Encoder

Instructions
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
HS45
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 5/8-1 1/8" [16-30mm]
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
HOLLOW SHAFT

DESCRIPTION When mounted to a machine shaft, the HS45 design eliminates the
The Avtron Model HS45 is a heavy duty incremental encoder (also need for shaft couplings, adapter flanges, or accessory mounting
known as tachometer or rotary pulse generator). Its output is directly faces. The high clamping-force collar holds the HS45 in place, even
proportional to shaft position (pulse count) or speed (pulse rate). The under severe vibration & shock. A high-performance composite shaft
HS45 operates down to zero speed and can be used for both control insert provides electrical isolation from motor shaft currents. The shaft
and instrumentation applications. 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 anti-
CAUTION rotation arm prevents housing rotation while allowing for shaft end
Do not utilize HS45 in hazardous locations which float.
require ATEX, UL, CUL, CSA, or other explosion protection
certification. HS45 is not certified for hazardous The HS45 utilizes magnetoresistive sensors. This proven technology
locations. Use XR models for hazardous applications. is ideal for rugged environments since it is immune to many
contaminants that cause optical encoders to fail. All of the HS45
electronics are potted, providing full protection against liquids.
The outputs are protected against short circuits and wiring errors.

HS45 PART NUMBERS AND AVAILABLE OPTIONS

Left Right
Model Bore Size Output Output Line Driver Connector Options Tether Channels Modifications
PPR PPR
HS45 Clamping End of Shaft: AF-60 XX-None 6- 5-24V in, 10 Pin MS Connector- X- None A- All
000- None
Collar Mount Center Bolt AG-100 AF-60 5-24V out* Small Encoder Pinout Flat Styles: 004- Super
A,B,A,B,Z,Z
U.S. Mount AH-120 AG-100 A- Avtron/BEI Pinout, w/o plug D- Fan Cover (req’d for 8,
Magnetic
C- 5/8” AA-128 AH-120 8- 5-24V in, B- Dynapar HS35 Pinout, w/o plug (T-bolt) 10 pin con-
Shielding
L- 16mm C- Avtron/BEI Pinout, mating plug
D- 3/4" AL-240 AA-128 5-15 out E- 4.5” NEMA 500- Add 100C
nectors)
(no taper) D- Dynapar HS35 Pinout, mating
E- 7/8" AN-256 AL-240 hi-power C-face temperature
M- 17mm plug
F- 1" AP-300 AN-256 F- 8.5” NEMA
For 6,7 range to shaft
(10:1 taper)
G- 1 1/8 AE-360 AP-300 9- 5-24V in, pin conns
FC-face bores 5/8-1”
10 Pin MS Connector-
U- All US Sizes AB-480 AE-360 5V fixed out only and 16mm-
Large Encoder Pinout
AQ-500 AB-480 *Recommended 4- Avtron/Northstar Pinout, mating Threaded Rod 25mm
Clamping AR-512 AQ-500 for single-ended plug Styles: B- A,B,A,B 6xx- Add over
Collar Mount AS-600 AR-512 applications G- 70-500mm (no marker) speed switch
Metric AV-900 AS-600 6 Pin MS Connector- w/bracket xx=speed
S- 16mm AJ-960 AV-900 Small Encoder Pinout P- 70mm fixed E- A,B,Z code
T- 18mm AW-1000 AJ-960 E- Avtron/BEI Pinout, w/o plug w/screw (single 9xx- Specify cable
V- 19mm AY-1024 AW-1000 F- Dynapar HS35 Pinout, w/o plug T- Fan Cover ended) length xx=feet
W- 20mm AZ-1200 AY-1024 70-500mm max 33ft
Y- 25mm CX-1500 AZ-1200 7 Pin MS Connector- w/T-bolt F- A,B (use w/ Option
3- 30mm A3-2000 CX-1500 Small Encoder Pinout (single “Q”,“W”, “Z”)
Z- All Metric A4-2048 A3-2000 J- Avtron/BEI Pinout, w/o plug Combinations: ended, no
Sizes A5-2500 A4-2048 K- Dynapar HS35 Pinout, w/o plug H- Fan Cover marker)
AD-4096 A5-2500 & 8.5”
A8-4800 AD-4096 Small EPIC Connector C-face
P- Avtron pinout, w/mate
A9-5000 A8-4800 M- Fan Cover
G- Northstar pinout w/mate
A0-Special A9-5000 & 4.5”
Q- Avtron pinout on remote base,
A0-Special C-Face
18” cable w/mate
Z- Avtron pinout on 18” cable w/mate U- Universal
(includes
Terminal Box w/terminal strip all styles)
H- USA, 1/2” conduit
L- Europe w/cord grip Dual/Ganged
Encoders:
8 Pin M12 Connector Y- Tether 2nd
T- Global pinout, w/o plug encoder to
U- USA Pinout, w/o plug 1st
(select any
12 Pin M23 Connector tether from
2- Leine and Linde pinout, w/o plug above list for
3- Hubner Pinout w/o plug first encoder)
W- Cable 18” (or special length)
R- Mini Twist Lock (Mini MS) w/ mating plug
S- Mini Twist Lock (Mini MS) on 3’
cable w/mating plug

