Nidec-Avtron Makes the Most Reliable Encoders in the World

8 9 0 1 E . P L E A S A N T VA L L E Y R O A D • I N D E P E N D E N C E , O H I O 4 4 1 3 1 - 5 5 0 8

T E L E P H O N E : ( 1 ) 2 1 6 - 6 4 2 - 1 2 3 0 • FA X : ( 1 ) 2 1 6 - 6 4 2 - 6 0 3 7

E - M A I L : t a c h s @ n i d e c - a v t r o n . c o m • W E B : w w w. a v t r o n e n c o d e r s . c o m

DESCRIPTION

The Avtron Model XR45, SMARTSafe™ is a heavy duty incremental encoder for hazardous atmosphere applications (also known as tachometer or rotary pulse generator). Its output is directly proportional to shaft position (pulse count) or speed (pulse rate). The

XR45 operates down to zero speed and can be used for both control and instrumentation applications.

CAUTION

The XR45 is designed for use in hazardous applications which require protection from gas or dust ignition for safe operation. Proper selection, wiring and installation procedures are essential to ensuring safe conditions.

When mounted to a machine shaft, the XR45 design eliminates the need for shaft couplings, adapter flanges, or accessory mounting faces. The high clamping-force collar holds the XR45 in place, even under severe vibration & shock. A high-performance composite shaft insert provides electrical isolation from motor shaft currents. The shaft insert permits models to fit a range of shaft sizes from 5/8” to 1 1/8”

[16mm - 30mm]; additional sizes available upon request. An antirotation arm prevents housing rotation while allowing for shaft end float.

The XR45 utilizes magnetoresistive sensors. This proven technology is ideal for rugged environments since it is immune to many contaminants that cause optical encoders to fail. All of the XR45 electronics are potted, providing full protection against liquids. The outputs are protected against short circuits and wiring errors.

Each XR45 has a two-phase output (A, B) 90° out of phase, with complements (A, B), (A Quad B Output). A marker pulse with complement (Z, Z) is also present.

The XR45 has a diagnostic package that includes Adaptive Electronics and a Fault-Check output and red/green LED for local indication. With this package, the XR45 can maintain itself, and provide an alarm if there is a problem before the problem causes un scheduled downtime.

ADAPTIVE ELECTRONICS

A perfect duty cycle consists of a waveform whose “high” and

“low” conditions are of the same duration (50%/50%). It is possible over time for the duty cycle and edge separation to change due to component drift, temperature changes, or mechanical wear.

The Adaptive Electronics extend the life of the XR45 by constantly monitoring and correcting duty cycle and edge separation over time.

The XR45 has been evaluated to be compliant with IEC60079-0:2007,

IEC60079-11:2011, EN60079-0:2009, EN60079-11:2012,

BSEN 61000-6-4:2007 and BSEN61000-6-2:2005 (Certificates of conformity: TRAC12ATEX0002X, TRAC12ATEX 0003X, IECEx TRC

12.0009X, and IECEx TRC12.0001X.)

THE XR45 IS CERTIFIED FOR USE IN:

Group II, Category 2 (ATEX/IECEx Zone 1), Gas Group IIC potentially explosive atmospheres when marked CE 0539

Ex

II 2 GD, Ex ib IIC

T4 Gb -40°C < Tamb < 80°C and used with an Avtron isolator marked

CE 0539

Ex

[II 2 GD] [Ex ib IIC Gb] -40°C<Tamb<80°C.

ATEX/IECEx Instructions

MODEL

XR45 SMARTSafe

TM

5/8” to 1-1/8” (16-30mm)

HOLLOW SHAFT FOR HAZARDOUS

APPLICATIONS

Group II, Category 2 (ATEX/IECEx Zone 21), Dust Group IIIC potentially explosive atmospheres when marked CE 0539

Ex

II 2 GD, Ex ib IIIC T200°CDb -40°C<Tamb<80°C and used with an Avtron isolator marked CE 0539

Ex

[II 2 GD] [Ex ib IIIC Db]

-40°C<Tamb<80°C .

Group II, Category 3 (ATEX/IECEx Zone 2), Gas Group IIC_* potentially explosive atmospheres when marked CE

Ex

II 3 GD, Ex ic

IIC* T4 Gc -40°C<Tamb<80°C

*see chart in specification section and used with a power supply that limits voltage and current per the chart in the specification section.

