to err is not divine. -...

sensors&connectivity

To Err is NOT Divine.

Error-Proofing Concepts to Prevent Product Defects and Drive Customer Satisfaction.

www.klinkmann.com6 / 2011

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sensors&connectivity

Photoelectric Sensors 34

Proximity Sensors 44

Limit Switches 52

Encoders 58

Condition Sensing Switches 62

Devicenet & Ethernet Media 66

Connection Systems 72PR

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FEATURES12 4 What’s New In Sensors and Connectivity Showcasing the Latest Products

8 Feature Article To Err is NOT Divine

12 Customer Success Stories Semtorq, Inc.

16 TechTips MultiSight Vision Sensor 101

20 eTools

22 Services & Support Rockwell Automation’s Services & Support offerings

24 Q&A Answers to Frequently

Asked Questions

26 Industry and Application Solutions See How Allen-Bradley Products Solve

Targeted Industry Applications

34 Products Sensors and Connectivity Product Portfolio

80 What’s Next A preview of upcoming products

DIRECT EDITORIAL COMMENTS TO:

Editor-in-chief | Todd M Bissell Tel (978) 446-3284 | [email protected]

Contributing Editors:Adonis Reyes | Brian Schriver | Camilo Aladro | Cato Bubnikowicz | Craig BrockmanJan Zuehlke | Jennifer Jones | Jennifer Shen | JJ Thiara | Mehdi Abtahi | Tanvi Desai

To Err is NOT Divine

8F E A T U R E A R T I C L E


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48MS MULTISIGHTTM

The Allen-Bradley 48MS MultiSight is an optical multi-pixel sensor with a pass/fail PNP output. The MultiSight uses three different methods of evaluation (pattern matching, contrast, and brightness) to detect or differentiate objects by means of previously defined optical characteristics, e.g. for separating “good” and “bad” parts. The main applications are in the field of industrial automation for quality assurance purposes. The MultiSight is an easy-to-use economical alternative to conventional vision systems for detecting presence or absence, completeness, position, markings, labeling, packaging, and components.

To learn more about the 48MS MultiSight, turn to page 37.

45BPD, 45BRD AND 45CPD LASER MEASUREMENT SENSORS

A reliable solution for your error proofing, inspection, positioning and measurement applications, Rockwell Automation’s line of Allen-Bradley laser measurement sensors offers optimal flexibility and performance. The new Allen-Bradley 45BPD and 45BRD are excellent solutions for a wide range of non-contact measurement applications requiring sensing range up to 300mm (approximately 1 foot), while the 45CPD line is ideal for applications requiring long range detection (up to 6 meters) and a small beam spot.

For full specifications, turn to page 37 of this publication.

44B ADJUSTABLE BACKGROUND/FOREGROUND

SUPPRESSION PHOTOELECTRIC SENSOR

The Allen-Bradley 44B adjustable background/foreground suppression photoelectric sensor is intended for industrial applications requiring the reliable detection of targets close to a surface that must be ignored by the sensor. Unlike standard diffuse style sensors, the 44B incorporates a dual receiver optical system to actively “see” both the target and background areas. This allows the sensor to suppress any background reflections.

For detailed specifications, please refer to page 38 of this publication.

IN SENSORS AND CONNECTIVITYNEWWHAT’S


45PVA DIFFUSE/RETROREFLECTIVE PARTS VERIFICATION ARRAYS

The Allen-Bradley 45PVA is a photoelectric Parts Verification Array designed for bin picking applications and object detection in the parts assembly industry. When used as part of a suitably configured bin-picking system, the 45PVA effectively prevents mis-picks to enhance efficiency and minimize down time.

It is also the ideal solution to address the “error proofing” initiatives prevalent in the automotive industry. The latest additions to the 45PVA family are retroreflective and diffuse sensing mode models available in two sizes with detection heights of 87mm (3.4 in) and 203mm (8 in).

To learn more about these new 45PVA Diffuse/Retroreflective Parts Verification Arrays, turn to page 41.

42EF RIGHTSIGHT LASERSIGHTTM

Building on the success of the Allen-Bradley RightSight photoelectric sensors, Rockwell Automation has introduced a new line of RightSight sensors with a visible laser light source, the 42EF LaserSight RightSight. Offering high-performance general purpose sensing in a compact, flexible package, this latest addition is available in diffuse, polarized retroreflective and transmitted beam models. These laser-based sensors are ideal for applications that require detection of small objects or in applications that require a narrow field of view. Plus, the higher margin allows for better detection of non-reflective targets and more reliable sensing in high contamination environments. Teachable models are also available for fast installation and simplified configuration at the push of a button.

To learn more about the RightSight LaserSight, turn to page 38.


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DEVICENETTM OPEN-STYLE MEDIA

Understanding the importance of a dependable DeviceNet network, Rockwell Automation offers a full suite of quick-connecting IP67 rated DeviceNet physical media components that eliminate wiring errors and protect the backbone of the network, while improving productivity and lowering the total cost of operation. This reliable, streamlined wiring philosophy is continued in the IP20 space with the introduction of overmolded DeviceNet open-style connectors. Thin cable 5-pin open-style DeviceNet cables provide simplified connection of open-style devices to round and flat media systems. They also allow the use of standard factory molded micro or mini drop connections throughout an installation, thus reducing the total number of parts needed in a typical system. The resulting connection point also simplifies troubleshooting of open-style field devices by allowing tool-free connection and disconnection.

For full specifications, turn to page 71 of this publication.

DIN VALVE CONNECTIVITY

Found predominantly in industrial hydraulic and pneumatic applications involving solenoid valves and pressure switches, DIN connectivity is used on a wide variety of devices from pressure transducers, proximity switches, level sensors and flow monitors to limit switches, thermostats, industrial thermometers and low energy motors. Addressing the growing need for flexible connectivity with fluid power electromechanical devices, Rockwell Automation has introduced a full complement of Allen-Bradley DIN cordsets and field attachable connectors as a standard solution for those complex control applications. Available in a variety of sizes and wiring configurations, Allen-Bradley DIN valve connection systems components simplify installation, modification and maintenance of your control system.

Refer to page 78 for complete details.

BULLETIN 1485C/1485G/889N FLEX RATED

DEVICENETTM ROUND CORDSETS AND PATCHCORDS

These new thick and thin DeviceNet cordsets and patchcords are specifically designed to withstand flexing applications. Thick media with .475 inch (12 mm) diameter gray PVC cable is rated for 5 million cycles, while thin media with a .275 inch (7mm) diameter gray PVC cable is rated for 10 million cycles. 16AWG Flex rated auxiliary power cordsets and patchcords are also available with a .52 inch (13 mm) diameter yellow TPE cable rated for 7 million cycles. All testing was done by flexing the cable on a bend radius ten times the diameter of the cable. This rugged media can be used in all applications where DeviceNet cordsets and patchcords are found and can be configured to various lengths.


871TM ALL-STAINLESS 3-WIRE DC

8 mm PROXIMITY SENSOR

To round out the 871TM stainless steel face/threaded stainless steel barrel product line, Rockwell Automation now offers an 8 mm version of this inductive proximity sensor. Like the 12 mm, 18 mm and 30 mm sensors in this line, the 8mm version will be available with all options: shielded or unshielded, Normally Open or Normally Closed NPN or PNP output, PVC or ToughLink Cable or micro quick disconnect. This line features full mechanical seals at all barrel openings and full epoxy encapsulation, making it an excellent choice for harsh-environment applications. The circuitry is equipped with short circuit, overload, transient noise, false pulse, reverse polarity and radio frequency interference protection.

To learn more about this new 871TM proximity sensor, turn to page 44 .

839E SOLID-STATE FLOW SWITCHES

The new Allen Bradley 839E Flow family of solid-state condition sensing switches is microprocessor based with no moving parts, which means longer lifecycles and less downtime. Constructed of rugged corrosion resistant 316 stainless steel, these compact new condition sensors withstand even the harshest industrial environments and feature an IP66 enclosure rating.

Allen-Bradley solid-state 839E flow switches monitor and display liquid media flow rate in the range from 0.03 to 3 m/s (0.1 to 9.84 ft/s). Each switch is available either with two independently programmable PNP (normally open / normally closed) outputs or 4-20mA analog output with single PNP output.


4-20mA SOLID-STATE

CONDITION SENSING SWITCHES

The new Allen Bradley 836E pressure, 837E temperature and 839E flow families of solid-state condition sensing switches are available with 4-20mA analog output and one PNP (normally open / normally closed) output. The analog output returns actual data back to control system while the PNP switch can be used for local alarm initiation. Plus, the span of the 4-20mA output can be adjusted to ¼ of the switch range to fit specific applications.

Refer to page 65 for complete details.




Discrete inductive and photoelectric sensorsIn this application, a 42EF RightSight photoelectric transmitted beam pair is used to position a cassette such that five 872C WorldProx inductive sensors can confirm screw presence.

F E A T U R E A R T I C L E

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Using Error-Proofing Concepts to Prevent

Product Defects and Drive Customer Satisfaction

Everyone knows it: People make mistakes. And when it comes to manufacturing, mistakes equate to lost time, lost money and ultimately lost customers. In today’s globally competitive market, product quality has emerged as a key differentiator. But if errors are so common and easy to make – and we all know they are – how does a manufacturer guarantee that they deliver quality product all the time? The answer: Design fool-proof products and processes that minimize the potential for mistakes to occur in the first place. Enter the concept of error-proofing.

To Err is NOT Divine

What is Error Proofing?

Error-proofing is an industry term that relates to the implementation of mechanisms to prevent product defects. Also known as Poka Yoke from the Japanese ‘poke’ (inadvertent errors) and ‘yokeru’ (to avoid), error-proofing is a common-sense concept developed and popularized in that country. Based on the philosophy that even the smallest number of defects is unacceptable, Poka Yoke maintains that the best way to eliminate defects is to prevent them from happening in the first place.

In general, there are three keys to stopping the proliferation of defects: Awareness, Detection and Prevention.

Awareness involves the acknowledgement of breakdowns in the manufacturing/assembly process and employing training, audio-visual aids and general assistance for personnel to combat those issues.

Detection introduces manual or automated inspection techniques to filter out defects.

Prevention which includes process improvements or automation to ensure no errors are (or can be) made.

Essentially, error-proofing drastically reduces defects through a combined effort of preventing errors and catching those that have been made as soon as possible. Awareness and detection techniques are crucial but, ideally, this effort is about focus on prevention. Everyday examples of prevention-centric error-proofing include a dialog box on your computer asking if you want to save a file before closing it, childproof caps on medicine bottles or speed-dial buttons on your phone that improve accuracy as well as speed. Industry examples range from simple color-coding to distinguish between components that otherwise look similar to a sensor connected to the electric nut-runner in an automobile plant that triggers a horn if a suspension assembly is moved to the next operation before a bolt is properly tightened. Sensors play a key role in error-proofing, and while most are used as simple detection devices, there are also a few sensors designed to be used as preventive measures.

Awareness Detection Prevention

Sensors in Error-Proofing

Sensors are employed at various stages throughout the manufacturing process to either initiate warnings such as audible or visual alarms (for low defect processes and those where part repairs can be made), process shutdown (for applications where problems must be corrected before production can resume, processes with higher defect rates and those where part repair is not possible), or auto-correction controls to provide an integrated test-feedback-repair loop.

In manufacturing and assembly, there are four basic types of errors:

• Missing Parts • Misassembled parts • Incorrect processing • Incorrect partsThe sensors used to detect these mishaps are of all shapes, sizes and technologies from standard inductive proximity and photoelectric sensors to vision sensors capable of analyzing a complex image and providing simple feedback, as well as specialty sensors designed specifically for the prevention aspect of error-proofing applications.

Discrete output (standard on/off ) sensors are the most common in error-proofing applications, used primarily to determine presence and positioning of a part or a feature on a part. Limit switches are cost-effective and easy to apply, but the fact that their operation requires contact with the part prohibits their use from many applications. Inductive sensors

are generally the most economical non-contact solution, assuming the parts to be detected are metallic and the sensor can be mounted close enough to the workpiece for the relatively small sensing ranges (less than 40mm) associated with inductive sensing technology. Available in a broad range of sizes, barrel/body materials and wiring configurations, inductive sensors are available in small barrel models ideal for space-critical applications, as well as flat pack and extended range versions for those applications where maximum sensing distance is key. Inductive proximity sensors are also extremely rugged – especially stainless steel-bodied and cube-style models – making them a good all-around error-proofing solution in harsh industrial environments.

For applications requiring increased sensing distances and/or detection of non-metallic parts, discrete photoelectric sensors are often the best – and simplest – solution. Infrared sensors in standard sensing modes (diffuse, retroreflective and transmitted beam) as well as more specialized sensors in background/foreground suppression, wide angle and fixed focus modes, address the lion’s share of error-proofing applications. Laser-based models are also available for sensing extremely small parts and part features at a relatively greater distance.

Specialized photoelectric sensors designed with error-proofing processes

in mind are available that address those situations where standard sensing

packages are not suitable or are too difficult to apply. Photoelectric light arrays utilizing

two-dimensional scanning technology can create a light screen to sense an object regardless

of its orientation provided that one axial dimension meets the minimum resolution

requirements. This is ideal for the detection of parts being ejected from a machine and

a host of other applications focused on “early detection” error-proofing.

application example


F E A T U R E A R T I C L E

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The MultiSight is an optical multi-pixel sensor with a pass/fail PNP output. Using three different methods of evaluation (pattern matching, contrast, and brightness), the MultiSight can detect or differentiate objects by means of previously defined optical characteristics, e.g. for separating “good” and “bad” parts. The main applications are in the field of industrial automation for quality assurance purposes. The MultiSight is an easy-to-use economical alternative to conventional vision systems for detecting presence or absence, completeness, position, markings, labeling, packaging, and components. For details on the 48MS MultiSight and its application, see Tech Tips, page 16.

No matter what you call it – error-proofing or Poka Yoke – sensors are an integral

part of the quality control process. And there’s no shortage of sensing technologies to effectively

address all your error-proofing applications, whether it’s simple presence sensing or complex

inspection. A complete and successful error-proofing effort will most likely involve a mix of these

sensing technologies as well as audio-visual aids, awareness training for personnel and some

creative thinking in the development of new preventative processes. All are key to driving not

only product quality, but customer satisfaction; manufacturing errors only become product

defects if they make it out the door – and into your customer’s hands.

Sensors in Error-Proofing continued

This same scanning technology is also used in Parts Verification Arrays (PVA) that are specifically geared toward error prevention, notably in bin picking applications. By spanning the sensing fields of multiple PVAs across assembly station bins and wiring them into a controller programmed with the necessary logic, a virtually error-free bin-picking process can be achieved. ‘Job lights’ on the sensors not only show the assembler the bins required to complete the current process, but will also indicate the correct picking sequence. In the event the assembler attempts to pick an incorrect part, a selectable warning light illuminates to indicate the error; additional fault enunciation can be achieved via controller logic in conjunction with a tower light or audible alarm.

Analog output sensors on the other hand, are used for precise part positioning with continuous monitoring. Associated with true distance/position measurement, analog output sensors provide a linear current or voltage output (4-20mA or 0-10V, respectively), often in conjunction with discrete switchpoints. While many inductive, ultrasonic and photoelectric sensors are offered in analog versions, the precision of laser measurement sensors has made them the predominant technology for error-proofing applications including not only distance measurement and position verification, but such diverse functions as part profiling, thickness measurement, hole depth checking and material warpage detection.

At the high-end of the sensing spectrum for error-proofing applications is vision technology, ranging from standalone vision sensors to complete vision systems. Complete vision systems are used for complex inspection applications and require the integration of a camera, lighting, a processor (usually a PC) and software, typically involving a fair degree of customization and programming expertise. But for many error-proofing applications, vision systems are overkill and cost-prohibitive. As a result, vision sensors have emerged as the preferred technology for applications requiring economical yet advanced sensing for determining presence or absence, completeness, position, markings, labeling, packaging and components. Vision sensors combine an imaging device, lighting and the necessary logic into a single, self-contained unit that provides a simple Pass/Fail output. Using multiple methods of evaluation (pattern matching, contrast and brightness) to detect or differentiate objects by means of previously defined optical characteristics, this Pass/Fail output is used to separate good parts from defective ones. Detection parameters are set up through simple configuration of pre-defined functions as opposed to the detailed software programming associated with vision systems. For more details on vision sensors, their operation and how they differ from vision systems, see Tech Tips on page 16.

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Transmitted beam photoelectric light arrays such as the Allen-Bradley 45AST utilize two-dimensional scanning technology to sense an object regardless of its orientation. This is ideal for the detection of parts being ejected from a machine as shown in the application to the left.

45PVA Bin Picking ApplicationIn this assembly process, an Allen-Bradley 45PVA is used for preventative error-proofing to show the worker the proper picking sequence and alert them in the event of a mis-pick.

• The PLC tells Bin 1 it is next and the Part Verification Array on Bin 1 lights up green. When the user selects from Bin 1, this is a ‘good’ selection. The process then moves on to the next step.

• But if the PLC tells Bin 3 it is next and the user selects from Bin 1, the Bin 1 PVA red warning light turns on indicating a ‘bad’ pick. An optional audible alarm could also be triggered by the PLC to indicate the error.

Using three different met(pattern matching, contrathe MultiSight can detectobjects by means of prevcharacteristics, e.g. for sep“bad” parts. The main appfield of industrial automaMultiSight is an easy-to-uvision systems for detectiposition, markings, labelion the 48MS MultiSight a

y

application examples

The new Allen-Bradley 45CPD laser measurement sensor is ideal for industrial applications requiring long range detection (up to 6m) with a small beam spot and non-contact measurement. The 45CPD is set up easily by mounting the sensor with the target within the sensing range and teaching the appropriate set-points for the application via convenient Teach-In buttons on the top of the sensor. In this application example, the 45CPD is used to determine dashboard presence and positioning in automotive assembly.


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Semtorq cuts wiring

time and costs with a

complete On-Machine

solution

C U S T O M E R S U C C E S S S T O R I E S F E AT U R I N G A L L E N - B R A D L E Y P R O D U C T S A N D S E R V I C E S

When Semtorq, a specialty automation systems manufacturer located in Aurora, Ohio, was preparing to introduce one of their signature machines – a welding tip dresser – to the global market, they knew that the machine would have to deliver what Semtorq equipment was already known for: quick uptime, little to no downtime and optimized OEE (Overall Equipment Efficiency). They also knew that one of the keys to maintaining that success was delivering the right solution at the right cost level – not an easy task, especially when it came to delivering

an innovative control system. Semtorq turned to Rockwell Automation, with whom they had much success in the past, to help them develop a modular control solution that would allow them to reach their defined goals – and a host of others.

A HISTORY OF SUCCESS – BY THE NUMBERS

Semtorq has been doing in-house mechanical and electrical machine design and fabrication for over 30 years, specializing

in build-to-order assembly stations and weld cells. Initially, the company was in the business of making letters, numbers

and signs – a good example is the metal lettering you see on the tops of mailboxes. They even patented the fabrication

process as well as the “kitting” of those letters and numbers for various applications.

As the business grew, Semtorq began fabricating brackets, small tools and machines to support their customers, which

led to their selling welding equipment. When one of their welding machine customers went bankrupt, Semtorq bought

that company in an effort to get their consigned welding equipment back which resulted in Semtorq not only getting a

floor full of equipment, but in their inheritance of a slew of welding customers. Just like that, Semtorq was officially in the

welding business. Joe Seme, President of Semtorq remembers, “Everything was Allen-Bradley – selector switches, relays…I

can’t tell you how many relay panels I’ve wired, how many relay diagrams I’ve drawn. Over the years, whenever we needed

some help and support, Rockwell Automation was always there to help us through the problems, sorting out issues,

moving us through generations of selector switches and relays to PLCs and panels.”

That relationship resulted in a long string of successes, one of which was a clean room machine for medical product

assembly. Semtorq, Rockwell Automation® and Rexel Midland, the local distributor, collaborated to build a control

architecture that included DeviceNetTM components with plug-and-play connectivity. Each machine station was outfitted

with plug-in I/O modules so that each station could be unplugged from the

main assembly and easily reassembled on-site. “When you plugged it all back in,

the machine started right up,” says Seme. “We still needed a panel to house the

components the customer wanted in the cabinet, notably the servo controls since

the servos at the time were open frame and would generate heat and move dust

around. They weren’t suitable for use in a clean room application without being

enclosed. But the lion’s share of control components were out on the machine.”

Over time, Semtorq integrated more plug-and-play components on their machines. And

with the industry changing so rapidly, Semtorq’s customers trusted Seme and his team

to do some discovery for them, supplying a broad spec that would allow Semtorq to

choose the best components to achieve the best solution at the right cost level.

And one of the areas that was ripe for cost savings was the control wiring. “We’re always

working toward trying to reduce the manpower to do the wiring jobs,” explains Seme.

“Wiring is expensive – you start adding it up, that’s a lot of time and money. We work

to reduce that. Some of the things that Rockwell Automation introduced to us are the

plug-in modules from the PLC rack to the terminal strip. It’s been a savings from the

panel wiring standpoint, but we’re tending to try to go to more plug-in, right out to

smart devices.”

Creeping up on what Rockwell Automation calls a complete On-MachineTM solution,

Semtorq would carry that plug-and-play momentum into their welding tip dresser, one

of their bread-and-butter machines that they planned to launch as a standard product

to the global market.

MAKING THE ON-MACHINE CONNECTION

“On-Machine” is a control design philosophy that moves the industrial controls and

hardware closer to the application or on the machine while minimizing the number

of components in the cabinet. The result is increased uptime and lower costs through

reduced wiring time; pre-configured, quick connect components as well as simplified

wiring layout and connections enable faster maintenance and repair – these were all the

things Semtorq was looking for. Joe Seme and his team thought a complete On-Machine

approach would be ideal for their new weld cells featuring quick-coupled DeviceNet

on robotically-held interchangeable dies and tip dresser, with on-board sensors.

