A/B/Y/Z(8) - Micropulse Linear Position Sensors
Contents
1. Fig 6 1 Connecting the communication box with a connector E www balluff com With a BTL7 A E KA_ _ transducer the communication lines La Lo and GND must be connected to the USB communication box Controller 1 a 8 pin Connection cable approx 0 6 m with luster terminal Fig 6 2 Connecting the communication box with a cable connection When reading or writing data via the Configuration Tool both LEDs flash green 6 3 Configuration options Prerequisites USB communication box connected to the transducer and PC Software correctly installed Transducer connected to the power supply Magnet on transducer Magnets and outputs One or two magnets can be selected factory setting one magnet Two outputs can be assigned independently Output functions Position position in the measuring range Velocity velocity of the magnet The sign indicates the direction of movement Movement from the null point to the end point is output with a positive sign Movement from the end point to the null point is output with a negative sign Max detectable velocity range of 10t0 10 m s Velocity no sign velocity of the magnet The direction of movement cannot be read Max detectable velocity range of O to 10 m s Differential position Distance between two magnets Selection is only possible if two magnets have been selected english2. BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 9 Adjust with the calibration device continued Switch the output to be adjusted optional il As standard the values are adjusted at output 1 and the values at output 2 are inverted accordingly From serial number 100503000xxxxx xx it is LED display Displayed values example possible to optionally switch adjustment from Initial situation Transducer with magnet within measuring range ip 5 39 V 9 15 mA Activate adjusting gt Press for at least 4 s sae 5 39 V 9 15 mA Switch the output to be adjusted gt Press and for at least 4 s until one LED flashes 0 2 green O O For output 2 or for output 1 changes with each switch O O gt Both LEDs will flash again once the buttons are released Continue with Set start point see page 21 LED legend O LED not on O LED green A A R R R LED flashing green O LED 1 and LED 2 flashing red red in alternation E www balluff com english BALLUFF BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 1 0 Reset all values with the calibration device reset NOTICE Interference in function Resetting all values while the system is running may result in malfunctions gt Stop the system before performing the re
3. BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA__ Micropulse Transducer Rod Style 9 Adjust with the calibration device continued Set end point Bring magnet to the new end point ipj gt Press for at least 2 s gt 2s The new end point is set with the last valid end value Adjust end value gt The end value can be changed using and The gradient of the curve changes see page 19 End calibration procedure Briefly press and simultaneously lt 1 s gt Set position value is saved End adjustment gt Briefly press and simultaneously lt 1 s lt 1s The current position value is displayed once the buttons are released il Any of the individual steps for settings can be selected The adjustment process can be ended at any time LED display Displayed values example LED1 LED2 AtOto10V At4to20 mA 9 89 V 19 13 mA IN IN A z A 1000v 20 00 mA 10 00V 20 00 mA 8 00 V 16 80 mA 8 00 V 16 80 mA 1 Briefly press button Current value is increased or LED legend O LED not on decreased by approx 1 mV or 1 pA If a button is held down longer than 1 s the step LED green interval is increased gt gt 4 gt gt 4 LED 1 and LED 2 flashing red green in alternation O LED 1 and LED 2 flashing red red in alternation BALLUFF english
4. 1 adapter cable approx 0 6 m condensed guide english BALLUFF 29 30 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 13 type code breakdown BTL7 A501 M0500 B S32 7 Micropulse transducer Interface A Analog interface voltage output O to 10 V E Analog interface current output 4 to 20 mA Supply voltage 5 10 to 30 V DC Output gradient 01 2 outputs configurable Nominal stroke 4 digit M0500 Metric specification in mm nominal length 500 mm Rod version fastening A Metric mounting thread M18x1 5 rod diameter 10 2 mm B Metric mounting thread M18x1 5 O ring rod diameter 10 2 mm Y 3 4 16UNF thread rod diameter 10 2 mm Z 3 4 16UNF thread O ring rod diameter 10 2 mm A8 Metric mounting thread M18x1 5 rod diameter 8 mm B8 Metric mounting thread M18x1 5 O ring rod diameter 8 mm Y8 3 4 16UNF thread rod diameter 8 mm Z8 3 4 16UNF thread O ring rod diameter 8 mm Electrical connection 32 8 pin M16 plug per IEC 130 9 115 8 pin M12 plug 140 10 pin plug KAO5 Cable 5m BALLUFF english BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 14 14 1 Converting units of length 1 mm 0 0393700787 inch 3 3 inches 0 03937008 0 07874016 0 11811024 0 15748031 0 19685039 0 23622047 0 27559055
