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BTL5-A/C/E/G_ _-M/U_ _ _ _-P-S 32/KA_ _

Balluff GmbHSchurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone +49 (0) 71 58/1 73-0Fax +49 (0) 71 58/50 10Servicehotline +49 (0) 71 58/1 73-3 70E-Mail: [email protected]://www.balluff.dehttp://www.balluff.dehttp://www.balluff.dehttp://www.balluff.dehttp://www.balluff.de

Technical DescriptionUser's Guide

english

BTL5-A/C/E/G_ _-M/U_ _ _ _-P-S 32/KA_ _Micropulse Linear Transducer in Profile Housing

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ducer system. In particular, stepsmust be taken to ensure that shouldthe transducer system becomedefective no hazards to persons orproperty can result. This includesthe installation of additional safetylimit switches, emergency shutoffswitches and maintaining the per-missible ambient conditions.

1.4 Scope

This guide applies to the modelBTL5-A/C/E/G...P... Micropulsetransducer.

An overview of the various modelscan be found in ➥ ➥ ➥ ➥ ➥ section 6 Ver-sions (indicated on part label) onpage 7.

Note: For special versions, whichare indicated by an -SA_ _ _ des-ignation in the part number, othertechnical data may apply (affect-ing calibration, wiring, dimensionsetc.).

Read this manual before installingand operating the Micropulse Trans-ducer.

1.1 Proper application

The BTL5 Micropulse transducer isintended to be installed in a ma-chine or system. Together with acontroller (PLC) or a processor(BTA) it comprises a position mea-suring system and may only beused for this purpose.

Unauthorized modifications andnon-permitted usage will result inthe loss of warranty and liabilityclaims.

1.2 Qualified personnel

This guide is intended for special-ized personnel who will perform theinstallation and setup of the system.

1.3 Use and inspection

The relevant safety regulations mustbe followed when using the trans-

1 Safety AdvisoryContents

1 Safety Advisory ..................... 21.1 Proper application .................. 21.2 Qualified personnel ................ 21.3 Use and inspection ................ 21.4 Scope ..................................... 2

2 Function andCharacteristics ..................... 3

2.1 Characteristics ....................... 32.2 Function ................................. 32.3 Available stroke lengths

and magnets .......................... 3

3 Installation ............................ 33.1 Transducer installation ........... 33.2 Floating magnets .................... 43.3 Captive magnets .................... 5

4 Wiring .................................... 6

5 Startup ................................... 75.1 Check connections ................ 75.2 Turning on the system ............ 75.3 Check output values .............. 75.4 Check functionality ................ 75.5 Fault conditions ...................... 75.6 Noise elimination .................... 7

6 Versions (indicatedon part label) ......................... 7

7 Technical Data ...................... 87.1 Dimensions, weights,

ambient conditions................. 87.2 Supply voltage (external) ........ 87.3 Outputs .................................. 87.4 Connection to processor ........ 87.5 Included in shipment .............. 87.6 Magnets (order separately) ..... 87.7 Accessories (optional) ............ 8

The following patents have beengranted in connection with thisproduct:US Patent 5 923 164Apparatus and Method for Auto-matically Tuning the Gain of anAmplifier

Emission tests:RF Emission

EN 55011 Group 1, Class ANoise immunity tests:Static electricity (ESD)

EN 61000-4-2 Severity level 3Electromagnetic fields (RFI)

EN 61000-4-3 Severity level 3Fast transients (Burst)

EN 61000-4-4 Severity level 3Surge

EN 61000-4-5 Severity level 2Line-induced noise induced byhigh-frequency fields

EN 61000-4-6 Severity level 3Magnetic fields

EN 61000-4-8 Severity level 4

The CE Mark verifiesthat our products meetthe requirements ofEC Directive

89/336/EEC (EMC Directive)

and the EMC Law. Testing in ourEMC Laboratory, which is accred-ited by DATech for Testing Electro-magnetic Compatibility, has con-firmed that Balluff products meetthe EMC requirements of the fol-lowing Generic Standards:

EN 50081-2 (emission)

EN 61000-6-2 (noise immunity)


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2.1 Characteristics

Micropulse transducers feature:— Very high resolution, repeatability

and linearity— Immunity to shock, vibration,

contamination and electrical noise— An absolute output signal— IP 67 per IEC 529

2.2 Function

The Micropulse transducer containsa tubular waveguide enclosed by anextruded aluminum housing. Amagnet attached to the movingmember of the machine is movedacross the top of the housing andits position constantly updated.

