Hubner EGS 40 Series Product guide

English
Translation of the original Operating and Assembly Instructions EGS40_MANUAL-en_R6(2018-11-07)ID74528.docx
ID 74528
Operating and Assembly Instructions
Electronic Overspeed Switch
EGS® 40
Option S (integrated EGS® 4 technology with incremental encoder type FG)
Read the Operating and Assembly Instructions prior to
assembly, starting installation and handling!
Keep for future reference!

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Trademark
EGS is a registered trademark of Johannes Hubner Fabrik elektrischer Maschinen GmbH.
Windows is a registered trademark of Microsoft Corporation in the Unites States and other countries.
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 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]
E-Mail: [e-mail]
www.huebner-giessen.com
Headquarters: Giessen
Court of registration: Giessen
Commercial register number: HRB 126
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 assembly instruction................................................................................ 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 Personal protective equipment................................................................................................... 7
2.5 Special dangers.......................................................................................................................... 7
2.5.1 Electrical current.................................................................................................... 7
2.5.2 Rotating shafts ...................................................................................................... 7
2.5.3 Safeguarding against restart.................................................................................. 7
3Technical data................................................................................................................. 8
3.1 Type plates ................................................................................................................................. 8
3.2 Type key ..................................................................................................................................... 9
3.2.1 Mechanical Data...................................................................................................10
3.3 Connected loads and values .................................................................................................... 10
3.3.1 Dimensions, connected loads, environment .........................................................10
3.3.2 Electrical Outputs .................................................................................................10
3.3.3 Speeds.................................................................................................................11
3.3.4 Switching performance.........................................................................................11
3.3.5 Degree of protection.............................................................................................12
3.3.6 Outputs.................................................................................................................13
3.3.7 incremental encoder type FG with integrated EGS® 4 technology (option S) ......13
4Structure and function ..................................................................................................14
4.1 Block diagram........................................................................................................................... 14
4.2 Brief description........................................................................................................................ 14
5Transport, packaging, and storage ..............................................................................15
5.1 Instructions for transport........................................................................................................... 15
5.2 Symbols on the packaging........................................................................................................ 15
5.3 Transport inspection ................................................................................................................. 16
5.4 Packaging................................................................................................................................. 16
6Installation and commissioning....................................................................................16
6.1 Versions.................................................................................................................................... 16
6.2 Installation tasks ....................................................................................................................... 17
6.2.1 Device execution for flange design (B5) or foot design (B35) ...............................17

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6.2.2 Assembly instruction no. 54690 for coupling type HK….5.....................................17
7Programming instruction..............................................................................................18
7.1 Preparing the computer............................................................................................................ 18
7.2 Installation of a new driver........................................................................................................ 18
7.3 Starting the software................................................................................................................. 21
7.3.1 EGS4xPro Main window.......................................................................................22
7.4 Setting up the software............................................................................................................. 24
7.5 Preparing the device................................................................................................................. 24
7.6 Reading out and saving data.................................................................................................... 24
7.7 Locking the device.................................................................................................................... 25
7.8 Switch test................................................................................................................................. 25
7.9 Monitoring................................................................................................................................. 25
7.10 Customer support..................................................................................................................... 26
8Faults..............................................................................................................................26
8.1 Safety........................................................................................................................................ 26
8.2 Fault table................................................................................................................................. 27
9Tests...............................................................................................................................27
9.1 Safety........................................................................................................................................ 27
9.2 Test schedule ........................................................................................................................... 28
10Disposal..........................................................................................................................28
11Replacement parts.........................................................................................................29
12Dimension drawings......................................................................................................30
12.1 Construction type B5 (flange)................................................................................................... 30
12.2 Construction type B35 (flange and foot)................................................................................... 31
12.3 Construction type B5 / B14 (flange / with 2. Shaft ends).......................................................... 32
12.4 Construction type B35 / B14 (flange and foot / with 2 shaft ends) ........................................... 33
12.5 EGSH 40 Dimension drawings................................................................................................. 34
13Connection diagrams ....................................................................................................38
13.1 Connections.............................................................................................................................. 38

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1General
1.1 Information about the assembly instruction
This assembly instruction provides important instructions for working with the device. It 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
Scope of delivery includes the overspeed switch, the EGS®40-Pro programming software (CD-ROM),
and the programming cable.
1.3 Explanation of symbols
Warnings are indicated by symbols in this operating manual. 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.
NOTE!
Indicates useful tips and recommendations as well as information for efficient and
trouble-free operation.
NOTE!
Mounting and disassembly by means of a hammer or similar tools is not permitted
(warranty void).
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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1.4Disclaimer
All information and instructions in this assembly instruction 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 manual
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
NOTE!
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 are available that can be reached per telephone, fax or email, see
manufacturer´s address on page 2.
2Safety
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 EGS®40 overspeed switches are used for 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.

