Avtron SMARTSafe XR4F User manual

XR4F 1
8901 E. PLEASANT VALLEY ROAD • INDEPENDENCE, OHIO 44131-5508
TELEPHONE: [phone]
• FAX: [phone]
E-MAIL: [email protected]
• WEB: www.avtronencoders.com
Encoder Instructions
XR4F SMARTSafe™
SOLID SHAFT B10 FLANGE
OR FOOT MOUNT
FOR HAZARDOUS APPLICATIONS
DESCRIPTION
The Avtron Model XR4F, SMARTSafe™ is a heavy duty incremental
encoder for hazardous atmosphere applications (also known
as tachometer or rotary pulse generator). Its output is directly
proportional to shaft position (pulse count) or speed (pulse rate). The
XR4F operates down to zero speed and can be used for both control
and instrumentation applications.
CAUTION
The XR4F is designed for use in hazardous applications
which require protection from gas or dust ignition for
safe operation. Proper selection, wiring and installation
procedures are essential to ensuring safe conditions.
The XR4F is designed for mounting on European B10 style flanges
(85mm flange, 100mm bolt circle), or on a foot mount bracket for
coupling. The XR4F is not recommended for pulley or chain drive
applications.
The XR4F utilizes magnetoresistive sensors. This proven technology
is ideal for rugged environments since it is immune to many
contaminants that cause optical encoders to fail. All of the XR4F
electronics are potted, providing full protection against liquids.
The outputs are protected against short circuits and wiring errors.
Each XR4F has a two-phase output (A, B) 90° out of phase, with
complements (A
–, B –), (A Quad B Output). A marker pulse with
complement (Z, Z
–) is also present.
The XR4F has a diagnostic package that includes Adaptive Electronics
and a Fault-Check output and red/green LED for local indication. With
this package, the XR4F can maintain itself, and provide an alarm if
there is a problem before the problem causes unscheduled downtime.
ADAPTIVE ELECTRONICS
A perfect duty cycle consists of a waveform whose “high” and
“low” conditions are of the same duration (50%/50%). It is possible
over time for the duty cycle and edge separation to change due
to component drift, temperature changes, or mechanical wear.
The Adaptive Electronics extend the life of the XR4F by constantly
monitoring and correcting duty cycle and edge separation over time.
The XR4F has been evaluated to be compliant with IEC60079-0:2007,
IEC60079-11:2011, EN60079-0:2009, EN60079-11:2012,
BSEN 61000-6-4:2007 and BSEN61000-6-2:2005 (Certificates of
conformity: TRAC12ATEX0002X, TRAC12ATEX 0003X, IECEx TRC
12.0009X, and IECEx TRC12.0001X.)
THE XR4F IS CERTIFIED FOR USE IN:
Group II, Category 2 (ATEX Zone 1), Gas Group IIC potentially
explosive atmospheres when marked CE 0539 Ex II 2 GD, Ex ib
IIC T4 Gb -40°C < Tamb < 80°C and used with an Avtron isolator
marked CE 0539 Ex [II 2 GD] [Ex ib IIC Gb] -40°C<Tamb<80°C.
Group II, Category 2 (ATEX Zone 21), Dust Group IIIC potentially
explosive atmospheres when marked CE 0539 Ex II 2 GD, Ex ib
IIIC T200°C Db -40°C<Tamb<80°C and used with an Avtron isolator
marked CE 0539 Ex [II 2 GD] [Ex ib IIIC Db] -40°C<Tamb<80°C .
Group II, Category 3 (ATEX Zone 2), Gas Group II_* potentially
explosive atmospheres when marked CE Ex II 3 GD, Ex ic IIC* Gc
T4 -40°C<Tamb<80°C
*see chart in specification section and used with a power supply
that limits voltage and current per the chart in the specification
section.
Group II, Category 3 (ATEX Zone 22), Dust group IIIC potentially
explosive atmospheres when marked CE Ex II 3 GD, Ex ic IIIC T
200°C Dc -40°C<Tamb<80°C.
See installation section for electrostatic charging hazard instructions
and other limitations.
INSTALLATION
WARNING
Installation should be performed only by qualified
personnel. Safety precautions must be taken to ensure
machinery cannot rotate and all sources of power are
removed during installation.
Equipment Group II, Category 2 (Zone 1), Gas group IIC, Dust
group IIIC (ATEX Zone 21): Available as a system only including
XR4F with line driver option 5 and an Avtron Isolator module XRB1
(P/N B35134).
System parameters are:
Um= 250V
Uo (open circuit voltage) = 7.14VDC max.
Io (short circuit current) = 420mA max.
Co (system capacitance) = 13.5uF max.
Lo (system inductance) = 0.15mH max.
Encoder parameters are:
Ui (input voltage) = 7.14VDC max.
Ii (fault current) = 420mA max.
Ci (internal capacitance) = 11.9uF max.
Li (internal inductance) = 0mH max.
The isolator XRB1 can be supplied as a separate module for location
in a safe area or in an explosion proof box on a short flexible cable
tethered to the encoder.
Equipment Group II, Category 3 (Zone 2), Gas group IIC, Dust
group IIIC (ATEX Zone 22): Requires an XR4F with line driver option
7 and a SELV (Energy Limited) or equivalent power supply which limits
voltage and current to the values in the table in the specifications.
If current limit is not inherent in the power supply a separate fuse
between the power supply and encoder can be used to limit current.

XR4F 2
NOTE:
Isolators, encoders and cable must be selected and
installed in accordance with the latest edition of
IEC/EN60079-14 and IEC/EN60079-25. Cable
characteristics must comply with IEC/EN60079-14 and
IEC/EN60079-25 and for zone 1 applications total
system capacitance between the isolator and encoder
(including cable) must be less than Co-Ci. Total system
inductance between the isolator and encoder must be
less than Lo-Li.
