Avtron XR56 SMARTSafe User manual

XR56 1
8901 E. PLEASANT VALLEY ROAD • INDEPENDENCE, OHIO 44131-5508
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ATEX/IECEx Instructions
XR56 SMARTSafe™
4 1/2” C-FACE MOUNT
MODULAR FOR HAZARDOUS
APPLICATIONS
DESCRIPTION
The Avtron XR56, SMARTSafe™ is a modular, two piece incremental
encoder for hazardous atmosphere applications (also known as a
tachometer or rotary pulse generator). It provides a two phase, A Quad
B frequency (pulse) output, with complements. The XR56 mounts on a
4.5” (NEMA 56C) Face.
CAUTION
The XR56 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.
Because the XR56 is modular, there are no bearings or couplings
required. This, combined with the latest magnetoresistive (MR)
sensor technology, allows the XR56 to provide superior mechanical
performance and increased reliability.
An Avtron XR56 can be configured with one or two independent
outputs. Each output has six signals: (A, B) 90° out of phase, with
complements (A
–, B –). A marker pulse with complement (Z, Z –) is also
provided.
Output resolution on the XR56 is determined by the sensor only.
Unlike older models, any PPRs can be mixed and matched. Selection
of the rotor is based only on the shaft mounting requirements (and not
PPR).
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 XR56 by constantly
monitoring and correcting duty cycle and edge separation over time.
The XR56 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 XR56 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.
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°C Db -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 II
* potentially explosive atmospheres when marked CE Ex II 3 GD,
Ex ic IIC* Gc T4 -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 II 3 GD, Ex ic
IIIC T 200°C Dc -40°C<Tamb<80°C.
See installation section for electrostatic charging hazard instructions
and other limitations.
INSTALLATION
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.
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 XR56 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.
Equipment Group II, Category 3 (ATEX/IECEx Zone 2), Gas group
IIC, Dust group IIIC (ATEX/IECEx Zone 22): Requires an XR56 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.
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 XR56 is not considered as a safety device and is not
suitable for connection into a safety system.

XR56 2
The XR56 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 XR56
may be subject. It is however the responsibility of the end user to
ensure that the XR56 is selected correctly for the potentially explosive
atmosphere in which the equipment is to be put into service.
The XR56 installation is similar to AV56. Installation and removal
videos for the AV56/67/85/115 are available on Avtron’s web site.
Refer to the back page of these instructions for outline and mounting
dimensions. The motor must comply with 1998 NEMA MG 1, section 4,
for tolerances on diameters and runout for shafts and accessory faces.
Axial float or endplay plus rotor location tolerance must be less than
±0.050”.
In preparation for installing the Model XR56 encoder, it is first
necessary to clean both the accessory motor shaft and the mounting
face. These surfaces must be inspected and any paint, burrs, or other
surface imperfections removed.
Installation procedures 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.
ROTOR INSTALLATION
The motor shaft must project at least 0.66 ” from the motor face. For
set screw rotors only: Apply anti-seize compound to the motor shaft.
For all rotors: Slide the rotor onto the shaft with the marking “Motor
side” facing in, (toward the motor face). The rotor centerline must
match the sensor centerline. To accomplish this, use the rotor locating
gauge (A28503) and slide the rotor onto the shaft until it is in the
proper position as shown in Figure 1. If a guage is not available, use
the stator housing alignment grooves as shown in Figure 3.
STANDARD CAM SCREW ROTOR INSTALLATION
Turn the cam screws of the rotor in the directions shown on the rotor
to engage the cams. Tighten to 50-60 in-lb [5.6 - 6.8 N-m] (See Figure
2) using the 3mm hex wrench. Total cam screw rotation will be less
than one turn.
CAUTION
Do not adjust the cam screws before motor shaft
mounting; bottoming out the screws, or backing them
out excessively, can lead to insufficient shaft holding
force. Thread locker is preapplied on the cam screws.
LARGE BORE SET SCREW ROTOR INSTALLATION
Apply thread locker to the rotor set screw holes, preferably from the
inside of the rotor bore before mounting. Tighten the rotor set screws
to 15 in-lb [2 N-m] using the 2mm T-handle hex wrench.