HS45 1
 LINE DRIVER OPTIONS
ELECTRICAL SPECIFICATIONS Electrical Specifications 6 8 9 Units
A. Operating Power (Vin) Input Voltage 5-24 5-24 5-24 VDC
1. Volts............................. 5-24 VDC in
2. Current........................ 100mA, each output, plus cable load Nom Output Voltage 5-24 5-15 5 VDC
B. Output Format
– – Line Driver 7272 4125 7272
1. 2O/ & Comp................. A,A, B,B (differential line driver)
– Output Resistance Typ 13 3 13 ohms
2. Marker:........................ 1/Rev Z, Z
C. Signal Type...................... Incremental, Square Wave, 50 +/-10% Maximum Peak Current 1500 3000 1500 mA
.................................... Duty Cycle. Maximum Average
120 350 120 mA
Current
D. Direction Sensing............ O/A leads O/ B for CW rotation as viewed
.................................... from the back of the tach looking at the Voh Typ VIN-1 VIN-1, max 15V out VIN-1 VDC

.................................... non-drive end of the motor. Vol Typ 0.5 0.4 0.5 VDC
E. Transition Sep................. 15% minimum 1000’ @ 5V
F. Frequency Range............ 0 to 165,000 Hz Cable Drive Capacity 500’ @ 12V 1000’ 1000’ feet
200’ @ 24V
G. PPR................................. 8-5000
Reverse
H. Line Driver Specs:........... See table yes yes yes
Voltage
I. Connectors:..................... See connector options on page 1 Protection Short
yes yes yes
Circuit
MECHANICAL Transient yes yes yes
A. Shaft Inertia..................... 1.59 lb-in-sec2 +V(out) Output voltage equal to input voltage.
B. Acceleration..................... 5000 RPM/Sec. Max. Alarm
C. Speed:............................. 5000 RPM Max (also see overspeed) Open collector, normally off, goes low on alarm,
Alarm*
D. Weight:............................ 10-12 lbs [4.5-5.5kg] sink 100mA max, 50VDC max
E. Vibration.......................... 20 Gs, 5-2000 Hz (any orientation) One per revolution. Pulse width
Marker
F. Shock.............................. 100 Gs, any orientation approximately 1/128 of a revolution
G. Shaft Engagement (clamp style)
5/8”-7/8” bore...................2” [51mm] min.
16-20mm bore..................51mm min. Each HS45 has a two-phase output (A, B) 90° out of phase, with
1”- 1 1/8” bore..................1.75” [45mm] min. complements (A, B), (A Quad B Output). A marker pulse with
25-30mm bore..................45mm min. complement (Z, Z) is also present.
with overspeed switch......2.65” +/-0.05” [68mm +/-1.27mm]
The HS45 has a diagnostic package that includes Adaptive Electronics
and a Fault-Check output and red/green LED for local indication.
ENVIRONMENTAL With this package, the HS45 can maintain itself, and provide an
Solid cast aluminum stator and rotor alarm if there is a problem before the problem causes un­scheduled
Fully potted electronics, protected against oil and water spray downtime.
Operating Temperature:.......-40°C to +100°C.
(note for shaft codes C-F, S-Y, +85C or use option 500 = +100C) ADAPTIVE ELECTRONICS
A perfect duty cycle consists of a waveform whose “high” and
MECHANICAL OVERSPEED SWITCH OPTION “low” conditions are of the same duration (50%/50%). It is possible
over time for the duty cycle and edge separation to change due
A. Shaft Inertia..................... +0.0018 lb-in-sec2 to component drift, temperature changes, or mechanical wear.
B. Acceleration..................... 3600 RPM/Sec. Max. The Adaptive Electronics extend the life of the HS45 by constantly
C. Speed:............................. 1.25 x Overspeed set point Max. monitoring and correcting duty cycle and edge separation over time.
Minimum trip speed: 700 RPM
Maximum trip: 3600 RPM FAULT-CHECK
Accuracy +/- 4% of trip point If the Adaptive Electronics reach their adjustment limit, the LED will
Hysteresis: 40% of trip point
turn red and Fault-Check alarm will notify the drive and operator of
D. Weight:............................. +2.55 lbs [+1.16kg]
an impending failure. This output can occur before a failure, allowing
E. Vibration:......................... 20 Gs, 5-2000 Hz (radial only)
F. Shock:............................. 100Gs, any orientation
steps to be taken to replace the unit before it causes unscheduled
G. Electrical Contact (NO/NC Contact)
downtime. Fault-Check annunciation is available as an “alarm” output
1. .................................... 6A/230VAC
through the connector.
2. .................................... 3A/380VAC
3. .....................................1A/125VDC SAFETY
H. Operating Temperature:......-40°C to +100°C. The HS45 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.