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2.3Improper 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.
It is not permitted to use the device in locations higher than 3000 m above sea level.
2.4 Personal protective equipment
For tasks such as assembly, disassembly or commissioning the use of personal protective equipment
such as safety footwear and protective work clothing is required.
The regulations specified by the owner and that are locally specified apply.
2.5 Special dangers
Residual risks that have been determined based on a risk analysis are cited below.
2.5.1 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.
2.5.2 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.
2.5.3 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
The type plate is located on the outside of the housing and contains the following information:
Manufacturer, Address
Type, year of construction
CE mark
Serial number (S/N)
Commission number (C/N)
Degree of protection
Supply voltage
Switching speed programmable
Switching voltage/max. switching current

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3.2 Type key
EGS(H) 40 K -HS –HV /20P - FG 40-1024G-90G-NG
Electronic Overspeed Switch
EGS
EGSH (hollow shaft design)
Series 40
Connection Method
K: Terminal box
KK: 2 Terminal boxes
Switching Voltage
max. 30 V DC (Standard)
HS: 30 … 230 V AC/DC
Supply Voltage
12 … 30 V DC (Standard)
HV: 100 … 240V AC (in second terminal box)
Inner diameter (hollow shaft version)
20 P: Ø 20 H7 mm with keyway (standard)
16 P: (Optional)
19 P: (Optional)
16 K: (Optional) K: Klemmung/clamp
25 K: (Optional)
Integrated incremental encoder
(in the second terminal box)
see (assembly) instructions FG 40

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3.2.1 Mechanical Data
Description
Data
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)
100 g (ca. 1000 m/s²)
EGS 40
Max. encoder
shaft load
Fa max. (axial) = 100 N
Fr max. (radial) = 120 N
Shaft end
11j6 x 30 mm (standard)
14j6 x 30 mm (optional)
Weight
EGS 40 K
EGS 40 KK
Approx. 3.3 kg
Approx. 3.6 kg
EGSH 40
Weight
EGSH 40 K
EGSH 40 KK
Approx .3,5 kg
Approx. 3,8 kg
3.3Connected loads and values
3.3.1 Dimensions, connected loads, environment
Specification
Value
Unit
Weight
approx. 3,5
kg
Dimensions
see dimensions sheet page
Supply voltage
12 … 30
V DC
Power consumption
80
mA
Switching voltage see type plate
(Special switching voltage, see type plate)
2 … 30
30 … 230
V DC
V AC/DC
Switching current
max. 300
mA
Device temperature range
-25 … +85
°C
max. shaft stress, shaft 11j6 x 30 and
14j6 x 30 (up to speed 3000 rpm)
axial, 100, radial, 120
on a half shaft length
N
3.3.2 Electrical Outputs
Variant
Switching
Contacts
Error
Outputs
Incremental
Output
Supply
Voltage
Connection
Diagram
See chapter 13.1
EGS(H)40K (HS)
2
1
12 30 VDC
PN132-400
EGS(H)40KK (HS)
4
2
12 30 VDC
PN132-400
EGS(H)40KK
–FG 40
2
1
6/8
12 30 VDC
PN132-420
+ Connection diagram for
FG40 see Operating
manual FG40
EGS(H)40KK (HS) –
HV
2
1
100 .. 240
V AC
PN132-420 +
PN100-400a
Option S
2
1
PN132-420

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3.3.3 Speeds
Programmable switching speeds (see type plate)
min.
max.
Unit
0.63
300
rpm
1,25
600
rpm
2,5
1200
rpm
5
2400
rpm
10
4800
rpm
20
7000
rpm
Supplemental mechanical restriction (continuous operation)
EGS®40 in IP 66/IP67
4000
rpm
EGS®40 in IP65
6000
rpm
Protection classes in accordance with EN 60 529
3.3.4 Switching performance
Specification
Value
Unit
Adjustment resolution
to 99.9 : 0.1
starting from 100 : 1
rpm
Switching accuracy
see diagram
Switching hysteresis
programmable, min. 10
%
Switching delay
programmable, 0 … 300
ms
Function as direction of rotation switch (right/left)
programmable
on/off
Monitoring of the switch functions
programmable
on/off

