MODEL XR47. Encoder Instructions DESCRIPTION INSTALLATION XR /4-1 1/8 [19-30mm] HOLLOW SHAFT FOR HAZARDOUS APPLICATIONS

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1 Encoder Instructions MODEL XR E. PLESNT VLLEY ROD INDEPENDENCE, OHIO TELEPHONE: (1) FX: (1) E-MIL: WE: 3/4-1 1/8 [19-30mm] HOLLOW SHFT FOR HRDOUS PPLICTIONS DESCRIPTION The vtron XR47 is a hollow shaft severe duty incremental encoder (also known as a tachometer or rotary pulse generator). It provides a two phase, Quad frequency (pulse) output, with complements. CUTION The XR47 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 XR47 design eliminates the need for shaft couplings, adapter flanges, or accessory mounting faces. The high clamping-force collar holds the XR47 in place, even under severe vibration & shock. 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 3/4 to 1 1/8 [19mm - 30mm]; additional sizes available upon request. n anti-rotation arm prevents housing rotation while allowing for shaft end float. The XR47 features extreme shock and vibration resistance. Combined with potted electronics and huge bearings, this creates our most rugged hollow shaft encoder for severe duty applications such as oil and gas drilling. The XR47 has six signals: (, ) 90 out of phase, with complements (, ). marker pulse with complement (, ) is also provided. The XR47 has been evaluated to be compliant with IEC :2007, IEC :2006, IEC :2006, EN :2009, EN :2007, EN :2007 and EN :2006. (Certificates of conformity: TRC12TEX0002X, TRC12TEX 0003X, IECEx TRC X, and IECEx TRC X.) The XR47 is certified for use in: Group ii, category 2 (TeX one 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 vtron isolator marked CE 0539 Ex [II 2 GD] [Ex ib IIC Gb] -40 C<Tamb<80 C. Group ii, category 2 (TeX one 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 vtron isolator marked CE 0539 Ex [II 2 GD] [Ex ib IIIC Db] -40 C<Tamb<80 C. Group ii, category 3 (TeX one 2), Gas Group iic_* potentially explosive atmospheres when marked CE Ex II 3 GD, Ex ic IIC* T4 Gc -40 C<Tamb<80 C Group ii, category 3 (TeX one 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. INSTLLTION CUTION e careful not to damage clamping fingers of hollow shaft during handling. Do not tighten clamping collar before installation onto motor shaft. WRNING 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 (one 1), Gas group IIC, Dust group IIIC (one 21): vailable as a system only including XR47 with line driver option 5 and an vtron Isolator module XR1 (P/N 35134). System parameters are: Um= 250V Uo (open circuit voltage) = 7.14VDC max. Io (short circuit current) = 420m 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) = 420m max. Ci (internal capacitance) = 11.9uF max. Li (internal inductance) = 0mH max. The isolator XR1 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 (one 2), Gas group IIC, Dust group IIIC (one 22): Requires an XR47 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/EN and IEC/EN Cable characteristics must comply with IEC/EN and IEC/EN 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 XR47 is not considered as a safety device and is not suitable for connection into a safety system. The XR47 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 XR47 may be subject. It is however the responsibility of the end user to ensure that the XR47 is selected correctly for the potentially explosive atmosphere in which the equipment is to be put into service. XR47 1