Group II, Category 3 (ATEX/IECEx Zone 22), Dust group IIIC potentially explosive atmospheres when marked CE

Ex

II3 GD, Ex ic

IIIC T200°C Dc -40°C<Tamb<80°C.

See installation section for electrostatic charging hazard instructions and other limitations.

INSTALLATION

CAUTION

Be careful not to damage clamping fingers of hollow shaft during handling. Do not tighten clamping collar before installation onto motor shaft.

WARNING

Installation should be performed only by qualified personnel. Safety precautions must be taken to ensure machinery cannot rotate and all sources of power are removed during installation.

For installations of Equipment Group II, Category 2 (ATEX/IECEx

Zone 1) Gas Group IIC & Dust group IIIC (ATEX/IECEx Zone 21):

Available as a system only including XR45 with line driver option 5 and an Avtron Isolator module XRB1 (P/N B35134).

System parameters are:

Um= 250V

Uo (open circuit voltage) = 7.14VDC max.

Io (short circuit current) = 420mA max.

Co (system capacitance) = 13.5uF max.

Lo (system inductance) = 0.15mH max.

Encoder parameters are:

Ui (input voltage) = 7.14VDC max.

Ii (fault current) = 420mA max.

Ci (internal capacitance) = 11.9uF max.

Li (internal inductance) = 0mH max.

The isolator XRB1 can be supplied as a separate module for location in a safe area or in an explosion proof box on a short flexible cable tethered to the encoder.

For installations of Equipment Group II, Category 3 (ATEX/IECEx

Zone 2) Gas group IIC, Dust group IIIC (ATEX/IECEx Zone 22):

Requires an XR45 with line driver option 7 and a SELV (Energy Limited) or equivalent power supply which limits voltage and current to the values in the table in the specifications. If current limit is not inherent in the power supply a separate fuse between the power supply and encoder can be used to limit current.

XR45 1

NOTE:

Isolators, encoders and cable must be selected and installed in accordance with the latest edition of

IEC/EN60079-14 and IEC/EN60079-25. Cable characteristics must comply with IEC/ EN60079-14 and

IEC/EN60079-25 and for zone 1 applications total system capacitance between the isolator and encoder (including cable) must be less than Co-Ci. Total system inductance

between the isolator and encoder must be less than Lo-Li.

The equipment is intended for a fixed installation and should be mounted so as to avoid electrostatic charging. The XR45 is not considered as a safety device and is not suitable for connection into a safety system.

The XR45 construction materials contain less than 6% magnesium by mass. These materials are not considered as able to trigger an explosion in normal operating modes in accordance with the requirements for category 2 or 3 equipment. These materials are not known to react with any explosive atmospheres to which the XR45 may be subject. It is however the responsibility of the end user to ensure that the XR45 is selected correctly for the potentially explosive atmosphere in which the equipment is to be put into service.

The XR45 installation is similar to HS45.

Refer to the back pages of these instructions for outline and mounting dimensions.

The hollow shaft XR45 design eliminates the potential for coupling failures from misalignment, however, excessive housing movement

(wobble) may cause undesirable vibrations and bearing damage. The higher the RPM, the more severe the vibration will be from housing movement. In a typical installation a housing movement of 0.007”

[0.18mm] TIR or less (as measured at the outside diameter of the main encoder body) will not have an adverse effect. For overspeed applications, TIR should be < 0.002” [0.05mm].

1) Disconnect power from equipment and encoder cable.

2) Use caliper gauge to verify motor shaft is proper diameter and within allowable tolerances: +0.000”, -0.0005” [+0.00,

-0.013mm].

3) Clean machine shaft of any dirt and remove any burrs.

4) Use dial indicator gauge to verify the motor shaft: Total Indicated

Runout (TIR) <0.002” [0.05mm].

5) Install the anti-rotation bracket tether to the face of the encoder using M6 Hex screws and lock washers, included with the tether.

Tighten to 65 in-lbs [7.5n-m]

5a) (optional) For non-through-shaft (end of shaft) applications, the optional rear cover may be installed for optimum performance against dirt, liquid sprays and impacts.

For Clamp Collar Mounting Style:

6) Loosen clamping collar screws.

NOTE

These screws have factory applied thread locker, no further thread locker application is required.

7) Test Fitting: carefully slide the encoder onto the shaft to verify fit.

