NorthStar HSD44 Series User manual

Encoder Installation Manual
NorthStar™brand
SERIES HSD44 Extreme Heavy Duty Encoder
Key Features
• O-Ring Housing with Pilot Seals Against
Motor for the Ultimate in Protection
• Isolated Coupling Compensates for Motor
Shaft Runout and Endplay
• Perfect for Off-Highway Vehicle Applica-
tions with High Shock and Vibration
• Unbreakable Code Disc
SPECIFICATIONS
Worldwide Brands: NorthStarTM • AcuroTM • DynaparTM • HengstlerTM • HaroweTM
European Sales Representitive
Hengstler GmbH (Germany)
Uhlandstrasse 49, 78554 Aldingen
www.hengstler.com
INNOVATION - CUSTOMIZATION - DELIVERY
Customer Service:
Tel.: [phone]
Fax: [phone]
[e-mail]
Technical Support
Tel.: [phone]
Fax: [phone]
[e-mail]
WWW.DYNAPAR.COM
Headquarters: 1675 Delany Road • Gurnee, IL 60031-1282 • USA NorthStar™ brand is a trademark of DYNAPAR. All rights reserved.
Document No. 702749-0001, Rev. C ©2012 DYNAPAR
STANDARD OPERATING CHARACTERISTICS
Code: Incremental
Resolution: 1024 PPR (pulses/revolution),
Others at special order
Format: Two channel quadrature (AB) with
Index (Z), and complementary outputs
Phase Sense: A leads B for CCW shaft rotation
viewing the shaft clamp end of the encoder
Quadrature Phasing: 90°±15°electrical
Symmetry: 180°±18°electrical
Waveforms: Squarewave with rise and fall times
less than 1 microsecond into a load capacitance
of 1000 pf
Electrical Immunity: 50 Meg ohm minimum
encoder shaft/frame to all connector pins
ELECTRICAL CONNECTIONS
MECHANICAL
Mechanical Interface: Electrically isolated
stainless steel shaft flex coupling
Mating Shaft Length: 0.47” to 0.83” (11.9mm
to 21mm)
Coupling: 16mm, flexible
Shaft Speed: 6000 RPM, max.
Bearings: 6107
Bearing life: 5 x 108revs at rated shaft Loading,
5 x 1011 revs at 10% of rated shaft loading.
(manufacturers’ specs)
Housing Material: Aluminum Alloy
Disc material: Stainless steel
Weight: 4 lbs.
ENVIRONMENTAL
Operating Temperature: -40 to 100°C
Storage temperature: -40 to 100°C
Shock: 400g, 6mSec
Vibration: 5-3000 Hz, 20g
Humidity: 98%, non-condensing
Enclosure Rating: NEMA 6
ELECTRICAL
Input Power: 5-30VDC. 50 mA max., not including
output loads.
Outputs: 5 -30 Volts DC, TTL
Frequency Response: 125 kHz (data & index)
Termination: 18” pigtail or 18” pigtail with MS
Connector. See Ordering Information
Mating Connector:
10 pin MS, style MS3106A-18-1S (MCN-N6)
Data A
Data A
Data B
Index
(180°ELEC) (90°ELEC)
A leads B, CCW (From Clamp End)
DATA AND INDEX
Not all complements shown
A shown for reference
Index Width: 150°to 300°
Function
Sig. A
Sig. B
Sig. Z
Power +V
Com.
Case
N/C
Sig. A
Sig. B
Sig. Z
Pin
A
B
C
D
F
G
E
H
I
J
Wire Color
BRN
ORG
YEL
RED
BLK
GRN
—
BRN/WHT
ORG/WHT
YEL/WHT

Page 2
IMPORTANT INSTALLATION INFORMATION
ELECTRICAL CONNECTIONS
Cable - The use of shielded cable is recommended
for all encoder installations. When a Dynapar brand
encoder is ordered, the type of termination is gener-
ally defined (usually the last selectable code in
Ordering Information). If a code for a cable was
indicated, the encoder was manufactured to include a
shielded cable. If any other type of termination was
selected or if selection of termi-nation type was not
requested, a cable assembly must be ordered. (The
cable assembly easily hooks onto the encoder’s
connector making it ready for wiring).
To determine which cable assembly to order, refer to
the Electrical Connections table (in the encoder’s
manual).
GENERAL GUIDELINES
Encoders provide quality measurements and long
life when common sense, care, and accurate
alignments are provided during installation. The
following general guide-lines will help to ensure a
trouble-free installation.