The equipment is intended for a fixed installation and
should be mounted so as to avoid electrostatic charging.
The XR4F is not considered as a safety device and is
not suitable for connection into a safety system.
The XR4F construction materials contain less than 6% magnesium
by mass. These materials are not considered as able to trigger
an explosion in normal operating modes in accordance with the
requirements for category 2 or 3 equipment. These materials are
not known to react with any explosive atmospheres to which the
XR4F may be subject. It is however the responsibility of the end
user to ensure that the XR4F is selected correctly for the potentially
explosive atmosphere in which the equipment is to be put into
service.
The XR4F installation is similar to AV45.
Refer to the back page of these instructions for outline and mounting
dimensions.
Equipment needed for installation
Supplied:
XR4F Encoder
(6) M6 x 16 Hex Head Screws
Optional:
Foot Mount Kit
Thread Locker (blue)
Not Supplied:
Open ended wrench 10mm
M4 hex wrench
Dial Indicator Gauge
Caliper Gauge
The encoder must be driven by a positive drive rather than a friction
drive. The following means of coupling are acceptable when properly
installed: Direct Coupling.
With a direct drive, use a flexible disc coupling and align the shafts as
accurately as possible. For motors with a pre-aligned flange, it is also
acceptable to use a “spider” or “jaw” coupling type. If a rubber slinger
disc is used, position it on the shaft so it will rotate freely.
CAUTION
Do not force or drive the coupling onto the shaft, or
damage to the bearings may result. The coupling
should slide easily on the shaft. Remove nicks and
burrs if necessary. Consider driving shaft endplay &
axial movement when positioning coupling.
For more details on alignment specifications, measurement
techniques, and special considerations in specifying and installing
drive components, refer to separate installation instructions in the
Avtron pulse generator handbook.
B10 FACE MOUNTING INSTRUCTIONS
1) Apply anti-seize compound [copper], included, to inner
circumference of coupling (both motor and encoder side).
2) Loosen set screws in coupling and apply thread locker to set
screws.
3) Place coupling on motor shaft, inserting to depth per
manufacturer’s instructions.
4) Attach coupling to motor shaft using set screws per
manufacturer’s instructions.
5) Bolt mounting flange (flowerpot) to motor C-Face, using thread
locker with fasteners, included.
6) Slide encoder shaft into other side of coupling. DO NOT FORCE.
Ensure keyway aligns with coupling set screw location.
7) Ensure C-Face on mounting flange matches and aligns with
encoder C-Face precisely.
8) Apply thread locker to hex cap screws.
9) Align bolt holes of encoder and flange, thread in hex cap
screws, using lock washers.
10) Tighten set screws on encoder side of coupling.
FOOT MOUNTING INSTRUCTIONS
Equipment needed for installation
Supplied:
1. Foot Bracket
2. (6) M6 button head cap screws
Not Supplied:
M4 Hex Wrench
Dial Indicator
The B10 flange / face is the preferred mounting method for the XR4F.
In certain cases, however, it may be necessary to foot-mount this
unit. The optional foot mounting bracket kits, Option 1, 2, or 3, will be
required for standard installations or replacement of foot mounted
Toshiba TS2113N, Hubner HOG & OG, and FG4 units.
Read all of the following instructions and the Avtron pulse generator
handbook prior to beginning any work.
The XR4F performance and life will be directly affected by the
installation. Following this sequence of steps is recommended.
1) Clean and inspect motor/driver shaft. Do not use force to
assemble coupling onto motor/driver shaft. The foot mounting
bracket must be secured to a flat, rigid, vibration free steel or
aluminum base which can be machined to accept the
mounting hardware.
2) Temporarily mount the XR4F to the foot bracket, install the
coupling to the XR4F and driver, and verify that the location is
suitable for installation.
3) If the XR4F encoder, bracket and coupling are suited to the
area, check motor/encoder shaft alignment with a straight
edge from multiple positions around the shaft circumference to
verify that it meets specifications.
4) While maintaining alignment, precisely mark the position of the
foot bracket on its mounting base.
5) Remove the XR4F. Transfer punch or layout the mounting hole
pattern as indicated on outline drawing.
6) Machine through holes or tap holes
in center of base slots to give some degree of freedom in final
alignment.
7) Reinstall the XR4F with the flexible coupling loosely in place,
and tighten down all mounting hardware. Check
motor/encoder shaft alignment with a straight edge from
multiple positions around the shaft circumference to verify that
it meets specifications.
8) Ensure any flat or keyway on the motor and encoder shaft are
aligned with the set screw holes of the flexible coupling. Apply
thread locker to coupling set screws and tighten per
manufacturer’s recommendations.
9) Recheck alignment and tighten all hardware after first several
hours of operation.

XR4F 3
VARIATION > ± 15%
PHASE A
PHASE B
MODIFICATION
The XR4F can be modified to easily adapt to new applications.
CAUTION
Do not attempt to modify the electrical connector
options of the XR4F while located in a hazardous
location or atmosphere. Doing so may create a severe
spark hazard which can result to damage to property,
injury, or even death.
TO CHANGE ELECTRICAL CONNECTOR STYLE:
1. Remove electrical power and disconnect the mating plug.
2. Unscrew the (4) M5 screws (4mm hex).
3. Pull the connector header away from the encoder gently.
4. Disconnect the ribbon connector to the encoder body.
5. Connect the ribbon connector to the new connector header
6. Attach the new connector header to the encoder using the (4) M5
screws. Tighten to 30 in-lbs [3.4n-m]. Be sure the ribbon
connector fits in the open pocket under the header and is not
crushed or pinched by the connector header.
