English

Operating and Assembly Instructions

Incremental Encoder FG 40

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 FG40_MANUAL-en_R13(2021-06-30)ID77727.docx

ID 77727
 Incremental Encoder FG 40

Trademark
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
Siemensstr. 7
35394 Giessen
Germany
Phone: +49 641 7969 0
Fax: +49 641 73645
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 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.
Johannes Hübner Fabrik elektrischer Maschinen GmbH is listed by Underwriters Laboratories.
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

Type UL model No.

FG 40 (solid shaft) FG 40 K-XXXX
FG 40 K-XXXX-S
FG 40 KK-XXXX
FG 40 L-XXXX
FG 40 L-XXXX-S
FG 40 LL-XXXX
FGH 40 (hollowshaft) FGH 40 K-XXXX
FGHJ 40 K-XXXX
FGH 40 K-XXXX-S
FGH 40 KK-XXXX
FGHJ 40 KK-XXXX
FGH 40 L-XXXX
FGHJ 40 L-XXXX
FGH 40 LL-XXXX
FGHJ 40 LL-XXXX

Subject to errors and changes due to technical improvements.

Copyright © Johannes Hübner

Fabrik elektrischer Maschinen GmbH
All rights reserved.

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Directory
1 General ............................................................................................................................ 5
1.1 Information about the 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
2 Safety ............................................................................................................................... 6
2.1 Responsibility of the owner ........................................................................................ 6
2.2 Intended use .............................................................................................................. 6
2.3 Improper use .............................................................................................................. 7
2.4 Personnel................................................................................................................... 7
2.5 Personal protective equipment ................................................................................... 7
2.6 Special dangers ......................................................................................................... 7
2.6.1 Electrical current .................................................................................................... 7
2.6.2 Rotating shafts / Hot surfaces ................................................................................ 7
2.6.3 Safeguarding against restart .................................................................................. 7
3 Technical Data ................................................................................................................ 8
3.1 Type plates ................................................................................................................ 8
3.2 Electrical and mechanical data ................................................................................... 9
3.2.1 For pulse rates (square wave pulses) .................................................................... 9
3.2.2 Output signals Sine / Cosine ................................................................................10
3.3 Type code .................................................................................................................14
3.3.1 For pulse rates (square wave pulses) ...................................................................14
3.3.2 For output signals Sine / Cosine ...........................................................................15
4 Transport, packaging and storage ...............................................................................16
4.1 Safety instructions for transport .................................................................................16
4.2 Incoming goods inspection ........................................................................................16
4.3 Packaging / disposal .................................................................................................16
4.4 Storage of packages (devices) ..................................................................................16
5 Mounting and commissioning ......................................................................................17
5.1 Safety instructions .....................................................................................................17
5.2 Technical information ................................................................................................17
5.3 Required tools ...........................................................................................................17
5.4 Mounting preparations ..............................................................................................18
5.5 Mounting B5 type (flange) incremental encoders ......................................................18
5.6 Mounting B35 type (flange and foot) incremental encoders .......................................20
5.7 Mounting tolerances for construction type B5 and B35..............................................21
5.8 Attaching additional devices ......................................................................................22
5.9 Electrical connection and start up..............................................................................24
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5.9.1 Preparing cables ..................................................................................................24

5.9.2 Electrical connection.............................................................................................24
6 Dismantling ....................................................................................................................26
6.1 Safety instructions .....................................................................................................26
6.2 Dismantling the encoder ...........................................................................................26
7 Faults ..............................................................................................................................27
7.1 Faults table ...............................................................................................................27
8 Inspections .....................................................................................................................28
8.1 Safety instructions .....................................................................................................28
8.2 Maintenance information ...........................................................................................28
8.3 Inspection schedule ..................................................................................................28
9 Disposal..........................................................................................................................28
9.1 Disposal procedure ...................................................................................................28
10 Replacement parts .........................................................................................................28
11 Dimension drawings ......................................................................................................29
11.1 Construction type B5 (flange) ....................................................................................29
11.2 Construction type B35 (flange and foot) ....................................................................31
11.3 Construction type B5/B14 (flange with 2 shaft ends) .................................................33
11.4 construction type B35/B14 (flange and foot with 2 shaft ends) ..................................35
11.5 Mounting options.......................................................................................................37
11.6 Additional dimension drawings – electrical socket design .........................................39
12 Connection diagrams ....................................................................................................42

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1 General

1.1 Information about the Operating and Assembly instructions

These Operating and Assembly Instructions provide important instructions for working with the device.
They 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

Incremental Encoder FG 40, Operating and Assembly Instructions.

