XR12 SMARTSafe™ Sensor

XR12 SMARTSafe™ Sensor

Large Bore Hazardous Duty Encoder Sensor

  • • cULus Class I, Div 1 Listed, Groups A,B,C,D
  • • cULus Class I Zone Group IIC
  • • cULus Class I, Div 2 Listed, Groups A,B,C,D
  • • ATEX IECEx Rated: Zone 1 & 2, 21 & 22
  • • Fits Shafts up to 7 7/8" [200mm]
  • • Ideal for Oil and Gas Drilling
  • • Fully Potted Electronics
  • • Up to 8192 PPR
  • • Wide Sensor-Rotor Gap: No Shimming or Scraping
  • • 3 Year No-Hassle Warranty
Outline Drawing
XR12 SMARTSafe™ modular incremental quadrature encoder sensors enable the world's first hazardous duty rotary encoders with removable electronics.  They are cULus, ATEX and IECEx certified and offer incredibly reliable no-bearing construction!  SMARTSafe sensors can be used in ATEX/IECEx gas and dust and UL gas hazardous environments.  Also available:  hollow shaft models (XR685), shafted models (XR485), no-bearing modular encoders (XR125, XR850), and modular sensors for smaller bore applications (XR5).

For Level 2 applications requiring ATEX/IECEx Zone 2 or 22 or cULus Class I, Division 2, Groups A,B,C,D use the XR12 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 XR56 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 mounting a tiny optical encoder with weak bearings on a wobbling stub shaft, mount XR12 directly on your machine and install the rotor on your main application or motor shaft.  Vibration, shock, liquids, dust and dirt won't harm SMARTSafe™ XR12 encoders!  Paint booths, draw works, coil tubing rigs...XR12 can keep them all working 24-7-365.

Eliminate the biggest cause of industrial encoder failure--eliminate the bearings with XR12 hazardous duty encoder sensors.
Operating Power: (add 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, 150 mA
Output Format: A Quad B with marker (A,A–, B,B–, Z,Z–)
Frequency Range: 0 to 165 KHz
PPR: 8-8192
Speed: 6000 RPM Max. (contact factory for higher speeds)
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 Positioning: +/-0.100" [+/-2.54mm] movement/misalignment
Sensor-Rotor Gap: 0.045", +0.015/-0.040" [1.14mm+0.38/-1.0]
Temperature: -40°C to 80°C (Storage -40°C to 100°C)
Environmental: Electronics-IP67 (see manual for details)
Vibration: 5-2000Hz, 18G; 100G Shock
Weight: 2.2 lbs. [1kg]
    Level 1: ATEX/IECEx Zone 1 & Zone 21 Group IIC
    Level 1: cULus Class I, Division 1 and Zone 0 Group A,B,C,D*
    Level 2: ATEX/IECEx Zone 2 & 22 Group IIC
    Level 2: cULus Class I, Division 2 Group A,B,C,D
*See installation drawings for Warnings and Limitations
  • Sensor PPR can be factory reprogrammed
  • Full protection against short circuits, reverse voltage, phase-to-phase shorts
  • Shrugs off dirt, oil, and water contamination
  • No glass disks to break or optics to fail
  • Sensor for XR125 encoder
  • Direct machine-mount capability
  • Self-Diagnostic LED and Alarm Output
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

  • 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.

  • C-Face

    A machined flange or elevated/recessed face provided on motors for mounting accessories. Typically provided on the drive end for gearbox/load mounting, C-faces may also be provided on the non-drive end for mounting encoders, brakes, and other accessories.

  • 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.

  • 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.

  • 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.

  • Magnetic Rotor

    A magnetized disk with multiple north and south poles lined up around the perimeter of the disk. A magnetoresistive sensor detects the transitions and generates the pulses generated by the magnetic encoder.

  • Magnetoresistive Sensor

    A sensor that detects the magnetic poles on an encoder's magnetic rotor and transforms them into pulses. Avtron magnetoresistive (MR) sensors use advanced technology to reject external magnetic signals such as brake solenoids and motor magnetic fields. MR sensors enable Avtron magnetic encoders to ignore dirt, oil, water, and other contaminants.

  • 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.

  • Rotor

    The disk-shaped portion of the modular encoder that is mounted on the motor shaft. Avtron modular encoders use magnetic rotors.

  • 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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