2 The XR47 installation is similar to XT45. Installation and removal videos for the XT45 are available on vtron s web site. Refer to the back page of these instructions for outline and mounting dimensions. The motor must comply with 1998 NEM MG 1, section 4, for tolerances on diameters and runout for shafts and accessory faces. In preparation for installing the Model XR47 encoder, it is first necessary to clean the accessory motor shaft. The surface 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. Equipment needed for installation Supplied: XR47 Encoder Optional: Required for one 1/one 21: XR1 Isolator nti-rotation rm Kit Thread Locker (blue) Not Supplied: 7/16, 3/8 Wrenches 3mm, 5mm, 7/16 T-handle hex wrenches or torque wrench with 3mm, 5mm, 7/16 bits (torque wrench required for Center olt Mounting Style). Dial Indicator Gauge The hollow shaft XR47 design eliminates the potential for bearing and coupling failures from misalignment, however, excessive housing movement (wobble) may cause undesirable vibrations. The higher the RPM, the more severe the vibration will be from housing movement. In a typical installation a housing movement of TIR or less (as measured at the outside diameter of the main encoder body) will not have an adverse effect. 1) Disconnect power from equipment and encoder cable. 2) Use caliper gauge to verify motor shaft is proper diameter and within allowable tolerances: , [+0.00, mm]. 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 M5 Hex screws and lock washers, included with the tether. 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) Insert shaft sizing insert into encoder. DO NOT FORCE. 8) 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. 8a) For end of shaft applications using the clamping collar system, place the XR [70-84mm] onto the shaft. Ensure the stub shaft does not contact the optional rear cover (remove cover if required). 8b) For thru-shaft applications using the clamping collar system, remove the rear shaft cover, retain the (4x) M4 socket head screw, and position the XR47 as required. 9) Tighten screws on clamping collar evenly until snug, then tighten each screw to 95 in-lb [10.7 Nm]. DO NOT USE STNDRD RIGHT NGLE WRENCH. Use only a T-handle hex wrench or torque wrench with hex bit. NOTE To verify proper collar installation: check to ensure the clamping collar compression washers are completely flattened. For clamping collar installation, proceed to step 10. OR FOR END OF ShaFT CENTER OLT mount STyLE: 6. Using the bolt(s) and thread locker provided, mount the 30mm diameter stub shaft on the motor. Use dial indicator to verify the stub shaft TIR <0.002 [0.05mm] 7. Remove the sealing plug from the XR Carefully slide the encoder onto the shaft to verify fit. Ensure a minimum of [1mm] between encoder and stub shaft 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. 9. Insert center mounting screw (M8x1.0x35 with elleville washers provided) through the body of the encoder into the stub shaft tapped hole and tighten to 424 in-lbs [48n-m] 9a. Replace rear sealing plug into XR47. Tighten to 150 in-lbs [17n-m] 10) ttach 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. Use additional washers as needed to install the bracket. The bracket should be parallel to the encoder face, 90 degrees to the shaft to avoid encoder bearing damage. 12) Turn shaft by hand and verify the shaft turns freely and does not produce excessive runout/wobble of the encoder (<0.007 TIR [0.18mm], Total Indicated Runout.) 13) Connect cable as shown in wiring diagram. 14) pply power to the encoder. 15) Rotate the shaft by hand, or using jog mode of the speed controller and verify proper direction. ENVIRONmENTaL CONSIDERaTIONS Special attention is to be given to conduit runs, interconnection wiring and NEM type enclosure mounting. Follow these steps to reduce potential problems: 1) lways mount connection points, conduit couplings, junction boxes, etc., lower than actual encoder. 2) For washdown areas, shroud or otherwise cover the encoder to prevent direct water spray. Do not attach the shroud directly to the encoder. REpaIRS REMOVL INSTRUCTIONS: FOR CLampING COLLaR mounting STyLE: 1. Unbolt tether arm from mounting point on motor. 2. Loosen both clamping collar screws. 3. Slide the encoder off the motor. XR47 2