They turned to Rockwell Automation and Rexel Midland to brainstorm on a system

that would allow them to realize their customer’s goals as well as their own.

So what is a welding tip dresser? Electric welding tips (or electrodes) wear out after

approximately 250 welds. Over the course of its lifetime, a welding electrode can distort

and grow in diameter by 25%, resulting in a reduction of current density in the tip and

ultimately the loss of welding capability. Traditional systems compensate by increasing

stepper circuits to boost heat, leading to the need for oversized transformers, the

introduction of additional EMF and the overall degradation of the welding circuit.

A tip dresser is essentially a portable milling machine – similar to a pencil sharpener –

that alleviates this issue by cleaning and restoring the tip to its original shape, increasing

electrode life and effectiveness.

Dressing Up

a Weld Cell

C U S TO M E R

PROF I L E


The plug-and-play components and DeviceNet architecture made for a completely

modular machine that could be assembled and tested quickly at the shop – and

at the job site – while requiring only a fraction of the wiring time associated

with typical point-to-point wiring. According to Joe Seme, “The cell is mechanically

assembled first with the wiring to follow. Since the wiring is done last, that is the piece

that always gets compressed in a time crunch. The reduction in wiring time we realized

through the On-Machine solution is crucial to our ability to make custom machines

while maintaining Just In Time delivery.”

SHOWING OFF ON-MACHINE

“It was terrific to see Semtorq’s confidence and enthusiasm about the value the

On-Machine solution could bring to themselves and their customers,” says

Mark Eitzman, Product Marketing, Rockwell Automation. “Their ability to recognize

and leverage the value of architectures sets them apart in the market,” Eitzman

continues. “Not only do they deliver a cutting-edge machine with optimal performance

and cost-efficiency, but they ensure their customers reap the benefits of simplified

installation and troubleshooting as well as the potential to extract valuable information

via network architectures.”

Semtorq’s relationship with Rockwell Automation and Rexel Midland has helped make

that a reality. Joe Seme elaborates, “We’ve always had a great working relationship and

were able to get Rockwell Automation and Rexel Midland to immediately come help out

– we’ve never had a problem getting support. Overall, when we work with those guys,

they come in with ideas that help us get to a point where we understand how these

architectures could work for us to make things easier for Semtorq and its customers.”

The success of that collaboration was in full view at Automation Fair 2006 in Baltimore,

where the Semtorq weld cell with the electrode tip dresser was in the spotlight as

part of the On-Machine solutions booth. It even got the attention of a film crew – Joe

Seme was interviewed and the machine was filmed as part of a video library on weld

cell design, Just-In-Time delivery and lean factory processes. And when it came down

to assembling the tip dresser on the show floor, Joe Seme summarizes by saying what

he’ll be able to say about all future Semtorq machines: “On-Machine allows you to put

components right out at the station, right where you need them. It’s a pretty clean

plug-and-play; it’s a cable, it’s a hook-up and everything just plugs together. And if

you’re doing a big integration job where there are multiple lines, you can build modular

stations and when you go to install, the installation time is much quicker – you’re not

paying for a lot of rigging and electricians time. The overall cost impact is less expensive.

Plus, from the customer’s side, it’s a lot easier for them to troubleshoot – they don’t have

tons of wires to worry about.”

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C U S T O M E R S U C C E S S S T O R I E S F E AT U R I N G A L L E N - B R A D L E Y P R O D U C T S A N D S E R V I C E S

C U S TO M E R

PROF I L E

The tip dresser is used as part of a multi-function weld cell designed around a robotic arm which grabs multiple

fixtures and positions them for the welding process (or in other cases, gluing, screw-driving or another assembly

process). The robotic arm quick-changes between fixtures so an operator can load one station while the robot is

working on another fixture.

The final On-Machine solution the team designed took full advantage of DeviceNet and the modular

components offered by Rockwell Automation. Not only was Semtorq able to capitalize on the quick assembly

and significantly reduced wiring time associated with the plug-and-play capabilities of On-Machine, but they

were able to provide a standard machine that was fast, efficient and easily integrated with their customer’s

existing facilities and processes.

Using DeviceNet, Semtorq was able to achieve the low build cost they were looking for while getting the

fast network speed needed for high speed applications. Each fixture was set up as a DeviceNet node, outfitted

with all the necessary Allen-BradleyTM sensors to check presence and position of the work-pieces by sensing

the clamping tool. The sensors were interfaced through weld-slag resistant Armor WeldBlockTM I/O via

Allen-Bradley quick-disconnect TPE (Thermoplastic Elastomer) patchcords. When the robot picks up each fixture,

the DeviceNet network detects the presence of the node within 250ms, allowing for quick fixture changeout

and ultimately a fast machine. The quick coupled DeviceNet interface gave them the reliability they need since

the controller now recognized all active I/O through the network connection. In the past, multiple conductors

would be sent through the robotic arm to the die. They were never 100% certain all the I/O was being picked

up on the die.

In addition, Allen-Bradley 836E solid-state pressure switches are tied into the pneumatic circuit to measure

the welding gun clamping pressure while a DeviceNet ArmorStartTM provides distributed motor control,

fault diagnostics (for failed motor or tip dresser jams), additional on-board I/O (for external devices including

blow-off valves and vacuum collection systems) as well as integrated lockout/tagout functionality. Allen-Bradley

Guardmaster light curtains and e-stops are interfaced through safety distibution boxes for machine guarding.

All components reside on DeviceNet interfaced through a CompactLogix Programmable Automation Controller.

S


TIPS

E C HHIGHLIGHTING THE

LATEST TRENDS

IN VISION SENSING

TECHNOLOGY

MultiSight Vision SensorCustomer satisfaction, product quality and high-yield manufacturing processes drive just about every market you can think of, and the term ‘error-proofing’ continues to be identified as one of the key initiatives to reaching today’s heightened goals in those areas. Error-proofing, in general, is a combined effort of awareness, detection and prevention techniques aimed at eliminating manufacturing defects. As it relates to industrial control, error-proofing is the application of technology – primarily sensors – to detect and ultimately prevent mistakes throughout the entire manufacturing or assembly process. Sensors of all kinds are used as the primary methods of inspection, ranging from the use of inductive proximity and photoelectric sensors for simple presence and positioning detection to complex vision systems for more elaborate inspection applications. But in recent years the emergence of vision sensors that bridge the gap between presence sensors and vision systems has helped to address a range of applications for which simple presence sensors weren’t suitable yet vision systems were overkill, both functionally and economically. This article will describe the functionality of vision sensing technology, illustrate the multiple methods of detection and show how they are used in error-proofing applications.

101

Presence Sensing vs. VisionPresence sensors are the most common and inexpensive error-proofing method. Generally used to confirm part presence and positioning for a manufacturing process, discrete sensors address simple error-proofing applications to determine if parts are missing, improperly assembled or in the correct position for the next manufacturing process. More advanced models such as laser measurement sensors can be used to detect a part feature and provide a continuous analog output for more precise feedback and positioning. The wide range of technologies and feature sets make standard presence sensors capable of addressing the bulk of error-proofing processes, but there are more complex error-proofing methods that standard sensors simply cannot handle. The alternative – until the introduction of vision sensors – was to employ high-end vision systems.

At the opposite end of the spectrum in terms of complexity and performance, vision systems consist of a camera placed at the point of inspection, a separate processor (either a specialized stand-alone processing module or PC), software and lighting. Vision systems, in many cases, are customized to suit the application and therefore require a full assessment of camera performance, custom software with high level programming (C, Visual Basic or a host of other proprietary languages) and often require an integrator for design, setup, troubleshooting and expansions (e.g. the addition of cameras for multiple inspections). The price tag for these complete solutions can start as low as $2,000 for an entry-level system, but can often climb upwards of $15,000. For a number of complex error-proofing efforts a vision system is the only solution, however, with the growing number of middle-of-the-road applications where vision systems are too advanced and sensors are not sophisticated enough, vision sensors entered the market to cover the broad area between.

Vision sensors, often known as multi-pixel sensors, bridge the gap between presence sensors and vision systems. Based on the same concept as vision systems but with the compact, self-contained design of a sensor, vision sensors are an ideal hybrid at a more appropriate cost point (generally less than $2,000) for moderately complex error-proofing installations. These stand-alone solutions contain multiple virtual detectors (allowing them to inspect multiple features), integrated lighting and basic on-board logic that delivers a single Pass/Fail output to the control system, as opposed to the

detailed data transferred by a vision system. And unlike vision systems, these sensors do not require high level programming; configuration is achieved by selecting pre-defined functions through simple software. Plus, vision sensors are frequently designed in rugged, water-tight (IP67) housings more suitable for industrial applications when compared to vision systems.

The Allen-Bradley 48MS MultiSight is an example of an optical vision sensor with a Pass/Fail PNP-type output. The MultiSight addresses those difficult applications that standard presence sensors cannot handle – thread detection, print confirmation and complex inspection, just to name a few – and does so while allowing for a degree of part position uncertainty that standard sensors cannot tolerate. That is, the MultiSight can check a part that is not in the exact same place every time, allowing for a degree of x- and y-axis flexibility. MultiSight is also an ideal solution for applications involving product mix and, therefore, machine process changeovers without the complex and time consuming setup required for standard sensors. Consisting of a self-contained imager (camera), lens, processing, I/O and lighting in a compact, IP67 package, the MultiSight contains multiple virtual detectors that can be logically linked or grouped for evaluation/inspection of multiple parts or part characteristics. It does this by employing three different evaluation methods – Pattern Matching, Contrast and Brightness – to detect or differentiate objects by means of previously defined optical characteristics, e.g. for separating “good” parts from “bad.” All aspects of these detection methods and product performance are selected easily through the supplied software, which is required only for configuration.

48 MS

Trigger Sensor

Cordset (48MS-CS-x)

Trigger Sensor Output

Power

I/O

Inspection Target

Fig 1. Typical MultiSight application setup

Vision Sensor BasicsThe image recorder of the MultiSight is a CCD chip with a resolution of 640 x 480 pixels. The sensor is designed for inspection and cannot provide measurement information. To operate the MultiSight, at least one virtual detector must be configured by designating a Region of Interest and defining tolerance levels; this virtual detector configuration is stored in the sensor’s non-volatile flash memory for reference when the sensor is in stand-alone operation mode (after configuration via PC or PLC is complete). The following sections of this article explain in detail the three different detection methods used by the MultiSight, and how those methods are employed in error-proofing applications.

1716 www.klinkmann.com6 / 2011

TIPS

E C H

BrightnessThe MultiSight uses an 8 bit gray-scale CCD chip to capture images. The chip assigns each pixel a value of 0 (black) to 255 (white). The Brightness Detector Type evaluates all pixels that are darker than gray-scale value 128 as dark, while anything above this value is considered bright. The detector examines the Region of Interest (ROI) and determines the brightness level by counting the number of bright pixels. If the brightness level falls between the configured minimum and maximum threshold levels, the detector passes the evaluation. While the position of each dark or bright pixel within the ROI does not affect the evaluation, the shutter speed of the imager has a significant effect on the number of pixels which are evaluated as dark and thus which images pass or fail this inspection.

Example: The two images below (Figure 6) produce exactly the same result in the brightness evaluation because in each case 9 of the 25 pixels are detected as dark. T

The Future of Vision SensingToday, vision sensors effectively fill the gap between standard sensors and complete vision systems. However, as the technology matures, vision sensors will start to blur the line between themselves and vision systems by offering higher functionality that rivals that of full systems. With future developments involving EtherNet/IP connectivity and the addition of virtual detectors (up to 32), MultiSight vision sensors will have the ability to pass additional data to the control system, provide simple position information and issue individual detector results, allowing them to address a wider (and more challenging) range of error-proofing applications without the complexity and cost associated with complete vision systems.

Fig 10.

Application ExamplesThe following are sample applications illustrating how the MultiSight’s various detection methods might be used.

In Figure 8, the MultiSight employs the Pattern Matching detector type to confirm that the holes are present and that they have been threaded.

Figure 9 shows the MultiSight verifying that a date code has been printed by using a Contrast detector type. When the date code is printed, the contrast is high; when it is not printed, the contrast is low. The MultiSight detects the difference between the contrast levels to determine if the date code has been printed.

Detection of an aerosol can nozzle and label using Pattern Matching and Brightness detector types is illustrated in Figure 10. In this application, two virtual detectors are configured and then logically linked to generate a single pass/fail output. The MultiSight detects the presence of both the nozzle and the label. The first virtual detector is configured with a detector type of Pattern Matching to detect the nozzle. The second detector uses Brightness evaluation determine label presence. The MultiSight performs an AND function on the results of the two detectors to generate a single pass/fail output.

Hole and thread detection via Pattern Matching

Fig 8.

Contrast detection for print confirmation

Fig 9.

Date code verification through Pattern Matching and Brightness detection

During MultiSight configuration, the user can define how the multiple detectors work together to determine the state of the pass/fail output. A detector can be stand-alone (inspection of a single characteristic), logically linked (multiple inspections on a single part), or grouped (multiple inspections on different parts).

Each component is inspected by a single detector. Detectors are subsequently linked logically for the inspection of multiple components or features of a product. The evaluation result of each detector is combined with the evaluation results of all the other detectors, resulting in a single pass/fail output. If the AND (All) logic is selected in the software, all selected detectors must pass evaluation for the MultiSight to

issue a PASS output. (If any single detector sees a defect, the sensor indicates a FAIL condition.) When OR (Search) logic is selected, the output gives a PASS indication in the event that any one of the detectors passes its evaluation.

The grouping of detectors makes it possible to check several characteristics on different parts without reconnecting the software during part changes. For example, during the first production shift of the day Part A is inspected for several characteristics, then during the second production shift Part B is inspected for a different set of characteristics. The sensor can be changed to evaluate either Part A or Part B without the user having to reconnect to the software via the Ethernet port.

Linking and Grouping Virtual Detectors

Pattern MatchingWith this evaluation method, the virtual detector looks for a pattern in the defined Region of Interest (ROI). By defining this ROI as larger than the pattern there is some tolerance in positioning of the inspected part. In addition, when Pattern Matching is used, the MultiSight compensates for homogeneous changes in light level. During setup the sensor is taught the pattern to be evaluated, which it stores in memory as a reference image. In run mode, the MultiSight continuously evaluates the ROI on the current image and compares the detected pattern with that of the reference image by performing a pixel-by-pixel normalized gray-scale correlation to the taught pattern. The evaluated pattern must match the taught pattern to a degree of conformity greater than the minimum threshold value (and less than the maximum threshold value) as set by the user. The sensor then turns the PNP type output ON or OFF (i.e., the part passes or fails the inspection).

Example: The sensor is taught the pattern in Figure 2.

In the row of three patterns shown in Figure 3, each pattern is recognized with 100% conformity because the evaluated pattern is exactly the same as the taught pattern from Figure 2, even though it is in a different position in the Region of Interest (ROI). It differs only in X and Y position and is not rotated.

In the row of three patterns shown in Figure 4, each pattern is recognized but with less than 100% conformity. Pass or Fail result is dependent on the threshold settings (degree of conformity) as set during configuration.

Pattern detection is tolerant of up to ± 5° of rotation. The next two images (Figure 5) would be recognized. Due to the slightly rotated orientation of the pattern, the conformity would be less than 100% even though there is 100% pixel conformity. Some patterns may be recognized with a bit more rotational displacement. In general, the more complex the pattern, the less it can be rotated and still be successfully detected.

Fig 6. Brightness detection conformity

ContrastThe Contrast Detector Type evaluates the difference between the brightness levels of the pixels in the ROI. An image that is all one shade of one color has low contrast. An image that is half white and half black has very high contrast.

Fig 7. Contrast evaluation

100%

0%

5%

Fig 2.

Fig 4.

Pattern Match with less than 100% conformity

Fig 5.

Pattern Match conformity with some rotation

Fig 3.

100% Pattern MatchSample Pattern


Integrated Architecture Builder (IAB) is a FREE easy-to-use graphical tool designed to help you configure and quote Logix control systems while ensuring system and component compatibility. With the new IAB 6.0, you can build a control system quickly and easily using control system wizards as well as other common Microsoft Windows tools such as tree views, drag-and-drop, and cut-copy-paste. IAB also allows you to open a multitude of related product documentation to assist you in configuring any of these systems. As you configure a system, the software performs validity checking, and you can generate a report to be used in quoting the control system. Plus, IAB software provides you with a number of options to help you optimize your ControlLogix, FlexLogix and CompactLogix configurations, including subsystem performance checks, network wizards and DIO platform comparisons. Version 6.0 also introduces new features – connection systems reporting, additional selection wizards – and support for new products such as ArmorStart distributed motor control, Armor I/O and connectivity products, to simplify the configuration of a complete On-Machine control system.

2120

The Rockwell Automation Product Selection Toolbox offers

a complete suite of programs for product selection and

configuration across product lines from project conception

through final design. From push buttons to motor control centers

and fully networked control systems, you’ll find the product

information and configuration assistance you need to help

your customers succeed with Rockwell Automation.

DESIGN LOGIX-BASED AND ON-MACHINE CONTROL SOLUTIONS ACCURATELY AND EFFICIENTLY WITH FREE SOFTWARE

"Integrated Architecture Builder (IAB) is a software tool for configuring Logix-based control

systems, including Distributed I/O and On-Machine cabling," says Pete Baron, Field Marketing

Service Leader, Rockwell Automation. "It helps you select equipment and generate bills of

material for NetLinx-based networks (DeviceNet, ControlNet, and EtherNet/IP)."

The Toolbox can be downloaded from www.ab.com/e-tools

or installed by ordering the DVD - Free!

Simplify the configuration of your

Logix-based and On-Machine systems

with Integrated Architecture Builder

6.0 from Rockwell Automation

FREE

Helps you specify the right equipment, ensuring compatibility and performance

Configures and generates bills of material including physical media for NetLinx-based networks (i.e., EtherNet/IP, ControlNet, and DeviceNet)

Easy-to-use drag-and-drop interface

Control platform ‘wizards’ to simplify design of your control system

Provides a graphical representation of your configurations

Performs system checking and generates system-level reports

Enhanced to simplify component selection and system design for On-Machine solutions

KEY BENEFITS

Project BOM A printable and exportable (Excel and XML) list of components for the entire control system, including all chassis, power supplies, modules and network media. You can also add supporting items such as software or services to the BOM.

Quick BOM A printable and exportable list of products for a particular subsystem, hardware or network view

Connection Systems reports Using convenient wizards, you can easily configure On-Machine cabling for each port of ArmorPoint, ArmorBlock and MaXum I/O modules. The wizard returns a printable graphical report that shows all the cables and connectors configured in an easy-to-read format.

Subsystem Wizards Quickly configure a controller, network and I/O by entering application data into wizard screens. The wizards apply rules and use parameters you can specify to automatically select controller, I/O modules, communication modules, power supplies and network configuration.

Drag & Drop Add modules to chassis and devices to networks by simply selecting items from a list of compatible items and dragging them into a network or chassis view.

Add Hardware Manually add individual chassis and other items, then add modules through drag & drop.

In addition to interactive design support, Integrated Architecture Builder produces several helpful reports:

ProposalWorks provides access

to information on a broad range of

Allen-Bradley products and services.

It features an easy-to-use product selection

interface to make it a snap to determine

the exact catalog number for the item

you need. You also get access to

current list pricing and supplemental

product information.

This proposal generation software contains

additional features such as customizable

documents, On-Machine connectivity

wizards, spare parts and services generators,

and the ability to break down a composite

number into separate parts.

CrossWorks is a tool available online

and as a desktop application which allows

you to easily cross reference competitive

catalog numbers to similar Allen-Bradley

products. If there is no cross found in

our database the desktop application

can be used to submit a cross directly

to Rockwell Automation for review.

eCADworks allows you to select

product 3D CAD drawings in AutoCAD.

This tool allows you access to thousands of

drawings for a wide range of Allen-Bradley

products and get assistance configuring

catalog numbers.

Rail Builder simplifies the design,

accuracy and order process for custom

Allen-Bradley DIN-Rails. This easy-to-use

software helps you identify, place and label

terminal blocks, circuit protection blocks,

relays and power supplies needed on a

mounting rail, and includes the necessary

supporting components such as end

barriers and partition plates. Once design

is complete, Rail Builder provides reports

to make ordering easy.

CenterONE is an intuitive software

application designed specifically for

configuring Motor Control Centers.

The user friendly interface helps reduce

errors and enables customers to get their

MCC's quickly.

MCS Star helps you configure Motor

Control System starters for rated motor

voltages from 230V up to 690V. The

program provides the correct catalog

number, wiring diagram and layout

drawing for the starters of your choice.

You even get assistance in selecting and

dimensioning all of the required busbar

rack components.

MotionAnalyzer assists the user

in selecting the correct motor for the

application, the proper drive, and a

gearbox (if required) and has effective

optimization capabilities that allow the

user to get the most out of the selected

motor and drive combination.

Restore and Backup allows you to

save and restore complex configurations

and any other critical program data.

In addition to Integrated Architecture Builder, the Product Selection Toolbox includes:


22 23

To gain a competitive edge, you need the right strategic

mix of PREDICTIVE, PREVENTIVE and REACTIVE maintenance

methods for your automation assets. Predictive methods

use comparative data to assess the probability of future

events and performance; you perform maintenance actions

when a need is identified. Preventive methods involve performing

maintenance actions on a predetermined, periodic basis to

anticipate and prepare for planned downtime. Reactive methods

involve maintenance actions only when obvious problems occur.

Optimize the Performance and Utilization of Your Automation Assets to Meet your Production and Business Goals.

Maintain Uptime and Competitive Advantage with the Rockwell Automation

Remote Support Services

Rockwell Automation®

Services & Support

For more information about our Remote Support Services go to:

www.rockwellautomation.com/services/remote. For information on the

complete Rockwell Automation Services & Support portfolio, see the inside

back cover or go to: www.rockwellautomation.com/services

One of the most essential elements in a successful

maintenance strategy is implementation of an efficient and

highly specialized technical support structure that addresses

the unique needs of your application and automation

environment, enabling you to identify and resolve problems

quickly, minimizing unplanned downtime, increasing your

productivity and improving your financial stability.