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3.3.5 Degree of protection
Protection class acc. to
DIN EN 60529
Sealing
Permissible
speed
Rotor moment of
inertia
Breakaway torque
EGS 40
IP65
Standard
≤6000 rpm
approx. 510 gcm²
approx. 6 Ncm
IP66
with labyrinth seal
≤6000 rpm
approx. 580 gcm²
approx. 6 Ncm
B5 IP66/IP67
B5/B14 IP66
with axial shaft seal
with axial shaft seal
B14
≤4000 rpm
approx. 510 gcm²
B5 approx. 8 Ncm
B5 IP66/IP67
B5/B14 IP66
with radial shaft seal
(for special
applications, e.g. wet
areas in rolling mills)
B14 axial shaft seal
≤3000 rpm
approx. 510 gcm²
B5 approx. 9 Ncm
EGSH 40
IP65
Standard
≤4000 rpm
approx. 1175
gcm²
approx. 10 Ncm
IP66
with labyrinth seal
≤4000 rpm
approx. 1325
gcm²
approx. 10 Ncm
IP66
with axial shaft seal
≤2000 rpm
approx. 1175
gcm²
approx. 25 Ncm
IP66
with radial shaft seal
(for special
applications, e.g. wet
areas in rolling mills)
≤2000 rpm
approx. 1175
gcm²
approx. 30 Ncm
NOTES!
If the cover plate is not fitted to the hollow shaft device EGS®40 the IP rating is
reduced to IP65.
NOTES!
At maximum speed the permissible ambient temperature will be reduced to 60°C.

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Switching accuracy:
3.3.6 Outputs
Variant
Switching contacts
Error outputs
EGS®40 K
2
1 System Check
EGS® 40 K
4
2 System Check
3.3.7 incremental encoder type FG with integrated EGS® 4 technology (option S)
The connections for the EGS® 40 technology are placed in a second terminal box of the incremental
encoder of type FG….
The terminal boxes are clearly marked with labels.
The functioning of the option S and all technical data correspond to the standard version EGS® 40 K.
NOTE!
For the function of the electronic overspeed switch the power supply of the FG 40
has to be connected in the first terminal box.
Schaltgenauigkeit EGS4
1
10
100
1000
10000
1 2 5 10 20 50 100
Drehwinkel zwischen erreichen der Schaltdrehzahl und Abschaltung [°]
Schaltdrehzahl [1/min]
alpha1 alpha10 alpha100
Switching accuracy EGS® 40
Switching speed [1/min
Angle of rotation between the switching speed and shut off [°]
Fig. 1: Diagram –switching accuracy EGS®4 (alpha: Angular acceleration in rad/s²).

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4Structure and function
4.1Block diagram
4.2Brief description
The integrated speed sensor consists of a pulse disk with optical scanning, and it generates a
speed-proportional frequency. The analysis unit (controller) further processes this frequency.
The actual speed is continuously compared with the programmed limit speeds in the read-only
memory (EEPROM). When a limit value is reached the analysis units triggers the associated
switch.
Analysis unit:
After applying the supply voltage there is a plausibility check and there after the device is ready for
operation.
Read-only memory:
The following data are stored in the programmable EEPROM read only memory:
The switching points / limit values for the switching speeds.
The switching performance (hysteresis, switching delay).
Date and time the last switching speed was programmed, with user ID.
A 8-digit user-defined device ID.
The device password.
(Details: Chapter 7 Programming instruction)
The programmed data are saved with the appropriate checksum and verified at each device start.
Serial interface:
The device is programmed via the RS232-interface using the supplied programming cable and the
EGS®40-Pro software.

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Switch
The EGS®40 overspeed switch is equipped with two swtiches and one System Check output. These
are galvanically separated from the analysis unit via optocoupler.
If the respective limit value is exceeded switch 1 or 2 opens.
If the “switching monitoring” function ( chapter 7 Programming) is actived then switch 1 and 2, as
well as the System Check switch will be monitrored for function.
NOTE!
A load current of at least 5 mA for switch monitoring is prerequisite.
The system check switch is closed in normal operating and opens in the event of:
Internal malfunctions
Switch malfunction (if monitoring is activated)
Power supply failure
If the System Check switch malfunctions (with activated monitoring) then switches 1 and 2 open
concurrently.
NOTE!
An interruption of the supply voltage for more than 20 ms causes a system reset (switch 1 and
2 as well as "System Check" switch open).
5Transport, packaging, and storage
5.1Instructions for transport
Improper transport
CAUTION!
Improper transport can cause property damage!
Comply with the symbols and warnings on the packaging.
5.2Symbols on the packaging
Protect from moisture
Keep packed goods dry and protected against moisture.
Protect from heat
Protect packaged goods form heat over 40°C and direct sunlight.