3 OR FOR END OF ShaFT CENTER OLT mounting STyLE: 1. Unbolt tether arm from mounting point on motor. 2. Unscrew & remove the sealing plug from the XR Unscrew & remove the center mounting bolt. 4. Slide the encoder off the shaft. 5. (optional) If the encoder does not remove easily, do NOT force. Instead, use the center bolt lifter method, detailed below: Center olt Lifter Method (optional) 5a. Reinsert and loosely tighten the bolt through the encoder body into the stub shaft. 5b. Loosen the reinserted bolt by approximately 5 turns. This will leave the screw head approximately even with the bottom of the seal plug hole threads. 5c. Reinsert and tighten the sealing plug cap. This will lift the encoder by pushing on the head of the center mounting bolt. The encoder should move axially ~0.2 [5mm] 5d. Check to see if the encoder can now be moved axially on the shaft. If it can, remove the seal cap and center bolt and remove the encoder. 5e. If the encoder cannot yet be moved by hand, repeat the lifting cycle as needed: remove the cap, loosen the bolt an additional ~5 turns, replace and retighten the cap, and the encoder will move an additional 0.2 [5mm] for each repetition. There are no field replaceable parts in an XR47. The unit should be returned to the factory for all repairs. WIRING INSTRuCTIONS CUTION e sure to remove power before wiring the encoder. e sure to ground the cable shield: vtron recommends grounding the shield at the isolator module for one 1 applications or in the drive cabinet for one 2 applications. Cable should not be grounded multiple places. n intrinsic safety ground is required at the XR1 Isolator Module. CUTION SMRTSafe 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 XR1 intrinsic safety ground connection required for hazard protection against ignition of explosive atmospheres! Wiring diagrams are shown in the following pages. CUTION one 1 and one 21 applications utilize the XR1 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. For bidirectional operation of the XR47, proper phasing of the two output channels is important. Phase channel leads Phase channel for clockwise shaft rotation as viewed from the anti-drive or accessory end of the motor (XR47 mounting end). 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 and at the use end of the wires. b) Differential 2 phase Wiring (see wiring diagram) Exchange either with in the phase pair OR with in the phase pair but NOT both. 3) pply 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/EN and IEC/ EN 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 WG (Industrial EPIC connector type options can use 14 WG). 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 WG wire should not be used for cable runs great er then 61 meters. If 20 WG is used with EPIC type connector (zone 2 configurations only) options the wire ends should be tinned. FauLT-ChECK fter 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 daptive 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. TROuLEShOOTING If the drive indicates a loss of encoder/tach fault and the XR47 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 XR4F. 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 XR4F and the rotor is properly located, replace the XR47 n oscilloscope can also be used to verify proper output of the XR47 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 5), replace any magnetized material nearby with non-magnetic material (aluminum, stainless) (shafts, etc). If variations persist, consider replacing with super-shielded models, option XR47 3

4 XR47 part NumERS and availale OpTIONS model XR47 Clamping Collar mount u.s. D- 3/4" E- 7/8" F- 1" G- 1 1/8" Clamping Collar mount metric L- 20mm m- 25mm N- 30mm ore Size End of Shaft: Center olt mount* J- 30mm* (no stub) K- fits GE 20 (stub shaft included) Left Output ppr af-60 ag-100 ah-120 aa-128 al-240 an-256 ae-360 aq-500 ar-512 as-600 av-900 * 30mm x 25mm stub shaft required for mounting aj-960 aw-1000 ay-1024 a-1200 a a a ad-4096 a a Right Output ppr XX-None 5- one 1 & 21 (5-7V in 5V out) For use with XR1 isolator 12-24V In 10.6V Out Line Driver Connector Options Tether Channels modifications 7-one 2 & V in, 5-24 V out one 1 & 21 Local protection 5- Flameproof Conduit ox w/o Gland 6- Flameproof Conduit ox w/ TEX rated Gland one 1 & 21 Remote protection & one 2 W- 18" flex cable y- 10 pin MS with plug on 12" cable X- None G- Torque arm a- ll 000- None 001- Omit Rear Shaft Cover 9xx- Specify cable length xx=feet (use w/ Option W ) XR47 4