Rockwell Automation® Remote Support Services,

one of eight major service groups within the Rockwell

Automation Services & Support portfolio, can help you

achieve your production and business goals. Our Remote

Support Services offer real-time troubleshooting and

monitoring of automation equipment and systems by

off-site automation specialists. Numerous service levels

and customization options are available to meet your

specific maintenance needs.

Among our Remote Support Services is TechConnectSM

Support, which offers three levels of support:

DirectConnectSM, eConnectSM, and PriorityConnectSM.

DirectConnect supplements your internal technical resources

with unlimited real-time phone support from product

support specialists at Rockwell Automation. DirectConnect

also gives you the ability to submit online support requests,

obtain software updates and access electronic technical

resources (including special knowledgebase features and

functions) to help you to obtain technical information and

troubleshoot problems prior to calling for support.

If you have non-critical support issues that do not require

immediate resolution, few planned process improvements,

or significant internal troubleshooting staff, eConnect will

give you the ability to submit online support requests,

download software updates and access our electronic

technical resources.

When you need support for highly complex systems or

mission-critical processes, PriorityConnect is the right choice.

In addition to all DirectConnect features, PriorityConnect will

route your support requests (phone or online) directly to a

select group of senior support specialists with the training

and experience to handle system and process-related issues.

PriorityConnect also offers exclusive online case management

tools, proactive case handling/follow-up, and automatic

shipment of software updates.

In addition to TechConnect, Rockwell Automation offers TeamSupportTM –

our highest level of remote technical support. With TeamSupport, every time

you call it will be answered directly by a member of a designated group of

application engineers selected to meet your specific needs. The designated

team is familiar with your automation system(s) and maintenance practices

– knowledge gained by reviewing your system documentation and completing

an on-site review of your automation equipment and process. To aid in

troubleshooting, your team will also have a high speed connection to your

system to view real-time system status and data (system is accessed only when

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Similar to the standard TeamSupport Services described above, TeamSupport 360

Services add continuous monitoring of critical alarms and process parameters

by our application engineers. Typically utilized in manufacturing processes with

high downtime costs and profit sensitivity, TeamSupport 360 can often eliminate

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improvement are provided.

When you implement a strategic maintenance approach that leverages vendor

provided services and support such as Rockwell Automation Remote Support

Services, you will improve productivity and financial stability, and gain a

competitive advantage.


INDUSTRY EXPERTS

NSWER

YOUR QUESTIONShttp://support.rockwellautomation.com

http://support.rockwellautomation.com

Q I have an application where I need to detect the presence of a 1/4 inch hole in 2 inch square metal sheets moving at 1000 sheets per minute. The application has a very dark background and I would like to see the beam for ease of alignment during routine plant maintenance. What is the best solution?

A Laser sensors are ideal for applications that require small parts detection, applications that require a narrow beam width (e.g. detection of objects through a narrow slit), or detection of objects from long range. A 42EF RightSight LaserSight sensor provides a small, visible beam spot (2 x 3.5 mm) and a fast response time, making this sensor a good solution for your application.

A Yes. Water has a very high dielectric constant, so a capacitive proximity sensor would have very good performance in this application.

Q I have a conveyor line on which I would like to mount the sensors from above looking down at the products riding on the conveyor. The problem is that if I turn down the sensitivity of my diffuse sensor enough to not see the conveyor, sometimes it won't detect the product either, especially if the product is a dark color or if the lens of the sensor gets a little dirty. How can I consistently detect product with a sensor mounted from above my conveyor line?

A The answer is to use a background suppression sensor instead of a diffuse sensor. Diffuse sensors change output state based on the amount of light they see reflected off the target. If the target is dark and therefore does not reflect much light, the diffuse sensor might not detect the product. Similarly, if the lens of the diffuse sensor is dirty the sensor will not see as much light off the target and may not detect it. This issue is a more serious problem if there is anything immediately behind the target, such as a conveyor belt, which forces the user to turn down the sensitivity of the diffuse sensor. For such applications, use a background suppression sensor instead of a standard diffuse sensor. The Series 44B Background Suppression Sensor can be used for ranges up to 300mm (1 ft) and the Series 42BT and 42BC models can be used for ranges up to 2m (6.6 ft). Background Suppression sensors are designed to minimize the effect of background reflections by using a light source and dual receiver optics system with mechanically adjustable control for maximum cutoff point precision. Using the multiple turn adjustment knob on the top of the sensor, a desired cutoff point can be set to meet the specific application requirement. The sensor will detect everything up to this range and nothing beyond it. By adjusting the cutoff point to immediately above the conveyor, the sensor will ignore the conveyor while always detecting the product, even if the product is dark in color or the lens is a bit dirty.

Q What is the difference between an 871TM AC/DC PLC Interfacer proximity sensor and a standard 871TM AC/DC sensor?

A PLC Input modules are sensitive to the leakage currents from standard 2-wire sensors. Because of this, special sensors, like the 871TM PLC Interfacer, were developed to have lower leakage currents and wider operating voltages. To lower the leakage current effect when using standard sensors, you would wire a bleeder resistor in parallel with the load. Examples of how to size bleeder resistors per the PLC/SLC/etc input modules can be found on page 102 of the Inductive, Ultrasonic, and Capacitive Sensor/Programmable Controller Interface Manual which is downloadable at: http://literature.rockwellautomation.com/idc/groups/literature/documents/wd/871-wd001_-en-e.pdf

Q How fast is the MultiSight? I need to check the label on 90 packages per minute.

A The MultiSight Vision Sensor has three algorithms - pattern matching, contrast and brightness. Pattern matching is the most commonly used. For a single, simple pattern matching detector the cycle time will be about 70ms, or 14 inspections per second, more than fast enough for 90 packages per minute. Each additional detector adds about 10ms, so if you were checking 4 aspects of the label by using 4 logically linked detectors, the cycle time would be about 100ms (70ms for the first detectors plus 3 times 10ms), or 10 inspections per second. The contrast and brightness algorithms are simpler and therefore faster. A single detector will have a cycle time between 40ms and 50ms. You can always check the cycle time by setting the trigger parameter to "Continuous" and checking the bottom right-hand corner of the software screen while the sensor is in run mode.

Q I am trying to confirm that a bumper has been mounted to the front of the car frame. The problem is that the frame is just a few inches behind it and a normal diffuse photoelectric sensor will not work. Normally I would use background suppression for this type of thing, but I can't get any closer than ten feet, and no one makes a background suppression sensor with that kind of range. How do I confirm the placement of this part?

A Use one of the discrete outputs of the 45CPD Laser Measurement Sensor. Typically the analog output of this sensor is utilized for such applications, but the two teachable discrete outputs are also great for long range (up to 6m / 19.6ft) background suppression applications. Simply set up the switch point between the distances of the bumper and the frame.

Q What can I use as a replacement for the obsolete 42SRU-6402 and 42SRU-6412 Series 6000 Retroreflective Code Reader?

A The 42SRU-6402 can be replaced by the Polarized Retroreflective 42SRU-6202. The 42SRU-6412 can be replaced by the MiniSight Polarized Retroreflective 42KL-P2LB-A2. Some new mounting provisions will have to be taken into account for the 42KL, as the mounting holes are in different locations and are on different center lines from those of the Series 6000 product.

Q I'm trying to determine if a cardboard box is wet or dry. How can I do this? I’ve heard that capacitive sensors are the way to go. Is this true?


26 27

SENSORSandSWITCHESin theAutomotive Industry

ToughWeld ™ 871ZC

Proximity Sensor871D WorldClamp™

Proximity Sensor

802T NEMA

Limit Switch

871TM All

Stainless Steel

Extended Range

Proximity Sensor

871D Cylinder Position

Proximity Sensor

TPE

Patchcord

871F Weld Field

Immune Flat Pack

Proximity Sensor

836E Solid-State

Pressure Switch

802T NEMA

Limit Switch

ToughWeld™

Cordset

ToughWeld™

Patchcord

ToughWeld™ 871P

VersaCube™ Weld Field

Immune Proximity Sensor

MatGuard™ Safety Mat

ToughWeld™

Patchcords

GuardShieldTM

Safety Light

Curtains

ToughWeld™ 871ZT

Equal Sensing

Proximity Sensor

Safety Relay:

MSR22LM

Muting Module

For complete technical specifications and ordering information, refer to our Sensors, On-Machine Connectivity and Safety catalogs. Or, visit our web sites at www.ab.com/sensors and www.ab.com/safety.


28 29

theMaterial Handling Industry

898D

Distribution

Box

836E Solid State

Pressure Switch

872C WorldProx™

Proximity Sensor

440N SensaGuard™

Non-Contact

Safety Switch

44N Zone

Control Sensor

RightSight™

Photoelectric

Sensor

889D Micro Cordset

Series 9000

Photoelectric Sensor

440G-MT Solenoid

Locking Switch

44B Background/Foreground

Suppression Photoelectric Sensor

440P Safety

Limit Switch

802B NEMA Compact

Limit Switch

875CP

Capacitive

Proximity

Sensor

22ZC Zone

Controller + 44R

Photoelectric

Sensor

42CM Metal

Cylindrical

Photoelectric

Sensor

440E Lifeline 4 Cable Pull

Switch + LRTS Cable

Tensioner System

SENSORSandSWITCHESin



30 31

thePackaging Industry

440P Safety

Limit Switch

802T NEMA

Limit Switch

898D

Distribution

Box

845T Incremental

Encoder

802B NEMA Compact

Limit Switch

GuardShield™

Safety Light Curtains

MSR57 Speed

Monitor

Safety Relay

873P Ultrasonic Sensor

802M NEMA Factory

Sealed Limit Switch

837E Solid State

Temperature Switch

ColorSight™ 9000

+ 43GR Glass Fiber

Optic Cables

871TM Extended Sensing

Range Proximity Sensor

872C WorldProx™

Extended Sensing

Range Proximity Sensor

Lifeline 4 Stainless Steel

Cable Pull Switch

871TM All Stainless

Steel Proximity Sensor

(Ferrous/Non-Ferrous Selective models also available)

SENSORSandSWITCHESin



32 33

SENSORSandSWITCHESfor

installation“By developing an alternative to our traditional, chassis-based

I/O, we have been able to reduce the installation time of our conveying systems by more than 50 percent”, said

Ron Newlum, engineering manager for AEC.

designDavid Ansell adds that On-Machine™ design can be a

time-saver, “With its more simplified design, we don’t have to go through two-week turnarounds for drawings.”

10

15

13

Control Tower ™ Stack Lights, Beacons & Horns Visual and audible indication to enhance safety and increase productivity in your environment

800Z Touch Button Connector and pre-cabled options

DeviceNet™ Push Button Stations Allen-Bradley® fully-assembled DeviceNet™ push button stations satisfy environments of light industrial or instrument grade applications

PanelConnect™ The next generation of plug-and-play interface modules that offer a simple connection through an enclosed cabinet wall

ArmorPoint™ I/O Modular I/O system with thirty module types. Its tight coupling with ArmorStart™ and its multi-network support provides additional flexibility for a variety of applications

ArmorBlock™ I/O Ideal for machinery applications where only input and output status are necessary

4

6

11

7

8

12

9

14

2

16

1

Networked

Non-Networked

ArmorBlock™ I/O

DeviceNet™

Push ButtonStations

Stack Lights

802DN DeviceNet Limit Switch

842D DeviceNet ™ Multi-Turn Absolute Encoder

800Z Touch Button

Horn

Horn

Horn

871TMSensor

872C Sensor

Valve

Photoelectric Sensors


PanelConnect™

PassiveDistributionBox

PassiveDistributionBox

Trojan™ TongueInterlock Switch

MT-GD2 Tongue Interlock Switch

Safety PassiveDistribution Box

E-Stop

800Z Touch Button

3 Phase-Power

Motor

PowerFlex™ 70

Beacon

ArmorBlock™

MaXum® I/O



DeviceNet™

Auxiliary Power

ArmorPoint™ I/O

Valve Bank ArmorStart™

3 Phase-Power

Control Voltage

Motor

Stack Light

3

5

For complete product information browse our on-line catalog library at www.ab.com/catalogs

On-Machine™ Applications

costsDavid Ansell, director of controls engineering and field operations at Acco Systems Inc., says, “If we would have just compared component cost, we would have never embraced On-Machine™ technology and realized the surprisingly significant financial savings it provided us.”

plug-and-playNick Mercorella, plant engineer at Continental P.E.T. Technologies Inc., states,

“We were able to install our entire system without ever screwing a wire down, thus eliminating any potential miswiring and the system debugging cost associated

with such problems. It’s true plug-and-play, which is exactly what we needed.”

Connection Systems A broad offering of rugged cordsets, patchcords, Y-cables, distribution boxes and field-attachable connectors to suit a range of environments from light-duty conveyor applications to automotive welding installations

Photoelectric Sensors Allen-Bradley photoelectric sensors are recognized as the most robust in the industrial automation marketplace. Designed

for reliable operation, our leading products boast feature sets aimed to satisfy mainstream applications found in many industries such as

material handling, packaging, food processing, transportation… the list goes on and on

Encoders Allen-Bradley encoders are a high-quality complement to Rockwell Automation’s PLC-based motion control

offering, providing both standard and advanced DeviceNet network-enabled models to fit your architecture of choice. They

offer preferred compatibility with other Allen-Bradley servo-positioning controls to deliver a complete application solution

Proximity Sensors Allen-Bradley proximity sensors set the standard for ruggedness, reliability and application flexibility. The diverse offering serves the full spectrum of customer needs, from light-duty packaging applications to the punishing environments on automotive welding equipment or the harsh washdowns in food processing plants

Limit Switches In this globally competitive economy, one of our major goals is to help make you more competitive – that’s why we have developed one of the broadest and most durable lines of limit switches in the industry

Network Media When low node costs, multi-vendor device support and hard wiring replacements are key, turn to Allen-Bradley® network media for ControlNetTM, Ethernet and DeviceNetTM applications. These products help speed setup of your network to lower system costs and reduce maintenance time

ArmorBlock™ MaXum® I/O Excellent for applications when diagnostics and local control are required

ArmorStart™ An integrated, pre-engineered combination starter for both full voltage, reversing, and variable frequency AC drive applications

PowerFlex™ 70 PowerFlex™ 70 NEMA 4X AC Drive features a UL-listed and IP66-rated enclosure that protects against high-pressure water spray, corrosion and circulating dust

Machine Safety The broadest line of safety components in the world, teamed with first-class safety systems and services


BULLETIN 42EF RIGHTSIGHT™

When your application requires the durability and performance of a full-featured photoelectric sensor but distances are shorter and space is tight, take a 90° turn to RightSight photoelectric sensors. RightSight takes many of the features of the Series 9000 and puts them in a smaller, more adaptable package to deliver excellent detection capabilities where size and shape matter. Universal voltage (21-264V AC/DC) options with short-circuit protection across the full voltage range are available on specific models.

Diffuse, polarized retroreflective, fiber optic, transmitted beam, background suppression, teachable, fixed focus and clear object models available.

DeviceNet-enabled models offer advanced diagnostic capability

Sealed housing can withstand washdown environments up to 1200 psi

Connection types: Cable, micro (M12) connector or pico (M8) connector

18mm threaded and through-hole mounting

options make these sensors easy to install

34

photoelectric

PHOTOELECTRIC SENSING USES A BEAM OF LIGHT TO DETECT

THE PRESENCE OR ABSENCE OF AN OBJECT. This technology is

an ideal alternative to inductive proximity sensors when the required

sensing distances are longer or when the item to be sensed is non-metal.

Allen-Bradley photoelectric sensors are recognized as the most robust in

the industrial automation marketplace. Designed for reliable operation,

our leading products boast feature sets aimed to satisfy mainstream

applications found in many industries such as material handling,

packaging, food processing, transportation… the list goes on and on.

Careful selection of the right features during the design cycle allows

us to offer sensors that meet your application needs while remaining

simple and easy to apply. For more specialized applications requiring a

non-standard connector or cable, customization of sensor connections

is also available. No matter how demanding your application, there’s an

Allen-Bradley photoelectric sensor option to satisfy your needs... and

your budget.

35

photoelectric sensors

sensorsBright LEDs let you monitor

power, output and margin

from any direction

Patented right angle

enclosure fits easily

into small spaces

DISCRETE LASER SENSORS

• Available in several different package styles

• Long range sensing – up to 40 meters with a standard 3 in. reflector

• Accurate sensing of small targets such as weld nuts, mounting clips, holes, or drill bits.

BULLETINS 42CA, 42CF, AND 42CM

12 AND 18MM CYLINDRICAL PHOTOELECTRIC SENSORS

Industry-standard 12 and 18mm cylindrical packages

Ideal for embedded mounting in general purpose sensing applications

• Precise detection of objects near a background surface that should be ignored

• Ideal for conveyor lines and vibratory bowl feeders

• Ranges of up to 200 mm (42BA), 300 mm (44B), 2 m (42BT and 42BC)

• Universal voltage AC/DC models with relay output (42BC)

Housed in industry-standard 12 and 18mm cylindrical packages, Allen-Bradley 42CA, 42CF, and 42CM cylindrical photoelectric sensors are available in a wide selection of sensing modes. All three models feature a yellow LED output indicator and a variety of connection types and accessories to ease installation.

• 10-30V DC operation • NPN or PNP outputs

• Fast response time (as low as 0.5ms for background suppression 42CA)

• Transmitted beam, diffuse and polarized retroreflective sensing modes (42CA, 42CF and 42CM); background suppression and retroreflective modes (42CA and 42CM)

• Laser diffuse, polarized retroflective and transmitted beam (42CM)

Variety of connection types

Highly visible LED status indicator

BACKGROUND SUPPRESSION PHOTOELECTRIC SENSORS

Compact 50 mm package

for application in

tight spaces

High impact

acrylic housing

with industry

standard mounting

options

QD connection rotates 90° for

flexibility and ease of installation

Six-turn knob for

precise set up

Infrared LED or visible red

LED depending on range

Vertical and horizontal

side-mount mounting

brackets

1 m or 2 m

mechanically

adjusted

background

suppression

Cable or quick

disconnect

options

44B 42BT


48MS MultiSight45CPD Analog Laser Sensor

PHOTOELECTRIC

SENSORS

Description/ Features

Sensing Modes and Max. Range

Operating Voltage

Response Time

Ph

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• Stand-alone vision sensor

• Easy handling and setup

• Compact, sturdy industrial housing

with IP 67 rating

• Integrated lighting

• Adjustable focus from 20 mm to infinity

• Short evaluation time (50…100 ms)

• 3 evaluation methods: pattern

matching, brightness, and contrast

• 10 virtual detectors

• Individual virtual detectors can

be logically linked or grouped for

evaluation of different objects with

several characteristics for inspection

• Ethernet connection for setup only

• Detector algorithms: Pattern Matching,

Contrast, Brightness

• 24V DC +/-10%

• 70ms+ (Pattern Matching)

• 40ms+ (Contrast and Brightness)

• Long distance

• Non-contact measurement

• Class 1 infrared laser for operation

• Class 2 visible red laser for setup

• IP67 enclosure

• Easy setup using teach buttons

• 4-20mA Analog output

• 2 Discrete PNP outputs

• 6 m Sensing range

• 18-30V DC

• Fast/slow: 13ms/30ms

45BPD Analog Laser Sensor


• Visible red class 2 laser

• IP67 enclosure

• 270˚rotatable connector

• Easy setup using teach buttons

• 4-20mA Analog output

• Discrete PNP output

• 30-100 mm or 80-300 mm sensing range

• 18-30V DC

• 0.4ms

36

Highly visible LED stability and output indicators

MULTISIGHT™

The Allen-Bradley MultiSight from Rockwell Automation is an optical multi-pixel sensor with a pass/fail PNP output. The MultiSight uses three different methods of evaluation (pattern matching, contrast, and brightness) to detect or differentiate objects by means of previously defined optical characteristics, e.g. for separating “good” and “bad” parts. The main applications are in the field of industrial automation for quality assurance purposes. The MultiSight is an easy-to-use economical alternative to conventional vision systems for detecting presence or absence, completeness, position, markings, labeling, packaging, and components.

• Perform multiple inspections with one sensor

• Simple setup using PC and configuration software

• Multiple job storage to facilitate flexible product changeovers

• Simple inspection tools for detecting presence or absence, completeness, position, markings, labeling, packaging, and components

• Economical alternative to conventional vision system for simple inspection applications

LASER DISTANCE MEASUREMENT SENSORS• Precision distance measurement sensors

with analog output for sensing ranges from 45 mm to 6 m

• Excellent for challenging discrete applications as well - 6m background suppression sensor

• 45CPD (6m range) uses Class 1 eye safe infrared laser

photoelectric sensors

Compact package ideal for tight spaces42KC MINIATURE RECTANGULAR

PHOTOELECTRIC SENSORSPackaged in a compact rectangular housing, the 42KC photoelectric sensor is available in three sensing modes: polarized retroreflective, standard diffuse and transmitted beam. Bulletin 42KC photoelectric sensors boast sensing distances of up to 7m depending on the model selected and have highly visible LED stability and output indicators for easy operation and maintenance.

• Three sensing modes • NPN or PNP outputs • Sensitivity adjustment

2m cable or pico QD connections

SPECIAL-PURPOSE SENSORSA full line of specialty sensors solves your toughest applications using technologies such as clear object detection, part verification arrays, fork-style sensing, optical and capacitive label sensing, array scanning, and true color detection.

