Avtron AV485 SMARTach™ III Encoders

Avtron AV485 SMARTach™ III Encoders

The Most Rugged Solid Shaft Encoder Available!

  • Severe Mill Duty
  • Up to 5000 PPR
  • Replaces Competitive Models Without Rewiring
  • Self-Diagnostic LED & Alarm Output
  • Foot or NEMA 56C Face Mount
  • Removable Sensors
  • IP66 Enclosure
  • High-Power Output Standard
  • Outputs Fully Short Circuit Protected
  • Optional Dual Isolated Outputs
Outline Drawing
AV485 SMARTach™ III severe duty magnetic encoders can be foot or NEMA 56C face/flange mounted. They feature our largest bearings on an ultra-wide stance for pulley and other rough applications.  Also available:  AV685 for hollow shaft mounting, and AV850 encoders for complete flowerpot/flange/coupling elimination.

The AV485 is designed to withstand the worst environments: buried in slag, coated in pulp, sprayed with salt water or cutting coolants, it keeps working. The modular, gull-winged design makes it easy to install and service; the base can be bolted in place without removing the encoder, and the AV5 wide-gap removable sensors require no adjustment or shimming.

The sensors are fully potted to protect against liquids, and are interchangeable between AV850, AV485, and AV685 encoders. The universal 5-24V design drives longer cables and is protected against wiring errors and surges. A second backup output is available with the same or different PPR, and offers completely separate electronics for maximum uptime. 

Adaptive Electronics: At power-up you know you installed it right! The green LED tells you your AV5 Sensor is aligned with the rotor and reading signal.  If at any time, the AV5 cannot produce consistent signals, the LED changes to red and the optional remote alarm contact activates. However, the encoder keeps working to give you time to schedule service.  Even wiring errors and short circuits that cause an over-temp situation will be detected and indicated by changing the LED to orange.  

For easy upgrades, the AV485 matches the bolt pattern and shaft location of older analog and digital models.

Keep your mill running today, and for years to come: install the AV485!
Operating Power: Volts: 5 - 24 VDC*
Current: 100mA nom, no load
Output Format: A Quad B with Marker (A,/A, B,/B, Z,/Z)
Second Isolated Output: Optional
Frequency Range: 
     @5V, @1m cable, 250 kHz Max
     @24V, @300m cable, #8 output, 45 kHz Max   
Maximum Cable Length: 1000' 
PPR: 4 - 50000***
Speed: 5000 RPM Max****
Electronics: Fully Encapsulated, IP67** 
Temperature: -40° to 120°C* (150°C rotor)^
Vibration: 18 g’s
Shock: 1 meter drop test
Chemical: Polyurethane enamel paint protects against salt spray, mild acids, and bases.
Weight:  14 lbs. [6.4 kg] / 16 lb [7.3 kg] dual output


* Electrical specifications for SMARTach III model (serial #30,000 or higher), consult Nidec Industrial Solutions for earlier model specifications.
** Certain connector options may reduce IP rating.
***(PPR) Standard maximum PPR is 5000. Consult Factory with your application for PPRs up to 50,000.
**** (Speed) Maximum RPM may be limited for PPR > 2,500. Consult Factory with your application.
^ -20°C to 80°C Standard, requires high-temperature model and instrument air feed for 120°C rating

All dimensions are in inches [millimeters].
Specifications and features are subject to change without notice.

  • Foot mount bolt pattern matches older analog models exactly
  • Optional K661 signal converter for direct replacement of analog tachs (BC42, 46, etc.)
  • Replaces Dynapar H56, Northstar RIM6200, NexGen 6200; Avtron M485, M727, M737; GE 5BC42/46
  • SMARTach II sensors find problems before they cause failures
  • Protected against: power-to-phase, short circuits, and reverse voltage wiring problems
  • Mix and match any PPR’s
  • Optional extended temperature ranges: -40°C to +80°C, -20°C to + 120°C*
  • Shaft grounding & overspeed switch optional
  • 1 Year No-Hassle Warranty
Industry General Food & Beverage Pulp & Paper Wood Products Wind Power Crane & Hoist Metals Mining Marine Oil & Gas

Light Mill Duty

AV20, AV25, AV6A, AV6M, Avtron Elevator Encoder, Cables and Connectors, Encoder Couplings, Encoder Programming Tool, HS25A, HS35A, HS6A, K661, 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, 		                   
Avtron's AV485 encoders replace many competitive models, including:

Lakeshore/Northstar: RIM TACH 6200, RIM6200, RIM620, R6 encoders
Dynapar:  60P, 62P, 63P encoders