The magnet defines the measuredposition on the waveguide. An inter-nally generated INIT pulse interactswith the magnetic field of the mag-net to generate a magnetostrictivetorsional wave in the waveguidewhich propagates at ultrasonicspeed.

The torsional wave arriving at theend of the waveguide is absorbed in

the damping zone. The wave arriv-ing at the beginning of thewaveguide creates an electricalsignal in the coil surrounding thewaveguide. The propagation time ofthe wave is used to derive the posi-tion. Depending on the version thecorresponding value is output as avoltage or a current either with risingor falling characteristic. This processtakes place with measuring highprecision and repeatability within thestroke range defined as nominalstroke length.

On both ends of the nominal strokelength is an area which provides anunreliable signal, but which may beentered.

The electrical connection betweenthe transducer, the processor/con-troller and the power supply is via acable, which depending on the ver-sion is either fixed or connectedusing a female connector.

Dimensions for installing theMicropulse transducer and for themagnets and control arm are foundon ➥➥➥➥➥ pages 4 and 5.

2 Function and Characteristics

3.1 Transducer installation

Ensure that no strong electrical ormagnetic fields are present in theimmediate vicinity of the trans-ducer.

Any orientation is permitted. Thesupplied mounting brackets andcylinder head screws allow thetransducer to be mounted on a flatmachine surface. A sufficient quan-tity of mounting brackets is sup-plied. These should be evenlyspaced (➥➥➥➥➥ Figs. 3-1 and 3-5). Therecommended spacing for longtransducers and extreme conditions(e.g. strong shock or vibration):A = 80 mm; spacing between theindividual brackets B = 250 mm.

The supplied isolation bushings areused to electrically insulate thetransducer from the machine(➥➥➥➥➥ Fig. 3-1and 3-5 and chapter 5.6Noise elimination).

The Micropulse transducer in profilehousing is suitable both for floating,i.e. non-contacting magnets(➥➥➥➥➥ Page 4) and for captive magnets(➥➥➥➥➥ Page 5).

3 Installation

Notch on housing to mark the beginning of the stroke range

Current position ofmagnet

Moving ma-chine part

Micropulse Transducer

Machine

Nominal stroke =Measuring range

Fig. 2-1: Basic arrangement

El.

conn

ectio

n

Dam

pin

g zo

ne

2.3 Available stroke lengthsand magnets

To provide for optimum fit in anyapplication, a wide range of stan-dard stroke lengths and magnets invarious form factors are available.Magnets and control arms musttherefore be ordered separately.

The following nominal strokelengths are available:

stroke lengths[mm]

increments[mm]

50 ... 1000 50

1000 ... 2000 100

2000 ... 4000 250

Other stroke lengths on request.


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Con

nect

orw

ith L

ED

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

Fig. 3-3: BTL5-P-5500-2 magnet

max. permissibletightening torque 2 Nm

3 Installation (cont.)

BTL5-P-4500-1 magnet, specialfeatures: Multiple magnets on thesame transducer can be turned onand off individually (PLC controlsignal).

The stroke range is offset 4 mmtowards the BTL connector/cable(➥➥➥➥➥ Fig. 3-4).

3.2 Floating magnets

The floating magnet (➥➥➥➥➥ Figs. 3-2 to3-4) is attached to the movingmember of the machine using non-magnetizable screws (brass, alumi-num). To ensure the accuracy of thetransducer system, the movingmember must carry the magnet on atrack parallel to the transducer.