5 SpECIFICaTIONS ELECTRICaL SpECIFICaTIONS. Operating Power (Vin) 1. Volts... See Line Driver Options 2. Current (No Load) Encoder m Encoder + Isolator m. Output Format 1. 2 O/ / & Comp...,,, (differential line driver) 2. Marker:... 1/Rev, C. Signal Type... Incremental, Square Wave, 50 +/-10%... Duty Cycle. D. Direction Sensing... O/ leads O/ for CW rotation as viewed... from the back of the tach looking at the... non-drive end of the motor. E. Transition Sep % minimum F. Frequency Range... 0 to 165,000 Hz G. PPR H. Line Driver Specs:... See table I. Connectors:... See connector options mechanical. Shaft Inertia lb-in-sec 2. cceleration RPM/Sec. Max. C. Speed: RPM Max. D. Weight: lbs [ kg.] E. Vibration Gs, Hz (any orientation) F. Shock Gs, any orientation G. Shaft Engagement (clamp style) ll sizes [70mm] ENVIRONmENTaL Solid cast aluminum stator and rotor. Less than 6% magnesium by mass. Fully potted electronics, protected against oil and water spray Non-contacting labyrinth seal provided. Operating Temperature: C to +80 C. LINE DRIVER OpTIONS Electrical Specifications 7 Isolator XR1 5 Units Input Voltage VDC Nom Output Voltage 5-24 (5-7 to Encoder) 10.6 Output Signals 5 VDC Line Driver 7272 IXDF Output Resistance Typ ohms maximum peak Current m maximum average Current m Voh Typ VIN VIN-1 VDC Vol Typ VDC Cable Drive Capacity protection alarm 5-12V 24V feet Reverse Voltage yes yes yes Short Circuit yes yes yes Transient yes yes yes marker +V(out)* larm* LED Output voltage equal to input voltage. Open collector, normally off, goes low on alarm, sink 100m max, 50VDC max Green=power on, Red=larm One per revolution. Pulse width approximately 1/128 of a revolution *larm not available with the following; line driver option 5 from isolator XR1, connector option G (Northstar TM compatible pinout), R and S ui Ii IIC II 250m 15V 25V 1 15V CI 1.8uf parameter Isolator Encoder Um 250V - Ui V Li - 440m Pi - 0.4W 5 12V one 2 power Supply Limits Ci UF Li - 0mH Uo 7.14V - Io 440m - Po 0.4W - Lo Co 1.5mH 13.5uF Lo/Ro - one 1 Table of entity parameters XR47 5

6 XR47 application Examples pplies to all Model XR47 Encoders one 2 & 22 models, except wiring option Y. Remote larm not available for one 1 & one 21. LRM OUTPUT CONNECTION vtron XR47 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. larm output using +V(OUT). +V(OUT) is equal to +V, the encoder power supply. ENCODER FUNCTIONL DIGRM OUTPUT OPTIONS W 4 P, H, L 2 FUNCTION LINE DRIVER NOTE 1 CR8 { LCK RED GREEN YELLOW LUE GRY ORNGE WHITE D G E H C I COM +V COMMON +V (Encoder Power) Ø Ø Ø Ø MRKER MRKER COMPLEMENT ROWN F 5 +V(OUT) 2 50m MX Q5 MMFT6661 VIOLET J 10 LM 7 GND 300 OHM MIN. Vcc OUT COM SOLID STTE RELY Example 2. larm Output Using Separate 24 VDC Power Supply and Relay. ENCODER FUNCTIONL DIGRM OUTPUT OPTIONS W 4 P, H, L 2 FUNCTION COMMON LINE DRIVER NOTE 1 CR8 LCK RED { GREEN YELLOW LUE GRY ORNGE WHITE D G E H C I COM +V V (Encoder Power) Ø Ø Ø Ø POWER SUPPLY *See note below MRKER MRKER COMPLEMENT - * VDC VC ROWN VIOLET F J V(OUT) LM 2 7 RELY Q5 MMFT6661 GND SINK 100 m MXIMUM *See specifications for one 2 Power supply limits XR47 6