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, 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.

NOTES!
Indicates useful tips and recommendations as well as information for efficient and trouble-
free operation.

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!

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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1.4 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 delivery 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 contacted by telephone, fax or email. See
manufacturer’s address on page 2.

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 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 FG 40 Incremental Encoders are used for measurement of rotations, for instance of electrical
and mechanical drives and shafts.
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.

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2.3 Improper 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.
2.4 Personnel
Installation and commissioning as well as disassembly routines must be carried out by skilled technical staff only.
2.5 Personal protective equipment
Wear personal protective equipment such as safety shoes and safety clothing to minimise risks to health
and safety when carrying out work such as installation, disassembly or commissioning. Adhere to all
applicable statutory regulations as well as the rules and standards determined by the owner.
2.6 Special dangers
Residual risks that have been determined based on a risk assessment are cited below.
2.6.1 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.

2.6.2 Rotating shafts / Hot surfaces

WARNING!
Danger of injury due to rotating shafts and hot surfaces!
Touching rotating shafts can cause serious injuries.
Therefore:
Do not reach into moving parts/shafts or handle moving parts/shafts during operation.
Close to protect from injury all access openings in flanges with the corresponding plug
screw, and provided you exposed rotating components with protective covers.
Do not open covers during operation. Prior to opening the covers ensure that all parts
have come to a standstill.
The encoder can become hot during prolonged use.
In case of contact risk of burns is existing.

2.6.3 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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3 Technical Data

3.1 Type plates

Nameplates for different device variations are shown below

Encoder with one terminal box Encoder with 2 terminal boxes (redundant version)

Encoder with 2 sinusoidal signals Encoder with round plug (not UL-listed)

The type plate is located on the outside of the housing and contains the following information:
Englisch Deutsch
Manufacturer, address Hersteller, Anschrift
Type:Incremental Encoder, Year of manufacture Typ: Inkrementaler Drehgeber, Baujahr
CE mark CE-Kennzeichnung
Serial number (S/N) Seriennummer (S/N)
Pulse rate Impulszahl
Degree of protection Schutzart
Supply voltage Versorgungsspannung
Outputs Ausgänge
Certification (only encoders with UL) Zertifizierung (nur Drehgeber mit UL)
QR-Code QR-Code

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3.2 Electrical and mechanical data

3.2.1 For pulse rates (square wave pulses)

Pulse rates Value
Standard pulse rates 500, 600, 1000, 1024, 1200, 2000, 2048, 2400, 2500
4000, 4096, 4800, 5000, 8192, 10000, 12000, 16000, 16384, 20000,
Special pulse rates 25000, 40000, 50000
(further pulse rates according to customers specification)

Connection data
12 V … 30 V DC
Supply voltage
For UL and CSA Class 2 supplied
No load-current approx. 50 mA at 24 V
Current limited, short-circuit proof push-pull line driver with integrated
Outputs
impedance adaptation for 30 to 140 Ω lines.
approx. as supply voltage, output saturation voltage < 0.4 V at IL 30
Pulse height (HTL)
mA
Output current max. 150 mA at 24 V (observe derating)
Internal resistance 75 Ω bei 24 V
Slew rate 200 V / µs with CL 100 pF

Duty cycle 1 : 1 ± 3 % for standard pulse rates

1 : 1 ± 5 % for special pulse rates up to 25000
pulses

90° ± 3 % for standard pulse rates

Square wave displacement 0°, 90°
90° ± 5 % or special pulse rates up to 25000 pulses

Max. frequency 200 kHz, Higher max. frequency on request

Special output voltage 5V (TTL)

Pulse height 5V, RS422-compatible (TIA/EIA-Standard)

Supply voltage 12 … 30 V DC (optional: 5 V DC)

For UL and CSA Class 2 supplied

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3.2.2 Output signals Sine / Cosine