Ensure a minimum of 1/8” [2mm] between encoder and mounting surface. DO NOT FORCE. Encoder should slide on easily. If the encoder does not fit easily, remove it, verify shaft size, and check for burrs and shaft damage.

XR45 2

8a) For end of shaft applications using the clamping collar system, place the XR45 at least 2” onto the shaft. (For larger bore shafts

1” [25mm] or larger, minimum shaft engagement is 1.75”

[45mm]; for overspeed applications the minimum engagement is

2.65” [67mm]) Ensure the stub shaft does not contact the rear

cover.

8b) For thru-shaft applications using the clamping collar system, remove the rear shaft cover (screws are retained by the cover) and position the XR45 as required. Thru-shaft installation is not available in overspeed applications.

9) Tighten screws on clamping collar evenly until snug, then tighten each screw as follows:

For bore sizes up to 1” [25mm] 38 in-lb [4.3 Nm]

For bore sizes >1” [25mm] 66 in-lb [7.5 Nm]

DO NOT USE A STANDARD RIGHT ANGLE WRENCH. Use only a

T-handle hex wrench or torque wrench with hex bit.

Or For End of Shaft Center Bolt Mount Style:

6) Remove the rear cover from the XR45.

7a) For 17mm taper shaft mount: Carefully slide the encoder onto the shaft to verify fit. DO NOT FORCE. Encoder should slide on easily. If the encoder does not fit easily, remove it, verify shaft size, and check for burrs and shaft damage.

7b) For 16mm center bolt shaft mount: Slide the centering ring over the motor shaft. Carefully slide the encoder onto the shaft to verify fit. DO NOT FORCE. Encoder should slide on easily. If the encoder does not fit easily, remove it, verify shaft size, and check for burrsand shaft damage.

8) Insert center mounting screw (M6 provided) through the body of the encoder into the stub shaft tapped hole and tighten to 66 in-lbs [7.5n-m]

9a) Replace rear cover XR45. Use a wrench on the external flats if necessary. Tighten cover screws.

10a) For threaded rod tethers, adjust to proper length by selecting combinations of short and long piece as required and thread together for final length adjustment. Attach free end of the anti-rotation arm to the bracket tether using the shoulder bolt

provided.

11) Secure free end of the anti-rotation bracket to frame using bolt or

T-bolt provided. The bracket should be parallel to the encoder face, 90 degrees to the shaft to avoid encoder bearing damage.

Use additional washers as needed to ensure the tether is parallel to the encoder face.

12) An M8 threaded hole is provided in the encoder shaft to permit a

M8 jack bolt for removal.

MODIFICATION

The XR45 can be modified in the field to easily adapt to new applications.

TO CHANGE ELECTRICAL CONNECTOR STYLE:

CAUTION

Do not attempt to modify the electrical connector options of the XR45 while located in a hazardous location or atmosphere. Doing so may create a severe spark hazard which can result in damage to property, injury, or even death.

1. Remove electrical power and disconnect the mating plug.

2. Unscrew the (4) M5 screws (4mm hex).

3. Pull the connector header away from the encoder gently.

4. Disconnect the ribbon connector to the encoder body.

5. Connect the ribbon connector to the new connector header

6. Attach the new connector header to the encoder using the

(4)M5 screws. Tighten to 30 in-lbs [3.4n-m]. Be sure the ribbon connector fits in the open pocket under the header and is not crushed or pinched by the connector header.

To CHANGE Bore Size Insert:

1. Remove electrical power.

2. Remove the encoder from any existing mounting.

3. Remove the rear encoder cover (if present) (4 screws are

retained)

4. Remove the retaining snap-ring around the insert.

5. Remove the insert from the encoder bore. The insert should slide out easily. DO NOT hammer on the insert to remove it.

6. Slide new insert inside encoder shaft.

7. Reinstall the retaining snap ring over the insert.

8. Reinstall the rear encoder cover as required.

WIRING

CAUTION

Be sure to remove power before wiring the encoder.

Be sure to ground the cable shield: Avtron recommends grounding the shield at the isolator module for Zone 1 applications or in the drive cabinet for Zone 2 applications. Cable should not be grounded multiple places. An intrinsic safety ground is required at the

XRB1 Isolator Module.

CAUTION

SMARTSafe encoders include a local ground lug for customer convenience and encoder frame grounding if required to meet local electric code requirements or site operator protection standards. This is NOT the required

XRB1 intrinsic safety ground connection required for hazard protection against ignition of explosive

atmospheres!