45BRD Analog Laser Sensor


• Visible red class 2 laser

• IP67 enclosure

• 270˚ rotatable connector

• Fixed Range

• 0-10V DC Analog output

• 45-85 mm Sensing range

• 18-28V DC

• 30ms

THE NEW FIBER OPTIC SELECTION GUIDE provides extensive technical information on the Allen-Bradley line of fiber optic cables used for photoelectric sensing applications. This document is based on the catalog pages but includes much more detail on sensing distance and other application information. Because of the differences in fiber optic cables, sensing distances can vary dramatically; that’s why each cable is now characterized to show performance with various Allen-Bradley photoelectric sensors. As a result, it is now much easier to compare models so that you can select the best sensor and cable for a given application. The Fiber Optic Selection guide is available on line in the Literature Library at www.ab.com/literature under publication number FIBERS-CA001A-EN-P.

Additional information: www.ab.com/catalogs or Fiber Optic Selection Guide FIBERS-CA001_-EN-Pwww.klinkmann.com6 / 2011

38 3938

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42CM 18mm Metal Cylindrical

42CB High Speed 18mm Cylindrical

42CF General Purpose 12mm Cylindrical

Series 9000 On/Off

• 500 microsecond response time

• Selectable LO/DO output

• Sensitivity adjustment

• Power and output indicators

• Retroreflective 7.2 m

• Polarized retroreflective 2.8 m

• Standard diffuse 150 mm

and 1000 mm

• 10 - 30V DC

• 500μsec

• 18mm industry standard package

• Wide selection of sensing modes

• 30V DC operation

• NPN or PNP outputs

• Fast response time

• Variety of connection types

• Retroreflective 4 m

• Polarized retroreflective 3 m

• Standard diffuse 100 mm (adjustable)

and 400 mm (adjustable)

• Background suppression 50 mm

and 100 mm

• Transmitted beam 14 m (adjustable)

• Laser models

• 10 - 30V DC

• 2ms (0.5ms for background suppression)


• Local teach button

• Accepts remote teach input

• Polarized retroreflective* 2m

• Standard diffuse† 100 mm and 300 mm

• Transmitted beam 4 m

• 10 - 30V DC

• 1.25 ms

• Durable housing design with 1200 psi

washdown rating

• 360° visible alignment and diagnostic

LED indicators

• Standard 30mm mounting

• Selectable light or dark-operate mode

• Teachable and linear diffuse

versions available

• Retroreflective* 9.14 m

• Polarized retroreflective* 5 m

• Standard diffuse 1.5 m†

• Long range diffuse 3 m


• Long range transmitted beam 152 m

• Infrared fiber optic

• Visible red fiber optic

• 10 - 40V DC • 10 - 55V DC, 20 - 40V AC

• 70 - 264V AC/DC • 45 - 264V AC, 40 - 264V DC

• 2-15ms

• Selectable On and/or Off delay, One Shot

or Delayed One Shot operating modes


washdown rating

• 360° visible alignment and

diagnostic LED indicators



• Retroreflective* 9.14 m• Polarized retroreflective* 5 m• Standard diffuse† 1.5 m• Long range diffuse† 3 m• Transmitted beam 61 m• Long range transmitted beam 152 m• Infrared fiber optic


• 10-40V DC • 10-55V DC, 20-40V AC

• 70-264V AC/DC • 45-264V AC, 40-264V DC

• 2-15ms

• Selectable dynamic or static diagnostic output


washdown rating


LED indicators





• Standard diffuse†. 1.5 m


• Long range transmitted beam 152 m

• 10-30V DC • 90-264V AC • 95-264V DC

• 2-15ms

• Self-teach operation

• Selectable strobing and/or COS operation

• Advanced diagnostics

• Advanced logic

• Autobaud



• Standard diffuse† 1.5 m


• ClearSight 1.2 m



• 11-24V DC

• 3ms

Additional information: www.ab.com/catalogs


Series 9000 Timing

Series 9000 Diagnostic

Series 9000 Hazardous Location

Series 9000 DeviceNet SmartSight

™

PHOTOELECTRIC

SENSORS



Operating Voltage

Response Time



Operating Voltage

Response Time

42EF RightSight LaserSight

• Class 1 visible laser

• Teach button or potentiometer

• Patented compact right angle housing

• Universal 18 mm mounting at

base and nose, and through hole

mounting

• 360° visible LED indicators

• PNP and NPN outputs

• Short circuit and reverse

polarity protection

• Polarized Retroreflective 15 m

• Diffuse 300 mm

• Transmitted Beam 40 m

• 24V DC +/- 10%

• 1ms

• 4ms (TB)

• Patented housing design with

1200 psi washdown rating§

• 360° visible indicators

• Universal 18mm mounting at base and

nose, and through hole mounting

• Short circuit protection across entire

voltage range

• Variety of output types

• Polarized retroreflective* 3m

• Retroreflective 4.5 m • Glass fiber optic*

• Diffuse 500 mm • Clear object 1.2 m

• Background suppression 50 mm, 100 mm

• Transmitted beam 20m, 4m, 8m

• DC Fixed focus diffuse 43mm,

red and green light source

• Sharp cutoff diffuse 130 mm

• DC Teachable diffuse 700 mm

• 10.8-30V DC • 21.6-264V AC/DC (N-FET)

• 0.5-8.3ms

• Universal 18mm cylindrical mounting

• Available in DC and 2-wire

AC/DC versions

• Durable housing design with

1200 psi washdown rating

• Switch selectable L.O./D.O.

• Visible indicators for power, output and

2.5x margin/short circuit protection

• Retroreflective* 5 m or 2.5 m

• Polarized retroreflective* 2 m or 1 m

• Diffuse 380 mm or 190 mm

• Wide angle diffuse 180 mm or 90 mm

• Fixed focus diffuse 43 mm or 16 mm

• Transmitted beam 30 m or 10 m

• Fiber optic, glass and plastic

• 10.8-30V DC

• 21.6-250V AC/DC

• DC =1ms • AC= 8.3 ms

• DC high speed = 300μs

42EF RightSight

• Minimal effect of target color

on sensing range

• 6 turn knob provides precise set up

• High impact acrylic housing

• NEMA 4X, 6P, IP67

• Industry standard mounting options

• 4-pin micro QD connection

with 90° swivel

• 360° visible power, output and

stability LED indicators

• Protected against mis-wiring

• Adjustable background suppression:

20 - 300 mm

• Adjustable foreground suppression:

20 - 200 mm

• 20 - 30V DC

• 1ms

44B Adjustable Background & Foreground Suppression

• Class 1 visible laser• Small spot size – 0.1 mm

@ 100 mm sensing distance• Teach button• Metal housing for heavy duty

industrial applications• 18mm cylindrical industry

standard package• PNP or NPN outputs• 2m cable or micro QD connector• Short circuit and reverse

polarity protection

• Polarized Retroreflective 30m

(w/ microcube reflector 92-118)

• Diffuse 300 mm

• Transmitted Beam 50 m

• 10 - 30V DC

• 0.5ms (TB)

• 0.7ms (diffuse and polarized retro)

42CM LaserSight

• Direct connection to DeviceNet

• Same durable RightSight package

• Advanced diagnostics

• Advanced logic features

• Selectable COS and strobing

operating modes

• Autobaud

• Selectable L.O./D.O.


• Diffuse 500 mm

• Background suppression 50 mm,

100 mm

• Transmitted beam 20 m, 4 m


• Sharp cutoff diffuse 130 mm

• 11-24V DC

• 3ms

* Distance using 3" reflector. † Distance using white paper. Distance varies, depending on sensing mode and fiber selected.

‡ Additional fiber optic sensors are available in the 5000, 6000, 7000, 9000 and 10,000 product families. See “sensing modes.” §

Patent number D401910.

• Low profile 18mm package

• Three highly visible LED indicators

(power, output and margin) on

polarized retroreflective, one

LED indicator (output) on other

sensing modes

• Short-circuit protected output

• Single and dual output versions


• Diffuse 380 mm

• Wide angle diffuse 200 mm

• Sharp cutoff 100 mm

• 10-30V DC

• 10ms

42KL MiniSight

42EF RightSight DeviceNet 44R AccuSight

42CA General Purpose 18mm Cylindrical

• Single output indicator


• Retroreflective* 4 m


• Standard diffuse† 100 mm

and 400 mm

• Background suppression

50 mm and 100 mm


• 10-30V DC

• 2ms (0.5 ms for background suppression)


• Intrinsically safe to North American standards

• Long-range, 106 m (350 ft) sensing distance

• Both NPN and PNP outputs

• 1200 psi washdown


• 24V DC using suitable safety barrier

• 10ms


Additional information: www.ab.com/catalogs40

PHOTOELECTRIC

SENSORS



Operating Voltage

Response Time



Operating Voltage

Response Time

• Ideally suited for darkroom

applications

• Reduced visible light emission


washdown rating


LED indicators



• Retroreflective 4.5 m

• Standard diffuse 0.91 m


• 10-40V DC

• 70-264V AC/DC

• 2-23ms

• Class II visible laser source

• Designed for long range and precision

sensing applications

• Same durable Series 9000 package

• Polarized retroreflective 40m

• Transmitted beam 300m

• 10-40V DC • 70-264V AC/DC

• 110-132V AC

• 500μs to 23ms

• Microprocessor-based

• LCD display for easy setup

• ControlWatch™ automatic

sensitivity adjustment

• Fuzzy logic-based diagnostics

• Self-teach operation

• ClearSight 1.2 m


• Polarized retroreflective 4.6 m

• Standard diffuse 2.7 m

• IR glass fiber optic

• VR plastic fiber optic

• Green fiber optic

• 10-30V DC

• Selectable 250μs to 4ms

• Optimized for clear object

detection

• Four types from high performance

(Series 10000), mid-range (Series

9000, pictured), to economical

(RightSight and Series 7000)

• Washdown rated models

• DC only and AC/DC models

• Variety of output types

• Polarized retroreflective up

to 1.2 m

• 10-40V DC

• 70-264V AC/DC

• 0.5 to 10ms

Ph

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• Adjustable long range background

suppression sensing mode

• Industry accepted housing design

• 360° visible status indicators

• DC and AC only models

• Transistor or EM-Relay output models

• Screw terminal connections

• Background Suppression 1 m and 2 m

• 12-24C DC 30mA

• 24-240V AC/DC, 30mA (DC), 15mA (AC)

• 20ms • 30ms

• L.O./D.O. switch


• Output indicators (red)

• Stability output (green) on NPN models

• Sharp cutoff diffuse†

- small sensor 30 mm/50 mm

- large sensor 100 mm/200 mm

• 12-24V DC

• 0.35ms

• 2-dimensional Array Scanning Technology

• Minimum object resolution

from 11 mm to 17 mm

• IP67 rated housing

• PNP or NPN output

• Scanning technology

800 mm or 2 m

• 12-24V DC

• 4-8 ms

• Back-lit LCD display • Self-Teach • Off delay

• Automatic or manual sensitivity adjustment

• Dual channel interference protection

• Selectable L.O. / D.O.

• “Power Bus” feature reduces wiring

• Visible red, blue, green, or white light source

• No tools required to attach/remove

fiber optic cables

• Retroreflective (bifurcated fiber)

• Standard diffuse (bifurcated fiber)

• Transmitted beam (individual fiber)

• 12-24V DC

• 600μs

• 35mm object resolution

• Robust aluminum enclosure

• Four heights to choose from

• Highly visible JOB and FAULT indicators

• Crosstalk immunity

• Low voltage DC operation

• Pick-to-Light sensor for bin

picking applications

• Optional protective metal brackets

• Transmitted beam 2 m (4 sizes)

• Retroreflective 2 m / Diffuse 400 mm

selectable (2 sizes)

• 12-24V DC

• 25-94ms (TB) • 120ms (Retro/Diffuse)

42BA Miniature Rectangular 45AST Area Array

45PVA Parts Verification Array

42BC Long Range Background Suppression

Bulletin 45FVL Digital Fiber Optic

• Adjustable sensing range

• LO/DO switch selectable

• NPN/PNP complementary outputs

• Infrared LED or visible red LED

depending on range

• 2m cable connection

• 1m or 2m mechanically adjusted

background suppression

• 12-24V DC

• 2ms

• Class 2 laser

• Selectable NPN or PNP outputs

• Rotatable focus lens allows

adjustment of laser spot to 0.5 mm

(0.01in)


• Fast response time


diffuse 50 mm to 300 mm

• 10-30V DC

• 200μsec

• True RGB color detection

• 8 color match precision settings

• Local and remote self-teach operation

• Pulse stretcher for high-speed

applications

• Glass fiber optic

• 10-30V DC

• Selectable 1.3ms to 10ms

• Cross-talk protection for up to 8 grouped units

• Selectable L.O. / D.O.

• “Power Bus” feature reduces wiring

• Stability output

• Visible red or white light source

• Dual LED indicators: Output (Orange),

Stability (Green)

• 8-turn sensitivity adjustment

• No tools required to attach/ remove

fiber optic cables

• Retroreflective (bifurcated fiber)

• Standard diffuse (bifurcated fiber)

• Transmitted beam (individual fiber)

• 12-24V DC

• 30μs, 250μs, or 500μs

Bulletin 45FSL Slim DIN-Rail Fiber Optic

• Senses clear labels on clear backing

• Senses opaque labels on clear backing

• Senses metallic labels on clear backing

• User interface lockout feature

• Heavy-duty metal housing

• Counts 50,000 labels per minute with

registration error less than 0.01 inch

• Capacitive (0.76 mm gap)

• 11-26V DC

• 10 μsec

45LFM Capacitive Label Sensor




• One-touch local and remote teach capability

• Fast 50μsec response time

• NPN/PNP output

• User interface lockout feature

• Transmitted beam (3 mm gap)

• 10-30V DC

• 50μsec

45LPT Optical Label Sensor

Additional information: www.ab.com/catalogsAdditional information: www.ab.com/catalogs

Series 9000 Darkroom

Gate Entry Sensing Solutions

Series 9000 LaserSight

Series 9000 ColorSight

Series 10,000

ClearSight Series

45MLD Diffuse Laser

42BT Background Suppression

• UL325 recognized vehicle gate entry solutions

• Based on industry proven Series 9000 sensors

• NEMA 4X, 6P, IP67 and 1200 psi washdown rating

• Offered as kits or individual components

• Standard UL508 listed sensors also available as kits

• 360° visible alignment and diagnostic LED

indicators

• SPDT electro-mechanical relay output

• Protected against mis-wiring

• UL325: Retroreflective 9.14 m (30ft.)

• UL508 Kits: Retroreflective 9.14 m,

Transmitted beam 61m

• 10 -55V DC/20 -40 V AC

• 70 - 264V AC/DC

• 15ms



PHOTOELECTRIC

SENSORS



Operating Voltage

Response Time



Operating Voltage

Response Time

45LST Optical Fork Sensor

• Fast 30μsec response time for

selected model

• NPN/PNP output

• cULus listed and CE marked for

all applicable directives

• Transmitted beam

(2-225 mm gap)

• 10-30V DC

• 30μs to 1ms

Ph

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(except transmitted beam)

• Stability (green) and output (red)

indicators (all models)

• Polarized retroreflective* 1.5 m



• 12-24V DC

• 0.5ms


• Output indicator




• Wide angle diffuse† 380 mm

• Fixed focus diffuse† 27.9 mm

• Transmitted beam 36.5 m



• Sharp cutoff diffuse† 76 mm

• 10-30V DC

• 20-132V AC/DC

• 20-264V AC/DC

• 0.2-18ms

• Selectable light or dark operate modes

• Separate head, base, output and timing

modules for increased flexibility

• 24V DC, 120V AC, 240V AC operation


• Retroreflective* 6 m – 10 m


• Standard diffuse† 1.5 m – 3 m

• Background suppression diffuse† 6.3-30.5 cm

• Wide angle diffuse 0.46 m

• Fixed focus diffuse† 50.8 mm



• 102-132V AC • 204-254V AC

• 10-30V DC • 40-54V AC/DC

• 20-30V AC/DC

• 1-20ms




• Alignment test points

• Plug-in timing and logic modules



• Standard diffuse† 3.6 m


• 102-132V AC • 195-253V AC

• 40-58V AC • 18-28V AC/DC

• 5-20ms

• Wide variety of sensing tips

• Individual and bifurcated

• PVC and Stainless steel sheathing

• Wide variety of metal and plastic

mounting brackets

• Large selection of reflectors

• Vertical/horizontal alignment brackets

Series 7000 LTD Miniature Rectangular

• Basic low cost version

• Single output indicator

• Reverse polarity protection

• Ease of installation and

maintenance

• Retroreflective* 2 m/3.6 m


• Anti-glare retroreflective*

2 m/3.6 m

• Transmitted beam 6.4 m

• 10-30V DC

• 1ms

• FM approved intrinsically safe design

• Multiple sensing modes

• Compatible with Series 897H IS barriers

• Modular housing design

• Screw terminal connections


• Polarized Retroreflective 6 m

• Standard Diffuse 2.1 m

• Infrared Fiber Optic/Fixed Focus/

Wide Angle Diffuse

• 13-29.5V DC

• 1ms

Series 6000 CompactSeries 5000 Red Line, Blue Line, Green Line

Series 5000 Intrinsically Safe

42KC Miniature Rectangular

• Selectable red or green light source

• 250μs response time

• Manual or automatic gain control

• Adjustable time delay

• Gating and latch functions

• Diagnostic output

• Color registration mark control 12.7 mm

• 10 - 30 V DC

• 0.25ms

Series 4000 42CRC Color Mark Detection



• Stability output (green)

on NPN models

• Output indicator (red)

• Retroreflective* 2 m

• Standard diffuse† 70 mm/200 mm/

300 mm/400 mm

• Transmitted beam 1 m/7 m/10 m

• Sharp cutoff diffuse 30 mm/40 mm

• 12-24V DC

• 0.35ms

42KB Micro Rectangular

• Very small package size

• Some models

with sensitivity adjustment

• Stability (green) and output (red)

indicators

• Standard diffuse† 30 mm/50 mm

• Sharp cutoff diffuse† 30 mm

• Transmitted beam 500 mm

• 12-24V DC

• 24V DC ±10% (Transmitted beam)

• 0.5ms

42KA Subminiature Flat Pack

Series 7000 Miniature Rectangular

• Compact general purpose sensor


• Output (red) indicator

• Small size

• Fast 500μsec response time


• Polarized retroreflective* 1.98 m


• Wide angle diffuse† 280 mm

• Fixed focus diffuse† 15 mm

• Transmitted beam 7.6 m/4.2 m


• Transparent object detection

• 11-28V DC

• 0.5-1.5ms




44N Zone Control Sensor

• Integrated zone control logic

• Supports singulation and slug

operation

• Compatible with a variety of valves

• Polarized retroreflective sense mode

• Durable housing and connections

• Low voltage DC operation

• Polarized Retroreflective 50.8 mm to

4.8 m (with 92-39 reflector)

• 10-30V DC

• Variable 200ms to 10s

22ZC Zone Control System

• Selectable pneumatic or powered roller

zone control logic

• Selectable advanced zone logic functions

• Selectable RUN/STOP delay timers

• Accepts mechanical or photoelectric

sensor inputs

• Drives pneumatic valve or powered

roller driver

• Proven flat cable IDC technology

• Compatible with a wide variety of

photoelectric and mechanical switches

• 24V DC

• 1ms


Series 4000 42RL Full Size Photoelectric AccessoriesFiber Optic Cables


Output indicator:

360° visibility

44

proximity sensors

ALLEN-BRADLEY PROXIMITY SENSORS SET THE

STANDARD FOR RUGGEDNESS, RELIABILITY AND

APPLICATION FLEXIBILITY. Choose from one of the industry’s

widest selections of inductive, capacitive and ultrasonic proximity

sensor models, all of which offer you no-touch object detection.

The most commonly-used proximity sensor is the inductive

type, which generates an electromagnetic field to sense metal

objects passing close to its face. This is usually the easiest sensing

technology to apply in applications where the metal object to be

detected is within an inch or two of the sensor face. The diverse

Allen-Bradley offering serves the full spectrum of customer

needs, from light-duty packaging applications to the punishing

environments on automotive welding equipment or the harsh

washdowns in food processing plants.

45

proximity sensors

• Stainless steel face and barrel for high strength

• Available with abrasion resistant, fire retardant ToughLink™ cable that exceeds SOOW-A requirements

• 1200psi (8270kPa) washdown capability and IP69K enclosure rating for contaminant and fluid ingress resistance

• Electrical protections against short circuits, overload, transient noise, false pulses and reverse polarity (DC models) to help reduce downtime and maintenance costs

• Extended range models allow greater distance between sensor and target, reducing the likelihood of damage from collision

BULLETIN 871P – VERSACUBE™

Long-range sensing, versatility and durability are all hallmarks of these special sensors. With sensing ranges of up to 40 mm for general purpose models and 35 mm for ToughWeld weld-field immune models, they provide great application flexibility. Certain models are now available with our ToughCoat Finish for improved weld slag resistance.

A unique five-way mount makes them easier to mount and adjust than any comparable sensor – all in a rugged, durable housing.

Same mounting hole pattern as similar cube style sensors

and limit switch style models for easy retrofitting

Electrical protection against short circuit, overload,false pulse,

transient noise, reverse polarity

Convenient, flexible mounting with a single screwdriver

Standard and weld-field immune models available

BULLETIN 871TM INDUCTIVE PROXIMITY SENSORS

Historically, the metalworking, food processing and material handling industries have been tough on sensors. Whether your application is in one of these industries or in another where the conditions are just as difficult, the Bulletin 871TM has been designed for you. It keeps you competitive by helping to keep production up and running.

