Avtron AV45 Series User manual

8901 E. PLEASANT VALLEY ROAD • INDEPENDENCE, OHIO 44131-5508
TELEPHONE: [phone]
• FAX: [phone]
E-MAIL:[email protected]
• WEB: www.avtronencoders.com
The AV45 is designed for mounting on European B10 style flanges
(85mm flange, 100mm bolt circle), or on a foot mount bracket for cou-
pling. The AV45 is not recommended for pulley or chain drive applica-
tions.
The AV45 utilizes magnetoresistive sensors. This proven technology
is ideal for rugged environments since it is immune to many contami-
nants that cause optical encoders to fail. All of the AV45 electronics
are potted, providing full protection against liquids. The outputs are
protected against short circuits and wiring errors.
Each AV45 has a two-phase output (A, B) 90° out of phase, with com-
plements (A
–, B –), (A Quad B Output). A marker pulse with complement
(Z, Z
–) is also present.
The AV45 has a diagnostic package that includes Adaptive Electronics
and a Fault-Check output and red/green LED for local indication. With
this package, the AV45 can maintain itself, and provide an alarm if
there is a problem before the problem causes unscheduled downtime.
DESCRIPTION
The Avtron Model AV45 is a heavy duty incremental encoder (also
known as tachometer or rotary pulse generator). Its output is directly
proportional to shaft position (pulse count) or speed (pulse rate). The
AV45 operates down to zero speed and can be used for both control
and instrumentation applications.
CAUTION
Do not utilize AV45 in hazardous locations which require
ATEX, UL, CUL, CSA, or other explosion protection cer-
tification. AV45 is not certified for hazardous locations.
Use XR models for hazardous applications.
Encoder
Instructions
AV45
SOLID SHAFT
B10 FLANGE OR FOOT MOUNT
AV45 PART NUMBERS AND AVAILABLE OPTIONS
Model Shaft Size
Left
Output
PPR
Right
Output
PPR
Line Driver Connector Options Foot Mount Bracket Channels Modifications
AV45 N- 10mm
H- 11mm, standard
T- 18mm
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
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
Note Dual
Output NA
with Foot
Mount
Bracket
6- 5-24V in,
5-24V out*
8- 5-24V in,
5-15 out
hi-power
9- 5-24V in,
5V fixed out
*Recommended
for single-ended
applications
Small EPIC Connector
P- Avtron pinout, w/mate
Terminal Box w/terminal strip
H- USA, 1/2” conduit
L- Europe w/cord grip
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)
X- None
(for B10 flange mount)
1- Toshiba TS2113N bolt
pattern (recommend “T”
18mm shaft)
(B35529 bracket)
2- POGxx, OGxx Hubner
(Baumer) bolt pattern
(B35555 bracket)
3- FG4 Johannes Hubner
bolt pattern
(B35338 bracket)
A- All
A,B,A,B,Z,Z
(req’d for 8,
10 pin con-
nectors)
B- A,B,A,B
(no marker)
E- A,B,Z
(single
ended)
F- A,B
(single
ended, no
marker)
000- None
004- Super
Magnetic
Shielding
6xx- Add over
speed switch
xx=speed
code
9xx- Specify cable
length xx=feet
max 33ft
(use w/ Option
“W”)
-
-
-
- -

ELECTRICAL SPECIFICATIONS
A. Operating Power (Vin)
1. Volts............................ 5-24 VDC in
2. Current ....................... 100mA, each output, plus cable load
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
G. PPR ................................ 8-5000
H. Line Driver Specs: .......... See table
I. Connectors: .................... See connector options on page 1
MECHANICAL
A. Shaft Inertia .................... 1.59 lb-in-sec2
B. Acceleration.................... 5000 RPM/Sec. Max.
C. Speed: ............................ 5000 RPM Max (also see overspeed)
D. Weight: ........................... 10-12 lbs [4.5-5.5kg]
E. Vibration ......................... 20 Gs, 5-2000 Hz (any orientation)
F. Shock ............................. 100 Gs, any orientation
G. Shaft Load:.....................
ENVIRONMENTAL
Solid cast aluminum stator and rotor
Fully potted electronics, protected against oil and water spray
Operating Temperature:.......-40°C to +100°C.
