Hubner MAG 200S Series Product guide

English
Translation of the
original operating and assembly instructions MANUAL-MAG-200S-ID-78786-R0(2022-11-23)
ID 78786
Operating and Assembly Instructions
Magnetic incremental encoder without bearings
Series MAG 200S
Read the operating and assembly instructions prior to
Assembly, starting installation and handling!
Keep for future reference!

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MANUAL-MAG-200S-ID-78786-R0(2022-11-23)
is a registered logo of
Johannes Hübner Fabrik elektrischer Maschinen GmbH.
All other 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 this manual.
However, the statutory rights of the respective owners remain unaffected.
Manufacturer / publisher
Johannes Hübner Fabrik elektrischer Maschinen GmbH
Siemensstr. 7
35394 Giessen
Germany
Telephone: [phone]
Fax: [phone]
Internet: www.huebner-giessen.com
E-Mail: [email protected]
This 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 re-
produce 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.
Johannes Hübner Fabrik elektrischer Maschinen GmbH is listed by Underwriters Labora-
tories.
UL certificates can be requested from us.
An overview of our UL devices can be found at the following link:
https://iq.ulprospector.com/info
UL File Number: E351535
Subject to errors and changes due to technical improvements.
Copyright © Johannes Hübner Fabrik elektrischer Maschinen GmbH
All rights reserved.

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Table of contents
1General.............................................................................................................5
1.1 Information about these 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...............................................................................................................7
2.1 Responsibility of the owner.............................................................................. 7
2.2 Intended use.................................................................................................... 7
2.3 Improper use.................................................................................................... 7
2.4 Personal protective equipment ........................................................................ 7
2.5 Personnel......................................................................................................... 8
2.6 Special dangers............................................................................................... 8
2.7 Electric current................................................................................................. 8
2.8 Rotating shafts................................................................................................. 8
2.9 Safeguarding against restart............................................................................ 8
2.10 Exceeding the maximum speed....................................................................... 8
3Technical data.................................................................................................9
3.1 Name plate ...................................................................................................... 9
3.2 Type key –pulse wheel ................................................................................. 10
3.3 Type key –scanning head............................................................................. 10
3.4 Electrical characteristics ................................................................................ 11
3.5 Mechanical characteristics............................................................................. 12
4Safety information concerning transport....................................................13
4.1 Goods inward inspection................................................................................ 13
4.2 Packaging (Disposal)..................................................................................... 13
4.3 Storing packages (devices)............................................................................ 13
5Mounting........................................................................................................14
5.1 Safety notes for mounting.............................................................................. 14
5.2 Mounting of pulse wheels for screw mounting............................................... 15
5.3 Mounting of pulse wheels with cone clamping element ................................. 16
5.4 Mounting of scanning heads.......................................................................... 17
6Connection diagrams ...................................................................................18
6.1 Scanning head with connection cable............................................................ 18
6.2 Scanning head with M23 round plug.............................................................. 19

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7Dimension drawings.....................................................................................20
7.1 Screw mounting with internal centering and bolt circle outside...................... 20
7.2 Screw mounting with internal centering and bolt circle inside........................ 22
7.3 Screw mounting with external centering and bolt circle outside..................... 24
7.4 Screw mounting with external centering and bolt circle inside....................... 26
7.5 Pulse wheel for clamping with cone clamping element.................................. 28

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1 General
1.1 Information about these Operating and Assembly Instructions
These Operating and Assembly Instructions contain important information about handling
the device. Read these Operating and Assembly Instructions carefully before commenc-
ing any work; observe at all times.
In addition, you must observe all local accident prevention regulations as well as general
health and safety rules that apply to the field of application of the device.
1.2 Scope of delivery
•Pulse wheel
•Scanning head/s
•Distance foil/s
•Fixing parts according to dimension drawing, if applicable
•Operating and Assembly Instructions
•EU Declaration of Conformity, UKCA Declaration of Conformity
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, per-
sonal 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 effi-
cient and trouble-free operation.
NOTES!
Do not put out the pulse wheel to strong magnetic fields.

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Special Safety Notice
DANGER!
Life-threatening danger due to electric shock!
Indicates a life-threatening situation due to electric shock. If the safety in-
structions 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.
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 de-
livery 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.

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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 op-
eration.
If these safety instructions are not complied with significant hazard can oc-
cur.
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, acci-
dent prevention, and environmental protection regulations that are applicable for the
devices area of implementation.
2.2 Intended use
The device has been designed and constructed exclusively for the intended use
described here.
Magnetic encoders are used for detection of angular movement and speed monitoring,
for instance of electrical and mechanical drives, hoisting gear, and conveying
machines.
Claims of any type due to damage arising from non-intended use are excluded; the
owner bears sole responsibility for non-intended use.
For UL and CSA: For the use in NFPA 79 applications only.
2.3 Improper use
It is forbidden to use the device in explosive atmospheres.
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, tar-
paulins etc.
•Using the device as a step, for example by people to climb onto a
motor.
It is not permitted to use the device in nuclear facilities and aircrafts.
2.4 Personal protective equipment
Wear personal protective equipment such as safety shoes and safety clothing to min-
imise risks to health and safety when carrying out work such as mounting, disassem-
bly or commissioning. Adhere to all applicable statutory regulations as well as the
rules and standards determined by the owner.

