Sensors Worldwide Technical Description / User’s Guide

BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S 32/KA_ _

Micropulse Linear Transducer
Digital Output / Profile Housing

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 1 2 3 4 5 Rugged,
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Rod Style B T L - 5 Compact
- P 1 - M 0 3 0 5 - P - S 3 2
Rod Style K A 0 5
Balluff - Linear Transducer

Generation 5

Output Type
Compact, Explosion-proof
I = Differential start/stop with tri-state bolt-in Rod Style
K = Differential stop - leading edge active
L = Differential pulse-width modulated Rod Style
M = Differential start/stop - leading edge active
N = Single ended start/stop - leading edge active
P = Differential start/stop - trailing edge active

Supply Voltage
1 = 24 Vdc ±20%
2 = ±15 Vdc ±2%

Normal Stroke Length

0 3 0 5 = 305mm active stroke
Housing Type
P = Standard Profile Housing

Connection Type

S 3 2 = 8-pin quick disconnect metal connector

K A 0 5 = Cable out (5m standard; specify length in meters)

Standard Stroke Lengths (consult factory for additional lengths)

Electrical Stroke

inches mm inches mm inches mm inches mm

2 0051 15 0381 42 1067 148 3759
3 0077 16 0407 48 1220 156 3962
4 0102 18 0457 50 1270
5 0127 20 0508 60 1524
6 0152 22 0560 70 1778
7 0178 24 0610 80 2032
8 0203 26 0661 90 2286
9 0230 28 0711 100 2540
10 0254 30 0762 110 2794
11 0280 32 0813 120 3048
12 0305 36 0914 130 3302
13 0330 40 1016 142 3606

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing

Contents 1 Safety Advisory

1 Safety Advisory ............... 2 Read this manual before installing and operating the Micropulse
1.1 Proper application .............. 2 Transducer.
1.2 Qualified personnel ............ 2
1.3 Use and inspection ............ 2
1.4 Scope ................................ 2 1.1 Proper application

2 Function and The BTL5 Micropulse transducer is intended to be installed in a

Characteristics ............... 3 machine or system. Together with a controller (PLC) or a proces-
2.1 Characteristics .................. 3 sor (BTA) it comprises a position measuring system and may only
2.2 Function ............................. 3 be used for this purpose.
2.3 Available stroke lengths Unauthorized modifications and non-permitted usage will result in
and magnets ..................... 3 the loss of warranty and liability claims.
3 Installation ..................... 3
3.1 Transducer installation ...... 3 1.2 Qualified personnel
3.2 Floating magnets ............... 4
3.3 Captive magnets ............... 5 This guide is intended for specialized personnel who will perform
the installation and setup of the system.
4 Wiring .............................. 6
1.3 Use and inspection
5 Startup ............................. 7
5.1 Check connections ........... 7 The relevant safety regulations must be followed when using the
5.2 Turning on the system ....... 7 transducer system. In particular, steps must be taken to ensure
5.3 Check output values ......... 7 that should the transducer system become defective no hazards to
5.4 Check functionality ............ 7 persons or property can result. This includes the installation of
5.5 Fault conditions ................. 7 additional safety limit switches, emergency shutoff switches and
5.6 Noise elimination ............... 7 maintaining the permissible ambient conditions.