MECHANICAL OVERSPEED SWITCH OPTION
A. Shaft Inertia .................... +0.0018 lb-in-sec2
B. Acceleration.................... 3600 RPM/Sec. Max.
C. Speed: ............................ 1.25 x Overspeed set point Max.
Minimum trip speed: 700 RPM
Maximum trip: 3600 RPM
Accuracy +/- 4% of trip point
Hysteresis: 40% of trip point
D. Weight:............................ +2.55 lbs [+1.16kg]
E. Vibration: ........................ 20 Gs, 5-2000 Hz (radial only)
F. Shock: ............................ 100Gs, any orientation
G. Electrical Contact (NO/NC Contact)
1. ................................... 6A/230VAC
2. .................................... 3A/380VAC
3. .....................................1A/125VDC
H. Operating Temperature:......-40°C to +100°C.
LINE DRIVER OPTIONS
Electrical Specifications 6 8 9 Units
Input Voltage 5-24 5-24 5-24 VDC
Nom Output Voltage 5-24 5-15 5 VDC
Line Driver 7272 4125 7272
Output Resistance Typ
13 3 13 ohms
Maximum Peak Current 1500 3000 1500 mA
Maximum Average
Current 120 350 120 mA
Voh Typ VIN-1 VIN-1, max 15V out VIN-1 VDC
Vol Typ 0.5 0.4 0.5 VDC
Cable Drive Capacity
1000’ @ 5V
500’ @ 12V
200’ @ 24V
1000’ 1000’ feet
Protection
Reverse
Voltage yes yes yes
Short
Circuit yes yes yes
Transient yes yes yes
Alarm
+V(out) Output voltage equal to input voltage.
Alarm* Open collector, normally off, goes low on alarm,
sink 100mA max, 50VDC max
Marker One per revolution. Pulse width
approximately 1/128 of a revolution
2
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 com-
ponent drift, temperature changes, or mechanical wear. The Adap-
tive Electronics extend the life of the AV45 by constantly monitor-
ing and correcting duty cycle and edge separation over time.
FAULT-CHECK
If the Adaptive Electronics reach their adjustment limit, the LED will
turn red and Fault-Check alarm will notify the drive and operator
of an impending failure. This output can occur before a failure,
allowing steps to be taken to replace the unit before it causes un-
scheduled downtime. Fault-Check annunciation is available as an
“alarm” output through the connector.
SAFETY
The AV45 is not considered as a safety device and is not suitable
for connection into a safety system. The mechanical overspeed
switch (option 6xx) is suitable for connection into safety systems.
CAUTION
Do not disassemble mechanical overspeed option.
Doing so may modify the overspeed set point or
cause the switch to malfunction. If the factory seals
are not intact on the overspeed switch, do not use
it--return to the factory for service and calibration.
WARNING
Installation should be performed only by quali-
fied personnel. Safety precautions must be taken
to ensure machinery cannot rotate and all sourc-
es of power are removed during installation.

3
Example 2. Alarm Output Using Separate 24 VDC Power Supply and Relay.
Applies to Model AV45 Encoders connector styles “H”, “L”, “P”, “W”
ALARM OUTPUT CONNECTION
Avtron AV45 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.
AV45
Remote Alarm
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
OUTPUT OPTIONS
A
B
D
G
E
H
C
I
F
J
9
4
5
10
2
8
3
7
6
1
+V(OUT)
Z
Z
A
B
B
A
+V
COM
Vcc
OUT
COM
300 OHM
MIN.