5. 14 BALLUFF english BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 5115 S140 KA__ 6 Configuration with the Micropulse Configuration Tool 6 1 Micropulse Configuration Tool NOTICE Interference in function Configuration with the Micropulse Configuration Tool while the system is running may result in malfunctions gt Stop the system before configuration The BTL7 A E USB Configurable transducer can be configured quickly and simply on a PC using the Micropulse Configuration Tool PC software The most important features include Online display of the current position of the magnet Graphical support for setting the functions and curves Display of information on the connected transducer Selectable number formats and units for display Resetting to factory settings is possible Demo mode without having transducer connected The PC software and associated manual can be found in the Internet under www balluff com downloads btl7 6 2 Connecting the USB communication box With BTL7 A E transducers with connectors the communication box must be looped in between the transducer and controller The communication box is connected to the PC via a USB cable Connection cable approx 0 3 m with connector plug USB cab Connection cable approx 0 3 m with connector socket 4o Controller 8 pin 6 pin
6. 8mm At least 11 mm Tab 4 1 Bore diameter if installed in a hydraulic cylinder E www balluff com 4 2 Preparing for installation Installation note We recommend using non magnetizable material to mount the transducer and magnet Horizontal assembly If installing horizontally with nominal lengths gt 500 mm we recommend tightening the outer rod at the end only possible with 10 2 mm or supporting it Hydraulic cylinder If installed in a hydraulic cylinder ensure that the minimum value for the bore diameter of the support piston is complied with See Tab 4 1 Mounting hole The transducer comes with an M18x1 5 ISO or 3 4 16UNF SAE mounting thread Depending on the version a mounting hole must be made before assembly Fig 4 4 Mounting hole 3 4 16UNF per SAE J475 O ring 15 3x2 4 Magnet Various magnets are available for the BTL7 transducer See Accessories on page 27 english BALLUFF 9 BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 4 Installation and connection continued 4 3 Installing the transducer NOTICE Interference in function Improper installation can compromise the function of the transducer and result in increased wear gt The mounting surface of the transducer must make full contact with the supporting surface gt The bore must be perfectly sealed O ring flat seal gt Make amountin
7. BALLUFF 15 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA__ Micropulse Transducer Rod Style 6 Configuration with the Micropulse Configuration Tool continued Freely configurable curve Null and end points can be read teach in or specified with the mouse For position the distance between the null point and end point must be at least 4 mm 0 15 inch and 100 mm s 4 inch s for velocity The curve can be inverted or copied from the other output The limits can be adjusted to the measuring range The error value can be set in accordance with the limits Boundary conditions for two magnets Two magnets can only be selected if the nominal length is gt 90 mm The distance between two magnets must be gt 65 mm Locking the calibration device The function to manually adjust the transducer with the calibration device can be locked making configuration only possible with the PC software DANGER Uncontrolled system movement When starting up if the position measuring system is part of a closed loop system whose parameters have not yet been set the system may perform uncontrolled movements This could result in personal injury and equipment damage gt The system must be taken out of operation before configuration gt Transducers may only be connected to the communication box for configuration The communication box must be removed after configuration 16 BALLUFF e
8. oINI IAJA JION 0 31496063 co 0 35433071 10 0 393700787 Tab 14 1 Conversion table mm to inches 1 inch 25 4 mm inches mm 4 25 4 50 8 76 2 101 6 127 152 4 177 8 ONIO Bejm 203 2 9 228 6 10 254 Tab 14 2 Conversion table inches to mm E www balluff com 14 2 Part labels BALLUFF MICROPULSE t USB Configurable BTLO6Y9 Ordering code BTL7 A501 M0500 B S32 type 07112200054321 DE Serial number Wks CE www balluff com Fig 14 1 BTL7 part label english BALLUFF 31 Evww balluff com Headquarters Germany Balluff GmbH Schurwaldstrasse 9 73765 Neuhausen a d F Phone 49 7158 173 0 Fax 49 7158 5010 balluff balluff de Global Service Center Germany Balluff GmbH Schurwaldstrasse 9 73765 Neuhausen a d F Phone 49 7158 173 370 Fax 49 7158 173 691 service balluff de US Service Center USA Balluff Inc 8125 Holton Drive Florence KY 41042 Phone 859 727 2200 Toll free 1 800 543 8390 Fax 859 727 4823 technicalsupport balluff com No 858412 726 E 01 111197 Edition 1009 Subject to modification Replaces edition 0803
9. transducer 5 GN green O to 10 V output 1 Not used 6 BU blue GND 7 BN brown 10 to 30 V 8 WH white Lb communication line Tab 4 2 Connection assignment BTL7 S32 KA_ _ 4 4 2 Connector S115 115 BTL7 interface in A501 E501 1 O V pin 3 2 O V pin 5 3 10 to 0 V2 output 2 20 to 4 mA output 2 Fig 4 10 e ee 0 4 La communication line pins of transducer 5 O to 10 V output 1 4 to 20 mA output 1 6 GND 7 10 to 30 V 8 Lb communication line Tab 4 3 Connection assignment BTL7 S115 1 Unassigned leads can be connected to the GND on the controller side but not to the shield 2 Factory setting can be freely configured with the PC software 3 Reference potential for supply voltage and EMC GND E www balluff com english BALLUFF 11 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 4 Installation and connection continued 4 4 3 Connector S140 140 BTL7 interface Bin A501 E501 A OV B Not used 4 to 20 mA output 1 Fig 4 11 Pin assignment of S140 view of C 10 to 0 V output 2 20 to 4 mA output 2 aa D 10 to 30 V E Not used F GND G La communication line H Lb communication line J O to 10 V output 1 Not used K Not used Tab 4 4 Connection assignment BTL7 S140 1 Unassigned leads can be connected to the GND on the
