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Hubner FG 41 Operating And Assembly Instructions Manual

Incremental encoder with functional safety
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English
Operating and assembly instructions
Incremental encoder with functional safety
FG 41 in solid shaft design
certified according to
and according to
Read the operating and assembly instructions prior to
assembly, starting installation and handling!
Keep for future reference!
Translation of the original operating and assembly instructions
ID 76644
EN 61508 part 1-7:2010 / IEC 62061:2015 SIL CL2 and
EN ISO 13849-1: PL d
EN 61508 Part 1-7:2010 / IEC62061:2015 SIL CL3 and
EN ISO 13849-1: PL e
Issue: 29.05.2020

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  • Page 1 English Operating and assembly instructions Incremental encoder with functional safety FG 41 in solid 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...
  • Page 2 Incremental Encoder FG 41 Manufacturer / Publisher Johannes Hübner Phone: +49 641 7969 0 Fabrik elektrischer Maschinen GmbH Fax: +49 641 73645 Siemensstr. 7 Internet: www.huebner-giessen.com 35394 Giessen / Germany E-mail: info@huebner-giessen.com Further current information on this product series can be found online in our Service Point.
  • Page 3 Incremental Encoder FG 41 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.

  • Page 4: Table Of Contents

    5.3 Required tools.......................... 25 5.4 Mounting preparations ......................25 5.5 Mounting of FG 41, construction type B5 (flange) ..............26 5.6 Mounting of encoders in construction type B35 (flange and foot) ..........28 5.7 Dismantling the FG 41 ......................29 6 Installation / Preparation for Commissioning ..............
  • Page 5 12.1 Mating connector ........................44 12.2 Mounting kit friction-enhancing shims ..................44 12.3 Coupling ..........................45 13 Dimension drawings ......................46 13.1 FG 41, construction type B5 ....................46 13.2 FG 41 construction type B35 (flange and foot) ................ 49...

  • Page 6: General Information

    The operating and assembly instructions are supplementary to other documentation, such as product data sheets, dimension drawings, dimension drawings, prospects, etc. The scope of delivery includes the incremental encoder FG 41 and the operating and assembly instructions. The operating and assembly instructions may be requested separately.

  • Page 7: General Functional Description

    Verband der Elektrotechnik, Elektronik und Informationstechnik (Association for Electrical, Electronic and Information Technologies) Repeat test Repetitive test to detect hidden dangerous failures in a safety-related system. (proof test) General functional description The rotary measuring system FG 41 is a safe and incremental position measuring system.
  • Page 8 Incremental Encoder FG 41 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) ·...

  • Page 9: Main Features

    There is no interpolation or signal multiplexing. All signal lines are led separately within the electronics. 1.3.1.1 Variant 1 (FG 41 SIN/COS) Incremental interface with analog output signals SIN±, COS± and Ref±; output level 1 Vss.

  • Page 10: Basic Safety Instructions

    Incremental Encoder FG 41 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.

  • Page 11: General Risks When Using The Product

    Incremental Encoder FG 41 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...

  • Page 12: Non-Intended Use

    Incremental Encoder FG 41 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...

  • Page 13: Mandatory Safety Checks / Measures

    Incremental Encoder FG 41 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 STOP task and safety function.

  • Page 14: Warranty And Liability

    Incremental Encoder FG 41 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...

  • Page 15: Safety Information

    Incremental Encoder FG 41 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.

  • Page 16: Transport, Packaging And Storage

    Incremental Encoder FG 41 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.

  • Page 17: Storage Of Packages (Devices)

    Incremental Encoder FG 41 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).

  • Page 18: Technical Data

    Incremental Encoder FG 41 4 Technical Data Safety Functional safety EN 61508 Part 1-7 Safety Integrity Level (SIL) SDI, SS1, SS2, SOS, SLP, SLI, SCA SLS, SSR, SSM, SLA, SAR EN ISO 13849-1 Performance Level (PL) SDI, SS1, SS2, SOS, SLP, SLI, SCA - PLd / Kat.

  • Page 19: Electrical Characteristics

    Incremental Encoder FG 41 Electrical characteristics 4.2.1 General Supply voltage 12…30 V DC acc. to IEC 60364-4-41, SELV/PELV Reverse polarity protection Short-circuit protection Yes, by internal 1 A safety fuse Yes, up to ≤ 60 V DC Overvoltage protection Current consumption without...

  • Page 20: Device-Specific

    Incremental Encoder FG 41 4.2.2 Device-specific Accuracy 10 bit, 11 bit, 12 bit; depending on the device Usable resolution configuration Safety-related + 2 bit interpolated Functional + 8 bit interpolated Variant 1 Incremental analog output signals Periods / revolution 1024, 2048, 4096 acc. to device variant Incremental signals SIN+, SIN–, COS+, COS–...