GND
FUNCTION
ENCODER
ØB
ØA
ØA
ØB
4-16 VDC SOLID STAT E RELAY
Q5
MMFT6661
LINE
DRIVER
NOTE 1
CR8
{
FUNCTIONAL DIAGRAM
50 mA MAXIMUM
“W”“4”“P”,“Q”,
“Z”“H”, “L”
ALM
MARKER
MARKER COMPLEMENT
COMMON
+V (Encoder Power)
{
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
“H”,“L”
OUTPUT OPTIONS
A
B
D
G
E
H
C
I
F
J
9
4
5
10
2
8
3
7
6
1
ALM
+V(OUT)
Z
Z
A
B
B
A
+V
COM
MARKER
MARKER COMPLEMENT
GND
FUNCTION
+V (Encoder Power)
COMMON
24
VDC
RELAY
+
-
POWER
SUPPLY 115 VAC
SINK 100 mA MAXIMUM,
WITHSTAND 50 V MAXIMUM
REFERENCED TO COMMON
Q5
MMFT6661
ENCODER
FUNCTIONAL DIAGRAM
ØB
ØA
ØA
ØB
LINE
DRIVER
NOTE 1
CR8
“W” “4” “P”,“Q”,
“Z”

4
WIRING DIAGRAMS
Avtron standard warranty applies. Copies available upon request.
Specifications subject to change without notice.
OPTION
“W”
(CABLE)
AABB B
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS
“J”, “K”
(7 PIN MS)
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
BROWN
VIOLET
BROWN
VIOLET
DIFFERENTIAL TWO PHASE WIRING APPLICATIONS
F
D
A
H
B
I
C
J
F
D
A
C
B E
NC NC
NC NC
NC NC
F
D
A
C
B E
NC NC
NC NC
OPTIONS
“E”, “F”
(6 PIN MS) (8 PIN M12) (8 PIN M12)
(8 PIN M12) (8 PIN M12)
(8 PIN M12) (8 PIN M12)
A B E
C D
F
NC NC NC NC NC NC
NC
NC
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–ØA, ØA
–
ØB, ØB
–ØA, ØA
–
ØB, ØB
–
CHANNELS CONNECTOR
<<CONNECTED ON 18" CABLE
* NC ON CHANNEL OPTION “B”
<< CONNECTED ON 18" CABLE
1 2 3 4 5 6 7 8
7 2 1 3 4 5 6 8
OPTIONS
“T”
OPTIONS
“U”
OPTIONS<<
“U”
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTION “W”
(CABLE)
A
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS<<
“J”, “K”, “M”, “N”
(7 PIN MS)
RED
BLUE
GREEN
BLACK
ORANGE *
SINGLE ENDED TWO PHASE WIRING APPLICATIONS, WITH OR WITHOUT MARKER | NOT RECOMENDED FOR OUTPUT OPTION “8”
D
B A
F
C*
D
B A
F
C*
OPTIONS<<
“E”, “F”, “G”, “H”
(6 PIN MS)
B
D
E A
C*
E, F
ØA, ØB, ØZ
E, F
ØA, ØB, ØZ
E, F
ØA, ØB, ØZ
CHANNELS CONNECTORS
* NC ON CHANNEL OPTION “F”
^ COMPLEMENTS INCLUDED BUT NOT USED
22 54
1
3 1 7
7 6
A
ØA, ØA
–^
ØB, ØB
–^
ØZ, ØZ
– ^
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
OPTION “W”
(CABLE)
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS<<
“J”, “K”, “M”, “N”
(7 PIN MS)
BLACK
RED
GREEN
SINGLE ENDED SINGLE PHASE WIRING APPLICATIONS | NOT RECOMENDED FOR OUTPUT OPTION “8”
F
D
A
F
D
A
OPTIONS<<
“E”, “F”, “G”, “H”
(6 PIN MS)
A B E
ØA
(ØA
–INCLUDED
BUT NOT USED)
ØA
(ØA
–INCLUDED
BUT NOT USED)
ØA
(ØA
–INCLUDED
BUT NOT USED)
DDD
CHANNELS CONNECTORS
1 2 3
7 2 1
OPTIONS<<
“T”
OPTIONS<<
“U”
A
ØA
–, ØB,
ØB
–, ØZ, ØZ
–ØA
–, ØB,
ØB
–, ØZ, ØZ
–
A
(ØA
–, ØB,
ØB
–, ØZ, ØZ
–
INCLUDED BUT NOT USED)
A
OPTIONS<<
“T”
AA AA
5NC
NC10
F
D
A
H
B
J
C
K
1