Mounting the Encoder
Do not shock the encoder. Do not subject the encoder to
axial or radial shaft stresses.
Do not tool the encoder
or its shaft. Do not use makeshift techniques to mount the encoder.
Do not use a rigid coupling.Do not disassemble the encoder.
Wiring the Encoder
•Never connect or disconnect the encoder connec-
tor or wiring while power is ON. Doing so may
damage the encoder.
•Power should always be connected to the + side
of DC power.
•Common should always be connected to the -
side of DC power.
•Never connect A, B, or Z to the + or - side of DC
power.
In some cases, there may be more than one table or
the table may be broken into sections due to different
output types. If so, refer to the information listed for
the output type selected for the encoder (in Ordering
Information).
Wiring should be run through dedicated conduits or
harnesses (not shared with any other wiring) which
are spaced at least 12 inches apart. This protects the
cable from physical damage while providing a degree
of electrical isolation. Also, do not run cable in close
proximity to other conductors which carry current to
heavy loads such as motors, motor starters,
contactors, or solenoids. Doing so could result in
electrical transients in the encoder cable which cause
undesired signal pulses.
NOTE: Never connect or disconnect the encoder
connector or wiring while power is ON. Doing so
may damage the encoder.
ELECTRICAL CONNECTIONS (cont.)
Grounding: For applications with high ground poten-
tial differences, DO NOT ground the encoder through
both machine and controls end. Connect the shield at
the controls end only. NOTE: If the shield is con-
nected at both ends, grounding problems that
degrade system performance can result.
CE Grounding Measures –For best EMC immunity
the cable screen must be grounded on both encoder
and controls end. For cable lengths longer than 30m
or outdoor applications, additional measures must be
implemented to comply with CE requirements. Con-
nection of the encoder to DC power supply network is
prohibited if CE compliance is required. CE-compliant
products are tested to EN61326-1 EMC.
In all cases, system CE compliance is ultimately the
responsibility of the manufacturer integrating the
encoder.
FEATURES
All encoders have the following electrical features:
•Power (+DC)
•Common
•Output Signal(s)
Power (also referred to as supply, power source, and
power +V/VCC) is always +DC for encoders. There-
fore, power should always be connected to the
positive (+) side of DC power. In addition, encoder
power should be regulated to within ±5% at the
encoder and should be free of induced transients.
Common (also referred to as Com, supply common,
and ground) is generally a black wire (verify via
Electrical Connections table).

Page 3
IMPORTANT INSTALLATION INFORMATION
FREQUENTLY ASKED QUESTIONS
There are additional colored wires which are not
referred to in the Electrical Specifications table.
What do I do with them?
Do not connect them to the receiving device.Any
unused encoder signal wires must be individually
insulated and tied back. They should NEVER be in
contact with common, power sources, or other
output signal lines.
The encoder is correctly connected to the
receiving device per the Electrical Specifications
table and the receiving device’s terminal strip
label; however, it’s counting in the wrong
direction. What’s wrong?
In order to reverse the counting direction, the output
signal connections must be switched. If the encoder
has a single ended output, swap A and B. If the
encoder has a differential line driver, swap A and – A.
I’ve connected the encoder and it doesn’t work (
No Outputs). What can I do?
Many encoders have internal protection circuits
which shut down the encoder to prevent damage if
the input power is not correct or the outputs are
overloaded. Check the following: Input Voltage (is it
too high?); Input Polarity (is it reversed?); and
Output Wiring (are they wired properly?).
I’ve read and followed the technical manual and
these guidelines and the encoder still doesn’t
work properly. Help!?
Calm down - help is at your fingertips! Simply pick up
the phone and dial our Applications Engineering
Department at 1-800-234-8731 (US & Canada) or
847-662-2666 from 8:00 AM to 4:45 PM (Central
time) Monday - Friday. One of our engineers will
gladly help you solve the problem.
FEATURES (cont.)
Common should always be connected to the negative
(-) side of DC power.
All encoders have at least one output signal (A);
however, it is common for encoders to have three
signals A, B, Z (may also be referred to as C, X, or
index). The outputs should each be connected to the
receiving device at the appropriate terminal. NOTE:
Never connect A, B, or Z to the + or - side of DC
power.
When encoders have a differential line driver, there
are two signals for each of the outputs. Each signal (A,
B and Z) has a compliment or inverse (– A, – B and – Z
referred to as A not, B not, and Z not). The signal and
its compliment (i.e. A and – A) are separate outputs.