10. 3 3 LED display LED 1 Cae _ WD Fig 3 2 Position of the BTL7 LED displays il In normal operation the LEDs indicate the operating states of the transducer LED 1 is assigned to output 1 LED 2 is assigned to output 2 see page 17 ff LED 1 LED 2 Operating state Green Normal function Magnet is within the measuring range Flashing red Measuring range left Magnet is outside the measuring range Red Error No magnet or magnet outside the limits Tab 3 1 LED displays in normal operation BTL7 A E501 M__ Micropulse Transducer Rod Style _ _ A B Y Z 8 S32 S115 S140 KA_ _ 4 Installation and connection 4 1 Installation variants Non magnetizable material Non magnetizable material min D2 Min D2 Minimum diameter of the bore see Tab 4 1 Fig 4 1 Installation variant in non magnetizable material Magnetizable material If using magnetizable material the transducer must be protected against magnetic interference through suitable measures e g spacer ring made of non magnetizable material a suitable distance from strong external magnetic fields Magnet Spacer ring made of non magnetizable material Magnet Spacer ring made of non magnetizable material Min D2 Minimum diameter of the bore see Tab 4 1 Fig 4 2 Installation in magnetizable material Tube diameter Bore diameter D2 10 2 mm At least 13 mm
11. Output BTL7 A501 Output voltage Max configuration Factory setting Load current BTL7 E501 Output current Max configuration Factory setting Load resistance Short circuit resistance 10 to 30 V DC lt 0 5 Veg lt 150 mA lt 180 mA lt 500 mA 10 ms Up to 36 V Up to 36 V 500 V AC 10 to 10 V 10 to 10 V O to 10 V 10 to O V lt 5 mA O to 20 mA 20 to O mA 4 to 20 mA 20 to 4 mA lt 500 ohms Signal cable to 36 V Signal cable to GND 11 5 Communication lines La Lb Short circuit resistance Signal cable to 36 V Signal cable to GND N Only position output For velocity output next higher measured value rate 500 us or 750 us 2 Individual specifications as per Balluff factory standard 9 For cw us The transducer must be externally connected via a limited energy circuit as defined in IEC 61010 a low power source as defined in IEC 60950 or a class 2 power supply as defined in NEC or CEC a A prerequisite is that no current can flow between GND and 0 V in the event of polarity reversal 5 Only with PC software Configuration Tool english BALLUFF 25 BTL7 A E501 M A B Y Z 8 S32 S115 S140 KA_ Micropulse Transducer Rod Style 1 1 Technical data continued 11 6 Dimensions weights Diameter of outer rod 8 mm or 10 2 mm Nominal length For 8mm 25 to 1016 mm For 10 2 mm 25 to 7620 mm Weight depends on Approx 2 kg m length Housing material Anodized aluminum Outer
12. defects and unresolvable faults occur in the transducer it should be taken out of service and secured against unauthorized use BALLUFF english 2 3 Meaning of the warnings Always observe the warnings in these instructions and the measures described to avoid hazards The warnings used here contain various signal words and are structured as follows SIGNAL WORD Hazard type and source Consequences if not complied with gt Measures to avoid hazards The individual signal words mean NOTICE Identifies a hazard that could damage or destroy the product A DANGER The general warning symbol in conjunction with the signal word DANGER identifies a hazard which if not avoided will certainly result in death or serious injury 2 4 Disposal gt Observe the national regulations for disposal BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 3 Construction and function Output signal with increasing characteristic Null point 04 Nominal length End point 60 BTL7 5115 BTL7 S32 Magnets 2 Measuring range Calibration device 3 BTL7 5140 Thread size B M18x1 5 Z 3 4 16UNF Mounting surface A 30 1 mm Y 2 0 04 1 Unusable area 2 Not included in scope of delivery 3 Not included in scope of delivery for BTL7 S140 12 8 Version D1
13. rod material Stainless steel 1 4571 Outer rod wall thickness For 8mm 0 9 mm For 10 2 mm 2mm Young s modulus Approx 200 kN mm Housing mounting via M18x1 5 or 3 4 16UNF threads Tightening torque Max 100 Nm Cable diameter Max 7 mm Permissible cable bending radius Fixed routing gt 35 mm Movable gt 105 mm Cable material PUR cULus 20549 80 C 300 V internal wiring N For BTL7 KA 26 BALLUFF english BTL7 A E501 M___ Micropulse Transducer Rod Style Accessories 12 Accessories are not included in the scope of delivery and must be ordered separately 12 1 Magnets BTL P 1013 4R BTL P 1014 2R 21 9 13 5 Fig 12 1 Magnet installation dimensions E www balluff com _ A B Y Z 8 S32 S115 S140 KA_ _ BTL P 1013 4R BTL P 1013 4S BTL P 1012 4R BTL P 1014 2R Weight Housing Approx 10 g Anodized aluminum Included in the scope of delivery for the BTL P 1013 4R BTL P 1013 4S BTL P 1012 4R 8 mm material polyoxymethylene POM Spacer BTL5 P 4500 1 magnet solenoid Weight Approx 90 g Housing Plastic Operating temperature 40 C to 60 C BTL P 1028 15R special accessories for applications with a supporting rod Weight Housing Approx 68 g Anodized aluminum 65 Fig 12 2 Special accessories BTL P 1028 15R 12 2 Mounting nut M18x1 5 mounting nut BTL A FKO1 E M18x