6 2
7 3
8
4 9
NC
NC
1
6 2
7 3
8
4 9
F
J
A
B D
G E
H
C I
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“R”, “S<<”
(10 PIN
TWIST-LOCK)
OPTIONS
“P”, “Q ”,“Z<<
<< ”
(10 PIN
INDUSTRIAL)
D
B A F
6 3 2 1 4C
6
3 2 1
4
B
E D A
C
AA
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“P”, “V”,“Z<<”
OPTIONS
“R”, “S<<”
(10 PIN
INDUSTRIAL)
(10 PIN
TWIST-LOCK)
1 6 2A
F D
1 6 2D
A B
AA
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“P”, “V”,“Z<<”
OPTIONS
“R”, “S<<”
(10 PIN
INDUSTRIAL)
(10 PIN
TWIST-LOCK)
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
(10 PIN MS)
A
5
10
1
6 2
7 3
8
4 9
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
CONDUIT BOX
OPTIONS
CONDUIT BOX
OPTIONS
“G” “4”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“3”
OPTIONS
(12 PIN M23)
“3”
OPTIONS
(12 PIN M23)
“3”
“H”,“L”
(10 PIN
INDUSTRIAL)
OPTIONS
(10 PIN MS)
OPTIONS
“G” “4”
(10 PIN
INDUSTRIAL)
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
(10 PIN MS)
OPTIONS
“G” “4”
(10 PIN
INDUSTRIAL)
NC NC
NC NC
NC NC NC NC
NC
NC 5NC
NC10
NC
NC
F
J
6
3 2 1
4
5
10
12
5 1
10
3
2
7
12
8 6
10
3
NC
NC
NC NC
NC NC
NC NC NC NC
NC
NC 5NC
NC10
NC
NC
F
J
1
10 12
2
7
2
1 6
5
10
6
10 12
NC
NC
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
NC
NC
10
12
6
5 8
1
3 4
2
7
10
12
8
1 5
6
3 4
ALM+
ALM
ALM+
ALM
ALM+
ALM
REF
SIGNAL
COM GND0V +V ØA ØA
–– ––
ØB ØB
–
Z Z
–
+Ub+E
2+ 2- 0+ 0-
K1- 1+
1-
K1+
––
K2+ K2- K0+ K0-
ALM+
ALM
ALM+
ALM
REF
SIGNAL
+V ØB ØA
–
COM
OZ
+Ub K2+
K1-
GND K0+
ALM+
ALM
+E 2+
1+
0V
0+
ALM+
ALM
ALM+
ALM
ALM+
ALM
COM GND 0V
0A
+V +Ub
–
K1
+E
1+
REF
SIGNAL
“H”,“L”
OPTIONS
CONDUIT BOX
“H”,“L”
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–

WIRING DIAGRAMS
OPTION
“W”
(CABLE)
AABB B
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS
“J”, “K”
(7 PIN MS)
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
BROWN
VIOLET
BROWN
VIOLET
DIFFERENTIAL TWO PHASE WIRING APPLICATIONS
F
D
A
H
B
I
C
J
F
D
A
C
B E
NC NC
NC NC
NC NC
F
D
A
C
B E
NC NC
NC NC
OPTIONS
“E”, “F”
(6 PIN MS) (8 PIN M12) (8 PIN M12)
(8 PIN M12) (8 PIN M12)
(8 PIN M12) (8 PIN M12)
A B E
C D
F
NC NC NC NC NC NC
NC
NC
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–ØA, ØA
–
ØB, ØB
–ØA, ØA
–
ØB, ØB
–
CHANNELS CONNECTOR
<<CONNECTED ON 18" CABLE
* NC ON CHANNEL OPTION “B”
<< CONNECTED ON 18" CABLE
1 2 3 4 5 6 7 8
7 2 1 3 4 5 6 8
OPTIONS
“T”
OPTIONS
“U”
OPTIONS<<
“U”
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTION “W”
(CABLE)
A
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS<<
“J”, “K”, “M”, “N”
(7 PIN MS)
RED
BLUE
GREEN
BLACK
ORANGE *
SINGLE ENDED TWO PHASE WIRING APPLICATIONS, WITH OR WITHOUT MARKER | NOT RECOMENDED FOR OUTPUT OPTION “8”