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

HS45 2
HS45
Remote Alarm
Applies to Model HS45 Encoders connector styles “H”, “L”, “P”, “Q”, “W”, “Z”, “4”

ALARM OUTPUT CONNECTION

Avtron HS45 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 OUTPUT OPTIONS

FUNCTIONAL DIAGRAM
“W” “P”,“Q”, FUNCTION
“4” “H”, “L”
“Z”

{
BLACK A 1 COM COMMON
RED B 6 +V +V (Encoder Power)
CR8
GREEN D 2 A ØA
YELLOW G 7 A ØA
LINE BLUE E 3 B ØB
DRIVER
GRAY H 8 B ØB
NOTE 1
ORANGE C 4 Z MARKER
WHITE I 9 Z MARKER COMPLEMENT
50 mA MAXIMUM
BROWN F 5 +V(OUT)
VIOLET J 10 ALM
300 OHM
MIN. Vcc
Q5
MMFT6661 GND
OUT

COM
4-16 VDC SOLID STATE RELAY

Example 2. Alarm Output Using Separate 24 VDC Power Supply and Relay.

ENCODER OUTPUT OPTIONS FUNCTION

FUNCTIONAL DIAGRAM
“W” “4” “P”,“Q”, “H”,“L”
“Z” COMMON

BLACK A 1 COM
+V (Encoder Power)
RED B 6 +V

{
CR8 -
GREEN D 2 A ØA
YELLOW G 7 A ØA POWER 24 115 VAC
LINE BLUE E 3 B SUPPLY VDC
ØB
DRIVER +
GRAY H 8 B ØB
NOTE 1
ORANGE C 4 Z MARKER
WHITE I 9 Z MARKER COMPLEMENT

BROWN F 5 +V(OUT) RELAY

VIOLET J 10 ALM

Q5 SINK 100 mA MAXIMUM,

MMFT6661 GND WITHSTAND 50 V MAXIMUM
REFERENCED TO COMMON

HS45 3
 Avtron standard warranty applies. Copies available upon request.
Specifications subject to change without notice.
DIFFERENTIAL TWO PHASE WIRING APPLICATIONS
PINOUT
CONNECTOR

OPTION OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS
“W” “A”, “B”, “C”, “D” “J”, “K” “E”, “F” “T” “U” “P”, “Q<<” , “Z<<” <<
“R”, “S ” “G” “4” “H”,“L” “2” “3”
(CABLE) (10 PIN MS) (7 PIN MS) (6 PIN MS) (8 PIN M12) (8 PIN M12) (10 PIN (10 PIN (10 PIN (10 PIN MS) CONDUIT BOX (12 PIN M23) (12 PIN M23)
INDUSTRIAL) TWIST-LOCK) INDUSTRIAL)
A A B B B A A A A A A A A A
CHANNELS

– – – – – – – – – – – – – –
ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA
– – – – – – – – – – – – – –
ØB, ØB
–
ØB, ØB
–
ØB, ØB ØB, ØB ØB, ØB ØB, ØB
–
ØB, ØB
– ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB REF
– – – – – – –
ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ SIGNAL
BLACK F F F A 1 7 1 F 1 A 1 10 10 COM GND 0V
RED D D D B 2 2 6 D 6 B 6 12 12 +V +Ub +E
GREEN A A A E 3 1 2 A 2 D 2 8 6 ØA K1- 1+
– –
1-
YELLOW H C C C 4 3 7 H 7 G 7 1 5 ØA K1+
WIRING DIAGRAMS