14. with the calibration device 21 1 0 Reset all values with the calibration device reset 24 E www balluff com english BALLUFF 3 BTL7 A E501 M A B Y Z 8 S32 S115 S140 KA _ Micropulse Transducer Rod Style 1 1 Technical data 25 11 1 Accuracy 25 11 2 Ambient conditions 25 11 3 Supply voltage external 25 11 4 Output 25 11 5 Communication lines La Lb 25 11 6 Dimensions weights 26 1 2 Accessories 27 12 1 Magnets 27 12 2 Mounting nut 27 12 3 Connectors and cables 28 12 3 1 BKS S32 S33M 00 freely configurable 28 12 3 2 BKS S232 S233 PU __ preassembled 28 12 3 3 BKS S115 S116 PU _ _ preassembled 29 12 3 4 BKS S140 23 00 freely configurable 29 12 4 USB communication box 29 1 3 Type code breakdown 30 1 4 Appendix 31 14 1 Converting units of length 31 14 2 Part labels 31 4 BALLUFF english BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 1 Notes to the user 1 1 Validity This guide describes the construction function and setting options for the BTL7 Micropulse Transducer with analog interface It applies to types BTL7 A E501 M____ A B Y Z 8 S32 S115 S140 KA__ see type code breakdown on page 30 The guide is intended for qualified technical personnel Read this guide before installing and operating the transducer 1 2 Symbols and conventions Individual instructions are indicated by a preceding triangle gt Instruction 1 Action sequences are num
15. 1 5 Mounting nut 3 4 16UNF BTL A FKO1 E 3 4 16UNF english BALLUFF 27 28 BTL7 A E501 M___ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 1 2 Accessories continued 12 3 Connectors and cables 12 3 1 BKS S32 S33M 00 freely configurable BKS S32M 00 Straight connector freely configurable M16 per IEC 130 9 8 pin Fig 12 3 Connector BKS S32M 00 BKS S33M 00 Angled connector freely configurable M16 per IEC 130 9 8 pin Fig 12 4 Connector BKS S33M 00 BALLUFF english 12 3 2 BKS S232 S233 PU __ preassembled BKS S232 PU _ _ Straight connector molded preassembled M16 8 pin Various cable lengths can be ordered e g BKS S232 PU 05 Cable length 5 m 66 LE ER 2 BERR RS b gt Fig 12 5 Connector BKS S232 PU _ _ BKS S233 PU _ _ Angled connector molded preassembled M16 8 pin Various cable lengths can be ordered e g BKS S233 PU 05 Cable length 5 m 20 Fig 12 6 Connector BKS S233 PU _ _ Pin Color 1 YE yellow GY gray PK pink RD red GN green BU blue BN brown WH white oo SNSJo lo P o Im Tab 12 1 BKS S232 5233 PU _ _ pin assignment BTL7 A E501 M___ Micropulse Transducer Rod Style 1 2 Accessories continued _ A B Y Z 8 S32 S115 S140 KA_ _ 12 3 3 BKS S115 S116 PU BKS S115 PU _ _ Straight connector molded on cable preassembled M1
16. 2 8 pin Various cable lengths can be ordered e g BKS S115 PU 05 Cable length 5 m preassembled Ile 5 M12x1 Fig 12 7 Connector BKS S115 PU _ _ BKS S116 PU _ _ Angled connector molded on cable preassembled M12 8 pin Various cable lengths can be ordered e g BKS S116 PU 05 Cable length 5 m Fig 12 9 Connector BKS S116 PU_ _ outlet Pin Color 1 YE yellow GY gray PK pink RD red GN green BU blue BN brown WH white oIslolo o m Tab 12 2 BKS S115 S116 PU_ _ pin assignment E www balluff com 12 3 4 BKS S140 23 00 freely configurable BKS S140 23 00 Straight connector freely configurable 10 pin 26 50 Fig 12 10 Connector BKS S1 40 23 00 12 4 USB communication box BTL7 A CB01 USB S32 For BTL7 A E501 with S32 connector Scope of delivery USB communication box USB cable 2 adapter cables each approx 0 3 m condensed guide BTL7 A CB01 USB S115 For BTL7 ESO1 with S115 connector Scope of delivery USB communication box USB cable 2 adapter cables each approx 0 3 m condensed guide BTL7 A CB01 USB S140 For BTL7 A E501 with S140 connector Scope of delivery USB communication box USB cable 2 adapter cables each approx 0 3 m condensed guide BTL7 A CB01 USB KA For BTL7 A E501 with cable connection Scope of delivery USB communication box USB cable
17. BALLUFF sensors worldwide BTL7 A E501 M_ _ A B Y Z 8 S32 S115 S140 KA_ _ User s Guide Ebr e english www balluff com BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 1 Notes to the user 5 1 1 Validity 5 1 2 Symbols and conventions 5 1 3 Scope of delivery 5 1 4 Approvals and markings 5 2 sty 2 1 Intended use 2 2 General safety notes for the position measuring system 2 3 Meaning of the warnings 2 4 Disposal 3 Construction and function 3 1 Construction 3 2 Function 3 3 LED display 4 Installation and connection 9 N 909060 To ON 4 1 Installation variants 9 4 2 Preparing for installation 9 4 3 Installing the transducer 10 4 3 1 Installation recommendation for hydraulic cylinders 10 4 4 Electrical connection 11 4 4 1 Connector S32 cable connection KA__ 11 4 4 2 Connector S115 11 4 4 3 Connector S140 12 4 5 Shielding and cable routing 13 5 Startup 14 5 1 Starting up the system 14 5 2 Operating notes 14 6 Configuration with the Micropulse Configuration Tool 15 6 1 Micropulse Configuration Tool 15 6 2 Connecting the USB communication box 15 6 3 Configuration options 15 Adjust with the calibration device not with BTL7 S140 7 1 Calibration device 17 7 2 Calibration procedure notes 17 7 3 Calibration procedure overview 18 7 3 1 Teach in 18 7 3 2 Adjust 19 7 3 3 Reset 19 8 Teach in with the calibration device 20 Gg Adjust