D
B A
F
C*
D
B A
F
C*
OPTIONS<<
“E”, “F”, “G”, “H”
(6 PIN MS)
B
D
E A
C*
E, F
ØA, ØB, ØZ
E, F
ØA, ØB, ØZ
E, F
ØA, ØB, ØZ
CHANNELS CONNECTORS
* NC ON CHANNEL OPTION “F”
^ COMPLEMENTS INCLUDED BUT NOT USED
22 54
1
3 1 7
7 6
A
ØA, ØA
–^
ØB, ØB
–^
ØZ, ØZ
– ^
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
OPTION “W”
(CABLE)
OPTIONS
“A”, “B”, “C”, “D”
(10 PIN MS)
PINOUT
OPTIONS<<
“J”, “K”, “M”, “N”
(7 PIN MS)
BLACK
RED
GREEN
SINGLE ENDED SINGLE PHASE WIRING APPLICATIONS | NOT RECOMENDED FOR OUTPUT OPTION “8”
F
D
A
F
D
A
OPTIONS<<
“E”, “F”, “G”, “H”
(6 PIN MS)
A B E
ØA
(ØA
–INCLUDED
BUT NOT USED)
ØA
(ØA
–INCLUDED
BUT NOT USED)
ØA
(ØA
–INCLUDED
BUT NOT USED)
DDD
CHANNELS CONNECTORS
1 2 3
7 2 1
OPTIONS<<
“T”
OPTIONS<<
“U”
A
ØA
–, ØB,
ØB
–, ØZ, ØZ
–ØA
–, ØB,
ØB
–, ØZ, ØZ
–
A
(ØA
–, ØB,
ØB
–, ØZ, ØZ
–
INCLUDED BUT NOT USED)
A
OPTIONS<<
“T”
AA AA
5NC
NC10
F
D
A
H
B
J
C
K
1
6 2
7 3
8
4 9
NC
NC
1
6 2
7 3
8
4 9
F
J
A
B D
G E
H
C I
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“R”, “S<<”
(10 PIN
TWIST-LOCK)
OPTIONS
“P”, “Q ”,“Z<<
<< ”
(10 PIN
INDUSTRIAL)
D
B A F
6 3 2 1 4C
6
3 2 1
4
B
E D A
C
AA
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“P”, “V”,“Z<<”
OPTIONS
“R”, “S<<”
(10 PIN
INDUSTRIAL)
(10 PIN
TWIST-LOCK)
1 6 2A
F D
1 6 2D
A B
AA
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
“P”, “V”,“Z<<”
OPTIONS
“R”, “S<<”
(10 PIN
INDUSTRIAL)
(10 PIN
TWIST-LOCK)
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
(10 PIN MS)
A
5
10
1
6 2
7 3
8
4 9
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
CONDUIT BOX
OPTIONS
CONDUIT BOX
OPTIONS
“G” “4”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“2”
OPTIONS
(12 PIN M23)
“3”
OPTIONS
(12 PIN M23)
“3”
OPTIONS
(12 PIN M23)
“3”
“H”,“L”
(10 PIN
INDUSTRIAL)
OPTIONS
(10 PIN MS)
OPTIONS
“G” “4”
(10 PIN
INDUSTRIAL)
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
OPTIONS
(10 PIN MS)
OPTIONS
“G” “4”
(10 PIN
INDUSTRIAL)
NC NC
NC NC
NC NC NC NC
NC
NC 5NC
NC10
NC
NC
F
J
6
3 2 1
4
5
10
12
5 1
10
3
2
7
12
8 6
10
3
NC
NC
NC NC
NC NC
NC NC NC NC
NC
NC 5NC
NC10
NC
NC
F
J
1
10 12
2
7
2
1 6
5
10
6
10 12
NC
NC
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
NC
NC
10
12
6
5 8
1
3 4
2
7
10
12
8
1 5
6
3 4
ALM+
ALM
ALM+
ALM
ALM+
ALM
REF
SIGNAL
COM GND0V +V ØA ØA
–– ––
ØB ØB
–
Z Z
–
+Ub+E
2+ 2- 0+ 0-
K1- 1+
1-
K1+
––
K2+ K2- K0+ K0-
ALM+
ALM
ALM+
ALM
REF
SIGNAL
+V ØB ØA
–
COM
OZ
+Ub K2+
K1-
GND K0+
ALM+
ALM
+E 2+
1+
0V
0+
ALM+
ALM
ALM+
ALM
ALM+
ALM
COM GND 0V
0A
+V +Ub
–
K1
+E
1+
REF
SIGNAL
“H”,“L”
OPTIONS
CONDUIT BOX
“H”,“L”
A
ØA, ØA
–
ØB, ØB
–
ØZ, ØZ
–
BREAK
(NC)
MAKE
(N0)
SAFETY
SYSTEM
125 VDC