BLUE B B B D 5 4 3 B 3 E 3 5 8 ØB K2+ 2+
– – –
GRAY I E E F 6 5 8 J 8 H 8 6 1 ØB K2- 2-
ORANGE C NC NC NC 7 6 4 C 4 C 4 3 3 Z K0+ 0+
– – –
WHITE J NC NC NC 8 8 9 K 9 I 9 4 4 Z K0- 0-
BROWN NC NC NC NC NC NC 5 NC NC F 5 2 NC ALM+ ALM+ ALM+
VIOLET NC NC NC NC NC NC 10 NC NC J 10 7 NC ALM ALM ALM

4
* NC ON CHANNEL OPTION “B”
<<
CONNECTED ON 18" CABLE

HS45
SINGLE ENDED TWO PHASE WIRING APPLICATIONS, WITH OR WITHOUT MARKER | NOT RECOMENDED FOR OUTPUT OPTION “8”
PINOUT
CONNECTORS

<< <<
OPTIONS OPTIONS
OPTION “W” OPTIONS OPTIONS OPTIONS OPTIONS<< OPTIONS
<<
OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS
<<
“P”, “V”,“Z ” “G” “4”
(CABLE) “A”, “B”, “C”, “D” “J”, “K”, “M”, “N” “E”, “F”, “G”, “H” “T” “U” “R”, “S<<” “H”,“L” “2” “3”
(8 PIN M12) (8 PIN M12) (10 PIN (10 PIN (10 PIN
(10 PIN MS) (7 PIN MS) (6 PIN MS) (10 PIN MS) CONDUIT BOX (12 PIN M23) (12 PIN M23)
INDUSTRIAL) TWIST-LOCK) INDUSTRIAL)
A E, F E, F E, F A A A – A – A A A A A
CHANNELS

– – – ØA, ØA ØA, ØA – – – – –
ØA, ØA ØA, ØB, ØZ ØA, ØB, ØZ ØA, ØB, ØZ ØA, ØA ^ ØA, ØA – – ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA
– – – ØB, ØB ØB, ØB – – – – –
ØB, ØB ØB, ØB ^ ØB, ØB –
ØZ, ØZ
–
ØZ, ØZ ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB REF
– – – – – – – –
ØZ, ØZ ØZ, ØZ ^ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ SIGNAL
RED D D B 2 2 6 D 6 B 6 12 12 +V +Ub +E
BLUE B B D 5 4 3 B 3 E 3 5 8 ØB K2+ 2+
1 2 A 2 D 2 1 6 –
GREEN A A E 3 ØA K1- 1+
BLACK F F A 1 7 1 F 1 A 1 10 10 COM GND 0V
ORANGE * C* C* C* 7 6 4 C 4 C 4 3 3 OZ K0+ 0+
BROWN NC NC NC NC NC 5 NC NC F 5 2 NC ALM+ ALM+ ALM+
VIOLET NC NC NC NC NC 10 NC NC J 10 7 NC ALM ALM ALM
* NC ON CHANNEL OPTION “F”
^ COMPLEMENTS INCLUDED BUT NOT USED
<<
CONNECTED ON 18" CABLE
SINGLE ENDED SINGLE PHASE WIRING APPLICATIONS | NOT RECOMENDED FOR OUTPUT OPTION “8”
PINOUT

CONNECTORS
<< <<
OPTIONS OPTIONS OPTIONS
OPTION “W” OPTIONS OPTIONS OPTIONS<< OPTIONS
<<
OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS
<<
“P”, “V”,“Z ” “R”, “S<<” “G” “4” “H”,“L” “2” “3”
(CABLE) “A”, “B”, “C”, “D” “J”, “K”, “M”, “N” “E”, “F”, “G”, “H” “T” “U”
(8 PIN M12) (8 PIN M12) (10 PIN (10 PIN (10 PIN
(10 PIN MS) (7 PIN MS) (6 PIN MS) (10 PIN MS) CONDUIT BOX (12 PIN M23) (12 PIN M23)
INDUSTRIAL) TWIST-LOCK) INDUSTRIAL)
A A
– – A A A A A
A D D D A A