Grommet strain relief

provides an interlock

between housing,

grommet and cable

ToughLink™ cable resists abrasion,

chemicals, fire and “wicking”

A specially formulated epoxy provides a secondary seal and

vibration resistance, resists impact, has low thermal expansion/

contraction and helps prevent coil/face separation

Grommet and LED lens resist

fluid or chemical penetration

Leak-proof

front end

Stainless steel face and barrel

resist impacts and abrasion

Long sensing range

5-position sensing face in one unit

Rugged and durable housing

(also available with

ToughCoatTM

Finish)

Compact size

Mini and micro quick-disconnect models

Standard, short barrel and

small barrel versions

Protected against transient

noise, short circuits, overload,

false pulse and reverse polarity

IP67 (IEC 529) and NEMA 6P

enclosure ratings

• Built using advanced manufacturing techniques for lower cost, to help you stay competitive

• 360°-viewable output indicators for easy operation and maintenance

• Electrical protections against short circuits, overload, transient noise, false pulses and reverse polarity (DC models) to help reduce downtime and maintenance costs

• Four connection options plus a wide range of barrel sizes (from 6.5 mm to 30 mm) for application flexibility

BULLETIN 872C AND 872CP WORLDPROX™

INDUCTIVE PROXIMITY SENSORS

The international marketplace is changing, demanding greater productivity, efficiency and reliability than ever before. Allen-Bradley WorldProx inductive proximity sensors can help you meet those demands. These general-purpose solid-state devices feature either a nickel-plated brass housing with a plastic face (872C) or an all-plastic face and barrel (872CP) at an economical price. And because they are both UL and c-UL listed as well as CE marked for applicable directives, you can count on wide-ranging acceptance in many global markets.

IP69K enclosure rating


871TM PLC Interfacer 871TM DeviceNet 872C WorldProx872C WorldProx Short Barrel

PROXIMITY

SENSORS


Nominal Sensing Distance

Diameter/Height

Shielding

Connections



Diameter/Height

Shielding

Connections

PR

OX

IMIT

Y S

EN

SO

RS

Selection Guide

• Stainless steel sensing face and barrel

• AC/DC in one device or DC only

• AC/DC models have 2 LEDs – power

on, output energized (flashing in

shorted condition); DC models have

1 LED – output energized

• DC models short barrel only

• Both 3-wire DC and 2-wire DC

models available

• 10-30V DC, 40-250V AC/DC

• 12mm: 2–4 mm

(extended range models 6–10 mm)

• 18mm: 5–8 mm


• 30mm: 10–1 5mm


• 8, 12, 18, 30 mm

• Shielded or unshielded

• PVC cable • ToughLink™ cable

• Mini QD • Micro QD

• Stainless steel sensing face

and barrel

• 12, 18, 30 mm diameter barrel

• NO or NC outputs

• Sensor ignores non-ferrous metals

• 10-30V DC

• Sensing distance from 1–8 mm

• 12, 18, 30 mm

• Shielded




and barrel

• 12,18, 30 mm diameter barrel

• NO or NC outputs

• Sensor ignores ferrous metals

• 10-30V DC


• 12, 18, 30 mm

• Shielded



47


and barrel

• 2-wire DC operation

• Intrinsically safe per FM and

CSA standards

• Standard barrel length

• 10-31.5V DC


• 12, 18, 30 mm



• Micro QD

871TM All-Stainless Steel

871TM Ferrous Selective

871TM Non-Ferrous Selective

871TM Hazardous Location

BULLETIN 871F – FLAT PACK

When your application demands long-range metal sensing, the 871F family of flat pack style sensors are a solid choice. Engineered for enhanced toughness and flexibility, the latest flat pack offers one of the longest sensing distances in the industry. This increased sensing distance reduces target-to-sensor impact by allowing the sensor to be mounted at a safer distance from the target area. The durable one-piece housing provides superior resistance to the elements thanks to a redesigned mechanical seal, rugged shroud construction and full epoxy encapsulation. Superior LED visibility and complementary outputs on standard models add even more appeal to this feature-rich inductive proximity sensor. Weld-field immune models also available.

IP67 (IEC529) IP69K and NEMA 6P enclosure ratings, 1200 psi washdown rating

Mini and micro quick-disconnect, ToughLink cable, and conduit

connection styles

Electrical protection: short circuit, overload, false pulse, transient noise,

reverse polarity


and barrel

• Designed for low load current PLC,

I/O, and PC applications

• Short barrel only

• 20-250V AC/DC


• 12, 18, 30 mm




• Stainless steel sensing face and barrel

• Direct connection to DeviceNet

• Autobaud • Teach/learn

• Discrete and Analog output

• Diagnostics: object too close,

too far, target always in, always out,

sensor operational

• Timing functions, motion detection

• 11-25V DC

• Sensing distances from 5–15 mm

• 1 8, 30 mm


• PVC cable • Mini QD

• Micro QD

• Threaded nickel plated brass barrel

• 360° LED

• 3-wire DC and 2-wire DC models

12, 18, 30 mm available.

(8 mm will be available in 2008)

• Relay output, QuadroPlex and Comp.

Output models available

• 10-30V DC


• 6.5, 8, 12, 18, 30 mm


• PVC and PUR cable

• Mini QD (18 and 30 mm

models only)

• Micro QD

• Pico QD (6.5, 8, 12, and 18 mm

models only)

• Threaded nickel plated brass barrel

• 360° LED • 3-wire operation

• 10-30V DC


• 12, 18, 30 mm


• PVC and PUR cable

• Mini QD (18 and 30 mm

models only)

• Micro QD

• Pico QD (12 and 18 mm

models only)

One-piece housing cover

DIN rail

mounting

capability

Industry standard mounting pattern

Long sensing range 50mm shielded,

65mm unshielded

TOUGHWELD BULLETIN 871ZC –

WELD-FIELD IMMUNE COPPER BARREL

Bulletin 871ZC inductive proximity sensors are designed for automotive welding applications and other environments where large magnetic fields are present. The rugged copper barrel resists chipping and wear, which helps avoid the weld slag accumulation that can cause other sensors to fail or lock on. Shielded models are now available with our ToughCoat Finish on the sensor face for improved weld slag resistance. The 871ZC 3-wire DC is available in 12, 18 and 30mm shielded and unshielded housings with a micro quick-disconnect connector. The 871ZC 2-wire AC/DC is offered in 12, 18 and 30 mm shielded configurations in micro and mini quick-disconnect styles.

High LED visibility

Heat resistant thermoset

plastic face (optional

ToughCoatTM

Finish available)

Weld-slag resistant

copper housing

Weld-field immune circuitry

TOUGHWELD BULLETIN 871Z –

WELD-FIELD IMMUNE PTFE-COATED BARREL

The Bulletin 871Z inductive proximity sensor provides a weld-field immune solution for both AC/DC and 3-wire DC applications. Its PTFE-coated housing resists weld slag while its specialized circuitry provides immunity to magnetic-field strengths exceeding 20,000A at 1 inch from the welding tip.

Weld-field immune circuitry for AC and DC applications

PTFE-coated housing resists weld slag

46


Additional information: www.ab.com/catalogswww.klinkmann.com6 / 2011


PROXIMITY

SENSORS



Diameter/Height

Shielding

Connections



Diameter/Height

Shielding

Connections

• Threaded nickel plated

brass barrel

• 360° LED

• 3-wire operation

• 10-30V DC

• Sensing distances from

4–20 mm

• 12, 18, 30 mm (8 mm will

be available in 2008)


• PVC cable

• Micro QD


brass barrel

• 360° LED

• 2-wire AC only operation

• 20-240V AC – 8 mm

• 20-250V AC


1–15 mm

• 8, 12, 18, 30 mm


• PVC cable

• Mini QD

• Micro QD


brass barrel

• 2-wire AC/DC operation

• 360° LED

• 20-250V AC/DC


2–15 mm

• 12, 18, 30 mm


• PVC cable

• Micro QD

• Threaded plastic barrel

• 10-30V DC


3–15 mm

• 12, 18, 30 mm


• PVC cable •

Micro QD

49

872C WorldProx Extended Sensing

872C WorldProx AC

872C WorldProx AC/DC

872CP WorldProx Polymer Barrel

871C NAMUR

871C Small Barrel

871C Polymer Barrel

871C Analog Output


brass barrel

• Intrinsically safe per FM,

CSA and CENELEC standards

• Meets DIN 19234 NAMUR

standard

• Short barrel length

• 5-15V DC (8.2V DC nominal)


1–15 mm

• 8, 12, 18, 30 mm


• PVC cable

• Micro QD

• Threaded or smooth nIckel

plated brass barrel

• Available in 3, 4, and 5 mm

diameter models

• Threaded and smooth

barrel models

• 10-30V DC


0.6–1 mm

• 3, 4, 5 mm

• Shielded

• PVC cable

• Pico QD

• Threaded plastic barrel

• 24-250V AC


5–15 mm

• 18, 30 mm


• PVC cable

• Threaded nickel plated brass

barrel

• Analog output


• 18-30V DC


.5–14 mm

• 12, 18, 30 mm


• PVC cable

PR

OX

IMIT

Y S

EN

SO

RS

Selection Guide

49

• Threaded copper barrel, thermoset

plastic face

• Weld field immune

• Available with or without

ToughCoat Finish

• Barrel and face resist weld slag

• 40–250V AC/DC, 10–30V DC


• 12, 18, 30 mm

• Shielded (AC/DC models)

• Shielded or unshielded (DC models)

• Mini QD

• Micro QD

• Nickel plated brass or aluminum body, stainless steel

probe, ceramic face • Weld-field immune circuitry

• Rugged low profile housing

• 3,000 psi (207 bar max.) pressure rated

• Housing 304 degree rotatable after installation

without breaking pressure seal

• Multiple standard probe lengths available

• 10-30V DC, 20-250V AC/DC

• 2 mm

• 37 mm (installed)

• Shielded

• Mini QD

• Micro QD

• Plastic housing • Weld field immune

• Superior LED visibility

• 100mm, 165mm and 200mm lead lengths available

• Small and large chicklet sizes available

• Industry standard mounting

• 10-30V DC, 20-150V AC/DC

• 2 mm

• 10-30V DC

• 20-150V AC/DC

• Shielded

• Micro QD

871ZC Weld Field Immune

871D Cylinder Position

871D WorldClamp Style

871C Polymer Barrel

• Threaded PTFE-coated barrel

• PTFE-coated mounting nuts


• Thermoset or PTFE face

• Fire retardant cable

• 10-30V DC, 40-250V AC/DC


• 12, 18, 30 mm

• Shielded

• ToughLink™ cable (AC/DC models)

• Mini QD

• Micro QD

871Z Weld-Field Immune

871P VersaCube

• Plastic housing, metal mounting base

• Weld field immune models available

• Available with or without ToughCoat Finish

• 5-position sensing head

• Rugged burn and weld-slag resistant housing

• Flexible mounting options allow retrofit to other cube

style and limit switch style sensors

• 10-60V DC, 20-250V AC/DC

• Equal sensing models available

• 15 or 25 mm

• 40 mm


• Mini QD

• Micro QD

802PR Limit Switch Style

871L/872L Limit Switch Style

• Plastic body, 17-position head

• Limit switch style has limit switch mounting dimensions

• 2-wire AC, 2-wire AC/DC or 3-wire DC

• Switch selectable NO or NC output (871L)

• Programmable NO or NC output (872L)

• Sensing ranges up to 40mm

• 10-60V DC, 20-250V AC/DC (871L)

• 20-250V AC, 10-30V DC (872L)

• 20 or 40 mm

• 120 mm


• Terminal w/ threaded conduit opening

• Mini QD

• Micro QD

• Solid state output • Top or side sensing models

• 90° indexing sensing heads • Corrosion resistant models

• Hazardous location models

• Limit switch mounting dimensions

• General Purpose • 1 amp output

• 20-250V AC/DC • 60-132V AC or 102-132V AC

• 17 mm

• 117-131 mm

• Shielded

• ToughLink™ cable

• Micro and Mini QD

• Terminals with threaded conduit

opening or conduit coupler

• 13 mm

• 117-131 mm

• Shielded

• STO cable

• Mini QD

• Terminals with threaded conduit

opening or conduit coupler





50

PROXIMITY

SENSORS



Diameter/Height

Shielding

Connections



Diameter/Height

Shielding

Connections

871FM Miniature Flat Pack

871F Flat Pack Standard and Weld-Field Immune

871F Block Style

871P Can Sensor

871R Ring

875C Capacitive

875CP Capacitive


• 11-12 mm


• PVC cable

• Plastic body

• Cable, terminal chamber or

quick-disconnect models

• DC models incorporate reverse

polarity, short circuit and

overload protection

• AC/DC models incorporate short

circuit and overload protection

• Sensing ranges to 65 mm


• 10-30V DC, 20-250V AC/DC

• Standard: 50–65 mm

• WFI: 40–50 mm

• 80 mm



• Terminals w/threaded conduit

opening • ToughLink™ cable

• Cast aluminum body

• Adjustable sensing range up to 70 mm

• 10-30V DC

• 70 mm

• 100 mm

• Unshielded

• PVC cable

• Micro QD

• Aluminum body

• 12 mm, 20 mm, 50 mm,

100 mm ring diameters


• 10-30V DC

• Sensing distances from 2.5–8 mm

• 24-44 mm

• Shielded

• PVC cable

• Micro QD

• Nickel plated brass barrel

• Capacitive technology senses

metals and non-metals,

liquid and solids

• Adjustable sensing distance

• 3-wire DC and 2-wire AC models

• 10-48V DC, 24-240V AC


• 12, 18, 30 mm (DC models)

• 18, 30 mm (AC models)

• Shielded

• PVC cable

• Pico QD (18 mm DC models)

• Micro QD (30 mm)

• Plastic barrel

• Capacitive technology senses

metals and non-metals, liquid

and solid

• 2-wire AC and 3-wire DC models

• Adjustable sensing distance

• 10-48V DC, 24-240V AC


• 18, 30, 34 mm

• Unshielded

• PVC cable

• Pico QD (18 mm DC models)

• Micro QD (30 & 34 mm)


• 10-12 mm


• PVC cable

• Pico QD

• Rugged stainless steel housing

• Short and long range models for

different can sizes

• DC can-motion detection model

available

• 10-30V DC, 30-150V AC/DC

• Sensing distances from 19–2 9 mm

• 38.1-44.5 mm

• Shielded

• PVC cable (10-30V DC models)

• Mini QD

PR

OX

IMIT

Y S

EN

SO

RS

Selection Guide

51

• Plastic barrel

• 2 programmable setpoints via

setup pushbutton

• 2 discrete and 1 analog output

• Analog output scaled between setpoints

• Discrete outputs can be programmed

for NO or NC

• 19-30V DC


• 30 mm

• N/A

• Micro QD

• Nickel plated brass barrel

• Metal, non-metal solid and liquid

sensing capability

• Adjustable sensing range

(switching models)

• Adjustable background suppression

(analog models)

• 18-30V DC


• 30 mm

• N/A

• PVC cable 2 m

• Plastic body

• Ideal solution for sensing clear materials

including glass or plastic bottles

• Designed to food industry standards

• 11-30V DC


• 69 mm

• N/A

• 300V PVC cable 2 m

873P Ultrasonic Programmable

873C Ultrasonic

873E RightSound Ultrasonic

• Plastic barrel

• Analog or discrete models

• Adjustable sensing distance for

discrete models

• Control pin for hold and

synchronize functions

• 18-30V DC


• 18, 30 mm

• N/A

• Micro QD

873P Ultrasonic Standard Analog or Discrete

proximity sensors



• Plastic body

• 2-wire AC and 3-wire DC models

• Four compact sizes: 28 x 16 x 11 mm, 40 x 26 x 12 mm,

25 x 50 x 10 mm (DC models) and 31 x 18 x 10 mm

• 10-30V DC • 90-250V AC


52 53

limit switches

IN THIS GLOBALLY COMPETITIVE

ECONOMY, ONE OF OUR MAJOR GOALS IS

TO HELP MAKE YOU MORE COMPETITIVE.

That's why we have developed one of the

broadest and most durable lines of limit

switches in the industry.

A limit switch is an electro-mechanical device

that consists of an actuator mechanically

linked to a set of contacts. When an object

comes into contact with the actuator, the

device operates the contacts to make or

break an electrical connection. Limit switches

are used in a variety of applications and

environments because of their ruggedness,

simple visible operation, ease of installation

and reliability of operation.

limit switches

BULLETIN 802T

LIMIT SWITCHES

802Ts are ideal for applications in which heavy-duty pilot ratings, a high degree of versatility and rugged NEMA Type 4 and 13 oil-tight (6P on select rotary shaft models) enclosures are desired, including:

• Conveyor systems

• Transfer machines

• Automatic turret lathes

• Milling and boring machines

• Radial drills

Pull-and-turn mode change on lever

style models allows easy selection

between clockwise operation,

counter-clockwise or both

Patented 3-way shaft seal design

offers superior fluid resistance

Front-mount design allows

mounting without exposing

electrical connections

Quad-ring seal

between operating

head and switch body BULLETIN 802M/MC

PRE-WIRED LIMIT SWITCHES

Bulletin 802M and 802MC compact pre-wired limit switches are factory-sealed to meet the demanding requirements for NEMA Type 1, 4, 4X, 6P, 13 and IP67 enclosures (802MC). A large variety of operating heads and levers are available to suit a wide range of applications, especially where the switch may be subject to washdowns, streams of coolant, or occasionally submerged in fluids commonly found on machines or in industrial processes.

• Pre-wired and factory-sealed

• Can withstand submersion under conditions exceeding NEMA 6P requirements

• Corrosion resistant (802MC models)

Patented Allen-Bradley 3-way

fluoroelastomer shaft seal

Highly resistant seals on cover,

cable entry and wire strands

prevent ingress of dust or fluids

Pre-wired cable or

connector saves

time and eliminates

internal wiring

Field convertible head to operate

clockwise, counter-clockwise or both

Stainless steel shaft and

hardware (802MC models)

Castle lock head design

Diaphragm seal between

operating head and switch

body offers extra protection

against contaminants when

operating head is removed

Mounts with two equal-

length screws for simplified

installation and hardware

requirements

Castle lock head design

NEMA 6P seals provide

enhanced protection

against fluid ingress

(select rotary

shaft models only)


54 55

BULLETIN 440P INTERNATIONAL STYLE LIMIT SWITCHES

The 440P limit switch family offers a full range of international style solutions for both safety and standard sensing applications. Available in three different body styles – 30 mm metal, 22 mm plastic and 15 mm plastic – with a broad selection of operator types, circuit arrangements and connection options, the 440P is ideal for a wide variety of applications. These include material handling, packaging, elevators, escalators, scissor lifts, industrial trucks and tractors, cranes and hoists, and overhead doors as well as general safety guarding applications.

The 22 mm plastic body style is available in positive

opening action two- and three-circuit models, with

seven different operator types:

• adjustable roller lever

• long adjustable roller

• adjustable rubber roller lever

• short lever

• hinge lever

• roller plunger

• dome plunger

• offset hinge lever

The metal body, 30 mm x 60 mm style is available in

positive opening action two- and four-circuit models

and seven different operator types:

• metal roller plunger

• metal dome plunger

• metal short lever

• metal adjustable lever

• metal rod lever

• metal spring rod

• telescopic arm

Large selection of actuator heads

Head can be rotated in 90° increments

before installation for ease of mounting

BULLETIN 802B COMPACT, PRECISION AND

SMALL PRECISION LIMIT SWITCHES

The 802B family of Allen-Bradley limit switches is designed to withstand today’s tough industrial environments. Its compact but rugged enclosure makes the 802B ideal for mounting in areas too small for traditional NEMA-style limit switches. Each model features a die-cast housing for durability as well as industry-standard mounting dimensions and operating characteristics for optimal application flexibility.

The compact style housing boasts a pre-wired 3-meter cable or connector version and triple-sealed construction, giving it NEMA 6 and IP67 enclosure ratings. The precision line offers 5 unique head configurations that can be ordered in two mounting styles: side mount or flange mount. Each different head is available as standard or with a rubber boot for additional sealing. The small precision family offers additional features in an even smaller package, providing a washdown-rated housing with 12 different head configurations.

Industry-standard mounting for easy

application within existing designs

limit switches

1/2" NPT conduit entry

for easier installation

Booted heads available for

superior enclosure sealing

Multiple actuator styles for

maximum flexibility

Multiple actuator styles

for maximum flexibility

Triple-sealed construction for superior performance in washdown applications

Die-cast metal housings

for increased ruggedness

3-meter cable and connector versions

available for application flexibility

PRECISION

COMPACT

SMALL PRECISION

IP66 enclosure protection

Available in either 22 mm mounting

with plastic body or 30 mm x 60 mm

mounting with metal body

The 15 mm plastic switch is available

with a roller plunger actuator.

Three mounting styles: side mount,

diagonal mount, flange mount

Gang mountable


56 57

LIMIT

SWITCHES

• Plug-in construction provides quick

and easy installation

• New front-mounting design with

equal-length mounting screws

make it easy to apply

• Simple mode-change mechanism

in head for easy setup

• 0° to 230° F (-18° to 110° C)

• Optional: -40° to 230° F

(-40° to 110° C)

• Lever, maintained, low operating

force, top and side push (with

or without rollers), cat whisker,

wobble stick, neutral position

• NEMA 4, & 13

(6P – select side rotary models)


Actuators

Enclosure Classification

1

LIM

IT S

WIT

CH

ES

Selection Guide

802T

Safety Plug-In

1485P

KwikLink Splice Kits

• Compact metal body is pre-wired to

maintain enclosure seals. Industry

standard mounting for ease of

installation

• 14° to 158° F (-10° to 70° C)

• Rotary arm, center rotary arm, wobble

stick, top push, top push bevel, top

push roller, top push cross roller, top

push panel mount, top push roller

panel mount, top push cross roller

panel mount (last three options also

available in booted versions)

• NEMA 1, 3, 4, 6, 12, 13 and IP67


Actuators

Enclosure Classification

1

802B

Compact

802B

Precision

802B

Small Precision

802T

Plug-In

871C Small Barrel

871C Polymer Barrel

802X

Hazardous Location

802XR

Sealed Contact Hazardous Location

801

General Purpose

802DN

DeviceNet

802G

Gravity Return

802X

Watertight

• For use in control reliable and

safety applications per ISO 14119• NEMA style mounting dimensions• Rugged metal construction for

harsh industrial environments• Plug-in style for quick and easy

installation• 0° to 230° F (-18° to 110° C)• Cable versions 0° to 140° F

(-18° to 60° C)

• Lever, top push roller, side

push vertical roller, side push

horizontal roller

• NEMA 4, 12, 13, 6P; IP67

1 Enclosures are designed and tested to the listed NEMA ratings (Ref. NEMA standard ICS 1-110)

• Precision style limit switch

available with industry standard

or flange mounting. Low trip

and reset points for more precise

sensing.