18. G we AB Y Z 10 2mm Thread M4x4 6 deep A8 B8 Y8 Z8 8mm No thread Fig 3 1 BTL7 transducer construction and function 3 1 Construction Electrical connection The electrical connection is made via a cable or a connector see type code breakdown on page 30 BTL housing Aluminum housing containing the processing electronics Mounting thread The transducers with 10 2 mm have an additional thread at the end of the rod to support larger nominal lengths We recommend assembling this transducer on the fastening screw thread BITL7 A B M18x1 5 BITL7 Y Z 3 4 16UNF E www balluff com Magnet Defines the position to be measured on the waveguide Magnets are available in various models and must be ordered separately see accessories on page 27 Nominal length Defines the available measuring range Rods with various nominal lengths from 25 mm to 7620 mm are available depending on the version 10 2 mm Nominal length from 25 mm to 7620 mm 88mm Nominal length from 25 mm to 1016 mm Damping zone Area at the end of the rod that cannot be used for measurements but which may be passed over Calibration device Additional device for calibrating the transducer not with BTL7 S140 english BALLUFF 7 8 BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 3 Construction and function continued 3 2 Function The Micropulse Tran
19. Max 30 m BTL7 E Max 100 m Tab 4 5 Cable lengths BTL7 N Prerequisite Construction shielding and routing preclude the effect of any external noise fields E www balluff com english BALLUFF 13 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 5 Me 5 1 Starting up the system A DANGER Uncontrolled system movement When starting up if the position measuring system is part of a closed loop system whose parameters have not yet been set the system may perform uncontrolled movements This could result in personal injury and equipment damage gt Persons must keep away from the system s hazardous zones gt Startup must be performed only by trained technical personnel gt Observe the safety instructions of the equipment or system manufacturer 1 Check connections for tightness and correct polarity Replace damaged connections Turn on the system 3 Check measured values and adjustable parameters and readjust the transducer if necessary il Check for the correct values at the null point and end point especially after replacing the transducer or after repair by the manufacturer 5 2 Operating notes Check the function of the transducer and all associated components on a regular basis Take the position measuring system out of operation whenever there is a malfunction Secure the system against unauthorized use
20. bered consecutively 1 Instruction 1 2 Instruction 2 il Note tip This symbol indicates general notes These symbols indicate the buttons on the 2 calibration device Symbols of this type indicate the LED displays N 1 3 Scope of delivery BTL7 transducer Calibration device not with BTL7 S140 Condensed guide il The magnets are available in various models and must be ordered separately E www balluff com 1 4 Approvals and markings UL approval c US File no E227256 US Patent 5 923 164 The US patent was awarded in connection with this product The CE Mark verifies that our products meet the requirements of EU Directive 2004 108 EC EMC Directive The transducer meets the requirements of the following generic standards EN 61000 6 1 noise immunity EN 61000 6 2 noise immunity EN 61000 6 3 emission EN 61000 6 4 emission and the following product standard EN 61326 2 3 Emission tests RF emission EN 55016 2 3 industrial and residential areas Noise immunity tests Static electricity ESD EN 61000 4 2 Severity level 3 Electromagnetic fields RFI EN 61000 4 3 Severity level 3 Electrical fast transients burst EN 61000 4 4 Severity level 3 Surge EN 61000 4 5 Severity level 2 Conducted interference induced by high frequency fields EN 61000 4 6 Severity level 3 Magnetic fields EN 61000 4 8 Sev
21. controller side but not to the shield 2 Factory setting can be freely configured with the PC software 5 Reference potential for supply voltage and EMC GND 12 BALLUFF english BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA__ Micropulse Transducer Rod Style 4 Installation and connection continued 4 5 Shielding and cable routing il Defined ground The transducer and the control cabinet must be at the same ground potential Shielding To ensure electromagnetic compatibility EMC observe the following Connect transducer and controller using a shielded cable Shield Braided copper shield with minimum 85 coverage Connector version Shield is internally connected to connector housing Cable version On the transducer side the cable shielding is connected to the housing Ground the cable shielding on the controller side connect with the protective earth conductor Magnetic fields The position measuring system is a magnetostrictive system It is important to maintain adequate distance between the transducer cylinder and strong external magnetic fields Cable routing Do not route the cable between the transducer controller and power supply near high voltage cables inductive stray noise is possible The cable must be routed tension free Bending radius for fixed cable The bending radius for a fixed cable must be at least five times the cable diameter Cable length BTL7 A
