Avtron AV5 SMARTach™ III Sensor Module for AV485/AV685/AV850

Avtron AV5 SMARTach™ III Sensor Module for AV485/AV685/AV850

Avtron AV5 SMARTach™ III

  • Wide-Gap Technology Eliminates Gapping and Shimming
  • Mount in AV485, AV685, and AV850 Encoders
  • Direct Machine-Mount Option
  • Permits Up to 4.5" [115mm] Through-Shaft
  • Fully Potted Electronics
  • -40°C to +100°C Standard; +120°C Option Requires Encoder Cooling
  • 3 Year No-Hassle Warranty
Outline Drawing
Avtron AV5 SMARTach III™ sensors are magnetoresistive, severe duty incremental quadrature sensors for the AV485, AV685, or AV850 rotary encoders. The AV5 is also usable in applications where an encoder housing is not needed – simply mount the AV5 with your bracket, and use an AV850 or other rotor.  Also available: XR5 and XR12 sensors for hazardous duty applications or XP5 for applications where explosion proof is a requirement. 

The AV5 is ideal for applications where mounting on a large diameter through-shaft is needed, including large hollow shafts for cooling water or air.  The AV5 sensor + AV850 rotor combination permits through-shafts up to 4.5" [115mm].

The AV5 offers a full range of electrical connector options, including IP67 cable, IP66 MS connectors, and IP65 Industrial with built-in terminal strips. The AV5 sensor is fully protected against all types of wiring errors, including short circuits, reverse voltage, and phase-to-phase shorts. It is one tough sensor! For larger bore applications, use AV12 sensors with the AV125 encoder (or as stand-alone).

The universal 5-24V design drives longer cables and is protected against wiring errors and surges.

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.
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: 5400 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:  2 - 3 lbs [0.9 - 1.36 kg] (will vary by connector options)

*  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.
^ Requires air cooling system option in AV485 & AV685 to reach +120°C rating

All dimensions are in inches [millimeters].
Specifications and features are subject to change without notice.
  • High resolution up to 5000 PPR
  • Sensor PPR can be factory reprogrammed
  • Full protection against short circuits, reverse voltage, phase-to-phase shorts
  • High-power outputs for long cable runs
  • Optional 24V in, 5V out option for low-voltage, long-cable applications
  • Diagnostic LED and alarm output contact indicates proper operation
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 SMARTach II Encoders enable replacement of unreliable, easily damaged sensors including:
RIM LD 240
RIM LD 256
RIM LD 480
RIM LD 512
RIM LD 960
RIM LD 1024
RIM LD 1024Z
RIM LD 1200
RIM LD 1200Z
RIM LD 2048




Pin-for-pin compatible with existing cabling including factory cables such as:

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

  • 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.

  • 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.

  • 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.

  • 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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