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2.5 Personnel
Installation and commissioning must be carried out by skilled technical staff only.
2.6 Special dangers
The following section describes the residual risks as determined by a risk analyse.
2.7 Electric current
DANGER!
Life-threatening danger due to electrical shock!
There is an imminent life-threatening hazard if live parts are touched. Dam-
age to insulation or to specific components can pose a life-threatening haz-
ard.
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.
2.8 Rotating shafts
WARNING!
Danger of injury due to rotating shafts!
Touching rotating shafts can cause serious injuries.
Therefore: Do not reach into moving parts/shafts or handle moving
parts/shafts during operation.
Do not open covers during operation. Prior to opening the covers ensure
that all parts have come to a standstill.
2.9 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.
2.10 Exceeding the maximum speed
WARNING!
If the maximum speed is exceeded it is possible that the resulting centrifu-
gal force could cause the pulse wheel to lose its mechanical integrity.

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3 Technical data
3.1 Name plate
Scanning head
Example name plate:
•Manufacturer, address, CE marking, UKCA marking
•Type
•For UL and CSA: Model No.
•Item No. (ID)
•Serial number (S/N)
•Pulses per revolution (PPR)
•Degree of protection (IP)
•Supply voltage (INPUT)
•OUTPUT
•QR code
•Year of manufacture (Y)
Pulse wheel
On the front side of the pulse wheel the following information is engraved:
•Serial number (S/N)
•Item No. (ID)
•Max. speed in 1/min (rpm)

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3.2 Type key –pulse wheel
MAG-P
200S
128
N
/50
R
Pulse wheel for magnetic
incremental encoder
without bearings
Series
Number of magnetic poles
Marker pulse track
Centering diameter
Pulse wheel with cone clamping element
3.3 Type key –scanning head
MAG-A
200S
C
1024
N
Scanning head for mag-
netic incremental encoder
without bearings
Series
Connection type:
C = Cable with free cable ends
R = 12-pole M23 round connector
Pulses per revolution (PPR)
Marker pulse output

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3.4 Electrical characteristics
Electrical characteristics
Supply voltage
12 … 30 V DC
For UL and CSA: Class 2
No-load current consumption
max. 50 mA at 24 V DC
Max. frequency
200 kHz
Connection type
(see chapter 6)
Cable with free cable ends
12-pole M23 device connector
incl. 12-pole M23 cable connector
Connection positions
(see chapter 7)
right
Standard
left
Option
Output signals
0° - signal (A) and inverted signal
90° - signal (B) and inverted signal
Marker pulse (N) and inverted signal
Error output (ERR) and inverted signal
Signal amplitudes
(see name plate)
HTL (approx. same as supply voltage)
Output current: 60 mA
Standard
TTL (5 V acc. to RS 422)
Option
Duty cycle
1:1 ± 3%
Phase shift 0°, 90°
90° ± 5%
Number of pulses
(see name plate)
512, 1024, 2048, 4096, 8192
square wave pulses per revolution (PPR)
Standard
bis max. 32768
square wave pulses per revolution (PPR)
Information for UL and CSA applications
Max. input current
200 mA
Max. output voltage
(see name plate)
30 V DC (HTL) or 5 V DC (TTL)
Max. output current
150 mA

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3.5 Mechanical characteristics
Mechanical characteristics
Dimension drawings
see chapter 7
Degree of protection of
scanning head
acc. to EN 60529
IP 68
(for UL and CSA: Type 1)
Max. speed
(see pulse wheel marking)
Pulse wheel without CFRP wrapping
2600 1/min (rpm)
Pulse wheel with CFRP wrapping
4000 1/min (rpm)
Axial tolerance
(Displacement of pulse
wheel and scanning head)
± 3 mm
Radial tolerance
(Air gap between pulse wheel
and scanning head)
Pulse wheel without CFRP wrapping
0.1 … 2.0 mm
Pulse wheel with CFRP wrapping
0.1 … 1.7 mm
Temperature range
Scanning head
Connection type
Cable
-40 … +85 °C
(for UL and CSA: -40 … +80 °C)
Connection type
M23 connector
-40 … +85 °C
Temperature range
Pulse wheel
-40 … +85 °C

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4 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.
4.1 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).
4.2 Packaging (Disposal)
The packaging is not taken back; dispose of according to the respective valid statutory
provisions and local regulations.
4.3 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).