OR
120 - 380 VAC
125 VDC
OR
120 - 380 VAC
MECHANICAL OVERSPEED SWITCH WIRING APPLICATIONS
Avtron standard warranty applies. Copies available upon request.
Specifications subject to change without notice.
5

INSTALLATION
Refer to the back page of these instructions for outline and
mounting dimensions.
Equipment needed for installation
Supplied:
AV45 Encoder
Optional:
Foot Mount Kit
Thread Locker (blue)
Not Supplied:
M5 T-handle hex wrenches or torque wrench with M5 bits
Dial Indicator Gauge
Caliper Gauge
The encoder must be driven by a positive drive rather than a friction
drive. The following means of coupling are acceptable when properly
installed: Direct Coupling.
With a direct drive, use a flexible disc coupling and align the shafts as
accurately as possible. For motors with a pre-aligned flange, it is also
acceptable to use a “spider” or “jaw” coupling type. If a rubber slinger
disc is used, position it on the shaft so it will rotate freely.
CAUTION
Do not force or drive the coupling onto the shaft, or
damage to the bearings may result. The coupling
should slide easily on the shaft. Remove nicks and
burrs if necessary. Consider driving shaft endplay
& axial movement when positioning coupling.
For more details on alignment specifications, measurement tech-
niques, and special considerations in specifying and installing drive
components, refer to separate installation instructions in the Avtron
PULSE GENERATOR HANDBOOK.
B10 FACE MOUNTING INSTRUCTIONS
1) Apply anti-seize compound [copper], included, to inner
circumference of coupling (both motor and encoder side).
2) Loosen set screws in coupling and apply thread locker to set
screws.
3) Place coupling on motor shaft, inserting to depth per
manufacturer’s instructions.
4) Attach coupling to motor shaft using set screws per
manufacturer’s instructions.
5) Bolt mounting flange (flowerpot) to motor C-Face, using thread
locker with fasteners, included.
6) Slide encoder shaft into other side of coupling. DO NOT
FORCE. Ensure keyway aligns with coupling set screw
location.
7) Ensure C-Face on mounting flange matches and aligns with
encoder C-Face precisely.
8) Apply thread locker to hex cap screws.
9) Align bolt holes of encoder and flange, thread in (4) hex cap
screws, using lock washers.
10) Tighten set screws on encoder side of coupling.
FOOT MOUNTING INSTRUCTIONS
Equipment needed for installation
Supplied:
1. Foot Bracket
2. Soc. Hd. Cap Screw
6
Not Supplied:
M5 Hex Wrench
Dial Indicator
The B10 flange / face is the preferred mounting method for the AV45.
In certain cases, however, it may be necessary to foot-mount this unit.