Wiring diagrams are shown in the following pages.

CAUTION

Zone 1 and Zone 21 applications utilize the XRB1 isolator which requires an intrinsic safety ground to provide hazard protection. Failure to connect this ground, or providing an inadequate safety ground path could result in an spark/ignition hazard which can result in property damage, injury, or even death.

Refer to the wiring diagrams and pinout and phasing tables for specific information on each option.

The XR45 can be wired for single phase or two phase, either with or without complements, with or without markers. For bidirectional operation, in most cases Phase A channel typically leads phase B channel for clockwise shaft rotation as viewed from the anti-drive or accessory end of the motor. See pinout and phasing tables for exceptions.

CORRECTIVE ACTION FOR PHASE REVERSAL

1) Remove Power.

2) Exchange wires on cable, either at encoder cable end, or at speed controller end (but not both).

a) Single Ended 2 Phase Wiring (see wiring diagram)

Exchange A with B

b) Differential 2 Phase Wiring (see wiring diagram)

Exchange

B

3) Apply Power.

either A with A in the phase A pair OR

B in the phase B pair but NOT both.

4) Verify encoder feedback is correct, using hand rotation of shaft, or jog mode of the speed controller.

XR45 3

Interconnecting cables specified in the wire selection chart are based on typical applications. Cable must be selected and installed in accordance with IEC/EN60079-14 and IEC/EN60079-25. Physical properties of cable such as abrasion, temperature, tensile strength, solvents, etc., are dictated by the specific application. General electrical requirements are: strand ed copper, 20 through 16 AWG

(Industrial EPIC connector type options can use 14 AWG). Each twisted wire pairs overall shield ed with braid or foil with drain wire, .05 uf of maximum total mutual or direct capacitance, outer sheath insulator.

See specifications for maximum cable length. Strand ed 20 AWG wire should not be used for cable runs great er then 61 meters. If 20 AWG is used with EPIC type connector (zone 2 configurations only)

options the wire ends should be tinned.

FAULT-CHECK

After power-up and the rotor position is checked by the sensor, the

Fault-Check LED will turn green.

If the adaptive electronics reach their adjustment limit for any reason, the Fault-Check alarm and LED will notify the drive and operator of an impending failure. The LED will turn red if the Adaptive Electronics reach their adjustment limit. This output occurs before an actual failure, allowing steps to be taken to replace the unit before it causes unscheduled downtime. Fault-Check annunciation is available as an

“alarm” output through the connector (zone 2 configurations only) and as an integral LED.

TROUBLESHOOTING

If the drive indicates a loss of encoder/tach fault and the XR45 fault-check LED is not illuminated, check the encoder power supply.

If power is present, check polarity; one indicator of reversed power supply is that all outputs will be high at the same time. If the drive indicates encoder fault, but the LED shows GREEN, then check the wiring between the drive and the encoder. If the wiring appears correct and in good shape, test the wiring by replacing the XR45. If the new unit shows GREEN, and the drive still shows encoder loss/tach fault, then the wiring is faulty and should be repaired or replaced.

If the alarm output and/or LED indicate a fault (RED) on a properly mounted XR45 and the rotor is properly located, replace the XR45.

An oscilloscope can also be used to verify proper output of the XR45 encoder at the encoder connector itself and at the drive/controller cabinet. If the outputs show large variations in the signals at steady speed (jitter or “accordion effect”, see figure below), replace any magnetized material nearby with non-magnetic material (aluminum, stainless) (shafts, etc). If variations persist, consider replacing with super-shielded models, option -004.

PHASE A

PHASE B

VARIATION > ± 15%

XR45 PART NUMBERS AND AVAILABLE OPTIONS

Model

XR45

Clamping

Collar Mount

U.S.