WIRING
CAUTION
Be sure to remove power before wiring the encoder.
Be sure to ground the cable shield: Avtron recommends
grounding the shield at the isolator module for Zone 1
applications or in the drive cabinet for Zone 2
applications. Cable should not be grounded multiple
places. An intrinsic safety ground is required at the
XRB1 Isolator Module.
CAUTION
SMARTSafe encoders include a local ground lug for
customer convenience and encoder frame grounding if
required to meet local electric code requirements or
site operator protection standards. This is NOT the
required XRB1 intrinsic safety ground connection
required for hazard protection against ignition of
explosive atmospheres! Wiring diagrams are shown in
the following pages.
Wiring diagrams are shown in the following pages.
CAUTION
Zone 1 and Zone 21 applications utilize the XRB1
isolator which requires an intrinsic safety ground
to provide hazard protection. Failure to connect this
ground, or providing an inadequate safety ground path
could result in an spark/ignition hazard which can
result in property damage, injury, or even death.
Refer to the wiring diagrams and pinout and phasing tables for
specific information on each option.
The XR4F can be wired for single phase or two phase, either with
or without complements, with or without markers. For bidirectional
operation, Phase A channel typically leads phase B channel for
clockwise shaft rotation as viewed from the anti-drive or accessory
end of the motor (XR4F mounting end). See pinout and phasing tables
for exceptions
NOTE
Wiring option “G” provides a pinout compatible with
NorthstarTM encoders, with a cable shield connection
on pin 10. Note that this option does not ground the
shield.
CORRECTIVE ACTION FOR PHASE REVERSAL
1) Remove Power.
2) Exchange wires on cable, either at encoder cable end,
or at speed controller end (but not both).
a) Single Ended 2 Phase Wiring (see wiring diagram)
Exchange A with B
b) Differential 2 Phase Wiring (see wiring diagram)
Exchange either A with A– in the phase A pair OR
B with B– in the phase B pair but NOT both.
3) Apply Power.
4) Verify encoder feedback is correct, using hand rotation
of shaft, or jog mode of the speed controller.
Interconnecting cables specified in the wire selection chart are
based on typical applications. Cable must be selected and installed
in accordance with IEC/EN60079-14 and IEC/EN60079-25. Physical
properties of cable such as abrasion, temperature, tensile strength,
solvents, etc., are dictated by the specific application. General
electrical requirements are: stranded copper, 20 through 16 AWG
(Industrial EPIC connector type options can use 14 AWG), each wire
pair individually shielded with braid or foil with drain wire, .05 uf of
maximum total mutual or direct capacitance, outer sheath insulator.
See specifications for maximum cable length. Stranded 20 AWG wire
should not be used for cable runs greater then 61 meters. If 20 AWG is
used with EPIC type connector options the wire ends should be tinned.
FAULT-CHECK
After power-up and the rotor position is checked by the sensor, the
Fault-Check LED will turn green.
If the adaptive electronics reach their adjustment limit for any reason,
the Fault-Check alarm and LED will notify the drive and operator of
an impending failure. The LED will turn red if the Adaptive Electronics
reach their adjustment limit. This output occurs before an actual
failure, allowing steps to be taken to replace the unit before it causes
unscheduled downtime. Fault-Check annunciation is available as an
“alarm” output through the connector (zone 2 configurations only) and
as an integral LED.
TROUBLESHOOTING
If the drive indicates a loss of encoder/tach fault and the XR4F
fault-check LED is not illuminated, check the encoder power supply.
If power is present, check polarity; one indicator of reversed power
supply is that all outputs will be high at the same time. If the drive
indicates encoder fault, but the LED shows GREEN, then check the
wiring between the drive and the encoder. If the wiring appears
correct and in good shape, test the wiring by replacing the XR4F. If the
new unit shows GREEN, and the drive still shows encoder loss/tach
fault, then the wiring is faulty and should be repaired or replaced.
If the alarm output and/or LED indicate a fault (RED) on a properly
mounted XR4F and the rotor is properly located, replace the XR4F.
An oscilloscope can also be used to verify proper output of the
XR4F encoder at the encoder connector itself and at the drive/
controller cabinet. If the outputs show large variations in the signals
at steady speed (jitter or “accordion effect”, see figure 5), replace any
magnetized material nearby with non-magnetic material (aluminum,
stainless) (shafts, etc). If variations persist, consider replacing with
super-shielded models, option -004.

