+ COS(x)2= 1". Safety-relevant errors are indicated by switching of the signal outputs
to tri-state. The reference signals N, Nare not evaluated from a safety viewpoint and may not
be used for safety-oriented purposes.
1.3.2 Principle of the safety function
System safety results when:
–the scanning channel is single fault safe thanks to its own diagnostic measures and circuit
measures
–the control checks that the received incremental data meet the expected tolerance window
according to the application.
–for variant 1, the control also checks the annulus relationship
SIN(x)2+ COS(x)2= 1; if the result is outside the tolerance range, the incremental data
must be evaluated as unsafe. In this way the control achieves an ideal error detection.
–when errors are detected the control introduces appropriate safety measures defined by
the system manufacturer
–the system manufacturer ensures, through correct mounting of the measuring system, that
the measuring system is always driven by the axis to be measured and is not overloaded.
A fault exclusion is required for mounting the measuring system to the drive function.
–the system manufacturer carries out a proven test during commissioning
–the downstream fail-safe processing unit evaluates the measuring system differentially

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2 Basic safety instructions
Explanation of symbols and notes
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.
DANGER!
Means that death or serious injury will occur if the required precautions are not
met.
WARNING!
Means that death or serious injury can occur if the required precautions are not
met.
CAUTION!
Means that minor injuries can occur if the required precautions are not met.
NOTICE!
Indicates a possibly dangerous situation that can result in material damage if it
is not avoided.
NOTES!
Indicates important information or features and application tips for the product
used.
NOTES!
Means that appropriate ESD-protective measures are to be considered
according to EN 61340-5-1 supplementary sheet 1.
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!

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General risks when using the product
The product, hereinafter referred to as the measuring system, is manufactured according to
state-of-the-art technology and accepted safety rules. Nevertheless, non-intended use can
pose a danger to life and limb of the user or third parties, or lead to impairment of the
measuring system or other property!
Only use the measuring system in perfect technical condition, and only for its intended use,
paying attention to safety and dangers, and in compliance with the operating and assembly
instructions! Faults which could threaten safety should be eliminated without delay!
Intended use
The safety measuring system can be used for the detection of angular movement and
processing of measured data for a downstream safety computer system in systems in which
the protection goals of "Protection of speed" and "Protection of direction of movement"
must be safely achieved. The complete processing chain of the safety function must then
satisfy the requirements of the applied safety standard.
The safety measuring system may only be used in safety applications in conjunction with a
control certified according to the applied safety standard.
The system manufacturer must check that the characteristics of the measuring system satisfy
his application-specific safety requirements. The responsibility or decision regarding the use of
the measuring system lies with the system manufacturer.
Intended use also includes:
observing all instructions in this operating and assembly instructions,
observing the nameplate and any prohibition or instruction symbols on the measuring
system,
observing the operating instructions from the machine/system manufacturer,
operating the measuring system within the limit values specified in the technical data,
ensuring that the fail-safe processing unit (F-Host) fulfils all required safety functions,
observing and using the checklist in the Appendix,
safe mounting (form-closed) of the measuring system to the driving axis, also see chapter
"Assembly" from page 25.

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Non-intended use
WARNING! NOTICE!
Danger of death, physical injury and damage to property in case of non-
intended use of the measuring system!
The following areas of use are especially forbidden:
–in environments where there is an explosive atmosphere
–for medical purposes
–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
Safety functions of the fail-safe processing unit
The Safety Computer System (SCS), to which the measuring system is connected, must
perform the following safety checks.
With regard to "Single fault safety" and "Ideal error detection" please see IFA directive "GS-
IFA-M21".
NOTES!
To enable the correct measures to be taken in the case of an error, the
following applies:
Safe state –passive, only for measuring system variant 1
In passive safe state the measuring system does not output any valid
SIN±/COS± –signals to the downstream fail-safe processing unit. The
processing unit detects the error through evaluation of the annulus relationship
SIN(x)2+ COS(x)2= 1. If the result is outside the tolerance range, the
incremental data are evaluated as unsafe. The downstream fail-safe processing
unit has an ideal error detection.
Safe state –active, only for measuring system variant 2
In active safe state the signal outputs are switched to tri-state. The processing
unit detects the error via an implemented cable breakage detection.