C- 5/8”

D- 3/4"

E- 7/8"

F- 1"

G- 1 1/8

U- All US Sizes

Clamping

Collar Mount

Metric

S- 16mm

T- 18mm

V- 19mm

W- 20mm

Y- 25mm

3- 30mm

Z- All Metric

Sizes

Bore Size

End of Shaft:

Center Bolt

Mount

L- 16mm

(no taper)

M- 17mm

(10:1 taper)

Left

Output

PPR

AF-60

AG-100

AH-120

AA-128

AL-240

AN-256

AP-300

AE-360

AB-480

AQ-500

AR-512

AS-600

AV-900

AJ-960

AW-1000

AY-1024

AZ-1200

CX-1500

A3-2000

A4-2048

A5-2500

AD-4096

A8-4800

A9-5000

A0-Special

Right

Output

PPR

XX-None

AF-60

AG-100

AH-120

AA-128

AL-240

AN-256

AP-300

AE-360

AB-480

AQ-500

AR-512

AS-600

AV-900

AJ-960

AW-1000

AY-1024

AZ-1200

CX-1500

A3-2000

A4-2048

A5-2500

AD-4096

A8-4800

A9-5000

A0-Special

Line Driver Connector Options Tether Channels Modifications

5- Zone 1 & 21

(5-7V in

5V out)

For use with XRB1 isolator

12-24V In

10.6V Out

7-Zone 2 & 22

5-24 V in,

5-24 V out

Zone 1 and 21 Remote Protection &

Zone 2 and 22

10 Pin MS Connector-

Small Encoder Pinout

A- Avtron/BEI Pinout, w/o plug

B- Dynapar HS35 Pinout, w/o plug

C- Avtron/BEI Pinout, mating plug

D- Dynapar HS35 Pinout, mating

plug

10 Pin MS Connector-

Large Encoder Pinout

4- Avtron/Northstar Pinout, mating

plug

6 Pin MS Connector-

Small Encoder Pinout

E- Avtron/BEI Pinout, w/o plug

F- Dynapar HS35 Pinout, w/o plug

7 Pin MS Connector-

Small Encoder Pinout

J- Avtron/BEI Pinout, w/o plug

K- Dynapar HS35 Pinout, w/o plug

X- None

Flat Styles:

D- Fan Cover

(T-bolt)

E- 4.5” NEMA

C-face

F- 8.5” NEMA

FC-face

Threaded Rod

Styles:

G- 70-500mm

w/bracket

P- 70mm fixed

w/screw

T- Fan Cover

70-500mm

w/T-bolt

Combinations:

H- Fan Cover

& 8.5”

C-face

M- Fan Cover

& 4.5”

C-Face

Small EPIC Connector

P- Avtron pinout, w/mate

G- Northstar pinout w/mate

U- Universal

(includes

all styles)

Terminal Box w/terminal strip

H- USA, 1/2” conduit

L- Europe w/cord grip

– –

D- A,A

(Diff

Phase)

,

Z,Z

(req’d

for 8, 10

pin

connec-

tors)

B- A,B,A,B

(no

marker)

E- A,B,Z

(single

ended)

F- A,B

(single

no

marker)

ended,

000- None

004- Super

Magnetic

Shielding

4xx- Special PPR

(see chart)

9xx- Specify cable length xx=feet max 33ft

(use w/

Option

“Q”,“W”, “Z”)

8 Pin M12 Connector

T- Global pinout, w/o plug

U- USA Pinout, w/o plug

12 Pin M23 Connector

2- Leine and Linde pinout,

w/o plug

3- Hubner Pinout w/o plug

W- Cable 18” (or special length)

R- Mini Twist Lock (Mini

MS) w/ mating plug

Provided

XR45 Encoder

Shaft Sizing Insert for all clamp style models

For 16mm center-bolt style ONLY: centering (tapered) ring

Equipment Needed for Installation

Optional

Anti-Rotation Arm Kit

Thread Locker (blue)

Not Provided

Open Wrenches

“G”, “P”, “T”, ”U”-Tether: 9mm, 10mm

“D”, “E”, ”F”,” H”, ”M”, ”U”-Tether: 7/16”,1/2”, 9/16”, 3/4”

M5 T-handle hex wrenches or torque wrench with M5 bits

(Torque wrench required for Center Bolt Mounting Style).

Dial Indicator Gauge

Caliper Gauge

XR45 4

SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

A. Operating Power (Vin)

1. Volts ...................................See line driver table

2. Current (No Load)

Encoder .............................100mA

Encoder + Isolator ...........150mA

B. Output Format

1. 2O/ & Comp ....................A,A–, B,B– (differential line driver)

2. Marker:...............................1/Rev Z, Z–

C. Signal Type ............................Incremental, Square Wave, 50 +/-10%

............................................Duty Cycle.

D. Direction Sensing .................O/ A leads O/ B for CW rotation as viewed

............................................from the back of the tach looking at the

............................................non-drive end of the motor.

E. Transition Sep. ......................15% minimum

F. Frequency Range ..................0 to 165,000 Hz

A.