XR4F 4
XR4F PART NUMBERS AND AVAILABLE OPTIONS
Model Shaft Size
Left
Output
PPR
Right
Output
PPR
Line Driver Connector Options Foot Mount Bracket Channels Modifications
XR4F N
- 10mm
H - 11mm, standard
T - 18mm
AF -60
AG -100
AH -120
AA -128
AL -240
AN -256
AP -300
AE -360
AB -480
AQ -500
AR -512
AS -600
AV -900
AJ -960
AW -1000
AY -1024
AZ -1200
CX -1500
A3 -2000
A4 -2048
A5 -2500
AD -4096
A8 -4800
A9 -5000
A0 -Special
XX -None
AF -60
AG -100
AH -120
AA -128
AL -240
AN -256
AP -300
AE -360
AB -480
AQ -500
AR -512
AS -600
AV -900
AJ -960
AW -1000
AY -1024
AZ -1200
CX -1500
A3 -2000
A4 -2048
A5 -2500
AD -4096
A8 -4800
A9 -5000
A0 -Special
Note Dual
Output NA
with Foot
Mount
Bracket
5- Zone 1 & 21
(5-7V in
5V out)
For use with XRB1
isolator
12-24V In
10.6V Out
7-Zone 2 & 22
5-24 V in,
5-24 V out
Zone 1 and 21 Local Protection
5- XRB1 in Ex box, cable tether, ¾
NPT, no gland
6- XRB1 in Ex box, cable tether, ATEX
gland
Zone 1 and 21 Remote Protection &
Zone 2 and 22
10 Pin MS Connector-
Small Encoder Pinout
A- Avtron/BEI Pinout, w/o plug
B- Dynapar HS35 Pinout, w/o plug
C- Avtron/BEI Pinout, mating plug
D-Dynapar HS35 Pinout, mating
plug
10 Pin MS Connector-
Large Encoder Pinout
4-Avtron/Northstar Pinout, mating
plug
6 Pin MS Connector-
Small Encoder Pinout
E- Avtron/BEI Pinout, w/o plug
F- Dynapar HS35 Pinout, w/o plug
7 Pin MS Connector-
Small Encoder Pinout
J- Avtron/BEI Pinout, w/o plug
K- Dynapar HS35 Pinout, w/o plug
Small EPIC Connector
P- Avtron pinout, w/mate
G- Northstar pinout w/mate
Terminal Box w/terminal strip
H- USA, 1/2” conduit
L- Europe w/cord grip
8 Pin M12 Connector
T- Global pinout, w/o plug
U- USA Pinout, w/o plug
12 Pin M23 Connector
2- Leine and Linde pinout,
w/o plug
3- Hubner Pinout w/o plug
W- Cable 18” (or special length)
R- Mini Twist Lock (Mini
MS) w/ mating plug
S- Mini Twist Lock (Mini
MS) on 3’ cable w/mat
ing plug
X- None
(for B10 flange mount)
1 - Toshiba TS2113N bolt
pattern (recommend “T”
18mm shaft)
(B35529 bracket)
2 - POGxx, OGxx Hubner
(Baumer) bolt pattern
(B35555 bracket)
3 - FG4 Johannes Hubner
bolt pattern
(B35338 bracket)
A - A,A
–, B,B –,
Z,Z
–
E - A,B,Z
(Single
ended)
000- none
4xx- Special PPR
(see chart)
9xx- Special
cable length
xx=length
x 0.3m (use
w/ Connector
Option “W”)
SPECIAL PPR OPTION CODES
OPTION CODE LEFT PPR RIGHT PPR
401 1270 None
402 150 None
403 50 None
404 512 16
405 16 None
406 6000 None

XR4F 5
ELECTRICAL
A. Operating Power (Vin)
1. Volts ........................... See Line Driver Chart
2. Current ....................... 100mA, each output, plus cable load
B. Output Format
1. 2O/ & Comp............... A,A–, B,B– (differential line driver)
2. Marker: ....................... 1/Rev Z, Z–
C. Signal Type .................... Incremental, Square Wave, 50 +/-10%
................................... Duty Cycle.
D. Direction Sensing ........... O/ A leads O/ B for CW rotation as viewed
................................... from the back of the tach looking at the
................................... non-drive end of the motor.
E. Transition Sep. ............... 15% minimum
F. Frequency Range........... 0 to 165,000 Hz
G. PPR ................................ 8-5000
H. Line Driver Specs: .......... See table
I. Connectors: .................... See connector options on page 1
MECHANICAL
A. Shaft Inertia .................... 0.0032 lb-in-sec2
B. Acceleration.................... 5000 RPM/Sec. Max.
C. Speed: ............................ 5000 RPM Max (also see overspeed)
D. Weight: ........................... 10-12 lbs [4.5-5.5kg]
E. Vibration ......................... 20 Gs, 5-2000 Hz (any orientation)
F. Shock ............................. 100 Gs, any orientation
G. Shaft Load:..................... Axial: 50lbs
ENVIRONMENTAL
Solid cast aluminum stator and rotor less than 6% magnesium by mass.
Fully potted electronics, protected against oil and water spray
Operating Temperature:.......-40°C to +80°C.
LINE DRIVER OPTIONS
Electrical Specifications 7Isolator XRB1 5 Units
Input Voltage 5-24 12-24 5-7 VDC
Nom Output Voltage 5-24 (5-7 to Encoder)
10.6 Output Signals 5 VDC
Line Driver 7272 IXDF604 7272
Output Resistance Typ
13 3 13 ohms
Maximum Peak Current 1500 3000 1500 mA
Maximum Average
Current 120 350 120 mA
Voh Typ VIN-1 10.6 VIN-1 VDC
Vol Typ 0.5 0.4 0.5 VDC
Cable Drive Capacity 500’ @ 5-12V
200’ @ 24V 1000’ 500’ feet
Protection
Reverse
Voltage yes yes yes
Short
Circuit yes yes yes
Transient yes yes yes
Alarm
+V(out)* Output voltage equal to input voltage.