CHANNELS
ØA, ØA ØA, ØA
– – – – – – – – – –
( ØA, ØB, ØA, ØB, ØA, ØB, ØB, ØB ØB, ØB ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA
– – ØA ØA ØA – – – – – – – – – – –
ØB, ØZ, ØZ – – – ØB, ØZ, ØZ ØB, ØZ, ØZ ØZ, ØZ ØZ, ØZ ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB
INCLUDED BUT (ØA INCLUDED (ØA INCLUDED (ØA INCLUDED – – – – –
ØZ, ØZ
REF
ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ
NOT USED) BUT NOT USED) BUT NOT USED) BUT NOT USED) SIGNAL
BLACK F F A 1 7 1 F 1 A 1 10 10 COM GND 0V
 << <<
OPTIONS OPTIONS
OPTION “W” OPTIONS OPTIONS OPTIONS OPTIONS
<<
OPTIONS
<<
OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS
CONNECTO

<<
“P”, “V”,“Z ” “G” “4”
(CABLE) “A”, “B”, “C”, “D” “J”, “K”, “M”, “N” “E”, “F”, “G”, “H” “T” “U” “R”, “S<<” “H”,“L” “2” “3”
(8 PIN M12) (8 PIN M12) (10 PIN (10 PIN (10 PIN
(10 PIN MS) (7 PIN MS) (6 PIN MS) (10 PIN MS) CONDUIT BOX (12 PIN M23) (12 PIN M23)
INDUSTRIAL) TWIST-LOCK) INDUSTRIAL)
A E, F E, F E, F A A A – A – A A A A A
CHANNELS

– – – ØA, ØA ØA, ØA – – – – –
ØA, ØA ØA, ØB, ØZ ØA, ØB, ØZ ØA, ØB, ØZ ØA, ØA ^ ØA, ØA – – ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA
Avtron standard warranty applies. Copies available upon request.
– – – ØB, ØB ØB, ØB – – – – –
ØB, ØB ØB, ØB ^ ØB, ØB –
ØZ, ØZ
–
ØZ, ØZ ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB REF
– – – – – – – –
ØZ, ØZ ØZ, ØZ ^ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ SIGNAL
Specifications subject to change without notice.
RED D D B 2 2 6 D 6 B 6 12 12 +V +Ub +E
BLUE B B D 5 4 3 B 3 E 3 5 8 ØB K2+ 2+
1 2 A 2 D 2 1 6 –
GREEN A A E 3 ØA K1- 1+
BLACK F F A 1 7 1 F 1 A 1 10 10 COM GND 0V
ORANGE * C* C* C* 7 6 4 C 4 C 4 3 3 OZ K0+ 0+
BROWN NC NC NC NC NC 5 NC NC F 5 2 NC ALM+ ALM+ ALM+
VIOLET NC NC NC NC NC 10 NC NC J 10 7 NC ALM ALM ALM
* NC ON CHANNEL OPTION “F”
^ COMPLEMENTS INCLUDED BUT NOT USED
<<
CONNECTED ON 18" CABLE
SINGLE ENDED SINGLE PHASE WIRING APPLICATIONS | NOT RECOMENDED FOR OUTPUT OPTION “8”
PINOUT
CONNECTORS

<< <<
OPTIONS OPTIONS OPTIONS
OPTION “W” OPTIONS OPTIONS OPTIONS<< OPTIONS
<<
OPTIONS OPTIONS OPTIONS OPTIONS OPTIONS
<<
“P”, “V”,“Z ” “R”, “S<<” “G” “4” “H”,“L” “2” “3”
(CABLE) “A”, “B”, “C”, “D” “J”, “K”, “M”, “N” “E”, “F”, “G”, “H” “T” “U”
(8 PIN M12) (8 PIN M12) (10 PIN (10 PIN (10 PIN
(10 PIN MS) (7 PIN MS) (6 PIN MS) (10 PIN MS) CONDUIT BOX (12 PIN M23) (12 PIN M23)
INDUSTRIAL) TWIST-LOCK) INDUSTRIAL)
A A
– – A A A A A
A D D D A A
CHANNELS