• 14° to 176° F (-10° to 80° C)

• Top push, top push roller,

top push cross roller, roller

lever, one-way roller lever; all

available in booted versions

• Non-Booted: NEMA 1 and IP60

• Booted: NEMA 1,3,4 and IP65

• Small Precision limit switches are

metal bodied for use in industrial

applications. 12 different styles

available for solving multiple

applications.

• 14° to 176° F (-10° to 80° C)

• Top push, top push roller, top

push cross roller, hinge lever,

short hinge lever, roller lever,

short roller lever, one-way roller

lever, short one-way roller lever

• NEMA 1,3,4,6,13 and IP67

871C NAMUR

• NEMA-style limit switch with direct

connection to DeviceNet networks

• 0 to 130° F (-18° to 54° C)

• Autobaud

• Dual outputs with distinct

programmable operating angles

• Teach and learn angle

• Each output programmable to N.O. or N.C.

• Programmable travel to reset (hysteresis)

• Configurable counters with resets on

each output

• Lever style

• NEMA 1, 4, 6P, 13 and IP67

• Plug-in gravity return switch,

designed for conveyor-type

operations with small or

lightweight objects

• 32° to 230° F (0° to 110° C)

• Stainless steel rod levers

• NEMA 1

• NEMA 4: Designed for

watertight applications

• -50° to 250° F (-46° to 121° C)

• Lever, maintained, top and side

push (with or without rollers),

wobble stick, neutral position

• NEMA 4

• NEMA Type 7 & 9: Designed for

hazardous locations

• -50° to 250° F (-46° to 121° C),

based on actuator type (refer to

catalog pages for details)

• Lever, maintained top and side


wobble stick

• NEMA 7, 9

• Class I, Groups B, C, or D

• Class II, Groups E, F or G

• Class III

• Designed for hazardous locations.

Contains a sealed glass contact

switch for greater contact

reliability

• -20° to 250° F (-29° to 121° C),

based on actuator type (refer to

catalog pages for details)



wobble stick

• NEMA 7, 9

• Class I, Groups B, C, or D

• Class II, Groups E, F or G

• General purpose limit switch for

a wide variety of applications

• 32° to 104° F (0° to 40° C)

• Lever, maintained, slow action,

snap action, ratchet type

• NEMA 1, 4, 7 & 9

802MC

Corrosion Resistant

• Compact, pre-wired switch

is factory sealed to meet the

requirements of demanding

applications, wet or dry• 32° to 180° F (0° to 80° C)

• Lever

• NEMA 1, 4, 4X, 6P & 13; IP67

• Exceeds requirements for NEMA 6P

802T

Non-Plug-In Style

• The non-plug-in limit switch

is ideal for applications which

require heavy-duty pilot ratings,

a high degree of versatility and a

rugged, oil-tight construction

• 0° to 130° F (-18° to 54° C)

• Optional: -20° to 250° F

(-29° to 121° C)




wobble stick, neutral position,

dual switch lever, air operated

• NEMA 13

802M

Factory Sealed

• Compact, pre-wired switch

is factory sealed to meet the

requirements of demanding

applications, wet or dry• 32° to 180° F (0° to 80° C)



neutral position

• NEMA 1, 4, 6P & 13

• Exceeds requirements for NEMA 6P

802R

Sealed Contact

• Similar in construction to the 802T

non-plug-in. A glass hermetically-

sealed reed switch is used as the

switching element to provide high

contact reliability

• -20° to 250° F (-29° to 121° C)




wobble stick

• NEMA 13

• Conforms to EN50047

(22 mm mounting)

• Glass reinforced thermoplastic

housing

• Most feature direct opening contacts

designed to meet IEC 947. Available

in snap-acting, slow make/ break

with 2 or 3 pole contact arrangement.

• Heads can be rotated in 90 degree

increments for flexible mounting

• -18° to 176° F (-25° to 80° C)

• Roller plunger, dome plunger, hinge

lever, short lever, offset hinge,

adjustable lever, large rubber roller

• IP66

440P-C

International Small Plastic

• Conforms to EN50041

(30 mm x 60 mm mounting)

• Cast aluminum housing

• Most feature direct opening

contacts designed to meet IEC

947. Available in snap-acting, slow

make/ break with 2, 3 or 4 pole

contact arrangement.

• Heads can be rotated in 90 degree

increments for flexible mounting

• -18° to 176° F (-25° to 80° C)

• Roller plunger, dome plunger,

short lever, adjustable lever, rod

lever, spring rod, telescope arm

• IP66

440P-M

International Large Metal


Additional information: www.ab.com/catalogs Additional information: www.ab.com/catalogs

Note: Temperature ratings below +32° F (0°C) are based on the absence of freezing moisture or water


encoders

BY CONVERTING SHAFT ROTATION INTO ELECTRONIC

PULSES, encoders are used to electronically monitor the

position of a rotating shaft. The encoder’s output pulses are

counted and evaluated by a control unit to determine machine

position and velocity, which provides exceptional accuracy and

flexibility when controlling motion. The high mechanical and

electronic operating speeds associated with encoders increase

system speeds and accuracy, decrease cycle times, and boost

overall productivity in the manufacturing environment.

Allen-Bradley encoders are a high-quality complement to

Rockwell Automation’s PLC-based motion control offering,

providing both standard and advanced DeviceNet network-

enabled models to fit your architecture of choice. They offer

preferred compatibility with other Allen-Bradley servo-

positioning controls to deliver a complete application solution.

encoders

BULLETIN 845H

HIGH-PERFORMANCE

INDUSTRIAL INCREMENTAL

ENCODER

The 845H provides forty-two code disk resolutions of up to 5,000 pulses per revolution and features state-of-the-art circuitry. The 845H is the industry standard Size 25 incremental encoder. With an electronic frequency response of 210 kHz, the 845H can provide 2,048 pulses per revolution at an operating speed of 6,000 revolutions per minute. Various output signal types are available in order to connect to a wide range of controllers.

BULLETIN 845T HEAVY-DUTY

INCREMENTAL ENCODER

The Bulletin 845T encoder is a heavy-duty, NEMA Type 4 and IP66-rated incremental shaft encoder that is housed in a compact, two-inch diameter enclosure. The 845T offers state-of-the-art encoder performance in an extremely robust package, providing code disk resolutions up to 3,000 pulses per revolution and a frequency response of up to 100kHz. Typical applications for the 845T include machine tools, packaging machinery, motion controls and robotics. The heavy-duty bearing assembly, rugged construction and high shaft loading capabilities make the 845T suitable for many of today's harsh industrial environments.

• Industry standard size 20, rugged, die-cast aluminum housing

• NEMA Type 4, & IP66 (IEC529) rated enclosure

• 15,000 RPM maximum slew speed

• Code disk resolution of up to 3,000 pulses per revolution

• Optional gated index

• Overvoltage and short circuit protection

Cable or connector

models available

Industry-standard size 20

(2.0” diameter) housing

BULLETIN 844D HOLLOW-SHAFT

INCREMENTAL ENCODER

Bulletin 844D blind-shaft and through-shaft incremental encoders mount directly to the monitored shaft via a split collar clamp on the encoder, eliminating the need for mounting plates and flexible couplings. As a result, overall cost and size are reduced considerably. Through-shaft models are installed by inserting the monitored shaft completely through the encoder, while blind-shaft models only require insertion of the end of the shaft. Shaft position is converted to digital pulses in an “A quad B” format.

An important feature of the 844D is high frequency response: 300 kHz for line drivers up to 8,192 PPR and 600 kHz above 8,192 PPR. This allows both high resolution (10,000 and 16,384 PPR) and high shaft speed (over 2,000 RPM at 16,384 PPR).

Differential line driver (DLD)

or push-pull outputs

Multiple shaft

diameters available

Industry standard HS35 style

(3.5” diameter) housing

120 to 16,384 pulses

per revolution (PPR)Mounting plate and flexible

coupling not required

Fits 1/2” to 1-1/8” diameter shafts

Cable, connector

or terminal block

connection options

Four output types: differential line

driver; current sink (NPN); open

collector (NPN); current source (PNP)

2.5" diameterHigh resolution

(up to 5,000 pulses

per revolution)

Flange or servo mount

58 59www.klinkmann.com

6 / 2011

61

BULLETIN 845G SINGLE-TURN

ABSOLUTE ENCODER

The Bulletin 845G is a NEMA Type 4 and 13, single-turn absolute encoder that digitizes shaft position for reliable readouts under a wide range of harsh conditions. This family has been enhanced to include BCD and Natural Binary outputs, push-pull and SSI output configurations and an increased operating temperature of 85°C.

As an added convenience, the 845G incorporates a zero set pin. Most absolute encoders must be de-coupled from the monitored shaft to synchronize the electrical and mechanical zero or home positions. The 845G can be set to zero by connecting DC+ to the zero set pin.

Size 25, NEMA Type

4 and 13 housing

Field-selectable direction

control (CW or CCW) for

increasing counts

Power and network

status LEDs

NEMA Type 4, 13,

IP66 (IEC 529)

Single micro or dual

micro connectors for

daisy-chaining

Eight programmable cams

with high/low limits

Programmable code

direction (CW or CCW)

Up to 8,192 pulses per turn and

a maximum of 8,192 turns

BULLETIN 842D DEVICENET™

MULTI-TURN ABSOLUTE

ENCODER

Bulletin 842D is a 26-bit absolute multi-turn shaft encoder offering direct connection to DeviceNet™ for advanced functionality with reduced wiring cost. This network capability eliminates the need for dedicated input cards and allows connection to the DeviceNet™ trunk line via a low-cost five-pin micro quick disconnect. Up to sixty-three 842D DeviceNet™ encoders can be interfaced to a PLC or other logic system through a single network connection. Providing up to 8,192 counts per revolution (CPR) over a maximum of 8,192 turns, the 842D also incorporates advanced diagnostics and many programmable options.

• Eight programmable cam functions that set a bit when the position is within one of eight value ranges

• Programmable code direction (CW or CCW position increment)

• Offset value enables the user to reset the output in relation to the machine’s mechanical position

• Output scaling, which lets you set the optimal counts per revolution for a particular application

• Rugged magnetic technology allows high-shock loading (100 g for 6 ms) and vibration (20 g at 10–2000 Hz)

• High temperature (85°C operating) and high humidity (98%) operation

• Multi-turn counting is accomplished through gearing and magnets

• Absolute position is saved on power failure without any battery back-up

• Change of State (COS) operating mode optimizes network bandwidth

Zero set pin for easy

shaft alignment

8- to 15-bit resolution (256 to 32,768 counts per

revolution) with Gray Code, Natural Binary and

Binary Coded Decimal (BCD) output options

Open collector,

TTL, push-pull or

SSI outputs

ENCODERS

Type

Resolution

Power Supply

Outputs

Housing Size (Diameter)

Shaft Size

Mounting

• Incremental blind-shaft or

through-shaft

• 10-2500 PPR

• 5V DC, 12V DC, or 8-24V DC

• Differential line driver• NPN open collector

• 51 mm (2.0")

• 3/8" (9.5 mm)• 1/2" (12.7 mm)

• Integral flex mount

844A/844B 845PY

EN

CO

DE

RS

Selection Guide

844D 845H845F

• Incremental blind-shaft or

through-shaft

• 120-16,384 PPR

• 5V DC, 10-30V DC, or

5-26V DC

• Differential line driver• Push-Pull

• 90 mm (3.5”)

• 1/2”, 5/8”, 3/4”, 7/8”,

1.0”, 1-1/8”, 30 mm

• Three tether options

& anti-rotation pin

• Incremental

• 1 to 5000 PPR

• 5V DC or 8-24V DC

• Source• Sink w/pullup• Differential line driver• Open collector

• 64 mm (2.5")

• 1/4" (6.35 mm)• 3/8" (9.5 mm)

• Standard coupler• High performance coupler

• Incremental

• 1 to 5000 PPR


• Source• Sink w/pullup• Differential line driver• Open collector

• 64 mm (2.5")

• 6 mm, 10 mm, 1/4", 3/8"

• Square flange• English servo

• Incremental

• 1 to 3000 PPR

• 5V DC, 11-20V DC or 24V DC

• Differential line driver

• 51 mm (2.0")

• 5/16" (7.9 mm)

• 5PY

845T

• Incremental

• 1 to 3000 PPR

• 5V DC, 11-20V DC

or 24V DC

• Push-pull

• Differential line driver

• 51 mm (2.0")

• 6 mm, 10 mm, 1/4", 3/8"

• Square flange

• English servo

Type

Resolution

Power Supply

Outputs

Housing Size (Diameter)

Shaft Size

Mounting

845GM845G845D842D842A

• Absolute multi-turn

(Natural binary or

Gray Code)

• 24 bits (2048-8192 CPR

& 256-8192 revolutions)

• 10-30V DC

• Synchronous

Serial Interface (SSI)

• 60 mm (2.36")

• 6 mm (.236")

• 10 mm (.394")

• Metric servo with 36

or 50mm pilot

• DeviceNet™ Absolute

multi-turn (Natural

binary)

• 26 bits (8192 CPR

& 8192 revolutions)

• 11-25V DC (24V DC

recommended)

• DeviceNet™

• 60 mm (2.36")

• 10 mm (.394")

• Metric servo

with 36mm pilot

• Absolute single turn

(BCD, Natural binary

or Gray Code)

• 8 to 12 bits

(256-1000 CPR)


• 5V TTL

• Open collector

• 64 mm (2.5")

• 6 mm, 10 mm,

1/4", 3/8"

• Square flange

• English servo


(BCD, Natural Binary

or Gray Code)

• 8 to 15 bits

(256-32,768 CPR)

• 5V DC, 10-30V DC,

or 8-24V DC

• 5V TTL

• Open collector

• Push-pull • SSI

• 64 mm (2.5")

• 3/8" (9.5 mm)

• Square flange

• English servo


(BCD, Natural Binary

or Gray Code)

• 8 to 15 bits

(256-32,768 CPR)

• 5V DC, 10-30V DC,

or 8-24V DC

• 5V TTL

• Open collector

• Push-pull • SSI

• 51 mm (2.0")

• 3/8" (9.5 mm)

• 6 mm (.236")

• 10 mm (.394")

• Square flange

• English servo

60


Additional information: www.ab.com/catalogswww.klinkmann.com6 / 2011

62 63

condition sensing

ALLEN-BRADLEY SOLID-STATE AND

ELECTROMECHANICAL CONDITION

SENSING DEVICES are designed to produce

high-quality results in a variety of rugged

environments. With models capable of

detecting pressure, temperature, flow, speed

and liquid levels, the condition sensing line

includes a wide range of switches to meet

your application needs.

condition sensing switches

BULLETIN 836E, 837E AND 839E

SOLID-STATE PRESSURE,

TEMPERATURE AND FLOW SWITCHES

The Bulletin 836E pressure, Bulletin 837E temperature and Bulletin 839E flow families of solid-state condition sensing switches are microprocessor based and designed with no moving parts, providing a longer service life and reducing downtime. Their rugged,

corrosion-resistant 316 stainless steel construction offers an IP66 enclosure rating and allows these compact new condition sensors to withstand harsh industrial conditions, and the laser-etched label is more durable than the standard adhesive labels commonly found on similar products.

Each switch can be obtained either with two independently programmable PNP normally open / normally closed outputs or 4-20 mA analog output with single PNP normally open / normally closed output. Plus, the industry-leading 4-character, 14-segment digital display shows condition indication and the unit of measure selected as well as detailed menu options during programming.

All options, including the dual setpoints, operating mode, and display preferences are quickly and easily configured via the built-in programming buttons or through optional WindowsTM-based configuration software that significantly reduces set-up time, especially for installations requiring a large number of switches.

Four-digit 14-segment digital display

Rugged, corrosion-resistant

316 stainless steel housing

Dual NO/NC independently

programmable PNP outputs or

4-20 mA analog output with single

PNP normally open / normally

closed output.

BULLETIN 836 AND

836T PRESSURE CONTROLS

Bulletin 836 and 836T pressure controls detect specific operating conditions of pneumatic and hydraulic applications. They are designed to provide long life and exceptional reliability. These devices can be used to provide control signals to an operator interface or directly start small single phase motors.

Bulletin 836 Products –

General Manufacturing & Process Industries

• Copper alloy or stainless steel bellow operation

• Adjustable differential pressure controls

• Single-pole double throw AC/DC rated contacts

Bulletin 836T Products –

Machine Tool & Automotive Industries

• Bellow or piston operation

• Adjustable differential pressure controls

• Two circuit AC/DC (NEMA A600) rated contacts

BULLETIN 837

TEMPERATURE CONTROLS

Bulletin 837 temperature controls are heavy-duty control circuit devices used in industrial applications where temperature must be maintained within preset limits. These devices can mount directly into a system or be remotely mounted up to 105 feet away using a bulb and capillary sensor.

Bulletin 837 features:

• Vapor sensing technology

• Adjustable differential

• Single-pole double-throw AC/DC rated contacts

External

mounting

holes

External bellows connection

Range and scale indicator

Bulb and capillary or direct

immersion sensing

Vapor sensing technology

switches


64 65

BULLETIN 840 AUTOMATIC

FLOAT SWITCHES

Bulletin 840 float switches are heavy-duty horsepower or control circuit rated devices which can be used to control and monitor liquid levels. A variety of mounting styles and operator assemblies are available.

Bulletin 840 Automatic

Float Switches feature:

• Tank or sump operation

• Stainless steel float and connecting rod

• AC/DC (NEMA A600/N300) rated contacts

Operating

lever

Conduit opening

Mounting brackets

• Microprocessor based with no

moving parts

• Rugged corrosion-resistant 316

stainless steel

• Independently programmable PNP

outputs or 4-20mA analog output

with single PNP output

• 4-character 14-segment digital display

• Easy-to-use software configuration tool

• Process pressure: -15 to 6000 psi

• Media temperature: -40 to +212°F

(-40 to +100°C)

_

• <0.5% of upper range

• IP66

• -40 to +185°F (-40 to +85°C)

• 250mA (per PNP output)

836E Solid-State Pressure Switches

837 Temperature Switches

CO

ND

ITIO

N S

EN

SIN

G S

WIT

CH

ES

Selection Guide

837E Solid-State Temperature Switches

836T Pressure Switches

836 Pressure Switches


moving parts


stainless steel







(-50 to +150°C)

–

• <0.2°C

• IP66

• -40 to +185°F (-40 to +85°C)


• Bellow Operation

• Copper alloy or stainless steel

materials

• High reliability, snap action silver

contacts

• Broad range of sensing

capabilities (air, water, oil,

liquids, vapors and gases)

• 30" Hg vacuum to 900 psi

• Independently Adjustable

.2 to 125 psi

• +/- 0.5%

• Open, Type 1, 4X, 4&13, 7&9

and 4&13

• -22 to +150ºF (-30 to +66ºC)

• Non-Inductive: 5A, 240V/3A, 600V

• Control Circuit - AC-125 VA,

24600V/DC-57.5 VA, 115230V

• Bellow or piston operation

• Bellows available in copper alloy

or stainless steel

• High reliability, snap action

silver contacts

• Broad range of sensing

capabilities (air, water, oil,

liquids, vapors, and gases)

• 30" Hg vacuum to 5000 psi


2 to 650 psi

• Bellows (+/-1%),

Piston w/o seal (+/-3%),

Piston w/ seal (+/-5%)

• Type 1/4/13, 7&9 and 4&13

• -22 to +150ºF (-30 to +66ºC)

• 2 Circuit - NEMA A600

• 4 Circuit - NEMA B150

• Bellow Operation

• Vapor sensing technology

• Bulb and capillary or direct

immersion sensing

• High reliability, snap action

silver contacts

• -60 to +570ºF


2 to 87ºF

• +/- 2ºF

• Open, Type 1, 4&13, 7&9

and 4&13

• -22 to +150ºF (-30 to +66ºC)

• Non-Inductive - 5A, 240V/3A, 600V

• Control Circuit - AC-125 VA,

24600V/DC-57.5 VA, 115230V

808 Low Speed Switches (Styles J and K)

• Motor Plugging, Motor Anti-

Plugging, Speed Sensing,

Direction of Rotation

• 15…80 RPM

• 1200 RPM

• Type 1/4/13, 7&9

• NEMA B600

• Style J - 1 N.O.

• Style K - 1 N.C.

• -22 to +150ºF

(-30 to +66ºC)

808 High Speed Switches (Styles M and R)

• Motor Plugging, Motor Anti-

Plugging, Speed Sensing,

Direction of Rotation

• 50…1000 RPM

• 2000 RPM

• Type 1/4/13, 7&9

• NEMA B600

• Style M - 1 N.O.

• Style R - 1 N.C.

• -22 to +150ºF

(-30 to +66ºC)

840 Low Operating Force Industrial Switch (Style A)

• Tank or Sump Operation

–

–

• Type 1, 4, 7&9

• NEMA A600 and N300

• 1 N.O./1N.C.,

2 N.O., or 2 N.C

• -22 to +150ºF

(-30 to +66ºC)

840 Heavy Duty Industrial Switch (Style B)


–

–

• Type 1, 4, 7&9


• 2 N.O.

• -22 to +150ºF

(-30 to +66ºC)

840 Motor Rated Industrial Switch (Style C)


–

–

• Type 1, 4, 7&9


• 3 N.O.

• -22 to +150ºF

(-30 to +66ºC)

840 General Purpose Switch (Style D/DS)


–

–

• Type 1


• 2 N.O.