Alarm* Open collector, normally off, goes low on alarm,
sink 100mA max, 50VDC max
LED Green=power on, Red=Alarm
Marker One per revolution. Pulse width
approximately 1/128 of a revolution
Ii
Ui
CI
IIC IIB
250mA 15V 25V
1.8uf
1A 15V
5A 12V
Zone 2 Power Supply Limits
Parameter Isolator Encoder
Um 250V -
Ui - 7.14V
Li - 440mA
Pi - 0.4W
Ci - 11.9UF
Li - 0mH
Uo 7.14V -
Io 440mA -
Po 0.4W -
Lo 1.5mH
Co 13.5uF
Lo/Ro -
Zone 1 Table of entity parameters
SPECIFICATIONS
*Alarm not available with the following; line driver option 5 from isolator XRB1, connector
option “G” (NorthstarTM compatible pinout), “R” and “S”

XR4F 6
A
A
B
B
Z
Z
-
+
5-7 Volts
Out
+
-
12-24
Volts In
A
A
B
B
Z
Z
ISOLATOR
P/N B35134
12-24
Volts Out
Customer Equipment
2 Phase Differential
+
-
A-
A+
B-
B+
Z-
Z+
gnd gnd
ZONE 1 HAZARDOUS AREA SAFE AREA
WIRING DIAGRAMS
LINE DRIVER OPTION 5
CONNECTOR OPTION 5 OR 6
Typical Cable 1000'(300M)max
18AWG, Individually Shielded Twisted Pair + Overall Shield
Rockbestos EXANE 125 Type P- P/N: 4TSP18 AWG
Ex Box
1'(.3M) to 5'(1.5M)
Cable Tether Intrinsic Safety Gnd
ENCODER
“LOCAL PROTECTION’
K1-
0+
K1+
K2-
1-
1+
K2+
GND
+E
0V
0-
2-
K0-
2+
Ub+
K0+
12-24
Volts Out
Customer Equipment
2 Phase Differential
+
-
A-
A+
B-
B+
Z-
Z+
Intrinsic Safety Gnd
K1-
0+
K1+
K2-
1-
1+
K2+
GND
+E
0V
0-
2-
K0-
2+
Ub+
K0+
A
A
B
B
Z
Z
-
+
5-7 Volts
Out
+
-
12-24
Volts In
A
A
B
B
Z
Z
ISOLATOR
P/N B35134
gnd gnd
ZONE 1 HAZARDOUS AREA SAFE AREA
“REMOTE PROTECTION’
ENCODER
Typical Cable 500'(150M)max
18AWG, 4 Twisted Pair + Overall Shield
Belden P/N 9554 or Alpha P/N 2244C Typ
See Attached for Connector
Option Pin Outs

XR4F 7
WIRING DIAGRAMS
Refer to Installation and Specification Sections for Requirements and Limitations
2 Pair
3 Pair
4 Pair
5 Pair
Belden Alpha
9552
9553
9554
1328A
2242C
2243C
2244C
2245C
5-24*
Volts Out
Customer Equipment
2 Phase Differential
+
-
A-
A+
B-
B+
Z-
Z+
K1-
0+
K1+
K2-
1-
1+
K2+
GND
+E
0V
0-
2-
K0-
2+
Ub+
K0+
ZONE 2 HAZARDOUS AREA SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Twisted Pair + Overall Shield
See Attached for Connector
Option Pin Outs
DIFFERENTIAL 2 PHASE WIRING
2 Pair
3 Pair
4 Pair
5 Pair
Belden Alpha
9552
9553
9554
1328A
2242C
2243C
2244C
2245C
5-24*
Volts Out
Customer
Equipment
+v
-v
A+
B+
Z+
GND
0+
K1+
0V
1+
K2+
+E
2+
Ub+
K0+
ZONE 2 HAZARDOUS AREA SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Twisted Pair + Overall Shield
See Attached for Connector
Option Pin Outs
SINGLE ENDED 2 PHASE WIRING
+v
alm
5-24*
Volts Out
Customer
Equipment
ZONE 2 HAZARDOUS AREA SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Triad + Overall Shield
See Attached for Connector
Option Pin Outs
SINGLE ENDED 1 PHASE WIRING
-v GND 0V
+v
+v Ub+ +E
A+ K1+
3 Conductor
Belden Alpha
9365 M9628010 *SEE SPECIFICATIONS FOR ZONE 2
POWER SUPPLY LIMITATIONS

XR4F 8
Pinouts and Phasing
0V
Gnd
A+
B+
Z+
+Vin
A-
B-
Z-
6 Pin MS, Avtron / BEI Pinout
E
B
CW
Pin #
A
E
D
NC
B
C
F
NC
6 Pin MS, Avtron / BEI Pinout
E
D
CW
Pin #
A
E
NC
NC
B
NC
NC
NC
6 Pin MS, Avtron / BEI Pinout
E
E
CW
Pin #
A
E
D
C
B
NC
NC
NC
6 Pin MS, Avtron / BEI Pinout
E
F
CW
Pin #
A
E
D
NC
B
NC
NC
NC
6 Pin MS, Dynapar HS35 Pinout
F
B
CCW
Pin #
A
E
D
NC
B
C
F
NC
6 Pin MS, Dynapar HS35 Pinout
F
D
CCW
Pin #
A
E
NC
NC
B
NC
NC
NC
6 Pin MS, Dynapar HS35 Pinout
F
E
CCW
Pin #
A
E
D
C
B
NC
NC
NC
6 Pin MS, Dynapar HS35 Pinout
F
F
CCW
Pin #
A
E
D
NC
B
NC
NC
NC
7 Pin MS, Avtron / BEI Pinout
J
B
CW
Pin #
F
A
B
NC
D
C
E
NC
7 Pin MS, Avtron / BEI Pinout
J
D
CW
Pin #
F
A
NC
NC
D
NC
NC
NC
7 Pin MS, Avtron / BEI Pinout
J
E
CW
Pin #
F
A
B
C
D
NC
NC
NC