  • Page 21: Ambient Conditions

    Incremental Encoder FG 41 Ambient conditions Vibration ≤ 100 m/s2, sine 50-2000 Hz EN 60068-2-6 Shock ≤ 1000 m/s EN 60068-2-27 , half-sine 11 ms Immunity to disturbance EN 61000-6-2 Transient emissions EN 61000-6-3 Working temperature -40 °C…+85 °C Ambient temperature (Ta) solid shaft = 84,1 –...

  • Page 22: Mechanical Characteristics Fg 41

    Incremental Encoder FG 41 Mechanical characteristics FG 41 Mechanically permissible speed £ 4000 rpm Degree of protection IP66/IP67 Observe ambient temperature for permissible Note working temperature Electrically permissible speed [rpm] = (output frequency [Hz] / no. of pulses per rev.) * 60 rpm...

  • Page 23: Type Code

    Incremental Encoder FG 41 Type code FG 41 G-90G- Incremental encoder Construction type = solid shaft B5 (flange) or B35 (flange and foot) Series Connections T = 12-pole round plug M23 K = Terminal strip in terminal box Pulses per rotation...

  • Page 24: Assembly

    Incremental Encoder FG 41 5 Assembly Safety instructions WARNING! At assembly, dismantling and other work to the device the basic safety instructions to chapter 2 must be observed. The assembly, dismantling and other work of the measuring system must only...

  • Page 25: Technical Notes

    21) only with screwed-on mating connectors or blind plugs! Deep groove ball bearings Incremental encoders FG 41 are fitted with maintenance-free, greased "for-life" deep groove bearings. Bearings must be changed by the manufacturer only. Opening the encoder renders the guarantee null and void.

  • Page 26: Mounting Of Fg 41, Construction Type B5 (Flange)

    Incremental Encoder FG 41 Mounting of FG 41, construction type B5 (flange) NOTES! · Mounting example and tightening torques (dimension drawing see chapter 13 ). The installation described below is offered as an example only and may vary according to the coupling and flange type. It is essential to observe the specific instructions provided by the manufacturer of the coupling.
  • Page 27 6. Lightly grease the shaft of the FG 41 (9). 7. Fit the FG 41 (12) into both the centering (8) and coupling hub (4) at the same time. 8. Secure the FG 41 using at least 6 screws and washers (10) distributed evenly around the circumference of the flange (7)! 9.

  • Page 28: Mounting Of Encoders In Construction Type B35 (Flange And Foot)

    2. Secure the coupling hub on the drive shaft (1) with the set - screw (2). 3. Lightly grease the shaft of the FG 41 (3). 4. Align the FG 41 shaft (3) to the drive shaft (1) and insert into the coupling hub.

  • Page 29: Dismantling The Fg 41

    Incremental Encoder FG 41 5. Fix the foot of the FG 41 to the console (8) with the 4 screws M8 and washers (4) supplied. If the unit is fastened with M6 screws, the 4 sleeves (11) must be inserted into the holes.

  • Page 30: Installation / Preparation For Commissioning

    Incremental Encoder FG 41 6 Installation / Preparation for Commissioning Electrical connection Terminal box connection 1. Open the terminal box cover (10) (see Fig. 2). CAUTION! Do not allow moisture to enter the terminal box when the cover is open! 2.

  • Page 31: Emc Requirements

    Incremental Encoder FG 41 EMC requirements WARNING! Deactivation of the safety function due to radiated or conducted interference sources! – Radiated interference sources due to radiophones, lightning strikes in networks, mobile phones and emissions from individual devices can cause malfunctions in the measuring system.

  • Page 32: Emc Conform Wiring Schemes

    Incremental Encoder FG 41 EMC conform wiring schemes 6.3.1 Connection scheme 1 FG 41 1x Ground connection (connection possibilities Avoid ground loops Connect all shields double-sided Shielding must not be interrupted Twisted pair wires (A,/A), (B,/ B) 6.3.2 Connection scheme 2...

  • Page 33: Connection Scheme 3

    Incremental Encoder FG 41 6.3.3 Connection scheme 3 FG 41 1x Ground connection (connection possibilities Avoid ground loops Connect all shields double-sided Shielding must not be interrupted Twisted pair wires (A,/A), (B,/ B)

  • Page 34: Ground Connection - Measuring System

    Incremental Encoder FG 41 Ground connection – measuring system In principle, it is recommended that the ground connection of the measuring system has a good conductive connection to the functional earth of the machine. (Cable with min. 4 mm²). An earthing terminal is provided on the measuring system for this purpose see dimension drawing HM 19 M 114093.