6 Versions 1.4 Scope

(indicated on part label) 7
This guide applies to the model Note: For special versions,
7 Technical Data ............... 8 BTL5-P/I/K/L/M...P... Micropulse which are indicated by an -
7.1 Dimensions, weights, transducer. SU_ _ _ designation in the
ambient conditions ............ 8 part number, other technical
7.2 Supply voltage (external) .... 8 An overview of the various models data may apply (affecting
7.3 Control signals .................. 8 can be found in section 6 Versions calibration, wiring, dimen-
7.4 Connection to processor ... 8 (indicated on product label) sions etc.).
7.5 Included in shipment ......... 8 on page 7.
7.6 Magnets (order separately) 8
7.7 Accessories (optional) ....... 8
7.8 Compatible processors
and displays ...................... 8
The CE Mark verifies that Group 1, Class A
our products meet the Noise immunity tests:
requirements of Static electricity (ESD)
EC Directive EN 61000-4-2
The following patents
have been granted in Severity level 3
89/336/EEC (EMC Directive)
connection with this Electromagnetic fields (RFI)
product: and the EMC Law. Testing in our EN 61000-4-3
US Patent 5 923 164 EMC Laboratory, which is accredited Severity level 3
Apparatus and Method for by DATech for Testing Electromag- Fast transients (Burst)
Automatically Tuning the netic Compatibility, has confirmed EN 61000-4-4
Gain of an Amplifier that Balluff products meet the EMC Severity level 3
requirements of the following Surge
US Patent 5 903 426 Generic Standards: EN 61000-4-5
Overvoltage Protection
Severity level 2
Apparatus for Data EN 50081-2 (emission)
Interface Line-induced noise induced by
EN 61000-6-2 (noise immunity) high-frequency fields
Emission tests: EN 61000-4-6
Severity level 3
RF Emission
EN 55011 Magnetic fields
EN 61000-4-8
Severity level 4

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing

2 Function and Characteristics

2.1 Characteristics
2.3 Available stroke length
Micropulse transducers feature: The torsional wave arriving at the and magnets
end of the waveguide is absorbed
— Very high resolution, in the damping zone. The wave To provide for optimum fit in any
repeatability and linearity arriving at the beginning of the application, a wide range of
— Bus-compatible interface waveguide creates an electrical standard stroke lengths and
signal in the coil surrounding the magnets in various form factors
(BTL5-I...) waveguide. The propagation time are available. Magnets and control
— Immunity to shock, vibration, of the wave is used to determine arms must therefore be ordered
contamination and electrical the position, which is presented separately.
noise on the output in various digital
formats. This takes place with See inside front cover for
— An absolute output signal high precision and repeatability available stroke lengths.
within the measuring range
— BTL to processor cable
indicated as the nominal
lengths up to 500 m stroke length. 3 Installation
— IP 67 per IEC 529 On both ends of the nominal
stroke length is an area which 3.1 Transducer installation
2.2 Function provides an unreliable signal, but
which may be entered. Ensure that no strong
The Micropulse transducer electrical or magnetic fields
contains a tubular waveguide The electrical connection between are present in the
enclosed by an extruded the transducer, the processor/ immediate vicinity of the
aluminum housing. A magnet controller and the power supply is transducer.
attached to the moving member via a cable, which depending on
of the machine is moved across the version is either fixed or
the top of the housing and its connected using a female Any orientation is permitted.
position constantly updated. connector. The mounting brackets and
cylinder head screws allow the
The magnet defines the Dimensions for installing the transducer to be mounted on a
measured position on the Micropulse transducer and for the flat machine surface. These
waveguide. An externally magnets and control arm are should be evenly spaced (Figs.
generated INIT pulse interacts found on pages 4 and 5. 3-1 and 3-5). The recom-
with the magnetic field of the mended spacing for long
magnet to generate a magneto- transducers and extreme
strictive torsional wave in the conditions (e.g. strong shock or
waveguide which propagates at vibration):
ultrasonic speed.
A = 80 mm; spacing between
the individual brackets
B = 250 mm.
The isolation bushings are used
Notch on housing to mark the beginning of the stroke range
to electrically insulate the
transducer from the machine
Nominal stroke = (Fig. 3-1and 3-5 and chapter 5.6
Measuring range Noise elimination).

Moving machine The Micropulse transducer in

Damping zone

part profile housing is suitable both

for floating, i.e. non-contacting
El. connection

Current position of magnet

magnets (Page 4) and for
captive magnets (Page 5).

Micropulse Transducer

Fig. 2-1: Basic arrangement

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing
3 Installation (cont.)