7 Pin MS, Avtron / BEI Pinout
J
F
CW
Pin #
F
A
B
NC
D
NC
NC
NC
7 Pin MS, Dynapar HS35 Pinout
K
B
CCW
Pin #
F
A
B
NC
D
C
E
NC
7 Pin MS, Dynapar HS35 Pinout
K
D
CCW
Pin #
F
A
NC
NC
D
NC
NC
NC
7 Pin MS, Dynapar HS35 Pinout
K
E
CCW
Pin #
F
A
B
C
D
NC
NC
NC
7 Pin MS, Dynapar HS35 Pinout
K
F
CCW
Pin #
F
A
B
NC
D
NC
NC
NC
8 Pin M12 Global Pinout
T
A
CW
Pin #
1
3
5
7
2
4
6
8
8 PIN M12 USA Pinout
U
A
CW
Pin #
7
1
4
6
2
3
5
8
0V
Gnd 1+ 2+ 0+ NC +E 1- 2- 0- NC NC NC
0V
Gnd
K1+
K2+
K0+
NC
+Ub
K1-
K2-
K0-
NC
NC
NC
0V
Gnd
A+
B+
Z+
Alm+
+Vin
A-
B-
Z-
Alm
NC
NC
12 Pin M23, Leine Linde Pinout 2 A1 CW Pin # 10 8 5 3 9 12 1 6 4 11 2 7
12 Pin M23, Hubner Pinout
2
A2
CCW
Pin #
10
5
8
2
9
12
6
1
4
11
2
7
12 Pin M23, Leine Linde Pinout, Inverted 3 A2 CW Pin # 10 8 5 3 9 12 1 6 4 11 2 7
Conduit Box W/10 Pin Terminal Strip H,L A CW Pin # 1 2 3 4 5 6 7 8 9 10
Conduit Box W/10 Pin Terminal Strip
H,L
A1
CW
Pin #
1
2
3
4
5
6
7
8
9
10
Conduit Box W/10 Pin Terminal Strip H,L A2 CCW Pin # 1 7 3 4 5 6 2 8 9 10
Phasing is defined as the direction of rotation
for which phase A leads B as viewed from the
back of the Encoder
Option
Code
Channel
Code Phasing Signal
Option
Code A1 Phasing Signal
Phasing is defined as the direction of rotation
for which phase A leads B as viewed from the
back of the Encoder
Option
Code
Channel
Code Phasing Signal
Option
Code A2 Phasing Signal
0V
Gnd
A+
B+
Z+
Alm+
+Vin
A-
B-
Z-
Alm
10 Pin MS Avtron / Northstar Pinout
Y
A
CW
Pin #
A
D
E
C
NC
B
G
H
I
NC
10 Pin MS Mini Twist Lock
R, S
A
CW
Pin #
F
A
B
C
NC
D
H
J
K
NC
10 Pin, Mini Industrial, Avtron Pinout
P
A
CW
Pin #
1
2
3
4
5
6
7
8
9
10
10 Pin, Mini Industrial, Northstar Pinout
G
A
CW
Pin #
1
2
3
4
NC
6
7
8
9
NC
10 Wire Cable
W
A
CW
Color
BLK
GRN
BLU
ORG
BRN
RED
YEL
GRA
WHT
VIO
Phasing is defined as the direction of
rotation for which phase A leads B as viewed
from the back of the Encoder
Option
Code
Channel
Code Phasing Signal
0V
GndA+B+Z+ Alm+ +Vin A- B- Z- Alm
10 Pin MS Avtron / BEI Pinout A, CA CW Pin #FABCNCD HI JNC 10 Pin MS Dynapar HS35 Pinout B, DA CCW Pin #FABCNCD HI JNC
10 Pin MS Avtron / Northstar Pinout 4ACW Pin #ADECNCB GH INC 10 Pin MS Mini Twist Lock R, SA CW Pin #FABCNCD HJKNC 10 Pin, Mini Industrial, Avtron Pinout PACW Pin #12345 678910
10 Pin, Mini Industrial, Northstar Pinout GACW Pin #1234NC6 789NC
10 Wire CableWACWColor BLKGRN BLUORG BRNRED YELGRA WHTVIO
0V
GndA+B+Z+ +Vin A- B- Z-
6 Pin MS, Avtron / BEI Pinout EBCW Pin #AEDNC BC FNC 6 Pin MS, Avtron / BEI Pinout EDCW Pin #AENCNCB NC NC NC
6 Pin MS, Avtron / BEI Pinout EECW Pin #AEDCBNC NC NC 6 Pin MS, Avtron / BEI Pinout EFCW Pin #AEDNC BNCNCNC 6 Pin MS, Dynapar HS35 Pinout FBCCW Pin #AEDNC BC FNC
6 Pin MS, Dynapar HS35 Pinout FDCCW Pin #AENCNCB NC NC NC 6 Pin MS, Dynapar HS35 Pinout FECCW Pin #AEDCBNC NC NC
6 Pin MS, Dynapar HS35 Pinout FFCCW Pin #AEDNC BNCNCNC
7 Pin MS, Avtron / BEI Pinout JBCW Pin #FABNC DC ENC 7 Pin MS, Avtron / BEI Pinout JDCW Pin #FANCNCD NC NC NC
7 Pin MS, Avtron / BEI Pinout JECW Pin #FABCDNC NC NC 7 Pin MS, Avtron / BEI Pinout JFCW Pin #FABNC DNCNCNC 7 Pin MS, Dynapar HS35 Pinout KBCCW Pin #FABNC DC ENC
7 Pin MS, Dynapar HS35 Pinout KDCCW Pin #FANCNCD NC NC NC 7 Pin MS, Dynapar HS35 Pinout KECCW Pin #FABCDNC NC NC
7 Pin MS, Dynapar HS35 Pinout KFCCW Pin #FABNC DNCNCNC
8 Pin M12 Global Pinout TACW Pin #13572 468
8 PIN M12 USA Pinout UACW Pin #71462 358
0V
Gnd1+2+0+NC+E1-2-0-NCNCNC
0V
GndK1+ K2+K0+ NC +UbK1- K2-K0- NC NC NC
0V
GndA+B+Z+ Alm+ +Vin A- B- Z- AlmNCNC
