4B Encoder-Flex 1024 User manual

INSTRUCTION
MANUAL
REV021224
Approvals
Encoder-Flex 1024
Digital Rotary Encoder
Part Number: EFLEX10242V34CAI/x

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TABLE OF CONTENTS
CUSTOMER SAFETY RESPONSIBILITIES........................................................................5
PRODUCT OVERVIEW.......................................................................................................8
PACKAGE CONTENT ........................................................................................................ 8
SPECIFICATIONS ..............................................................................................................9
APPROVALS ....................................................................................................................10
DIMENSIONS...................................................................................................................11
SPECIFIC CONDITIONS OF USE.....................................................................................12
STANDARD WIRING DIAGRAM ......................................................................................13
INSTALLATION................................................................................................................14
OPERATION.....................................................................................................................16
COMMUNICATION OPTIONS .........................................................................................21
PRODUCT WARRANTY ...................................................................................................28

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CUSTOMER SAFETY RESPONSIBILITIES
4B appreciates your business and is pleased you have chosen our products to meet
your needs.
Please read in its entirety and understand the literature accompanying the product
before you place the product into service. Please read the safety precautions
carefully before operating the product. With each product you purchase from 4B,
there are some basic but important safety considerations you must follow to be sure
your purchase is permitted to perform its design function and operate properly and
safely, giving you many years of reliable service. Please read and understand the
Customer Safety Responsibilities listed below. Failure to follow this safety directive
and the Operation Manuals and other material furnished or referenced, may result in
serious injury or death.
SAFETY NOTICE TO OUR CUSTOMERS
A. In order to maximize efficiency and safety, selecting the right equipment for
each operation is vital. The proper installation of the equipment, and regular
maintenance and inspection is equally important in continuing the proper
operation and safety of the product. The proper installation and maintenance
of all our products is the responsibility of the user unless you have asked 4B to
perform these tasks.
B. All installation and wiring must be in accordance with Local and National
Electrical Codes and other standards applicable to your industry. (Please see
the article “Hazard Monitoring Equipment Selection, Installation and
Maintenance” at www.go4b.com/usa). The installation of the wiring should be
undertaken by an experienced and qualified professional electrician. Failure to
correctly wire any product and/or machinery can result in the product or
machine failing to operate as intended, and can defeat its design function.
C. Periodic inspection by a qualified person will help assure your 4B product is
performing properly. 4B recommends a documented inspection at least
annually and more frequently under high use conditions.
D. Please see the last page of this manual for all warranty information regarding
this product.
CUSTOMER SAFETY RESPONSIBILITIES
1. READ ALL LITERATURE PROVIDED WITH YOUR PRODUCT
Please read all user, instruction and safety manuals to ensure that you understand
your product operation and are able to safely and effectively use this product. If the

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equipment is used in a manner not specified in this manual, the protection provided
by the equipment may be impaired.
2. YOU BEST UNDERSTAND YOUR NEEDS
Every customer and operation is unique, and only you best know the specific needs
and capabilities of your operation. Please call the 24-hour hotline at 309-698-5611
for assistance with any questions about the performance of products purchased from
4B. 4B is happy to discuss product performance with you at any time.
3. SELECT A QUALIFIED AND COMPETENT INSTALLER
Correct installation of the product is important for safety and performance. If you
have not asked 4B to perform the installation of the unit on your behalf, it is critical
for the safety of your operation and those who may perform work on your operation
that you select a qualified and competent electrical installer to undertake the
installation. The product must be installed properly to perform its designed functions.
The installer should be qualified, trained, and competent to perform the installation in
accordance with Local and National Electrical Codes, all relevant OSHA Regulations,
as well as any of your own standards and preventive maintenance requirements, and
other product installation information supplied with the product. You should be
prepared to provide the installer with all necessary installation information to assist
in the installation.
4. ESTABLISH AND FOLLOW A REGULAR MAINTENANCE AND INSPECTION
SCHEDULE FOR YOUR 4B PRODUCTS
You should develop a proper maintenance and inspection program to confirm that
your system is in good working order at all times. You will be in the best position to
determine the appropriate frequency for inspection. Many different factors known to
the user will assist you in deciding the frequency of inspection. These factors may
include but are not limited to weather conditions; construction work at the facility;
hours of operation; animal or insect infestation; and the real-world experience of
knowing how your employees perform their jobs. The personnel or person you select
to install, operate, maintain, inspect or perform any work whatsoever, should be
trained and qualified to perform these important functions. Complete and accurate
records of the maintenance and inspection process should be created and retained
by you at all times.
5. RETAIN AND REFER TO THE OPERATION MANUAL FOR 4B’S SUGGESTED
MAINTENANCE AND INSPECTION RECOMMENDATIONS
As all operations are different, please understand that your specific operation may
require additional adjustments in the maintenance and inspection process essential