CAUTION
Use only a T-handle or torque hex wrench to tighten set
screws; using a right angle wrench will not provide
enough holding force, and the rotor may slip.
STATOR HOUSING INSTALLATION
The stator housing is attached to the motor using four socket head
cap screws (4) 3/8”-16 x 1.25”, locating on a 5.88” bolt circle. Longer
bolts (not included), are required for sandwich installation between a
motor and a brake. Install the four mounting bolts using thread locker
and torque to approximately 20-30 ft lbs [27 to 40 N-m] using the
5/16” T-handle hex wrench.
VERIFY ROTOR LOCATION
To ensure the rotor is properly located on the shaft: remove the back
cover if factory-preinstalled, and verify that the outer face of the rotor
is at the same depth as the alignment grooves, using a straight edge
tool. (Figure 3)
CAUTION
Do not use silicone sealants or caulk of any kind on the
motor or encoder face; these can cause misalignment
or sensor scraping damage. The XR56 electronics are
fully sealed; water may enter and leave the rotor area as
needed. A drain hole option is available if frequent
moisture buildup is expected.
COVER INSTALLATION
Covers must not interfere with the motor shaft or rotor. The longest
shaft that can be used without interfering is 0.72” [18.3mm] with a
standard flat cover (Cover Style option “F”) and 2.55” [64.8mm] with
an extended “pie pan” cover (Cover Style option “E”). Through shaft
covers with seals are available for other applications (Cover Style
option “T”).
EXTENDED COVER MOUNT (Cover Style option “E”)
The extended cover mounts to the encoder housing using quantity 4
#6-32 x 0.31” screws, lock washers, and thread locker.
THRU SHAFT AND FLAT COVER INSTALLATION
(Cover Style option “T” and “F”)
The housing has a machined step in the outboard face to accept the
cover and a recessed groove for the retaining ring. Insert the cover,
line up ears on cover, smooth side facing out, fully into the machined
step until it seats against shoulder. Using a spiral assembly method,
install the retaining ring by first inserting the squared off end into the
machined groove. Flex the ring and insert it into the groove walking
it around the perimeter (A flat blade screwdriver can be used). Final
position should have the ring fully seated into groove. Remove the
cover by reversing above procedure, starting with the tang end.
V-RING INSTALLATION FOR THRU SHAFT COVERS
(Cover Style option “T”)
For thru shaft covers, verify that the shaft passes completely through
the hole in the cover. Apply a small amount of silicone lubricant to
the cover plate around the thru shaft hole. The V-Ring seal should
compress axially when it is pressed against the clean, smooth face
of the cover plate. See Figure 4 for proper installation and V-Ring
compression.
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.

XR56 3
Refer to the wiring diagrams and pinout and phasing tables for
specific information on each option.
The XR56 can be wired for single phase or two phase, either with
or without complements, with or without markers. For bidirectional
operation, Phase A channel typically leads phase B channel for
clockwise shaft rotation as viewed from the anti-drive or accessory
end of the motor (XR56 mounting end). Refer to the pinout and
phasing tables for exceptions.
NOTE:
Wiring option “G” provides a pinout compatible with
NorthstarTM encoders, with a cable shield connection
on pin 10. Note that this option does not ground the
shield.
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 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. 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: stranded copper, 20 through 16 AWG
(Industrial EPIC connector 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 specifications for maximum cable length. Stranded 20 AWG wire
should not be used for cable runs greater then 61 meters. If 20 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.
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 XR56
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 XR56. 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):
1. Remove the rear cover, and use the built-in gauge to check the
location of the rotor (see Figure 1). Ensure the label marked “This
side out” and/or cam screws is/are facing away from the motor.
2. Remove the XR56 from the motor. Clean the housing mounting
surface for the XR56 housing. Ensure the XR56 is directly
mounted on the motor, with no sealant, gasketing, or other
materials, and is firmly bolted in place.
If the alarm output and/or LED indicate a fault (RED) on a properly
mounted XR56 and the rotor is properly located, replace the XR56.