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5.3Transport inspection
Check delivery immediately upon receipt for completeness and possible transport damage.
5.4Packaging
Handling packaging materials
The packaging is not taken back and must be disposed of in accordance with the respective statutory
regulations and local guidelines.
Storage of packed goods
Store in a dry and dust-free location.
If stored for longer periods (> 6 months) we recommend sealing the devices in foil,
possibly with a desiccant.
Do not expose to aggressive media.
Storage temperature: - 15 °C … +40 °C.
For storage periods longer than 6 months: Contact the manufacturer.
6Installation and commissioning
6.1Versions
CAUTION!
Consider chapter 2
EGS 40K standard version
1 terminal box, 2 programmable switching points, system check, switching voltage: 2 V … 30 VDC,
optional 30 … 230 VAC/DC, max. switching load 0.3 A.
EGS 40KK optional (partially redundant) version
2 terminal boxes, 2 + 2 programmable switching points, two-fold system check, switching voltage: 2 V
… 30 VDC, optional 30 … 230 VAC/DC, max. switching load 0.3 A.
EGS®40K… devices must only be used for the monitoring of overspeeds in safety-relevant machinery
and installations when applicable rules, regulations and laws are observed and they have to be
periodically tested. The tests must be recorded and have to be periodically tested. The tests must be
recorded and have to be evidenced (see test schedule 9.2).
Furthermore we wish to draw your attention to the relevant nationally applicable laws, regulations and
standards as well as the operating instructions that govern the safety and commissioning of individual
components and the complete installation as well as the periodically testing (electrical and mechanical
function tests).

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6.2Installation tasks
6.2.1 Device execution for flange design (B5) or foot design (B35)
1. Use a play-free coupling.
2. Ensure precise catered attachment, particularly with foot design B35 (double coupling HKD5 is
recommended).
3. Fix device in place via flange or foot.
4. Make the connections in the terminal box ( Appendix, Connection diagrams).
6.2.2 Assembly instruction no. 54690 for coupling type HK….5
1. Select coupling bore with G7 fit (tolerance field is above the zero line).
2. Push the coupling onto the shaft with easy movement. Finishes ream the associated bore if
necessary.
3. Secure the hub against axial offset with M4 radial set screw (with tip). The set screw presses
on the feather key so that the shaft is not damaged.
Consider the permissible compliance:
Type
Axial
Radial
Angular
HK 5 …
±1 mm
-
approx. 0.5 °
HKD 5 …
±1,5 mm
0.5 mm
-
CAUTION!
Danger of damage or breakage if the coupling is not improperly handled ( Fig. 1).
No hard impacts on coupling and shaft
Do not deform the coupling
Do not exceed compliance as specified
Precisely align coupled machines
NOTE
The more precise the attachment,
the longer the service life of the coupling and bearing encoder
and the lower the degree of influence on encoder signal quality (harmonics)
Additional instructions on couplings are provided in the current Hubner Giessen catalog "Torsion-
resistant stiff couplings for encoders".
Fig. 1

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7Programming instruction
When the device is connected to a PC via a USB port for the first time it will be recognized as new
hardware.
7.1Preparing the computer
System prerequisites:
Windows®98 / NT / 2000 / XP, for transfer of administrator rights to the program: Vista-compatible
Windows 7
CD-ROM drive, USB interface.
Use the supplied CD-ROM or download the current version of the EGS®40-Pro from our homepage
(see page 2).
7.2Installation of a new driver
Connect the device to your PC using the supplied USB to mini USB cable.
Pay attention to the fact that you have Administration Rights.
The "New hardware found pop-up" is displayed informing you that
a new "USB device" or a HJG device is connected.
The Hardware Update Wizard window opens automatically.
In response to the question requesting a Windows update select
"No, not this time", then click "Next".
Select the option "Install software from a list or another source",
then click "Next".

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Select only the "Browse the following source also" option as the
source, then click "Browse". Select the "Win 2000 XPVISTA"
directory from the driver package, then click "OK" to confirm. To
install the "USB Serial Converter" driver click "Next".
Click "Continue installation".
When the USB Serial Converter has been installed click
"Finish".
Installing the SERIAL USB Driver
The New hardware found pop-up displays immediately after USB driver has been installed.
Now you must install the USB Serial Port driver. The Installation
Wizard window should open automatically.

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In response to the question requesting a Windows update
select "No, not this time", then click " Next".
Select the option "Install software from a list or another
source", then click "Next".
Select only the "Browse the following source also" option as
the source, then click "Browse". Select the "Win2000
XPVISTA" directory from the driver package, then click "OK"
to confirm. To install the "USB Serial Port" driver click "Next".
Click "Continue installation".
Once the installation process is complete click "Finish".