The optional foot mounting bracket kits, Option 1, 2, or 3, will be re-
quired for standard installations or replacement of foot mounted Toshi-
ba TS2113N, Hubner HOG & OG, and FG4 units. Read all of the fol-
lowing instructions and the Avtron PULSE GENERATOR HANDBOOK
prior to beginning any work.
The AV45 performance and life will be directly affected by the installa-
tion. Following this sequence of steps is recommended.
1) Clean and inspect motor/driver shaft. Do not use force to
assemble coupling onto motor/driver shaft. The foot mounting
bracket must be secured to a flat, rigid, vibration free steel or
aluminum base which can be machined to accept the
mounting hardware.
2) Temporarily mount the AV45 to the foot bracket, install the
coupling to the AV45 and driver, and verify that the location is
suitable for installation.
3) If the AV45 encoder, bracket and coupling are suited to the
area, check motor/encoder shaft alignment with a straight
edge from multiple positions around the shaft circumference to
verify that it meets specifications.
4) While maintaining alignment, precisely mark the position of the
foot bracket on its mounting base.
5) Remove the AV45. Transfer punch or layout the mounting hole
pattern as indicated on outline drawing.
6) Machine through holes or tap holes
in center of base slots to give some degree of freedom in final
alignment.
7) Reinstall the AV45 with the flexible coupling loosely in place,
and tighten down all mounting hardware. Check
motor/encoder shaft alignment with a straight edge from
multiple positions around the shaft circumference to verify that
it meets specifications. Use thread locker supplied on cap
screws which mount AV45 to foot bracket.
8) Ensure any flat or keyway on the motor and encoder shaft are
aligned with the set screw holes of the flexible coupling. Apply
thread locker to coupling set screws and tighten per
manufacturer’s recommendations.
9) Recheck alignment and tighten all hardware after first several
hours of operation.
MODIFICATION
The AV45 can be modified in the field to easily adapt to new
applications.
TO CHANGE ELECTRICAL CONNECTOR STYLE:
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.

WIRING
CAUTION
Be sure to remove power before wiring the encoder.
Be sure to ground the cable shield: It can be con-
nected to case ground at the encoder, or grounded
as the receiving device, but should not be grounded
on both ends. See note below for Danaher/North-
star wiring.
Refer to the wiring diagrams for specific information on each
option.
The AV45 can be wired for single phase or two phase, either with
or without complements, with or without markers. For bidirection-
al operation, Phase A channel leads phase B channel for clock-
wise shaft rotation as viewed from the anti-drive or accessory end
of the motor (AV45 mounting end).
CAUTION
Be sure to observe maximum current limits for me-
chanical overspeed switch option. Exceeding these
limits can cause arcing and cause switch failure;
this may result in property damage, injury or even
death.
NOTE
Wiring option “G” provides a pinout compat-
ible with NorthstarTM encoders, with a cable shield
connection on pin 10. Note that this option does
not ground the shield; Avtron still recommends
grounding the shield at the drive end of the cable
for all wiring options.
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 and B at the use end of the wires.
b) Differential 2 Phase Wiring (see wiring diagram)
Exchange either A with A
–in the phase A pair OR
B with B
–in the phase B pair but NOT both.
3) Apply Power.
4) Verify encoder feedback is correct, using hand rotation
of shaft, or jog mode of the speed controller.
Interconnecting cables specified in the wire selection chart are
based on typical applications. Physical properties of cable such
as abrasion, temperature, tensile strength, solvents, etc., are dic-
tated by the specific application. General electrical requirements
are: stranded copper, 22 through 16 AWG (Industrial EPIC con-
nector type options can use 14 AWG), each wire pair individually
shielded with braid or foil with drain wire, .05 uf of maximum total
mutual or direct capacitance, outer sheath insulator. See specifica-
tions for maximum cable length. Stranded 22 AWG wire should not
be used for cable runs greater then 61 meters. If 22 AWG is used
with EPIC type connector 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.