An oscilloscope can also be used to verify proper output of the
SMARTSafe™ 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 below), check
rotor position. If the rotor position is correct, the motor or shaft may be
highly magnetized. Replace any magnetized material nearby with non-
magnetic material (aluminum, stainless) (especially shafts). For GE
CD frame motors and similar styles, Avtron offers non-magnetic stub
shafts. If variations persist, consider replacing the encoder with super-
shielded models, option -005, or use retrofit shielding kits AVSKxxx yy
z, where xxx=model (ex: 56A), yy=rotor
(ex: CB), and z=cover (ex: F).
NOTE:
Do not use rotors from THIN-LINE I (M56, M56S, M67, M85,
M115) with XR56 This will cause incorrect PPR output, but
the XR56 LED will remain green.
ENCODER REMOVAL
The XR56 stator housing can be removed by loosening and removing
the socket head cap screws.
CAM SCREW ROTOR REMOVAL
Disengage the (2) cam screws by turning them counterclockwise
less than 1 full turn. The cam heads will visibly move away from the
shaft. Remove the rotor by hand by pulling it away from the motor. If
the rotor will not move, do NOT use a gear puller, and do not use a
heat gun. Instead, insert two M6 screws, >25mm length into the Jack
Screw Holes shown in Fig 2. Alternately tighten the screws to push the
rotor away from the motor and remove it.
LARGE BORE SET SCREW ROTOR REMOVAL
Disengage the (2) set screws by turning them counterclockwise until
removed from the rotor. Retain the set screws. Remove the rotor by
hand by pulling it away from the motor. If the rotor will not move, do
NOT use a gear puller, and do not use a heat gun. Instead, pry the
rotor away from the motor gently, being careful to only pry against the
rotor metal hub and not the magnetic outer strip.
VARIATION > ± 15%
PHASE A
PHASE B

XR56 4
XR56 PART NUMBERS AND AVAILABLE OPTIONS
Model Housing
Type
Shaft Size
(Thru-Shaft Rotor) Cover Style Line Driver Single/Left Output (PPR)
Right Output
(PPR) Connector Modifications
XR56A 1- Single Output
2- Double Output
C0- None-std. Shaft Size
XX- None
Thru-Shaft Rotor (Metric)
US Metric
CA- 0.500 D2- 10mm
CB- 0.625 D3- 12mm
CC- 0.875 DB- 14mm
CD- 0.938 DC- 15mm
CE- 1.000 DD- 16mm
CF- 1.125 D4- 18mm
CG- 1.250 DE- 19mm
CH- 1.375 DF- 24mm
CT- 1.500 DG- 28mm
CJ- 1.625 DH- 30mm
CK- 1.750 DT- 32mm
CL- 1.875 DJ- 36mm
CM- 2.000 DK- 38mm
CN- 2.125 DL- 42mm
CQ- 2.250 DM- 45mm
CP- 2.375 DN- 48mm
CR- 2.500 DP- 52mm
TS- 2.625*DR- 55mm
TU- 2.875*DS- 60mm
TV- 3.000*MU- 65mm*
T4- 3.125*MV- 70mm*
T7- 3.188*MW- 75mm*
MY- 80mm*
MZ- 85mm*
E- Extended
Shaft Cover
F- Flat Cover
T- Flat Thru-
Hole Cover with
Shaft Seal
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 & 21
Remote Protection &
Zone 2 and 22
P- 10 Pin EPIC Industrial
w/ Plug
G- 10 Pin Industrial w/ Plug
(Northstar pinout)
W- 3 Ft. Cable, Sealed
Y- 10 pin MS w/plug on
12” Cable
R- Mini Twist Lock (Mini
MS) w/ mating plug
000- No Modification
005- Super Magnetic Shielding
4xx- Special PPR Code,
consult factory
9xx- Special Cable Length,
xx=length in feet
Equipment Needed for Installation
Provided Optional Not Provided
AV56 Stator/Housing
Socket Hd Cap Screw 3/8"-16 x 1.25" (4)
AV56 Rotor
Socket Set Screw #M4 x 8mm (2) or Pre-Installed
Cam Screw
Thread locker (blue)
Extended Shaft Cover w/ Screws 6-32 x 0.31" (4)
Lock Washers
Thru Shaft Cover w/ V-Ring Seal and Silicone
Lubricant XRB1 Isolator (PN B35134)
REQUIRED for Zone 1 Applications
Phillips Screwdriver
2mm Hex Wrench (T-Handle Style for set screw
Rotors)
3mm Hex Wrench
5/16" Hex Wrench
* Set Screw Rotor Only
0- Non-
std.
F- 60
G- 100
H- 120
A- 128
L- 240
N- 256
P- 300
E- 360
B- 480
Q- 500
R- 512
S- 600
V- 900
J- 960
Y- 1024
Z- 1200
3- 2000
4- 2048
5- 2500
D- 4096
8- 4800
9- 5000
F- 60
G- 100
H- 120
A- 128
L- 240
N- 256
P- 300
E- 360
B- 480
R- 512
S- 600
V- 900
J- 960
Y- 1024
Z- 1200
3- 2000
4- 2048
5- 2500
D- 4096
8- 4800
9- 5000
0- Non-
Std.
X- None

XR56 5
SPECIFICATIONS
LINE DRIVER OPTIONS
LINE DRIVER OPTIONS
Electrical Specifications 7Isolator XRB1 5 Units
Input Voltage 5-24 12-24 5-7 VDC
Nom Output Voltage 5-24 (5-7 to Encoder)
10.6 Output Signals 5 VDC
Line Driver 7272 IXDF604 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 10.6 VIN-1 VDC
Vol Typ 0.5 0.4 0.5 VDC
Cable Drive Capacity 500’ @ 5-12V
200’ @ 24V 1000’ 500’ 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
LED Green=power on, Red=Alarm
Marker 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” (NorthstarTM compatible pinout), “R” and “S”
ELECTRICAL
A. Operating Power (Vin)
1. Volts .............................See Line Driver Option Chart
2. Current.........................100mA, each output, no load
B. Output Format
1. 2O/ & Comp.................A, , B, (differential line driver)
2. Marker..........................1/Rev, 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. Phase 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
J. Integral LED Indicator.......GREEN: power on, unit ok. RED: alarm on
MECHANICAL
A. Rotor Inertia .....................0.17-0.36 Oz. In. Sec.2
B. Acceleration .....................5000 RPM/Sec. Max.
C. Speed ..............................5400 RPM Max.
D. Weight..............................2-3 lbs [0.9kg to 1.36kg].
E. Sensor to Rotor
Air Gap (nominal).............0.030” [0.76mm]
Tolerance .........................±0.015” [0.38mm]
F. Rotor Axial Tolerance........±0.050” [±1.27mm]
ENVIRONMENTAL
Solid cast aluminum stator and rotor
Less than 6% magnesium by mass
Fully potted electronics, protected against
oil and water spray
V-Ring seals provided on through shaft
covers Operating Temperature:
-40 to 80°C, 0-100% condensing humidity
See “Description” section for information
on hazardous location environments
II UI CI
IIC IIB
250mA 15V 25V
1.8uf
1A 15V
5A 12V
Zone 2 Power Supply Limits
Parameter Isolator Encoder
Um 250V -
Ui - 7.14V
Li - 440mA
Pi - 0.4W
Ci - 11.9UF
Li - 0mH
Uo 7.14V -
Io 440mA -
Po 0.4W -
Lo 1.5mH
Co 13.5uF
Lo/Ro -
Zone 1 Table of entity parameters
CONNECTOR SPARE PARTS
STYLE OPTION
CODE ENCODER SIDE CABLE SIDE PLUG
Industrial
EPIC on
Encoder
P,G
315233 Base 315231 Hood
315229 Terminal 315230 Terminal
401112 Adapter
Mini-MS
Twist Lock R 315296 Base 316110 Plug
10 pin MS
on cable Y
314383 In-Line 315932 Plug
411216
Cable Bushings
411217
411218
411219
SPECIAL PPR OPTION CODES
OPTION CODE LEFT PPR RIGHT PPR
401 1270 None
402 150 None
403 50 None
404 512 16
405 16 None
406 6000 None

XR56 6
Thinline II Spare Parts
(AV56/AV56S/AV67/AV85/AV115/ XR56/XR56S/XR67/XR85/XR115 Only)
SAE/USA Sizes
Shaft
Size
Rotors AV56, AV56S,
AV67, AV115,
XR56, XR56S, XR67 &
XR115
Rotor
AV56S &
XR56S
Thru-Shaft Covers
Option
Code
Cam
Screw
Set Screw
Stainless
Rotor
AV56, AV56S,
AV67, AV115,
XR56, XR56S,
XR67 & XR115
Cover Kit
AV85/XR85
Cover /kit Seal Only
.500/.4995 CA AVTR1-CA AVTR2-TA A36521-TA A36523-TA 471960
.625/.6245 CB AVTR1-CB AVTR2-TB A36521-TB A36523-TB 471877
.875/.8745 CC AVTR1-CC AVTR2-TC A36521-TC A36523-TC 471963
.9375/.9370 CD AVTR1-CD AVTR2-TD A36521-TD A36523-TD 471963
1.000/.9995 CE AVTR1-CE AVTR2-TE A36521-TE A36523-TE 471964
1.125/1.1245 CF AVTR1-CF AVTR2-TF A36521-TF A36523-TF 471965
1.250/1.2495 CG AVTR1-CG AVTR2-TG A36521-TG A36523-TG 471967
1.375/1.3745 CH AVTR1-CH AVTR2-TH A36521-TH A36523-TH 471952
1.500/1.4995 CT AVTR1-CT AVTR2-TT A36521-TT A36523-TT 471969
1.625/1.6245 CJ AVTR1-CJ AVTR2-TJ A36521-TJ A36523-TJ 471969
1.750/1.7495 CK AVTR1-CK AVTR2-TK A36521-TK A36523-TK 471970
1.875/1.8745 CL AVTR1-CL AVTR2-TL A36521-TL A36523-TL 471970
2.000/1.9995 CM AVTR1-CM AVTR2-TM A36521-TM A36523-TM 471971
2.125/2.1245 CN AVTR1-CN AVTR2-TN A36521-TN A36523-TN 471972
2.250/2.2495 CQ AVTR1-CQ AVTR2-TQ A36521-TQ A36523-TQ 471972
2.375/2.3745 CP AVTR1-CP AVTR2-TP A36521-TP A36523-TP 471953
2.500/2.4995 CR AVTR1-CR AVTR2-TR A36521-TR A36523-TR 471954
2.625/2.6245 TS N/A AVTR2-TS A36521-TS A36523-TS 471954
2.875/2.8745 TU N/A AVTR2-TU A36521-TU A36523-TU 471956
3.000/2.9995 TV N/A AVTR2-TV A36521-TV A36523-TV 471956
3.1250/3.1245 T4 N/A AVTR2-T4 A36737-T4 A36523-T4 471957
3.1875/3.1870 T7 N/A AVTR2-T7 A36737-T7 A36523-T7 471957
1.125" w/.25" Keyway B33334-2
15/16" w/.25" Keyway B33334-1
Extended and Flat Cover Plates
Shaft Size Model Extended Shaft Cover Kit Flat Cover Kit
Any AV56A, AV67, AV115 ,
XR56A, XR67, XR115 A35841 A37298
Any AV56S , XR56S A36526 A37298
Any AV85 , XR85 A35841 A36525

XR56 7
Thinline II Spare Parts
(AV56/AV56S/AV67/AV85/AV115/XR56/XR56S/XR67/XR85/XR115 Only)
Metric Sizes
Shaft
Size
Rotors AV56A, AV67,
AV85, AV115, XR56A,
XR67, XR85, XR115
Thru-Shaft Covers
Option
Code
Cam
Screw Set Screw
AV56, AV56S,
AV67, AV115,
XR56, XR56S,
XR67, XR115,
Cover Kit
AV85/XR85
Cover /kit Seal Only
10mm D2 AVTR1-D2 N/A A36522-M2 A36524-M2 471959