Pulse rates Value
Standard pulse rates 500, 600, 1000, 1024, 1200, 2000, 2048, 2400, 2500
Connection data
5 V … 30 V DC
Supply voltage
For UL and CSA Class 2 supplied
No load-current Approx. 120 mA at 5 V, approx. 50 mA at 24 V
Max. frequency 200 kHz, higher max. frequency on request

2 sinusoidal signals A and B each with inverted signals

Reference pulse with inverted signal
Output signals Signal amplitude 1 V pp / RL = 120 Ω
Error signal and inverted signal
Signal amplitude 5V

Resolution 1024 signal periodes

Duty cycle 1 ± 0,1

Phase shift A, B 90° ± 1°

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Protection class Sealing Permissible Rotor moment of Breakaway torque

acc. to speed inertia
DIN EN 60529

IP65 Standard ≤ 6000 min -1 510 gcm² 6 Ncm

IP66 with labyrinth seal ≤ 6000 min -1 580 gcm² 6 Ncm

IP66/IP67 with axial shaft ≤ 4000 min -1 510 gcm² 8 Ncm

seal

IP66/IP67 with radial shaft ≤ 3000 min -1 510 gcm² 9 Ncm

seal (for special
applications, e.g.
wet areas in
rolling mills)
(UL and CSA
Type 1)

Encoder temperature ranges

Standard 0°C… + 70°C

Special temperature ranges -25°C… + 85°C

-40°C… + 85°C For UL/CSA max. +70°C
-5°C… + 100°C

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) 150 g (=1500 m/s²)

Fa, max. (axial) = 100 N

Max. encoder shaft load
Fr, max. (radial) = 120 N

Shaft dimensions 11j6 x 30 mm (standard)

14j6 x 30 mm (optional)

Type AK approx. 2,8 kg

Weight Type K approx. 3,1 kg
Type KK approx. 3,6 kg

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Signal outputs

Basic version
Basic channel 0° (A) and pulse channel 90° (B)
Internal system diagnostics with error
output (ERROR)
Each with inverted signals

Option N
N
Reference pulse (N) mechanically defined; one
square-wave pulse per revolution; with inverted N
signal

Option 2F
Twice as many pulses as basic channel by
combining the 0° and 90°channels

Option B
Rapid direction of rotation detection at each
edge of the 0° and 90°channels
Can be combined with Option F

Option B2
Rapid direction of rotation detection at each
edge of the 0° and 90° channels; additional
standstill recognition

Option B3
Rotation-dependent output signals. This option
supports counter cards with separate
UP/DOWN pulse inputs. Basic channel signals
are issued at option output 1 when rotation is
clockwise and at option output 2 when rotation
is counterclockwise.

Option S
See separate Operating and Assembly
Electronic overspeed switch with two Instructions EGS® 40
independently programmable switching points

Fiber optic option

As an alternative to conventional signal Max. frequency 100 kHz
transmissions via copper cables encoder signals
can also be transmitted via fiberoptic cables.

The signal sequence 0°, 90° applies for clockwise rotation seen from the drive shaft direction.
To obtain the same signal sequence for counter clockwise rotation the clamp 0°, 90° has to be
connected see connection diagram.

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Signal outputs for output signals sine / cosine

Basic channel 0° (A) and pulse

channel 90° (B).
Reference pulse (N) mechanically
defined; one square-wave pulse per
revolution; with inverted signal
Each with inverted signal.
Internal system diagnostics with
error output (ERROR).

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3.3 Type code

3.3.1 For pulse rates (square wave pulses)

FG 40 K 1024 G 90G NG 2F S

Incremental encoder

Series
connections, radial design
K: Terminal box
R: Burndy®-plug
C: Connection cable
L: Fiber optic connection
S: 15-pole EMC industrial plug

KK: 2 terminal boxes, i.e. redundant

version or with option S
further combined connections available
connections, axial design
AK: Terminal box
AR: Burndy®-plug
AC: Connection cable
Pulses per revolution
Basic signal output
Basic channel 0° (A)
Pulse channel 90° (B)
Each with inverted signals
NG: Option reference pulse with inverted signal
N2: Reference pulse, mechanically fixed with
LED check (red)
for display of reference pulse
2F: Option 2F
B: Option B
B2: Option B2
B3: Option B3
S: Option S
Options see pages before

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3.3.2 For output signals Sine / Cosine

FG 40 K 1024 S N

Incremental encoder

Series
connections, radial design
K: Terminal box
R: Burndy®-plug
C: Connection cable
L: Fiber optic connection
S: 15-pole EMC industrial plug

KK: 2 terminal boxes, i.e. redundant version

Resolution
1024 signal periods per revolution
Output signals
2 sinusoidal signals A and B each with inverted signals
NG: Option reference pulse with inverted signal

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4 Transport, packaging and storage

4.1 Safety instructions for 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.

4.2 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).