Connect each output to a separate input.
NOTE: Never connect these signals together or to
the + or - side of DC power. Never connect differ-
ential signals to the same input.
CONNECTIONS
Obviously not all receiving devices are the same.
However, connecting your encoder to one, no matter
what type or brand it may be, is not difficult.As
discussed in the previous section, all encoders have
certain electrical features. Each of these features/
functions are identified in the encoder’s Electrical
Connections table along with its corresponding pin
and wire color. Each wire specified in the table must
be connected to the receiving device.
Determining where to connect each wire is as easy as
following the Electrical Connections table and match-
ing each wire to the proper terminal on the receiving
device. In general, no matter what type of receiving
device you are using, the terminal strip is marked,
indicating the proper location for each function/wire.
These markings may either be numbers or text labels
identifying functions. If they are numbers, the receiv-
ing device’s manual should define what function
corresponds to each number.
Since receiving devices are made by various manu-
facturers, not all text labels/references are the same.
There are various ways to identify each function.
Following are a few examples:
Note: Encoders that
feature differential
outputs will also have
complementary outputs
referenced as
–
A, – B, – Z, (A-not, B-not,
Z-not).
Typical
Encoder
Power
Common
Signal A
Signal B
Index
Referred to as:
Vcc; +Power
DC Power
12VDC
Referred to as:
Comm
–Power
–DC
Referred to as:
Input A
A+
Sig. A
Referred to as:
Input B
B+
Sig. B
Referred to as:
Marker
Z
Sig. C

Page 4
MECHANICAL lINSTALLATION
A. GENERAL OVERVIEW
The NorthStar Series HSD44 is a harsh-duty speed
and position transducer that when mounted to a
rotating shaft, produces output pulses that are
directly proportional to the shaft speed and direction.
The encoder is attached to the motor shaft via a
stainless steel flexible coupling that compensates for
motor shaft end-play and run-out. The clamp is also
electrically isolated from the encoder to ensure
motor shaft currents do not ground through the
encoder bearings. Due to this specialized coupling,
special precautions must be taken during installation
as outlined in this manual.
B. SHAFT EXTENSION
Solid shaft preferred, keyway allowed (key must be
removed); flatted shaft must not be used. The shaft
extension length range is .47” to .625”. Installations
that use a press-fit or screwed-on stub shaft adapter
should align the stub shaft to 0.002" TIR or less
using a dial indicator.
C. REQUIRED TOOLS & MATERIALS
Caliper & Dial Indicator Gages Shaft Checks
1/4" Hex Key Wrench Shaft Clamp Access Plug
5/32" Ball End Hex Key Wrench Shaft Collar Clamp and Shaft
Clamp Alignment Screw
3/16" Hex Key Wrench Encoder Mounting Screws
10mm Hex Key Wrench Stopping Plug
Open End Adjustable Wrench Cable Gland
7/64" Hex Key Wrench Terminal Box Cover
1/8" Flat Blade Screwdriver Terminal Block Wiring
Torque Wrench, 20–75 inch pound range Tightening Fasteners
Threadlocker, Loctite 242 or equivalent Retaining Fasteners
Tool Purpose
CAUTION: Upon initial inspection of the shaft
coupling area of the HSD44 you will notice a 10-
32 screw that extends through the encoder body
and into the shaft coupling.
DO NOT remove this Coupling Locating Screw
until directed to do so in Step 9 of the Installa-
tion Procedure.
Please familiarize yourself with the following as
seen in the magnified view drawing below:
1. Shaft Clamp Screw
2. Shaft Clamp Access Plug
3. Flex Coupling Locating Screw
4. Coupling Locating Hole
Note: The encoder can be mounted on shafts of
varying lengths (MIN 0.47 in, MAX 0.83 in).
ESD44 MOTOR MOUNT REQUIREMENTS
PILOT
3.345 +.005
-.000
.47 MIN. TO
MAX.
SHAFT LENGTH
.83
MIN.
PILOT DEPTH
.110
6X 1/4-20 X 0.70 MIN.
EQUALLY SPACED ON
A 3.937 B.C.
16MM OR
5/8" SHAFT
Note: Please refer to this figure when
performing Installation Steps 7 –11.