B.

C.

D.

G. PPR .........................................8-5000

H. Line Driver Specs: .................See table

I. Connectors: ...........................See connector options

MECHANICAL

Shaft Inertia

Acceleration

0.0041 lb-in-sec2

5000 RPM/Sec. Max.

Speed: 5000 RPM Max (also see overspeed)

Weight: 10-12 lbs [4.5-5.5kg]

E.

F.

Vibration 20 Gs, 5-2000 Hz (any orientation)

Shock 100 Gs, any orientation

G. Shaft Engagement (clamp style)

5/8”-7/8” bore...................2” [51mm] min.

16-20mm bore..................51mm min.

1”- 1 1/8” bore..................1.75” [45mm] min.

25-30mm bore..................45mm min.

ENVIRONMENTAL

Solid cast aluminum stator and rotor. Less than 6% magnesium by mass.

Fully potted electronics, protected against oil and water spray

Operating Temperature:.......-40°C to +80°C.

Electrical Specifications

Input Voltage

Nom Output Voltage

Line Driver

Output Resistance Typ

Maximum Peak Current

Maximum Average

Current

Voh Typ

Vol Typ

Cable Drive Capacity

7

5-24

5-24

7272

13

1500

120

V

IN

-1

0.5

500’ @ 5-12V

200’ @ 24V

LINE DRIVER OPTIONS

Isolator XRB1 5

5-7 12-24

(5-7 to Encoder)

10.6 Output Signals

IXDF604

3

3000

350

10.6

0.4

5

7272

13

1500

120

V

IN

-1

0.5

1000’ 500’

Protection

Reverse

Voltage

Short

Circuit

Transient

+V(out)* yes yes yes yes yes yes yes yes yes

Output voltage equal to input voltage.

Units

VDC

VDC ohms mA mA

VDC

VDC feet

Alarm

Marker

Alarm*

LED

Open collector, normally off, goes low on alarm, sink 100mA max, 50VDC max

Green=power on, Red=Alarm

One per revolution. Pulse width approximately 1/128 of a revolution

*Alarm not available with the following; line driver option 5 from isolator XRB1, connector option “G” (Northstar

TM

compatible pinout), “R” and “S”

Ii

250mA

1A

IIC

15V

Ui

IIB

25V

15V

CI

1.8uf

5A 12V

Zone 2 Power Supply Limits

XR45 5

Parameter

Um

Ui

Li

Pi

Ci

Li

Uo

Io

Po

Lo

Isolator

250V

-

-

-

-

-

7.14V

440mA

0.4W

1.5mH

Co 13.5uF

Lo/Ro -

Zone 1 Table of entity parameters

Encoder

-

7.14V

440mA

0.4W

11.9UF

0mH

-

-

-

WIRING DIAGRAMS

ZONE 1 HAZARDOUS AREA

“REMOTE PROTECTION’

