Avtron XR850 SMARTSafe™ Encoders

Avtron XR850 SMARTSafe™ Encoders

Hazardous Duty No-Bearing Modular Encoder

  • • Fits NEMA 8.5" Flanges
  • • Fits Shafts up to 4 1/2" [115mm]
  • • ATEX/IECEx Rated for Zone 1, 2, 21 & 22 Applications
  • • Ideal for Oil and Gas Drilling
  • • No Bearings to Wear Out
  • • Up to 5000 PPR
  • • Self-Diagnostic LED and Alarm Output
  • • 3 Year No-Hassle Warranty
  • • cULus Class I Division 1 Groups A,B,C,D Listed
  • • cULus Class I Zone 0 Group IIC
  • • cULus Class I Division 2 Groups A,B,C,D Listed
Outline Drawing
XR850 SMARTSafe 8.5" modular incremental quadrature rotary encoders are a breakthrough in hazardous duty encoders.  They are ATEX/IECEx, cULus approved and offer reliable no-bearing construction!  SMARTSafe encoders can be used in UL gas and ATEX/IECEx gas and dust hazardous environments.  Also available:  hollow shaft models (XR45, XR47, XR685), shafted models (XR4F, XR485), no-bearing modular encoders to fit other flange sizes (XR56, XR67, XR85, XR115, XR125, XR850), and modular sensors (XR5, XR12).

For Level 2 applications requiring ATEX/IECEx Zone 2 or 22 or UL Class I, Division 2, Groups A,B,C,D, use the XR850 directly in your application, with no barrier, isolator or cable gland required.

For Level 1 applications requiring ATEX/IECEx Zone 1 or 21 use the XRB1 or XRB2 isolator in your control cabinet which permits the use of intrinsically safe wiring instead of explosion proof conduit or glands. The XR850 can also be used in UL Class I, DIV 1 and Zone 0 applications using the XRB2 Isolator.

Unlike the competition, Avtron SMARTSafe encoder systems are protected against short circuits, power-to-output wiring, and output-to-ground faults.

Instead of mounting a tiny optical encoder with weak bearings on a wobbling stub shaft, mount XR850 directly on your main application shaft. Vibration, shock, liquids, dust and dirt won't harm SMARTSafe XR850 encoders! Paint booths, draw works, coil tubing rigs...XR850 can keep them all working 24-7-365. 

Eliminate the biggest cause of industrial encoder failure eliminate the bearings with XR850 hazardous duty encoders.
Operating Power: (add load and cable drive current as req'd)
Level 1 (XRB1). 12-24VDC In, 10.6V Out, 150 mA
Level 1 (XRB2): 12-24VDC lnfOut, 150 mA
Level 2 Protection: 5-24VDC In/Out, 150mA
Output Format: A Quad B with marker (A,A\; B,B\, Z,Z\)
Frequency Range: 0 to 165 KHz
PPR: 8-6000
Speed: 5000 RPM
Maximum Cable Length:
Level 1: Encoder 500' Isolator 1000'
Level 2 (5 to 12 VDC in) 500'
Level 2 (15 to 24 VDC in) 250'
Rotor Position: +/- 0.100” [+/- 2.54mm].
Sensor Rotor Gap: 0.04", +0.015"/-0.030" [1.02mm +0.38/-0.76mm]
Temperature: -40°C to 80°C (storage -40°C to 100°C)
Environmental: IP54 (see manual for details)
Vibration: 5-2000Hz, 20G, 100G Shock
Weight: 9lbs [4kg]
Certifications:
Level 1: ATEX/IECEx Zone 1 & 21 Group IIC
Level 1: cULus Class I Div 1 and Zone 0 Group A,B,C,D*
Level 2: ATEX/IECEx Zone 2 & 22 Group IIC
Level 2: cULus Class I Div. 2 Groups A,B,C,D
*See installation drawings for Warnings and Limitations.
  • Easy-swap XR5 electronic sensors
  • Sensors can be directly machine-mounted
  • Shrugs off dirt, oil, and water contamination
  • No glass disks to break or optics to fail
  • 4,500,000+ hour MTBF design                                                           
Industry General Food & Beverage Pulp & Paper Wood Products Wind Power Crane & Hoist Metals Mining Marine Oil & Gas