4.3 Packaging / disposal

The packaging is not taken back and must be disposed of in accordance with the respective statutory
regulations and local guidelines.

4.4 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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5 Mounting and commissioning

5.1 Safety instructions

Personnel
Installation and commissioning must be carried out by skilled technical staff only.

NOTES!
Observe the safety instructions contained in Chapter 2 when installing or working on the
device!

5.2 Technical information

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!

Ambient temperature
The max. permissible ambient temperature depends on the speed and degree of protection of the
device, the signal frequency, the length of the signal cable and the place of installation (please refer to
Chapter 3.2).

Degree of protection
To fulfil degree of protection requirements the diameter of the connection cable must correspond to that
of the cable gland (please refer to Chapter 11 dimension drawings)!

Deep groove ball bearings

FG incremental encoders 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.

Screw retention
We recommend using Loctite® 243 threadlocker (medium strength) on all fastening screws to prevent
loosening.

5.3 Required tools

 Spanners: 10 mm, 22 mm, 24 mm
 Allen keys: 2 mm, 3 mm
 Flat-blade screwdrivers:
 Assembly grease
 Loctite® 243 (medium strength threadlocker)

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5.4 Mounting preparations

1. Ensure all accessories are available (please refer to Chapter 11 Dimension drawings).

NOTES!
Fastening screws and earth cable are not included in the range of supply.

2. Preparing the place of attachment: Clean the (motor) shaft, centering, bolting surfaces and fastening
threads; check for damage. Repair any damage!

5.5 Mounting B5 type (flange) incremental encoders

NOTES!
For a mounting example please refer to dimension drawing HM 09 M 57 263a (Chapter 11.1).

1
2
)
3
4
5
6
7
8

9
10
11

12
13
14

15
Figure 1: FG 40 construction type B5 16
17

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1. Lightly grease the (motor) shaft (1) and centering (9).

2. Fit coupling (2) onto (motor) shaft.

NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!

3. Secure the coupling hub on the (motor) shat with a grub screw or cheese head screw (10) (depending
on the coupling type).

4. Fasten the intermediate flange (3) to the motor using the fastening screws (12).

NOTES!
If possible, fit the intermediate flange in a manner that ensures the screwed sealing plug
(14) points downwards!

5. Lightly grease the encoder shaft (5) and centering (4).

6. Fit the encoder (8) into both the centering (4) and coupling hub at the same time.

NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!

NOTES!
If possible, fit the device in a manner that ensures the cable gland points downwards
Exchange the position of the cable gland (16) and the blanking plug (15), if necessary.

7. Secure the encoder with 4-6 screws (6) evenly distributed around the circumference of the flange.

8. Remove the sealing plug (14) from the access bore (13) to the coupling.

9. Secure the coupling hub on the encoder shaft with a grub screw or cheese head screw (11)
(depending on the coupling type).

NOTES!
To carry out this task, it may be necessary to turn the (motor) shaft to the correct position.

10. Replace the sealing plug (14) to seal the access bore to the coupling.

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5.6 Mounting B35 type (flange and foot) incremental encoders

NOTES!
B35 type encoders can be attached by means of a flange (B5, please refer to Chapter 5.5) or
foot (B3):
For a mounting example please refer to dimension drawing HM 09 M 102 240a (Chapter 11.2).

16

1
2 17

19

10
11
5
18

Figure 2: FG 40 construction type B35

20

1. Lightly grease the (motor) shaft (1).

2. Fit coupling (2) onto (motor) shaft.

NOTES!
You must be able to mount the coupling without force. Ream out the bores of used
couplings, if necessary!

NOTES!
We recommend our zero-backlash, torsion-resistant double-joint coupling HKD5 to
attach B35 type encoders. Please refer to the catalogue Torsion Resistant Couplings for
Encoders.
3. Secure the coupling hub on the (motor) shaft with a grub screw or cheese head screw (10)
(depending on the coupling type).