ENCODER

See Attached for Connector

Option Pin Outs

Typical Cable 500'(150M)max

18AWG, 4 Twisted Pair + Overall Shield

Belden P/N 9554 or Alpha P/N 2244C Typ

SAFE AREA

A

A

B

-

+

B

Z

Z

5-7 Volts

Out

12-24

Volts In gnd gnd

Z

Z

-

B

B

A

A

+

Intrinsic Safety Gnd

A-

A+

B-

B+

Z-

Z+

-

K1-

K1+

K2-

K2+

K0-

K0+

GND

+ Ub+

1-

1+

2-

2+

0-

0+

0V

+E

12-24

Volts Out

XR45 6

WIRING DIAGRAMS

ZONE 2 HAZARDOUS AREA

DIFFERENTIAL 2 PHASE WIRING

Typical Cable 500'(150M)max

ENCODER LINE

DRIVER OPTION 7

18AWG, Twisted Pair + Overall Shield

See Attached for Connector

Option Pin Outs

2 Pair

3 Pair

4 Pair

5 Pair

SAFE AREA

Belden Alpha

9552

9553

9554

1328A

2242C

2243C

2244C

2245C

A-

A+

B-

B+

Z-

Z+

-

K1-

K1+

K2-

K2+

K0-

K0+

GND

+ Ub+

1-

1+

2-

2+

0-

0+

0V

+E

5-24

*

Volts Out

ZONE 2 HAZARDOUS AREA

SINGLE ENDED 2 PHASE WIRING

Typical Cable 500'(150M)max

ENCODER LINE

DRIVER OPTION 7

See Attached for Connector

Option Pin Outs

18AWG, Twisted Pair + Overall Shield

2 Pair

3 Pair

4 Pair

5 Pair

SAFE AREA

Belden Alpha

9552

9553

9554

1328A

2242C

2243C

2244C

2245C

-

A+

+

B+

GND

K1+

Ub+

K2+

0V

1+

+E

2+

Z+

+v alm

K0+ 0+

5-24

*

Volts Out

ZONE 2 HAZARDOUS AREA

SINGLE ENDED 1 PHASE WIRING

ENCODER LINE

DRIVER OPTION 7

See Attached for Connector

Option Pin Outs

Typical Cable 500'(150M)max

18AWG, Triad + Overall Shield

3 Conductor

Belden Alpha

9365 M9628010

SAFE AREA

A+

K1+ 1+

+ Ub+ +E

- GND 0V

5-24

*

Volts Out

*

SEE SPECIFICATIONS FOR ZONE 2

POWER SUPPLY LIMITATIONS

Refer to Installation and Specification Sections for Requirements and Limitations

XR45 7

Pinouts and Phasing

XR45 8

Pinouts and Phasing

XR45 9

XR45

Remote Alarm

Applies to Model XR45 Encoders connector styles except “E”, “F”, “J”, K”, “G”, R”, “S” “4”. Remote Alarm not available for Zone 1 & Zone 21.

ALARM OUTPUT CONNECTION

Avtron XR45 encoders provide an alarm signal if maintenance is required under specific circumstances. Following are application examples provided to help install the alarm output.

Example 1. Alarm output using +V(OUT). +V(OUT) is equal to +V, the encoder power supply.

ENCODER

FUNCTIONAL DIAGRAM

LINE

DRIVER

NOTE 1

Q5

MMFT6661

CR8

{

“W”

BLACK

RED

GREEN

YELLOW

BLUE

GRAY

ORANGE

WHITE

BROWN

VIOLET

F

J

I

H

C

D

G

E

A

B

OUTPUT OPTIONS

“4” “P”, “Z” “H”, “L”

1

6

5

10

3

8

4

9

2

7

COM

+V

B

B

A

A

Z

Z

+V(OUT)

ALM

“2”

10

12

2

7

5

6

3

4

8

1

GND

FUNCTION

COMMON

+V (Encoder Power)

ØA

ØA

ØB

ØB

MARKER

MARKER COMPLEMENT

50mA MAX

300 OHM

MIN.

SOLID STATE RELAY

Vcc

OUT

COM

Example 2. Alarm Output Using Separate * VDC Power Supply and Relay.

ENCODER

FUNCTIONAL DIAGRAM

LINE

DRIVER

NOTE 1

CR8

{

BLACK

RED

GREEN

YELLOW

BLUE

GRAY

ORANGE

WHITE

BROWN

VIOLET

“W”

D

G

E

H

C

I

A

B

F

J

OUTPUT OPTIONS

“4” “P”,“Z” “H”,“L”

3

8

4

9

2

7

1

6

5

10

COM

+V

A

A

B

B

Z

Z

+V(OUT)

ALM

“2”

5

6

3

4

8

1

10

12

2

7

Q5

MMFT6661

GND

FUNCTION

COMMON

+V (Encoder Power)

ØA

ØA

ØB

ØB

POWER

SUPPLY

*See note below

MARKER

MARKER COMPLEMENT

-

*

VDC

+

300 OHM

MIN.

115 VAC

Vcc

OUT

COM

SOLID STATE RELAY

SINK 100 mA MAXIMUM

*See specifications for Zone 2

Power supply limits

XR45 10

TETHER OPTION: D and F

TETHER OPTIONS: G, P, T and U

19.69 [500mm] MAXIMUM DISTANCE

2.76 [70mm]

MINIMUM DISTANCE

USE 5mm HEX

TORQUE TO

65 IN-LBS. [7.5 N-M]

0.28 [7mm] MAX. THICKNESS

FOR THRU HOLE MOUNTING

TORQUE TO

65 IN-LBS. [7.5 N-M]

±1.50 [38mm] OFFSET FOR

12 IN. [305MM] ROD END CENTERS

CUSTOMER

ATTACHMENT

POINT

90° ± 15°

5.80 REF.

[ 147MM ]