NL

Nominal stroke

Mounting brackets with isolation bushings and M5 x 22

cylinder head screws, DIN 912, max. tightening torque 2
Nm
Fig. 3-1: Dimensional drawing (BTL5...P-S 32 transducer with floating magnet BTL5-P-3800-2)

max. permissible
55 tightening torque 2 Nm
45
E 21 E C
28
Ø 4.2
20

15
D

61 +10
1

Fig. 3-2: BTL5-P-3800-2 magnet Fig. 3-3: BTL5-P-5500-2 magnet Fig. 3-4: BTL5-P-4500-1
electromagnet (24 V/100 mA)

3.2 Floating magnets

The floating magnet (Figs. 3-2 Ma gnet type Distance Offset BTL5-P-4500-1 magnet,
to 3-4) is attached to the "D" "C" special features: Multiple
moving member of the machine BTL5-P-3800-2 0.1 ... 4 ±2 magnets on the same
using non-magnetizable screws transducer can be turned on
(brass, aluminum). To ensure BTL5-P-5500-2 5 ... 15 ± 15
and off individually (PLC control
the accuracy of the transducer BTL5-P-4500-1 0.1 ... 2 ±2 signal).
system, the moving member
must carry the magnet on a
track parallel to the transducer. Ensure that the The stroke range is offset 4
distance E between mm towards the BTL
The following table provides parts made of connector/cable (Fig. 3-4).
figures in [mm] for the spacing magnetizable
which must be maintained material and the
between magnet and transducer BTL5-P-5500-2 magnet is at
and for the permissible center least 12 mm (Fig. 3-3).
offset:

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing
3 Installation (cont.)

NL

Nominal stroke Black,

round
marking

Mounting brackets with isolation bushings and M5 x 22

cylinder head screws, DIN 912,
max. tightening torque 2 Nm

Fig. 3-5: Dimensional drawing (BTL5...P-KA transducer with captive magnet BTL5-F-2814-1S)

Ball joint "B" Black, round

DIN 71805, marking Mechanically joined to M5
stud using 2 nuts Max. angle offset
rotates horizontally
Max. parallel offset

BTL5-M-2814-1S: X = 48.5 Y = 57
Fig. 3-6: BTL5-F-2814-1S magnet BTL5-N-2814-1S: X = 51 Y = 59.5
Fig. 3-7: BTL5-M/N-2814-1S magnet

3.3 Captive magnets

Lateral forces are to be avoided Ball joint "B" DIN 71805,
when using captive magnets rotates horizontally (part of
(Figs. 3-6 and 3-7). Connections BTL5-F-2814-1S) magnet)
are required here which permit the
corresponding degree of freedom
with respect to the direction of
movement of the magnet along
the stroke range. It is assumed
that the BTL5-F-2814-1S magnet
is connected to the machine Jam nut DIN 934 M5
member using a connecting rod.
The BTL2-GS08...A connecting Swivel eye DIN 648
rod (Fig. 3-8) is available as an
accessory (please indicate length Fig. 3-8: BTL2-GS08-_ _ _ _-A
LS when ordering). connecting rod

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing
4 Wiring

Digital, RS485 differential Digital, Single-ended

24 V (P, M, I, K, L, R) 24 V (N)
1 YE Interrogate + Input
3 1 YE Interrogate + Input
7 5 3 PK Interrogate - Input 2 GY Pulse + Output
2 GY Pulse + Output 7 BN
8 2 +24 V
5 GN Pulse - Output 6 BU GND
6 4 7 BN 8 WH
1 +24 V GND
View of mating 6 BU GND
0117a026
connector, wiring side 8 WH GND
0117a025

Digital, RS485 differential Digital, Single-ended

±15 V (P, M, I, K, L, R) ±15 V (N)
1 YE Interrogate + Input 1 YE Interrogate + Input
3 PK Interrogate - Input 2 GY Pulse + Output
2 GY Pulse + Output 7 BN +15 V
5 GN Pulse - Output 6 BU GND
7 BN 8 WH - 15 V
+15 V
6 BU GND 0117a028