• -22 to +150ºF

(-30 to +66ºC)



moving parts


stainless steel






• Process flow: 0.03 to 3 m/s

(0.1 to 9.84 ft/s)


(-20 to +85°C)

–

• Temperature accuracy: 2K (1.8°F)

• IP66

• -40 to +185°F (-40 to +85°C)


839E Solid-State Flow Switches

BULLETIN 808 SPEED SWITCHES

Bulletin 808 speed switches are pilot devices used for detecting motor speed or direction of rotation. This product utilizes internal magnetic coupling technology to eliminate the possibility of mechanical wear or hydraulic leakage. Allen-Bradley speed switches are time proven products built for accuracy and reliability, and designed for use in your most demanding environments.

Bulletin 808 Speed Switches also feature:

• Magnetic coupling technology

• Side mounted adjustment screws

• AC/DC (NEMA B600) rated contacts

Type 7 & 9 enclosure

Speed adjusting screws

(each side)

Type 1/4/13 enclosure

CONDITION

SENSING

SWITCHES


Operating Range

Differential

Repeat Accuracy

Enclosure Options

Ambient Operating Temp

Contact Ratings (Std)

Typical Applications

Operating Range

Max Shaft Operating Speed

Enclosure Options

Electrical Ratings

Contact Arrangement

Ambient Operating Temp



66 6766

devicenet &

WHEN LOW NODE COSTS, MULTI-VENDOR

DEVICE SUPPORT AND HARD WIRING

REPLACEMENT ARE KEY, TURN TO

ALLEN-BRADLEY PHYSICAL MEDIA

FOR NETWORKING APPLICATIONS.

Rockwell Automation offers the widest variety of

network physical media to meet your application

needs. These products help speed setup of your

network to lower system costs and reduce

maintenance time.

67

devicenet & ethernet media

Mini- or micro-style drop cable connections

provide application flexibility

Thru-trunk connection

simplifies installation

IP67, NEMA 6P, and 1200 psi washdown

rated for harsh industrial environments

T-PORT COUPLER AND ACCESSORIESWith physical space at a premium in virtually every application, rugged compact designs are in high demand. Rockwell Automation’s next generation of T-ports in both micro and mini styles have been designed to meet this need. With an average 26% reduction on physical volume and more keyway orientation options to aid in cable routing, the new design meets the challenges of the increasingly reduced space available for physical media. And these products are designed and built to meet IP67, NEMA 6P, and 1200psi (8270kPa) requirements to provide one of the most rugged and durable families of product in the industry.

But space saving size is not the only added feature; with mounting holes that mount flush on the mounting surface, the addition of a mounting hole on micro models, and rotating coupling nuts on all connectors, the new designs help ease installation and save installation time. Additionally, new micro versions with female to male/female configuration allow direct connection of the micro T-port to the auxiliary power input on Bulletin 1732 ArmorBlock™ 8-point I/O. Also, new products such as gender changers and right angle adapters have been added to help in managing complex network layouts, creating solutions that save you time in design and installation.

ethernet mediaBULLETIN 1485C ROUND MEDIARockwell Automation offers two types of round media for DeviceNet: thick and thin. Thick media, with a 1/2-inch (12.2 mm) diameter gray PVC jacket, is primarily used as the trunk line on the DeviceNet network. Thin media, with its 1/4-inch (6.9 mm) yellow CPE or gray PVC jacket, can be used either as the trunk line or as the drop cable that connects the trunk line to each field device. Each is available either on spools or in a variety of pre-terminated lengths, with custom lengths also available to fit specific application needs.

Newly available are High Flex DeviceNet round media

• DeviceNet thick high flex is rated to 5M cycles based upon a bend radius of 15 times the cable diameter (diameter = 12.2 mm or 0.48 inches).

• DeviceNet thin high flex is rated to 10M cycles based upon a bend radius 15 times the cable diameter (diameter = 6.9 mm or 0.27 inches).

• Testing is done using twist and flex equipment.

Pre-terminated cables for use with ArmorBlock™ MaXum I/O are also available. These cordsets provide connection to both I/O and power and are available in a variety of lengths and connecting configurations.

DEVICEPORT™ MULTI-PORT TAPDevicePort taps are passive splitters which connect multiple network devices to the DeviceNet trunk in less physical space than multiple T-port taps, reducing the number of physical taps on the trunk line from as many as eight to just one. DevicePort taps are available as either thru-trunk versions, which connect directly to the trunk line, or drop-connector versions, which interface to the trunk through a single T-port tap. They are offered with 4, 6, or 8 mini or micro connector ports in sealed enclosures for application flexibility.

Yellow CPE or gray PVC cables

Thick or thin cable types

Mini or micro style

Through holes for

easy mounting

Mini- or micro-style trunk

and drop connections

Right or left keyway

orientations


68 6968 69

DEVICENET OPEN-STYLE MEDIAThin cable 5-pin open-style DeviceNet overmolded cables provide simplified connectivity of open-style devices to round and flat media systems. They eliminate the need for screw-terminal connections when attaching to open-style field devices. They also allow the use of standard factory molded micro or mini drop connection throughout an installation, thus reducing the total number of parts needed in a typical system. The resulting connection point also simplifies troubleshooting open-style field devices by allowing tool-free connection and disconnection.

The following are available:

• Female DeviceNet Open-style to Micro Male or Female Connector

• Female DeviceNet Open-style to Mini Male or Female Connector

• Female DeviceNet Open-style to flying leads

• Double-ended Female DeviceNet Open-style patchcord

KWIKLINK™ FLAT MEDIA SYSTEMKwikLink is the quickest, easiest way to get connected with DeviceNet. A physical media system consisting of flat cable and snap-on modular connectors, it can save you as much as 50% over the cost of installing other DeviceNet media. That’s because you don’t have to use predetermined trunk lengths, so you’re free to put drops wherever you need them. Other advantages include:

• Insulation displacement connectors eliminate the need to cut or strip cable to make a secure trunk connection

• Sealed connectors feature IP67, NEMA 6P, NEMA 13 and 1200psi washdown enclosure ratings

• Modular design allows you to mix and match to create the wiring version you need

• Inherent noise resistance due to the low loss, low capacitance, well-balanced KwikLink cable and DeviceNet’s differential type of transmission

• Installation flexibility saves time and wastes less material, making KwikLink the lowest-cost DeviceNet media option

ETHERNET M12 MEDIAAs EtherNet becomes increasingly utilized in industrial control, survival of the physical media in rugged or harsh environments is becoming a necessity. Typical EtherNet RJ45 style connectors are not designed to withstand vibration, fluids, and other contaminants that can make installation difficult and lead to costly downtime. To address these application challenges Rockwell Automation offers industry standard 4-pin D–coded M12 connectors with an IP67 rating.

BULLETIN 1485K KWIKLINK DROP CABLES These PVC-jacketed, 4-wire drop cables are designed for use exclusively with the KwikLink flat media system. Each attaches to the trunk using a micro-style KwikLink connector and is available with a mini connector, micro connector or flying leads on the device end.

BULLETIN 1485C KWIKLINK CABLEThis specialized flat media’s asymmetric profile helps prevent incorrect assembly of connectors on the cable. KwikLink cable is available with either TPE or PVC jacketing and in class 1 or class 2 rated versions.

BULLETIN 1485T AND 1485P

KWIKLINK CONNECTORS The KwikLink connector consists of two main components. An insulation displacement connector (IDC) module clamps onto the flat cable trunk line, piercing the cable insulation. Next, an interface module snaps on top of the IDC module to provide your choice of connection style to the trunk.

Each insulation displacement connector module

comes with one of six interface module styles:

• Micro connector

• Open style with screw terminals (often used in enclosures)

• Terminating resistors

• Integral drop cable (pigtail) with pre-wired mini-connector

• Integral drop cable (pigtail) with flying leads

• Blank (to seal unused connectors)

Selectable output fault latching

Short circuit, open-wire,

no-load detection

Rotary node address switches

and autobaud detection

Hardware watchdog circuitry

Selectable input filter times

Self-configuring

PNP/NPN inputs

BULLETIN 1792 I/O ON KWIKLINKArmorBlock MaXum I/O on DeviceNet takes full advantage of the KwikLink flat media system’s benefits. The entire system is rated IP67 and NEMA 4X, allowing you to reduce or eliminate the number of enclosures or trays necessary to protect either the media or the block. The KwikLink flat cable passes directly through the MaXum block, minimizing the space needed to mount the block to your machinery. With ArmorBlock, the IDC connection is included, so there are no extra taps required.

M12 to RJ45 Adaptor

• 22 AWG conductors

• Female receptacle

• 4-pin D-coded M12 configuration

• Viton o-ring

• M12 to RJ45 bulkhead

• IP67, 1200 psi (8270 kPa) washdown rating

Insulation Displacement Connector

• Field installable with no hand tools needed

• Straight male or female shielded versions

• Allows easy modification of existing cable installations

• Insulation displacement technology for secure and reliable installation

• Metal body unit excellent in shielding applications

• IP67 enclosure rating

devicenet & ethernet media


70 7170

DEVICENET &

ETHERNET

MEDIA

• Keyed flat trunk cable for use

with Insulation Displacement

Connectors (IDCs)

• N/A

• Keyed to prevent wiring mishaps

• TPE or PVC jacket

• Class 1 or class 2 rated cable versions

• Available in spools up to 420 m

• Vampire connectors for use with

KwikLink flat cable in general

purpose applications

• IP67

• Micro QD

• Plug and play installation

• Two-piece housing

• Designed for general

purpose applications

• Insulation Displacement

Connectors (IDCs) for use with

KwikLink flat cable

• Sealed: NEMA 6 & 13; IP67;

1200 psi washdown

• Unsealed: NEMA 1; IP60

• Micro

• Open-style

• Terminator

• UL listed and CSA certified

• Valox construction


• Insulation Displacement Connector

with integral class 1 round cable

pigtail for interfacing a device or

power supply to flat cable


1200 psi washdown

• Unsealed: NEMA 1, IP60

• Mini QD

• Conductor


• Allows Class 1 drop to KwikLink system

• Includes IDC connector and

pigtail module


Connections

Extra Features

DE

VIC

EN

ET

& E

TH

ER

NE

T M

ED

IA Selection G

uide

71

1485P KwikLink General Purpose Connectors

1485P KwikLink Connectors

1485T & 1485P Pigtail KwikLink Connectors

1485P

KwikLink Splice Kits

1485K

KwikLink Drop Cables

1485C

Thick Media

1485R & 1485G

Thin Media

• A pair of Insulation Displacement

Connectors factory-joined with Class

1 round cable for splicing together

two sections of a flat cable network


1200 psi washdown

• Unsealed: NEMA 1, IP60

• KwikLink module to KwikLink module


• Available in standard splice kit and

power isolation splice kit versions

• Includes IDC connectors, splice module

and flat cable end caps

• 4-wire unshielded drop cables

for use exclusively with

KwikLink systems

• Mini QD

• Micro QD

• Conductor

• For use only with KwikLink Flat

Media system

• Epoxy coated coupling nut

• PVC jacket

• 1/2" (12.2mm) cable for

DeviceNet trunkline

• DeviceNet thick high flex is rated to

5M cycles based upon a bend radius

of 15 times the cable diameter

(diameter = 12.2 mm or

0.48 inches)

• Mini QD

• Conductor

• Field attachable connectors

• Terminators

• Cable spools

• Panel-mount receptacles

• PVC jacket

• Standard cordset lengths up to 30 m

• Available in raw spools up to 500 m

• 1/4" (6.9mm) cable for DeviceNet

trunkline or droplines

• DeviceNet thin high flex is rated to

10M cycles based upon a bend

radius 15 times the cable diameter

(diameter = 6.9 mm or 0.27 inches)

• Mini QD

• Micro QD

• Conductor

• Field attachable connectors

• Terminators

• Cable spools

• Panel-mount receptacles

• Yellow TPE or gray PVC jacket

• Standard cordset lengths up to 6 m

• Available in raw spools up to 600 m


Connections

Extra Features

1485P KwikLink Splice Kits

1485K KwikLink Drop Cables

1485C Thick Media

1485R & 1485G Thin Media

• Connects a single drop line to

the trunk

• NEMA 6P, 12 & 13; IP67;

1200 psi washdown

• T-ports: 4- and 5-pin Mini QD,

5-pin Micro QD

• Gender Changer: Mini male

to mini male, Mini male to

mini female

• Config Changer: Mini male to

mini female

• T-port: Right or left keyway for

positioning purposes on

mini QD versions

• 4-pin patchcords, receptacles,

T-ports, terminal chambers,

bulkhead pass-through

connectors and accessories for

auxiliary power for DeviceNet

• IP67, NEMA 6P, 1200 psi

washdown

• 4-pin Mini QD

• 5-pin Micro QD

• Yellow PVC jacket

• Standard patchcord lengths

up to 10 m

• 4-pin T-ports and shorting plugs

wired to provide both auxiliary

power and a single channel

safety circuit

NOTE: safety circuit is passive

and not part of the DeviceNet

communication network.

• Mini QD

• Red PBT housing

• Male or female shorting

plugs available

• For use in conjunction with

standard auxiliary power

media components

1485C KwikLink Cable

• Passive multi-port tap for up to

8 smart devices

• NEMA 4, 6P; IP67;

1200 psi washdown

• Mini QD

• Micro QD

• 4, 6 or 8 ports

• Connection to trunk via drop line

or thru-trunk connection

871C NAMUR

871C Small Barrel

871C Polymer Barrel

1485P DevicePort

1485P T-Port

889N Auxiliary Power Media

EtherNet M12 Media

1485A Bulkhead Pass-Through Connectors

1485T PowerTap

• M12 Ethernet Industry standard

4-pin D–coded with an IP67 rating

• Insulation Displacement Connector

• RJ45 to M12 Adaptor

• Rated for 32V, 4A

• IP67

• Mini or micro bulkhead

pass-through connectors for

convenient routing of DeviceNet

wiring through panel walls

• IP67

• 5-pin mini

• 5-pin DC micro

• Mini QD

• Micro QD

• 600V assembly rating

• Nickel-plated brass housing

standard

• Stainless steel housing versions

available

• Passive coupling device used

to limit trunk current

• NEMA 3, 4X, 12 & 13; IP67;

1200 psi washdown

• Cage-clamp terminal strips

• Allows for multiple power supplies

to be connected to the trunk

without mutual interference

• 7.5A or 3.0A fuse protection (2x)

• Thick media and thin media versions

871C Polymer Barrel

898N Auxiliary Power/ Single

Channel Safety Media

1485P DeviceBox

• Passive sealed junction boxes

for up to 8 smart devices

• NEMA 3, 4X, 12 & 13;

1200 psi washdown

• Cage-clamp terminal strips

• 2, 4, or 8 ports

• Cord grip openings

• Direct connection to trunk with

terminal strip connections

• Thick media and thin media versions

• 24V assembly rating


DeviceNet Open-Style Media

• Adaptor, Cables and connectors that

provide convenient transition from

open-style DeviceNet

• Available lengths are 1, 2, 3, 4, 5 and

6 meters

• Female DeviceNet Open-style to Micro

(M12) Male or Female Connector

• Female DeviceNet Open-style to Mini

(7/8”) Male or Female Connector

• Female DeviceNet Open-style to cable

• Double ended Female DeviceNet

Open-style patchcord

• Adaptor is 250V DC, 4A


Additional information: www.ab.com/catalogs www.klinkmann.com6 / 2011

BULLETIN 898 DISTRIBUTION BOXESThese distribution boxes are a great way to increase flexibility and cut costs. They lower your labor costs by reducing installation and troubleshooting time. They take up less space than loose wires, look neater and more organized, and keep cable replacement simple in areas where cables are easily damaged. Other features include:

• Available in 3-pin Pico, 3- and 4-pin Mini, 4-pin DC Micro and 3-pin AC Micro Style

• Available with 4, 6, 8 or 10 ports

• Parallel-wired connectors

• PNP or NPN wired LED and non-LED versions available

• Pre-wired main cable or mini-plus-style quick disconnect main cable connector (or terminal block on DC Micro Style)

Rugged PET housing

Pre-wired main cable or mini-plus style QD

72

connection systems

NOW THERE’S NO NEED TO CALL ALL OVER

TOWN TO GET CONNECTED, BECAUSE

YOU CAN MEET ALL YOUR CONNECTION

NEEDS WITH JUST ONE CALL TO ROCKWELL

AUTOMATION. We offer a wide variety of

Allen-Bradley cables, cordsets, patchcords,

Y-cables, distribution boxes and receptacles to

satisfy even the toughest industry applications.

73

connection systems

Multiple mounting thread options

BULLETIN 888 RECEPTACLESIncrease your wiring flexibility with these easy-to-use receptacles. Their modular design provides panel mount capability, helps keep things neat and organized, and allows simple replacement in areas where cables are likely to be damaged or replaced frequently. All versions offer:

• Standard 12-inch leads (additional lengths available)

• Single (DC) or Dual (AC) keyway

• IEC color code

A variety of options are available including:

• Male or female types

• 2- to 12-pin versions

• 1/2”-14 NPT, 1/4”-18 NPT, M8 x 0.5 or M14x1 mounting threads

• Anodized aluminum shell or rugged die cast Zinc body

16 AWG (Mini and Mini-Plus), 22 AWG (Micro) and 24 AWG (Pico) conductors

4-pin/3-wire, 4-pin/4-wire, or 5-pin types

Male or female styles

BULLETINS 871A AND 889D

FIELD-ATTACHABLE CONNECTORSAlso known as terminal chambers, Allen-Bradley field-attachable connectors are passive devices for use with raw cable. These 3-, 4-, 5- and 8- pin models contain screw terminals or insulation displacement connectors for quick and easy assembly of custom cables on the plant floor. They can be straight or right-angled and are available for use with various cable diameters. Available in:

Screw terminals or insulation displacement connection

Straight or right angle

Available in male

and female versions

BULLETIN 889 CORDSETS AND PATCHCORDSFeaturing industry standard Pico, DC Micro, AC Micro, Mini and Mini-Plus style overmolded connectors, Allen-Bradley cables provide secure connection for proximity sensors, limit switches, photoelectric sensors and other field devices. These cordsets and patchcords provide:

• Connection between field devices and receptacle ports

• Straight and right angle connectors

• Multiple jacket types: PVC, PUR, TPE, Toughlink and Toughweld.

• Standard 1, 2, 5 and 10m lengths

• Standard 16, 18, 22 and 24 AWG cable

• Ratcheting coupling nut for added vibration resistance

• Y-cable and splitter models

• DC micro-to-mini and DC micro-to-pico cable models

Patchcords (connector each end), cordsets (connector to flying leads)

IEC color code standard on male and female cordsets Epoxy coated zinc

coupling nuts standard

Straight or right angle

• DC Micro - IDC - Screw terminal

• Mini screw terminal

• AC Micro screw terminal

• Pico - IDC - Screw terminal


BULLETIN 889M M23 STYLE CORDSETS, PATCHCORDS AND RECEPTACLES

Featuring industry standard 12- and 19-pin connectors, the Allen-Bradley M23 cables provide secure connection for high pin count field devices utilizing M23 style connectors. Connectors can be straight or right-angled and are physically keyed to prevent wiring mishaps. Allen Bradley M23 style cabling options include:

• Cordsets: cable with integral female connectors at one end and flying leads at the other

• Patchcords: cable with integral connector at each end (one male, one female)

• M23 connector receptacles are also offered for bulkhead/panel installation. These 12 pin male connectors are ideal for use in enclosures and on field devices with M20 conduit openings, and allow for custom wiring configurations

• Terminal chambers, or field attachable connectors, are passive field-installable connectors for use with raw cable. Allen-Bradley M23 Style terminal chambers contain solder cups and machined housing components for reliable installation and assembly.

74 75

connection systems

CONTROL POWER MEDIA (ARMORSTARTTM

)

The control power media offers a mini disconnect cable that provides a secure connection to the ArmorStart Distributed Motor Controller. The control power media components are a 6-pin/5-used configuration to prevent mis-wiring with network connectors. Connectors can be straight or right-angled and are physically keyed to prevent wiring mishaps.

The cabling options include:

Cordsets: Cable with integral male or female connector at one end and flying leads at the other

• Available in 2 m, 5 m, or 10 m lengths.

Patchcords: Cable with integral connector at each end (one male, one female)

• Available in 1 m, 2 m, 3 m, 5 m, or 10 m lengths.

The control power tees offer flexibility in system design. The 6-pin/5-used T-port connects a single drop line to the trunk. Two types of tees are offered. The E-Stop In tee is used to connect to the Bulletin 800F On-Machine E-Stop station using a control power media patchcord. The E-Stop Out tee is used with cordset or patchcord to connect to the ArmorStart Distributed Motor Controller.

The receptacles provide a termination point at the panel and ArmorStart Distributed Motor Controller. The female receptacles can be used for a panel mount connection. The male receptacles will be used for a quick disconnect at the ArmorStart Distributed Motor Controller with gland plate design.

Variety of cordsets

available to connect

components to

distribution boxes

QUICK-DISCONNECT SOLUTIONS FOR SAFETY COMPONENTS

Allen-Bradley Safety Connection Systems are complete wiring solutions dedicated to machine safety. These connector-based systems consist of safety wired T-ports and distribution boxes as well as patchcords and shorting plugs. Specifically intended for use with dry-contact safety switches, safety connection systems provide flexible and reliable connections between safety interlock switches, E-stops, cable pull switches and safety relays. While this system is ideal for use with these components, it is not suitable for use with light curtains, safety mats or pressure sensitive safety edges.

Allen-Bradley Safety Connection Systems are designed to:

• Reduce installation cost • Ease system expansion • Simplify troubleshooting

• Promote system modularity • Provide for safety PLC input expansion

• Support systems up to Category 3 (per EN954-1)

Although Allen-Bradley Safety Connection Systems are based on quick-disconnect technology, the associated safety components are not limited to those with built-in connectors. A variety of alternate methods can be employed to interface safety switches to the system.