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5Mounting
5.1 Safety notes for mounting
Risk of destruction by mechanical shock
•Powerful impacts such as blows with a hammer can destroy the scanning head.
•Never use force. Everything fits together easily when fitted properly.
•Use appropriate puller tools to disassemble.
Risk of destruction by mechanical overloading
•Never position the magnetic incremental encoder upright on the magnetic band.
•Ensure the magnetic band is not subjected to mechanical force.
Risk of destruction by sticky liquids
•Sticky liquids can damage the scanning head and the pulse wheel.
Dismantling a magnetic incremental encoder glued to the shaft can lead to its de-
struction.
Risk of destruction by external magnetic fields
•External magnetic fields can destroy the magnetisation of the encoder.
Consequently, do not use magnetic holders, in particular during fitting/dismantling
procedures.
Avoiding disturbances
•Use a shielded encoder cable.
•Avoid laying of disturbing cables (e.g. motor cables) in parallel to the encoder ca-
ble or keep as short as possible.
•Maintain the largest possible distance between disturbing cables and the en-
coder cable
Risk of damage by ferromagnetic particles
•Ferromagnetic particles (for example metallic dust) can become deposited on the
pulse wheel and lead to a loss of measurements.
Use protective casing, if necessary.
Danger of explosion
•The magnetic encoder may not be used in explosion-threatened areas.

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5.2 Mounting of pulse wheels for screw mounting
Note also the information provided by the dimension drawing before
mounting (see chapter 7).
Mounting preparation
Inspect the shaft carefully before mounting. Clean the shaft and remove any defor-
mations or burrs that may be present.
The max. permissible run-out error is 0.6 mm.
Secure all screw connections with Loctite® 243 (medium-strength)!
A torque wrench has to be used for all screws!
Die beiden Symbole TOP auf Polrad und Abtastkopf müssen in
die gleiche Richtung zeigen.
Step 1:
Mount the pulse wheel on the shaft and secure it with the
screws supplied.
The number and size of the screws supplied depend on
the pulse wheel variant delivered.
Step 2:
Tighten the screws crosswise with the appropriate tighten-
ing torque from the following table:
Screw size
Property
class
Tightening
torque
M5
8.8
5 Nm
M6
8.8
8 Nm
M8
8.8
20 Nm
M10
8.8
40 Nm
M12
8.8
70 Nm
TOP

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5.3 Mounting of pulse wheels with cone clamping element
Note also the information provided by the dimension drawing before
mounting (see chapter 7).
Mounting preparation
Inspect the shaft carefully before mounting. Clean the shaft and remove any defor-
mations or burrs that may be present.
The max. permissible run-out error is 0.6 mm.
Secure all screw connections with Loctite® 243 (medium-strength)!
A torque wrench has to be used for all screws!
Die beiden Symbole TOP auf Polrad und Abtastkopf müssen in
die gleiche Richtung zeigen.
Step 1:
Mount the pulse wheel with the unclamped clamping ring
on the motor shaft.
The clamping element inside the pulse wheel consists of
two slotted tapered rings. Minimize the unbalance of the
pulse wheel by ensuring that both slots have an offset of
180°
Step 2:
Align the pulse wheel in the axial direction to the scanning
head as shown on the dimension drawing (see chapter 7).
Secure the pulse wheel on the motor shaft by tightening
the 6 clamping screws M6 x 16 –A2-70 of the clamping
ring with a tightening torque of 7 Nm.
A torque wrench must be used for tightening to avoid ex-
cessive stress on the screws and the pulse wheel!
TOP

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5.4 Mounting of scanning heads
Step 1:
Use the supplied distance foil to align the scanning head to
the pulse wheel.
Depending on the pulse wheel variant, use the appropriate
distance foil from the following table:
Pulse wheel variant
Distance foil
without CFRP wrapping
Thickness 1,0 mm
with CFRP wrapping
Thickness 0,7 mm
For alignment, place the distance foil between the scanning
head and the pulse wheel.
Do not let any dirt get between the scanning head, distance
foil and pulse wheel until the alignment is complete.
Step 2:
Attach the scanning head to a fixed part of the machine using
the 3 supplied crews M8 x 40 –8.8 and the corresponding
washers!
Tightening torque: 20 Nm
If the attachment point does not provide a good electrical
connection to earth potential, use the protective conductor
terminal for earthing the scanning head.
Make sure when mounting the scanning head that the dis-
tance foil can be removed easily (max. 0.1 mm play).
Remove the distance foil.
Correct axial alignment of the scanning head:
Scanning head
Pulse wheel

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6 Connection diagrams
6.1 Scanning head with connection cable
NOTES for UL and CSA!
Do only use copper cables!

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6.2 Scanning head with M23 round plug
NOTES for UL and CSA!
Do only use copper cables!

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7 Dimension drawings
7.1 Screw mounting with internal centering and bolt circle outside
MAG 200S
Screw mounting - internal centering - bolt circle outside
HM 22 M 117671