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4. Align the encoder shaft (5) to the (motor) shaft and insert into the coupling hub.

NOTES!
Use shims (19) to achieve the correct vertical alignment to the base plate (20).
Observe information in Chapter 5.7about mounting errors and max. permissible
mounting tolerances!

5. Fasten encoder foot with 4 M6 hexagon head screws (18).

6. Secure the coupling hub on the encoder shaft with the grub screw or cheese head screw (11)
(depending on the coupling type).

5.7 Mounting tolerances for construction type B5 and B35

NOTES!
Angle misalignment and parallel displacement between the (motor) shaft and the encoder
shaft are mounting errors and should be kept as small as possible.
Mounting errors
- Cause radial forces to act on the encoder shaft.
- Reduce the service life of the bearings and the coupling.
- Degrade the quality of the signals (harmonic content).

Mounting tolerances for our zero-backlash, torsion-resistant couplings HK5 and HKD5:

Coupling Axial offset Angular error Parallel offset

HK 5 ± 1 mm 0.5° -

HKD 5 ± 1.5 mm 0.5° 0.5 mm

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5.8 Attaching additional devices

NOTES!
Encoders in construction type B5/B14 have a second shaft end with integrated coupling
half (1) and a B 14 flange (2) on the non-drive end onto which it is possible to fit an
additional device with a B5 flange, for example an incremental encoder, absolute shaft
encoder or an overspeed switch. A second coupling half with elastomer ring (5, Figure 4),
which is available as an accessory, is required to fit an additional device.
Installation example see dimension drawing HM 09 M 102 245 (Chapter 11.5).
This design option makes it possible to combine up to four devices.

1
2
3
4

Figure 3:

When supplied ex works the second shaft end is protected by a cover plate (3) secured with 6x M6x20
hexagon head screws (4).

CAUTION!
Do not remove the housing cover secured with Torx screws! These devices are not
equipped with a second shaft end.

1. Loosen the hexagon head screws (4).

NOTES!
The fastening screws (4) can be used later to secure the additional device (7).

2. Remove the cover plate (3).

NOTES!
Ensure no liquids or dirt are allowed ingress into the device when the cover plate is
removed.
Mount the cover again, if you experience installation delays.

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WARNING!
If no second device is added ensure the cover plate is fitted to protect and cover the
second shaft end.

Figure 4:
5

3. Slide on the coupling half (5) with elastomer ring up to the collar of the shaft of the additional
device (7), and secure by tightening the grub screw (6).

NOTES!
The correct distance between both coupling halves has now been set.

Figure 5:
2 4 7

4. Mount the attachment (7) to the B 14 flange (2) of the rotary encoder.

5. Fix the attachment (7) with 6 x hex bolts M6 x 20 – 8.8. For this step the mounting screws (4)
of the cover can be used.

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5.9 Electrical connection and start up

NOTES!
You must observe applicable EMC guidelines when routing cables!

NOTES for UL and CSA!

Do only use copper cables!

5.9.1 Preparing cables

1. Strip cable insulation.

2. Crimp wire-end ferrules.

5.9.2 Electrical connection

1. Open the terminal box cover (16, Fig.1).

CAUTION!
Do not allow moisture to enter the terminal box when the cover is open!

2. Remove the cap of the cable gland (17, Fig. 1).

3. Feed the cable into the terminal box trough the cable gland.

NOTES!
The signal cable shielding can be connected directly to the housing via the EMC cable
gland. A coil spring integrated in the cable gland ensures all-round contact is made with
the bare cable shielding to ensure a good shield connection. This type of shield connection
should be preferred.
Alternatively, if equipotential boning currents are anticipated it is possible to connect the
cable shielding to a shield terminal in the terminal box. A capacitor between the shield
terminal and the encoder housing prevents the flow of equalizing current.
To achieve an effective shielding the cable shield must also be connected in the electrical
cabinet.

4. Tighten the cable gland and blanking plugs using a spanner.

NOTES!
Prior to delivery cable glands and blanking plugs are tightened finger tight only. To ensure
that the terminal box is reliably sealed tighten all cable glands and blanking plugs before
starting up for the first time.
5. Use a spanner to tighten the cable gland until the cable is securely clamped and properly sealed.