ØA, ØA ØA, ØA
– – – – – – – – – –
( ØA, ØB, ØA, ØB, ØA, ØB, ØB, ØB ØB, ØB ØA, ØA ØA, ØA ØA, ØA ØA, ØA ØA, ØA
– – ØA ØA ØA – – – – – – – – – – –
ØB, ØZ, ØZ – – – ØB, ØZ, ØZ ØB, ØZ, ØZ ØZ, ØZ ØZ, ØZ ØB, ØB ØB, ØB ØB, ØB ØB, ØB ØB, ØB
INCLUDED BUT (ØA INCLUDED (ØA INCLUDED (ØA INCLUDED – – – – –
ØZ, ØZ
REF
ØZ, ØZ ØZ, ØZ ØZ, ØZ ØZ, ØZ
BUT NOT USED) BUT NOT USED) BUT NOT USED) SIGNAL
WIRING DIAGRAMS

NOT USED)
BLACK F F A 1 7 1 F 1 A 1 10 10 COM GND 0V
RED D D B 2 2 6 D 6 B 6 12 12 +V +Ub +E
GREEN A A E 3 1 2 A 2 D 2 1 6 –
0A K1 1+
BROWN NC NC NC NC NC 5 NC NC F 5 2 NC ALM+ ALM+ ALM+
VIOLET NC NC NC NC NC 10 NC NC J 10 7 NC ALM ALM ALM

5
HS45
MECHANICAL OVERSPEED SWITCH WIRING APPLICATIONS
MAKE
(N0)
125 VDC
OR
120 - 380 VAC
SAFETY
SYSTEM
125 VDC
OR BREAK
120 - 380 VAC (NC)
 WARNING 8a) For end of shaft applications using the clamping collar system,
Installation should be performed only by qualified place the HS45 at least 2” onto the shaft. (For larger bore shafts
personnel. Safety precautions must be taken to ensure 1” [25mm] or larger, minimum shaft engagement is 1.75”
machinery cannot rotate and all sources of power are [45mm]; for overspeed applications the minimum engagement is
removed during installation. 2.65” [67mm]) Ensure the stub shaft does not contact the rear
cover.
INSTALLATION
8b) For thru-shaft applications using the clamping collar system,
Refer to the back page of these instructions for outline and mounting remove the rear shaft cover (screws are retained by the cover)
dimensions. and position the HS45 as required. Thru-shaft installation is not
available in overspeed applications.
Equipment needed for installation
Supplied: 9) Tighten screws on clamping collar evenly until snug, then tighten
HS45 Encoder each screw as follows:
Shaft Sizing Insert for all clamp style models For bore sizes up to 1” [25mm] 38 in-lb [4.3 Nm]
For 16mm center-bolt style ONLY: centering (tapered) ring For bore sizes >1” [25mm] 66 in-lb [7.5 Nm]
DO NOT USE A STANDARD RIGHT ANGLE WRENCH. Use only a
Optional: T-handle hex wrench or torque wrench with hex bit.
Anti-Rotation Arm Kit
Thread Locker (blue) Or For End of Shaft Center Bolt Mount Style:

Not Supplied: 6) Remove the rear cover from the HS45.

Open Wrenches
“G”, “P”, “T”, ”U”-Tether: 9mm, 10mm 7a) For 17mm taper shaft mount: Carefully slide the encoder onto
“D”, “E”,”F”,”H”,”M”,”U”-Tether: 7/16”,1/2”, 9/16”, 3/4” the shaft to verify fit. DO NOT FORCE. Encoder should slide on
M5" T-handle hex wrenches or torque wrench with M5 bits easily. If the encoder does not fit easily, remove it, verify shaft
(Torque wrench required for Center Bolt Mounting Style). size, and check for burrs and shaft damage.
Dial Indicator Gauge
Caliper Gauge 7b) For 16mm center bolt shaft mount: Slide the centering ring over
the motor shaft. Carefully slide the encoder onto the shaft to
The hollow shaft HS45 design eliminates the potential for coupling verify fit. DO NOT FORCE. Encoder should slide on easily. If the
failures from misalignment, however, excessive housing movement encoder does not fit easily, remove it, verify shaft size, and check
(wobble) may cause undesirable vibrations and bearing damage. The for burrs and shaft damage.
higher the RPM, the more severe the vibration will be from housing
movement. In a typical installation a housing movement of 0.007" 8) Insert center mounting screw (M6 provided) through the body of
[0.18mm] TIR or less (as measured at the outside diameter of the the encoder into the stub shaft tapped hole and tighten to 66 in-
main encoder body) will not have an adverse effect. For overspeed lbs [7.5n-m]
applications, TIR should be < 0.002” [0.05mm].
9a) Replace rear cover onto the HS45. Use a wrench on the external
1) Disconnect power from equipment and encoder cable. flats if necessary. Tighten the cover screws.