22. erity level 4 il More detailed information on the guidelines approvals and standards is included in the declaration of conformity english BALLUFF 5 6 BTL7 A E501 M__ Micropulse Transducer Rod Style _ _ A B Y Z 8 S32 S115 S140 KA_ _ 2 ET 2 1 Intended use The BTL7 Micropulse Transducer together with a machine controller e g PLC comprises a position measuring system It is intended to be installed into a machine or system Flawless function in accordance with the specifications in the technical data is ensured only when using original BALLUFF accessories use of any other components will void the warranty Opening the transducer or non approved use are not permitted and will result in the loss of warranty and liability claims against the manufacturer 2 2 General safety notes for the position measuring system Installation and startup may only be performed by trained specialists with basic electrical knowledge Specialists are those who can recognize possible hazards and institute the appropriate safety measures due to their professional training knowledge and experience as well as their understanding of the relevant regulations pertaining to the work to be done The operator is responsible for ensuring that local safety regulations are observed In particular the operator must take steps to ensure that a defect in the position measuring system will not result in hazards to persons or equipment If
23. g hole with thread possibly with countersink for the O ring acc to Fig 4 3 or Fig 4 4 gt Screw the transducer with fastening screw thread into the mounting hole max torque 100 Nm Install the magnet accessories For nominal lengths gt 500 mm Tighten the outer rod at the end only possible with 10 2 mm or support it il Suitable nuts for the mounting thread are available as accessories see page 27 4 3 1 Installation recommendation for hydraulic cylinders If you seal the hole with a flat seal the max operating pressure will be reduced in accordance with the larger pressurized surface If installing horizontally in a hydraulic cylinder nominal lengths gt 500 mm we recommend affixing a slide element to protect the rod end from wear il Dimensioning of the detailed solutions is the responsibility of the cylinder manufacturer The slide element material must be suitable for the appropriate load case medium used and application temperatures E g Torlon Teflon or bronze are all possible materials Slide element Fig 4 5 Example 1 transducer installed with slide element BALLUFF english The slide element can be screwed on or bonded Secure the screws so they cannot be loosened or lost Select a suitable adhesive Slide surface Flow gap en e rod BTL outer rod E element Fig 4 6 Detailed view and top view of slide element There must be a ga
24. nglish BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 5115 S140 KA__ 7 Adjust with the calibration device not with BTL7 S140 7 1 Calibration device The calibration device is an additional device for calibrating the transducer if configuration with a PC and software is not possible Prerequisite Button function has not been locked by the PC software button lock Calibration device is in place The transducer is connected to the system controller Voltage or current values from the transducer can be read using a multimeter or the system controller il If the button function is locked this lock must be removed using the PC software Settings The transducer has the following factory settings that can be adjusted with the calibration device One magnet position function at both outputs output 1 with a rising curve and output 2 with a falling curve identical measuring range for both outputs During adjustment the same start points and end points are set for both outputs No other function can be selected and no further transducer may be used If the button function is locked the lock can only be removed if these conditions have been fulfilled 7 2 Calibration procedure notes Before calibrating Place the calibration device on the connection side of the transducer gt When finished with calibration Remove the calibration device to prevent change
25. o the output value can be read out at output 1 in the delivery state il As standard the values are adjusted at output 1 Before and the values at output 2 are inverted ame accordingly From serial number 100503000xxxxx xx it is After possible to optionally switch adjustment from output 1 to output 2 see page 23 End point Steps ee gt Move magnet to the new start position Read new start point by pressing the buttons gt Set the new start value by pressing the buttons Fig 7 5 Adjust a new end value 7 3 3 Reset il The detailed procedure for the reset is described on page 24 Restoring the transducer to its factory settings Before New After start value gt Start point Fig 7 4 Adjust a new start value E www balluff com english BALLUFF 19 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 8 Teach in with the calibration device NOTICE Interference in function Teach in while the system is running may result in LED display Displayed values example malfunctions gt Stop the system before performing teach in LED1 LED2 AtOto10V At4to20mA Initial situation Transducer with magnet within measuring range pP 5 39 V 9 15 mA A A Activate