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NOTES!
Prevent lateral pulling forces acting on the cable and plugs so as not to impair the degree
of protection of the cable gland.

6. Connect the supply voltage and signal cable (please refer to the connection diagrams, Chapter
11).

CAUTION!
Do not apply supply voltage to the signal outputs, as this will destroy the device!

7. Applicable to alternative shield connection only: fit cable lug to cable shield and connect to the
shield terminal (please refer to the connection diagrams, Chapter 12).

NOTES!
To achieve a good shielding effect the cable shield be kept as short as possible.

8. Close the terminal box cover.

NOTES!
Before closing the terminal box cover check and if necessary clean both seal surfaces
and the gasket.

CAUTION!
Ensure when closing the terminal box cover that no cable becomes jammed.

9. Secure earth cable to earth terminal (7).

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6 Dismantling
6.1 Safety instructions
Personnel
Dismantling must be carried out by skilled technical staff only.

WARNING!
Observe the safety instructions contained in Chapter 2 when inspecting or working on
the device!

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!

6.2 Dismantling the encoder

Remove all electrical cables from the device before dismantling. To dismantling the encoder follow the
instructions given in Chapters 5.5 and 5.6 or 5.8 in the reverse order.

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7 Faults

7.1 Faults table

Faults Possible cause Remedy

Soiled terminal box gasket or Clean terminal box gasket and

seal surfaces seal surfaces

Damaged terminal box gasket Replace terminal box gasket

Moisture in the terminal box Cable gland/blanking plug not Tighten cable gland/blanking
tightened plug

Unsuitable cable for cable gland Use suitable cable and cable
glands

Supply voltage not connected Connect supply voltage

No output signals
Connection cable reversed Wire correctly

Unsuitable cable Use data cable with conductors

arranged as twisted pairs and
common shield
Output signals subject to
Cable shield not connected Connect cable shield at both
interference
ends

Cable routing not EMC Observe applicable EMC

compliant guidelines when routing cables

Signal end stage overloaded Check pin assignment; observe

connection diagram

Do not assign unused outputs

Signal interruptions

Outputs short-circuited Do not connect outputs with

supply voltage or GND

Contact Hubner-Service (page 2) if none of the remedies listed above provides a solution)!

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8 Inspections

8.1 Safety instructions

WARNING!
Skilled technical staff only are permitted to inspect the device and its installation.
Observe the safety instructions contained in Chapter 2 when inspecting or working on
the device!

8.2 Maintenance information

The device is maintenance-free. However, to guarantee optimum fault-free operations we recommend
that you carry out the following inspections.

8.3 Inspection schedule

Interval Inspections

Inspect the coupling for damage and ensure it is free of play

Ensure the fastening screws are properly tightened

Yearly
Ensure cable connections and connection terminals are
securely seated

Following approx 16 000 … 20 Check deep groove ball bearings are running smoothly and
000 hours of operation / higher listen for running noises
levels of continuous load

9 Disposal

9.1 Disposal procedure

The manufacturer is not obliged to take back the device.
The device is classed as electronic equipment and subject to the WEEE Directive; observe local,
country-specific laws when disposing of the device.
For information on environmentally sound disposal please contact your local authority or a specialist
disposal company.

10 Replacement parts
The replacement parts listed below can be obtained via the service address on page 2.
Replacement parts Comment

Cover Cover for the 2nd shaft end or for the hollow shaft bore (gAS)

Cable gland M 20 x 1.5

Terminal box cover Including flat seal and screws

Feather key Specify shaft dimensions or feather key dimension

Programming cable and software

Screw plug For closing the access to the coupling

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11 Dimension drawings
Further dimension drawings on our website or on request.