FIGURE 5
VARIATION > ± 15%
PHASE A
PHASE B
7
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 Adap-
tive 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 annun-
ciation is available as an “alarm” output through the connector and
as an integral LED.
TROUBLESHOOTING
If the drive indicates a loss of encoder/tach fault and the AV45
fault-check LED is not illuminated, check the encoder power sup-
ply. 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 re-
placing the AV45. 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 AV45 and the rotor is properly located, replace the AV45.
An oscilloscope can also be used to verify proper output of the
AV45 encoder at the encoder connector itself and at the drive/con-
troller cabinet. If the outputs show large variations in the signals
at steady speed (jitter or “accordion effect”, see figure 5), replace
any magnetized material nearby with non-magnetic material
(aluminum, stainless) (shafts, etc). If variations persist, consider
replacing with super-shielded models, option -004.

Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
B1O FLANGE MOUNT STYLE
SHOWN: SINGLE OUTPUT, CONDUIT BOX
8
7.04
[178.8]
4.25
[108.0]
6.52
[165.6]
4.66
[118.4]
3.25
[82.6]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.53
[115.1]
7.04
[178.8]
4.25
[108.0]
6.52
[165.6]
4.66
[118.4]
3.25
[82.6]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.53
[115.1]

Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
B1O FLANGE MOUNT STYLE
SHOWN: DUAL OUTPUT, M23 CONNECTOR
10
4.66
[118.4]
3.25
[82.6]
4.24
[107.7]
6.71
[170.4]
8.50
[215.9]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]
4.66
[118.4]
3.25
[82.6]
4.24
[107.7]
6.71
[170.4]
8.50
[215.9]
2.10
[53.3]
4.53
[115.1]
0.26
[6.6] X 6
3.94
[100.0]
3.35
[85.0]

Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
TOSHIBA TS2113N FOOT MOUNT STYLE
SHOWN: “P” INDUSTRIAL CONNECTOR 18MM
SHAFT, SUPER MAGNETIC SHIELDING “004”
6.00
[152.4]
8.29
[210.5] 7.10
[180.3]
5.90
[149.9]
4.72
[120.0]
2.68
[68.0]
2.80
[71.0]
2.16
[54.9]
2.67
[70.0]
2.03
[51.6]
4.66
[118.4]
0.71
[18.00]
0.47 [12.00]
1.57 [40.0]
0.35
[8.8]
4.34
[110.3]
6.00
[152.4]
8.29
[210.5] 7.10
[180.3]
5.90
[149.9]
4.72
[120.0]
2.68
[68.0]
2.80
[71.0]
2.16
[54.9]
2.67
[70.0]
2.03
[51.6]
4.66
[118.4]
0.71
[18.00]
0.47 [12.00]
1.57 [40.0]
0.35
[8.8]
4.34
[110.3]
10

Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in inches [mm].
FOOT MOUNT STYLE WITH OVERSPEED
SHOWN: “P” INDUSTRIAL CONNECTOR 11MM SHAFT
6.00
[152.4]
8.21
[208.5]
4.52
[114.9]
0.30
[7.5]
5.32
[135.1] 0.35
[8.8]
1.18
[30.0]
4.54
[115.4] 6.88
[174.7]
1.18 [30.0]
[11.0] 0.433
2.03
[51.6]
2.68
[68.0]
2.16
[54.9]
2.36
[60.0]
1.73
[68.0]
4.33
[110.0]
7.16
[181.9]
4.48
[113.9]
6.00
[152.4]
8.21
[208.5]
4.52
[114.9]
0.30
[7.5]
5.32
[135.1] 0.35
[8.8]
1.18
[30.0]
4.54
[115.4] 6.88
[174.7]
1.18 [30.0]
[11.0] 0.433
2.03
[51.6]
2.68
[68.0]
2.16
[54.9]
2.36
[60.0]
1.73
[68.0]
4.33
[110.0]
7.16
[181.9]
4.48
[113.9]
11
REV: 07-25-12
8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A.
(1) 216-642-1230 • FAX [phone] • www.avtronencoders.com