Avtron XR97 SMARTSafe™ Sensor

Avtron XR97 SMARTSafe™ Sensor

Hazardous Duty Encoder Sensor

  • • 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
  • • Fits Shafts up to 3 3/16" [85mm]
  • • Ideal for Oil and Gas Drilling
  • • Fully Potted Electronics
  • • Up to 5000 PPR
  • • Wide Sensor-Rotor Gap: No Shimming or Scraping
  • • 3 Year No-Hassle Warranty
  • • ATEX/IECEx Zone 1,2,21,22
Outline Drawing
XR97 SMARTSafe™ modular sensors enable OEMs to achieve a world first-- hazardous duty encoders with removable electronics, embedded inside their machine.  They are ATEX, IECEx and cULus 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 larger bore applications (XR5, XR12).

For Level 2 applications requiring ATEX/IECEx Zone 2 or 22 or cULus Class I, Division 2, Groups A,B,C,D use the XR97 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 XR97 directly on your machine and install the rotor on your main application shaft.  Vibration, shock, liquids, dust and dirt won't harm SMARTSafe encoders!  Paint booths, top drives, draw works, coil tubing rigs...XR97 can keep them all working 24-7-365.

Eliminate the biggest cause of encoder failure--eliminate the bearings with XR97 hazardous duty encoder sensors.
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
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"1-0.030" [1.02mm +0.381-0.76mm]
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: 2.2lbs [1kg]
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.
  • 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
  • 4,500,000+ hour MTBF design
  • Full protection against short circuits, reverse voltage, phase-to-phase shorts
  • Direct Machine-Mount
  • 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,
XR97 SMARTSafe™ encoder sensors can be used to replace many competitive models including:

H20, H25, H38, H40 encoders
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

Baumer Hubner:
EEx OG 9, FOG 9, POG 9, POG 9 G, POG 90, POG 10, POG 10 G, POG 11, POG 11 G
EEx HOG 161, HOG8, HOG9, HOG10, HOG11, HOG131, HOG161, HOG163, HOG165 encoders

BEI Ideacod encoders:

Dynapar encoders:
X25 encoder

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

  • 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.

  • Flameproof

    Also known as Explosion Proof, flameproof encoders have additional protection/safety enhancements for use in explosive atmospheres. Flameproof encoders 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 encoders may require the use of additional, external protection/current limiting devices outside of the hazardous area. Avtron offers hollow shaft M6C Flameproof 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.

  • Line Driver

    The chip or output circuit that forms the electrical pulses output from the encoder. Avtron has extremely advanced line driver technology to prevent damage from overvoltage and short circuits. Avtron offers optional high-power line drivers to permit Avtron encoder signals to travel farther down long wires to remote controller/drive locations without the need for repeaters or amplifiers.

  • 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.

  • Marker Pulse

    The Marker Pulse occurs once per revolution. The purpose of the marker pulse is to provide a repeatable home position location for positioning applications. The marker pulse is often abbreviated as "ØZ" or "Z" in the USA and "C" or "N" in Europe.

  • 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.

  • MR

    Magnetoresistive (MR) sensors are used in Avtron encoders to provide high accuracy and superior reliability versus optical sensing systems.  For more information on magnetoresistivity:  Wiki:  http://en.wikipedia.org/wiki/Magnetoresistive

  • 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.

  • Optical Sensors

    Optical Sensors are typically phototransistors or other light sensors which sense the light emitted by the light source, as interrupted by, or passed through, the optical disk.

  • 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.

  • Pulses

    Pulses are also known as counts and are the low voltage output transitions which indicate movement of the encoder. Encoders are rated by resolution or PPR (pulses per revolution). Pulses are not the same as lines.

  • 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.

  • Rotary Encoder

    A rotary encoder provides position and/or speed feedback information about a rotating shaft.  Rotary encoders may be hollow shaft, no-bearing modular, coupled solid shaft style.  They may provide absolute positioning information, or incremental velocity feedback. Avtron rotary encoders are designed and built to be far more reliable than ordinary rotary encoders. Avtron encoder white papers on our blog provide more details of how and why Avtron rotary encoders are more reliable.

  • Rotor

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

  • Severe Duty

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

  • T.I.R.

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

  • UL Listed

    UL Listed Avtron encoders can be directly applied to any hazardous duty application which requires Class and Division, Class and Zone or AEX certification.  Note that UL Listing is a different system than ATEX or IECEx.  Ensure the model you select has the UL listing which meets the application requirements.

  • 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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