XR45 11

3.01

[76.5]

2.87

[73.0]

1.71

[43.5]

04.53

[115.1]

8.73

[222.0]

3.29

[83.5]

0.24

[6.1]

4.25

[108.0]

6.57

[167.0]

4.25

[108.0]

CLAMP STYLE

SHOWN: SINGLE OUTPUT, 1” BORE, INDUSTRIAL

CONNECTOR, 4.5” C-FACE TETHER

SHAFT ENGAGEMENT:

Minimum:

5/8”-7/8” bore

16-20mm bore

2” [51mm]

51mm

1”- 1 1/8” bore 1.75” [45mm]

25-30mm bore 45mm

with overspeed switch 2.65” [68mm]

Maximum (With Cover or Overspeed):

All bore sizes 2.70” [68.6mm]

3.01

[76.5]

2.87

[73.0]

1.71

[43.5]

0.24

[6.1]

8.73

[222.0]

3.29

[83.5]

04.53

[115.1]

4.25

[108.0]

Features and specifications subject to change without notice.

Avtron standard warranty applies. All dimensions are in inches [mm].

XR45 12

4.25

[108.0]

6.57

[167.0]

2.85

[72.5]

1.69

[43.0]

8.67

[220.1]

6.71

[170.5]

4.33

[110.0]

0.20

[5.0]

8.50

[216.0]

4.24

[108.0]

CLAMP STYLE

SHOWN: DUAL OUTPUT, 5/8” BORE, 10 PIN MS

CONNECTORS, 8.5” C-FACE TETHER

SHAFT ENGAGEMENT:

Minimum:

5/8”-7/8” bore

16-20mm bore

2” [51mm]

51mm

1”- 1 1/8” bore 1.75” [45mm]

25-30mm bore 45mm

with overspeed switch 2.65” [68mm]

Maximum (With Cover or Overspeed):

All bore sizes 2.70” [68.6mm]

2.85

[72.5]

1.69

[43.0]

0.20

[5.0]

8.67

[220.1]

6.71

[170.5]

4.33

[110.0]

4.24

[108.0]

Features and specifications subject to change without notice.

Avtron standard warranty applies. All dimensions are in inches [mm].

XR45 13

8.50

[216.0]

04.52

[115.0]

1.06

[27.0]

4.69

[119.2]

6.95

[176.7]

4.25

[108.0]

6.51

[165.5]

4.24

[107.8]

2.9

[76.1]

1.83

[46.6]

16mm CENTER BOLT STYLE

SHOWN: SINGLE OUTPUT, CONDUIT BOX,

ANTI-ROTATION ARM OPTION “P”

SHAFT ENGAGEMENT:

Minimum: 1.73” [44mm]

Maximum: 2.09” [53mm]

0.34

[8.7]

1.06

[27.0]

4.69

[119.2]

6.95

[176.7]

04.52

[115.0]

4.24

[107.8]

Features and specifications subject to change without notice.

Avtron standard warranty applies. All dimensions are in inches [mm].

XR45 14

4.25

[108.0]

6.51

[165.5]

2.9

[76.1]

1.83

[46.6]

0.34

[8.7]

1.06

[27.0]

04.52

[115.0]

6.60

[167.7]

0.13

[3.35]

4.33

[110.2]

1.83

[46.6]

17mm CENTER BOLT STYLE

SHOWN: SINGLE OUTPUT, M23 CONNECTOR, ANTI-ROTATION

ARM OPTION “P”

SHAFT ENGAGEMENT:

20mm +/-0.1mm

Shaft shall be 17mm diameter with 10:1 taper

1.83

[46.6]

1.06

[27.0]

1.83

[46.6]

4.25

[108.0]

6.51

[165.5]

04.52

[115.0]

6.60

[167.7]

0.13

[3.35]

4.33

[110.2]

0.34

[8.7]

2.99

[76.1]

1.83

[46.6]

4.24

[107.8]

4.25

[108.0]

6.51

[165.5]

0.34

[8.7]

4.24

[107.8]

These instructions have been reviewed and the product evaluated as suitable for our application.

Company Name

Authorized Company Representative

Title Date

Features and specifications subject to change without notice.

Avtron standard warranty applies. All dimensions are in inches [mm].

E N C O D E R S

8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A.

(1) 216-642-1230 • FAX (1) 216-642-6037 • www.avtronencoders.com

XR45 15

REV: 09/12/13