Avtron XR115 SMARTSafe™ Encoders

Avtron XR115 SMARTSafe™ Encoders

Revolutionary No Bearing Design

  • • Fits IEC 115mm Motor Flanges
  • • ATEX/IECEx Rated for Zone 1, 2, 21 & 22 Applications
  • • Ideal for Oil and Gas Drilling
  • • No Bearings to Wear Out
  • • Fully Potted Electronics
  • • Up to 5000 PPR
  • • Wide Sensor-Rotor Gap: No Shimming or Scraping
  • • Protected Against Wiring Errors
  • • 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
XR115 SMARTSafe 115mm modular incremental quadrature rotary encoders are a breakthrough in hazardous duty encoders.  They are ATEX and UL approved and offer incredibly reliable no-bearing construction!  SMARTSafe encoders can be used in gas and ATEX dust hazardous environments.  Also available:  hollow shaft models (XR45, XR47, XR685), shafted models (XR4F, XR485), and no-bearing modular encoders to fit other flange sizes (XR56, XR67, XR85, XR125, XR850).

For Level 2 applications requiring ATEX/IECEx Zone 2 or 22 or UL Class I, Division 2 (Gas) Groups A,B,C,D use the XR115 directly in your application, with no barrier, isolator or cable gland required.

For Level 1 applications requiring ATEX/IECEx Zone 1 or 21 protection 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 XR115 can also be used in UL Class I Div 1 & 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 relying on a tiny optical encoder with weak bearings, install the most rugged encoders available for your drilling or industrial applications.  Vibration, shock, liquids, dust and dirt won't harm SMARTSafe encoders!  Paint booths, draw works, coil tubing rigs...XR115 can keep them all working 24-7-365.

Eliminate the biggest cause of Industrial Encoder failures. Eliminate the bearings with XR115 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 In/Out, 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
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'
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: 2-3lbs [.9-1.4kg]
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.
  • Replaces Hubner POG and OG and other shafted flange-mount encoders
  • Eliminates large & costly flange adapters & flowerpots
  • Fits shafts 10 - 85 mm
  • Thin profile reduces overall motor depth
  • No air gap adjustment required
  • 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,
XR115 SMARTSafe™ encoders can replace many competitive models including:

Baumer Hubner (remove flange adapter):
EEx OG 9, FOG 9, POG 9, POG 9 G, POG 90, POG 10, POG 10 G, POG 11, POG 11 G

HS35, H37, H38, H40, L25 explosion proof and intrinsically safe encoders
924-08062-001, 924-08062-002, 924-08062-003, 924-08063-001, 924-08063-002, 924-08064-001, 924-08064-002, 924-08172-001, 924-08172-002, 924-08173-001, 924-08173-002, 924-08174-001, 924-08174-002, EM-DR1-IS-5-RTB-24V/V, EM-DR1-IS-5-RTB-24V/4, EM-DR1-IS-5-RTB-24V/OC intrinsic safety barriers & systems

BEI Ideacod encoders:

Dynapar encoders:
X25 encoder

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

And many other hazardous area, intrinsically safe and explosion-proof ATEX rated encoders. 
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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.

  • 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.

  • 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.

  • Flange Adapter

    A Flange Adapter provides the NEMA 56C motor mounting face and properly locates the encoder shaft. The encoder shaft and motor shaft are then connected using a flexible coupling. (Drawing "A") Often flange adapters can be eliminated by directly mounting a modular encoder such as an Avtron AV125, AV850, AV56, AV67, AV85, AV115 unit on the motor flange. (Drawing "B")

  • Flowerpot

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

  • Heavy Mill Duty

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

  • 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.

  • 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.

  • Shimming

    Often, to produce precise stub shaft, modular encoder, or foot mount installation, shims are placed between the two items to be aligned. Avtron encoders are designed to eliminate the need for shimming. Many competitors’ modular encoders still require shimming for proper operation.

  • 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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