Avtron XR485 SMARTSafe™ Encoders

Avtron XR485 SMARTSafe™ Encoders

Hazardous Duty Shafted Encoder for Severe Environments

  • Severe Mill Duty
  • ATEX/IECEx Rated for Zone 1, 2, 21 & 22 Applications
  • Foot or NEMA 56C Face Mount
  • Fully Potted Electronics
  • Up to 5000 PPR
  • Self-Diagnostic LED and Alarm Output
  • 1 Year No-Hassle Warranty
  • cULus Class I Div 1 Groups A,B,C,D
  • cULus Class I Zone 0 Group IIC
  • cULus Class I Div 2 Groups A,B,C,D
Outline Drawing
XR485 SMARTSafe solid shaft encoders are a breakthrough in hazardous duty encoders for NEMA C-face and foot mount applications.  They are ATEX/IECEx and UL approved and offer incredibly reliable construction!  SMARTSafe encoders can be used in ATEC/IECEx gas and dust and UL gas hazardous environments.  Also available:  hollow shaft models (XR45, XR685), Euro shafted models (XR4F), no-bearing modular encoders (XR56, XR85, XR115, XR125, XR850), and modular sensors (XR5, XR12).

For applications requiring ATEX/IECEx Zone 2 or 22 or UL Class I, Division 2, Groups A,B,C,D, use the XR485 directly in your application, with no barrier, isolator or cable gland required.

For applications requiring UL Division 1, ATEX/IECEx Zone 1 or 21 use the XRB3 isolator in your control cabinet which permits the use of intrinsically safe wiring instead of explosion proof conduit or glands. XRB3 Isolator Systems enable use in Class I Div 1 and Zone 0 applications.  

Unlike the competition, Avtron SMARTSafe encoder systems are fully protected against short circuits, power-to-output wiring, and output-to-ground faults at every point.  Wiring errors won't harm this system!

Instead of depending on a tiny optical encoder with weak bearings use XR485.  Vibration, shock, liquids, dust and dirt won't harm SMARTSafe XR485 encoders!  Paint booths, draw works, coil tubing rigs...XR485 can keep them all working 24/7/365.

Eliminate encoder failures in your hazardous environment application-select XR485 today!
Operating Power: (add cable drive current as req'd)
     Division 1, Zone 1 (XRB3):  12-24VDC In, 10.6V Out, 150mA
     Division 2, Zone 2:  5-24VDC In/Out, 100mA 
Output Format: A Quad B with marker (A,/A, B,/B, Z,/Z)
Frequency Range: 0 to 165 KHz
PPR: 8-5000
Speed: 5500 RPM Max. (contact factory for higher speeds)
Maximum Cable Length
     Division 1, Zone 1:  400' [120m]
     Division 2, Zone 2:  500' [150m] @ 5-12V; 200' [60m] @ 24V
Temperature: -40°C to 80°C (Storage -40°C to 100°C)
Environmental: Electronics-IP67, IP66 overall (see manual for details)
Vibration: 5-2000Hz, 18G; 100G Shock
Weight: 14 lbs. [6.4 kg]/16lbs [7.3kg] dual output
     ATEX/IECEx Zone 1 & Zone 21 Group IIC
     cULus Class I, Division 1 and Zone 0 Group A,B,C,D*
     ATEX/IECEx Zone 2 & 22 Group IIC
     cULus Class I, Division 2 Group A,B,C,D
*See installation drawings for Warnings and Limitations
  • Foot mount bolt pattern matches explosion-proof analog models exactly
  • Optional K661 signal converter for direct replacement of analog tachs (BC66, etc.)
  • Replaces BEI H38, H40 & Dynapar X25 models
  • Shrugs off dirt, oil, and water contamination
  • Protected against: power-to-phase, short circuits, and reverse voltage wiring problems
  • No glass disks to break or optics to fail
Industry General Food & Beverage Pulp & Paper Wood Products Wind Power Crane & Hoist Metals Mining Marine Oil & Gas

Light Mill Duty

AV20, AV25, AV6A, AV6M, Avtron Elevator Encoder, Cables and Connectors, Encoder Couplings, Encoder Programming Tool, HS25A, HS35A, HS6A, K661, SC65

Mill Duty

AV32, Cables and Connectors, Encoder Couplings, HS35M, HS35X, HS6M, K661, M185, M3, M3(small), RAHS35M

Heavy Mill Duty

AV115, AV125, AV44, AV45, AV56, AV56-Wind, AV56S, AV67, AV85, AV850, AVSK, Cables and Connectors, Carlen Replacement, HS44, HS45, K661, M4, M4(small), XP5, XR115, XR12, XR125, XR45, XR4F, XR5, XR56, XR67, XR85, XR850, XR97, XRB1, XRB2, XRB3

Severe Mill Duty

AV12, AV30, AV485, AV5, AV685, Cables and Connectors, Carlen Replacement, Encoder Couplings, HS40, K661, M484, M6, M6C, M7, XP5, XPH1, XPH8, XR12, XR485, XR5, XR685, XR97, XRB1, XRB2, XRB3,
XR485 SMARTSafe™ encoders can replace many competitive models including:

H20, H25, H38, H40

Baumer Hubner:
EEx OG 9, FOG 9, POG 9, POG 9 G, POG 90, POG 10, POG 10 G, POG 11, POG 11 G

BEI Ideacod encoders:

Dynapar encoders:
X25 encoder

RSI 58X-,RVI 58X-, RVI84, 14-1436X, 14-14361, 14-14366

And many other intrinsically safe and explosion-proof encoders.
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In This Section

  • A Quad B

    A Quad B refers to the set of output quadrature signals from an incremental quadrature encoder to indicate speed and direction, including complements: A, A NOT, B, B NOT (, , , ). Most Avtron encoders offer A Quad B output at no extra cost.  For more information on quadrature- Wikipedia: http://en.wikipedia.org/wiki/Quadrature_phase

  • ATEX

    ATEX is a directive used worldwide for equipment, including encoders, to be used around or in explosive atmospheres. ATEX certified equipment is NOT necessarily interchangeable with US-based UL Class/Division or Class/Zone rated equipment, nor IECEx rated equipment. ATEX is an alternative and different system. Review our full line of Avtron Explosion Protected, ATEX certified encoders, including M6, M6C and XR models.

  • BC66

    A heavy duty analog tachogenerator manufactured by General Electric, part number 5BC66xxxxx, NEMA 56C face or foot mount, coupled. It is now obsolete. It may be replaced by an Avtron encoder combined with a K661 converter solution.

  • DC Tachogenerators

    Also known as Analog Tachogenerators. Small DC generators that output a voltage in proportion to speed. They cannot indicate position, only speed and direction of rotation. A common mounting style of analog tachogenerator was the General Electric BC42 and BC46 Series with NEMA 56C Foot or Face Mount, and the smaller 5PY flange mount unit. Analog tachogenerators can be replaced with modern digital encoders. Avtron offers a complete retrofit package using the existing flange adapter and coupling already on the motor and a Frequency to Voltage Converter like the Avtron K661, which resides in the drive cabinet.

  • Face or Flange Mount

    A machined surface (NEMA 56C, NEMA FC) on the non-drive end of the motor is used to mount bearingless or pancake encoders such as Avtron AV56 THIN-LINE II™ encoders. Solid shaft, coupled tachometers also flange mounted using flange adapters, also called flowerpots.

  • Flowerpot

    A term for the flange adapter used to mount a solid shaft encoder to a motor face.

  • Foot Mount

    Foot Mount encoders are bolted to a motor foot, shelf, or other nearby location. The solid shaft encoder is coupled to the shaft to be monitored. Modern Avtron encoders (AV485) require a separate foot mounting bracket. To eliminate coupling and alignment maintenance issues, foot mounting installations can be upgraded to a hollow shaft encoder such as the AV685.

  • Incremental Encoder

    An encoder that produces pulses in proportion to distance moved or rotated. Incremental encoders can also have a marker pulse Z, Z NOT (, ) once per revolution to provide a position reference. Avtron produces a full range of incremental rotary encoders.

  • Intrinsically Safe / Intrinsic Safety

    Is a system designed to improve equipment safety by limiting spark energy values in equipment used in hazardous areas.  Intrinsic Safety is a different system of protection than Explosion Proof or Flameproof.  Many Explosion Proof and Flameproof encoders can be replaced with Intrinsically Safe encoders, provided the installation instructions are followed correctly and the system is compliant with the approved installation drawing.  Intrinsically safe Avtron XR encoders are available in Level 1 protection and Level 2 protection. 

  • Magnetic Encoder

    Magnetic and magnetoresistive encoders typically use a magnetized rotor with north and south poles lined up around the perimeter of the disk. A magnetoresistive sensor detects the transitions, and these are the counts or pulses generated by the encoder. Magnetic encoders withstand dirt, dust, water, and temperature changes far better than optical encoders.

  • NEMA 56C

    A NEMA 56C face or flange mount, also known as bearingless or pancake encoder, is a 4.5" flange with (4) bolts located in a 5.88" circle. Originally designed as the standard for mounting solid shaft, coupled tachometers on flange adapters, the NEMA 56C is also a standard for mounting modular encoders. Avtron AV56 THIN-LINE II™ encoders mount on NEMA 56C faces. Marathon Blue Max and Black Max AC motors feature a NEMA 56C face on the non-drive end.

  • Optical Encoder

    An Optical Encoder typically uses a light source shining through, or reflecting off, an optical disk with lines or slots that interrupt the beam of light to an optical sensor. Electronics count the interruptions of the beam and generate the encoder’s output pulses.

  • PPR

    Pulses Per Revolution. Most Avtron encoders output quadrature pulses, with four times as many lines as pulses. Often lines can be counted in the drive/speed controller for higher resolution applications.

  • Severe Duty

    Severe Duty encoders have the best ability to withstand temperature cycling, extreme temperatures, contaminants, bearing loads and physical abuse.

  • Solid Shaft

    Solid Shaft encoders are coupled to the shaft to be measured. The solid shaft encoder body is typically C-Face mounted using a flange adapter, or some models can be foot mounted.

  • Tachometer

    Also known as a tach, a device which indicates speed of rotation. Modern tachometers are actually rotary incremental encoders which indicate position, speed, and direction of rotation.

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