8 WH -15 V
0117a027

Note the following When routing the cable between straignt right-angle
when making BKS-S 32M-00 BKS-S 33M-00
the transducer, controller and
Cable entry
electrical connec- power supply, avoid proximity to
(PG 9 fitting)
tions: high voltage lines to prevent noise
coupling.
System and control cabinet
must be at the same Especially critical is inductive
ground potential. noise caused by AC harmonics
(e.g. from phase-control devices),
To ensure the electromagnetic against which the cable shield
compatibility (EMC) which provides only limited protection.
Balluff warrants with the CE
Mark, the following instruc- Cable length max. 500 m ;
tions must be strictly Ø 6 to 8 mm.
followed. Fig. 4-1: Connector (optional)
High noise immunity on the line
BTL transducer and the between the transducer and
processor/control must be processor is provided by the
connected using differential line drivers used for
shielded cable. the RS 485/422 interface. The
differential signal is carried to the BKS connector,
Shielding: Copper filament processor, which makes it
braided, 80% coverage. view towards
available as analog or digital
information for solder side of
The shield must be tied to the female BKS-S
connector housing in the further processing.
32M-00 or BKS-S
BKS connector (Fig. 4-1); see
33M-00
instructions accompanying
the connector.
Fig. 4-2: Pin assignments BKS,
In the cable version the cable connector type BTL
shield is connected to the
housing in the PG fitting.
The cable shield must be
grounded on the control side,
i.e., connected to the
protection ground.
Pin assignments can be
found in Table 4-1. Connec-
tions on the controller side
may vary according to the
controller and configuration
used.
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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing
4 Wiring (cont.)
INIT YE
START/STOP GY
INIT PK
BTL5-P1...KA_ _

START/STOP GN

processor or
GND BU

controller
+24 V BN

Fig. 4-3: BTL5-P1...KA_ _ with processor controller, wiring example

5 Startup

5.1 Check connections 5.3 Check output values 5.5 Fault conditions
Although the connections are After replacing or repairing a When there is evidence that the
polarity reversal protected, transducer, it is advisable to verify transducer system is not
components can be damaged the values for the start and end operating properly, it should be
by improper connections and position of the magnet in manual taken out of service and
overvoltage. Before you apply mode. If values other* than those guarded against unauthor-
power, check the connec- present before the replacement or ized use.
tions carefully. repair are found, a correction should
be made.
5.6 Noise elimination
5.2 Turning on the system * Transducers are subject to
modification or manufacturing Any difference in potential -
Note that the system may tolerances. current flow - through the cable
execute uncontrolled move- shield should be avoided.
ments when first turned on or Therefore:
when the transducer is part of a 5.4 Check functionality
closed-loop system whose – Use the isolation bushings,
parameters have not yet been The functionality of the transducer and
set. Therefore make sure that system and all its associated – Make sure the control
no hazards could result from components should be regularly cabinet and the system in
these situations. checked and recorded. which the BTL5 is contained
are at the same
ground potential.

6 Versions (indicated on part label)

Supply voltage 1 = DC 24 V, 2 = DC ±15 V

Electr. connect., S32: with connector,
BTL5-P1-M0450-P-S32 KA05: with 5 m cable
Micropulse
Linear Transducer

Profile form factor

Nominal stroke (4 digits): M = Metric units [mm]
U = Inch units [1/10 in.]
Digital output signals: BTL5-N... BTL5-P... BTL5-M... BTL5-I... BTL5-K... BTL5-L...

