Avtron XR685 SMARTSafe™ Encoders

Avtron XR685 SMARTSafe™ Encoders

Severe Duty Hollow Shaft Encoder for Hazardous Applications

  • • Severe Duty
  • • Up to 5000 PPR
  • • ATEX/IECEx Rated for Zone 1, 2, 21 & 22 Applications
  • • IP66 Enclosure
  • • Replaces Competitive Models Without Rewiring
  • • Fully Potted Electronics
  • • Self-Diagnostic LED and Alarm Output
  • • 1 Year No-Hassle Warranty
  • • cULus Class I Div 1 Groups A, B, C, D
  • • cULus Class I Zone 0 Group IIC
  • • cULus Class I Div 2 Groups A, B, C, D
Outline Drawing
XR685 SMARTSafe hollow shaft incremental quadrature rotary encoders are a breakthrough in hazardous duty encoders.  They are ATEX/IECEx and UL approved and offer huge bearings for maximum life.  SMARTSafe encoders can be used in ATEX/IECEx gas and dust and UL gas hazardous environments.  Also available:  hollow shaft models in other bore sizes (XR45, XR47), shafted models (XR4F, XR485), no-bearing modular encoders (XR56, XR67, XR85, XR115, XR125, XR850), and modular sensors (XR5, XR12).

For Level 2 applications requiring ATEX/IECEx Zone 2 or 22 or UL Class I, Division 2, Groups A,B,C,D use the XR685 directly in your application, with no barrier, isolator or cable gland required.

For Level 1 applications requiring ATEX/IECEx Zone 1 or 21 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. XRB2 Isolator Systems enable use in Class I Div 1 and Class I Zone 0 applications. 

Unlike the competition, Avtron SMARTSafe encoder systems are fully protected against short circuits, power-to-output wiring, and output-to-ground faults at every point.  Wiring errors won't harm this system!

Instead of depending on a tiny optical encoder with weak bearings use XR685.  Vibration, shock, liquids, dust and dirt won't harm SMARTSafe XR685 encoders!  Paint booths, draw works, coil tubing rigs...XR685 can keep them all working 24-7-365.

Eliminate encoder failures in your hazardous environment application-select XR685 today!
Operating Power: (add cable drive current as req'd)
    Level 1 Protection:  12-24VDC In, 10.6V Out, 150mA
    Level 2 Protection:  5-24VDC In/Out, 100mA 
Output Format: A Quad B with marker (A,A–, B,B–, Z,Z–)
Frequency Range: 0 to 165 KHz
PPR: 8-5000
Speed: 4000 RPM Max. (contact factory for higher speeds)
Maximum Cable Length
    Level 1:  400' [120m]
    Level 2:  500' [150m] @ 5-12V; 200' [60m] @ 24V
Temperature: -40°C to 80°C (Storage -40°C to 100°C)
Environmental: Electronics-IP67, IP66 overall (see manual for details)
Vibration: 5-2000Hz, 18G; 100G Shock
Weight: 15 lbs. [6.4 kg]; 17lbs [7.7kg] dual output
Certifications:  
    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

  • Optional K661 signal converter for direct replacement of analog tachs (BC66, etc.)
  • Shrugs off dirt, oil, and water contamination
  • Huge range of stub shaft adapters available to fit shafts from 1 3/8" to 12" & most major motor brands
  • Protected against: power-to-phase, short circuits, and reverse voltage wiring problems
  • No glass disks to break or optics to fail
  • End of shaft and thru shaft models available
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

  • 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.

  • 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.

  • 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.

  • Contamination

    Also known as contaminants, such as water, dirt, dust, oil, and other compounds which enter an encoder through seal failure and can cause optical errors. If the contamination is abrasive, it can also cause bearing failures in the encoder. Modular encoders are very resistant to contamination as they use magnetoresistive sensors and have no bearings.

  • 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.

  • 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.

  • Hollow Shaft

    Hollow Shaft encoders mount by passing the shaft of the motor into or through the encoder. Hollow shaft encoders are easy to mount and replace but are vulnerable to damage. Also, the weight of the encoder must be considered for small motor shafts < 0.75" diameter. Avtron offers a full range of hollow shaft encoders, including: AV685, HS25A, HS35A, HS35M, M3, M4, M6, M7, XP45.

  • 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.

  • 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.

  • 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.

  • Tachometer

    Also known as a tach, a device which indicates speed of rotation. Modern tachometers are actually rotary incremental encoders which indicate position, speed, and direction of rotation.

  • Torque Arm

    A type of anti-rotation arm used to mount hollow shaft encoders to large frame motors. It features a threaded rod for adjustable radius.

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