26. p between the slide element and piston bore that is sufficiently large for the hydraulic oil to flow through Options for fixing the magnet Screws Threaded ring Press fitting Notches center punching il If installed in a hydraulic cylinder the magnet should not make contact with the outer rod The hole in the spacer ring must ensure optimum guidance of the outer rod by the slide element Fig 4 7 Fixing of magnet An example of how to install the transducer with a supporting rod is shown in Fig 4 8 on page 11 BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 4 Installation and connection continued 4 4 Electrical connection Magnet Depending on the model the electrical connection is made e ge BTLRP 1028 19R using a cable BTL7 KA or a connector BTL7 S32 BTL7 S115 BTL7 S140 The connection or pin assignments for the respective version can be found in Tables 4 2 to 4 4 il Note the information on shielding and cable routing on page 13 Supporting rod made of non magnetizable material Fig 4 8 Example 2 transducer installed with supporting rod 4 4 1 Connector S32 cable connection KA__ S32 KA BTL7 interface Pin Cable color A501 E501 1 YE yellow Not used 4 to 20 mA output 1 2 GY gray OV 3 PKpink 10 to 0 V2 output 2 20154 mAP output 2 ee 4 RD red La communication line
27. s gt Keep the calibration device for later use il Automatic deactivation If the buttons on the calibration device are not pressed for approx 10 min programming mode is automatically ended Values for null and end point Any desired position of the magnet can be used as the null or end point However the null and end points may not be reversed The absolute null and end points must lie within the minimum or maximum limits of what can be output The distance between the null point and end point must be at least 4 mm il The last set values are always saved regardless of whether the setting was ended using the buttons or automatically after 10 min have expired Fig 7 1 Calibration device in place End point a fp Output gradient Linear Unit Min value Null value End value Max value Error transducer value Rising output 1 BIL7 A V 0 5 6 10 0 10 5 10 5 BTL7 E mA 3 6 4 0 20 0 20 4 3 6 Falling output 2 BTL7 A V 10 5 10 0 O 0 5 0 5 BTL7 E mA 20 4 20 0 4 0 3 6 3 6 Tab 7 1 Factory settings value table E www balluff com english BALLUFF 17 18 BTL7 A E501 M___ Micropulse Transducer Rod Style _ A B Y Z 8 S32 S115 S140 KA_ _ 7 Adjust with the calibration device continued 7 3 Calibration procedure overview 7 3 1 Teach in il The detailed procedure for teach in is de
28. scribed on page 20 The factory set null point and end point is replaced by a new null point and end point The null point and end point can be set separately the output gradient changes Steps gt Move magnet to the new null position gt Read new null point by pressing the buttons The current end point remains the same Fig 7 2 Reading new null point Move magnet to the new end position gt Read new end point by pressing the buttons The current null point remains the same BALLUFF english New measuring length 100 Fig 7 3 Reading new end point gt The curves can be inverted by actuating the button During inverting the curves of both outputs are inverted For example a rising curve for output 1 is changed to a falling curve and a falling curve from output 2 is changed to a rising curve BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 7 Adjust with the calibration device continued 7 3 2 Adjust gt Move magnet to the new end position gt Read new end point by pressing the buttons il The detailed procedure for adjustment is gt Set the new end value by pressing the buttons described on page 21 ff The factory set null point and end point is replaced by a new start point and end point and the associated output values can be adjusted The start and end values can be adjusted as you like up to the limits The change t
29. sducer contains the waveguide which is protected by an outer stainless steel tube rod A magnet is moved along the waveguide This magnet is connected to the system part whose position is to be determined The magnet defines the position to be measured on the waveguide An internally generated INIT pulse interacts with the magnetic field of the magnet to generate a torsional wave in the waveguide which propagates at ultrasonic speed The component of the torsional wave which arrives at the end of the waveguide is absorbed in the damping zone to prevent reflection The component of the torsional wave which arrives at the beginning of the waveguide is converted by a coil into an electrical signal The travel time of the wave is used to calculate the position Depending on the version this information is made available as a voltage or current with rising or falling gradient The following functions can be selected for the output values Position Velocity with or without leading sign Differential position Two outputs that can be independently assigned are available Two magnets can be used il The entire function scope can only be configured with the PC software Micropulse Configuration Tool To do this the USB communication box must be connected see Accessories on page 28 If you do not have the PC software the transducer can be adjusted using the calibration device see page 17 ff BALLUFF english