The following table provides figuresin [mm] for the spacing which mustbe maintained between magnet andtransducer and for the permissiblecenter offset:

Magnet type Distance" D "

Offset" C "

BTL5-P-3800-2 0.1 ... 4 ± 2

BTL5-P-5500-2 5 ... 15 ± 15

BTL5-P-4500-1 0.1 ... 2 ± 2

Fig. 3-1: Dimensional drawing (BTL5...P-S 32 transducer with floating magnet BTL5-P-3800-2)

NL

Nominal stroke

Mounting brackets with isolation bushingsand M5 x 22 cylinder head screws, DIN 912,max. tightening torque 2 Nm

55

28

45

21

Ø 4.2

20

61 +

101

15

E E C

D

Ensure that the distance Ebetween parts made ofmagnetizable material and

the BTL5-P-5500-2 magnet is atleast 12 mm (➥➥➥➥➥ Fig. 3-3).


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3 Installation (cont.)

3.3 Captive magnets

Lateral forces are to be avoidedwhen using captive magnets(➥➥➥➥➥ Figs. 3-6 and 3-7). Connectionsare required here which permit thecorresponding degree of freedomwith respect to the direction ofmovement of the magnet along the

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

Mounting brackets with isolation bushingsand M5 x 22 cylinder head screws, DIN 912,max. tightening torque 2 Nm

Nominal stroke Black,roundmarking

Magnet

NL

Fig. 3-8: BTL2-GS10-_ _ _ _-Aconnecting rod

Jam nut DIN 934 M5

Swivel eye DIN 648

Ball joint "B" DIN 71805, rotates hori-zontally (part of BTL5-F-2814-1S)

Ball joint "B"DIN 71805,rotates horizontally

Black, roundmarking

Fig. 3-6: BTL5-F-2814-1S magnet Fig. 3-7: BTL5-M/N-2814-1S magnet

Mechanically joined to M5stud using 2 nuts

Max. angle offset

Max. parallel offset

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

stroke range. It is assumed that theBTL5-F-2814-1S magnet is con-nected to the machine memberusing a connecting rod. TheBTL2-GS10...A connecting rod(➥➥➥➥➥ Fig. 3-8) is available as an ac-cessory (please indicate length LGwhen ordering).


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4 Wiring

Note the following when makingelectrical connections:

System and control cabi-net must be at the sameground potential.

To ensure electromagnetic com-patibility (EMC), which Balluffverifies by the CE Marking, thefollowing points must be strictlyobserved.

BTL transducer and the proces-sor/control must be connectedusing shielded cable.

Shielding: Copper filamentbraided, 80% coverage.

The shield must be tied to theconnector housing in the BKSconnector (➥➥➥➥➥ Fig. 4-1); see in-structions accompanying the con-nector.

In the cable version the cable shieldis connected to the housing in thePG fitting.

The cable shield must begrounded on the control side, i.e.,connected to the protectionground.

Pin assignments can be found in➥➥➥➥➥ Table 4-1. Connections on thecontroller side may vary accordingto the controller and configurationused.

When routing the cable between thetransducer, controller and powersupply, avoid proximity to high volt-age lines to prevent noise coupling.Especially critical is inductive noisecaused by AC harmonics (e.g. fromphase-control devices), againstwhich the cable shield provides onlylimited protection.

Cable length max. 20 m; Ø 6 to8 mm. Longer lengths may be usedif construction, shielding and routingare such that external noise fieldswill have no effect on signal integrity.