12 Pin M23, Leine Linde Pinout 2A1CWPin #108 53 9121 6411 27 12 Pin M23, Hubner Pinout 2A2CCW Pin #105 82 9126 1411 27 12 Pin M23, Leine Linde Pinout, Inverted 3A2CWPin #108 53 9121 6411 27 Conduit Box W/10 Pin Terminal StripH,L ACWPin #12345 678910
Conduit Box W/10 Pin Terminal StripH,L A1 CW Pin #12345 678910
Conduit Box W/10 Pin Terminal StripH,L A2 CCW Pin #17345 628910
Phasing Signal
Opon
Code A2 Phasing Signal
Phasing is defined as the direcon of
rotaon for which phase A leads B as viewed
from the back of the Encoder
Phasing is defined as the direcon of
rotaon for which phase A leads B as viewed
from the back of the Encoder
Phasing is defined as the direcon of
rotaon for which phase A leads B as viewed
from the back of the Encoder
Opon
Code
Channel
Code
Opon
Code A1
Signal
Opon
Code
Channel
Code Phasing
Signal
Phasing Signal
Opon
Code
Channel
Code Phasing

XR4F 9
Pinouts and Phasing
0V
Gnd A+ B+ Z+ +Vin A- B- Z-
6 Pin MS, Avtron / BEI Pinout
E
B
CW
Pin #
A
E
D
NC
B
C
F
NC
6 Pin MS, Avtron / BEI Pinout E D CW Pin # A E NC
NC
BNC NC NC
6 Pin MS, Avtron / BEI Pinout
E
E
CW
Pin #
A
E
D
C
B
NC
NC
NC
6 Pin MS, Avtron / BEI Pinout E F CW Pin # A E D
NC
BNC NC NC
6 Pin MS, Dynapar HS35 Pinout F B CCW Pin # A E D
NC
B C F NC
6 Pin MS, Dynapar HS35 Pinout
F
D
CCW
Pin #
A
E
NC
NC
B
NC
NC
NC
6 Pin MS, Dynapar HS35 Pinout F E CCW Pin # A E D C B NC NC NC
6 Pin MS, Dynapar HS35 Pinout
F
F
CCW
Pin #
A
E
D
NC
B
NC
NC
NC
7 Pin MS, Avtron / BEI Pinout J B CW Pin # F A B
NC
D C E NC
7 Pin MS, Avtron / BEI Pinout J D CW Pin # F A NC
NC
DNC NC NC
7 Pin MS, Avtron / BEI Pinout
J
E
CW
Pin #
F
A
B
C
D
NC
NC
NC
7 Pin MS, Avtron / BEI Pinout J F CW Pin # F A B
NC
DNC NC NC
7 Pin MS, Dynapar HS35 Pinout
K
B
CCW
Pin #
F
A
B
NC
D
C
E
NC
7 Pin MS, Dynapar HS35 Pinout K D CCW Pin # F A NC
NC
DNC NC NC
7 Pin MS, Dynapar HS35 Pinout K E CCW Pin # F A B C D NC NC NC
7 Pin MS, Dynapar HS35 Pinout
K
F
CCW
Pin #
F
A
B
NC
D
NC
NC
NC
8 Pin M12 Global Pinout T A CW Pin # 1 3 5 7 2 4 6 8
8 PIN M12 USA Pinout
U
A
CW
Pin #
7
1
4
6
2
3
5
8
0V
Gnd
1+
2+
0+
NC
+E
1-
2-
0-
NC
NC
NC
0V
Gnd
K1+
K2+
K0+
NC
+Ub
K1-
K2-
K0-
NC
NC
NC
0V
Gnd
A+
B+
Z+
Alm+
+Vin
A-
B-
Z-
Alm
NC
NC
12 Pin M23, Leine Linde Pinout
2
A1
CW
Pin #
10
8
5
3
9
12
1
6
4
11
2
7
12 Pin M23, Hubner Pinout
2
A2
CCW
Pin #
10
5
8
2
9
12
6
1
4
11
2
7
12 Pin M23, Leine Linde Pinout, Inverted
3
A2
CW
Pin #
10
8
5
3
9
12
1
6
4
11
2
7
Conduit Box W/10 Pin Terminal Strip
H,L
A
CW
Pin #
1
2
3
4
5
6
7
8
9
10
Conduit Box W/10 Pin Terminal Strip
H,L
A1
CW
Pin #
1
2
3
4
5
6
7
8
9
10
Conduit Box W/10 Pin Terminal Strip
H,L
A2
CCW
Pin #
1
7
3
4
5
6
2
8
9
10
Phasing is defined as the direction of rotation
for which phase A leads B as viewed from the
back of the Encoder
Option
Code
Channel
Code Phasing Signal
Option
Code A1 Phasing Signal
Phasing is defined as the direction of rotation
for which phase A leads B as viewed from the
back of the Encoder
Option
Code
Channel
Code Phasing Signal
Option
Code A2 Phasing Signal
0V
Gnd
A+
B+
Z+
Alm+
+Vin
A-
B-
Z-
Alm
10 Pin MS Avtron / Northstar Pinout
Y
A
CW
Pin #
A
D
E
C
NC
B
G
H
I
NC
10 Pin MS Mini Twist Lock
R, S
A
CW
Pin #
F
A
B
C
NC
D
H
J
K
NC
10 Pin, Mini Industrial, Avtron Pinout
P
A
CW
Pin #
1
2
3
4
5
6
7
8
9
10
10 Pin, Mini Industrial, Northstar Pinout
G
A
CW
Pin #
1
2
3
4
NC
6
7
8
9
NC
10 Wire Cable
W
A
CW
Color
BLK
GRN
BLU
ORG
BRN
RED
YEL
GRA
WHT
VIO
Phasing is defined as the direction of
rotation for which phase A leads B as viewed
from the back of the Encoder
Option
Code
Channel
Code Phasing Signal

XR4F 10
Applies to all Model XR4F Encoders Zone 2 & 22 models, except wiring option “T”, “U”, “3” Remote Alarm not available for Zone 1 & Zone 21.