Start Stop Start Stop Start Stop Start Stop Stop Gate
Single Ended (Trailing Edge (Leading Edge (RS-485 (Leading Edge (Pulse-width-
Active) Active) Multiplex) Active) Modulated)

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing

7 Technical Data

The following are typical values at DC 24 V and 25 °C. Fully operational after power-up, with full accuracy after
warm-up. Values are with BTL5-P-3800-2, BTL5-P-4500-1 or BTL5-P-5500-2 magnet held at a constant
offset from the transducer or with captive magnet BTL5-F/M/N-2814-1S (see magnet section for exceptions):

Resolution < 2 µm 7.3 Control signals Control arm (optional)

Hysteresis < 4 µm BTL2-GS08-_ _ _ _-A
Repeatability < 6 µm INIT pulse Aluminum, dimensions Fig. 3-
(resolution + hysteresis) Level +5 V RS 485/422 driver 8
System resolution (BTL5-.... + BTA) Length 1 µs (max. 3 µs) Various standard lengths LS
is determined by the processor or available (please specify when
external controller. Pulse lengths over 3 µs ordering)
can damage the unit.
Recommended sampling rate:
7.7 Accessories (optional)
Nominal length f Standard
7.4 Connection to processor
< 1000 mm 0.5 to 2 kHz Connectors Fig. 4-1
Shielded cable,
< 2000 mm 0.5 to 1 kHz
max. length 500 m, Ø 6 to 8 mm.
> 2000 mm 0.5 kHz 7.8 Compatible processors and
displays
Non-linearity: 7.5 Included in shipment
Nom. length < 500 mm > 500 mm Transducer Fig. 3-1 ... for BTL5-P1
or Fig. 3-5
±100 µm ±0.02 %
(with mounting brackets, Analog output processor cards:
isolation bushings and screws, BTA-A 0...10 and 10...0 V
Temperature coefficient not incl. magnet) BTA-C 0...20 or 20...0 mA *
< (6 µm + 5 ppm * nominal length)/K BTA-E 4...20 or 20...4 mA *
Shock loading 100 g/6 ms BTA-G -10...10 and 10...-10 V
7.6 Magnets (order separately)
per IEC 68-2-27 1 * also: 0...10 V and 10...0 V
Continuous shock 100 g/2 ms
• Spacing, offset and installation Digital output processor cards:
per IEC 68-2-29 1
pages 4 and 5 BTA-D11 20 bit, binary
Vibration 12 g, 10 to 2000 Hz
Operating temp. –40 °C to +85 °C BTA-S11 16 setpoint outputs
per IEC 68-2-6 1
BTA-H11 22 bit,
1
Individual specifications as per BTL5-P-3800-2 Fig. 3-2 BCD, Gray/binary or
Balluff factory standard Weight approx. 12 g
SSD, Gray
Housing plastic
BTA-V11 Velocity output card
Parallel, digital and analog output
7.1 Dimensions, weights, ambient BTL5-P-5500-2 Fig. 3-3
conditions Weight ca. 40 g Displays:
Housing plastic BDD-07-9 digital display, 7-digit
• Nominal length < 4000 mm Non-linearity: for BTA-H, BTA-S and BTA-V
• Dimensions pages 4 and 5 Nom. length < 500 mm > 500 mm BDD-AM10-1-P display and
• Weight approx. 1.4 kg/m controller with 2 relay outputs
• Housing anodized aluminum ±150 µm ±0.03 % FS
BDD-CC08-1-P display and
• Housing attachment: controller with 8 setpoints
Mounting clamps with isolation BTL5-P-4500-1 Fig. 3-4
bushings and screws Weight approx. 90 g
• Operating temp. –40 °C to +85 °C Housing plastic
• Humidity < 90%, non-condensing Operating temp. –40 °C to +60 °C
• Protection class per IEC 529 IP 67
when closed up BTL5-F-2814-1S Fig. 3-6
Weight approx. 28 g
7.2 Supply voltage (external) Housing plastic