30. set The reset function can be used to restore all the settings to the factory settings For a reset the magnet may also be located outside the measuring range LED display LED1 LED2 Activate reset i gt Simultaneously press and for at least 4 s gt 4s Release buttons O Reset is activated Reset A R gt Press and for at least 4 s s4s 2 Release buttons All values are reset gt Current position value is displayed Reset is deactivated Abort reset il Resetting can be aborted without any changes being saved after the Activate reset step gt Briefly press and simultaneously lt 1 s lt is O gt Release buttons Current position value is displayed LED legend O LED not on LED green A AA A AA LED flashing green red LED 1 and LED 2 flashing green red simultaneously 24 BALLUFF english BTL7 A E501 M__ Micropulse Transducer Rod Style _ _ A B Y Z 8 S32 S115 S140 KA_ _ 11 tect cat 11 1 Accuracy The specifications are typical values for the BTL7 A E at 24 V DC and room temperature with a nominal length of 500 mm in conjunction with the BTL P 1013 4R BTL P 1013 4S BTL P 1012 4R or BTL P 1014 2R magnet The BTL is fully operational immediately with full accuracy after warm up il For special versions other technical data may apply Special versions are indicated by the suffi
31. stment LED1 LED2 AtOto10V At4to20mA Initial situation Transducer with magnet within measuring range E i O 5 39 V 9 15 mA A Activate adjusting A gt Press for at least 4 s gt As D O 5 39 V 9 15 mA Set start point y Bring magnet to the new start point op L i 1 04 V 4 82 MA gt Press for at least 2 s gt 2s The new start point is set with the last valid start 0 00 V 4 00 MA value Adjust start value The start value can be changed using and The gradient of the curve changes see page 19 0 00 V 4 00 mA 2 00 V 7 20 MA 2 00 V 7 20 MA End calibration procedure Briefly press and simultaneously lt 1 s gt Set position value is saved For setting the end point adjusting the end value and exiting adjustment see page 22 il Any of the individual steps for settings can be selected The adjustment process can be ended at any time 1 Briefly press button Current value is increased or LED legend O LED not on decreased by approx 1 mV or 1 pA AA If a button is held down longer than 1 s the step ean infervaliis increased LED green LED 1 and LED 2 flashing green red in alternation A AR O LED 1 and LED 2 flashing red red in alternation E www balluff com english BALLUFF 22
32. teach in AA gt Press for at least 4 s 545 539v 9 15 mA Set null point Y Bring magnet to the new null point Er 1 04 V 4 82 mA gt Press for at least 2 s gt 2s Q oO A A AR CO o gt The new null point is set once the button is 0 00 V 4 00 mA released Set end point E Y Pp Bring magnet to the new end point 9 89 V 19 13 mA gt Press for at least 2 s gt 2s 2 O A A A A The new end point is set once the button is 10 00 V 20 00 mA released Invert curves gt Simultaneously press and for at least 4 s until 0 2 both LEDs are illuminated in red gt 4s The curves of both outputs are inverted once the buttons are released O O End teach in gt Briefly press and simultaneously lt 1 s lt 1s 0 2 gt The current position value is displayed once the buttons are released il Any of the individual steps for settings can be selected The teach in process can be ended at any time LED legend O LED not on O LED green AA AA LED 1 and LED 2 flashing green green in LED red alternation 20 BALLUFF english BTL7 A E501 M_ _ _ _ A B Y Z 8 S32 S115 S140 KA_ _ Micropulse Transducer Rod Style 9 Adjust with the calibration device NOTICE Interference in function Adjustment while the system is running may result in LED display Displayed values example malfunctions gt Stop the system before performing adju
33. x SA on the part label Repeat accuracy Voltage typical Current typical 10 um 5 um Sampling rate With one magnet Dependent on the nominal length 250 us 5 5 ms At nominal length 500 mm 500 us With two magnets Dependent on the nominal length 375 us to 8 25 ms At nominal length 500 mm 750 us Non linearity at Nominal length lt 500 mm 50 um Nominal length gt 500 to lt 5500 mm 0 01 FS Nominal length gt 5500 mm 0 02 FS Temperature coefficient lt 30 ppm K nominal length 500 mm magnet in the middle of the measuring range Max detectable velocity 10 m s 11 2 Ambient conditions Operating temperature 40 C to 85 C Operating temperature for UL Max 80 C only BTL7 KA Storage temperature 40 C to 100 C Relative humidity lt 90 non condensing Outer rod pressure rating when installed in hydraulic cylinders For 8mm lt 250 bar For 10 2 mm lt 600 bar Shock rating 150 g 6 ms per EN 60068 2 27 Continuous shock 150 g 2 ms per EN 60068 2 29 Vibration per EN 60068 2 6 Degree of protection per IEC 60529 Connector S32 S115 5140 IP67 when attached Cable KA_ _ IP68 20 g 10 to 2000 Hz E www balluff com 11 3 Supply voltage external Voltage stabilized Ripple Current draw at 24 V DC BTL7 A501 BTL7 E501 Inrush current Reverse polarity protection Overvoltage protection Dielectric strength GND to housing 11 4
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