Prewired for dual or single channel with N.C or N.O. options – for maximum flexibility

Up to 8 micro AC or DC connectors allows multiple component connection

T-Port/Splitter designed for use with dual-channel safety devices

with 4-pin DC micro connector

Shorting plug designed for use with safety

wired distribution boxes allowing unused

connectors to be terminated

High visibility yellow jacket offers

good environmental resistance

INSULATION DISPLACEMENT CONNECTORS (IDC)

Using field attachable connectors on preleaded sensors, cable spools, or single ended cordsets provides instant custom length cables that maintain the advantages of a fully connector-based system. Insulation Displacement Connectors (IDC) terminate cables without stripping and connecting individual leads to screw terminals. Field Attachable Insulation Displacement connectors are available in DC Micro and Pico connectors.

Rockwell Automation offers the convenience of IDC connections in receptacle form for bulkhead or panel installation. This 4-wire zinc die-cast connector is ideal for terminating wires to enclosures with the flexibility of field customization. Multiple cables can be terminated with the Allen-Bradley passive IDC distribution box. The ports each have a 3-wire termination and are available on an 8-port box. The 3-pole IDC insert (sold separately) which is needed to make the connection has a much lower profile than a connector on a standard distribution box. LED versions are available for use with PNP (sourcing) inputs.

BULLETIN 889S/V/W/Y/Z DIN VALVE STYLE CORDSETS AND FIELD ATTACHABLE CONNECTORSAllen-Bradley DIN-compatible cables and field attachable connectors provide standard connectivity and environmental protection, and the surge protection circuitry option protects the solenoid coils within other devices from potentially disruptive current spikes.

• Quick-disconnect capability for valves and other devices • Indicating LED option • Available with protective circuits • Assortment of sizes (8-18 mm) and wiring configurations • Cordsets offered in 18AWG black PVC cable

(20AWG black PUR cordsets also available)• Cordsets are NEMA 6 and IP67, Field Attachable

Connectors are NEMA 4 and IP65


Safety Connection Systems M23 style

Insulation Displacement Connectors (IDC)

76

CONNECTION

SYSTEMS

Description

Features

Rated Voltage

Rating

Connector/Body Dimensions (reference)

Description

Features

Rated Voltage

Rating


• Female mini and illuminated mini cordset

• Male mini cordset

• Male to female mini patchcord

• 2, 3, 4, 5 and 6 pin connector types

• Straight and right angle versions

• Heavy duty STOOW 16 AWG or standard 18 AWG cable

• Oil resistant yellow PVC jacket

• Coiled cord available

• Right angle female connector

• ToughLink and ToughWeld

• Straight female connector to straight or

right angle male

• Straight male connector

• 16 AWG: 600V • 18 AWG: 300V

• NEMA 4, 6P, 12, 13, IP67, 1200 PSI Washdown

• Straight: 62 mm x 27 mm (Female mini cordset)

• Right angle: 44 mm x 46 mm (Female mini cordset)

• 41 mm x 46 mm (Female Illuminated mini cordset)

• Male Straight: 62 mm x 27 mm (male cordset)

• Right Angle: 44 mm x 46 mm (male cordset)

• Female DC and illuminated DC micro cordset

• Male DC micro cordset

• Male to female DC micro patchcord

• 2, 3, 4, 5, and 8 pin connector types

• Straight or right angle connectors

• 22 AWG or 18 AWG cable

• Yellow or black cable

• Standard or braided versions

• Multiple jacket types: PVC, TPE,

ToughLink, ToughWeld, PUR

• PNP or NPN LED versions

• 250V • 300V • 10-30V DC (Female Illuminated)

• NEMA 6P, IP67, 1200 PSI Washdown

• Straight: 47 mm x 14 mm (female cordset)

• Right angle: 14 mm x 32 mm (female cordset)

• Straight: 51 mm x 14 mm (male cordset)

• Right Angle: 35 mm x 14 mm (male cordset)

• T-ports • Distribution boxes • Patchcords

• Receptacles • Shorting Plugs

• Available with or without enunciation

• Distribution boxes with up to 8 ports

• Red safety color except for receptacles

• 10-30 VDC except receptacles are

either 36 VDC/30 VAC or 300 V

• IP67, NEMA 6P except for receptacles

• see catalog pages

• Straight and right angle male and female

12 pin cordsets and patchcords

• Receptacles • Field Attachable connectors

• Black or yellow PVC jacket

• 9, 11, 12, and 19 pin configurations

• 18 or 18/22 AWG

• 63 V

• IP67, NEMA 6P, 1200 psi washdown

for patchords, cordsets and receptacles

• IP65 for Field Attachables

• 26 mm x 50 mm and up

• Female mini-plus cordset

• Male to female mini-plus patchcord

• 7, 8, 9, 10 and 12 pin connector types

• Straight and right angle versions


• Mates with main connectors on 898-series

distribution boxes

• Straight configuration

• Straight female connector

• Mates 898-series distribution boxes to 1667-series

PanelConnect

• Heavy duty STOOW 16AWG or 18AWG cable

• 16AWG: 600V • 18AWG: 300V


• Straight: 51 mm x 32 mm

• Right angle: 56 mm x 67 mm

• 56 mm x 28 mm (Female Cordset)

• 56 mm x 28 mm (Male to Female Patchcord)

• Distribution boxes

• Receptacles

• 8 ports

• 4 pin straight configuration

• Brass with nickel plated body

• 24 - 22AWG

• Distr. Box: 10-30 VDC

• Receptacle: 32 V

• IP67, 1200 psi washdown

• Distr. Box: 152 mm x 60 mm x 18 mm

• Receptacle: 34 mm x 17 mm

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77

• Female AC micro cordset

• Male to female AC micro patchcord

• 3, 4, 5 and 6 pin connector types

• Straight or right angle connector

• Standard 18 AWG or braided

22 AWG cable


• ToughWeld

• 250V

• IP67



• Female EAC micro cordset

• 3 or 4 pin connector types

• Straight or right angle versions

• Standard 22 AWG cable


• 300V

• IP67



• DC Micro to Pico Patchcord

• Female illuminated pico cordset

• Male to female pico patchcord and cordsets

• 3 or 4 pin connector types

• Straight or right angle

female connector


• Oil resistant PVC or PUR cable

• PNP or NPN LED versions

• 60V AC / 75V DC • 10-30V DC • Illuminated

• Screw-on type: IP67 • Snap-on type: IP65

• see catalog

• Male DC micro to female pico patchcord

• 4 pin male DC micro to 3 or 4 pin pico

connectors

• Straight or right angle connectors



• 60VAC/75V DC

• IP67

• DC micro: 31 mm x 26 mm

• Straight pico: 43 mm x 8 mm

• Right-angle pico: 17 mm x 43 mm

• Male DC micro to 2 female pico

• 3 and 4 pin pico connector types

• Straight or right angle connector styles

• Standard 24AWG cable

• Oil resistant PVC or PUR cable

• 60V AC / 75V DC

• LED version: 10-30V VDC

• IP67

• Y-connector: 52 mm x 20 mm


• Right-angle pico: 26 mm x 18 mm x 10 mm

889N Mini-Plus Style Cordsets/Patchcords

889N Mini-Style Cordsets/Patchcords

889D DC Micro-Style Cordsets and Patchcords

• Male DC to female mini patchcord

• 4 pin male DC micro to 4 pin mini connectors

• Straight DC micro to straight mini connector



• 300V

• IP67, NEMA 4, 6P, 12 and 13

• DC micro: 31 mm x 26 mm


• Right-angle pico: 17 mm x 43 mm

• DC micro Y-cables

• 4 pin connector types

• Straight DC micro Y-connector to two straight

or right angle DC micro connectors

• Y-connector to two cables

• Standard 18 and 22 AWG cable

• Oil resistant yellow PVC jacket, TPE

• 250V 4A

• NEMA 6P, IP67, 1200 psi Washdown

• Y-connector: 23 mm x 40 mm

• Straight micro: 14 mm x 47 mm

• Right-angle micro: 14 mm x 32 mm

• DC micro splitters

• Pico splitters

• 2, 3, and 4 pin DC micro male to two

4 pin DC micro female connector types

• 2 - 3 pin pico female to 4 pin pico or

DC micro female connector types

• PUR body

• Micro: 250V

• Pico: 60V AC / 75V DC

• NEMA 6P, IP67

• 40 mm x 40 mm x 13 mm

• Micro to pico: 27 mm x 39 mm x 15 mm

• Pico to pico: 27 mm x 38 mm x 11 mm

889R AC Micro Style Cordsets and Patchcords

889B EAC Micro-Style Cordsets

889P Pico Style Cordsets and Patchcords

889P DC Micro to Pico Patchcords

879PZ Pico to DC Micro Y-Cables

898D and 898P DC Micro- and Pico-Style Splitters

879D DC Micro V- and Y-Cables

871A & 889N DC Micro to Mini Patchcords






78

CONNECTION

SYSTEMS

Description

Features

Rated Voltage

Rating


Description

Features

Rated Voltage

Rating


Receptacles

898P Pico-Style Distribution Boxes

898N Mini-Style Distribution Boxes

898D DC Micro-Style Distribution Boxes

898R AC Micro-Style Distribution Boxes

• Mini distribution boxes

• 3 and 4 pin mini connector type

• Side mount inputs

• 4, 6, or 8 port parallel wired

• LED and non-LED versions

• Mini-Plus style quick disconnect

master connector

• Rugged yellow PET body

• Non-LED models: 600V

• LED models:120V AC

• NEMA 4, 6P, 12, 13 IP67,

1200 PSI Washdown

• 4 port: 98 mm x 73 mm x 38 mm

• 6 port: 14 3mm x 73 mm x 38 mm

• 8 port: 187 mm x 73 mm x 38 mm

• DC micro distribution boxes

• 4 pin DC micro connector types

• Top mount inputs


• PNP or NPN wired LED and

non-LED versions

• Single input or dual inputs per port

• Prewired master cable or

mini-plus style QD

• Terminal Block

• Rugged grey Pocan body

• 10-30V DC

• IP67, 1200 PSI

• 4 port: 102 mm x 60 mm x 20 mm

• 6 port: 127 mm x 60 mm x 20 mm

• 8 port: 152 mm x 60 mm x 20 mm

• AC micro distribution boxes

• 3 pin AC micro connector type

• Side mount inputs



• Mini-plus style quick disconnect

master connector

• Rugged yellow PET body

• 300V (Non-LED models)

• 120V AC (LED models)

• IP67, NEMA 6P

• 4 port: 98 mm x 73 mm x 38 mm

• 6 port: 143 mm x 73 mm x 38 mm

• 8 port: 187 mm x 73 mm x 38 mm

• Mini-plus receptacles • Mini receptacles • DC micro receptacles

• AC micro receptacles • Pico receptacles

• 2, 3, 4, 5, 6, 7, 8, 9, 10 and 12 pin connector

• Male and female versions

• 1/2-14 NPT threads

• 16, 18, 22 or 24 AWG conductors

• Oil resistant PVC conductor insulation

• Rugged anodized aluminum body and PVC insert

• Rugged die cast zinc body

• Front or rear mount styles

• Gold over nickel plated brass

• 16AWG: 600V • 18AWG: 300V


• 33 mm x 32 mm • 25.4 mm x 25.4 mm

• 24 mm x 24 mm • 24 mm x 18 mm

• Male: 19 mm x 10 mm

• Female: 16 mm x 10 mm

• Pico distribution boxes

• 3 pin pico connector type

• Top mount inputs

• 4, 6, 8, 10, or 12 port parallel wired

• PNP LED versions

• Pre-wired master cable

• Rugged grey Pocan body

• 4 ,6 port with 8 pin DC

Micro Main Connector

• 10-30V DC

• IP67

• 4-port: 92 mm x 24 mm x 18 mm

• 6-port: 118 mm x 24 mm x 18 mm

• 8-port: 144 mm x 22 mm x 18 mm

• 10-port: 170 mm x 22 mm x 18 mm

• 12 port: 196 mm x 22 mm x 18 mm

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79

• Male or female mini

terminal chambers

• 3, 4 and 5 pin connector types


• Screw terminal connection

• PBT connector body

• Supports cable O.D.s from

6 mm to 14 mm

• 600V

• IP67, NEMA 6P



• Male or female DC micro

terminal chambers

• 4, 5 and 8 pin connector types


• Single and dual cable models

• Straight and right angle models




4 mm to 8 mm

• 1-4 pin thermistor model

• 250V (8 pin = 60V)

• IP67



• Cable spools

• 3-, 4-, 5- and 6-conductor

AWM styles

• Braided shield or unshielded versions

• Yellow, blue or black PVC cable

jacket and yellow PUR and TPE

• 22AWG or 18AWG conductors

• IEC or automotive color code

• 300V

–

• Standard cable lengths of 50, 100

and 200m


• Male or female AC micro terminal

chambers

• 3 pin connector type

• Straight and right angle models


• Nylon connector body


4 mm to 8 mm

• 250V

• IP67, NEMA 6P



• Mini-plus and M23-style quick disconnect

• Supports 16 and 32 point AC and DC

inputs (for sensors) or outputs

(for pneumatic valves)

• Supports 16 point AC and DC input

modules (sink & source)

• Supports 1746, 1756, 1769, 1771 and

1794 I/O platform

• 10-265V DC and AC

• IP65, NEMA 1, 4, 4X, 12

• 114.5 mm x 88 mm x 43 mm and

114.5 mm x 143 mm x 43 mm

• 16-point input for 8 port distribution boxes

(LED and non-LED) OR 16-point output for

direct connection to pneumatic valves via

4/8 port distribution boxes

889S, 889V, 889W, 889Y, 889Z DIN Valve Cordsets and Field Attachable Connectors

• DIN Valve cordests

• DIN Valve Field Attachables

• Built-in surge suppression and quick disconnect

• Wiring configurations ranging in various sizes 8-18mm


• 12AWG and 20AWG cable

• Multiple jacket types: black PVC and PUR

• AC/DC Voltages: 24, 115, 230 and 0-250V

• Cordsets: NEMA 6, IP67 • Field Attachables: NEMA 4, IP65

• Cordset Styles: Valve A (18 mm), Valve B (11 mm), Valve C (9.4 mm)

• Field Attachable Connectors: Valve A (18 mm), Valve B (11 mm),

Valve BEU (10 mm), Valve C (9.4 m), Valve CEU (8 mm)

• Male or female DC micro

terminal chambers

• 3 and 4 pin connector types


• Straight and right angle styles

• Insulation Displacement Connection (IDC)

technology

• Fits cable O.D.s from 4.0 mm

to 5.1 mm

• 32V/50V

• IP67


• Right angle:

39 mm x 39 mm x 15 mm

• Male or female pico

terminal chambers



• Straight connector style

• Insulation Displacement

Connection (IDC) technology

• Fits cable O.D.s from 4.0 mm

to 5.1 mm

• 32V

• IP67

• Male: 41 mm x 12 mm

• Female: 43 mm x 12 mm

• Male or female pico terminal chambers


• Straight connectors



• AWG 20

• 60V, 4 A

• IP67


871A Mini-Style Terminal Chambers (Field Attachable)

871A DC Micro-Style Terminal Chambers (Field Attachable)

871A Pico-Style Terminal Chambers (Field Attachable)

871A AC Micro-Style Terminal Chambers (Field Attachable)

1667 PanelConnect

889D DC Micro-Style IDC Terminal Chambers (Field Attachable)

889P Pico-Style IDC Terminal Chambers (Field Attachable) Cable Spools





what’s next a sneak preview of future Sensing and Connectivity products from Rockwell Automation

MULTISIGHT WITH ETHERNET/IP This new development will maximize the capability of the new MultiSight Vision Sensor by making all of the sensor’s analytical data available on the network for detailed product inspection information. An Add-On Profile for your Logix PLC program will create predefined tag names for inspection values, position information, and the results of multiple virtual detectors. This network connection will also allow the user to show the image file on a PanelView or store it for future reference. The EtherNet/IP model will include more virtual detectors - 32 in total - to maximize the number of locally stored configurations. This model will also include a new Contour algorithm with full 360-degree rotational compensation, allowing the detection of a line contour in any orientation. Coming first quarter 2008.

45FPL - NEXT GENERATION FIBER OPTIC SENSOR The 45FPL DIN rail mountable fiber optic sensor will feature dramatically improved sensing ranges and a bigger, brighter display than the current family. The large teach button and easy setup will enable fast implementation and adjustment. One push of the button will change the readout from current light level to the taught light level. Available January 2008.

NEXT GENERATION COLORSIGHT The newest addition to the ColorSight family of true color detecting sensors will be housed in a 50 mm x 50 mm rectangular package. Three teachable outputs will allow multiple color matching and sorting. The color scan feature will allow a single output to be taught multiple colors, useful for general sortation and enabling very wide color tolerance. Most color sensors on the market are extremely sensitive to changes in operating distance – a change of less than 2 mm between the sensor and the target can cause the sensor to change state. The next generation Allen-Bradley ColorSight will feature best-in-class tolerance for change in scanning distance--up to +/- 6mm! The sensor will also feature a gating input, teach button lockout, and remote teach. An optional off-delay pulse stretcher (50ms) will be key for high-speed applications. For advanced users that want a true color RGB output, a model with an RS-485 serial port will also be available, allowing the user to match any number of colors by analyzing the color components with a PLC or PC program. Coming January 2008.

842HR SINE COSINE ENCODERS Bulletin 842HR is a 15-bit high resolution sine-cosine encoder with Hiperface interface and position accuracy of +/- 5 arc seconds. The 842HR will be ideal for high performance digital servo drive systems that require absolute feedback for position control and high resolution incremental feedback for speed control. Available May 2008.

M12 D-CODED ETHERNET CONNECTIVITY M12 D-coded patchcords will be the next addition to the growing Allen-Bradley Ethernet connectivity portfolio. The overmolded M12 connectors will create an industrialized, two pair connection, combining metal coupling nuts and a durable cable to offer enhanced noise immunity with high electrical and mechanical performance. M12 D-Coded patchcords will provide standard connectivity for a broad range of Rockwell Automation products and general industrial Ethernet applications. Coming Fall 2007.

RJ45 CONNECTIVITY New Ethernet RJ45 media will be a rugged, reliable connectivity solution for all applications from the office floor to the plant floor. More durable than standard office-grade network cable, these cables and connectors will allow for high network integrity and performance. Cables will provide a secure connection thanks to enhanced strain relief for maximum support at the connectors. Plus, you’ll see a full complement of RJ45 Ethernet connectivity components including field-attachable Insulation Displacement Connectors (IDC) and an IP67 housing for the RJ45 connector option (known as Variant 1) on field-attachable connectors and receptacles for harsh industrial environments. Available Fall 2007.

SOLID-STATE CONDITION SENSORS WITH SANITARY CONNECTIONSThe all-new line of sanitary connectors for Allen-Bradley 83xE solid state condition sensors will allow the switches to be used in an even wider range of applications. The 316L stainless steel construction of the switch coupled with the new sanitary connectors, laser etched marking and IP67 rating will make these switches the ideal solution for food, beverage, dairy, pharmaceutical and other applications requiring equipment washdown. Available October 2007.

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Technical Phone Support Center

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Rockwell Automation Sales Office, Field Support Dispatch (outside U.S.) and/or Open Enrollment Training Location

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The global Rockwell Automation Services & Support network includes over 1000 field support engineers, phone support specialists, asset management professionals, training instructors and repair technicians. Our broad network of automation specialists utilize the global resources of Rockwell Automation to provide local, award-winning services and support for your automation equipment.

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U.S./Canada 1.440.646.3434Canada (CALLOUT SERVICES ONLY) Call local Rockwell Automation Sales Office Weekdays 8am-5pm local time 1.800.422.4913 Weekends, holidays, weekdays 5pm-8am local time

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a sneak preview of future Sensing and Connectivity products from Rockwell Automation

SOLID-STATE LEVEL SWITCHES New Allen-Bradley level switches will be yet another addition to the expanding solid-state condition sensing switch line. Suitable for use with all fluids in tanks, containers and pipelines, this new level switch is constructed of rugged 316L stainless steel, is easy to install and provides visible level status via an LED display. Ideal applications include overfill or top level detection and lower level or dry-running protection for medium temperatures up to 150°C. Available March 2008.

NON-DISPLAY SOLID-STATE CONDITION SENSORS Rockwell Automation is also adding non-display pressure and temperature transmitters to its Allen-Bradley solid-state condition sensing product offering. The pressure transducer will measure absolute and gauge pressure up to 6000 psi, while the temperature transmitter will provide a 4-20 mA output for temperature measurement from -60 to +320°F. Allen-Bradley non-display pressure and temperature transmitters will be an economical solution for accurate and reliable pressure and temperature measurements. Available April 2008.

WORLDPROX II 12 mm NICKEL-PLATED BRASS INDUCTIVE PROXIMITY SENSORS The WorldProx plastic face/threaded Nickel-plated brass barrel inductive proximity sensor line currently consists of standard, short barrel and extended sensing range models. Rockwell Automation will offer a new 12mm sensor in this line with a fully embeddable barrel (no unthreaded section at the end) and PUR or PVC cable connection options. The standard cable lengths will be expanded to include not only 2 meter cables, but also 5 and 10 meter cable versions. Rockwell Automation will offer these same new features in the 8 mm, 18 mm and 30 mm versions in the near future. Coming mid 2008.

802T-*G* LOW ENERGY LIMIT SWITCHES Since low energy loads do not arc or burn the contacts clean, contaminants may cause erratic switch behavior. Allen-Bradley low energy limit switches from Rockwell Automation are designed with welded gold and silver alloy contacts to provide a protective barrier against surface oxides. Using a stationary waffle-shaped contact to optimize contact pressure to stabilize the contact resistance in the region of the micro load, these new limit switches will be suitable for machine connectivity and low voltage facilities. Allen-Bradley low energy limit switches will also incorporate a prism-shaped crossbar contact to provide high pressure that will penetrate foreign particles which could prevent contact closure. Available March 2008.

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Look for new issues of these Rockwell Automation magazines throughout 2007 and beyond.

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Publication SC-BR001A-EN-P – September 2007 Copyright ©2007 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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