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2.5.1 Mandatory safety checks / measures
Measures for commissioning, changes
SCS error reaction
Check that the desired automation task is executed as required.
STOP
Check by the SCS
SCS error reaction
Check of incremental data according to the present automation
task and safety function.
STOP
Two-channel monitoring of incremental outputs for cable
breakage.
For tri-state state
-> STOP
Only for variant 1
Evaluation of the condition SIN(x)2+ COS(x)2= 1. The number
of checks / revolution corresponds to the number of
periods/revolution: 1024, 2048 or 4096
For the safety functions SDI, SS1, SS2, SOS, SSR, SSM an
annulus monitoring with DC = 90 % is required.
For the SLS safety function a two-channel evaluation of the
frequency from (SIN/COS) with a DC of 90 % is required.
If outside tolerance
-> STOP
Only for variant 2
A cable break detection is required for the evaluation of the
square pulse signals.
In the safe state, the output drivers are in tri-state
(high-resistance state).
If a cable break is de-
tected
-> STOP
Only for variant 2
Evaluation of the incremental data in differential mode and verifi-
cation with respect to antivalence, quadrature and against phase
equivalence between channels A and B
If outside tolerance
-> STOP

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Warranty and liability
In principle the "General Terms and Conditions" of Johannes Hübner - Fabrik elektrischer
Maschinen GmbH apply. These are available to the operator with the Order Confirmation or
when the contract is concluded at the latest. Warranty and liability claims in the case of
personal injury or damage to property are excluded if they result from one or more of the
following causes:
Non-observance of these operating and assembly instructions
Non-intended use of the measuring system
Improper assembly, installation and start-up of the measuring system
Work carried out incorrectly on the measuring system
Operation of the measuring system with technical defects
Mechanical or electrical modifications to the measuring systems undertaken autonomously
Repairs carried out autonomously
Third party interference and Acts of God
Deployment of non-qualified personnel
Opening of the measuring system or modifying it
Declaration of Conformity
The device is tested in accordance with the following Directives:
2006/42/EG, 2014/30/EU and 2011/65/EU (EU)
S.I. 2008/1597, S.I. 2016/1091 und S.I. 2012/3032 (UK).
Organizational measures
The operating and assembly instructions must always be kept ready-to-hand at the place of
use of the measuring system.
In addition to the operating and assembly instructions, generally valid legal and other binding
regulations on accident prevention and environmental protection must be observed and
communicated.
The respective applicable national, local and system-specific provisions and requirements
must be observed and communicated.
The operator is obliged to inform personnel on special operating features and requirements.
Prior to commencing work, personnel working with the measuring system must have read
and understood the chapter 2 "Basic safety instructions" on page 10.
The nameplate and any prohibition or instruction symbols applied on the measuring system
must always be maintained in a legible state.
Do not undertake any mechanical or electrical modifications to the measuring system, except
for those expressly described in this operating and assembly instructions.
Repairs may only be undertaken by the manufacturer or a center or person authorized by the
manufacturer.
Personnel selection and qualification; basic obligations
All work on the measuring system must only be carried out by qualified personnel.
Qualified personnel includes persons, who, through their training, experience and instruction,
as well as their knowledge of the relevant standards, provisions, accident prevention
regulations and operating conditions, have been authorized by the persons responsible for
the system to carry out the required work and are able to recognize and avoid potential
hazards. They are capable of identifying and avoiding potential hazards.
The definition of “qualified personnel” also includes an understanding of the standards VDE
0105-100 and IEC 364 (source: e.g. Beuth Verlag GmbH, VDE-Verlag GmbH).

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The responsibility for assembly, installation, commissioning and operation must be clearly
defined. The obligation exists to provide supervision for trainee personnel.