Light Mill Duty

AV20, AV25, AV32, AV6A, AV6M, HS25A, HS35A, HS6A, HS6M, K661,
                   

Mill Duty

AV32, HS35M, K661, M185, M3, M3(small), RAHS35M
                   

Heavy Mill Duty

AV115, AV125, AV45, AV5, AV56, AV56S, AV67, AV85, AV850, AV850Test, AVSK, Carlen Replacement, HS45, K661, M4, M4(small), XR115, XR12, XR125, XR45, XR4F, XR5, XR56, XR85, XR850, XR97, XRB1, XRB2
                   

Severe Mill Duty

AV12, AV30, AV485, AV5, AV685, Carlen Replacement, HS40, K661, M484, M6, M6C, M7, XR12, XR485, XR5, XR685, XR97, XRB1, XRB2,
                   
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In This Section

  • 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.

  • Cam Screw Rotor™

    A Cam Screw Rotor eliminates the problems associated with slipping rotors of other types; it uses two cam (eccentric) head screws. The screws are preloaded into the rotor; simply rotate them (approximately 90°-180°) to fully engage the shaft (4-6 ft-lbs) using a standard hex (Allen) wrench. Cam screw rotors are available on AV850, AV56, AV67, AV85, and AV115 THIN-LINE II™ encoders. Cam Screw Rotor Patent # 7,485,997. Cam Screw Rotor™ is a trademark of Avtron.

  • Contamination

    Also known as contaminants, such as water, dirt, dust, oil, and other compounds which enter an encoder through seal failure and can cause optical errors. If the contamination is abrasive, it can also cause bearing failures in the encoder. Modular encoders are very resistant to contamination as they use magnetoresistive sensors and have no bearings.

  • Encoder

    A device which indicates position and speed via a set of digital outputs. Incremental encoders output quadrature (A Quad B) signals, and may add a marker pulse once per revolution.  Absolute encoders typically indicate position via a digital message, a set of parallel outputs, or analog values.

  • Explosion Protected

    Also known as Flameproof, explosion protected equipment has additional protection/safety enhancements for use in explosive atmospheres. Explosion Protected devices maybe placed directly into hazardous areas within their nameplate rating. No additional equipment is required if installation instructions are followed properly. By comparison, Intrinsically Safe devices may require the use of additional, external protection/current limiting devices outside of the hazardous area. Avtron offers hollow shaft M6C Explosion Protected encoders.

  • Heavy Mill Duty

    Heavy Mill Duty encoders are designed to withstand temperature cycling, extreme temperatures, contaminants, bearing loads, and physical force.

  • 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.

  • Modular Encoders

    Modular Encoders mount to a machined C-face or flange adapter on the motor (drive or non-drive end). Modular encoders consist of a rotor that mounts on the shaft, and a stator that bolts to the motor frame. Modular encoders are very rugged, and Avtron encoders feature Wide-Gap sensors to avoid complex shimming or fitting to the motor. Modular C-face encoders are typically used on DC motors; but some AC motors, such as Rockwell’s RPM III AC and Marathon’s Blue and Black Max motors, have C-faces standard on the non-drive end for mounting an encoder.

  • Optical Disk

    An Optical Disk is typically a glass, metal, or plastic disk with fine lines or slots etched around the perimeter that interrupt the beam of light from the light source to an optical sensor. Optical disks can be quite fragile. Avtron uses only shatterproof optical disks with Wide-Gap technology.

  • 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.

  • Resolution

    Resolution describes how many individual slices or positions can be reported by an incremental or absolute encoder.  For incremental encoders the number of PPR (pulses per revolution) expresses resolution; for absolute encoders, PPR, or counts per turn or bits of resolution may be listed.

  • Sensor Crash

    When the rotating disk in an encoder contacts the sensor (optical or magnetic/magnetoresistive), it damages or destroys the sensor. Sensor crashes can be caused by excessive vibration, shaft runout, or alignment problems in encoder mounting. Avtron encoders feature Wide-Gap technology to eliminate sensor crashes.

  • Wide-Gap Technology

    Avtron encoders use special optical sensors and magnetoresistive sensors, combined with proprietary circuit designs to allow the sensor to be located much farther from the magnetic rotor or optical disk. This eliminates sensor crashes and makes mounting easy and forgiving of mechanical variation.

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