Fig. 4-2: Pin assignments BKS,connector type BTL

BKS connector,view towards solderside of femaleBKS-S 32M-00 orBKS-S 33M-00

Table 4-1: Wiring assignment

straigntBKS-S 32M-00No. 99-5672-19-08(Binder part no.)

right-angleBKS-S 33M-00No. 99-5672-78-08

Fig. 4-1: Connector (optional)

Cable entry(PG 9 fitting)

Output signalsPin Cable BTL5-A_1 -C_0 -C_7 -E_0 -E_7 -G_1 1 YE yellow not used ➂ 0...20 mA 20...0 mA 4...20 mA 20...4 mA not used ➂ 2 GY grey 0 V ➀ 3 PK pink ➁ 10...0 V 10...0 V 10...0 V 10...0 V 10...0 V 10...–10 V 4 not used 5 GN green ➁ 0...10 V 0...10 V 0...10 V 0...10 V 0...10 V –10...10 V

Supply voltage (external)Pin Cable BTL5-A/C/E/G1_ BTL5-A/C/E/G2_ 6 BU blue GND ➀ ➃ GND ➀ ➃ 7 BN brown +24 V +15 V 8 WH white do not connect –15 V

➀ The analog transducer outputsare potential-free. When connect-ing to a module with non-poten-tial-free inputs, ground loops maycause erroneous signals. Avoidthis by defeating the potential-free function in the transducer:jumper Pin 2 and Pin 6 in thefemale connector (➥➥➥➥➥ Fig. 4-2).

➁ A small voltage difference(< 10 mV) appears between pin 3and 5 due to seperate outputdrivers.

➂ Unused leads can be tied toGND on the control side, but theymust never be connected to theshield.

➃ Reference GND for supplyvoltage and EMC!


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5 Startup

5.1 Check connections

Although the connections are polar-ity reversal protected, componentscan be damaged by improper con-nections and overvoltage. Beforeyou apply power, check the connec-tions carefully.

5.2 Turning on the system

Note that the system may executeuncontrolled movements when firstturned on or when the transducer ispart of a closed-loop system whoseparameters have not yet been set.Therefore make sure that no haz-ards could result from these situa-tions.

If there is no magnet in the strokerange, the integrated function moni-tor provides the following definedoutput signals:

6 Versions (indicated on part label)

Supply voltage 1 = DC 24 V, 2 = DC ±15 VElectr. connection S32: with connector,

BTL5-A11-M0450-P-S32 KA05: with 5 m cableProfile form factor

Nom. length (4 digits), M = metric in mmU = inches in 1/10 inch

Analog interface: Voltage output A_1 = 10 ... 0 V and 0 ... 10 VG_1 = 10 ... –10 V and –10 ... 10 V

Current output C_0 = 0 ... 20 mA E_0 = 4 ... 20 mAC_7 = 20 ... 0 mA E_7 = 20 ... 4 mA

Mic

rop

ulse

Line

ar T

rans

duc

er

Voltage output 10 Vincreasing decreasingUA > 10 V < 0 V

Current output 20 mAincreasing decreasingIA > 20 mA 0 mA for BTL5-C...IA > 20 mA < 4 mA for BTL5-E...

5.3 Check output values

After replacing or repairing a trans-ducer, it is advisable to verify thevalues for the start and end positionof the magnet in manual mode. Ifvalues other* than those presentbefore the replacement or repair arefound, a correction should be made.* Transducers are subject to modifi-

cation or manufacturing tolerances.

5.4 Check functionality

The functionality of the transducersystem and all its associated com-

ponents should be regularlychecked and recorded.

5.5 Fault conditions

When there is evidence that thetransducer system is not operatingproperly, it should be taken out ofservice and guarded against unau-thorized use.

5.6 Noise elimination

Any difference in potential - currentflow - through the cable shieldshould be avoided. Therefore:– Use the isolation bushings, and– Make sure the control cabinet

and the system in which theBTL5 is contained are at thesame ground potential.

4 Wiring (cont.)

YE

GY

PK

GN

BU

BN

4...20 mA

0 V

10...0 V

0...10 V

GND

+24 V

Fig. 4-3: BTL5-E10...KA _ _ with processor card/controller, wiring example

pro

cess

or/

cont

rolle

r w

ithan

alog

inp

ut

BTL

5-E

10...