Regulated supply voltage BTL5-M-2814-1S Fig. 3-7

BTL5-_1... DC 20 to 28 V Weight approx. 32 g
Ripple < 0.5 V pp Housing anodized
BTL5-_2... DC ±14.7 to ±15.3 V aluminum
Current draw < 90 mA (at 1 kHz) Contact surface plastic
Inrush < 3 A/0.5 ms
Polarity reversal protection built-in BTL5-N-2814-1S Fig. 3-7
Overvoltage protection Weight approx. 35 g
Transzorb diodes Housing anodized
Electric strength aluminum
GND to housing 500 V Contact surface plastic

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 BTL5-P/I/K/L/M_-M/U_ _ _ _-P-S32/KA_ _
Micropulse Linear Transducer
Digital Output / Profile Housing

7 Magnet and Control Arm Diagram Refernces

NL
Nominal stroke

Fig. 3-1: Dimensional

drawing (BTL5...P-S 32
transducer with floating
magnet BTL5-P-3800-2)

Mounting brackets with isolation bushings and M5 x 22 cylinder

head screws, DIN 912, max. tightening torque 2 Nm
NL
Nominal stroke
Fig. 3-5: Dimensional
drawing (BTL5...P-KA
transducer with captive
magnet BTL5-F-2814-
1S)

Mounting brackets with isolation bushings and M5 x 22 cylinder head

screws, DIN 912, max. tightening torque 2 Nm max. permissible
tightening torque 2 Nm
55
45
E 21 E C
28
Ø 4.2
20

15
D

61 +10
1

Fig. 3-2: BTL5-P-3800-2 magnet Fig. 3-3: BTL5-P-5500-2 magnet Fig. 3-4: BTL5-P-4500-1
electromagnet (24 V/100 mA)
Ball joint "B" Black, round
marking Mechanically joined to M5 Max. angle offset
DIN 71805, Max. parallel offset
stud using 2 nuts
rotates horizontally

BTL5-M-2814-1S: X = 48.5 Y = 57
BTL5-N-2814-1S: X = 51 Y = 59.5

Fig. 3-7: BTL5-M/N-2814-1S magnet

Fig. 3-6: BTL5-F-2814-1S magnet

Ball joint "B" DIN 71805, straignt right-angle

rotates horizontally (part of BKS-S 32M-00 BKS-S 33M-00
BTL5-F-2814-1S) magnet) Cable entry
(PG 9 fitting)

Jam nut DIN 934 M5

Swivel eye DIN 648
Fig. 3-8: BTL2-GS08-_ _ _ _-A Fig. 4-1: Connector (optional)
connecting rod

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Sensors Worldwide Technical Description / User’s Guide

Complete Product Range

Germany Inductive Photoelectric MicropulseTM

Sensors Sensors Transducers
Global Headquarters
Balluff GmbH
Schurwaldstraße 9
73765 Neuhausen a.d.F.
Telefon: +49 (0)71 58/1 73-0
Telefax: +49 (0)71 58/50 10
Hotline: +49 (0)71 58/1 73-370
Web: www.balluff.de Capacitive
Sensors
Magnetic Field
Sensors
E-mail: [email protected]

USA
North American Headquarters
Balluff Inc.
8125 Holton Drive
Florence, KY 41042
Electromechanical Identification
Phone: (859) 727-2200 Sensors Systems
Toll-free: 1-800-543-8390
Fax: (859) 727-4823
Web: www.balluff.com
E-Mail: [email protected]

Canada
Balluff Canada, Inc. Connectors &

Doc. no. 883599/Mat. no. 317097 • Edition 0308 ; Subject to Modification

2840 Argentia Road, Unit #2 Accessories
Mississauga, Ontario L5N 8G4
Phone: (905) 816-1494
Toll-free: 1-800-927-9654
Fax: (905) 816-1411
Web: www.balluff.ca
E-mail: [email protected]

Mexico
Balluff de Mexico S.A. de C.V
Prol. Av. Luis M. Vega #109
Col. Ampliacion Cimatario
Queretaro, QRO 76030
Phone: (++52 442) 212-4882,
224-3583, 224-3171
Fax: (++52 442) 214-0536
E-mail: [email protected]

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