Carlen Encoder Replacement

Carlen Encoder Replacement

Replace Your Carlen Controls Obsolete Encoders and Tachometers

  • Directly replace Carlen models
  • Fully potted electronics available
  • Improved temperature range
  • No-bearing options
  • Diagnostic LED & outputs
  • Keep your site running without unplanned downtime
Outline Drawing
Nidec Avtron offers direct replacements for obsolete Carlen Controls encoders and tachometer models.

Models that can be directly replaced include:

CC290T = AV485
CC340T = HS45/M4
CC350T = AV485
CC450AA = AV30
CC450AE/CC451AE = AV30
CC451AEMT = AV30
CC550 = AV685
CC600 = HS45/M4
CC700 = AV685
CC1200 = AV685

Avtron encoders are also available with common accessories bundled with Carlen Controls units for heavy and severe mill duty applications.  These include: built-in mechanical overspeed switches, dual or backup outputs, shaft electrical isolation systems, stub shafts for MD motor frames.

Some Carlen models can be replaced by no-bearing Avtron encoders such as AV125 and AV850, further increasing durability and adding many years of product life.

Avtron encoder models offer equal or improved specifications from Carlen models:

Examples: (Carlen => Avtron)
Operating Temperature:  - 0C to 70C = > -40C to +100C
Frequency Range:  0-100kHz => 0 - 165kHz
TIR Allowed:  0.0005 T.I.R => 0.002 T.I.R

  • Mechanical overspeed option available
  • MD frame motor stub shafts available
  • Dual/redundant output options
  • Replaceable electronics
Industry General Food & Beverage Pulp & Paper Wood Products Wind Power Crane & Hoist Metals Mining Marine Oil & Gas

Light Mill Duty

AV20, AV25, AV4, AV6A, AV6M, Avtron Elevator Encoder, Cables and Connectors, Encoder Couplings, Encoder Programming Tool, HS25A, HS35A, HS4, HS6A, K661, Rush AV4 Program, 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,
Carlen models that can be directly replaced by Avtron encoders include:
Carlen CC290T
Carlen CC340T
Carlen CC350T
Carlen CC450-AA
Carlen CC450-AE
Carlen CC450-AEMT
Carlen CC550
Carlen CC600
Carlen CC700
Carlen CC1200
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In This Section

  • Absolute Encoder

    Absolute indicates the position of the rotor or shaft referenced to a fixed starting position. If power is turned off and then on, the encoder recalls the position correctly. It may output the position information on a set of output wires (parallel), or it may output the absolute position using a communications bus, such as Profibus or DeviceNet. Absolute encoders can be single-turn or multi-turn. For more information, Wikipedia:

  • 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.

  • 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.

  • Heavy Mill Duty

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

  • Isolated Outputs

    Isolated Outputs provide two or more completely separate output signals from the encoder. These separate signals can be wired to two or more devices, or used for redundant control systems for more uptime. Avtron isolated encoder outputs are always created using fully redundant electronics and sensors, isolated from each other and from the housing for maximum reliability.

  • 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.

  • Resolver

    A device typically used to indicate absolute rotary position (angle) and velocity. A resolver is excited by an AC sine wave and produces amplitude modulated (analog) AC waves which indicate the rotor position. Avtron offers the Rotasyn Resolver.

  • Single Turn

    Single turn refers to absolute encoders--the encoder accurately reports the position within 360 degrees of travel to the resolution specified.  Multiple turns are ignored--multiturn absolute encoders are required to track and report position over multiple turns as well as the position within 1 turn.  Avtron absolute single-turn encoders are more durable because they don't use glass disks.  For more information about absolute rotary encoders:  Wikipedia:

  • 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.

  • SSI

    SSI (Synchronous Serial Interface) is a fieldbus used by Avtron absolute encoders to communicate speed and position to a controller.  SSI is extremely simple and fast.  SSI is also an effective, open vendor alternative to proprietary encoder fieldbuses such as EnDAT and HyperFace.   For more information about SSI-Wikipedia:

  • Stub Shaft

    The portion of the shaft (often on the non-drive end of the motor) used to mount an encoder. To add an encoder to a motor or other shaft that lacks enough extra shaft length to install the encoder, an additional shaft length is added. The stub shaft is threaded into the center of the motor shaft, or the existing motor shaft is enclosed in a sleeve that grips the shaft. Avtron offers many standard and custom stub shafts.

  • T.I.R.

    Total Indicated Runout. This is a measurement of how much a shaft wobbles with each revolution (shaft runout).

  • 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.

  • Wiegand wire

    Wiegand wires generate a pulse of electricity in a coil as a magnet passes near the wire.  Wiegand wires are used in Avtron absolute magnetic encoders to self-power the multi-turn counting engine, so even if the encoder has no power when turned, the absolute encoder correctly reports the number of turns and position.  This allows Avtron to eliminate the glass disks and gears that cause failures in other absolute encoders.  For information on the Wiegand effect-Wikipedia: , Wiegand wire:

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