7 WIRING DIaGRamS ONE 1 HRDOUS RE LOCL PROTECTION SFE RE Ex ox ENCODER 1'(.3M) to 5'(1.5M) Cable Tether LINE DRIVER OPTION 5 CONNECTOR OPTION 5 OR Volts Out Volts In + gnd gnd ISOLTOR P/N Typical Cable 1000'(300M)max 18WG, Individually Shielded Twisted Pair + Overall Shield Rockbestos EXNE 125 Type P- P/N: 4TSP18 WG - K K K K K K GND 0V + Ub+ +E Customer Equipment 2 Phase Differential Volts Out Intrinsic Safety Gnd ONE 1 HRDOUS RE REMOTE PROTECTION SFE RE ENCODER Typical Cable 500'(150M)max 18WG, 4 Twisted Pair + Overall Shield elden P/N 9554 or lpha P/N 2244C Typ Volts Out Volts In + gnd gnd ISOLTOR P/N Intrinsic Safety Gnd - K K K K K K GND 0V + Ub+ +E Customer Equipment 2 Phase Differential Volts Out See ttached for Connector Option Pin Outs XR47 7

8 WIRING DIGRMS WIRING DIaGRamS ONE 2 HRDOUS RE DIFFERENTIL 2 PHSE WIRING SFE RE Typical Cable 500'(150M)max ENCODER LINE 18WG, Twisted Pair + Overall Shield DRIVER OPTION 7 See ttached for Connector Option Pin Outs 2 Pair 3 Pair 4 Pair 5 Pair elden lpha 2242C 2243C 2244C 2245C - K1- + K K K K K GND 0V Ub+ +E Customer Equipment 2 Phase Differential 5-24* Volts Out ONE 2 HRDOUS RE SINGLE ENDED 2 PHSE WIRING SFE RE Typical Cable 500'(150M)max ENCODER LINE 18WG, Twisted Pair + Overall Shield DRIVER OPTION 7 See ttached for Connector Option Pin Outs 2 Pair 3 Pair 4 Pair 5 Pair elden lpha 2242C 2243C 2244C 2245C -v GND 0V + K1+ +v Ub+ +E + K K v +v alm 5-24* Volts Out Customer Equipment ONE 2 HRDOUS RE SINGLE ENDED 1 PHSE WIRING SFE RE ENCODER LINE DRIVER OPTION 7 See ttached for Connector Option Pin Outs Typical Cable 500'(150M)max 18WG, Triad + Overall Shield elden lpha 3 Conductor 9365 M K v Ub+ +E -v GND 0V Customer Equipment 5-24* Volts Out *SEE SPECIFICTIONS FOR ONE 2 POWER SUPPLY LIMITTIONS Refer to Installation and Specification Sections for Requirements and Limitations XR47 8

9 PinouTs nd PhsinG Phasing is defined as the direc on of rota on for which phase leads as viewed Op on Code Channel Code from the back of the Encoder Phasing Signal 0V Gnd lm+ +Vin lm 10 Pin MS vtron / EI Pinout, C CW Pin # F C NC D H I J NC 10 Pin MS Dynapar HS35 Pinout, D CCW Pin # F C NC D H I J NC 10 Pin MS vtron / Northstar Pinout Y CW Pin # D E C NC G H I NC 10 Pin MS Mini Twist Lock R, S CW Pin # F C NC D H J K NC 10 Pin, Mini Industrial, vtron Pinout P CW Pin # Pin, Mini Industrial, Northstar Pinout G CW Pin # NC NC 10 Wire Cable W CW Color LK GRN LU ORG RN RED YEL GR WHT VIO XR47 9

10 OuTLINE DImENSIONS and OpTION DETaILS ShaFT ENGaGEmENT: Minimum: 2.75 [70mm] Maximum (With Cover): 3.31[84mm] Features and specifications subject to change without notice. vtron standard warranty applies. ll dimensions are in inches [mm] E. PLESNT VLLEY RD., INDEPENDENCE, OH 44131, U.S.. (1) FX (1) XR47 10 REV: