Micropulse AR... Optimized for the Mobile Hydraulics of the Future

General DataRod Series AR

Micropulse ARTransducers

Position detection inmobile hydraulics

Sensors are being usedincreasingly to extend usefullife and improve safety inmobile equipment. The newMicropulse AR Transducerfrom Balluff senses thepiston position in mobilehydraulic cylinders.The sensor operates on theproven magnetostrictiveprinciple. The compact sizeof the transducer makes itideal for use in pivot bearingand spherical eye endcylinders or large borecylinders. The processingelectronics integrated in thetransducer has beendesigned to meet the strictEMC Directives for industriallift trucks, agricultural andforestry equipment andearthmoving machinery.

Compatibilitytesting according toEMC Directives

ISO 14982 Agriculturaland Forestry MachineryISO 13766Earthmoving MachineryISO 7637-1/2/3Road VehiclesEN 12895 Industrial TrucksEN 50121-3-2Railway ApplicationsISO 11452-5Electromagnetic HF field,200 V/m

AR.2

Note! Before construction,installation and startupplease familiar yourself withthe user's guide to befound at www.balluff.com.

e1

Integrated in cylinders for controlledwork processes, safety and productivity

e1 Type-Approval

The e1-Type Approval isgranted by the GermanFederal Motor TransportAuthority KBA and confirmsthat special motor vehiclestandards have beenmaintained.The devices may bemounted on vehicles whichtravel on public roads. Thestandards describe EMCconditions under which thedevices must operatewithout failure. e1 approvedMicropulse transducers areindicated by the designation"-SA265-" in the partnumber.

BTL6 Rod AR

BTL6-...-M_ _ _ _-E2/E28-_ _ _ _

100 g/6 ms per IEC 60068-2-2750 g/2 ms

12 g, 10...2000 Hz per EN 60068-2-6yes

500 V DC (GND to housing)IP 67

Outer tube 1.4571 stainless, flange 1.4404 stainless350 bar when installed in hydraulic cylinder250 bar when installed in hydraulic cylinder

Cable connection or pigtail

EN 55011 Group 1, Class A/BIEC 61000-4-2 Severity Level 3IEC 61000-4-3 Severity Level 3IEC 61000-4-4 Severity Level 3IEC 61000-4-5 Severity Level 2IEC 61000-4-6 Severity Level 3IEC 61000-4-8 Severity Level 4

0025, 0050, 0075, 0100, 0125, 0150, 0175, 0200, 0225, 0250, 0275, 0300,0325, 0350, 0375, 0400, 0425, 0450, 0475, 0500, 0550, 0600, 0650, 0700,0750, 0800, 0850, 0900, 0950, 1000, 1100, 1200, 1300, 1400, 1500 or1mm increments on request

Series

Order code

Shock loadContinuous shockVibrationPolarity reversal protectedDielectric strengthProtection per IEC 60529Housing materialPressure rating with 10.2 mm outer tube E2Pressure rating with 8 mm outer tube 28Connection typeEMC tests:RF EmissionStatic Electricity (ESD)Electromagnetic Fields (RFI)Rapid Transients (BURST)Surge VoltageLine-induced DisturbancesMagnetic FieldsStandard nominal stroke lengths [mm]with 8 mm outer rod (style E28) is the max.nom. stroke length 1016 mm

AR.3

Micropulse ARTransducers

General DataRod Series AR

www.balluff.com

GeneralData

AnalogInterface

Digital PulseInterface

InstallationNotes

Magnet

Balluff TestingLaboratory

Magnet

Nominal stroke = measuring area Damping zone(unusable area)

Magnet

Nominal stroke = measuring area Damping zone(unusable area)

Magnet

Nominal stroke = measuring area Damping zone(unusable area)

Housing E2/E28,BTL6-...-E2/E28-_ _ _ _-LA

Cable outaxial with pigtail

Housing E2/E28,BTL6-...-E2/E28-_ _ _ _-KA

Cable outaxial centric

Housing E2/E28,BTL6-...-E2/E28-_ _ _ _-KE

Cable outaxial eccentric

BTLAR

E2E28

A (mm)10.2

8

G (mm)Thread M4 × 4/6 deep

No thread

E2E28

A (mm)10.2

8

G (mm)Thread M4 × 4/6 deep

No thread

E2E28

A (mm)10.2

8

G (mm)Thread M4 × 4/6 deep

No thread

BTL6-A/BBTL6-E/CBTL6-P

B25.229.7525.2

C131316

BTL6-A/BBTL6-E/CBTL6-P

B25.229.7525.2

BTL6-A/BBTL6-E/CBTL6-P

B25.229.7525.2

C131316

SeriesOutput signalTransducer interfaceCustomer-side interface

Order code

Output voltageOutput currentLoad currentRipple max.Load resistanceSystem resolution

HysteresisRepeat accuracySampling ratemax. non-linearity

Temperature Voltage outputcoefficient Current outputSupply voltageCurrent drawPolarity reversal protectedOvervoltage protectedDielectric strengthOperating temperatureStorage temperature

Pin assignments ColorOutput signals GY

GNOperating voltage BU

BNShield connected to housing

Analog InterfaceRod Series AR

Micropulse ARTransducers

AR.4

Please enter code for outputsignal, nominal stroke,housing style and connectiontype in the order code!

▼

Scope of delivery:– Transducer– Short guide

Dimensions and mechanical data AR.3Please order separately:Magnets see page AR.9

▼

The propagation time of anultrasonic wave, induced bymagnetostriction, is used todetermine the position of themagnet.

The position is output as ananalog value which rises.This is done with highprecision and repeatabilitywithin the measuring areadesignated as the nominalstroke length. If there is nomagnet within the measuringarea, an error signal isoutput. At the rod end is adamping zone. When amagnet is in this zone theoutput is spurious. Theelectrical connectionbetween the transducer, thecontroller and the powersupply is accomplishedusing a cable or pigtail.

Output signal rising

Magnet position1 Within the measuring area2 Magnet not present

Output signal

Error signal

Null point End point

Analog InterfaceRod Series AR

AR.5

Micropulse ARTransducers

www.balluff.com

BTLAR

BTL6 Rod ARanalog

Eanalog

BTL6-E500_-M_ _ _ _-_ _ _-_ _ _ _ _

4...20 mm

≤ 500 Ohms±7 µA

BTL6-E500...0 V output4...20 mm

GND10...30 V DC

BTL6 Rod ARanalog

Banalog

BTL6-B500-M_ _ _ _-_ _ _-_ _ _ _ _

0...5 mm

max. 2 mA≤ 2 mV

±1.5 mV

BTL6-B500...0 V output0...5 mm

GND10...30 V DC

BTL6 Rod ARanalog

Aanalog

BTL6-A500-M_ _ _ _-_ _ _-_ _ _ _ _

0...10 mm

max. 2 mA≤ 5 mV

±1.5 mV

BTL6-A500...0 V output0...10 mm

GND10...30 V DC

BTL6-_500-M_ _ _ _-_ _ _-_ _ _ _ _Ordering example:

Connection type

Axial outKA02 PUR cable 2 m

Axial eccentric outKE02 PUR cable 2 m

Axial outLA00,3 PUR pigtail 0.3 m

0025, 0050, 0075, 0100, 0125,0150, 0175, 0200, 0225, 0250,0275, 0300, 0325, 0350, 0375,0400, 0425, 0450, 0475, 0500,0550, 0600, 0650, 0700, 0750,0800, 0850, 0900, 0950, 1000,1100, 1200, 1300, 1400, 1500or in 1mm increments onrequest

Standardnominal stroke [mm] HousingOutput signal

A 0...10 VB 0...5 VE 4...20 mA

E2 outer tubeØ 10.2 mm

E28 outer tubeØ 8 mm,max. nominalstroke 1016 mm

≤ 4 µmSystem resolution/min. 2 µm

fSTANDARD = 1 kHz±200 µm up to 500 mm nominal stroke

typ. ±0.02 % ≥ 500 nominal stroke[150 µV/°C + (5 ppm/°C × P × U/L)] × ΔT[0.6 µA/°C + (10 ppm/°C × P × I/L)] × ΔT

10...30 V DCtyp. ≤ 60 mA

yesyes

500 V DC (GND to housing)–40...+85 °C–40...+100 °C

GeneralData

AnalogInterface

Digital PulseInterface

InstallationNotes

Magnet

Balluff TestingLaboratory

Digital Pulse InterfaceP510, Rod Series AR

Micropulse ARTransducers

AR.6

Block diagram of the P-interface

P510 interface

Compatible with Balluff BTAprocessors and controllersand modules from variousmanufacturers, includingSiemens, B & R, Bosch,Phoenix Contact, Mitsubishi,Sigmatek, Parker, Esitron,WAGO and others. Reliablesignal transmission even overcable lengths of up to 500mbetween the BTA processorand the transducer isassured by the especiallynoise-immune RS485 diffe-rential drivers andreceivers. Noise signals areeffectively suppressed.

P510 universal forrising and falling edgeevaluation

As a consequence of diffe-rent control philosophies,digital pulse interfaces areavailable in two differenttypes depending on thecontroller.The difference is in whichedge is used for processing.In the "P-interface" the fallingedges are used for timing

and in the "M-interface" therising edges.To reduce the number ofdifferent models to aminimum, the "P510-interface" was created as auniversal pulse interfacewhich combines bothfunctions.The reference point for thepropagation timemeasurement is the "Start"pulse.

ASIC INFO:+49 7158 173-241

High-accuracydigitizing chip for P510pulse interface

Companies who developtheir own control andprocessing electronics canuse the Balluff digitizingchip to implement a highlyaccurate P-type interfaceat low cost and withoutgreat effort. The digitizingchip was developed as ahigh-resolution,parameterizable ASIC forMicropulse transducershaving a P-type pulseinterface.

Digitizing chip 44QFP

CPU-Controller

4/8Bit-BUS

5 V Osc.

INIT

Micropulse transducer with1 to 4 magnets

Controller orprocessing electronics

P-pulse signal

Advantages

– High displacement resolution:the actual resolution of theBTL displacement measuringsystem of 1 µm is fullysupported by the resolution ofthe 133 ps chip (at low clockfrequency 2 or 20 MHz)

– Position data from4 magnets can be processedsimultaneously

– 4-/8-bit processor interface

Series

Transducer interfaceCustomer-side interface

Order code

System resolutionRepeat accuracyRepeatabilityResolutionNon-linearity

Supply voltageCurrent drawOperating temperatureStorage temperature

Pin assignments ColorIn-/output signals Input YE

Output GYInput PKOutput GN

Operating voltage BUBN

Shield connected to housing

Digital Pulse InterfaceP510, Rod Series AR

AR.7

Micropulse ARTransducers

www.balluff.com

BTLAR

Please enter code for outputsignal, nominal stroke,housing style and connectiontype in the order code!

▼

Scope of delivery:– Transducer– Short guide

Dimensions and mechanical data AR.3Please order separately:Magnets see page AR.9

▼

BTL6-P510-M_ _ _ _-_ _ _-_ _ _ _ _Ordering example:

Axial outKA02 PUR cable 2 m

Axial eccentric outKE02 PUR cable 2 m

Axial outLA00,3 PUR pigtail 0.3 m

Connection type

0025, 0050, 0075, 0100, 0125,0150, 0175, 0200, 0225, 0250,0275, 0300, 0325, 0350, 0375,0400, 0425, 0450, 0475, 0500,0550, 0600, 0650, 0700, 0750,0800, 0850, 0900, 0950, 1000,1100, 1200, 1300, 1400, 1500or in 1mm increments onrequest

Standardnominal stroke [mm] Housing

E2 outer tubeØ 10.2 mm

E28 outer tubeØ 8 mm,max. nominalstroke1016 mm

GeneralData

AnalogInterface

Digital PulseInterface

InstallationNotes

Magnet

Balluff TestingLaboratory

BTL6 Rod AR

Pulse P510Pulse P510

BTL6-P510-M_ _ _ _-_ _ _-_ _ _ _ _

processor-dependent≤ 10 µm≤ 20 µm≤ 10 µm

±200 µm up to 500 mm nominal stroketyp. ±0.02 %, max. ±0.04 % 500...1500 mm nom. stroke length

10...30 V DC≤ 60 mA (at 1kHz)

0...+70 °C–40...+100 °C

BTL6-P510-M... INIT

START/STOPINIT

START/STOPGND

+24 V DC

P1 P510 M1

Micropulse ARTransducers

AR.8

Installation NotesRod Series AR

Series AR BTL Micropulsetransducers are designed forintegration in hydrauliccylinders. The transducer ismechanically supported atthe housing. 3 M5 setscrews spaced at 120 °Chold the transducer, whichfits into a Ø 48 H8 hole.

Sealing is accomplishedusing the supplied O-ringand support ring.The magnet ring, which isintegrated into the piston,marks the actual positionof the piston as it moveswithout contact.

Spacer made of non-magnetizable material

Magnet

Installation examples

Non-magnetizable material

Magnet

Note! Before construction,installation and startupplease familiar yourself withthe user's guide to befound at www.balluff.com.

Set screwDIN 914 M5×8

Fixing the transducerusing 3 M5 set screwsspaced 120 °C

Spacer made of non-magnetizable material

Magnet

� Installation on piston side� Installation from rear� Installation on piston side, in magnetic piston material

�

�

�

The metal surrounding of the cylinder replaces the needed cable shield when the BTL AR...LA, cable out pigtail version isinstalled in the cylinder. The pigtail version cannot be used without additional EMC protection (shield).

MagnetRod Series AR

Micropulse ARTransducers

AR.9www.balluff.com

Descriptionfor series

Order code

MaterialWeightMagnet traverse speedOperating temperature/storage temperature

Order code PA 60 fiberglass reinforced

MaterialWeightMagnet traverse speedOperating temperature/storage temperature

MagnetBTL6 rod

BTL-P-1012-4R

Alapprox. 12 g

any–40...+100 °C

BTL-P-1012-4R-PA

PA 60 fiberglass reinforcedapprox. 10 g

any–40...+100 °C

MagnetBTL6 rod

BTL-P-1014-2R

Alapprox. 10 g

any–40...+100 °C

MagnetBTL6 rod

BTL-P-1013-4R

Alapprox. 12 g

any–40...+100 °C

BTL-P-1013-4R-PA

PA 60 fiberglass reinforcedapprox. 10 g

any–40...+100 °C

BTLAR

MagnetBTL6 rod

BTL-P-0814-GB-PAF

Ferrite PA 6approx. 1.5 g

any–40...+100 °C

GeneralData

AnalogInterface

Digital PulseInterface

InstallationNotes

Magnet

Balluff TestingLaboratory

Balluff Testing LaboratoryMicropulse ARTransducers

AR.10

Objective: Simulate themechanical loads on aproduct over its working life.Balluff products are oftenfitted in machines whenmechanical vibrations andimpacts occur. For reliableoperation they must bedesigned to be immune tovibration and shock. In theBalluff test laboratory allproducts are therefore testedbefore series release fortheir mechanical stability.

The features of the vibration test equipment at Balluff are as follows:

Manufactured by Unholtz-Dickie CorporationModel SA 15-S092-BP SAI60-H560B-24-LPsinusoidal force vector 4.4 kN 35.6 kNrandom force vector 4.4 kN 35.6 kNshock force vector 8.8 kN 73 kNmax. sinusoidal acceleration 100 g 89 gmax. random acceleration 100 g 74 gmax. shock acceleration 200 g 210 gmax. sinusoidal velocity 2.0 m/s 1.9 m/smax. shock velocity 5.1 m/s 3.5 m/smax. amplitude 51 mmp-p 51 mmp-pFrequency range up to 3.5 kHz up to 2.7 kHz

The following tests can beperformed on thisequipment:

– Sinusoidal testing– Noise testing– Shocks

in addition one equipment iffitted with an FFT analyzer.

Tests can be performed tothe following standards:

MIL STD 202EN 60068-2-6EN 60068-2-27EN 60068-2-29EN 60068-2-64DIN EN 50155IEC / EN 61373GL 2001

Reliability doesn't happen by chanceTests and checks during the development process improve theproduct and give protection against "surprises" in service.

AR.11

BTLAR

www.balluff.com

GeneralData

Analog Inter-face

Digital PulseInterface

InstallationNotes

Magnet

Balluff TestingLaboratory

1.Electro-magneticcompatibility (EMC)

2.Product-specifictests

3.Shock, sinusoidaland noise tests

4.Other

Test equipmentESD generator ESD 30C, EM test with IEC fingerand relay discharge moduleGTEM cell 1500, MEBSignal generator SML, Rohde & SchwarzHF amplifier model 100W1000M1, ARHF amplifier model CBA9429, SCHAFFNERHF circuit network RFSN, SCHAFFNERWattmeter NRVS, Rohde & SchwarzWattmeter head NRV-Z 51, Rohde & SchwarzDirectional coupler RK 100, MEBDirectional coupler C6187, VERLATONEField strength measurement system HI-6005, HoladaySoftware MEB IMM, SCHAFFNERBurst generator EFT 503, EM-TestCapacitive coupler HFK, EM-TestHybrid generator CE-SURGE, Hilo-TestCoupling / decoupling network CDN 104Coupling / decoupling network CDN 202Signal generator SMH, Rohde & SchwarzHF amplifier model 150A100A, ARCoupling / decoupling network M2, MS3, S4, S9,AF2, AF4, RJ45/5EM injection clamp F-203I-23mm, FCCSoftware MEB IMM, Schaffner MEBSelf-built test equipment, Balluff GmbH

Self-built test equipment, Balluff GmbH

GTEM cell 1500, MEBMeasurement logger SM41, MEBSoftware, MEBMeasurement logger ESHS 30, Rohde & SchwarzNetwork simulator ESH3-Z5, Rohde & SchwarzShield CubicleFrame antenna HLA6120, SCHAFFNERMeasurement logger ESHS 30, Rohde & SchwarzShield Cubicle

Self-built test equipment, Balluff GmbHSelf-built test equipment, Balluff GmbH

Self-built test equipment, Balluff GmbH

Shock and vibration equipment, modelSA15-S092-PB and model SAIGO H560B-24LP,Unholtz-Dickie with software modules for:Sinusoidal vibrationsShocksNoise testsSignal analysis

X-ray inspection equipment RTX 113,HEEB-INOTEC

TestsImmunity from discharge of static electricity(EN 61000-4-2)Immunity from electro-magnetic fields(EN 61000-4-3)

Immunity from rapid transient interference (bursts)(EN 61000-4-4)Immunity from abrupt voltage surges(EN 61000-4-5)

Immunity from mains-borne high-frequency interference (EN 61000-4-6)

Immunity from magnetic fields withpower transmission frequencies (EN 61000-4-8)Immunity from voltage dips, short breaks inpower supply and voltage fluctuations(EN 61000-4-11)Radiated emissions(EN 55011)

Mains-borne emissions(EN 55011)

Emissions, HF magnetic field(DIN EN 300 330-1)

Making capacity / breaking capacity (EN 60947-5-2)Testing cable anchoring of devices with integralconnection cables(EN 60947-5-2)Short circuit testing (EN 60947-5-2)

Shock, sinusoidal and noise testing

(EN 60068-2-6)(EN 60068-2-27; EN 60068-2-29)(EN 60068-2-64)

X-ray analysis

Test equipment in the test laboratory

Overview –Industry Standard

Micropulse ARTransducers

Balluff GmbHSchurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone +49 7158 173-0Fax +49 7158 5010balluff@balluff.de N

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For additional transducers, seethe BTL main catalog, ourCD-ROM, DVD-ROM or go online!

www.balluff.com

Closed-loop controland higher dynamicswith SSI-SYNC

The absolute positioninformation from theMicropulse Transducer issent synchronously tothe axis control card. Thissynchronous dataacquisition enables exactcalculation of the velocityand acceleration.

The right feedbacksystem forevery application

– Non-contact, wear-freesystem

– Very reliable with highprotection rating

– Pressure rated forintegration in cylinders

– Wide variety ofinterface options

– Special form factors,e. g., for EX or redundantapplications

By feeding these statevariables (velocity andacceleration) back, thedamping and naturalfrequency of a hydraulicsystem are increased. Thesemeasures permit greaterloop gain and with it bettercontrol behavior and higherdynamics.

Profile Special series3× redundant

Compact rodfor EX zone

Compact rodStandard rod