11mm DA AVTR1-DA N/A A36522-MA A36524-MA 471959
12mm D3 AVTR1-D3 N/A A36522-M3 A36524-M3 471960
14mm DB AVTR1-DB N/A A36522-MB A36524-MB 471961
15mm DC AVTR1-DC N/A A36522-MC A36524-MC 471961
16mm DD AVTR1-DD N/A A36522-MD A36524-MD 471877
18mm D4 AVTR1-D4 N/A A36522-M4 A36524-M4 471962
19mm DE AVTR1-DE N/A A36522-ME A36524-ME 471951
24mm DF AVTR1-DF N/A A36522-MF A36524-MF 471964
28mm DG AVTR1-DG N/A A36522-MG A36524-MG 471965
30mm DH AVTR1-DH N/A A36522-MH A36524-MH 471966
32mm DT AVTR1-DT N/A A36522-MT A36524-MT 471967
36mm DJ AVTR1-DJ N/A A36522-MJ A36524-MJ 471968
38mm DK AVTR1-DK N/A A36522-MK A36524-MK 471969
42mm DL AVTR1-DL N/A A36522-ML A36524-ML 471969
45mm DM AVTR1-DM N/A A36522-MM A36524-MM 471970
48mm DN AVTR1-DN N/A A36522-MN A36524-MN 471971
52mm DP AVTR1-DP N/A A36522-MP A36524-MP 471971
55mm DR AVTR1-DR N/A A36522-MR A36524-MR 471972
60mm DS AVTR1-DS N/A A36522-MS A36524-MS 471953
65mm MU N/A AVTR1-MU A36522-MU A36524-MU 471954
70mm MV N/A AVTR1-MV A36522-MV A36524-MV 471955
75mm MW N/A AVTR1-MW A36522-MW A36524-MW 471956
80mm MY N/A AVTR1-MY A36737-MY A36524-MY 471957
85mm MZ N/A AVTR1-MZ A36737-MZ A36524-MZ 471958

XR56 8
ALIGNMENT NOTCH
ALIGN ROTOR FACE
WITH BOTTOM
OF NOTCHES
IN HOUSING
ALIGNMENT
GROOVES
STRAIGHT
EDGE TOOL
MOTOR
ENCODER
V-RING SEAL
COVER PLAT E
APPLY GREASE TO
COVER WHERE SEAL
CONTACTS
SHAFT
ENCODER
“A”
ACCESSORY
MOUNTING FACE
COVER PLAT E
RETAINING RING
V-RING WIDTH
SEE CHART
0.21" [5.3] MIN
0.27" [6.9] MIN
0.31" [7.9] MIN
0.38" [9.7] MIN
“A”
ADD’L SHAFT
LENGTH REQ’D
FOR V-RING
0.19" ± 0.02" [4.6±0.5]
0.24" ± 0.03" [6.1±0.8]
0.28" ± 0.04" [7.1±1.0]
0.35" ± 0.05" [8.9±1.3]
2.75"- 3.00" [70.0-79.4]
0.38" [9.7] MIN
0.35" ± 0.05" [8.9 ±1.3]
Add +0.22" [5.6] for cover depth
>3.00 [>75mm]
1.50"- 2.63" [38.1-66.7]
0.87"-1.38" [22.2-34.9]
0.50"-0.63" [12.7-15.8]
V-RING WIDTH
INSTALLED
SHAFT DIAMETER
5.6-6.8 N-M
TIGHTEN: 50-60 IN-LB
TO LOCK ROTOR
ROTATE CAM SCREWS
OF NOTCHES
IN HOUSING
ALIGN ROTOR FACE
WITH BOTTOM
ALIGNMENT NOTCH
Jack Screw Holes
M6
CW CW
MOTOR FACE CONFIGURATION
(4) 3/8" - 16
0.005” [0.127] M A
5.875" [149.2]
0.030" [0.75] MAX x 45°CHF
-B-
-A-
0.002" [0.05]
0.004" [0.10] B
A
(4) 3/8"-16 x 1.25"
TIGHTENING TORQUE
20-30ft - lbs [27-40 NM]
(2) M4 x 0.7 x 6.0 LG
SET SCREW
TIGHTENING
TORQUE - 2 NM
ROTOR SETTING TOOL
SUPPLIED
COVER
RETAINER
45°
4.500" [114.3]
DIA
0.66” MIN [16.76]
0.72” MAX [18.29] for “F” flat cover
2.55 MAX [64.8mm] for "E" cover
SEE SPARE PARTS
CHART FOR AVAILABLE
SHAFT SIZES
0.160” [4.1] MAX
0.658" ± 0.050"
[16.71 ± 1.27]
0.440” ± 0.005”