2) Use caliper gauge to verify motor shaft is proper diameter and 10a) For threaded rod tethers, adjust to proper length by selecting
within allowable tolerances: +0.000", -0.0005" [+0.00, -0.013mm]. combinations of short and long piece as required and thread
together for final length adjustment. Attach free end of the anti-
3) Clean machine shaft of any dirt and remove any burrs. rotation arm to the bracket tether using the shoulder bolt
provided.
4) Use dial indicator gauge to verify the motor shaft: Total Indicated
Runout (TIR) <0.002" [0.05mm]. 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
5) Install the anti-rotation bracket tether to the face of the encoder face, 90 degrees to the shaft to avoid encoder bearing damage.
using M6 Hex screws and lock washers, included with the tether. Use additional washers as needed to ensure the tether is parallel
Tighten to 65 in-lbs [7.5n-m] to the encoder face.

5a) (optional) For non-through-shaft (end of shaft) applications, the 12) An M8 threaded hole is provided in the encoder shaft to permit a
optional rear cover may be installed for optimum performance M8 jack bolt for removal
against dirt, liquid sprays and impacts.
MODIFICATION
For Clamp Collar Mounting Style:
The HS45 can be modified in the field to easily adapt to new
6) Loosen clamping collar screws. applications.

NOTE TO CHANGE ELECTRICAL CONNECTOR STYLE:

These screws have factory applied thread locker, no
further thread locker application is required. 1) Remove electrical power and disconnect the mating plug.

7) Test Fitting: carefully slide the encoder onto the shaft to verify 2) Unscrew the (4) M5 screws (4mm hex).
fit. Ensure a minimum of 1/8" [2mm] between encoder and
mounting surface. DO NOT FORCE. Encoder should slide on 3) Pull the connector header away from the encoder gently.
easily. If the encoder does not fit easily, remove it, verify shaft
size, and check for burrs and shaft damage. 4) Disconnect the ribbon connector to the encoder body.
5) Connect the ribbon connector to the new connector header

HS45 6
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 PHASE A
crushed or pinched by the connector header.
TO CHANGE BORE SIZE INSERT:
1) Remove electrical power.
PHASE B
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.
VARIATION > ± 15%
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.
FIGURE 5
7) Reinstall the retaining snap ring over the insert.
Interconnecting cables specified in the wire selection chart are based
8) Reinstall the rear encoder cover as required. on typical applications. Physical properties of cable such as abrasion,
temperature, tensile strength, solvents, etc., are dictated by the
WIRING specific application. General electrical requirements are: strand­ed
copper, 22 through 16 AWG (Industrial EPIC connector type options
CAUTION can use 14 AWG), each wire pair individually shield­ed with braid or foil
Be sure to remove power before wiring the encoder. with drain wire, .05 uf of maximum total mutual or direct capacitance,
Be sure to ground the cable shield: It can be connected outer sheath insulator. See specifications for maximum cable length.
to case ground at the encoder, or grounded as the Strand­ed 22 AWG wire should not be used for cable runs great­er then
receiving device, but should not be grounded on both 61 meters. If 22 AWG is used with EPIC type connector options the
ends. See note below for Danaher/Northstar wiring. wire ends should be tinned.