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to permit the monitoring device to perform its intended function. Retain the Operation
Manual and other important maintenance and service documents provided by 4B and
have them readily available for people servicing your 4B equipment. Should you have
any questions, please call the 24-hour hotline number 309-698-5611, contact your
local distributor, or use one of the contact ways available in our website
www.go4b.com/usa.
6. SERVICE REQUEST
If you have questions or comments about the operation of your unit or require the unit
to be serviced please call the 24-hour hotline number 309-698-5611, contact your
local distributor, or use one of the ways available in our website www.go4b.com/usa.
Please have available product part numbers, serial numbers, and approximate date of
installation. In order to assist you, after the product has been placed into service,
complete the online product registration section which is accessed via our website
www.go4b.com/usa.
WARNING
Moving parts can crush and cut.
Lockout power before removing guard or servicing.
Do NOT operate with guard removed.

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PRODUCT OVERVIEW
The Encoder-Flex 1024 is a rotary shaft encoder designed to detect shaft speed, shaft
position, gate position, and shaft direction. This solid-state encoder features
electronics that are potted and totally sealed in a stainless steel body and are
completely mechanically isolated from the rotating shaft. Because the shaft does not
enter the sensor body, there are no entry points for moisture and dust ingress.
The Encoder-Flex 1024 comes standard with Modbus RTU communications and can
be programmed from 1 to 1024 targets per revolution with free PC software. This
software also provides a dashboard of the sensor position and calibrated parameters.
The running mode and calibration can be configured using the free software or
included calibration magnet.
The Encoder-Flex 1024 is powered via a 12-24 VDC supply and provides the following
outputs:
•Quadrature Pulse (Speed/Relative Rotation)
•4-20mA or 0-20mA (Speed/Absolute Position/Multi-Turn Absolute Position)
•RS485 Modbus (All Properties)
The quadrature pulse output is a normally dual-channel signal that can be used with
a PNP or NPN input device. See “PNP Pulse Output Wiring Example” for a sample
PNP wiring diagram using just the A channel.
PACKAGE CONTENT
1 x Encoder-Flex 1024
1 x Setup and calibration magnet
1 x High flex securing strap
1 x Instruction manual

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SPECIFICATIONS
Operating Voltage Range 12 VDC to 24 VDC (Optimal) – 26.2 VDC max
Power Max 2W
Speed Range 0-2,000 RPM
Outputs •4-20mA or 0-20 (21mA Max, 330ΩMax)
•Quadrature (500Hz Max)
•Pulse (500Hz Max)
•Modbus RTU (RS485 115200 bps)
Resolution Adjustable 1 to 1024 Pulses Per Revolution
Enclosure 304 Stainless Steel
Shaft Type •M12 (EFLEX10242V34C/
0)
•1/2" – 13 UNC (EFLEX10242V34C/
1)
•D-Type (EFLEX10242V34C/
2)
•3/8” - 16 UNC (EFLEX10242V34C/
3)
Operating Temperature -30°C (-22°F) to +50°C (122°F)
Cable 9 ft. (3m) – Shielded 8 Conductor + Bare Earth
Calibration Magnetic or PC Software
Conduit Entry 1/2” NPT
Weight 1.8lbs (0.8kg)

