EncoderWorks can supply FG2AK-1024G-90G-NG as a custom compatible replacement solution when the installed drive requires 1024 PPR standard scaling, AK terminal-strip wiring, solid-shaft mounting, 0°/90° phase relationship, inverted signal outputs, N reference pulse behavior, EMC cable entry, and 200 kHz counter compatibility to remain unchanged. The main failure boundary is a drive that receives stable square-wave pulses but develops wrong speed scaling, direction reversal, reference loss, terminal-strip wiring errors, or intermittent feedback because the pulse count, shaft coupling, signal assignment, or shielding path has changed. Typical production lead time: 15 working days.
This model belongs to the FG 2 incremental solid-shaft encoder platform for standard drives in heavy industry. The 1024 PPR value is a standard pulse-rate configuration, so replacement work should focus on reference scaling, A/B/N terminal mapping, coupling alignment, IP66 sealing, and EMC-stable cable routing. It should not be treated as an FGHJ hollow-shaft encoder, an AKK two-system version, or an AL fiber-optic configuration.
System Limits
The first system limit is 1024 PPR scaling. If the controller is configured for 600, 1000, 1200, 2048, or another pulse value, the encoder may output clean signals while speed, travel, and position values become wrong. Edge-counting mode, gear ratio, direction logic, and speed conversion should be checked before startup.
The second limit is AK terminal-strip signal assignment. The terminal strip must preserve the installed mapping for 0° channel, 90° channel, N reference pulse, and their inverted outputs. If one phase pair is swapped, one inverted signal is omitted, or the N reference signal is assigned to the wrong input, the machine may fail during homing, direction reversal, or synchronized positioning.
The third limit is solid-shaft mechanical alignment. The replacement must match the shaft interface, coupling position, flange mounting, and installation length required by the machine. Coupling misalignment, excessive radial load, axial preload, shaft shock, or poor centering can create bearing stress and appear as pulse jitter, unstable speed feedback, or reference-pulse repeatability errors.
Wiring & Installation
Before replacement, record the terminal-strip wiring for supply voltage, GND, shield, 0°/90° signal sequence, inverted outputs, N reference pulse, and any status or diagnostic signal used by the machine. Confirm that the receiving counter is scaled for 1024 PPR and that the system expects the same phase sequence and reference-pulse logic.
During mechanical installation, clean the shaft, coupling bore, flange face, centering surface, and fastening threads. Fit the coupling smoothly, avoid hammering the encoder shaft, and keep axial and radial loads within the installed machine boundary. The encoder should sit squarely against the mounting face without forcing the coupling to compensate for alignment error.
For EMC stability, use shielded cable through the correct EMC cable gland, route feedback wiring away from inverter, motor, brake, contactor, and power cables, and maintain a low-impedance shield connection. After commissioning, verify pulse count, direction, N reference repeatability, terminal-strip sealing, shielding continuity, and stable operation through the required speed range.
Custom Compatible Solution
EncoderWorks can configure the replacement around the installed FG 2 solid-shaft and terminal-strip interface:
- Match 1024 PPR square-wave incremental output with 0°/90° channel behavior and inverted signal outputs
- Preserve AK one-system terminal-strip connection, N reference pulse behavior, supply range, output level, and controller input compatibility
- Adapt the solid-shaft mounting interface, flange fit, coupling position, sealing boundary, and cable-entry orientation
- Review 200 kHz counter margin, terminal-strip signal mapping, EMC cable gland, shield grounding, coupling load, and reference-pulse stability
Key Data
| Item | Data |
|---|---|
| Model | FG2AK-1024G-90G-NG |
| Encoder type | Incremental solid-shaft encoder |
| Series | FG 2 |
| Connection structure | AK, one system with terminal strip |
| Pulses per revolution | 1024 PPR |
| Pulse-rate class | Standard pulse rate |
| Signal output | Square wave, 0° and 90° channels |
| Inverted signals | Yes, G output configuration |
| Reference pulse | NG, N reference pulse with inverted signal |
| Supply voltage | 12–30 VDC |
| Output level | HTL, approximately supply voltage; TTL option available |
| Maximum frequency | 200 kHz |
| Protection class | IP66 |
| Shaft / mounting focus | Solid shaft, coupling alignment, flange fit |
| Key replacement checks | 1024 PPR scaling, AK terminal-strip mapping, A/B phase, N reference pulse, EMC shielding |