Analog Tachogenerators including:
GE BC42, BC44, BC62

And other NEMA 56C Flange-mounted coupled encoders and tachogenerators including 
Avtron's K727B, K727U, K927A, K927B, M3-1, M3-2, M4-1, M4-2, M385, M485, M727, M727A, M737, M737A, M738, M785, M938, M939, M940, M945 Encoders

For direct model replacements, try our cross reference page
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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

  • Analog Tachogenerators

    Also known as DC tachogenerators, Analog Tachogenerators are small DC generators that output a voltage in proportion to speed. They cannot indicate position, only speed and direction of rotation. A common mounting style of analog tachogenerator was the General Electric BC42 and BC46 Series with NEMA 56C Foot or Face Mount, and the smaller 5PY flange mount unit. Analog tachogenerators can be replaced with modern digital encoders. Avtron offers a complete retrofit package using the existing flange adapter and coupling already on the motor and a Frequency to Voltage Converter like the Avtron K661, which resides in the drive cabinet.

  • BC42

    An analog tachogenerator manufactured by General Electric, part number 5BC42xxxxx, NEMA 56C face or foot mount, coupled. It is now obsolete. It may be replaced by an Avtron encoder combined with a K661 converter solution.

  • BC46

    An analog tachogenerator manufactured by General Electric, part number 5BC46xxxxx, NEMA 56C face or foot mount, coupled. It is now obsolete. It may be replaced by an Avtron encoder combined with a K661 converter solution.

  • BC66

    A heavy duty analog tachogenerator manufactured by General Electric, part number 5BC66xxxxx, NEMA 56C face or foot mount, coupled. It is now obsolete. It may be replaced by an Avtron encoder combined with a K661 converter solution.

  • 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.

  • Coupled/Coupling

    Refers to a flexible device that is used to link a solid shaft encoder to the shaft to be monitored. Avtron strongly recommends isolated, flexible disk style couplings in heavy duty applications to maximize encoder bearing life. For light mill duty applications, flexible helical couplings are a great option. If there's a large amount axial shaft movement or misalignment, shift to magnetic couplings.

  • DC Tachogenerators

    Also known as Analog Tachogenerators. Small DC generators that output a voltage in proportion to speed. They cannot indicate position, only speed and direction of rotation. A common mounting style of analog tachogenerator was the General Electric BC42 and BC46 Series with NEMA 56C Foot or Face Mount, and the smaller 5PY flange mount unit. Analog tachogenerators can be replaced with modern digital encoders. Avtron offers a complete retrofit package using the existing flange adapter and coupling already on the motor and a Frequency to Voltage Converter like the Avtron K661, which resides in the drive cabinet.

  • 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.

  • 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.

  • 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.

  • 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.

  • Industrial EPIC

    The preferred encoder connector of most users in North America. It contains a full size terminal strip and, unlike the MS connector, requires no soldering for quick field connections. Avtron offers pin-for-pin exact replacements for competitors’ models using industrial EPIC® style connectors. EPIC® is a registered trademark of the Lapp Group.

  • 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.

  • 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

  • MS Connector

    The most used encoder connector style in North America. Available in 6, 7, and 10 pin versions, with 10 pins being the most common. Avtron offers pin-for-pin exact replacements for competitors’ models using MS connectors. MS connectors are extremely reliable but require soldering. Many users prefer industrial EPIC ® style connectors instead. EPIC® is a registered trademark of the Lapp Group.

  • NEMA 56C

    A NEMA 56C face or flange mount, also known as bearingless or pancake encoder, is a 4.5" flange with (4) bolts located in a 5.88" circle. Originally designed as the standard for mounting solid shaft, coupled tachometers on flange adapters, the NEMA 56C is also a standard for mounting modular encoders. Avtron AV56 THIN-LINE II™ encoders mount on NEMA 56C faces. Marathon Blue Max and Black Max AC motors feature a NEMA 56C face on the non-drive end.

  • Quadrature

    To determine which direction an encoder is revolving, encoders output quadrature signals: two streams of pulses, A & B, generated at 90° timing angles. (Also called A Quad B) A leading B indicates rotation in one direction; B leading A indicates the encoder is rotating in the opposite direction. Example: “A leads B with clockwise rotation as viewed from the encoder face on an HS45 encoder." Many encoders with quadrature outputs also have complementary outputs: A NOT and B NOT signals.

  • RE210

    An analog tachogenerator manufactured by Baldor/Reliance, NEMA 56C face or foot mount, coupled. It may be replaced by an Avtron encoder combined with a K661 converter solution.

  • Severe Duty

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

  • 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.

  • 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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