SHAFT CLAMP
ACCESS PLUG
FLEX COUPLING
LOCATING SCREW
2
3
SHAFT
CLAMP SCREW
1
COUPLING
LOCATING HOLE
4
HSD44 COUPLING/CLAMP INSTALLATION

Page 5
STEP 1: Please reference the below diagram
titled "EN 44 Motor Mount Requirements" to
ensure that a correct mounting interface is
provided for the mechanical installation of this
encoder. The HSD44 has a 0.110 inch piloted
face that is concentric with the Flex Coupling.
Be sure to create a concentric pilot with the six
1/4-20 inch threaded holes on customer
equipment as shown in the diagram.
STEP 2: Ensure the mounting interface and shaft
extension are free of dirt, grease, or any other
foreign matter. Check the shaft Total Indicated
Run-out (TIR), and ensure that it does not exceed
0.005” TIR.
STEP 3: Using the 1/4” hex key, remove the Shaft
Clamp Access Plug from the side of the encoder
body.
STEP 4: Place the 5/32” ball end hex key into the
access hole and loosen the Shaft Collar Clamp
Screw. Place a small amount of threadlocker on
the screw threads and re-install it into the Clamp
Collar. Re-thread the screw into the clamp
loosely. DO NOT TIGHTEN. Remove the 5/32”
ball end hex key from the access hole.
STEP 5: Place a Lockwasher onto each
1/4-20 x 1” Encoder Mounting Screw (6 required).
Apply a small amount of threadlocker to the screw
threads.
STEP 6: While observing the proper orientation of
the cable exit, slide the encoder straight over the
motor shaft extension, and engage the encoder's
Flex Coupling. Note again, shaft engagement is
MIN 0.47" MAX 0.83".
Note: Please refer to ‘HSD44 Coupling/Clamp
Installation” figure (previous page) when perform-
ing Installation Steps 7 – 11.
STEP 7: Install the six Encoder Mounting Screws
using the 3/16” hex key and torque to 75 inch
pounds.
STEP 8: Using the 5/32” hex key, tighten the Shaft
Clamp Screw. Torque to 36 inch pounds. Remove
the 5/32” hex key.
CAUTION: The motor shaft must NOT be
rotated until Step 9 (below) is performed,
or damage to the encoder flex coupling will
result.
STEP 9 Using the 5/32 hex key, completely remove
the 10-32 x 1.5” Flex Coupling Location Screw.
This screw is no longer needed for installation,
instead replace with the shorter 10-32 x 7/8" screw.
Obtain the 10-32 x 7/8” SHCS from the hardware
kit (this screw has an o-ring under the head). Apply
a small amount of threadlocker to the screw
threads. Using the 5/32” hex key install the screw
into the Coupling Locating Hole and torque to 20
inch pounds. The purpose of this shorter screw is
to block the hole while in operation.
STEP 10 Apply a small amount of threadlocker to
1/8” NPT Shaft ClampAccess Plug threads. Using
the 1/4 hex key, install the plug and torque to 60
inch pounds.
MECHANICAL lINSTALLATION

Page 6
Part Number Description
HSD44T1024A3A Extreme Heavy Duty Encoder with 18 inch pigtail wire connections
HSD44T1024A3A-0 1 Extreme Heavy Duty Encoder with 18 inch pigtail wire connections and extended pilot (.156”)
HSD44T1024A3K Extreme Heavy Duty Encoder with 18 inch pigtail with 10 pin MS connector
HSD44T1024A3K-01 Extreme Heavy Duty Encoder with 18 inch pigtail with 10 pin MS connector and extended pilot (.156”)
Accessories
Part Number Description
HSD44ADAPTER45 4-1/2” NEMA Motor Adapter Plate
HSD44ADAPTER85 8-1/2” NEMA Motor Adapter Plate
DIMENSIONS (in. [mm])
3.343
[84.91]
.93
[23.62]
4.40
[111.76]
2.4
[60.96]
.107 [2.72]
.600 +.200 [5.08]
-.050 [1.27]
PILOT
I.D. .6295 +.0/-.0005
PILOT CAVITY
Ø3.346
[84.99]
CLEARANCE FOR 1/4-20 SHCS (6)
ON Ø3.937 [100.0] BC EQUALLY SPACED
COLLAR: 10-32 x 1/2 SS SHCS
TIGHTENED WITH A 5/32 BALL
DRIVER ALLEN WRENCH
O RING
CABLE EXIT
SHAFT CLAMP
ACCESS PLUG
16 MM SHAFT EXTENSION 1/4-20 x 1 SS SHCS
SUPPLIED WITH THE
ENCODER
SHAFT INSERTION LIMIT: .625 [15.88]
ORDERING INFORMATION