KA

_ _


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Resolution < ±2 µm+ Hysteresis < ±4 µm= Repeatability < ±6 µm=̂ Voltage < ±0.1 mV=̂ Current < ±0.16 µA

Sampling rate fStandard

= 1 kHz

Non-linearity:Nom. length < 500 mm > 500 mm

±100 µm ±0.02 % FS

Temperature coefficientVoltage output:[150 µV/K + (5 ppm/K * P * V/NL)] * ∆T

Current output:[0.6 µA/K + (10 ppm/K * P * I/NL)] * ∆TV = output voltage range in [V]I = output current range in [mA]NL = nominal length in [mm]∆T = temperature difference in [K]P = magnet position in [mm]Shock loading 100 g/6 msper IEC 68-2-27 1

Continuous shock 100 g/2 msper IEC 68-2-29 1

Vibration 12 g, 10 to 2000 Hzper IEC 68-2-6 1

1 Individual specifications as perBalluff factory standard

7.1 Dimensions, weights,ambient conditions

Nominal length < 4000 mmDimensions ➥➥➥➥➥ pages 4 and 5Weight approx. 1.4 kg/mHousing anodized aluminumHousing attachmentMounting clamps with isolationbushings and screwsOperating temp. –40 °C to +85 °CHumidity < 90%, non-condensingProtection class per IEC 529 IP 67when closed up

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 thetransducer or with captive magnet BTL5-F/M/N-2814-1S (see magnet section for exceptions):

7.2 Supply voltage (external)

Regulated supply voltageBTL5-_1... DC 20 to 28 VRipple < 0.5 Vpp

BTL5-_2... DC ±14.7 to ±15.3 VCurrent draw < 150 mAInrush < 3 A/0.5 msPolarity reversal protection built-inOvervoltage protectionTranszorb diodesElectric strengthGND to housing 500 V

7.3 Outputs

BTL5-A...Output voltage 0...10/10...0 VLoad current < 5 mARipple < 5 mVBTL5-G...Output voltage –10...10/10... –10 VLoad current < 5 mARipple < 5 mVBTL5-C...Output current 0...20/20...0 mALoad resistance < 500 OhmBTL5-E...Output current 4...20/20...4 mALoad resistance < 500 Ohm

7.4 Connection to processor

Analog interface:With S32 connector for shieldedcable (max. length, see "Wiring"),diameter 6 to 8 mm,or with integral cable KA05 (5 mlong)

7.5 Included in shipment

Transducer ➥➥➥➥➥ Fig. 3-1or ➥➥➥➥➥ Fig. 3-5(with mounting brackets, isolationbushings and screws, not incl. mag-net)

7.6 Magnets(order separately)

Spacing, offset and installation➥➥➥➥➥ pages 4 and 5

Operating temp. –40 °C to +85 °C

BTL5-P-3800-2 ➥➥➥➥➥ Fig. 3-2Weight approx. 12 gHousing plasticBTL5-P-5500-2 ➥➥➥➥➥ Fig. 3-3Weight approx. 40 gHousing plasticNon-linearity:Nom. length < 500 mm > 500 mm

±150 µm ±0.03 % FS

BTL5-P-4500-1 ➥➥➥➥➥ Fig. 3-4Weight approx. 90 gHousing plasticOperating temp. –40 °C to +60 °CBTL5-F-2814-1S ➥➥➥➥➥ Fig. 3-6Weight approx. 28 gHousing plasticBTL5-M-2814-1S ➥➥➥➥➥ Fig. 3-7Weight approx. 32 gHousing anodized aluminumContact surface plasticBTL5-N-2814-1S ➥➥➥➥➥ Fig. 3-7Weight approx. 35 gHousing anodized aluminumContact surface plastic

Control arm (optional)BTL2-GS10-_ _ _ _-AAluminum, dimensions ➥ ➥ ➥ ➥ ➥ Fig. 3-8Various standard lengths LG avail-able (please specify when ordering)

7.7 Accessories (optional)

Connectors ➥➥➥➥➥ Fig. 4-1

No.

817

112

E •

Ed

ition

010

5; S

pec

ifica

tions

sub

ject

to

chan

ge •

Rep

lace

s ed

ition

010

1.

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