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APPROVALS
EFLEX1024….CAI…
Class II Division 1 Groups E,F&G T200100°C
AEx / Ex ta IIIC T200100°C Da IP66
-30ׄ°C ≤ Ta ≤ +50°C
MET Labs listing – E115704
EFLEX1024….CAI…
CML23ATEX3223X, CML23UKEX3224X
Ex II 1 D Ex ta IIIC T200100°CDa IP66
-30ׄ°C ≤ Ta ≤ +50°C
IECEx
EFLEX1024….C…
IECEx CML23.0081X
Ex ta IIIC T200100°CDa IP66
-30ׄ°C ≤ Ta ≤ +50°C

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DIMENSIONS
NOTE: Dimensions are in mm

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SPECIFIC CONDITIONS OF USE
1. The Encoder-Flex 1024 shall be connected to a suitable external earth via the
mounting holes or via the mounting screws and a suitable ring crimp.
2. The integral cable shall be terminated in a suitably certified enclosure or in a
safe area.
3. The supply circuit of the system where the equipment is connected shall be
protected by a suitably rated fuse capable of interrupting a prospective short
circuit current of 1.5 kA.

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STANDARD WIRING DIAGRAM
All wiring must be in accordance with local and national electrical codes and should
be undertaken by an experienced and qualified electrician.
If required by local installation code, use dust/liquid tight flexible metal conduit with
approved fittings to protect the sensor cables.
If required, mount a suitable junction box within the supplied length of the product’s
cable and (if required, using a suitable conduit to protect the cables) make the
necessary wiring connections inside this junction box.
Encoder Wire Description
PNP Pulse Output Wiring Example
Conductors x 8 - 24AWG
Drain - 22AWG

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Current Loop Output Wiring Example
PTD110V6 Wiring Example
PTD110V6
Programing
Instructions

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INSTALLATION
The Encoder-Flex 1024 should be mounted to a rotating shaft using the threaded or
D-profile shaft of the encoder. A belt or bracket can be mounted onto the two
recessed screw threads and this can be used to provide further mechanical support
but is primarily for the purpose of stopping slight movements in the device housing.
All installations must conform to the local electrical wiring regulations (such as NEC,
CEC, EN IEC 60079-14).
The below instructions are given in metric to match the hardware provided with the
sensor. The mounting holes for the M6 bolts are thru holes and can be mounted on
either side.

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OPERATION
Layout
The Encoder-Flex 1024’s interface consists of two bi-color (red/green) LED’s labeled
Input and Set. Additionally, in the center of the device is a magnetic target (labeled
CALIBRATE) which can be used to control the operating mode and calibration. A
special calibration magnet is supplied, but any dual pole magnet can be used.
Startup Operation
When powered on, the LED marked (SET) should flash green three times, the LED
marked (INPUT) shows the step progress so may or may not be red.
Operating Modes
The Encoder-Flex 1024 has 3 main operating modes:
•Multi-Turn (Gate Position) – Set LED solid red.
•Continuous Angle – Set LED solid green.
•Speed Mode – Set LED fast green blink.
Each one of these modes has an Analog (current loop) output that is calibrated
when the mode is selected.
MULTI-TURN (GATE POSITION)
Multi turn mode allows the device to be set up to measure proportional angular
position over a number of rotations of the shaft. During normal operation if a North
Pole of a magnet is held over the calibration point, the mode is switched to Multi
Turn Configuration. This sets the start point for the multi turn operation so the shaft
the encoder is connected to should be in its starting location. For example, a gate
should be fully closed(4mA). The user should then operate the machine to its end
point, in the case of a gate this would be fully open (20mA).