11.1 Construction type B5 (flange)

FG 40 K With radial terminal box HM 08 M 57 221a

FG 40 AK With axial terminal box HM 08 M 57 024a

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FG 40 KK Redundant version HM 08 M 57 223a

Mounting example for construction type B5

FG 40 K HM 09 M 57 263a
with flange and coupling HK 522

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11.2 Construction type B35 (flange and foot)

FG 40 K With radial terminal box HM 08 M 57 222a

FG 40 KK Redundant version HM 08 M 57 224a

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Mounting example for construction type B35

FG 40 K HM 09 M 102 240a
With coupling HKD 522

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11.3 Construction type B5/B14 (flange with 2 shaft ends)

Construction type B5/B14

FG 40 K HM 09 M 102 541
(flange with 2 shaft ends)

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FG 40 KK redundant version HM 09 M 102 549

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11.4 construction type B35/B14 (flange and foot with 2 shaft ends)

construction type B35/B14

FG 40 K HM 09 M 102 280
(flange and foot with 2 shaft ends)

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FG 40 KK redundant version HM 09 M 101 548

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11.5 Mounting options

FG 40 K FG 40 K with coupled unit HM 09 M 102 245

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FG 40 KK FG 40 KK with coupled unit HM 09 M 102 627

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11.6 Additional dimension drawings – electrical socket design

additional dimension drawing

FG 40 R/RR HM 09 M 102 270
electrical socket design FG 40 R/RR

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additional dimension drawing

FG 40 L/LL HM 09 M 103063
electrical socket design FG 40 L/LL

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additional dimension drawing

FG 40 S/SS electric connection implementation FG 40 S/SS HM 12 M 105755
15 pole EMC

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12 Connection diagrams

Shielding:
The shield of the signal cable can be
connected
directly to the housing of the encoder by the
cable gland. Alternatively the shield of the
signal cable can be connected to K11 via a
capacitor(10nF / 500V) to the housing of the
encoder.

FG 40 Standard Terminal box

10 pole printed circuit spring terminal block

type Phoenix ZFKDS

Connection data:
wire section
0,2-1,5 [mm²]

Alternative Shielding

FG 40 Standard without reference pulse Terminal box

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Socket insert view

Crimp contacts for

cross-sectional
data of wire from
0,52 up to 1,5 mm²

Shield:
The shield of the signal cable is
directly to be connected with the
socket housing.

Crimping tool: Burndy® No. MR 8 GE 5

FG 40 Standard (not for UL/CSA) Burndy® plug

Connection cable

6x2x0,56 twin-standard, shielded

Type: HE-2LVCC-CY AWG 20b

acc. to VDE 0881

Cross-section: 0,56 mm²

Temperature: -20 °C to + 105 °C
Outside dia: 10,1 mm

shield is connected to casing

other cables- / temperature ranges

on request

FG 40 Standard (not for UL/CSA) Connection cable

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12 pole printed circuit spring terminal block type

Phoenix ZFKDS

Connection data:
Wire section
0,2-1,5 [ mm² ]

Shielding:
The shield of the signal cable can be connected
directly to the housing of the encoder by the
cable gland. Alternatively the shield of the cable
can be connected to K13 via a capacitor (10nF /
500V) to the housing of the encoder.

Alternative Shielding

FG 40 Option 2F Terminal box

10 pole printed circuit spring terminal block

type Phoenix ZFKDS

Connection data:
Wire section
0,2-1,5 [ mm² ]

Shielding:
The shield of the signal cable can be connected
directly to the housing of the encoder by the
cable gland. Alternatively the shield of the cable
can be connected to K13 via a capacitor (10nF /
500V) to the housing of the encoder.

Alternative Shielding

FG 40 Option B Terminal box

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12 pole printed circuit spring terminal block type

Phoenix ZFKDS

Connection data:
Wire section
0,2-1,5 [ mm² ]

Shielding:
The shield of the signal cable can be connected
directly to the housing of the encoder by the
cable gland. Alternatively the shield of the cable
can be connected to K13 via a capacitor (10nF /
500V) to the housing of the encoder.

Alternative Shielding

FG 40 Option B2 Terminal box

10 pole printed circuit spring terminal block type

Phoenix ZFKDS

Connection data:
Wire section
0,2-1,5 [ mm² ]

Shielding:
The shield of the signal cable can be connected
directly to the housing of the encoder by the cable
gland. Alternatively the shield of the cable can be
connected to K13 via a capacitor (10nF / 500V) to
the housing of the encoder.

Alternative Shielding

FG 40 Option B3 Terminal box

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FG 40 connection sheme PN 109-470 terminal box

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FG 40 connection sheme PN 109-415 (nicht für UL/CSA) EMC industrial plug

FG 40 connection sheme 649 Option S(nicht für UL/CSA) Burndy plug

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FG 40 connection sheme 148 400b Sine /cosine output

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