[11.20 ± 0.13]
0.265” ± 0.005”
[6.73 ± 0.13]
SEE SPARE PARTS
CHART FOR ROTOR ID
3.819" [97.00]
ROTOR OD
Counterbore
on XR56S
No Counterbore
on XR56A
U.S. Patent
7, 737, 601 & 7, 485, 997
FIG 1
FIG 2
FIG 4
FIG 3

XR56 9
WIRING DIAGRAMS
12-24
Volts Out
Customer Equipment
2 Phase Dierential
+
-
A-
A+
B-
B+
Z-
Z+
Intrinsic Safety Gnd
K1-
0+
K1+
K2-
1-
1+
K2+
GND
+E
0V
0-
2-
K0-
2+
Ub+
K0+
A
A
B
B
Z
Z
-
+
5-7 Volts
Out
+
-
12-24
Volts In
A
A
B
B
Z
Z
ISOLATOR
P/N B35134
gndgnd
ZONE 1 HAZARDOUS AREA SAFE AREA
“REMOTE PROTECTION’
ENCODER
Typical Cable 500'(150M)max
18AWG, 4 Twisted Pair + Overall Shield
Belden P/N 9554 or Alpha P/N 2244C Typ
See Attached for Connector
Option Pin Outs
0V
Gn
d
A
+
B
+
Z+ Alm
+
+Vi
n
A- B- Z
-
Al
m
10 Pin MS Avtron / on 12” Cable
Y
A
CW Pin
#
A
D
E C NC BG HIN
C
10 Pin MS Mini Twist Lock R
A
CW Pin
#
F
A
B
C
N
C
D
HJ
K
N
C
10 Pin, Mini Industrial, Avtron Pinout P
A
CW Pin
#
12345 67 8910
10 Pin, Mini Industrial, Northstar Pinout G
A
CW Pin
#
1234N
C
67 89N
C
3’ Cable Sealed W
A
CW Colo
r
BLK GRN BLU ORG BRN RED YE
L
GRA WHT VIO
Phasing is dened as the direction of
rotation for which phase A leads B as viewed
from the back of the Encoder
Option
Code
Channel
Code Phasing Signal
PINOUTS AND PHASING

XR56 10
WIRING DIAGRAMS
Refer to Installation and Specication Sections for Requirements and Limitations
2 Pair
3 Pair
4 Pair
5 Pair
BeldenAlpha
9552
9553
9554
1328A
2242C
2243C
2244C
2245C
5-24*
Volts Out
Customer Equipment
2 Phase Dierential
+
-
A-
A+
B-
B+
Z-
Z+
K1-
0+
K1+
K2-
1-
1+
K2+
GND
+E
0V
0-
2-
K0-
2+
Ub+
K0+
ZONE 2 HAZARDOUS AREA
SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Twisted Pair + Overall Shield
See Attached for Connector
Option Pin Outs
DIFFERENTIAL 2 PHASE WIRING
2 Pair
3 Pair
4 Pair
5 Pair
Belden Alpha
9552
9553
9554
1328A
2242C
2243C
2244C
2245C
5-24*
Volts Out
Customer
Equipment
+
-
A+
B+
Z+
GND
0+
K1+
0V
1+
K2+
+E
2+
Ub+
K0+
ZONE 2 HAZARDOUS AREA
SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Twisted Pair + Overall Shield
See Attached for Connector
Option Pin Outs
SINGLE ENDED 2 PHASE WIRING
+v
alm
5-24*
Volts Out
Customer
Equipment
ZONE 2 HAZARDOUS AREA
SAFE AREA
ENCODER LINE
DRIVER OPTION 7
Typical Cable 500'(150M)max
18AWG, Triad + Overall Shield
See Attached for Connector
Option Pin Outs
SINGLE ENDED 1 PHASE WIRING
-GND 0V
+Ub+ +E
A+ K1+
3 Conductor BeldenAlpha
9365 M9628010 *SEE SPECIFICATIONS FOR ZONE 2
POWER SUPPLY LIMITATIONS
1+

XR56 11
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
OUTPUT OPTIONS
9
4
5
10
2
8
3
7
6
1
Vcc
OUT
COM
300 OHM
MIN.