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The user then should use the North Pole of a magnet on the calibration point once
more and the end point will be set. The encoder will now continue to monitor the
shaft and will keep track of the proportion of movement between the start and end
points.
The 4-20mA current output is linearly proportional to the current position of the
operating machine. In the event the machine operates past the limits set on the
device the output will remain locked to 0% (4mA) or 100% (20mA).
If the machine/shaft is moved when power is disconnected from the Encoder-Flex
1024 then the device will be able to continue to keep track when powered back on
up to half a turn on the shaft. If the machine/shaft is moved further than this without
power then the Encoder-Flex 1024 will need to be recalibrated for Multi Turn in the
method previously described.
CONTINUOUS ANGLE (360°)
Continuous angle mode indicates that the device will keep track of the angle of the
device’s shaft. The zero of the shaft’s rotational angle is set when this mode is
switched to by using the South Pole on the calibration point.
The output of the 4-20mA current loop when the current output mode is set to Auto
(default) will be proportional to the current angle relative to the users set zero point,
e.g.
•0 degrees = 4mA
•90 degrees = 8mA
•180 degrees = 12mA
•240 degrees = 16mA
•360 degrees = 20mA
If the shaft goes through a full rotation, it will roll over from 360° (20mA) back to 0°
(4mA).
Speed Mode
Speed mode works in a similar manner to continuous angle. The main difference
being that the 4-20 mA current loop will react to rotational speed relative to a
calibrated speed. This mode is accessed by holding the South Pole of a magnet over
the calibration point.

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Once Speed mode is selected, the device will calibrate the 4-20 mA current loop
output based on the shaft speed at that moment. As such it is recommended to first
leave the device in Angle mode, turn on the machine and wait until it achieves 100%
speed before finally using the magnet to set Speed mode.
Once calibrated in this way the 4-20mA output in Auto current mode will display the
following behavior:
•4mA = 0% speed
•17mA = 100% speed
•20mA = 123% speed
The current output is linearly proportional to the speed with 17mA representing
100% of the speed.
Pulse/Quadrature Output
The pulse/quadrature outputs will always output in all 3 modes. The input LED will
match what is currently on the pulse channel A. The pulse rate is determined by the
PPR (pulse per revolution) that can only be set using the software interface. The
default PPR is 64.
During an error state the set LED will flash several times in sequence. And the output
may not act as expected. This flash can be green or red. If this occurs, please note
the color and number of flashes that are repeating and contact 4B for further
instructions.
Changing Mode
The operating mode of the Encoder-Flex 1024 can be switched using the magnetic
target input on the front of the device or via the RS485 Modbus connection (or GUI).
The magnetic target can detect the difference between the North Pole or South Pole
of a magnet that is applied to it. Apply the magnet for 5 seconds or until the SET
LED behavior changes. The information ahead will explain when a North Pole or
South Pole should be used.
Magnetic Setup
Encoder-Flex 1024 Mode Selection and Calibration with magnet (4-20 mA Output)
Set LED
Calibration Point
Magnet

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1. MULTI-TURN MODE (GATE POSITION)
Action
Set LED feedback (Red)
1.1
Turn the shaft to the start position
1.2
Place the red magnet (N) on the
calibration point
1.3
Hold the magnet in place for 3
seconds
1.4
Remove the magnet.
4 mA is set
1.5
Turn the shaft to the end position
1.6
Place the red magnet (N) on the
calibration point
1.7
Hold the magnet in place for 3
seconds
1.8
Remove the magnet.
20 mA is set
2. CONTINUOUS ANGLE MODE (360°)
Action
Set LED feedback (Green)
2.1
Turn the shaft to the start position (0°)
2.2
Place the blue (S) magnet on the
calibration point
2.3
Hold the magnet in place for 3
seconds
2.4 Remove the magnet. 4-20 mA is set
2.5
If light pattern matches as shown
perform steps 2.1-2.4 again.
4 mA
20mA
12 mA
100%
0%
50%
4-20 mA Scale
20/4 mA
8 mA
16 mA
12 mA
360°/0°
90°
180°
270°
4-20 mA Scale

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3. SPEED MODE
Action
Set LED feedback (Green)
3.1
Turn on the machine and wait until it
achieves 100% speed.
3.2
Place the blue magnet (S) on
the calibration point
3.3
Hold the magnet in place for 3
seconds
3.4 Remove the magnet. 4-20 mA is set
Note
If light is solid green preform steps 3.1-
3.4 again.
NOTE
During boot up the set LED will flash green 3 times. This lets you know all systems
are normal.
4 mA
20 mA
17 mA
100%
0%
123%
4-20 mA Scale
Mode Cycle
Flow Chart