Refer to the wiring diagrams for specific information on each option. FAULT-CHECK
After power-up and the rotor position is checked by the sensor, the
The AV45 can be wired for single phase or two phase, either with Fault-Check LED will turn green.
or without complements, with or without markers. For bidirectional If the adaptive electronics reach their adjustment limit for any reason,
operation, Phase A channel leads phase B channel for clockwise shaft the Fault-Check alarm and LED will notify the drive and operator of
rotation as viewed from the anti-drive or accessory end of the motor an impending failure. The LED will turn red if the Adaptive Electronics
(AV45 mounting end). reach their adjustment limit. This output occurs before an actual
failure, allowing steps to be taken to replace the unit before it causes
CAUTION unscheduled downtime. Fault-Check annunciation is available as an
Be sure to observe maximum current limits for “alarm” output through the connector and as an integral LED.
mechanical overspeed switch option. Exceeding these
limits can cause arcing and cause switch failure; this TROUBLESHOOTING
may result in property damage, injury or even death. If the drive indicates a loss of encoder/tach fault and the HS45
fault-check LED is not illuminated, check the encoder power supply.
NOTE If power is present, check polarity; one indicator of reversed power
Wiring option “G” provides a pinout compatible with supply is that all outputs will be high at the same time. If the drive
NorthstarTM encoders, with a cable shield connection indicates encoder fault, but the LED shows GREEN, then check the
wiring between the drive and the encoder. If the wiring appears
on pin 10. Note that this option does not ground the correct and in good shape, test the wiring by replacing the HS45. If the
shield; Avtron still recommends grounding the shield at new unit shows GREEN, and the drive still shows encoder loss/tach
the drive end of the cable for all wiring options. fault, then the wiring is faulty and should be repaired or replaced.
CORRECTIVE ACTION FOR PHASE REVERSAL If the alarm output and/or LED indicate a fault (RED) on a properly
1) Remove Power. mounted HS45 and the rotor is properly located, replace the HS45.
2) Exchange wires on cable, either at encoder cable end,
or at speed controller end (but not both). An oscilloscope can also be used to verify proper output of the HS45
a) Single Ended 2 Phase Wiring (see wiring diagram) encoder at the encoder connector itself and at the drive/controller
Exchange A and B at the use end of the wires. cabinet. If the outputs show large variations in the signals at steady
b) Differential 2 Phase Wiring (see wiring diagram) speed (jitter or “accordion effect”, see figure 5 above), replace any
Exchange either A with A– in the phase A pair OR magnetized material nearby with non-magnetic material (aluminum,
B with B– in the phase B pair but NOT both. stainless) (shafts, etc). If variations persist, consider replacing with
3) Apply Power. super-shielded models, option -004.
4) Verify encoder feedback is correct, using hand rotation
of shaft, or jog mode of the speed controller.

HS45 7
 TETHER OPTION: D,F

TETHER OPTIONS: G, P, T, U

19.69 [500mm] MAXIMUM DISTANCE

USE 5mm HEX

TORQUE TO
2.76 [70mm] 65 IN-LBS. [7.5 N-M]
MINIMUM DISTANCE

0.28 [7mm] MAX. THICKNESS

FOR THRU HOLE MOUNTING

±1.50 [38mm] OFFSET FOR

12 IN. [305MM] ROD END CENTERS
TORQUE TO
65 IN-LBS. [7.5 N-M]

CUSTOMER
ATTACHMENT 90° ± 15°
POINT

5.80 REF.
[ 147MM ]

HS45 8
 TETHER OPTION: Y
TANDEM MOUNT

Spacer Ring

Outboard Tandem
Bracket

Inboard Tandem
Bracket

Apply tether kit (any style) to inboard encoder to tether motor.

Refer to prior tether options for dimensions and assembly instructions.

NOTE
Do not use tandem bracket assembly to tether the
encoder to the motor.

HS45 9
 CLAMP STYLE
SHOWN: SINGLE OUTPUT, 1” BORE, INDUSTRIAL
CONNECTOR, 4.5” C-FACE TETHER

SHAFT ENGAGEMENT:
Minimum:
5/8”-7/8” bore 2” [51mm]
16-20mm bore 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]

Features and specifications subject to change without notice.

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

HS45 10
 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 2” [51mm]
16-20mm bore 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]

Features and specifications subject to change without notice.

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

HS45 11
 16mm CENTER BOLT STYLE
SHOWN: SINGLE OUTPUT, CONDUIT BOX,
ANTI-ROTATION ARM OPTION “P”

SHAFT ENGAGEMENT:
Minimum: 1.73” [44mm]

Maximum: 2.09” [53mm]

Features and specifications subject to change without notice.

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

HS45 12
 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

Features and specifications subject to change without notice.

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

HS45 13
 HS45 WITH OVERSPEED SWITCH
SHOWN: 16MM CENTER-BOLT MOUNT, SINGLE
OUTPUT, M23 INDUSTRIAL CONNECTOR

SHAFT ENGAGEMENT:
Clamp Style:
Minimum: 2.65” [68mm]
Maximum: 2.70” [68.6mm]

17mm Center-Bolt Style

20mm +/-0.1mm
Shaft shall be 17mm diameter with 10:1 taper

16mm Center-Bolt Style

Minimum: 1.73” [44mm]
Maximum: 2.09” [53mm]

Features and specifications subject to change without notice.

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

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

(1) 216-642-1230 • FAX (1) 216-642-6037 • www.avtronencoders.com
REV: 07-22-16

HS45 14