ALARM OUTPUT CONNECTION
Avtron XR4F encoders provide an alarm signal if maintenance is required under specific circumstances. Following are application
examples provided to help install the alarm output.
Example 1. Alarm output using +V(OUT). +V(OUT) is equal to +V, the encoder power supply.
XR4F
Remote Alarm
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
OUTPUT OPTIONS
A
B
D
G
E
H
C
I
F
J
9
4
5
10
2
8
3
7
6
1
4
3
2
7
8
6
5
1
12
10
+V(OUT)
Z
Z
A
B
B
A
+V
COM
ENCODER
Q5
MMFT6661
LINE
DRIVER
NOTE 1
CR8
{
FUNCTIONAL DIAGRAM
“W”“4”“P”, “Z”“H”, “L”
ALM
Vcc
OUT
COM
300 OHM
MIN.
GND
FUNCTION
ØB
ØA
ØA
ØB
VDC SOLID STAT E RELAY
50 mA MAXIMUM
MARKER
MARKER COMPLEMENT
COMMON
+V (Encoder Power)
“2”
{
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
“H”,“L”
OUTPUT OPTIONS
A
B
D
G
E
H
C
I
F
J
9
4
5
10
2
8
3
7
6
1
ALM
+V(OUT)
Z
Z
A
B
B
A
+V
COM
MARKER
MARKER COMPLEMENT
GND
FUNCTION
+V (Encoder Power)
COMMON
VDC
RELAY
+
-
POWER
SUPPLY 115 VAC
SINK 100 mA MAXIMUM,
Q5
MMFT6661
ENCODER
FUNCTIONAL DIAGRAM
ØB
ØA
ØA
ØB
LINE
DRIVER
NOTE 1
CR8
“W” “2”
“4” “P”,“Z”
4
3
2
7
8
6
5
1
12
10
*
*See specifications for Zone 2 power supply limits
Example 2. Alarm Output Using Separate * VDC Power Supply and Relay.

XR4F 11
Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
B1O FLANGE MOUNT STYLE
SHOWN: SINGLE OUTPUT, CONDUIT BOX
7.04
[178.8]
4.25
[108.0]
6.52
[165.6]
4.66
[118.4]
3.25
[82.6]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.53
[115.1]
7.04
[178.8]
4.25
[108.0]
6.52
[165.6]
4.66
[118.4]
3.25
[82.6]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.53
[115.1]

XR4F 12
Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
B1O FLANGE MOUNT STYLE
SHOWN: DUAL OUTPUT, M23 CONNECTOR
4.66
[118.4]
3.25
[82.6]
4.24
[107.7]
6.71
[170.4]
8.50
[215.9]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.66
[118.4]
3.25
[82.6]
4.24
[107.7]
6.71
[170.4]
8.50
[215.9]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]

XR4F 13
TOSHIBA TS2113N FOOT MOUNT STYLE
SHOWN: “P” INDUSTRIAL CONNECTOR 18MM
SHAFT, SUPER MAGNETIC SHIELDING “004”
6.00
[152.4]
8.29
[210.5] 7.10
[180.3]
5.90
[149.9]
4.72
[120.0]
2.68
[68.0]
2.80
[71.0]
2.16
[54.9]
2.67
[70.0]
2.03
[51.6]
4.66
[118.4]
0.71
[18.00]
0.47 [12.00]
1.57 [40.0]
0.35
[8.8]
4.34
[110.3]
6.00
[152.4]
8.29
[210.5] 7.10
[180.3]
5.90
[149.9]
4.72
[120.0]
2.68
[68.0]
2.80
[71.0]
2.16
[54.9]
2.67
[70.0]
2.03
[51.6]
4.66
[118.4]
0.71
[18.00]
0.47 [12.00]
1.57 [40.0]
0.35
[8.8]
4.34
[110.3]
Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].

XR4F 14
FOOT MOUNT STYLE WITH OVERSPEED
SHOWN: “P” INDUSTRIAL CONNECTOR 11MM SHAFT
6.00
[152.4]
8.21
[208.5]
4.52
[114.9]
0.30
[7.5]
5.32
[135.1] 0.35
[8.8]
1.18
[30.0]
4.54
[115.4] 6.88
[174.7]
1.18 [30.0]
[11.0] 0.433
2.03
[51.6]
2.68
[68.0]
2.16
[54.9]
2.36
[60.0]
1.73
[68.0]
4.33
[110.0]
7.16
[181.9]
4.48
[113.9]
6.00
[152.4]
8.21
[208.5]
4.52
[114.9]
0.30
[7.5]
5.32
[135.1] 0.35
[8.8]
1.18
[30.0]
4.54
[115.4] 6.88
[174.7]
1.18 [30.0]
[11.0] 0.433
2.03
[51.6]
2.68
[68.0]
2.16
[54.9]
2.36
[60.0]
1.73
[68.0]
4.33
[110.0]
7.16
[181.9]
4.48
[113.9]
REV: 11-28-12
8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A.
216-642-1230 • FAX [phone] • www.avtronencoders.com
SMARTSafe™ is a trademark of Avtron Industrial Automation, Inc.
Features and specications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches (mm).
These instructions have been reviewed and the product evaluated as suitable for our application.
Company Name
Authorized Company Representative
Title Date