  • Page 35: Permitted Cable Length

    Incremental Encoder FG 41 Permitted cable length The permissible cable length at the transmission of incremental signals depends on the output frequency, the applied supply voltage and the ambient temperature of the measuring system, see the following diagrams. 6.6.1 Analog incremental-signals (SIN/COS) Output frequency in kHz Fig.

  • Page 36: Square Wave Incremental-Signals (Ttl/Htl)

    Incremental Encoder FG 41 6.6.2 Square wave incremental-signals (TTL/HTL) TTL-Interface: Output frequency in kHz Fig. 4: Maximum permissible cable length for TTL interface HTL-Schnittstelle: Output frequency in kHz Fig. 5: Maximum permissible cable length for HTL interface...

  • Page 37: Connection Instructions For Plug Connection

    Incremental Encoder FG 41 Connection instructions for plug connection The electrical equipment features are mainly determined by the variable connection technology. NOTES! The connection can only be made in conjunction with the device-specific pin assignment! When the measuring system is delivered, a printed version of the pin assignment is enclosed and can also be downloaded later.

  • Page 38: Variant 1, Analog Incremental Signals (Sin/Cos)

    Incremental Encoder FG 41 Variant 1, analog incremental signals (SIN/COS) The number of periods / revolution is dependent on the device variant. Resolutions of 1024, 2048 and 4096 periods / revolution are supported. Measuring the signals against 0 V gives the following signal curve: Fig.

  • Page 39: Variant 2, Square - Wave Incremental Signals (Ttl/Htl)

    Incremental Encoder FG 41 Variant 2, square - wave incremental signals (TTL/HTL) The number of pulses / revolution is dependent on the device variant. Resolutions of 1024, 2048 and 4096 pulses / revolution are supported. The output levels are also specified by the factory setting; TTL output stages and HTL output stages are supported.

  • Page 40: Connection Diagram

    Incremental Encoder FG 41 8 Connection diagram 12-pole round plug FG 41T Connection diagram PN 228-400a FG 41K Connection diagram PN 228-410 Terminal box...

  • Page 41: Replacing The Measuring System

    Incremental Encoder FG 41 9 Replacing the Measuring System The following points must be noted when replacing the measuring system: ● The new measuring system must have the same article number (ID) as the measuring system being replaced; any deviations must be expressly clarified with Johannes Hübner Giessen.

  • Page 42: Checklist

    Incremental Encoder FG 41 10 Checklist We recommend that you print out and work through the checklist for commissioning, when replacing the measuring system and when changing the parameterization of a previously accepted system, sign it and store it as part of the overall system documentation.

  • Page 43: Maintenance

    Incremental Encoder FG 41 11 Maintenance WARNING! At inspection of the measuring system and the mounting, the basic safety instructions contained in chapter 2 must be observed. The inspection of the measuring system and the mounting must only be carried out by qualified personnel! The device is maintenance-free.

  • Page 44: Accessories

    Incremental Encoder FG 41 12 Accessories The accessories/spare parts listed below can be ordered from the service address on page 2 if required Mating connector Mating connector: BG-109647 Mounting kit friction-enhancing shims 12.2 Mounting kit friction-enhancing shims, order no.: ID 24806 for enhancing friction in screw connections 4 pcs.

  • Page 45: Coupling

    Incremental Encoder FG 41 Coupling We recommend our zero-backlash, torsio-resistant couplings with fault exclusion HKS(I) 5 (single joint couplings) or HKDS(I) 5 (double joint couplings) for mounting the FG 41. The couplings meet the following requirements: Description Value shock resistance...

  • Page 46: Dimension Drawings

    Incremental Encoder FG 41 13 Dimension drawings FG 41, construction type B5 FG 41 T 12-pole round plug M23 HM 19 M 114093...
  • Page 47 Incremental Encoder FG 41 FG 41 K Terminal box HM 19 M 114100...
  • Page 48 Incremental Encoder FG 41 FG 41 K Mounting Example with screw-on flange and HM 19 M 114343 coupling HKS 522...

  • Page 49: Fg 41 Construction Type B35 (Flange And Foot)

    Incremental Encoder FG 41 FG 41 construction type B35 (flange and foot) FG 41 T 12-pole round plug M23 HM 19 M 113973...
  • Page 50 Incremental Encoder FG 41 FG 41 K Terminal box HM 19 M 114101...
  • Page 51 Incremental Encoder FG 41 Mounting Example construction type B35 and FG 41 K HM 19 M 114336 coupling HKDS 522...

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