GND
FUNCTION
ENCODER
ØB
ØA
ØA
ØB
SOLID STAT E RELAY
Q5
MMFT6661
LINE
DRIVER
NOTE 1
CR8
{
FUNCTIONAL DIAGRAM
50 mA MAXIMUM
“L”,“W”“P”,“Z”
MARKER
MARKER COMPLEMENT
COMMON
+V (Encoder Power)
{
BLACK
RED
GREEN
YELLOW
BLUE
GRAY
ORANGE
WHITE
BROWN
VIOLET
OUTPUT OPTIONS
9
4
5
10
2
8
3
7
6
1
MARKER
MARKER COMPLEMENT
GND
FUNCTION
+V (Encoder Power)
COMMON
*
VDC
+
-
POWER
SUPP
*See note below
LY 115 VAC
SINK 100 mA MAXIMUM,
Q5
MMFT6661
ENCODER
FUNCTIONAL DIAGRAM
ØB
ØA
ØA
ØB
LINE
DRIVER
NOTE 1
CR8
“L”,“W”“P”,“Z”
*See specifications for Zone 2
power supply limits
Example 2. Alarm Output Using Separate * VDC Power Supply and Relay.
Applies to all XR56 models, except, wiring options “G”, “R”, and “S”.
ALARM OUTPUT CONNECTION
Avtron THIN-LINE II encoders provide an alarm signal if maintenance is required under specific circumstances. An alarm LED
indicator is also available. Green indicates power on, red indicates alarm on. 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.
THIN-LINE II™ - Zone 2/22 Only
Application Examples
Vcc
OUT
COM
300 OHM
MIN.
SOLID STAT E RELAY

XR56 12
0.83
[21.1]
4.500
4.497
[114.300]
[114.224]
DIA
0.12 [3.05]
0.18 [4.57]
4.5015
4.5055
[114.3381]
[114.4397]
DIA
OPTIONAL COVER
FOR EXTENDED SHAFT MOTORS
1.97
[50.0]
2.73 [69.4]
2.87 [72.9]
OPTION “Y”
0.441 [11.201]
CAM SCREWS
Ø 0.88 [22.352]
THRU, 180° APART
ON A 2.50 [63.50] DIA.
FOR AVAILABLE
BORE SIZES,
SEE PAGE 1 P/N TABLE.
45°
±10°
90°
±10°
CAM SCREW ROTOR
Ø3.82 [97.00]
0.441 [11.201]
SET SCREW ROTOR
FOR AVAILABLE
BORE SIZES,
SEE PAGE 1 P/N TABLE.
(2) M4 x 0.7 x 6.0 LG
SET SCREW
TIGHTENING
TOQUE - 2 NM
0.441 ±0.005
[11.20 ±0.13]
0.265 ±0.005
[6.73 ±0.13]
OPTIONAL ISOLATED DUAL OUTPUT
1/2-14 NPT
OPTION “P”, “G”
PLUG-IN INDUSTRIAL
CONNECTOR ADDITIONAL
OPTIONS SHOWN
0.410 [10.41] DIA
4 HOLES EQUALLY SPACED
ON A 5.875 [149.225] DIA
RETAINING
RING
(TANG END)
8.04
[204.2]
4.87
[123.8]
7.53
[191.3]
5.50 [139.7]
45°
2.75
[69.85]
STANDARD
FLAT COVER
36.00 [914.4] MIN
OPTION “W”
SEALED FLEXIBLE CABLE
1.09 [27.6]
12.00 [305] MIN
OPTION “R”
MINI MS WITH PLUG
3 – DIMENSIONS IN INCHES [MILLIMETERS]
2 – ALL DIMENSIONS ARE APPROXIMATE
1 – WEIGHT: 2.5 - 4LBS [1.13 TO 1.81 KG].
NOTES:
Features and specifications subject to change without notice.
Avtron standard warranty applies. All dimensions are in Inches [mm] approx.
OUTLINE DRAWING
8901 E. PLEASANT VALLEY RD., INDEPENDENCE, OH 44131, U.S.A.
(1) 216-642-1230 • FAX [phone] • www.avtronencoders.com
These instructions have been reviewed and the product evaluated as suitable for our application.
Company Name
Authorized Company Representative
Title Date
Cable Lenght:
Option “Y” 12” MIN
REV: 09/12/13