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Safety information
WARNING! NOTICE! NOTES!
Destruction, damage and malfunction of the measuring system!
–Only carry out wiring work or opening and closing of electrical connections
with the system de-energized.
–Do not undertake any welding work if the measuring system is already wired
or switched on.
–Falling below or exceeding the permissible operating temperature limit
values must be prevented through an appropriate heating/cooling measure
at the place of installation.
–The measuring system must be installed so that no direct moisture can affect
the measuring system.
–Suitable aeration/ventilation and heating/cooling measures must be provided
at the place of installation to prevent the temperature falling below the dew
point (condensation).
–If an overvoltage of > 7 V DC is accidentally applied to the incremental
analog output signals SIN+, SIN-, COS+, COS-, Ref+ or Ref-, the measuring
system must be checked at the factory, stating the reasons or
circumstances. The measuring system must be taken out of operation
immediately.
–The power supply must be protected with a fuse suitable for the supply lead
cross-section.
–Cables used must be suitable for the temperature range.
–A defective measuring system must not be operated.
–Make sure that the installation environment is protected from aggressive
media (acids etc.).
–Avoid shocks (e.g. hammer blows) to the shaft during installation.
–The use of the devices as a step, etc. is not intended use.
–Opening the measuring system is forbidden.
–The type plate specifies the technical characteristics of the measuring
system. If the type plate is no longer legible or if the type plate is completely
missing, the measuring system must not be operated.
–In case of storage as well as in the operation of the measuring system
unused connecting plugs have to be provided either with a mating connector
or with a protective cap. The IP protection class is to be selected according
to the requirements.

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NOTES!
The measuring system contains components and assemblies susceptible
to electrical discharge, which can be destroyed if incorrectly handled.
Touching the measuring system connection contacts with the fingers must be
avoided or the relevant ESD protective measures must be applied.
NOTES!
Disposal
If disposal has to be undertaken after the lifespan of the device, the respective
applicable country-specific regulations are to be observed.
3 Transport, packaging and storage
NOTES!
Shipping information
–Do not drop the device or subject it to heavy impacts!
The device contains an optical system.
–Use only the original packaging.
Inappropriate packaging material may cause damage to the unit in transit.
–Storage temperature: -40 °C...+85 °C
–Store in a dry place.
Safety instructions for transport
NOTICE!
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.
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).
Packaging (disposal)
The packaging is not taken back and must be disposed of in accordance with the respective
statutory regulations and local guidelines.

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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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4 Technical Data
Safety
Functional safety
EN 61508 Part 1-7
Safety Integrity Level (SIL)
(1) SDI, SS1, SS2, SOS, SLP, SLI, SCA
-2
(1) SLS, SSR, SSM, SLA, SAR
-3
EN ISO 13849-1
Performance Level (PL)
(1) SDI, SS1, SS2, SOS, SLP, SLI, SCA
- PLd / Kat. 3
(1) SLS, SSR, SSM, SLA, SAR
- PLe / Kat. 3
Startup time
Time between POWER-UP and safe incremental
output
Variant 1
30 ms
Variant 2
50 ms
PFH / PFHD, "High demand" operating
mode
Variant 1
5,34 * 10-9 1/h
Variant 2
6,57 * 10-9 1/h
Notice
Measuring system is used only in applications with high
or continuous demand rate
MTTFd
high
Variant 1
1558 a
Variant 2
622 a
(2) DCavg
Medium (90 %)
Internal process safety time
Time between occurrence of an F-Error and alarm
indication
Overall system
1 ms
Process safety angle
Angle between error occurrence and alarm indication
Through channel-internal self-diagnosis
± 0.3510°, at 1024 periods;
± 0.1760°, at 2048 periods;
± 0.0879°, at 4096 periods;
in relation to the measuring system shaft
T1 repeat test (proof test)
20 years
(1) according to EN 61800-5-2
(2) The assessment occurred in accordance with Note 2 on Table 6 of EN ISO 13849-1

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Electrical characteristics
4.2.1 General
Supply voltage
12…30 V DC acc. to IEC 60364-4-41, SELV/PELV
Reverse polarity protection
Yes
Short-circuit protection
Yes, by internal 1 A safety fuse
Overvoltage protection
Yes, up to ≤60 V DC
Current consumption without
load
at 24 V DC
Analog output signals
< 20 mA
Square-wave output signals
< 40 mA